MODEL

4CM21
4000 WATT- 129 VOillAC, -:RE~:R.EA'il'ONAlVEHIClE
GENERATOR SET OWNER'S MANUAL
CONTENTS
SUBJECT PAGE SUBJECT • PAGE
Service and Adjustment Points 2 Trouble Shooting-Engine 7
Engine General Specifications 2 Schematic Diagram-Generator Set ~ 8
Fuel Consumption 2 Generator Service 9
Generator - General Details '" 2 Trouble Shooting-Generator 9
Pre-Start Instructions ....................•... 3 Controller Operation ..•....................... 9
Starting-Stopping Procedures 3 Engine Parts Identification ..........•........ 10
Preventive Maintenance .. ~ 3 Parts Ordering~nstructions 11
Battery Connection 3 Engi ne Parts ' 11
Service Schedule 4 Mounting Parts 12
Air Cleaner Service 4 Exhaust Parts 12
Lubricating Oil 4 Generator Parts ..........•.................... 13
Carburetor Adjustment 5 Controller Parts 14
Automatic Choke Adjustment 5 Storage Instructions 15
Governor Adj ustment 6 Opt i ona 1 Accessori es 15
Cooling System Service , ~ 6 Operating Hour-Service Log .......•.•.......... 16
Ignition System Service 7 Warranty .................•.........•.......... 16

SAFETY PRECAUTIONS
Safety is built into every engine driven generator; however, like any other electro-mechanical device it can present serious threat to life and
limb if imprudently operated and maintained, Remember that the best safeguards against accidents are to keep ever mindful of the potential
dangers and to always use good common sense. In the interest of safety, some general precautions are presented below - keep these in mind!
WARNING - HIGH VOLT AGE! Remember that the function of a generator set is to produce electricity and wherever electrical energy is
present, there is the potential danger of electrocution. Keep everyone, especially children, away from the set while it is running and take pre-
cautions to prevent unqualified personnel from tampering with or attempting to operate your generator set. Have the set and electrical circuits
serviced only by qualified technicians and make sure that the battery is disconnected before any service is performed to prevent unintentional
starting. Wiring should be inspected frequently - replace leads that are frayed or in poor condition. Be especially careful not to come in contact
with electrical equipment when standing in water or on wet ground or when your hands are wet.
WARNING - LETHAL EXHAUST GAS! The engine powering your generator discharges deadly carbon monoxide as part of the exhaust
• gas when operating. Carbon monoxide is particularly dangerous in that it is odorless but keep in mind that it can cause death if inhaled for even
a short period of time. Never operate the generator set inside a building unless the exhaust gas is piped safely outside or operate in any area
where exhaust gas could accumulate and seep back inside an occupied building. Keep exhaust system tight and in good condition at all times to
prevent leakage. Avoid breathing exhaust fumes when working on or near the generator set.
WARNING - DANGEROUS FUELS! Use extreme caution when handling, storing and using fuels - they are highly volatile and explosive
in vapor state. Store gasoline only in approved red containers clearly marked GASOLINE - store in well-ventilated area out of the reach of
children and away from any flame or spark producing equipment. Don't store gasoline inside home or any occupied building. Never add fuel to
tank while engine is running to prevent spilled fuel from igniting on contact with hot parts or from ignition spark. With gaseous fuel, make sure
the system meets all safety codes and have it serviced only by qualified technicians.
WARNING - MOVING, HOT PARTS! Imprudent operation creates hazards to life and limb - never operate with safety guards removed,
keep hands, feet, clothing away from moving and hot parts. Remember that an engine gets hot while running, and exhaust system components
get extremely hot. Know how to make emergency stops - don't allow inexperienced persons to operate your set. Always disconnect battery or re-
move spark plug while working on equipment. Never tamper with governor setting to gain more power - the governor establishes safe operat-
ing limits. Overspeed not only shortens engine life but can be extremely hazardous.
WARNING - GENERAL PRECAUTIONS! Handle starting batteries carefully - they are filled with acid which can eat thru clothing, bum
skin, and cause blindness. Keep in mind that a battery gives off highly flammable hydrogen gas while being charged - charge only in well venti~
lated area. While electrical energy produced in an engine ignition system may not be strong enough to cause injury, reaction to shock produced
could cause you to pull away and into contact with hot or moving parts - keep away from ignition system while operating. Never operate with-
out adequate muffler or with faulty exhaust system - exposure to excessive noise is not only tiring but can lead to impairment of hearing.

KOHLER CO., KOHLER, WIS. 53044

 STOP-START
SWITCH
AIR CLEANER

FUEL PUMP

OIL
.DRAIN
T OIL
AND
FILL TUBE
DIPSTICK

FIGURE 1 -- MAIN COMPONENTS-SERVICE & ADJUSTMENT POINTS

Engine: Kohler 4-stroke cycle, air-cooled single cylinder gasoline Model K321 engine. All have the
Kohler patented ACR (Automatic Compression Release) feature for quick, easy starting. Other general
specifications are:

LUBE OIL CAPACITy 1-3/4 Quarts

SPARK PLUG SIZE (XH-10 or Equivalent) l4mm
SPARK PLUG GAP 025"
BREAKER POINT GAP 020"
BATTERY (55 amp. hr. minimum) 12 volt
FUEL (Regular grade gasoline) 85 Octane Minimum

The following chart is provided to help you calculate the approximate fuel consumption of your
set at various load levels.
APPROXIMATE FUEL CONSUMPTION
.46
.575
.74
FULLGallon
3/4
1/2 Gallon
LOAD
LOAD
APPROXIMATE CONSUMPTION IN GALLONS (U.S. STD.) PER HOUR AT

1/4 LOAD

Generator: Kohler rotating armature (alternating current) type with built-in exciter which functions as
a starting motor to crank the engine during starting then switches to its generating function after the
engine starts. Exciter cranking permits higher cranking speeds for longer periods of time thus provides
better starting under all conditions.

2

PRE - START INSTRUCTIONS
Before each start,
OIL LEVEL: Must be in safe range.
AIR INLETS: Must be clear.
COMPARTMENT: Keep interior clean.
OPERATING INSTRUCTIONS
open the compartment and make the following checks:
AIR CLEANER: Must be properly installed.
FUEL FILTER: Service if needed.
~ Make sure supply is adequate.

STARTING - STOPPING PROCEDURE

The START-STOP switches inside the motor home and on the controller are momentary contact
switches which means that they must be held in the STAR T position until the set starts running or
when stopping, held in the STOP position until the unit comes to a complete halt. Whenever possible,
allow a brief cooling period by running the unit at low or no load for a few moments just prior to shut-
down.

PREVENTIVE MAINTENANCE
In addition to the routine services listed in this manual, there are other important steps that
should be taken to keep 3. generator set in top condition. Usually, tools and instruments required for
these additioClal steps are not available to the generator set owner. For this reason, the set should be
returned periodically to an authorized Service Center for complete servicing and tune-up. The benefits
of such service will not only be noted immediately in improved performance, but, most important, in
continued satisfactory operation during a long, trouble free service life.

A
BATTERY POSITIVE TO
RELAY "C" POSITIVE (p)

BATTERY NEGATIVE TO
"N" TERMINAL

USING SEPARATE BATTERY

FOR GENERATOR SET

GROUND
STRAP
TO
VEHICLE
FRAME

B
BATTERY POSITIVE TO
RELAY "C" POSITI VE (p)

USING SAME BATTERY

AS VEHICLE ENGINE

VEHI CLE FRAME

GROUND STRAP BATTE RY NE GA TI VE

VEHI CLE FRAME TO VEHI CLE FRAME

FIGURE 2 -- BATTERY CONNECTIONS-(A) SEPARATE BATTERY (B) SAME BATTERY AS VEHICLE ENGINE

I
 SERVICE PROCEDURE
SERVICE SCHEDULE
OCCURS
• EVERY FIRST)
Check 200 HOURS
mounti ng OR EVERY
bolts and viYEAR I
bro mounts. I!II I~
!I
genera torpoints.
brushes.
. II
.Check breaker
DAILY EVERY
••• Service
(OR 100 HOURS
"Tune
BEFORE spark
up"
Retighten EACH
at(ORplug.
12 MONTHS
START
authori
electrical UP)
zed -- WHICHEVER
servi ce center.
connections.
I I Replace air cleaner element.

AIR CLEANER
Engine is equipped with a dry type air cleaner. Every 50 hours remove element and service by
tapping element lightly against flat surface to dislodge loose surface dirt--do not clean in any liquid or
blowout with compressed air as this will ruin filter material in element. ~ce (with genuine Kohler
replacement element only) after each 100 hours £l' if guod clean operating conditIons are encountered,
thlS can be extended up to 200 hours.

LUBRICATING OIL
To be on the safe side, check oil in engine crankcase daily or before each start to insure that the
level is in the safe range between the Land F marks on dipstick. Do not operate set if level exceeds
the "F" mark or if b.elow "L" mark.

I CAUTION: CHECK OIL ONLY WHEN SET IS NOT IN OPERATION. I

Change oil at 50 hour intervals or every 6 months--whichever occurs first. Change more fre-
quently if operating under dirtv, dusty conditions, If possibl~, drain oil while hot.

OIL CAPACITV-1% GTS.

Use only oils having the API Service se classifications. Use SAE 30 weight oils when tempera-
ture is above 32° F., SAE 10W-30 for 0° F. to 32° F. range or SAE 5W-20 when temperature falls
below 0° F.

BACK PLA~E~
SEAL ""

COVER

GENUINE

FIGURE 3 -- OIL LEVEL MARKS ON DIPSTICK FIGURE 4 -- AIR CLEANER COMPONENTS

4
•
 -I
CARBURETOR ADJUSTMENT
Lack of power and black sooty exhaust smoke usually indicates that fuel mixture is too rich. An
"overrich" mixture may also be caused by a clogged air cleaner--check this before readjusting carbu-
retcH. Fuel mixture nlay be too lean if engine "skips" or backfires. Note that an overrich condition
cou1d a1so be caused by an inlproperly adjusted choke.

Main Fuel Adjustment: For preliminary setting, turn MAIN FUEL screw in clockwise direction until it
bottoms lightly (do not force) then back out Z turns. With engine thoroughly warmed up and running at
1800 RPM· and full load; turn MAIN FUEL screw in until engine slows down (lean setting) then turn
screw out until engine regains speed and then starts to slow down (overrich setting). Turn screw back
in until it is positioned halfway between lean and overrich settings--when properly adjusted, engine
will operate with steady governor action.

Idle Adjustrnent: On generator set app1ications, the idle systenl functions only as the engine UHnes up
thru idle range to 1800 RPM. For this reason, idle system has o'11y a mo~entary effect. To adjust.
stop engine then turn IDLE FUEL screw all the way in (clockwise) until it bottoms lightly (do not force
screw), then back out 1-1/4 turns--no further adjustment is needed.

MOVE LEVER IN DIRECTION

t
MAIN FUEL OF ARROW TO INCREASE CHOKE

#43 DRILL

(2 TURNS)
ADJUSTMENT~ ~ (.089") _
----......... F1
II

----- CHOKE
LEVER
LEV ER
CLAMP
ARM

BOLT~

IDLE FUEL
NOTCH
CHOKE PLATE ADJUSTMENT
IN
(1-1/4 TURNS)
BASE

FIGURE 5 - CARBURETOR ADJUSTMENTS FIGURE 6 - AUTOMATIC CHOKE ADJUSTMENT

AUTOMATIC CHOKE
Chokes are set at the factory but may have to be readjusted to suit local conditions. Remove air
cleaner from carburetor to observe position of choke plate. Choke adjustment must be made on cold
engine. If starting in extreme cold, choke should be in full closed position before engine is started. A
lesser degree of choking may be needed in milder temperatures. If adjustment is required, proceed as
follows: .

1. Move choke arm until hole in cross shaft lines up with slot in bearings.
Z. Insert #43 drill (.089) thru hole and push all the way down to engine manifold to engage in
notch in base of choke unit (see accompanying figure).
3. Loosen clamp bolt on choke lever, push arm upwardto move choke plate toward closed
position for increased choke or away to decrease choking effect. When properly positioned,
tighten clamp bolt then remove drill.
4. After replacing air cleaner, check for evidence of binding in linkage--correct if necessary.
Be sure choke is fully open when engine is at normal operating temperatures.

5
GOVERNOR ADJUSTMENT
The governor functions to maintain engine speed under changing load conditions and also acts as
a speed limiting device. Governor is set in the factory and further adjustment should not be required
unless linkage works loose or becomes disconnected. Readjustment should be made if engine surges
with changing load or if speed drops considerably when a normal load is applied.

Initial Adjustment: With engine stopped, loosen (do not remove) hex. nut securing governor arm to
governor cross shaft. Grasp end of cross shaft with pliers and turn shaft as far as possible in counter-
clockwise direction--tab on shaft will stop internally against governor gear mechanism. Hold shaft in
this position, pull governor arm all the way away from carburetor then retighten governor arm nut to
complete initial adjustment.

Speed Adjustment: This set must be operated at 1800 RPM. If frequency or overspeed condition is
suspected, check RPM with hand tachometer and readjust as follows: With constant speed arrangement,
loosen speed adjusting nut to decrease speed or tighten to increase speed.

THROTTLE
LINKAGE

GOVERNOR ARM

CROSS SHAFT CARBURETOR

SPEED ADJUSTING NUTS

ARM
RETAINING
NUT

SPEED CONTROL BRACKET

FIGURE 7 - GOVERNOR COMPONENTS AND ADJUSTMENT POINTS

Sensitivity Adjustment: If speed drops considerably when a normal load is applied, governor should be
set for greater sensitivity. If set too sensitive, speed surging will occur with changing load. Governor
sensitivity is adjusted by repositioning governor spring in holes provided on arm and speed control
brackets. Increase tension on spring (and sensitivity) by moving spring hooks into holes spaced further
apart--conversely, decrease sensitivity by reducing tension on spring. Recheck engine speed and
readjust as needed after changing sensitivity.

COOLING SYSTEM
Kohler Air- Vac cooling is used on this set. With this system, cooling air is drawn into the genera-
tor set compartment, circulated from the generator end, around the cooling fins and finally ejected as
heated air downward thru the Air- Vac scroll at the flywheel end of engine. High-temperature cutout on
cylinder head will stop the generator set if overheating occurs. Keep intake louvers, generator cooling
openings, cooling fins and scroll work clean and unobstructed at all tiDIes to prevent overheating--do not
operate with blower housing, scroll or cooling shrouds removed as this will also cause overheating.

6
 FIGURE 8 -- COOLING AIR CIRCULATION FIGURE 9 -- BREAKER POINT GAP

IGNITION SYSTEM
Spark Plug: Every 100 hours remove plug and check condition. Good operating conditions are indicated
1£ plug has light coating of gray or tan deposit. A dead white, blistered coating could indicate overheat-
ing. A black (carbon) coating may indicate an "overrich" fuel mixture caused by clogged air cleaner or
improper carburetor adjustment. Do not sandblast, wire brush, scrape or otherwise service plug in
poor condition--best results are obtained with new plug. Set standard and resistor type spark plug gap
at .025". Tighten plug to 22 ft. lbs. torque when installing. Use 14 mm resistor type XH10 plug for
suppression of radio noise.

Breaker Points: Every 200 hours breaker points should be inspected and serviced. If oxidized, dirty
or oily, clean with coarse cloth--do not use emery cloth or- sandpaper. Slightly pitted points can be
dressed with point file--replace badly pitted or burned points. The gap must be adjusted after points
are serviced or replaced since this setting establishes ignition timing. To adjust, turn engine over by
hand until points are at maximum opening--check with feeler gauge. If gap is not. 020", loosen adjust-
ing screw then shift movable plate until. 020" gap is obtained. After retightening screw, recheck to
make sure gap is still properly set. ---

TROUBLE SHOOTING - ENGINE

If trouble occurs, don't overlook causes that seem too obvious to be considered such as an empty
fuel tank--check for the simplest causes first. To operate, an engine must have fuel, a good ignition
spark and, of course, good compression--keep this in mind when trying to pinpoint the cause.
HARD STARTING OR LOSS OF POWER KNOCKING
a. Faulty ignition. a. Fuel octane too low.
1. Leads grounded or loose. b. Ignition timing wrong.
2. Breaker points faulty or c. Carbon build-up in combustion
improperly gapped. chamber.
3. Spark plug faulty or improp- d. Engine overheated.
erly gapped.
4. Coil or condenser defective. OCCASIONAL "SKIP" AT HIGH SPEED
b. Faulty carburetion. a. Spark plug fouled, faulty or gap
1. Fuel line clogged (dirt-gum). too wide.
2. Fuel pump faulty. b. Ignition timing wrong.
3. Carburetor dirty or improp- c. Carburetor improperly adjusted.
erly adjusted.
OV ERHEA II NG
4. Choke faulty or improperly adjusted.
c. Poor compression. a. Ai r intake openi ngs to compartment
obstructed
1. Head loose or gasket leaking.
b. Oil 1eve 1 too high (or low).
2. Valves sticking or leaking. c. Fuel mixture too lean.
3. Piston rings worn.
d. Ignition timing wrong.
OPERATING ERRATICALLY e. Engine overloaded.
f. Tappet clearance too close.
a. Clogged fuel line.
g. Air vac outlet obstructed.
b. Water in fuel.
c. Vent in fuel system plugged. BACKFIRING
d. Faulty fuel pump. a. Carburetor set too lean (Main
e. Gasket leaking (carb.-manifold). Fue 1) .
f. Governor improperly set. b. Breaker points improperly gapped
g. Carburetor improperly adjusted. (timing) .
c. Valve sticking.

I
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I LOAD

I
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LY-1804-ILl22~1 I L.Z 15 GROUNIID

Ii
-',
LW-JOI6-1500
WH!TE

LW-1803-91!5 STOP

Cyclic I NOT USED ON

TWO WIRE PLANTS
I
Compensator I
+ 12 VOLT -
I
--
... J
IIIIIIIIII I
LI u! L2

Cyclic THIS DRAWING

PROPERTY

OF DESIGN
AND
IN DESIGN AND DETAIl.. IS OUR
MUST NOT BE USED EXCEPT
IN CONNECTION WITH auI'! WORI(. ALL RIGHTS
OR INVENTION ARE RESE:R ••••ED.

Compensator
KOH LER CO.
KOHLER. WIS., U.S.A.
NAME
DIAGRAM WIRING

248374
••• 0<;. lit· •• <lI.ImI)
 GENERATOR SERVICE
Generators do not normally require service on a regular basis; however, it is a good idea to
remove the end cover and check the commutator and brushes at least every six months or every 50
hours or more often under dusty, dirty conditions. Make a visual check of the commutator first--if a
thin skinlike film of uniform thickness is evident on the surface, this usually indicates normal operation
--this film acts as a lubricant and promotes longer brush life. If the surface is streaked or has ridges
of dirt, clean it with a coarse cloth or, if this doesn't work, use fine sandpaper or a commutator stone--
do not use emery cloth. Lift brushes and check surface--replace brush if unevenly worn or when worn
~to about 1/2". Use genuine Kohler replacement brushes only--substitutes may not be of correct
material and will wear out rapidly or cause commutator damage. Other common causes for rapid brush
wear are wrong brush tension, rough commutator surface, high mica on commutator and brush chatter.
Blow dust out with i!.l. compressed air after servicing generator.

TROUBLE SHOOTING-GENERATOR
Some common causes of possible generating problems that can be detected and corrected without
test instruments are listed below. If routine service or the suggested corrective action fails to solve
the particular problem, contact a qualified electrical technician to remedy the malfunction. The infor-
mation on Controller Operation provided on pages 8 and 9 is furnished to help the technician pinpoint
causes of generator and controller problems.

PROBLEM If all • possible

Readjust
OVERLOAD:
LOOSE
Poor Have
ENGINE
Check
(full
If TERMINAL
brushtechnician
SPEED
Make
CheckforCheck
load).
engine
governor TOO
sure
Repair
electricalCONNECTIONS:
loose
speed
contact
labors
speed LOW:
and
check
negative
for
or
withsprings
loose
service
caused
loads
while for
are
by this
terminal
or
running
sensitivitybuild
on atPOSSIBLE
brushes
engine
bad
tachometer--loadas
condition.
or
up
the CAUSE
connections--clean
is as
sticking
grounded.
needed.
speed
jerks
of
same
dirt
required. in oily
should
while
time,
or holders.
beandfilm
being
overloadtighten
1800 RPM
cranked,
on
EATED:
short
ondition.
or--clean
condition •
circuitDIRTY
BATTERY
OPEN
SHORT
with
•may
mayin
ENGINE COMMUTATOR:
AC
clogged LEADS
GENERATOR
IN line.
coarse AC
exist--turn
showIN up
airin REVE
CI
POOR orRSED:
RCUIT:
clothFIELD:
cleaner
off fine
CONDITION:
reduced stone
unnecessary
oroutput.
any or
Faulty
other sandpaper.
loads
ignition,
condition
. excessive
~ausing poor carbon,
performance
poor compression,
of the engine

CONTROLLER
The controller, which is the unit on top of the generator, controls the set thru all phases of
operation. The set may be started and stopped at the switch on the controller or the switch inside the
motor horne. Refer to the controller illustration on page 14 for parts identification and to the wiring
diagram on the opposite page to trace the sequence of operation as explained in the following.
1. SWITCH IN STAR T POSITION: This completes the starting circuit allowing battery current to flow
from the positive terminal thru cranking contactor C and back to battery negative terminal. This
current magnetically draws contacts of C closed which allows heavy battery current to flow thru
the cranking series windings and the exciter armature thus motoring the engine for starting. The
initial current also activates the choke coil. The switch must be released to open the cranking
circuit immediately after the engine starts.
2. SWITCH I~ R UN (CENTER) POSITION: Switch returns to run position when released. Engine
quickly comes up to speed and power is furnished from the generator collector rings thru terminals
Ll and L2. As exciter voltage rises, lCR and 2CR relay coils energize. Contacts of lCR con-
nect the battery charging circuit to the battery. Contacts of 2CR allow the battery charging relay
(regulator relay) RR to sense battery voltage which varies the charge rate from 1 to 6 amps by
opening or closing the circuit thru resistor lR2.

3. SWITCH IN STOP POSITION: This grounds out the magneto ignition system at terminal 5 to stop
the engine- -the switch must be held in the stop position until the engine comes to a complete halt--
if released too soon the engine may restart.

.--
~7
 PARTS ORDERING INSTRUCTIONS
Most of the parts listed on the following pages are for routine services while others, such as the
repair kits, are for overhaul of faulty components. Complete assemblies are also listed for unit
replacement of components in the event this method is more advantageous timewise.
Authorized Kohler service centers have the complete list of parts for this set and should be
called upon for repair and replacement whenever possible. Refer to the yellow pages of your telephone
directory for the nearest dealer. When ordering parts, always report the MODEL, SERIAL AND
SPECIFICA TION numbers as found on the nameplate--this data will enable the dealer to procure the
correct part for your generator set.

K321 ENGINE PARTS

A-235327
237476
230020
235168
235011
220297
X-489-1
240013Rotator
220174
235786
ITEM A-220136
237658
235838
237671
A-236252
B-235646
235582
235041-S
220791Boot
235561
235054
237012
237552
A-235741
X-271-30
X-379-9
220980
235815
235070
235376
235757Gasket
237475
236474Gasket
Condenser
Camshaft
Grommet
237678Baffle,
PART Dipstick
277227DESCRIPTION
Cover
NO.
Rotor
Tube,
Valve,
Va 1ve,
Gasket,
Cover,
Scro~
Head,
Plug,
Plate,
Spring
Rod,
Gasket
Bearing,
Seal,
Stator,
Tappet
F1ywhee
Baffle,
Support
Housing,
Retainer
Points
Sea oil
1,
cy1
oil ai
spark
1, push i
(set)fi
exhaust
head
intake
scroll 11
r-vac
nder
Block,
bearing
1
(.010)
magneto
ball (XH-10)
(upper)
(rear)
cylinder
blower
(lower) head
cylinder
(front) ITEM II A-237344
147
235776
237129230989
B-237104
A-236631
235116E1
275341Gasket
237423
PART
237423Seal
237424
236763
462 01
237462
A-21 Crankshaft
Cover
Base
Gasket
02
X-276-6
235026
235353
235118F
275143
A-235807
ElNO.
ement
DESCRIPTION
01
235048Gasket
235631Plate
275144Gasket
235047Reed
235117Baffle
Nut,
bow,
il
Cutout
Rod,
Linkage
A-236271
Gasket,
Cover,
Pi ston
Ring
Nut,
Pump,
Line,
Base, lockexhaus
Carburetor
te wing
r
conn.
Filter,
set
Baff1 - hi.
cover
valve
(std.)
fue
fue
oil
e, t
carburetor
(std.)
fuel
(std.)
11pan
gear
pansi temp.
de
26
23
24c
24f
27d
27b
27c
27e
22
24b
24d
24e
27f
35
29
24g
33
32
34 47 516 01
235025
235466
AC-1536
275167
240285 I 235652 Valve, fuel solenoid
37
21
24a
25
31
30
36
28 I Choke, automati c
27a

11

•
r MOUNTING PARTS

(237467 ) (237464j ENGINE (L.H.)

/BRACKET
SUPPORT, GENERATOR~

BRACKET
/III~
CARBURETOiNG! NE (R. H. ) I'
(237465) SIDE
~SUPPORT, ENGINE*
(237466)

* NOTE: Rail centerline mounting parts shown--slide-out tray mounting uses same engine brackets but
supports are part of tray (slide tray part number 237500).

/WASHER
BRACKET~NER<TOR) ~~ WASHER

ii jf ~ (X-25-100)
·-·=.::::=~--=- :L--"::::?,
..
I:c=--------,'T----;.:-:-::.::. 'I 1

SPACERS TEE, RUBBER :,~-;:_-_-_::-:._-:.~----.-_', ~

(237451)~----:~--::t----, CUP (237452)
3" LONG FOR
GENERATOR END .,': '~
(X-400-82 -
-- JCj----, SPRING

2 REQUIRED)
::
oi
(237463)
SUPPORT ..r
2-7/8" LONG FOR
ENGINE END
NUT---------
(X-400-84 -
2 REQUIRED) ~ "" ""WASHER
(X-25-101)
(X-83-2) / LOCK
BOLT (X-7-35)
WASHER

EXHAUST PARTS (OPTIONAL)

MUFFLER, QUIET-TUNED
(237485)

TAILPIPE NOT FURNISHED NOT SHOWN

BY KOHLER--FACE AWAY SPARK ARRESTOR
FROM AI R STREAM (237949)

STRAP,
J;A
HANGER
(237535)
(237549)

12
 SEE BRUSH, BRUSH SPRING DETAIL BELOW

-
ITEM 1
4 I 14
4
1 8
1
QTY. PART NUMBER DESCRIPTION
19
8
10
11
4
16
14
15
17
18
6
5
7
13
12
9
3
2 1
1 242365 Cover, generator end
I 242830 Bracket, end
242596 Ri ng, brush
X-758-1 Beari ng, ba 11
A-252209 Armature - assembly
A-242391 Pole, field - assembly
237793 Frame, generator
242294 Baffle, air
242281 Fan, cooling
252163 Support, engine-generator
252164 Guard, generator support
A-242014 Coil, field - assembly
242196 Bol t, thru
242088 Resistor, fiel d
242663 Stud, resistor
242840 Nut, resistor stud
232414 Condenser, AC (0-392)
232413 Condenser, DC (0-242)
233773 Compensator, cyclic
283741 Diode, cyclic compensator
242189 Brush, AC
242191 Spring (AC & DC brushes)
242230 Brush, DC

./ ~ -DCBRUSH

~SPRING' AC & DC BRUSH

13

•
 RR

~CONTROLLER - ASSEMBLY (COMPLETE)

CONTROLLER PARTS LISTING

237747
248367
248375
245269 Connector
Resistor
PART NUMBER R2
245445
248366
X-567-4
233442
237939
248371
243890
266118
248370
245291
X-363-2
245448
248376
X-363-1
A-248895 Relav RR
DESCRIPTION
Solenoid,
Connector,
Cover,
Box,
Relayp,controll
Switch,
Controller
Resistor,
Bracket,
Block,
Stri 2CR controller
crankinq
1ead
controller
lCRrockerer
external
-na
switch
lR2 (C)
assembly
resistor
terminal
termi mounting
1 mounting
mounting (Right
(Complete) Side)
(Left Side)
ITEM

14
STORAGE INSTRUCTIONS
If your generator set is to be out of service for a considerable length of time, the following steps
should be taken to preserve the set before placing it in storage.

STEP 1: Drain oil from crankcase (while hot) then flush with clean light weight oil. Refill crankcase
with regular weight oil after flushing with the light oil.
STEP 2: Drain fuel from filter sediment bowl, carburetor bowl, and fuel tank. This is done to pre-
vent the gasoline from becoming "stale" which results in formation of gum.
STEP 3: Remove the spark plug, pour about 1 tablespoon of oil into the hole, crank the engine several
times then reinstall the spark plug.
STEP 4: Clean exterior surfaces of generator set then spread a light film of oil over any unpainted
metallic surfaces which could corrode.

STEP 5: Place dust cover over the generator set and store in cool, dry space.

POPULAR OPTIONS
Some of the popular generator set accessory kits which can be quickly added to your recreational
vehicle are described below. These are available from your local Kohler Generator Set Dealer.
HOUR-METER KITS: The hour meter kit includes an attractive panel with hour meter and stop-start
switch as shown below. The hour meter registers the total running time on your generator set. With
this, you'll know exactly when it's time to service your generator set. You can also start and stop your
generator set at the switch on this panel--an amber light in the switch glows whenever the set is running.
The panel can be mounted in a convenient location on the dashboard or partition in your recreational
vehicle. Order Kit #A-237955 when a IO-foot length of coaxial cable is required or Kit #A-237956 when
a 3D-foot long coaxial cable is needed.
LIGHTED STOP-STAR T SWITCH KITS: Without a lighted indicator switch you may have a hard time
determining if your generator set is actually running. These kits include an indicating stop-start switch,
coaxial leads and all hardware for mounting in convenient spot in your recreational vehicle. The switch
glows with an amber light whenever the generator set is operating. In addition to the convenience of
knowing at a glance whether your set is running or not, this feature eliminates the possibility of damage
due to attempts to start the set when it is already running. Order Kit #237961 for switch with IO-foot
long coaxial lead or Kit #237962 for 3D-foot coaxial lead.

CONNECTOR PLUGS
INTO RECEPTACLE
IN CONTROLLER
I HOUR METER KIT I

START
KDHLER
GENERATDR SET

Ie ~
@111[]][[]]]111(l)
SWITCH (PART OF

METER
II~ TOTAL HOURS STOP
II
HOUR

LIGHTED
METER KIT)

INDICATOR

HOUR--1
~ HOUR-METER
PANEL

15
r
r
OPERATING HOUR - SERVICE lOG
The following is provided to help you keep an accnD"lUlative record of operating hours on your
generator set and the dates required services were perfonned. Enter hours to the nearest quarter
hour.
HOURS RUN
OPERATING
ACCUMULATIVE HOURS
SERVICE RECORD HOURS RUN
OPERATING
ACCUMULATIVEHOURS
SERVI Ct: RECORD
DATE DATE! SERVICE DATE DATE 1 SERVICE
III
!~
:I:IiI:iI:I I
RUN I
:I:;IIIII:I! I

Limited On~-Year Generator Set & Accessories

Your Kohler Generator Set and Accessories have been manufactured and inspected with care by
Warranty *
experienced workdl'en~ Kohler Co. warrants for One year, each generator set and its accessories
to be free from defects' in materials and workmanship if properly installed, maintained and operated
in accordance with the Owner's Manual instructions.

Repair or replacement at Kohler's option will be furnished to the customer where inspection to
Kohler Co. 's satisfaction discloses any such defects in normal usage within one year after sale to
the original user.
NO CLAIM WILL BE ALLOWED FOR CONSEQUENTIAL DAMAGE OR FOR ANY EXPENSE OTHER
THAN MATERIALS AND LABOR FOR REPAIR OR REPLACEMENT AT KOHLER CO. 'S FACTORY
OR AN AUTHORIZED SERVICE STATION.
:1
ANY IMPLIED WARRANTY IS LIMITED IN DURATION TO THE DURATION OF THIS ONE-YEAR
WARRANTY.
*In compliance with 1975 Consumer Product Warranties Law
KOHLER CO. KOHLER, WISCONSIN 53044
~

TP1040/527 ULI
KOHLER
KOHLER CO. KOHLER, WISCONSIN 53044 FOUNDED IN 1873
•
•