Kohler 4EFRKM Operation Download Page 17

TP-6081 4/00

5

Section 3 Scheduled Maintenance

Section 3 Scheduled Maintenance

3.1 General Maintenance

Accidental starting.
Can cause severe injury or death.

Disconnect the battery cables before
working

on

the

generator

set.

Remove the negative (--) lead first
when

disconnecting

the

battery.

Reconnect the negative (--) lead last
when reconnecting the battery.

WARNING

Disabling the generator set.

Accidental starting can

cause severe injury or death.

Before working on the

generator set or equipment connected to the set, disable the
generator set as follows: (1) Disconnect the power to the
battery charger, if equipped. (2) Remove the battery cables,
negative (--) lead first. Reconnect the negative (--) lead last
when reconnecting the battery. Follow these precautions to
prevent the starting of the generator set by the remote
start/stop switch.

Rotating parts.
Can cause severe injury or death.

Operate the generator set only when
all guards, screens, and covers are in
place.

WARNING

Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death.

Keep

hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running.

Replace

guards, screens, and covers before operating the generator
set.

NOTICE

Hardware damage.

The engine and generator set may use

both American Standard and metric hardware. Use the correct
size tools to prevent rounding of the bolt heads and nuts.

See the Safety Precautions and Instructions at the
beginning of this manual before attempting to service,
repair, or operate the generator set. Have an authorized
distributor/dealer perform generator set service.

Engine Service.

Perform generator set engine service

at the intervals specified by the engine operation
manual.

Generator Set Service.

Perform generator set service

at the intervals specified by the generator set operation
manual.

If the generator set operates under dusty or dirty
conditions, use

dry

compressed air to blow dust out of

the alternator. With the generator set running, direct the
stream of air in through the cooling slots at the alternator
end.

Routine Maintenance.

Refer to the following generator

set service schedule, the engine service schedule, and
the hourmeter located on the generator set controller to
determine when to schedule routine maintenance.
Service more frequently generator sets that are subject
to extreme weather or dusty or dirty conditions.

Service Log.

Use the Operating Hour Service Log

located in the back of this manual to document
performed services.

Service Schedule.

Perform maintenance on each item

in the service schedule at the designated intervals for
the life of the generator set.

For example, an item

requiring service every 100 hours or 3 months also
requires service after 200 hours or 6 months, 300 hours
or 9 months, and so on.

Summary of Contents for 4EFRKM

Page 1: ...Commercial Mobile Generator Sets Models 5ERKM 4EFRKM TP 6081 4 00 Operation...

Page 2: ...Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING California Proposition 65...

Page 3: ...et 4 2 4 3 Stopping the Generator Set 4 Section 3 Scheduled Maintenance 5 3 1 General Maintenance 5 3 2 Service Schedule 6 3 3 Lubrication System 8 3 3 1 Oil Specifications 8 3 3 2 Oil Check 8 3 3 3 O...

Page 4: ...TP 6081 4 00 Table of Contents Notes...

Page 5: ...t the power to the battery charger if equipped 2 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the st...

Page 6: ...to the following D Light headedness dizziness D Physical fatigue weakness in joints and muscles D Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision D Stomachache vomi...

Page 7: ...whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configurethe installation to electrically ground the generator set transfer switch a...

Page 8: ...thecrankshaft hardwareorrotorthrubolt whenmaking adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt c...

Page 9: ...Assistance Service Information Please contact a local authorized distributor dealer for sales service or other information about Kohler Generator Division products To locate a local authorized distri...

Page 10: ...readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator s...

Page 11: ...23316 Spark Plug 63 132 01 S Spray Paint Black 221292 Voltage Regulator Fuse 10 amp 223316 Figure 1 Maintenance and Service Parts x in 001 004 List of Related Literature Figure 2 identifies related li...

Page 12: ...TP 6081 4 00 iv Maintenance and Service Parts Related Literature Notes...

Page 13: ...ide 11 Lifting eye 12 Muffler 13 Exhaust outlet nonservice side 14 Spark plug 15 Air cleaner 16 Carburetor 17 Oil drain valve 18 Oil check oil fill 19 Fuel feed pump 20 Fuel inlet 21 Cooling air inlet...

Page 14: ...TP 6081 4 00 2 Section 1 Service Views Notes...

Page 15: ...vel Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstruction...

Page 16: ...arging Fuse This fuse protects the battery charging circuitry Voltage Regulator Fuse This fuse protects the voltage regulator circuitry Remote Start Connector A 6 pin connector on the controller s bac...

Page 17: ...use bothAmericanStandardandmetrichardware Usethecorrect size tools to prevent rounding of the bolt heads and nuts See the Safety Precautions and Instructions at the beginning of this manual before att...

Page 18: ...nkcase 3 3 4 X 20 hrs break in period X COOLING SYSTEM Check the air intake and cooling areas for obstructions and clean as necessary X Check X Clean IGNITION SYSTEM Check the spark plug condition adj...

Page 19: ...nd have it serviced if necessary X ENGINE AND MOUNTING Check for fuel and oil leakage X Retighten all nuts and bolts X Check the mounting bolts vibromounts and tighten as necessary X 200 hrs Check and...

Page 20: ...ove it Maintain the oil level between the Full and Add marks on the dipstick as shown in Figure 3 2 See Section 1 Service Views for the dipstick location 1 TP 5586 3 2 1 Full mark 2 Add mark Figure 3...

Page 21: ...t Dispose of used engine oil and other contaminants in a safe approved manner 3 4 Fuel System 3 4 1 Fuel Specifications Use a clean good quality unleaded fuel with an octane number of 87 Use fresh gas...

Page 22: ...s occupants install a carbon monoxide detector Consult the coach builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to rou...

Page 23: ...Gap bridged spark plug Built up deposits and gap between the electrodes closing Oil or carbon fouling Clean and regap the spark plug Oil fouled spark plug Wet black deposits on the insulator shell bor...

Page 24: ...mm 0 028 0 031 in 7 Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap See Figure 3 6 Position the side electrode directly over...

Page 25: ...cid Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when it is ch...

Page 26: ...d moisture from mixing with the fuel 5 Remove the spark plug Pour approximately 1 tablespoon of engine oil into the spark plug hole Crank the engine two or three revolutions to lubricate the cylinder...

Page 27: ...he generator set installation manual I M and the engine service manual Engine S M to correct the indicated problem Corrective action and testing often require knowledge of electrical and electronic ci...

Page 28: ...TP 6081 4 00 16 Section 4 Troubleshooting Notes...

Page 29: ...ot locked tight x x x Disconnect the engine harness twist lock connector then reconnect it to the controller ctrica Loose or inoperative spark plug wire x x x x x 3 8 Reconnect or replace wire Elec Fa...

Page 30: ...TP 6081 4 00 18 Section 4 Troubleshooting Notes...

Page 31: ...gative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Hazardous voltage Can cause severe injury or death...

Page 32: ...TP 6081 4 00 20 Section 5 Diagrams and Drawings GM11960 Figure 5 1 Schematic Wiring Diagram...

Page 33: ...TP 6081 4 00 21 Section 5 Diagrams and Drawings GM11960 Figure 5 2 Point to Point Wiring Diagram...

Page 34: ...TP 6081 4 00 22 Section 5 Diagrams and Drawings Notes...

Page 35: ...e CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg degree dept department...

Page 36: ...onal Safety and Health Administration O V overvoltage oz ounce p pp page pages PA packed accessory PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase PHC Phillips hea...

Page 37: ...Log Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were performed Enter hours to the nearest quarter hour OPERATING HOURS SERVIC...

Page 38: ...TP 6081 4 00 A 4 Appendix Notes...

Page 39: ......

Page 40: ...381 Web site www kohlergenerators com Fax 920 459 1646 U S A Sales Fax 920 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444 Kohlerr Power System...

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