Kohler 4EFRKM Operation Download Page 6

TP-6081 4/00

II

Safety Precautions and Instructions

Engine Backfire/Flash
Fire

Fire.
Can cause severe injury or death.

Do not smoke or permit flames or
sparks near fuels or the fuel system.

WARNING

Servicing the fuel system. A flash
fire can cause severe injury or death.

Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when

removing

the

fuel

line

or

carburetor.

Servicing the air cleaner. A sudden
backfire can cause severe injury or
death.

Do not operate the generator

set with the air cleaner removed.

Combustible materials. A fire can
cause

severe

injury

or

death.

Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC

for

electrical

fires

or

as

recommended by the local fire code or
an authorized agency.

Train all

personnel

on

fire

extinguisher

operation

and

fire

prevention

procedures.

Exhaust System

Carbon monoxide.
Can

cause

severe

nausea,

fainting, or death.

The

exhaust

system

must

be

leakproof and routinely inspected.

WARNING

Generator set operation.

Carbon

monoxide can cause severe nausea,
fainting, or death.

Carbon monoxide

is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid
breathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
building unless the exhaust gas is
piped safely outside. Never operate
the generator set where exhaust gas
could accumulate and seep back inside
a potentially occupied building or
vehicle. Do not obstruct the exhaust
outlet when parking your vehicle. The
exhaust gases must discharge freely to
prevent

carbon

monoxide

from

deflecting into the vehicle.

Carbon

monoxide

symptoms.

Carbon monoxide can cause severe
nausea, fainting, or death.

Carbon

monoxide is a poisonous gas present in
exhaust gases.

Carbon monoxide

poisoning symptoms include but are
not limited 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, vomiting, nausea

If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep.

Alert others to the

possibility

of

carbon

monoxide

poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.

Installing the exhaust tail pipe.
Carbon monoxide can cause severe
nausea, fainting, or death.

Install the

exhaust system tail pipe to prevent the
drawing of discharged exhaust gases
into

the

vehicle

interior

through

windows, doors, air conditioners, and
other openings. Do not use flexible tail
piping because it could crack and allow
lethal exhaust fumes to enter the
vehicle.

Inspecting

the

exhaust

system.

Carbon monoxide can cause severe
nausea, fainting, or death.

For the

safety of the vehicle’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
routine exhaust system inspection, test
the carbon monoxide detector per the
manufacturer’s instructions and keep
the detector operational at all times.

Fuel System

Explosive fuel vapors.
Can cause severe injury or death.

Use extreme care when handling,
storing, and using fuels.

WARNING

The fuel system.

Explosive fuel

vapors can cause severe injury or
death.

Vaporized fuels are highly

explosive.

Use extreme care when

handling and storing fuels. Store fuels
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
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines.

Use flexible

sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.

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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