Service Parts Engine Engine Model: KG0.L Generator Models: /0RCL 8RCLB 5--6CCL TP-690 9/8b
Table of Contents Description Page Introduction... Number System Significance... Illustrations... How to Find Part Numbers... : Cylinder Head Assembly (Part )... : Cylinder Head Assembly (Part )... 5 : Cylinder Block Assembly (Part )... 6 : Cylinder Block Assembly (Part )... 7 5: Crankshaft Assembly... 8 6: Camshaft Assembly... 9 7: Oil Pump, Oil Strainer and Oil Pan... 0 8: Oil Dipstick and Oil Filter... 9: Intake System... 0: Exhaust System... : Cooling System (Part )... : Cooling System (Part )... 5 : Starter and Alternator... 6 : Electrical System... 7 5: Engine Sensors... 8 6: Fuel System... 0
This manual lists service replacement parts for Kohler KG0 engines. 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. Introduction (and other information sections). Contains introductory material about part numbers, illustrations, and hardware. Group Parts Lists. List the part numbers of parts in the groups. Numbering System Significance This manual uses the following numbering systems: Model. The product identification number located on the nameplate. Engines break down into groups. Group Number. A unique number representing a parts group needed to assemble a generator set function. For example, Group 5 is the Crankshaft Assembly group. Part Number. The part number identifies an individual assembly, subassembly, component, or accessory kit. Introduction Illustrations Illustrations (or exploded-view drawings) best representing the widest range of variations accompany most groups in this manual. Illustrations do not depict all details and may not show all parts. Do not substitute illustrations for assembly or disassembly. HowtoFindPartNumbers Use the following steps to locate a service replacement part.. Locate the nameplate to identify the model number.. Page forward to locate the group or find the appropriate page in the Table of Contents.. Find the part on the illustration and note the item number of the part or find the part description in the parts list. TP-690 9/8
: Cylinder Head Assembly (Part ) 5 5 6 7 8 9 0 KO77 GM967 Valve, PCV GM96 Nut, Acorn GM96 Washer, Valve Cover Sealing GM96 Cap, Oil Filler 5 GM969 Cover, Valve 6 - Gasket, Valve Cover (order item 5) 7 GM960 Bolt, Rocker Arm Shaft 8 GM967 Rocker Arm (No Lobe) 9 GM968 Spring, Rocker Arm Shaft 0 GM969 Rocker Arm (with lobe) GM96 Rocker Arm Shaft GM96 Stud (M8 x 5) (not shown) GM965 Gasket, Cylinder Head Rear Block Off Plate GM966 Gasket, Cylinder Head GM96 Cylinder Head Rear Block Off Plate GM96 Bolt, Hex Head (M8 x ) (not shown) 5 GM968 Seal, PCV Valve TP-690 9/8
: Cylinder Head Assembly (Part ) 8 5 6 7 9 6 7 0 8 KO78 GM965 Bolt, Cylinder Head 0 GM966 Washer, Cylinder Head 0 GM9660 Keeper, Valve 6 GM966 Cap, Exhaust Valve Spring 5 GM966 Spring, Valve 8 6 GM966 Seal, Valve 8 7 GM966 Seat, Valve Spring 8 8 GM9659 Cap, Intake Valve Spring 9 GM9658 Sleeve, Spark Plug 0 GM9657 Seal, Spark Plug Sleeve GM9650 Valve, Intake GM969 Valve, Exhaust GM965 Head, Cylinder (includes valve seats) GM965 Bracket, Clip (not shown) GM9655 Pin, round (B8 x ) (not shown) 6 GM967 Stud, Manifold 8 7 GM968 Nut w/washer 8 8 GM9656 Plug, Oil galley (/8 in. NPT) TP-690 9/8 5
: Cylinder Block Assembly (Part ) 8 6 9 5 5 KO79 GM967 Pin, Locating (B8 x 8) GM9666 Pin, Locating (B0 x ) GM9656 Plug, Oil galley (/8 in. NPT) GM950 Main Bearing Shell Kit 5 5 GM95 Thurst Plate Kit 6 GM9665 Plug (/8 in. NPT) 8 GM967 Cylinder Block 9 GM967 Pin, Dowel 6 TP-690 9/8
: Cylinder Block Assembly (Part ) 9 8 0 7 5 6 KO87 GM967 Oil Seal, Crankshaft Rear GM969 Plate, Oil Seal Closure GM969 Bolt, Hex Head w/washer (M8 x ) (not shown) 5 GM968 Gasket, Timing Chain Housing GM968 Oil Seal, Timing Chain Cover 5 GM9678 Cover, Timing Chain Cover 5 GM9679 Pin, Round (B6 x 6) (not shown) 5 GM9795 Bolt, Hex Head w/washer (M6 x 0) (not shown) 6 5 GM9680 Bolt, Hex Head w/washer (M6 x 5) (not shown) 5 6 GM9677 Gasket, Timing Chain Housing 7 GM9675 Housing, Timing Chain 7 GM9676 Bolt, Hex Head w/washer (M8 x 6) (not shown) 7 GM9757 Bolt, Hex Head w/washer (M8 x 0) (not shown) 8 GM9688 Bracket, Ignition Coil 8 GM975 Bolt, Hex Head w/washer (M8 x 0) (not shown) 9 GM9690 Gasket, Rear Oil Seal Closure 0 GM9686 Cover, Fuel Pump 0 GM9676 Bolt, Hex Head w/washer (M8 x 6) (not shown) 0 GM975 Bolt, Hex Head w/washer (M8 x 0) (not shown) GM9685 Gasket, Fuel Pump Cover GM968 Bracket, Speed Sensor GM968 Clip, Speed Sensor Harness TP-690 9/8 7
5: Crankshaft Assembly 6 5 7 8 9 7 0 KO70 GM970 Bolt, Flywheel 6 GM9699 Flywheel w/ Ring Gear GM9698 Crank Shaft GM95 Piston Ring Kit 5 GM9696 Piston 6 GM9707 Pin, Piston 7 GM9697 Bearing, Rod (Std) 8 GM9705 Rod, Connecting 9 GM9706 Key, Wooddruff (5x7.5x9) 0 GM970 Gear, Crankshaft Timing GM970 Pulley & Damper Set, Crankshaft GM970 Bolt, Crankshaft Pulley GM9700 Pin, Locating (B8 x ) 8 TP-690 9/8
6: Camshaft Assembly 7 8 9 5 6 KO7 GM970 Camshaft GM97 Bolt, Camshaft (not shown) GM97 Washer, Plain (not shown) GM97 Washer, Lock (not shown) GM97 Gear, Camshaft Timing GM97 Thrust Plate, Camshaft GM9676 Bolt, Hex Head w/washer (M8 x 6) (not shown) GM976 Damper, Timing Chain (Set) GM977 Bolt, Hex Head w/washer (M8 x 6) (not shown) 5 GM970 Chain, Timing 6 GM978 Tensioner, Timing Chain Set 6 GM979 Bolt, Hex Head w/washer (M8 x 0) (not shown) 7 GM9708 Rod, Push 8 8 GM9709 Lifter, Hydraulic 8 9 GM97 Key, Woodruff (5x7.5x9) TP-690 9/8 9
7: Oil Pump, Oil Strainer and Oil Pan KO78 GM97 Strainer, Oil Assembly GM97 Gasket, Oil Strainer (not shown) GM9676 Bolt, Hex Head Assembly w/washer (M8 x 6) (Strainer -Engine Block) (not shown) GM975 Bolt, Hex Head Assembly w/washer (M8 x 0) (Oil Pump -Strainer) (not shown) GM976 Pan, Oil GM978 Bolt, Hex Head (M8 x ) (not shown) 6 GM979 Washer, Lock (not shown) GM970 Washer, Flat (not shown) GM97 Nut, Hex Type (M8) (not shown) GM97 Pump, Oil Assembly GM97 Bolt, Hex Head Assembly w/washer (M8 x 5) (Oil Pump -Engine Block) (not shown) GM97 Shaft, Oil Pump Drive GM97 Bolt, Hex Head w/washer (M8 x 5) (not shown) 0 TP-690 9/8
8: Oil Dipstick and Oil Filter 6 5 GM969 Filter, Oil GM978 Adapter, Oil Filter GM979 Bolt, Hex Head (M8 x 5) (not shown) GM970 Tube, Dipstick Assembly GM97 Nut, Hex Type (M6) (not shown) GM975 Dipstick, Oil 5 GM976 Gasket, Oil Filter Adapter 6 GM977 Switch, Oil Pressure TP-690 9/8
9: Intake System Bracket 5 KO77 GM97 Intake Manifold, Upper GM97 Gasket, Throttle Body (not shown) GM976 Intake Manifold, Lower GM977 Clip (not shown) GM978 Screw, Socket Head Cap (not shown) GM97 Bracket, Manifold (not shown) GM9676 Bolt, Hex Head w/washer (M8 x 6) (not shown) GM975 Gasket Set, Intake 5 GM979 Bracket, Intake 5 GM9750 Screw, Socket Head Cap (M6 x 6) (not shown) TP-690 9/8
0: Exhaust System 5 KO77 GM975 Manifold, Exhaust GM967 Stud, Intake/Exhaust Manifold GM968 Nut w/washer Intake/Exhaust Manifold GM975 Gasket, Exhaust Manifold Outlet 5 GM975 Gasket, Intake/Exhaust Manifolds TP-690 9/8
: Cooling System (Part ) KO78 GM975 Belt, Drive GM9760 Pulley, Drive Belt GM976 Bolt, Hex Head w/washer (M6 x 6) (not shown) GM9756 Water Pump Assembly GM9757 Bolt, Hex Head w/washer (M8 x 0) (not shown) GM9758 Bolt, Hex Head w/washer (M8 x 65) (not shown) GM979 Washer, Lock (not shown) GM970 Washer, Flat (not shown) GM97 Nut, Hex (M8) (not shown) GM9759 Stud (M8 x 60) (not shown) - Gasket, Water Pump (order water pump) TP-690 9/8
: Cooling System (Part ) 9 7 0 8 5 6 KO88 GM977 Coolant Inlet Connector GM9757 Bolt, Hex Head w/washer (M8 x 0) (not shown) GM977 Gasket, Cylinder Head Block Off Plate GM9770 Plate, Cylinder Head Coolant Block Off GM975 Bolt, Hex Head w/washer (M8 x 0) (not shown) GM9765 Housing, Thermostat GM9689 Bolt, Hex Head w/washer (M8 x 0) (not shown) 5 GM976 Thermostat 6 GM976 Cover, Thermostat Housing 6 GM976 Stud (M8 x 0) (not shown) 6 GM979 Washer, Lock (not shown) 6 GM970 Washer, Flat (not shown) 6 GM97 Nut, Hex (M8) (not shown) 7 GM9769 Gasket, Coolant Bypass Cover 8 GM9766 Gasket, Thermostat Housing 9 GM977 Gasket, Inlet Connector 0 GM9767 Plate, Cooling Sys. Bypass Closure 0 GM9768 Stud (M8 x 0) (not shown) 0 GM97 Nut, Hex Type (M8) (not shown) TP-690 9/8 5
: Starter and Alternator KO76 GM977 Starter Assembly GM978 Bracket, Alternator Adjustment GM978 Bolt, Hex Head w/washer (M8 x 5) (not shown) GM978 Bolt,Hex Head w/washer (M0x.5x75) (not shown) GM9775 Alternator, Battery Charging GM9776 Nut, Hex Type (M0) (not shown) GM9777 Washer, Flat (not shown) GM9778 Washer, Lock (not shown) GM9779 Bracket, Alternator GM9780 Bolt, Hex Head w/washer (M0 x 0) (not shown) GM978 Bolt, Hex Head Assembly w/washer (M0x.5x5) (Alternator -Engine Block) (not shown) 6 TP-690 9/8
: Electrical System, RCL Engine Wiring Harness KO7 RCL GM9786 Coil, Ignition GM9787 Bolt, Hex Head w/washer (M6 x 50) (not shown) GM9788 Washer, Flat (not shown) GM97 Nut, Hex Type (M6) (not shown) GM9785 Plug, Spark GM9789 Wire Set, Ignition set GM0985 Harness, Engine Wiring See 6: Fuel System and Miscellaneous for Model 0RCL/8RCLB, 5-6CCL TP-690 9/8 7
5: Engine Sensors KO75 RCL GM9796 Sensor, Speed (Crankshaft position) GM9797 Bolt, Hex Head w/washer (M6 x ) (not shown) GM9790 Sensor, Coolant Temperature GM979 Sensor, TMAP (RCL) GM9795 Bolt, Hex Head w/washer (M6 x 0) (not shown) GM00 Sensor, Oxygen (HEGO) 0RCL/8RCLB, 5-6CCL GM9796 Sensor, Speed (Crankshaft position) GM9797 Bolt, Hex Head w/washer (M6 x ) (not shown) GM9790 Sensor, Coolant Temperature GM965 Sensor, TMAP (0RCL/8RCLB) GM9795 Bolt, Hex Head w/washer (M6 x 0) (not shown) GM00 Sensor, Oxygen (HEGO) 8 TP-690 9/8
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6: Fuel System and Miscellaneous, RCL 6 0 6 9 5 7 8 5 7 8 8 7 6 9 5 6 9 0 5 0 5 5 7 GM877--J 0 TP-690 9/8
6: Fuel System and Miscellaneous, RCL 8050009 Clamp, Spring GM877 Backplate,.L, D ALT. GM879 Adapter, Flywheel,.L, D ATL. 5 GM879 Fuel Hose Bracket 6 GM879 Bracket, Fuel Control 7 GM8795 Adapter, ETB to Intake Manifold 8 GM888 Socket Head Cap Screw (M6 x x 0) 9 GM888 Socket Head Cap Screw (M6 x x 75) 0 GM888 Socket Head Cap Screw (# - x.5 in.) GM8879 Valve, Fuel Control GM8880 Gasket, ETB GM888 Body, Elect. Throttle 5 GM888 Adapter, Mixer 6 GM888 O-Ring 7 GM8885 Gasket, Mixer 8 GM8886 Mixer 9 GM8808 Hose, Fuel Control to Intake Manfold 0 GM88 Regulator, Dual Fuel GM995 ECM GM8955 Ring, Quad 5 GM97005 - Hose,.L N/A DFR Vac. 6 M5A -08-80 Washer, Plain 8. ID x 6.0 OD 7 M5A -0-80 Washer, Plain 0.5 ID x 0.0 OD 8 M9-0800 -8 Screw, Hex Cap 6 9 M9-080 -60 Screw, Hex Cap 0 M9-0806 -60 Screw, Hex Cap (M8 x 6) M96-000 -60 Screw, Hex Cap M96-00 -8 Screw, Hex Cap GM008 Valve, shutoff (/8-8 NPT) S -0 Elbow, street (90 x /8 in. NPTF) 5 X-75-0 Plug, pipe (/8 in. NPTF) 6 X -0 - Pipe (/8 in. NPT x.5 in.) 7 X -0 - Pipe (/8 in. NPT x.5 in.) TP-690 9/8
6: Fuel System and Miscellaneous, RCL 8 6 7 9 6 9 7 8 5 6 0 8 7 9 0 9 5 5 8 0 0 8 7 5 Items not shown:, 6 GM0567-- TP-690 9/8
6: Fuel System and Miscellaneous, RCL 8050009 Clamp, Spring 6 GM008 Valve, Shutoff (/8-8 NPT) GM0560 Harness, Engine,.L N/A GM0567 Bracket, Fuel Controller 5 GM0567 Hose, Fuel Control Valve 6 GM0567 Hose, Fuel VAC 7 GM877 Backplate,.L, D ALT 8 GM879 Adapter, Flywheel,.L,D ALT 9 GM8779 Engine, GW.L, Long Block 0 GM879 Bracket, Fuel Hose Support GM8795 Adapter, ETB To Intake Manifold GM888 Shcs,M6xx0mm GM888 Shcs, M6 x x75 mm GM888 Shcs, # - x.5 in. Lg 5 GM8880 Gasket, ETB 6 GM888 Body, Elec. Throttle Assy. 7 GM888 Adapter, Mixer 8 GM888 O-Ring 9 GM8885 Gasket, Mixer 0 GM8886 Mixer, ERC GM88 Dual Fuel Regulator, ERC GM8955 Ring, Quad GM969 Filter,.L Oil GM957 Bracket, Support LH 5 GM958 Bracket, Support RH 6 GM995 Nameplate 7 GM9696 Fuel Control Valve,.L Turbo, ERC 8 GM97005 - Hose,.L N/A DFR VAC. 9 GM995 ECM,.L N/A. ERC 0 M5A -08-80 Washer, Plain 8. ID x 6 OD M5A -0-80 Washer, Plain 0.5 ID x 0 OD M9-0800 -8 Screw, Hex Cap 6 M9-080 -60 Screw, Hex Cap M9-0806 -60 Screw, Hex Cap 5 M96-000 -60 Screw, Hex Cap 6 M96-00 -8 Screw, Hex Cap 7 S -0 Elbow, Street (90 x /8 in. NPTF) + Vibra 8 X-75-0 Plug, Pipe (/8 in. NPTF) 9 X -0 - Pipe (/8 in. NPT x.5 in.) 0 X -0 - Pipe (/8 in. NPT x.5 in.) X -68-6 Cable Tie 8 TP-690 9/8
6: Fuel System and Miscellaneous, 0RCL/8RCLB, 5-6CCL 70 69 6 6 5 65 7 57 9 8 8 5 0 8 7 68 6 6 69 8 5 0 9 0 9 0 7 8 6 6 8 9 Harness Not shown 8 5 9 7 9 5 5 7 56 7 8 5 58 50 5 7 66 67 6 6 9 55 6 59 7 5 GM889--J TP-690 9/8
6: Fuel System and Miscellaneous, 0RCL/8RCLB, 5-6CCL 8050006 Clamp, /6 Hose Spring 8050009 Clamp, 5/6 Hose Spring GM0058 Spark Plug,.L Turbo GM0059 Wires,.L Turbo Spark Plug (Set) 5 GM008- Sleeve, Heat Shield 6 GM877 Backplate,.L, D Alt. 7 GM879 Adapter, Flywheel,.L, D Alt. 8 GM8795 Adapter, Electronic Throttle Body (ETB) to intake 9 GM888 Screw( M6x.0x0mm) 6 0 GM8880 Gasket - ETB to ETB Adapter GM888 Electronic Throttle Body GM8957 Adapter, Turbo - Turbo to Exhaust Maniflod GM956 Turbo,.L GM96 Stand-off, GW.L Oil Cooler Adapter 5 GM969 Filter,.L Oil 6 GM9 Mixer 7 GM95 Stud, M8 x x - Turbo to Turbo Adapter 8 GM95 Engine,GW.,Turbocharge 9 GM95 Line, Turbo Oil Feed 0 GM95 Line, Turbo Oil Return GM9857 Gasket, Turbo Oil Return Flange GM9860 Gasket - Mixer GM9865 Nut, M8 x.5 Flange - Turbo to Turbo Adapter GM90 Fitting, M to JIC - 7 Deg. 5 GM90 Fitting, /8 NPT to JIC - 7 Deg. 6 GM957 Bracket, Support LH 7 GM958 Bracket, Support RH 8 GM969 Fitting, M8 to JIC -8 7 Deg. 9 GM9 Harness, GW.L Turbo Wiring 0 GM958 Adapter, Mixer to Turbo Compressor Inlet GM965 Screw, Hex Cap,/-0 x.65 Lg GM980 Gasket - O-Ring - Mixer Adapter to Turbo GM95 P-Clip,.L Turbo Oil Feed Line 5 GM979 Adapter, GW.L Oil Cooler 6 GM95 Spacer,.L Turbo Oil Feed Line 7 GM9695 Bracket -.L Turbo Fuel Controller 8 GM9696 Fuel Control Valve (FCV) 9 GM9698 Dual Fuel Regulator (DFR) 0 GM9699- Hose,.L Turbo FCV to Mixer Vacuum GM9699- Hose,.L Turbo FCV to DFR Vacuum GM97005- Hose,.L Turbo DFR Breather GM98908 Bracket -.L Turbo Coil Mounting GM9896 Coil,.L Turbo Standard Tower 5 GM9909 Fasteners - SHCS 6 GM996 ECM,.L Turbo 50 M5-0-80 Washer, Plain 7 M5A-05-80 Washer, Plain 8 8 M5A-06-80 Washer, Plain 9 M5A-08-80 Washer, Plain 8. ID x 6.0 OD 5 M9-06050-9 Screw, Hex Cap M6 x.00 x 50 Lg. 5 M9-0800-8 Screw, Hex Cap M8 x.5 x 0Lg. 6 5 M9-0606-60 Screw, Hex Cap 5 M9-080-60 Screw, Hex Cap (Ground Bolt for harness) 55 M9-0805-60 Screw, Hex Cap (FCV Bracket Mounting Bolts) 56 M9-05-50 Nut, Hex 5mm 57 M9-06-6 Nut, Hex 6mm 58 M96-000-60 Screw, Hex Cap 59 M96-00-8 Screw, Hex Cap 6 X-7- Clamp, muffler,.6 in. GM9855 Gasket, Turbine Inlet (not shown) 6 GM008 Valve, shutoff (/8-8 NPT) 6 GM0699 Plate, temperature sender 65 GM070 Gasket, temperature sender 66 GM058 Adapter, oil pressure 67 S -68 Washer, plain 68 S -0 Elbow, street (90 x /8 in. NPTF) + Vibra 69 X-75-0 Plug, pipe (/8 in. NPTF) 70 X-75- Plug, pipe (/ in. NPTF) 7 X-75- Plug, pipe (/8 in. NPTF) 7 X -0 - Pipe (/8 in. NPT x.5 in.) 7 X -0 - Pipe (/8 in. NPT x.5 in.) TP-690 9/8 5
TP-690 9/8b E 0, 06, 08 by Kohler Co. All rights reserved. KOHLER CO., Kohler, Wisconsin 50 Phone 90-57-, Fax 90-59-66 For the nearest sales/service outlet in the US and Canada, phone -800-5- KOHLERPower.com