Kohler 4EFRKM Operation Download Page 9

TP-6081 4/00

i

Introduction

Introduction

This

manual

provides

operation

instructions

for

5ERKM/4EFRKM model generator sets.

Refer to the engine operation manual for generator set
engine scheduled maintenance information.

This manual may be used for models not listed on the
front cover.

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.

Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the

Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.

The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately
skilled and suitably trained maintenance personnel
familiar with generator set operation and service.

Before installing a mobile generator set, obtain the
most current installation manual from your local
distributor/dealer. Only qualified persons should
install the generator set.

x:in:001:002:a

Service 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 distributor/dealer inside
the U.S.A. and Canada

D

Look on the product or in the information included with
the product

D

Consult the Yellow Pages under the heading
Generators— Electric

D

Visit the Kohler Generator Division web site at

www.kohlergenerators.com

D

Call 1-800-544-2444

To locate a local authorized distributor/dealer
outside the U.S.A. and Canada

D

Look on the product or in the information included
with the product

D

Consult the telephone directory under the heading
Generators—Electric

D

Visit the Kohler Generator Division web site at
www.kohlergenerators.com

D

Contact the nearest regional office

Africa, Europe, Middle East

London Regional Office
Langley, Slough, England
Phone: (44) 1753-580-771
Fax:

(44) 1753-580-036

Australia

Australia Regional Office
Queensland, Australia
Phone: (617) 3893-0061
Fax:

(617) 3893-0072

China

China Regional Office
Shanghai, People’s Republic of China
Phone: (86) 21-6482 1252
Fax:

(86) 21-6482 1255

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: (91) 80-2284270

(91) 80-2284279

Fax:

(91) 80-2284286

Japan

Japan Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax:

(813) 3440-2727

Latin America

Latin America Regional Office
Lakeland, Florida, U.S.A.
Phone: (941) 619-7568
Fax:

(941) 701-7131

South East Asia

Singapore Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax:

(65) 264-6455

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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