tp5394 5CKMR - Bryant RV Services
 KOHLER.
Service
RV/Mobile Generator Sets
4 в
Na
-
Models:
4CKM
4CFKM
5CKM
4CKMR
4CFKMR
5CKMR
© 9001
KOHLER.
EN GENERATORS
INTERNATIONALLY REGISTERED
POWER SYSTEMS Pasos ra
Table of Contents
SUBJECT PAGE SUBJECT PAGE
Safety Precautions and Instructions ...... | CoolingSystem .......................... 3-6
Introduction ..........2.0.200 0000 sauce use i Ignition System. .......... iL... 3-7
бегисе Азы !апсе ....................... Description ........0200200000 000 e san seen 0 3-7
Spark Plugs ...........eeeerrecrerveoe. .. 3-8
Section 1. Specifications ................ 1-1 TIMING «eee eee eee eee es 3-9
General Specifications Ce ee eee eee 1-1 Gasoline Fuel System 11 3-11
Engine LL 2 a a 4 4 8 0 8 8 4 8 4 0 0 0 4 ee 0 1 1 4 0 eee 1-2 Description LL 3-11
Generator ................eereeeerrerreo. 1-4 Specification—Gasoline ................... 3-11
Accessories ....... o.oo in... 1-8 Gasoline Fuel Filter ....................... 3-11
Remote Panels ........................... 1-8 Gasoline Carburetor ...................... 3-12
Remote Start/Stop Panel .................. 1-8 DEeSCHPtiON «oven 3-12
Remote Start/Stop Panel With Hourmeter.... 1-8 Gasoline Choke ......................0 3-13
Wiring Harnesses ........................ 1-8 LP Fuel System ..............e.eeeeereoo. 3-14
Exhaust Systems ......................... 1-8 Description ..................eeerceereco. 3-14
LP Conversion Kit ........................ 1-8 Specification—LP Fuel .................... 3-15
Below-Floor Mounting Trays ............... 1-8 LP Gas System Component Description
and Adjustment Procedures .............. 3-16
Section 2. Operation ..................... 2-1 Electronic Governor ................eeeo_. 3-22
Ргез{ай СпесКкИ®! ........................ 2-1 Air Cleaner ине... 3-22
Controller ........ ccc. 2-1 Battery «o.oo a 3-23
Starting Procedure ....................... 2-2 Battery Charging (if equipped) .............. 3-93
Stopping Procedure ...................... 2-2 Cleaning Battery ................eoeeeeeo 3-24
Anti-icing Checking Electrolyte Level ................. 3-24
(For Gasoline Models Only) .............. 2-2 Checking Specific Gravity ................. 3-24
entr Cleaner Prehcal)— 5.5 Cylinder Head Service .................... 3-25
Positive Temperature Coefficient Plate Cleaning Head Deposits ................... 3-25
Anti-icing System (Anti-icing Plate) ........ 2-3 Adjusting Valve Clearance ................. 3-25
Automatic Deicing System Wattage Requirements ................e... 3-26
(Combustion and Preheater) .............. 2-3 Generator Service ............00....…. 3-27
Circuit Protection ....................... 2-4 General ...... eee eee eee 3-27
Engine Safety Shutdowns ................. 2-5 Storage Procedure ....................... 3-27
Low Oil Pressure Shutdown ................ 2-5
Overspeed Shutdown ..................... 2-5 Section 4. General Troubleshooting ...... 4-1
nels .................. 2- ,
Optional Rete рае о 55 Sections. Controller Troubleshooting .... 4
Remote Start Panel With Hourmeter ........ 2-6 9 eee tee J
Starting .............e_eerecorrrererre00. 5-2
Section 3. Scheduled Maintenance ....... 3-1 Running ECE EEE EEE EERE 5-3
GENETAl «eet eee 3-1 Electronic Governor ........................ 5-3
Service Schedule ........................ 3-2 Anti-lcing TN 5-4
Lubrication System ..................ee... 3-3 Battery Charging ........................ « 54
Description ..............ee.ee00000rereo 3-3 Stopping ....................000000 00 5-5
Oil Check ............. 2.2.2.0... 0... 3-3 Automatic Safety Shutdowns .............. 5-6
Addie oie Cee RR se Section 6. Generator /Controiler
AIG MH eee ee Troubleshooting ............... concn. 6-1
OifChange .................cieenn 3-5 Controller Circuit Board ................... 6-1
QilFilter RG 3-6
TP-5394 12/94 Table of Contents
SUBJECT
Section 7. Component Testing and
Adjustment ..........._.eoeereeenecuecdor.
Theory of Operation, Single-Phase, 4-Lead
Generators with PowerBoost™ ШЕ ........
Theory of Operation, Three-Phase
(12-Lead econnectable) Generators
vit PowerBoostM V ....................
Generator Troubleshooting ................
Separate Excitation ......................
PowerBoost* INE Voltage Regulator ........
PowerBoost™ IlIE Voltage Regulator Test
Procedure .................... e...
PowerBoost" IIIE Voltage
Regulator Adjustment ...................
PowerBoost™ V Voltage Regulator Test ....
PowerBoost™ V Voltage
Regulator Adjustment ................—.—..
Controller Circuit Board ...................
Engine/Generator Components ............
Rotor ..........o oeeeceerrrrrorono o econ.
Stator, 1 Phase ..............eoe—erevveoo
Checking Stator Continuity and Resistance ..
Stator, 3 Phase (12 Lead) .................
Table of Contents
SUBJECT
Brushes .....1111111 11 LL LR a eat a ae
Electronic Governor...............…..…..…
Section 8. Disassembly/Reassembly ....
Disassembly ............................
Reassembly ............................
Section 9. Wiring Diagrams .............
Four-Lead Reconnectable
(Single-Phase) Generator Sets .........
Twelve-Lead Reconnectable
(Three-Phase) Generator Sets ..........
Generator Set Wiring Diagrams ...........
Appendix A. Glossary of Abbreviations ...
Appendix B. Common Hardware
Application Guidelines ................
Appendix C. Common Hardware
ntification ................. ool
Appendix D. General Torque
Specifications .........e.e.——c_eoeerrrneavoo
TP-5394 12/94
Safety Precautions and Instructions
A generator set, like any other electromechanical
device, can pose potential dangers to life and limb if
improperly maintained or imprudently operated. The
best way to prevent accidents is to be aware of the
potential dangers and to always use good common
sense. In the interest of safety, some general
precautions relating to the operation of a generator set
follow. Below are some general precautions relating to
the operation of a generator set. SAVE THESE
INSTRUCTIONS.
A DANGER
Danger indicates the presence of a hazard that will
cause severe personal injury, death, or substantial
property damage if the danger is ignored.
A WARNING
Warning indicates the presence of a hazard that can
cause severe personal injury, death, or substantial
property damage if the warning is ignored.
A CAUTION
Caution indicates the presence of a hazard that will or
can cause minor personal injury or property damage If
the caution is ignored.
NOTE
Note communicates installation, operation, or
maintenance information that is important but not
hazard related.
Safety decals are affixed to the generator set in
prominent places to advise the operator or service
technician of potential hazards. The decals are
reproduced here to improve operator recognition. Fora
further explanation of decal information, refer to the
safety precautions throughout this manual. Before
operating or servicing the generator set, be sure you
understand the messages of these decals. Replace
decals if missing or damaged.
TP-5394 12/94
Accidental Starting
WARNING
Pe
Accidental starting.
Can cause severe injury or death.
Disconnect battery cables before working on
generator set (negative lead first and reconnect it
last).
Accidental starting can cause severe injury or
death. Disconnect battery cables (remove negative
lead first and reconnect it last) to disable generator set
before working on any equipment connected to
generator set. The generator set can be started by the
remote start/stop switch unless this precaution is
followed.
Safety Precautions and Instructions |
Battery
A WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Use protective goggles and clothes. Battery acid can
cause permanent damage to eyes, burn skin, and eat
holes in clothing.
Sulfuric acid in batteries can cause severe injury or
death. Sulfuric acid in battery can cause permanent
damage to eyes, burn skin, and eat holes in clothing.
Always wear splash-proof safety goggles when working
around the battery. If battery electrolyte is splashed in
the eyes or on skin, immediately flush the affected area
for 15 minutes with large quantities of clean water. Seek
immediate medical aid in the case of eye contact. Never
add acid to a battery once the battery has been placed in
service. This may result in hazardous spattering of
electrolyte.
Explosion can cause severe injury or death. Battery
gases can cause an explosion. Do not smoke or permit
flame or spark to occur near a battery at any time,
particularly when it is being charged. Avoid contacting
terminals with tools, etc., to prevent burns and sparks
that could cause an explosion. Remove wristwatch,
rings, and any other jewelry before handling battery.
Never connect negative (—) battery cable to positive (+)
connection terminal of starter solenoid. Do not test
battery condition by shorting terminals together. Sparks
could ignite battery gases or fuel vapors. Ventilate any
compartment containing batteries to prevent
accumulation of explosive gases. To avoid sparks, do
not disturb battery charger connections while battery is
being changed. Always turn battery charger off before
disconnecting battery connections. Remove negative
lead first and reconnect it last when disconnecting
battery.
II Safety Precautions and Instructions
Engine Backfire/Flash Fire
A WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flame or spark to occur
near fuel or fuel system.
A flash fire can cause severe injury or death. Do
not smoke or permit flame or spark to occur near
carburetor, fuel line, fuel filter, fuel pump, or other
potential sources of spilled fuel or fuel vapors. Use a
suitable container to catch all fuel when removing fuel
line or carburetor.
A sudden backfire can cause severe injury or death.
Do not operate with air cleaner removed.
TP-5394 12/94
Exhaust System
A WARNING
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Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and
routinely inspected.
Carbon monoxide can cause severe hausea,
fainting, or death. Never operate the generator set
inside a building unless the exhaust gas is piped safely
outside. Never operate in any area where exhaust gas
could accumulate and seep back inside an occupied
building or vehicle. Be careful when parking your
vehicle to avoid obstructing the exhaust outlet. The
exhaust gases must discharge freely to prevent carbon
monoxide from deflecting into the vehicle. Avoid
breathing exhaust fumes when working on or near the
generator set. Carbon monoxide is particularly
dangerous because it is an odorless, colorless,
tasteless, nonirritating gas that can cause death if
inhaled for even a short period of time.
TP-5394 12/34
Carbon monoxide can cause severe nausea,
fainting, or death. Carbon monoxide is a poisonous
gas which is present in exhaust gases. Carbon
monoxide poisoning symptoms include but are not
limited to the following:
e Light-headedness, dizziness
e Physical fatigue, weakness in joints and muscles
e Sleepiness, mental fatigue, inability to concentrate
or speak clearly, blurred vision
e Stomachache, vomiting, nausea
If any of these symptoms is experienced and carbon
monoxide poisoning is possible, affected persons
should seek fresh air immediately. They should remain
active. They should not be permitted to sit, lie down, or
fall asleep. Alert others to the situation. If the condition
of affected persons does not improve within minutes of
breathing fresh air, they should seek medical attention.
Carbon monoxide can cause severe nausea,
fainting, or death. Install exhaust system tail pipe so
discharged exhaust gases will not be drawn into vehicle
interior through windows, doors, air conditioners, etc.
Do not use flexible tail piping since this type could crack
and allow lethal exhaust fumes to enter the vehicle.
Carbon monoxide can cause severe nausea,
fainting, or death. In addition to routine inspection of
the exhaust system, install a carbon monoxide detector.
Consult your coach builder or dealer for installation of
approved detectors. Inspect your detector before each
generator set use.
Safety Precautions and Instructions Ill
Fuel System
A WARNING
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Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing,
and using fuels.
Explosive fuel vapors can cause severe injury or
death. All fuels are highly explosive in a vapor state.
Use extreme care when handling and storing fuels.
Store fuel in a well-ventilated area away from
spark-producing equipment and out of the reach of
children. Never add fuel to the tank while the engine is
running since spilled fuel may ignite on contact with hot
parts or from ignition spark. Do not smoke or permit
flame or spark to occur near potential sources of spilied
fuel or fuel vapors. Keep fuellines and connections tight
and in good condition. Do not replace flexible fuel lines
with rigid lines. Flexible sections are used to avoid
breakage due to vibration. If any fuel leakage, fuel
accumulation, or electrical sparks are noted, DO NOT
OPERATE GENERATOR SET. Repair systems before
resuming generator set operation
Explosive fuel vapors can cause severe injury or
death. Take additional precautions when using the
following fuels:
Gasoline—Store gasoline only in approved red
containers clearly marked GASOLINE.
Propane (LP)—Adequate ventilation is mandatory.
Propane is heavier than air; install gas detectors low in
room. Inspect detectors often.
IV Safety Precautions and Instructions
Explosive fuel vapors can cause severe injury or
death. Spilled fuel can cause an explosion. Use a
container to catch fuel when draining fuel system. Wipe
up all spilled fuel after draining system.
Explosive fuel vapors can cause severe injury or
death. Fuel leakage can cause an explosion. Check LP
vapor gas fuel system for leakage using a soap-water
solution with fuel system test pressurized to 6-8 ounces
per square inch (10-14 inches water column). Do not
use test solutions that contain ammonia or chlorine,
since the soap will not bubble for an accurate leakage
test.
Explosive fuel vapors can cause severe injury or
death. Fuel leakage can cause an explosion. Check LP
liquid withdrawal gas fuel system for leakage using a
soap-water solution with fuel system test pressurized
not less than 90 psi (621 kPa). Do not use test solutions
that contain ammonia or chlorine, since the soap will not
bubble for an accurate leakage test.
Hazardous Noise
A CAUTION
Hazardous noise.
Can cause loss of hearing.
Never operate generator set without a muffler or
with a faulty exhaust system.
TP-5394 12/94
Hazardous Voltage/
Electrical Shock
A WARNING
Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards and
electrical enclosures in place.
A WARNING
Hazardous voltage.
Backfeed to utility system can cause severe
injury, death, or property damage.
Do not connect to any building electrical system
without connecting through an approved device
and after building main switch is open.
Hazardous voltage can cause severe Injury or
death. Whenever electricity is present, there is the
hazard of electrocution. Open main circuit breakeron all
power sources before servicing equipment. Electrically
ground the generator set and electrical circuits when in
use. Never come into contact with electrical leads or
appliances when standing in water or on wet ground, as
the chance of electrocution is increased under such
conditions.
TP-5394 12/94
Hazardous voltage can cause severe injury or
death. Short circuits can cause bodily injury and/or
equipment damage. Do not contact electrical
connections with tools or jewelry while adjustments are
made. Remove wristwatch, rings, and jewelry that can
cause short circuits.
Hazardous voltage can cause severe injury or
death. High voltage is present at the heat sink of the
voltage regulator. Do not touch voltage regulator heat
sink when testing or electrical shock will occur.
(PowerBoost™ , PowerBoost™ Ill, and PowerBoost™ V
voltage regulator models only.)
Hazardous backfeed voltage can cause severe
injury or death. Do not connect generator set to any
building/campground electrical system without
connecting through an approved device and after
building/campground main switch is open. Backfeed
connections can cause serious injury or death to utility
personnel working to repair a power outage and/or
personnel in the vicinity. Unauthorized connection to
utility electrical system may be unlawful in some states
and/or localities. A transfer switch must be installed to
prevent interconnection of generator set power and
other sources of power.
Heavy Equipment
A WARNING
Unbalanced weight.
Improper lift can cause severe injury or death
or equipment damage.
Do not use lifting eyes.
Use a sling under skid to lift generator set.
Safety Precautions and Instructions V
Hot Parts
A WARNING
TA
E
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on generator set until it is allowed to
cool.
Hot parts can cause severe injury or death. Do not
touch hot engine parts. An engine gets hot while running
and exhaust system components get extremely hot.
Fire can cause severe injury or death. Hot exhaust
system can ignite adjacent combustible materials. Do
not locate electrical wiring, fuel lines, or combustible
material above the exhaust muffler. Exercise caution
when parking your vehicle to prevent grass fires started
by exhaust system and hot exhaust gases.
Fire can cause severe injury or death. Hot generator
set can ignite debris in compartment. Keep the
compartment and generator set clean and free of debris
and combustible materials to minimize chances of fire.
Do not block fuel/oil drain opening in generator set
mounting tray. Cut a corresponding hole in the
subflooring for drain opening if subflooring is used.
VI Safety Precautions and Instructions
Moving Parts
A WARNING
Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards and
electrical enclosures in place.
A WARNING
ко
Rotating parts.
Can cause severe injury or death.
Do not operate generator set without all guards,
screens, and covers in place.
Flying projectiles can cause severe injury or death.
Retorque all crankshaft and rotor hardware after
servicing. Do not loosen crankshaft hardware or rotor
thrubolt when making adjustments or servicing
generator set. Rotate crankshaft manually in a
clockwise direction only. Loose hardware can result
from turning crankshaft bolt or rotor thrubolt
counterclockwise. Personal injury can occur from loose
hardware causing hardware or pulley to come off engine
when generator set is running.
Exposed moving parts can cause severe injury or
death. Keep hands, feet, hair, clothing, and test leads
away from belts and pulleys when generator set is
running. Replace guards, screens, and covers before
operating generator set.
TP-5394 12/94
Notes
NOTICE
This generator set has been rewired from its
nameplate voltage to: |
246242
NOTICE
This is a positive terminal only.
Do not attach negative lead!
NOTE
Affix notice to generator set after reconnecting to a
voltage different than the nameplate. Order voltage
reconnection decal 246242 from authorized service
distributors/dealers.
NOTE
Hardware Damage! Engine and generator set may
use both American Standard and metric hardware. Use
the correct size tools to prevent rounding of bolt heads
and nuts.
TP-5394 12/94
NOTE
When replacing hardware, do not substitute with
inferior grade hardware. Screws and nuts are
available in different hardness ratings. American
Standard hardware uses a series of markings and
metric hardware uses a numeric system to indicate
hardness. Check markings on bolt head and nuts for
identification.
NOTE
This generator set does not comply with United
States Coast Guard (U.S.C.G.) requirements and
must not be used for marine applications. Use only
generator sets specified for marine use in marine
installations. U.S.C.G. Regulation 33CFR183 requires
a generator set to be ignition protected when used in a
gasoline-fueled environment.
NOTE
Do not tee into fuel injected fuel systems. Use a two dip
tube arrangement for fuel supply. Consult an authorized
service dealer for further fuel system installation
information.
NOTE
Do not leave generator sets equipped with the optional
swing-down tray in the tilted position for any extended
period (30 minutes or more). Always place unit in the
normal mounting position when not performing service.
Safety Precautions and Instructions VII
Introduction
Your vehicle is equipped with a dependable Kohler
alternating-current generator set. Service requirements
of the generator set are minimal but it is important to
perform the required services at the prescribed
intervals. Please take a few moments to read through
this manual then carefully follow all service
recommendations to keep your set in top condition.
Keep this manual in your vehicle for future reference.
See Figure 1-1 and Figure 1-2 to identify and locate
major components.
Service Assistance
Check the yellow pages of your telephone directory
under the heading GENERATORS-ELECTRIC for
Kohler Generator Service Dealers/Distributors in your
area.
KOHLER CO., Kohler, Wisconsin 53044
Phone: 414-565-3381
FAX: 414-459-1646 (North American Sales)
414-459-1614 (International)
For sales and service in U.S.A. and Canada
Phone: 1-800-544-2444
TP-5394 12/94
Provide MODEL, SPECIFICATION, SERIAL, and
ENGINE numbers from the generator nameplate to
receive current parts and information for your generator
set.
Model No.
Specification No.
Serial No.
Engine No.
Introduction |
Section 1. Specifications
General Specifications
ACKM/ACKMR (60 Hz) 5CKM/5CKMR (60 Hz)
24.83 x 18.46 x 13.98
(631 x 469 x 355)
24.83 x 18.46 x 13.98
Dimensions—L x W x H—in. (mm.) (631 x 469 x 355)
Weight—Ibs. (Kg) 258 (117) 268 (121.5)
Air requirements:
Combustion—cfm (m3/min.) 20 (0.6) 20 (0.6)
Cooling—cfm (m#/min.) 340 (9.6) 340 (9.6)
Free air opening—sq. in. (sq. cm) 85 (548) 85 (548)
4CFKM/ACFKMR (50 Hz)
Dimensions —L x W x H—in. (mm) 24.83 x 18.46 x 13.98 (631 x 469 x 355)
Weight—Ibs. (kg) 258 (117)
Air requirements:
Combustion—cfm (m3/min.) 20 (0.6)
Cooling—cfm (m3/min.) 340 (9.6)
Free air opening—sq. in. (sq. cm) 85 (548)
Fuel Consumption Gasoline—gph (Lph)
Load 25% 50% 75% 100%
4CKM/4CKMR (60 Hz) 0.48 (1.8) 0.58 (2.2) 0.70 (2.6) 0.89 (3.4)
4CFKM/4CFKMR (50 Hz) 0.39 (1.5) 0.48 (1.8) 0.59 (2.2) 0.75 (2.8)
5CKM/5CKMR (60 Hz) 0.45 (1.7) 0.58 (2.2) 0.75 (2.8) 1.04 (3.9)
LP gas—gph (Lph)
4CKM/4CKMR (60 HZ) 0.46 (1.7) 0.69 (2.6) 0.77 (2.9) 0.99 (3.8)
4CFKM/4CFKMR (50 Hz) 0.39 (1.5) 0.58 (2.2) 0.65 (2.5) 0.82 (3.1)
5CKM/5CKMR (60 Hz) 0.54 (2.0) 0.80 (3.0) 0.90 (3.4) 1.15 (4.4)
TP-5394 12/94
Specifications 1-1
Below lists some general engine specifications
manual for specific service details.
Engine
. Refer to the appropriate service section and the engine service
ACKMACFKM 5CKM/
4CKMR/4CFKMR 5CKMR
Manufacturer Kohler
Model M18 | M20
Cycle 4
Number cylinders 2
Compression ratio 6.0:1 6.6:1
Displacement—cu. in. (L) 42.18 (0.69) 46.98 (0.77)
Rated horsepower:
60 Hz 8.9 9.5
50 Hz 7.4 7.9
RPM:
60 HZ 1800
50 Hz 1500
Bore—in. (mm) 3.12 (79.25) 3.12 (79.25)
Stroke—in. (mm) 2.75 (69.85) 3.06 (77.72)
Valve material Stellite®
Valve clearance—in. (mm):
Intake
0.003-0.006 (0.076-0.152)
Exhaust
0.011-0.014 (0.279-0.355)
Cylinder block material
Aluminum crankcase with cast iron cylinders (not sleeved)
Cylinder head tightening torque—it. Ibs. (Nm)
15-20 (20-27)
Cylinder head material
Aluminum
Piston rings
2 compression/1 oil
Crankshaft material
Heat treated ductile iron
Bearings, number & type
2, replaceable sleeve
Governor
Electronic
Governor magnetic pickup air gap in. (mm)
0.040 (1.02) 0.005 (0.127)
Lubrication system
Full pressure
Oil capacity (with filter)—qts. (L)
1.5 (1.4) | 2.5 (2.36)
Oil type (API)
SF or SG
Oil pressure—psi (kPa)
30-40 (207-276)
1-2 Specifications
TP-5394 12/94
Engine (Continued)
4CKM/4CFKM/ 5CKM/
ACKMR/ACFKMR 5CKMR
Fuel type:
Gasoline (octane rating)
87 octane unleaded (90 research rating method)
LP vapor gas (inlet pressure)
7-11 in. water column, 4-6 oz. per sq. in.
LP liquid withdrawal (inlet pressure) 50 psi
Fuel pump pressure ratin .
(gasoline models only) 9 2-3.5 psi (14-24 kPa)
Battery voltage 12
Battery ground Negative
Battery recommendation 290 cold cranking amp @ 0° F (—18° C) 55 amp hr.
Spark plug type Kohler part number 52 132 02
Spark plug gap:
Gasoline—in. (mm) 0.025 (0.64)
LP gas—in. (mm) 0.018 (0.46)
Spark plug tightening torque—t. lbs. (Nm) 10-15 (13.6-20)
Ignition system Electronic
Ignition module to magnet air gap 0.008-0.012
Engine firing order 1-2-1
Ignition timing (@ 1800 rpm)—60 Hz
Ignition module controlled
Ignition timing (@ 1500 rpm)—50 Hz
Ignition module controlled
Primary resistance
1.0-1.5 ohms
High tension leads
22,000-42,000 ohms max. per lead
Starter motor
Bendix-drive electric starter motor
Cranking current at 70° F (21° C) 100 amps
Cooling system Air cooled
Intake manifold bolt torque—it. lbs. (Nm) 12.5 (17)
TP-5394 12/94
Specifications 1-3
Generator
charging)
4CKM/ACKMR 5CKM/5CKMR
Rated kW 4 5
Rated kW (LP liquid withdrawal) 4 4.6
Rated kW (LP liquid withdrawal with battery 3.7 4.3
Frequency—Hz
60
Rated voltage
120 volt, 2-wire, single phase 120/240 volt, 3-wire, single phase
Rated amps (120 volt) 33.3 41.7
Rated amps (240 volt) 16.7 20.8
Rated amps 12-volt battery charging system 0-15 amps—regulated
Generator type 4-pole rotating field
Shaft rpm, 60 Hz 1800
Voltage regulation + 2%
Frequency regulation + 0.5%
inimum recommen learance for vibration
ano cooling —tfront. side” top. rear). mato 0.6 in. (15.2 mm)
Number of output leads 4, reconnectable
Stator resistance (ohms)** leads:
1-2, 3-4, 33-44 0.34
55-33 2.8
B1-B2 0.15
C1-CP, C2-CP 0.14
Rotor field voltage/current readings at rated voltage (hot) 240v
No load 17v/3.1a 17v/3.1a
Full load 27v/4.6a 32v/5.3a
Stator output voltages with separately excited rotor using 12-volt battery
1-2, 3-4, 33-44 90
33-55 135
B1-B2 14
ACFKM/ACFKMR
Rated kW 3.3
Frequency—Hz 50
Rated voltage 110 volt, 2-wire, single phase 110/220 volt, 3-wire, single phase
Rated amps (110 volt) 30.0
Rated amps (220 volt) 15.0
Generator type 4-pole rotating field
Shaft rpm, 50 Hz 1500
Voltage regulation + 2%
Frequency regulation + 0.5%
Minimum recommended clearance for vibration
and cooling— (front, side”, top, rear)
0.6 in. (15.2 mm)
Number of output leads (single phase)
4, reconnectable
Number of output leads (three phase)
12, reconnectable
* 1 using floor or end free-air opening, refer to
**
the Operation and Installation Manual for correct clearances.
Most ohmmeters will not give accurate readings when measuring less than 1 ohm. Consider the stator
good if obtaining a low resistance reading (continuity) and there is no evidence of shorted windings
(discoloration). Do not confuse a low resistance reading with a reading indicating a shorted winding.
1-4 Specifications
TP-5394 12/94
Generator (Continued)
| 4CFKM/4CFKMR
Stator resistance (ohms)** leads:
1-2, 3-4, 33-44 0.40
55-33 2.8
B1-B2 0.15
C1-CP, C2-CP 0.14
Rotor field voltage/current readings at rated voltage (hot) 220v
No load 21v/3.9a
Full load 33v/5.8a
Stator output voltages with separately excited rotor using 12-volt battery
1-2, 3-4, 33-44 90
33-55 114
B1-B2 14
All Models
Rotor resistance (ohms) 3.5-5.5
Excitation method
Solid state brush
Coupling type
Tapered shaft, thrubolt
Overbolt torque—in. Ibs. (Nm)
60 (7)
Voltage regulator type (single-phase models)
PowerBoost™ [IIE
Voltage regulator type (three-phase models)
PowerBoost™ V
Insulation (rotor and stator)
Class 155, epoxy varnish, vacuum impregnated
Winding material
Copper
Bearing, number and type
1, replaceable ball
Circuit protection:
Controller
15-amp fuse
Voltage regulator
5-amp fuse
Battery charging (if equipped)
25-amp circuit breaker
Deicing module (if equipped—newer
models)
5-amp fuse
**
Most ohmmeters will not give accurate readings when measuring less than 1 ohm. Consider the stator
good if obtaining a low resistance reading (continuity) and there is no evidence of shorted windings
(discoloration). Do not confuse a low resistance reading with a reading indicating a shorted winding.
DERATION: All units are rated 1.0 power factor. D
erate approximately 4.0% per 1000 ft. (300 m) above sea level and
1% for each 10°F (5.5°C) increase in temperature above 85°F (29°C).
Tor
que Specifications
Generator
Overbolt torque—in. Ibs. (Nm)
60 (7)
Thrubolt torque—ft. Ibs. (Nm)
40-55 (54-75)
Engine
Cylinder head torque—ft. Ibs. (Nm)
15-20 (20-27)
Spark plug torque—ft. lbs. (Nm)
10-15 (14-20)
Intake manifold bolt—ft. Ibs. (Nm)
125 (17)
TP-5394 12/94
Specifications 1-5
—
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. Choke Adjustment
. Carburetor 10
. Oil Fill/Oil Check 10:
. Air Cleaner
. Nameplate
15-Amp Controller Fuse
. 5-Amp Voltage Regulator Fuse
. Line Circuit Breakers
. Fuel Pump
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10. Oil Drain
11. Start-Stop Switch
12. Battery Positive Connection
13. Oil Filter
14. Electronic Governor Magnetic Pickup (inside baffle)
15. Electronic Governor Actuator
16. Spark Plugs
17. Voltage Regulator
18. Oil Sump (5CKM only)
19. Load Leads
20. Fuel Filter
21. Remote Control Connector
ADV-5728-F
1-6
Figure 1-1. Service View 4/5CKM-RV or 4CFKM-RV
Specifications
TP-5394 12/94
O
CONFIDANT >
. Choke Adjustment
Carburetor
. Oil Fill/Oil Check
. Air Cleaner
Nameplate
. Extended Shaft (Option)
15-Amp Controller Fuse
. 5-Amp Voltage Regulator Fuse
. Line Circuit Breakers
. Fuel Pump
. Oil Drain
. Start-Stop Switch
. Battery Positive Connection
. Oil Filter
. Electronic Governor Magnetic Pickup (inside baffie)
. Electronic Governor Actuator
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ONDVANAONSHOOCONODUAON-
. Spark Plugs
‚ 25-Amp Battery Charging Circuit Breaker (Option—
auto-resettable)
19. Voltage Regulator
20. Load Leads /
21. Fuel Filter o
22. Remote Control Connector co
—
|
22
o
—— -
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5
ADV-5780-B
Figure 1-2. Service View 4/5CKMR-Mobile or 4CFKMR-Mobile
TP-5394 12/94 Specifications 1-7
Accessories
Several accessories are available to finalize the
installation or to add convenience to operation and
service. Obtain the most current information by
contacting your local Kohler dealer/distributor.
Following are accessories available at the time of print
of this publication.
Remote Panels
Kohler offers optional remote panels for mounting
wherever convenient inside the motorhome. Remote
panel harness plug has the four-square configuration.
Remote panels require an extension wiring harness for
hookup to the generator set controller.
Remote Start/Stop Panel
Allows starting/stopping from a location remote of the
generator set. Overall mounting dimensions are 4 1/16
in. (103 mm) by 2 1/8 in. (54 mm) with a minimum
mounting depth of 2 1/4 in. (57 mm).
Remote Start/Stop Panel With
Hourmeter
Allows starting/stopping from a location remote of the
generator set. Overall mounting dimensions are 4 in.
(102 mm) by 2 in. (51 mm) with a minimum mounting
depth of 25/16 in. (59 mm). Refer to TT-798 instructions
for assembly.
Wiring Harnesses
Kohler Co. supplies wiring harnesses of varying lengths
to simplify electrical connections between the generator
set controller and the remote panel. Top quality
gold-plated contacts are used for greatest corrosion
resistance. Harnesses of 3 ft. (91 cm), 15 ft. (38 cm), 30
ft. (76 cm), and 40 ft. (102 cm) are offered with keyed
(error-proof) plugs for the controller and the Kohler
remote panel. One end has the four-square plug for
connection to remote panel. The other plug end has the
six in-line configuration for connection to the generator
set controller.
1-8 Specifications
Kohler offers a one foot (0.3 m) wiring harness with a
keyed plug for the controller and pigtails for connection
to customer-supplied start switch, generator ON light,
hourmeter, etc. Pigtail harness plug has the six in-line
configuration for hookup to the generator set controller.
Exhaust Systems
Aluminum coated for durability, all Kohler mufflers are
designed for minimal back pressure to allow full rated
power output. The U.S. Forestry approves Kohler spark
arrestors. All required elbows, clamps, brackets, etc.,
are provided in kits. Refer to TT-870 instructions for
assembly.
Available muffler kits include:
Right-side exhaust outlet for generator set mounted
above floor.
Left-side exhaust outlet for generator set mounted
above floor.
Front exhaust outlet for generator set mounted below
floor.
Rear exhaust outlet for generator set mounted below
floor.
Side exhaust outlet for generator set mounted below
floor.
Center tap bottom exhaust outlet for generator set
mounted below floor.
LP Conversion Kit
An LP vapor withdrawal kit is available with all of the
necessary components for installation. This kit applies
only to certain models—consult factory. Refer to
TT-1034 instructions for assembly.
Below-Floor Mounting Trays
A below-floor mounting kit for use with the standard tray
is available. Housing kit and hinge kit for use with the
below-floor mounting kit are also available. Refer to
TT-802 instructions for enclosure and hinge kit
assembly and TT-835 instructions for mounting tray
assembly.
TP-5394 12/94
Section 2. Operation
Prestart Checklist
To ensure continued satisfactory operation; check the
following items before each startup.
Oil Level: Keep at or near full mark (not over).
Air Inlets: Keep clear and unobstructed.
Compartment: Maintain a clean interior.
Air Cleaner: Clean and properly installed.
Air Shrouding: Keep tight and in proper position.
Exhaust: Clear and unobstructed tail pipe. Tight muffler
and piping connections.
Electrical: Tighten connections (including battery).
Controller
The Kohler relay controller, located on the generator set,
includes the components required for generator set
operation. See Figure 2-1 for components and the
paragraphs below for component description. If the
generator set stops automatically during operation,
determine if the shutdown is due to low oil pressure. If
so, determine and correct the cause of the low oil
pressure shutdown before restarting the set.
1. Generator Start/Stop Switch. Placing this switch
in the Start position starts the generator set
engine. Placing switch to Stop position stops the
engine. In either case, switch returns to neutral
center position when released.
2. Controller Fuse. A 15-amp fuse protects
controller circuitry against damage in the event of
a short circuit.
3. Remote Panel Connector. A 6-pin connector on
controller side panel allows connection of remote
panels to controller.
TP-5394 12/94
4. Deicing Module Fuse. A 5-amp fuse protects the
deicing module in the event of a short circuit.
(Newer gasoline models only.)
5. Voltage Regulator Fuse. A 5-amp fuse protects
the voltage regulator circuitry against damage in
the event of a short circuit.
6. AC Circuit Breaker(s). The circuit breakers
protect the generator against damage in the event
of a sustained overload. These circuit breakers
are also used to disconnect the load from the
generator set. To close the circuit to the load, place
the circuit breaker(s) in the ON position.
3
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. Generator Start/Stop Switch
. Controller Fuse
. Remote Panel Connection
. Deicing Module Fuse
. Voltage Regulator Fuse
. AC Circuit Breaker(s)
Figure 2-1. Controller
On > ON —
Operation 2-1
Starting Procedure
Place the Start/Stop switch in the start position and hold
in this position until the engine is running, then release.
Do not crank engine continuously for more than 10
seconds at a time. Allow a 60-second cooldown period
between cranking attempts if the engine does not start.
If the unit fails to start after three attempts, contact an
authorized service dealer/distributor for repair. Follow
the instructions below to start/stop the generator set.
The starter motor may burn out if these instructions are
not followed.
NOTE
If the engine starts and then stops, allow the engine to
come to a complete stop before making a restart
attempt. If the flywheel ring gear is still rotating when the
starter pinion gear is engaged, the pinion gear will clash
which may damage the ring gear teeth.
Stopping Procedure
Whenever possible, allow a brief cooling period by
running the set at low or no load for a few minutes just
prior to shutdown. To stop, rock the switch to the stop
position and hold until the set comes to a complete halt.
If the generator set shuts down automatically, identify
and correct the problem before attempting to restart.
Anti-icing
(For Gasoline Models Only)
When operating the generator set in cold conditions,
moisture in the incoming air may condense in the
carburetor assembly, especially after stopping the
generator set. The condensed moisture can then
freeze, creating ice crystals that inhibit normal
carburetor operation. To avoid these conditions, each
generator set has one of three types of anti-icing
systems detailed in the following paragraphs.
2-2 Operation
Manual Anti-icing System
(Air Cleaner Preheat)
The manual anti-icing system permits the user to route
heated manifold air to the carburetor intake when
ambient temperatures are low. The manual system is
identified by the anti-icing adjustment leverfound onthe
air cleaner. See Figure 2-2.
When operating a generator with manual anti-icing at
temperatures of approximately 40° F (4° C) or less,
move the anti-icing lever up to the winter position. At
temperatures of approximately 70° F (21° C) or above,
move the anti-icing lever down to the summer position.
For ambient temperatures between 40° and 70° F (4°
and 21° C), the anti-icing lever may be left in either
position.
NOTE
Be aware of reduced generator output if operating the
set in temperatures above 70° F (21° C) with the
adjustment lever in the winter position.
1. Winter/Summer Lever
Figure 2-2. Manual Anti-icing System
TP-5394 12/94
Positive Temperature Coefficient
Plate Anti-icing System
(Anti-icing Plate)
Early Models
The positive temperature coefficient (PTC) anti-icing
system consists of an electric-heating element mounted
between the intake manifold and the carburetor. See
Figure 2-3. This device operates at 12 vdc.
The heater within the PTC runs whenever the generator
setis running. Athermistor, also withinthe PTC, controls
the amount of heat produced by the electric heater.
When it is cold, the thermistor automatically allows
maximum current (approximately 3 amperes) to flow
through the heater and thus produces the maximum
amount of heat. As the thermistor temperature
increases, current flow to the heater decreases (to a
minimum of 0.75 amperes), reducing the heater output.
No manual operation is required because the operation
of this anti-icing system is completely automatic.
1. Graphite Spacer
2. Heater
3. Gasket
Figure 2-3. PTC Anti-icing System
TP-5394 12/94
Automatic Deicing System
(Combustion and Preheater)
Current Models
The automatic deicing system consists of a deicing
module and two temperature switches. An electric
heater within the module automatically warms the
incoming air when the generator set is running and the
ambient temperature is low. This device operates at 120
vac. The system can be recognized by the module
mounted between the carburetor air horn and air
cleaner. See Figure 2-4.
Two temperature switches control the operation of the
heater. A low-level switch turns on power to the heater
only when the ambient air temperature is approximately
60° F (16° C) or less. A high-level switch cycles off
heater power when the deicing module temperature
climbs to approximately 185° F (85° C).
No manual operation is required because the operation
of this anti-icing system is completely automatic.
FA-277000-B
1. Deicing Module (includes high-limit thermostat and heater)
2. Low-Limit Thermostat (located on manifold)
3. 5-amp Deicing Fuse
Figure 2-4. Automatic Deicing System
Operation 2-3
Circuit Protection
Refer to Figure 2-5 and the following descriptions to
identify circuit protection components.
1.
input (Controller) Fuse (15 Amp). A replaceable
15-amp fuse protects the controller circuitry. If the
generator engine will not crank and the battery
and/or other connections are tight, the controller
fuse may be blown.
Deicing Module Fuse (5 Amp) (on newer
gasoline models only). A replaceable 5-amp
fuse protects the controller circuitry against shorts
in the deicing module. If fuse blows again after
replacement, check and repair the deicing module
and its wiring.
Voltage Regulator Fuse (5 Amp). A replaceable
5-amp fuse protects the voltage regulator circuits.
If the fuse is blown, the generator will not continue
running.
AC Circuit Breakers. These circuit breakers trip
when faults occurinthe AC output (load) circuits to
protect the generator stator windings. If a circuit
breaker trips, check the load circuits for shorts or
excessive wattage requirements. After fault is
corrected, reset AC circuit breaker to the ON
position.
Battery-Charging Circuit Breaker (25 Amp).
This circuit breaker trips to protect the
battery-charging circuit, including the
battery-charging windings of the generator stator,
in the event of a short. If this circuit breaker trips,
refer to the troubleshooting procedures to isolate
and repair the problem. This breaker
automatically resets. See Figure 1-2 for location.
2-4 Operation
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1. Controller Fuse
2. Deicing Module Fuse
3. Voltage Regulator Fuse
4. AC Circuit Breaker(s)
Figure 2-5. Controller Circuit
Protection Components
TP-5394 12/94
Engine Safety Shutdowns
Low Oil Pressure Shutdown
The low oil pressure shutdown feature protects the
engine against internal damage if the oil pressure drops
below 3 1/2 psi + 1 1/2 psi (24.1 kPa) due to oil pump
fault or other malfunction. It does not protect against
damage due to operating withthe oil level below the safe
range—it is not a low oil level shutdown. The only
protection against running out of oil is checking the level
regularly and adding oil as needed. Figure 2-6 shows
the location of the low oil pressure (LOP) switch.
1-905
1. Low Oil Pressure Switch
Figure 2-6. Low Oil Pressure Switch
TP-5394 12/94
Overspeed Shutdown
The generator set employs an electronic governor to
regulate the engine speed. This regulation assures that
generator output remains within £0.25 percent of the
specified frequency (50 or 60 Hz). The electronic
governor also monitors for overspeed conditions in
order to prevent engine runaway. The governor shuts
down the generator set engine if the output frequency
exceeds 60 Hz (for 50 Hz models) or 72 Hz (for 60 Hz
models).
Operation 2-5
Optional Remote Panels
Remote Start Panel
The remote stat panel (Figure 2-7) allows
starting/stopping from a location remote of the
generator set. A 6-pin connector on the controller
permits connection of the panel to the generator set.
Procedures for starting and stopping from the remote
panel are the same as those given for the controller
panel.
O
KOHLER
GENERATOR
START
STOP
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1-905
Figure 2-7. Remote Start Panel
2-6 Operation
Remote Start Panel With Hourmeter
The remote start panel with hourmeter (Figure 2-8)
allows starting/stopping from a location remote of the
generator set. The hourmeter on the panel records total
generator operating time to facilitate scheduling of
maintenance. The panel also includes a light. If the light
is lit, the generator is running. A 6-pin connector on the
controller permits connection of this panel to the
generator set. Procedures for starting and stopping from
the remote panel are the same as those given for the
controller panel.
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Figure 2-8. Remote Start Panel With Hourmeter
TP-5394 12/94
Section 3. Scheduled Maintenance
General
Schedule routine maintenance according to the Service
Schedule following and the hourmeter located on the
controller. If subjecting the generator to extreme
operating conditions, service the unit more frequently.
The following pages provide instructions for performing
most of the scheduled services. If tools and instruments
required for these services are not available to the
generator set owner, the set should be returned
periodically to an authorized service dealer/distributor
for complete servicing and tune-up. The benefits of such
service will be improved performance and continuous
satisfactory operation during a long trouble-free service
life.
A WARNING
OXY
X
Can cause severe injury or death.
Accidental starting.
Disconnect battery cables before working on
generator set (negative lead first and reconnect it
last).
Accidental starting can cause severe injury or
death. Disconnect battery cables (remove negative
lead first and reconnect it last) to disable generator set
before working on any equipment .connected to
generator set. The generator set can be started by the
remote start/stop switch unless this precaution is
followed.
TP-5394 12/94
NOTE
Perform the items listed in the service schedule at the
designated intervals for the life of the generator. For
example, an item to be serviced “every 50 hours or 6
months” must also be serviced after 100 hours or 12
months, 500 hours or 2 years, etc. The generator will
eventually accumulate enough hours to warrant a
complete overhaul. The exact time at which extensive
service will be necessary cannot be predicted. However,
rough operation, lack of power, and excessive oil use
indicate serious generator set problems. As part of a
preventive maintenance program, service the engine
(clean cylinder head, inspect valves, check
compression, etc.) and generator (replace bearing,
inspect wiring, remove debris, etc.) at the earliest
indication that a problem exists.
NOTE
Do not leave generator sets equipped with the optional
swing-down tray in the tilted position for any extended
period (30 minutes or more). Always place unit in the
normal mounting position when not performing service.
Scheduled Maintenance 3-1
Service Schedule
Perform Service at Intervals Indicated (es)
Before
Each
Startup
Every 50
Hours or 6
Months
Every 100
Hours or
12 Months
Every 500
Hours or
Two Years
Check exhaust outlet
©
Check oil level
Check fuel supply
Keep cooling air inlets and outlets clean and
unobstructed
Remove loose dirt from compartment
Check electrolyte level in battery
Check air cleaner (replace if dirty)
Drain collection pipe (LP liquid-fueled units only—if
equipped)
Change lube oil (change oil initially after first
five hours of operation)
**
Replace lube oil filter
**
Service or replace spark plugs
Check battery specific gravity
Check and tighten electrical connections
Check and tighten mounting bolts and
vibromounts
Blow dust out of generator
Clean spark arrestor
Check for stepper motor/throttle shaft coupling
wear
(250 hours)
Check valve-tappet clearance
Service cylinder heads
*x*k
®
Check compression
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o
Inspect liquid withdrawal LP fuel filter
Replace fuel filter
* Applies to 5 kW
** Applies to 4 kW
*** Performed by an authorized Kohler service dealer/distributor
NOTE
Unleaded gasoline is recommended. If using leaded
gasoline, service cylinder heads every 250 hours.
3-2 Scheduled Maintenance
TP-5394 12/94
Lubrication System
Description
The engine has a positive-pressure lubrication system
that includes an internal oil pump, a replaceable oil filter,
and a low oil pressure shutdown switch.
Oil Check
Check crankcase oil level daily or before each start. To
check oil level, remove oil cap/dipstick assembly and
wipe dipstick clean. See Figure 3-1. Reposition dipstick
in crankcase and insert it all the way down into the tube.
Remove dipstick and check the level. Oil level should
read between max and min marks on dipstick. See
Figure 3-2. Do not operate set if oil level exceeds the
max mark or registers below the min mark on dipstick.
1-905
Figure 3-1. Oil Check
TP-5394 12/94
al
1. Max Mark
2. Min Mark
Figure 3-2. Lube Oil Level
NOTE
Do not check oil level when the set is in operation. The
engine must be stopped and on a level surface when
checking oil. Shut down the generator and wait several
minutes before checking oil to ensure an accurate oil
reading.
Scheduled Maintenance 3-3
Oil Specifications
Oil used in factory generator set testing is drained
before shipping. Before operating a new set, fill the
engine crankcase to the specified capacity with a
straight-weight oil having a viscosity appropriate for
your particular climate. Do not use synthetic oils during
the first five hours of operation or the rings may not seat
properly. Change the oil immediately after the first five
hours of operation.
Use high-quality detergent oils meeting the
requirements of SAE service class SF or SG in Kohler
M18 and M20 engines. Straight-weight 30 oil is
preferred. If using multi-viscosity oil in temperatures
above 32° F (0° C), be aware of the resulting increase in
oil consumption and combustion deposits. Base oil type
selection on air temperature at time of operation.
Consult the SAE viscosity grade chart (see Figure 3-3).
3-4 Scheduled Maintenance
Do not mix different brands of oils. Possible
incompatibility could cause a breakdown of lubricating
ingredients and reduce engine protection.
RECOMMENDED SAE VISCOSITY GRADES
v т
°F —0 0 20 32 40 60 80 100
fa i 4 i E
y Ч y 1 Y
°C —30 —20 —10 0 10 20 30 40
Figure 3-3. Temperature Range Expected Before
Next Oil Change
TP-5394 12/94
Adding Oil
It is normal to add some oil between oil changes. The
amount will vary with the usage. Open fill cap and pour in
a small amount of oil using a funnel or other suitable
pouring device. Wait a few minutes and check level. If
necessary, add more oil and then check again. Each
time add small quantities and check to prevent
overfilling.
OIL CAPACITY
(with Filter)
Generator Model Qts. (L)
4 КМУ ..1.L112 0210 aa aan ee 1.5 (1.4)
E AT 2.5 (2.4)
Figure 3-4. Engine Oil Capacity
Oil Change
On a new engine, change the oil after the first 5 hours of
operation and thereafter at the intervals specified in the
service schedule. Whenever possible, change oil while
the engine is still warm.
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1. Oil Drain Petcock
Figure 3-5. Oil Drain Petcock
TP-5394 12/94
. Place a container below the oil drain hole and open
the oil drain petcock (located beneath the dipstick).
See Figure 3-5. Allow sufficient time for the old oil
to drain completely. Close oil drain petcock.
Dispose of used engine oil in an environmentally
safe manner.
2. Remove oil fill cap dipstick. See Figure 3-1.
3. If the engine oil filter is to be replaced, see Oil Filter
following.
. Fill crankcase with amount and type of oil as
specified in Figure 3-3 and Figure 3-4.
5. Start the generator set and check for oil leaks.
. Stop the generator set. Remove the dipstick and
wipe clean, reinsert as far as possible, and remove
to check oil level. Add oil, as necessary, to bring
level up to max mark.
NOTE
Too high an oil level causes high oil consumption
and carbonizing in the engine. Low oil level will
cause engine damage.
Scheduled Maintenance 3-5
Oil Filter
Replace the oil filter every time the oil is changed. See
Figure 3-6 and refer to the following procedure.
1. Oil Filter
Figure 3-6. Oil Filter Location
. Loosen oil filter by turning it with a filter wrench in a
counterclockwise direction. Oil filteris 3 in. (76 mm)
dia. and has 14 flutes (sides). Use rags to clean up
spilled oil. Remove and discard.
2. Clean contact surface on oil filter adapter.
3. Lightly lubricate the gasket surface of the new oil
filter with the fresh engine oil. Thread oil filter to
adapter until gasket makes contact, hand tighten
an additional one-half turn.
. Fill crankcase with fresh oil and check for leaks as
detailed in steps 4-6 of Oil Change procedure on
previous page.
Cooling System
To prevent generator set overheating damage, keep the
compartment cooling air inlets clean and unobstructed
at all times.
A fan on the rotor of the generator draws cooling air into
the compartment through the generator cooling slots
and expels it at the engine-generator adapter. The
engine of the generator set features an Air-Vac™
reverse-flow cooling system. Fins on the engine
flywheel pull cooling air past the fins of the cylinder
heads and heated air is discharged downward and out
of the compartment through the discharge chute. See
Figure 3-7.
3-6 Scheduled Maintenance
Figure 3-7. Cooling Air Circulation
TP-5394 12/94
Ignition System
Description
The 4 KW and 5 kW generator sets are equipped with a
dependable electronic magneto ignition system
(Figure 3-8) containing the following:
e A magnet assembly permanently affixed to the
flywheel.
e An electronic magneto ignition module mounted to
the #1 side cylinder barrel.
e A controller which stops the engine by grounding
the ignition module.
As the flywheel rotates and the magnet assembly
moves past the ignition module, a low voltage is induced
in the primary windings of the module. When the primary
voltage is precisely at its peak, the module induces a
high voltage in its secondary windings. This high voltage
creates a spark at the tip of the spark plugs, igniting the
fuel-air mixture in the combustion chambers. Other than
periodically checking/replacing the spark plugs, no
maintenance, timing, or adjustments are necessary with
this ignition system.
IM
. Diode
. 0.008/0.012 in. (0.20 /0.30 mm) Air Gap
. Ignition Module
. Magnet
. Spark Plugs
. High Tension Lead
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7. Coil Assembly
8. Laminations
9. Terminal
10. High Tension Lead
11. Flywheel
12. Controller
Figure 3-8. Electronic Magneto Ignition System
TP-5394 12/94
Scheduled Maintenance 3-7
Spark Plugs
At the interval recommended in the service schedule,
service spark plugs as follows:
1. Remove spark plug wires by grasping boot and
turning slightly while pulling. Do not pull on wire.
See Figure 3-9.
NOTE
Pulling wire rather than boot may cause damage to
wire or terminal.
1-905
1. Boot
2. Spark Plug
Figure 3-9. Removing Spark Plug Boot
3-8 Scheduled Maintenance
2. Loosen spark plug with a ratchet and spark plug
socket with a rubber insert to prevent damage to
spark plug. If possible, use compressed air to
remove dirt around each spark plug before
completing spark plug removal. This procedure will
prevent dirt from falling into combustion chamber.
. Remove and examine each spark plug for
conditions described in Figure 3-12.
. Wipe spark plugs clean with a rag. Then file center
electrode so its top is flat and perpendicular to the
spark plug axis. Should replacement be necessary,
see Specifications, Engine in Section 1 for spark
plug type.
NOTE
Do not sandblast, wire brush, scrape, or otherwise
service spark plug in poor condition. For best
results replace the plug.
TP-5394 12/94
5. Before installing any spark plug, check the gap.
See Figure 3-10. The proper gap is attained when
the feeler gauge (or wire) passes between the
spark plug electrodes. It should pass easily, but
with some resistance or drag; otherwise, adjust as
necessary.
The correct gap is 0.025 in. (0.64 mm) for gasoline
models and 0.018 in. (0.46 mm) for LP gas models.
N
JA
ZN
(5) «7
SSID N ^^
Ç ON =
Nu
1. Spark Plug
2. Gap Gauge
Figure 3-10. Checking Spark Plug Gap
6. If necessary use gapping tool to gently bend side
electrode in order to correct gap. See Figure 3-11.
Be sure side electrode remains centered over
center electrode. Repeat steps 5 and 6 until gap is
properly adjusted.
TP-5394 12/94
1. Spark Plug
2. Gapping Tool
Figure 3-11. Adjusting Spark Plug Gap
7. Install spark plug in cylinder head, be careful not to
bump electrode and alter gap. Rotate spark plug
clockwise until resistance is felt.
8. Tighten each spark plug with a torque wrench to a
torque of 10-15 ft. Ibs. (14-20 Nm). If a torque
wrench is not available, tighten each spark plug
until resistance is felt; then tighten with a ratchet an
additional 1/4 turn. Do NOT overtighten as this may
strip the cylinder head threads or alter the gap
setting.
9. Check spark plug wire connector in boot for
accumulated dirt, grease, etc., and clean as
necessary. Firmly push spark plug boot onto spark
plug.
Timing
The timing of the spark is automatically controlled by the
ignition module. No ignition timing adjustments are
necessary or possible with this system. If timing
problems are encountered, check ignition module air
gap. See Engine Service Manual for details.
Scheduled Maintenance 3-9
ea
E EE errar ette
Normal
Light gray or tan deposit on firing tip.
Good operating conditions and
maintenance.
Gap bridged Built-up deposits closing gap between Oil or carbon fouling. Clean and regap
electrodes. plug.
Oil fouled Wet black deposits on the insulator shell Excessive oil entering combustion
bore electrode.
chamber through worn rings and pistons,
excessive clearance between valve
guides and stems, or worn or loose
bearings. Replace plug.
Carbon fouled
Black, dry fluffy carbon deposits on
insulator tips, exposed shell surfaces and
electrodes.
Using too cold range plug, weak ignition,
clogged air intake or improper carburetor
adjustments, defective fuel pump,
overrich fuel mixture, or excessive
no-load operation. Clean and regap plug.
Lead fouled Dark gray, black, yellow, or tan deposits; Highly leaded fuel. Replace plug.
or a glazed coating on the insulator tip.
Preignition Melted electrodes and possibly blistered Wrong type of fuel, incorrect timing or
insulator. Metallic deposits on insulator
suggest internal engine damage.
advance, too hot of a plug, burnt valves
or engine overheating. Replace plug.
Overheating
White or light gray insulator with small
black or gray/brown spots with bluish
(burnt) appearance on electrode.
Engine overheating, wrong type of fuel,
loose spark plugs, too hot of a plug, low
fuel pump pressure or incorrect ignition
timing. Replace plug.
wom
Severely eroded or worn electrodes.
Caused by normal wear and failure to
replace plug at prescribed interval.
Replace plug.
3-10 Scheduled Maintenance
Figure 3-12. Evaluating Spark Plug Condition
TP-5394 12/94
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