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Service Parts

Service Parts

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Published by Fred
Parts manual and breakdown for Kohler, 8.5RES and 11RMY.
Parts manual and breakdown for Kohler, 8.5RES and 11RMY.

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Published by: Fred on Dec 01, 2009
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10/25/2012

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Residential/Commercial Generator Sets
Models:
8.5/11RMY 8.5/12RES
TP-5868 1/04f
Service Parts
 
Table of Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Numbering System Significance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Illustrations 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to Find Part Numbers 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hardware References 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specification Number Index 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 1: Crankshaft 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 2: Crankcase 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 3: Lubrication 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 4: Cylinder Head/Valve/Breather 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 5: Ignition/Electrical 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 6: Blower Housing & Baffles 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 7: Starting System 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 8: Carburetor 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 9: Engine Controls 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 10: Air Intake/Filtration 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 11: Exhaust 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 12: Gasket Set 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 103: Fuel System 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 105: Engine 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 107: Nameplate and Decals 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 109: Skid and Plant Mounting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 112: Starter 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 116: Exhaust 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 201: Generator and Mounting 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 301: Controller and Mounting 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 501: Housing and Mounting 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Group 701: Literature 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel System Kit 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust System Kit 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical System Kits 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Miscellaneous Kits 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix A. Abbreviations A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix B. Common Hardware Application Guidelines A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix C. General Torque Specifications A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix D. Common Hardware Identification A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix E. Common Hardware List A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 
1TP-5868 1/04
Introduction
This manual lists service replacement parts for8.5/11RMY and 8.5/12RES generator sets.At the time of print this manual applied to the generatorset specification (spec) numbers listed in theSpecification Number Index. On occasion this manualmay apply to specs not listed in the SpecificationNumber Index.Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.This manual includes the following main sections:
Table of Contents.
Lists the sections of the manual.
Introduction (and other information sections).
Contains introductory material about part numbers,illustrations, and hardware.
Specification Number Index.
Lists the generator setspecs and groups.
GroupPartsLists.
Listthepartnumbersofpartsinthegroups.
Kit Sections.
List modules and accessories and theirparts.
Appendices.
Include Abbreviations, CommonHardware Application Guidelines, General TorqueSpecifications, Common Hardware Identification, andCommon Hardware List.
x:in:004:002
Numbering System Significance
This manual uses the following numbering systems:
Specification Number.
The product identificationnumber located on the generator set nameplate.Specification numbers break down into groups.
GroupNumber.
Auniquenumberrepresentingapartsgroupneededtoassembleageneratorsetfunction. Forexample, Group 101 is the Air Intake group.
Variation or Module Number.
A group might haveseveral variations. Each variation performs the samefunction with different parts lists. For example, a 50 Hzgenerator alternator and a 60 Hz generator alternatorboth perform the same function; however, with differentparts. Each difference requires a group variation ormodule number.
Part Number.
The part number identifies an individualassembly, subassembly, component, or accessory kit.
x:in:004:003:a
Illustrations
Illustrations (or exploded-view drawings) bestrepresenting the widest range of variations accompanymostgroupsinthismanual. Illustrationsdonotdepictalldetails and may not show all parts. Do not useillustrations for assembly or disassembly.
x:in:004:004:a
How to Find Part Numbers
Use the following steps to locate a service replacementpart.1. Locatethegeneratorsetnameplateto
identifythegenerator set spec number
.2. Locate a second generator set nameplate listingaccessories to
identify installed modules
. Onsomemodelstheaccessorynameplateismountedinside the generator junction box.3.
Turn to the Specification Number Index 
. Thefirst column lists the generator set spec numbers.Theheadingsidentifythegroupsofpartsthatmakeup the generator set.4.
Identify the group
most likely to include theservice part number.5.
Find the group variation number
at theintersection of the spec number row and the groupcolumn. Note the variation number.6.
Page forward to locate the group
identified instep 4 or find the appropriate page in the Table ofContents.7.
Findthepartontheillustration
andnotetheitemnumber of the part or
findthepart descriptioninthe parts list
.8. Select
the part number that corresponds toyour group variation
. The first column lists theillustration item number. Find the variationidentified in the Specification Number Index or themodule number found on the generator setnameplate in the appropriate column on the rightsideofthepartslisttable. Findthequantityusedatthe intersection of the item number row and thevariationcolumn. Ablankspaceattheintersectionmeans the variation/module does not use that partnumber.
x:in:004:005
Hardware References
Many common hardware items do not appear in partsmanualsorwillappearascommonhardwareentries. common hardware entry lists the size of the hardware.For example, an item that appears as “Hardware,3/8-16” in the text means that the piece is 3/8-16 size.Obtain common hardware locally or, if contacting thefactory,usetheCommonHardwareListintheappendixto identify the common hardware part number andspecifications. See Common Hardware ApplicationGuidelines in the appendix for mating hardwareinstructions.Some hardware items require a specific size or someother characteristic. In that case, use the part numberlisted in the text.
Whenreplacinghardware,donotsubstituteinferiorgradehardware.
Replacementhardwaregradeshouldbe equal to or better than the grade of themanufacturer’s original hardware. Use the CommonHardware List in the appendix to identify the commonhardware hardness.
x:in:004:006

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