Service Parts Residential/Commercial Generator Sets Models: 24RCL 30RCL 38RCLB See Group 701: Literature, inside this manual for part number of the engine parts catalog TP-6908 9/18c
Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Numbering System Significance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 How to Find Part Numbers . . . . . . . . . . . .
Introduction This manual lists service replacement parts for Kohler Power Systems generator sets. See front cover for list of models. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. This manual includes the following main sections: Table of Contents. Lists the sections of the manual.
Specification Number Index Group Description Air Intake Cooling System Engine Nameplate and Decals Skid and Plant Mounting Alternator and Mounting Control and Harness Circuit Breaker and Mounting Sound Shield Enclosure Literature Group Description Air Intake Cooling System Engine Nameplate and Decals Skid and Plant Mounting Alternator and Mounting Control and Harness Circuit Breaker and Mounting Sound Shield Enclosure Literature Group Description Air Intake Cooling System Engine Nameplate and Decals Skid
Air Intake GM90232--GR1 2 17 7 17 17 10 8 15 16 8.1 19 5 6 13 12 9 18 4 14 11 14 19 GM90232--C Item 2 4 5 6 7 8 8.1 9 10 11 12 13 14 15 16 17 18 19 6 Part Number X-507-13 X-386-141 GM14200 GM32869 GM89895 GM90280 GM90281 GM91330 GM93779 M125A-08-80 M6923-08-80 M933-06010-60 M933-08016-60 X-215-19 X-380-3 X-426-1 X-426-2 X-426-9 Description Hose, Radiator, Straight, 3 in. ID Line, Flex Mount, air cleaner ( 6.76”id) Hose, 90 Deg. Elbow Hose, 90 Deg.
Air Intake GM90232--GR2 3.1 9 3 1 5 7 8 6 2 4 11 10 GM90232--F Item 1 2 3 3.1 4 5 6 7 8 9 10 11 TP-6908 9/18 Part Number 344754 GM14200 GM90280 GM90281 GM95583 M6923-08-80 M933-08016-60 X-25-40 X-386-141 X-426-1 X-426-2 X-426-9 Description Connector, hose Mount, Air Cleaner ( 6.76”ID) Air Cleaner Assy Element, Air Cleaner Hose, Air Intake Nut, Hex 8MM Screw Washer, Plain, .281 ID X .625 in. OD Line, Flex Clamp, hose, 2.81/3.75 in. Clamp, hose, 2.31/3.25 in. Clamp, hose, .25/.70 in.
Air Intake, continued GM92369--GR1 4 9 3 3.1 1 1 9 2 7 8 10 5 6 GM92369--A Item 1 2 3 3.1 4 5 6 7 8 9 10 8 Part Number 344754 GM14200 GM90280 GM90281 GM92385 M6923-08-80 M933-08016-60 X-386-109 X-386-141 X-426-1 X-426-9 Description Connector, hose Mount, air cleaner ( 6.76”id) Air Cleaner Assy. Element, Air Cleaner Hose, Air Intake Nut, Hex 8mm Screw, Hex Cap Fuel line, flexible Line, Flex Fuel Clamp, hose, 2.81/3.75 in. Clamp, hose, .25/.70 in.
Notes TP-6908 9/18 9
Cooling System GM90230--GR1 11 14 32 12 14 4 8 39 20 10 22 41 38 26 21 38 24 21 35 27.
Cooling System GM90230--GR1 Item 2 3 4 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27.
Cooling System, continued GM92075--GR1 14 3 22 20 14 16 54 51 6 38 40 26 12 12 51 12 40 39 12 40 23 6 30 17 5 57 15 12 21 52 53 46 25 13 12 11 30 34 29 29 36 12 25 25 37 37.
Cooling System, continued GM92075--GR1 Item Part Number 2 3 5 19000 08075 19000 08075 19010 08118 6 19010 08118 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 37 37.
Cooling System, continued GM92075--GR2 11 14 32 12 14 3 8 39 20 10 22 41 38 26 21 38 24 21 35 27.
Cooling System, continued GM92075--GR2 Item 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27.
Cooling System, continued GM104806--GR1 14 23 24 3 52 33 11 47 36 2 37 44 32 18 58 61 58 19 17 57 6 51 32 54 21 35 34 27 41.
Cooling System, continued GM104806-GR1 TP-6908 9/18 Item Part Number 2 3 4 6 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 41.
Cooling System, continued GM104806--GR2 14 23 11 24 3 12 30 2629 10 33 41 36 17 37 31 27 13 2 32 11 18 19 17 6 32 35 34 27 38.
Cooling System, continued GM104806-GR2 TP-6908 9/18 Item Part Number 2 3 4 6 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38.
Engine GM90228--GR1 3 * 11 * * 25 10 * * * 4 17 * 7 8 19 * * 21 5 * * 20 6 28 14 * 22 2 * 27 9 17 13 15 16 18 26 22 4 12 24 20 19 * See engine part manual GM90228--E 20 TP-6908 9/18
Engine GM90228--GR1 Item 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 TP-6908 9/18 Part Number 32000 00110 GM61432 GM78761-1 GM87711 GM87838 GM90277 GM91311 GM91571 GM92753 GM93422 GM96976 M125A-08-80 M125A-10-80 M933-08012-60 M934-08-60 M961-10025-82 X-22-5 X-215-15 X-218-13 X-218-22 X-426-12 X-519-20 X-545-244 X-545-245 X-582-15 X-722-8 Description Tape, Black Bonding Strap, Poly Battery Screw, Sheetmetal Engine Assembly Bracket, Fuel Solenoid Pipe, Exhaust Blanket, Exhaust Hos
Engine, continued GM92074--GR1 7 4 23 11 6 24 18 9 35 22 16 36 22 18 28 19 10 24 28 22 28 24 41 27 21 19 24 34 26 38 24 * 8 12 * 37 20 2 15 13 20 22 39 40 33 2 17 32 14 3 * See engine part manual GM92074--E 22 TP-6908 9/18
Engine, continued GM92074--GR1 Item 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 32 33 34 35 36 37 38 39 40 41 TP-6908 9/18 Part Number Description Quantity 151385 237548 336851 GM22535 GM61432 GM78761-1 GM88249 GM92079 GM95022 GM95605 GM95606 GM95607 GM95614 GM96290 GM96976 M125A-08-80 M125A-10-80 M6921-06016-60 M933-08020-60 M933-10025-82 M934-08-60 M961-10025-82 SA-472 X-22-10 X-25-26 X-216-12 X-218-9 X-426-12 X-545-246 X-545-247 X-582-15 X-582-8 X-672-39 X-722-8 X-6210-7 Elb
Engine, continued GM105676--GR1 10 7 3 13 16 23 21 26 18 25 19 28 20 5 22 15 13 12 4 8 1 9 27 22 20 28 11 19 6 24 14 17 5 17 14 GM105676-- 24 TP-6908 9/18
Engine, continued GM105676--GR1 Item 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 TP-6908 9/18 Part Number 32000--00110 GM105674 GM61432 GM78761--1 GM87838 GM90277 GM91311 GM91571 GM92753 GM93422 GM96976 M125A--08--80 M125A--10--80 M933--08020--60 M934--08--60 M961--10025--82 X--22--5 X--215--15 X--218--13 X--218--22 X--426--12 X--468--1 X--519--20 X--545--244 X--545--245 X--582--15 X--722--8 Description Tape, Bonding Engine Assy., 2.
Nameplate and Decals GM78523-GR1 Not illustrated Part Item Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 26 239789 249808 249809 249810 257438 257441 258815 273780 294520 GM15299 GM20577 X-6275-3 GM81760 GM15301 Description Decal, notice, neutral bonded to frame Decal, warning rotating parts Decal, Caution Hot Engine Decal, warning hot coolant Decal, danger moving rotor Decal, warning lifting eye Decal, warning voltage backfeed Decal, warning explosion Decal, danger, high voltage Decal, Rainproof Enclosure De
Skid and Mounting GM91038--GR1 16 5 13 17 8 17 18 3 6 22 20 15 9 10 25 2 24 7 23 11 21 24 12 19 14 21 Item 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19 20 21 22 23 24 25 TP-6908 9/18 4 12 Part Number X-577-27 276476 290418 GM28552 GM51689 GM59015 GM87458 GM87459 GM91039 GM93089 M125A-10-80 M6923-08-80 M6923-10-80 M931-08045-60 M931-12065-60 M125A-12-80 M933-08025-60 M933-10020-60 M933-10035-60 M982-12-80 X-22-15 X-25-140 X-75-58 X-426-10 X-781-22 18 GM91038--B Description Hose, ru
Alternator and Mounting GM87474-36 38 37 6 30 32 23 18 22 4 29 21 5 1 35 24 10 33 8 21 34 18 31 3 17 16 28 9 15 11 19 7 12 8 39 14 20 13 2 28 GM87474--C TP-6908 9/18
Alternator and Mounting GM87474-Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19 20 21 22 23 24 28 29 30 31 32 33 34 35 36 37 38 39 Part Number A-229152 GM87122 GM87123 GM87126 GM87132 M125A-05-80 M125A-06-80 M125A-10-80 M125A-12-80 M6923-10-80 M912-06016-60 M912-08020-92 M931-12065-60 M933-08025-82 M933-10025-60 M933-10025-82 X-22-1 M982-12-80 X-22-7 X-25-129 X-25-140 X-51-8 X-67-135 X-283-3 X-712-17 X-6422-15 X-6422-42 GC31594 GC87121-3 GC87128 See chart GM87134-3 GM87978 See chart GM78761-1 M933-
Alternator and Mounting, continued Saddle Box GM93034-1 1 5 3 6 9 2 1 14 8 13 7 4 Part Number Description Qty GM78761-1 GM83895 GM92873 GM92874 GM92902 M7985A-05030-20 M934-05-50 X-22-11 See chart See chart See chart See chart See chart See chart See chart M6923-06-80 M933-06010-60 M933-06016-60 M933-06025-20 X-25-40 X-6086-24 Screw, Sheetmetal Resistor Panel, Cover Panel, Side Guard, Resistor Screw, Pan Head Machine Nut, Hex 5mm Lock .262 ID x .
Notes TP-6908 9/18 31
Alternator and Mounting, continued GM97041-- 38 36.4 37 6 30 28 36 32 23 18 22 36.7 36.5 36.2 36.3 36.1 4 25 21 35 5 1 42 29 41 24 10 36.8 36.
Alternator and Mounting, continued GM97041-Item Part Number 11 12 13 14 15 16 16 17 18 19 20 21 22 23 24 25 28 29 30 31 32 33 34 35 36 37 38 39 36.1 36.2 36.3 36.4 36.5 36.6 36.7 36.
Control and Harness GM91287-- 66 41 36 40 15 40 13 70 11 34 26 62 67 63 17 22 61 32 46 3 29 30 23 33 30 23 19 12 34 8 24 31 2 37 65 10 64 44 27 20 18 64 26 34 45 31 5 42 47 1 35 21 39 38 60.2 43 16 46 14 28 23 47 33 30 60.
Control and Harness GM91287-Item Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 59 60 60.1 60.
Control and Harness, continued 2 1 GM89864 Item 1 2 36 Part Number GM92089 GM89865 Description Controller, Service RDC2 (ref.
Notes TP-6908 9/18 37
Circuit Breaker and Mounting GM91321-- 3 2 1 10 8 9 7 6 5 Harness 4 GM91321--B 38 TP-6908 9/18
Circuit Breaker and Mounting GM91321-Item 1 2 3 4 5 6 7 8 9 10 Part Number See chart GM78761-1 See chart See chart See chart See chart See chart See chart M934-04-50 X-6216-1 Description Quantity Breaker, Circuit Screw, Sheetmetal Bracket, Circuit Breaker Cover, Junction Box Harness,Circuit Breaker Wiring Screw, Pan Head Machine Washer,plain Washer, lock, Nut, Hex 4mm Screw, Phillips hex crimptite 1 4 1 1 1 2 2 2 2 5 Part Number Module No.
Circuit Breaker and Mounting, continued GM105396-12 11 13 7 8 9 4 6 10 1 Item not shown: 5 40 2 3 GM105396-- TP-6908 9/18
Circuit Breaker and Mounting GM105396-Part Number (qty.) Module No.
Sound Shield Enclosure GM91044-3 19 20 22 21 17 2 3 2 22 5 11 16 11 7 3 11 8 10 9 4 18 3 12 6 GM91321--B Item 2 3 4 5 6 7 8 9 10 11 11 12 13 16 17 18 19 20 21 22 Part Number 25493 00006 GM78761-1 GM82880 GM82922 GM88560 LK-1036-1515 M125A-08-80 M933-08020-60 M982-08-80 X-22-12 M125A-06-80 X-468-1 X-722-2 See chart See chart See chart See chart See chart See chart See chart Description Seal, Push-On Trim Screw, Sheetmetal Bracket, Exhaust Mounting Latch, Opening Tool Silencer Lead Washer,
Sound Shield Enclosure GM97051 1 19.1 19 18 5 20 17 1 17 18 3 13 4 13 8 13 10 11 1 12 6 2 1 15 14 7 GM97051--C Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 19.
Literature Not illustrated Item Part Number TP--6479 TP--6901 TP--6902 TP--6903 TP--6904 TP--6905 TP--6906 TP--6907 TP--6908 TP--6878 44 Description Warranty, 5--Yr., Standby O/M Engine KG2204/T 2.2L LPG/NG S/M Engine KG2204/T 2.2L LPG/NG S/M Kohler KG2204/T 2.2L LPG/NG Diagnostic P/C Engine KG2204/T 2.
Optional Kits Qty. Description Part No. Battery,1/12V,650CCA,Wet GM89020--KP1 Block Heater 500W, 120V GM90235--KP1 Block Heater 500W, 240V GM90235--KP2 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 1 1 4 2 Battery, wet charged (12V, 650 CCA) Block Heater, 500W, 120V Shield, Heat Bracket, Block Heater Mtg. Pipe, Nipple (3/8” npt x 2.00”) Coupling, pipe ( 3/8”npsc) Hose,.63 in. ID, 30 in. Hose,.63 ID, 13.75 in. Clamp, hose, .69/1.25 in.
Optional Kits, continued Qty. Description Part No. Load Control Module, w/ Terminal Blocks GM77177-KP2-QS Load Control Module, w/ Harness, CSA GM77177-KP3-QS 1 1 Load Control Module Assy, w/ Term.
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV Ah AHWT AISI ALOP alt. Al ANSI AO APDC API approx. AQMD AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CAN CARB CB cc CCA ccw. CEC cert.
k K kA KB KBus kg kg/cm2 kilo (1000) kelvin kiloampere kilobyte (210 bytes) Kohler communication protocol kilogram kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k: kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/Screw Length: When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method. Steps for common hardware application: 1.
Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Size Assembled into Aluminum Grade 2 or 5 Assembled into Cast Iron or Steel Torque Measurement Grade 2 Grade 5 Grade 8 8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) — 10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) — 10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) 1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 — (132) 1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144) 5/16-18 Nm (in. lb.) 13.6 (120) 21.
Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head with Washer Lock or Elastic Grade 5 Flat Head (FHM) Square Grade 8 Round Head (RHM) Cap or Acorn Grade 8/9 (Hex Socket Head) Pan Head Wing Hex Socket Head Cap or Allent Head Cap Washers Metric 5.
Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Hex Head Bolts (Grade 5) Part No. Dimensions Hex Head Bolts, cont. Part No. X-465-17 X-465-6 X-465-2 X-465-16 X-465-18 X-465-7 X-465-8 X-465-9 X-465-10 X-465-11 X-465-12 X-465-14 X-465-21 X-465-25 X-465-20 1/4-20 x .38 1/4-20 x .50 1/4-20 x .62 1/4-20 x .75 1/4-20 x .88 1/4-20 x 1.00 1/4-20 x 1.25 1/4-20 x 1.50 1/4-20 x 1.75 1/4-20 x 2.
Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Hex Head Bolts (Partial Thread) M931-05055-60 M931-06040-60 M931-06055-60 M931-06060-60 M931-06060-SS M931-06070-60 M931-06070-SS M931-06075-60 M931-06090-60 M931-06145-60 M931-06150-60 M5-0.80 x 55 M6-1.00 x 40 M6-1.00 x 55 M6-1.00 x 60 M6-1.00 x 60 M6-1.00 x 70 M6-1.00 x 70 M6-1.00 x 75 M6-1.00 x 90 M6-1.00 x 145 M6-1.
Metric, continued Part No. Hex Nuts Dimensions Type M934-03-50 M3-0.50 Standard M934-04-50 M934-04-B M4-0.70 M4-0.70 Standard Brass M934-05-50 M5-0.80 Standard M934-06-60 M934-06-64 M6923-06-80 M982-06-80 M6-1.00 M6-1.00 M6-1.00 M6-1.00 Standard Std. (green) Spiralock Elastic Stop M934-08-60 M6923-08-80 M982-08-80 M8-1.25 M8-1.25 M8-1.25 Standard Spiralock Elastic Stop M934-10-60 M934-10-60F M6923-10-80 M6923-10-62 M982-10-80 M10-1.50 M10-1.25 M10-1.50 M10-1.50 M10-1.
Index Listed below are part numbers and page numbers of modules listed in this manual. Italicized numbers refer to the page numbers on which modules appear.
TP-6908 9/18c E 2014, 2016, 2018 by Kohler Co. All rights reserved. KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.
