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Kohler 5ERKM Operation

Kohler 5ERKM Operation

Commercial mobile generator sets
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Operation
Commercial Mobile Generator Sets
Models:
5ERKM
4EFRKM
TP-6081 4/00

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Summary of Contents for Kohler 5ERKM

  • Page 1 Operation Commercial Mobile Generator Sets Models: 5ERKM 4EFRKM TP-6081 4/00...
  • Page 2 California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ..3.3.1 Oil Specifications ....3.3.2 Oil Check .
  • Page 4 Notes Table of Contents TP-6081 4/00...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Electromechanical equipment, Accidental Starting Battery acid. Sulfuric acid in including generator sets, transfer batteries can cause severe injury or switches, switchgear, and accessories, death. Sulfuric acid in the battery can WARNING can cause bodily harm and pose cause blindness and burn skin.
  • Page 6 Engine Backfire/Flash Generator set operation. Carbon Inspecting the exhaust system. monoxide can cause severe nausea, Carbon monoxide can cause severe Fire fainting, or death. Carbon monoxide nausea, fainting, or death. For the is an odorless, colorless, tasteless, safety of the vehicle’s occupants, install nonirritating gas that can cause death if a carbon monoxide detector.
  • Page 7 Explosive fuel vapors can cause Hazardous Voltage/ Short circuits. Hazardous severe injury or death. Take voltage/current can cause severe Electrical Shock additional precautions when using the injury or death. Short circuits can following fuels: cause bodily injury and/or equipment damage. Do not contact electrical WARNING Gasoline—Store gasoline only in...
  • Page 8 Hot Parts NOTICE WARNING Voltage reconnection. Affix a notice to the generator set after reconnecting WARNING the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from authorized service Rotating parts. distributor/dealer. Can cause severe injury or death. Hot engine and exhaust system.

  • Page 9: Introduction

    Information in this publication represents data available familiar with generator set operation and service. 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 Before installing a mobile generator set, obtain the whatsoever.
  • Page 10 Product Information Engine Identification Record the product identification information from the Product identification numbers determine service parts. engine nameplate. Record the product identification numbers in the spaces Manufacturer below immediately after unpacking the products so that Model Number the numbers are readily available for future reference. Serial Number Record field-installed kit numbers after installing the kits.

  • Page 11: Maintenance And Service Parts/Related Literature

    Maintenance and Service Parts/Related Literature Maintenance and Service Parts List of Related Literature Figure 1 identifies maintenance and service parts for Figure 2 identifies related literature available for the your generator set. Obtain a complete list of generator sets covered in this manual. Only trained and maintenance and service parts from your authorized qualified personnel should install or service the generator distributor/dealer.
  • Page 12 Notes Maintenance and Service Parts/Related Literature TP-6081 4/00...

  • Page 13: Section 1 Service Views

    21. Cooling air inlet 11. Lifting eye 22. Extended shaft (generator specification available) Figure 1-1 5ERKM/4EFRKM Service View Note: Consult the installation drawing in the spec sheet Note: Consult an authorized distributor/dealer or the or the installation manual for the fuel and battery service manual for items not shown.
  • Page 14 Notes Section 1 Service Views TP-6081 4/00...

  • Page 15: Section 2 Operation

    Ensure that the carbon monoxide detector is (1) in the start. If the unit fails to start after three attempts, vehicle, (2) functional, and (3) energized whenever contact an authorized Kohler distributor/dealer the generator set operates. for repair. Failure to follow these guidelines may result in starter motor burnout.

  • Page 16: Controls And Indicators

    2.4.1 Controls and Indicators 2.4.2 Starting the Generator Set The following table describes the controls and indicators Hold the generator set controller start/stop switch or the located at the controller: remote start/stop switch in the START position until the unit starts. Name Description Start/Stop Switch...

  • Page 17: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance 3.1 General Maintenance NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct WARNING 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.

  • Page 18: Service Schedule

    3.2 Service Schedule After Every Every 50 Hrs 100 Hrs 300 Hrs Reference Before Perform Service at Intervals Indicated (X) 1 Month 3 Months Yearly Section Starting FUEL SYSTEM Check the fuel level and fill as necessary Check the choke operation Lubricate the carburetor and choke linkage 3.4.2 (200 hrs)
  • Page 19 Service Schedule, continued After Every Every 50 Hrs 100 Hrs 300 Hrs Reference Before Perform Service at Intervals Indicated (X) Section Starting 1 Month 3 Months Yearly ELECTRICAL SYSTEM Keep the battery charged and in good condition Check and tighten the electrical connections Clean the battery cables * (200 hrs) Check the starter drive and have it serviced if necessary *...

  • Page 20: Lubrication System

    Capacity accurate reading. To check the oil level, remove the L (Qts.) Model dipstick and wipe the end clean. Reinsert the dipstick 5ERKM 2.0 (2.1) and remove it. Maintain the oil level between the Full 4EFRKM 2.0 (2.1) and Add marks on the dipstick, as shown in Figure 3-2.

  • Page 21: Fuel System

    Do not use gasoline left over from the previous season. 5. Close the oil drain valve. Kohler Co. recommends unleaded fuel because it 6. Remove the oil fill cap. leaves fewer combustion chamber deposits. Never mix oil with fuel.

  • Page 22: Air Cleaner

    3.5 Air Cleaner Exhaust System Inspection Points At the interval specified in the service schedule, Inspect At the intervals specified in the service schedule, clean the exhaust system. See Section 1, Service Views, for or replace the air cleaner element. Clean the element the exhaust outlet location.

  • Page 23: Cooling Areas

    3.7 Cooling Areas Spark Plug Service Procedure 1. Remove the spark plug wire by grasping the spark Cleaning the Air Intake/Cooling Areas plug boot and turning it slightly while pulling. Do not pull the wire. Pulling on the wire rather than the To prevent generator shutdown or damage because of boot may damage the wire or the terminal.
  • Page 24 5. Clean the spark plug by wiping it with a rag. Note: Do not sandblast, wire brush, scrape, or otherwise service a spark plug in poor condition. Obtain a new plug for the best results. 6. Check the spark plug gap before installing any spark plug.

  • Page 25: Battery

    3.9 Battery 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, Consult battery manufacturer’s instructions particularly when it is charging. To prevent burns and sparks regarding battery care and maintenance.

  • Page 26: Generator Storage

    3.10 Generator Storage 6. Clean the exterior of the generator set and spread a light film of oil or silicon spray over exposed Follow the procedure below when storing the generator surfaces that may be subject to rust or corrosion. set for 3 months or more.

  • Page 27: Section 4 Troubleshooting

    Section 4 Troubleshooting This section contains generator set troubleshooting, Corrective action and testing often require knowledge of diagnostic, and repair information. electrical and electronic circuits. To avoid additional problems caused by incorrect repairs, have an Use the following chart as a quick troubleshooting authorized service distributor/dealer perform service.
  • Page 28 Notes Section 4 Troubleshooting TP-6081 4/00...
  • Page 29 Trouble Symptoms Generator Excessive Section/ Generator Generator No or low Generator Generator Generator set cranks Low/High Publication set does not but does set starts generator set stops set lacks High fuel abnormal Probable Causes Actions Reference crank hard voltage suddenly power overheats consumption...
  • Page 30 Notes Section 4 Troubleshooting TP-6081 4/00...

  • Page 31: Section 5 Diagrams And Drawings

    Section 5 Diagrams and Drawings WARNING WARNING Moving rotor. Hazardous voltage. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working on the generator set.
  • Page 32 GM11960- Figure 5-1 Schematic Wiring Diagram Section 5 Diagrams and Drawings TP-6081 4/00...
  • Page 33 GM11960- Figure 5-2 Point-to-Point Wiring Diagram TP-6081 4/00 Section 5 Diagrams and Drawings...
  • Page 34 Notes Section 5 Diagrams and Drawings TP-6081 4/00...

  • Page 35: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity Fahrenheit, female ABDC after bottom dead center cubic inch displacement fglass. fiberglass alternating current centerline flat head machine (screw) analog to digital centimeter fl.
  • Page 36 kg/cm kilograms per square milliwatt rnd. round centimeter microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat. gas natural gas right side kilojoule National Bureau of Standards room temperature vulcanization...

  • Page 37: Appendix B Operating Hour Service Log

    Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed. Enter hours to the operating hours on your generator set and the dates nearest quarter hour. OPERATING HOURS SERVICE RECORD DATE HOURS TOTAL...
  • Page 38 Notes A-4 Appendix TP-6081 4/00...
  • Page 40 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 Systems Asia Pacific Headquarters TP-6081 4/00 7 Jurong Pier Road Singapore 619159 E Kohler Co., 2000. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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