Related Manuals for Kohler 5ERKM
Summary of Contents for Kohler 5ERKM
- Page 1 Service Commercial and Recreational Mobile Generator Sets Models: 5ERKM 4EFRKM TP-6079 3/00...
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Page 2: Table Of Contents
......Wiring Diagram 5ERKM/4EFRKM ... . -
Page 3: Safety Precautions And Instructions
Safety Precautions and Instructions IMPORTANT SAFETY Battery electrolyte is a diluted Accidental Starting INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear... - Page 4 Battery short circuits. Explosion Combustible materials. A fire can Carbon monoxide symptoms. can cause severe injury or death. cause severe injury death. Carbon monoxide can cause severe Generator set engine fuels and fuel nausea, fainting, or death. Carbon Short circuits can cause bodily injury vapors are flammable and explosive.
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Page 5: Fuel System
Fuel System Hazardous Noise WARNING CAUTION WARNING Hazardous voltage. Backfeed to the utility system can cause severe injury, death, or property damage. Hazardous noise. Explosive fuel vapors. Can cause hearing loss. Can cause severe injury or death. Connect the generator set to the building’s electrical system only Never operate the generator set Use extreme care when handling,... -
Page 6: Hot Parts
Electrical backfeed to the utility. Servicing the exhaust system. Hot WARNING Hazardous backfeed voltage can parts can cause severe injury or cause severe injury death. death. Do not touch hot engine parts. Connect the generator set to the The engine and exhaust system building/campground electrical system components become extremely hot only through an approved device and... - Page 7 NOTICE NOTICE Notice Hardware damage. The engine and Canadian installations only. NOTICE generator set may use both American standby service connect the output of Standard and metric hardware. Use the generator set to a suitably rated the correct size tools to prevent transfer switch in accordance with This generator set has been rounding of the bolt heads and nuts.
- Page 8 Notes VI Safety Precautions and Instructions TP-6079 3/00...
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Page 9: Introduction
Information in this publication represents data available Maintenance work must be performed by appropriately at the time of print. Kohler Co. reserves the right to skilled and suitably-trained maintenance personnel, change this publication and the products represented familiar with generator set operation and service. -
Page 10: Service Assistance
Fax: (65) 264-6455 D Consult the Yellow Pages under the heading Generators— Electric D Visit the Kohler Generator Division web site at Product Information www.kohlergenerators.com D Call 1-800-544-2444 Product identification numbers determine service parts. Record the product identification numbers in the spaces... -
Page 11: Section 1 Specifications
Section 1 Specifications 1.1 General 1.4 Generator The 5ERKM and 4EFRKM units are powered by a Component Specifications one-cylinder, air-cooled, four-cycle gasoline engine. Hot exciter field voltage/current readings at rated voltage Kohler Co. develops all Kohler mobile generator set No load (63 Hz) (volts/amps) 10.1/4.4... -
Page 12: Service Views
19. Extended shaft (generator specification available) 9. Remote start connector (nonservice side) 20. Engine battery charging voltage regulator 10. Lifting eye 21. End bracket cover plate 11. Muffler 22. PowerBoostäIIIE voltage regulator Figure 1-1 5ERKM/4EFRKM Service Views Section 1 Specifications TP-6079 3/00... -
Page 13: Section 2 Scheduled Maintenance
Section 2 Scheduled Maintenance 2.1 General 2.2 Lubrication System Use oil that meets the American Petroleum Institute WARNING (API) classification of SC or SH. Using unsuitable oil or neglecting an oil change may result in engine damage that is not covered by the engine warranty. Figure 2-1 shows the recommended Society of Automotive Engineers (SAE) viscosity designation for given operating temperature ranges. -
Page 14: Air Intake System
2.3 Air Intake System Inspect the exhaust system components (exhaust manifold, exhaust line, exhaust clamps, and muffler) for At the interval specified in the service schedule, inspect, cracks and corrosion. clean, or replace the air filter element. Check for corroded or broken metal parts and replace them as needed. -
Page 15: Section 3 Fuel System
Section 3 Fuel System 3.2 Fuel Pump WARNING Electric fuel pumps draw fuel from the fuel tank through a filter and supply clean fuel at the proper pressure and quantity to the generator set engine carburetor. Fuel Pump Test Procedure: Explosive fuel vapors. -
Page 16: Carburetor Troubleshooting
3.3 Carburetor Troubleshooting Bi-metallic Strip Test Procedure: 1. Start and run the generator set until it reaches This section is for fuel-related problems and basic normal operating temperature. (5--10 minutes). carburetor troubleshooting. See Figure 3-2 for carburetor component identification. 2. If the choke plate lever can be rotated counterclockwise adjust or replace the bi-metallic Note: When troubleshooting the fuel system, it is strip. -
Page 17: Flooding
3.3.3 Flooding 3.5 60 and 50 Hz Conversions Flooding occurs from a float level set too high, an To convert the generator set to 50 or 60 Hz follow the inoperative bi-metallic strip, an inoperative choke procedure below. pull-off, a sticking choke plate or float, or a fuel inlet needle held off its seat either by improper seating or dirt Governor 50 or 60 Hz Conversion Procedure: particles. - Page 18 Notes Section 3 Fuel System TP-6079 3/00...
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Page 19: Section 4 Controller Troubleshooting
Section 4 Controller Troubleshooting 4.1 Sequence of Operation 4.1.1 Start This section describes the controller sequence of Press the start/stop switch to the START position to operation during the generator start, run, stop, and fault close the start/stop switch between N and 47 (local or shutdown modes and describes the relay testing remote). -
Page 20: Stop
4.1.3 Stop 4.1.4 Low Oil Level (LOL) Safety Switch Close the start/stop switch between N and 43 (local or When the oil level is low, the LOL shutdown switch remote). contacts close energizing the K4 relay (LED4 lights). The generator set shuts down, as described in The K4 relay energizes (LED4 lights). -
Page 21: Troubleshooting
4.3 Troubleshooting Use the following flow chart as an aid in troubleshooting the wires between components. Always disconnect the main circuit board and the entire generator set. If the external components (remote start/stop switches, the prescribed remedy does not correct the problem, the engine gauge panel, dry relay contact kits, etc.) before circuit board may have to be replaced. - Page 22 Go to B Does the engine start? (next page). Is the K4 relay LED lit? Is there continuity between P4-5 and N? Is 12-volts DC present Is the fuel at the fuel pump pump working? (P9-2)? Is there continuity between P1-9 and P9-1? Troubleshoot the engine.
- Page 23 Does the engine continue Does using the stop switch to run after the start stop the engine? switch is released? The generator set is functioning properly. Did the K4 relay LED light? Does the K1 relay LED light? Is the start/stop switch functional? Does the K5 relay LED Replace the...
- Page 24 Is there AC output when the start button is held and the unit is running? Is there approximately 12 VDC at the brushes? Replace the Is there 12 volts AC output at circuit board. the B1/B2 stator winding? Separately excite the generator set to determine if other components are inoperative.
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Page 25: Section 5 Generator Troubleshooting
Section 5 Generator Troubleshooting 5.1 General 5.1.1 General Troubleshooting To determine the cause of no- or low-AC output , refer to Before beginning following troubleshooting the following steps and the troubleshooting flow chart procedures, read all the safety precautions at the (Figure 5-1). -
Page 26: Separate Excitation
5.1.2 Separate Excitation 7. Remove the jumper wire and reverse the positive (+) and negative (--) leads on the rotor. By separately exciting the generator to determine the Repeat step 5. If the ammeter is stable, ground the presence of a faulty voltage regulator, it is possible to negative (--) lead at its new location on the rotor to determine if a running fault exists in the rotor and/or the engine block. -
Page 27: Powerboostt Iiie Voltage Regulators
5.2 PowerBoostä ä ä ä IIIE Voltage Regulator Test Procedure: Regulators 1. Connect the components as shown in Figure 5-4. The generator set is equipped with a PowerBoostt IIIE 2. Turn the variable transformer setting to zero. Plug voltage regulator. See Figure 5-3. in the variable transformer. -
Page 28: Voltage Regulator Adjustment
5.2.2 Voltage Regulator Adjustment Voltage Regulator Adjustment Procedure: 1. Stop the generator set. The factory sets the voltage regulator and, under normal circumstances, the regulator requires no further 2. Turn the remote rheostat, if equipped, to the adjustment. However, if the voltage regulator has been midpoint. -
Page 29: Rotor
10. Set the engine speed to 47.5 Hz for 50 Hz machined appearance. Wipe the collector rings with a generator sets and 57.5 Hz for 60 Hz generator dry, lint-free cloth. Use a commutator stone to remove sets for the desired cut-in frequency. the groves on the collector rings. -
Page 30: Stator
5.4 Stator Note: When taking an ohmmeter reading using lead 55, make the connection prior to the The stator consists of a series of coils of wire laid in a in-line fuse. laminated steel frame. The stator leads supply voltage 5. -
Page 31: Brushes
5.5 Brushes Replace brushes if they show excessive or uneven wear. The brushes provide a current path from the voltage Use a retainer wire (such as a paper clip) to contain the regulator to the collector rings. Because the brushes brushes during disassembly and reassembly. - Page 32 Notes Section 5 Generator Troubleshooting TP-6079 3/00...
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Page 33: Section 6 Component Troubleshooting
Section 6 Component Troubleshooting 6.1 Engine/Generator Components See Figure 6-1 through Figure 6-3 for engine/generator tables. Check each component using a multimeter to component testing. With the generator set battery verify that the switches function and that voltage is connected, check the wiring harness and the present at each component. - Page 34 To further check the generator set components, WARNING disconnect the battery and remove the wiring harness plugs from the controller circuit board. Use an ohmmeter to check the continuity of the components and to isolate inoperative components. Refer to Figure 6-2 and Figure 6-3. Moving rotor.
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Page 35: Remote Panel (Optional)
If difficulty with the remote operation occurs, test the 6.2 Remote Panel (optional) switch. See Figure 6-4 and Section 8.4 for Kohler Co. offers a remote panel with a start/stop switch troubleshooting the remote start/stop switch. and a hourmeter for connection to the generator set. Component... - Page 36 Notes Section 6 Component Troubleshooting TP-6079 3/00...
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Page 37: Section 7 Generator Disassembly/Reassembly
Section 7 Generator Disassembly/Reassembly 7.1 Disassembly WARNING Disconnect the external connections—battery cables at the battery (negative (--) lead first), AC-output leads in the controller, remote start panel at the controller P3 connector, and the fuel line at the fuel pump filter inlet. Observe all of the safety precautions listed during the Explosive fuel vapors. - Page 38 Disassembly Procedure: 14. Tilt the generator set up and brace it with a block of wood. See Figure 7-3. 1. Place the start/stop switch in the STOP position. 15. Remove the end bracket overbolts. Use a rubber 2. Disconnect the generator set engine starting mallet to separate the end bracket from the stator battery, the negative (--) lead first.
- Page 39 201-191-1 1. Generator adapter plate bolt, quantity 4 11. Fan guard 2. Generator adapter 12. Fan guard bolts, quantity 2 3. Brush holder assembly 13. End bracket 4. Brush holder shim 14. Pipe plug 5. Rotor bolt 15. End drive fitting (for marine application only) 6.
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Page 40: Collector Ring And Bearing Replacement
7.2 Collector Ring and Bearing Minimum diameter, mm (in.) 57.15 (2.250) Replacement Maximum finish, microinches 32.00 Maximum eccentricity, mm (in.) 0.08 (0.003) 1. Unsolder the collector ring leads from the collector Maximum out-of-round, mm (in.) 0.01 (0.0002) ring terminals. Figure 7-6 Collector Ring Dimensions 2. -
Page 41: Section 8 Reconnection And Wiring Diagrams
Section 8 Reconnection and Wiring Diagrams 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 42: Reconnection Diagram 100--120 V, 60 & 50 Hz
8.1 Reconnection Diagram 8.3 Reconnection Diagram 100- -120 V, 60 & 50 Hz 220- -240 V, 50 Hz ADV-5857 ADV-5857 8.4 Remote Start Panel 8.2 Reconnection Diagram 100- -120/200- -240 V, 60 & 50 Hz Stop Local 10--amp P1-9 switch fuse Start P1-14... -
Page 43: Wiring Diagram 5Erkm/4Efrkm
8.5 Wiring Diagram 5ERKM/4EFRKM GM11960- TP-6079 3/00 Section 8 Reconnection and Wiring Diagrams... - Page 44 Notes Section 8 Reconnection and Wiring Diagrams TP-6079 3/00...
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Page 45: 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 46 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...
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Page 47: Appendix B Common Hardware Application Guidelines
Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2. -
Page 48: Appendix C General Torque Specifications
Appendix C General Torque Specifications Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated literature instructions give no specific torque values. threads. All torque values are +0%/--10%. The charts list values for new plated, zinc phosphate, or American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel... -
Page 49: Appendix D Common Hardware Identification
Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM) -
Page 50: Appendix E Common Hardware List
Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14... - Page 51 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Hex Nuts M931-06040-60 M6-1.00 x 40 M933-04006-60 M4-0.70 x 6 M934-03-50 M3-0.50 Standard...
- Page 54 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-6079 3/00 7 Jurong Pier Road Singapore 619159 E Kohler Co., 2000. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...