RV GENERATOR

SERVICE MANUAL
3.5KW-7.5KW
(with relay controller)

KOHLER -
GENERATORS,.’
 Table of Contents

Page Page

Safety Precautions ....................... i Section 6. Generator

Section 1. Introduction and Specifications
l-l. Introduction ............................. l-l 6-l. General .......................... 6-1
l-2. Model 3.5 CM21-RV ...................... l-l 6-2. Troubleshooting .................... 6-1
l-3. Model 4.5 CM21-RV (single) .............. l-l 6-3. Generator Disassembly ............... 6-l
l-4. Model 4.5CKM21-RV (twin) ............... 1-I 6-4. Build-up Circuit .................... 6-7
l-5. Model 5.5 CM21-RV ...................... l-l 6-5. Brushes .......................... 6-8
1-6. Model 7 CM21-RV ........................ l-l 6-6. Slip Rings ........................ 6-9
l-7. Model 7.5 C21-RV ........................ 1-2 6-7. Exciter / Voltage Regulator ............ 6-9
1-8. Oil Specifications ........................ l-4 6-8. Stator .......................... 6-I 1
1-9. Fuel Specifications ....................... l-5 6-9. Rotor. ......................... 6-11
6-10. Separate Field Excitation ............. 6-11
Section 2. Operation
6-11. Voltage Sensing Relay ............... 6-12
6-l 2. Generator Reassembly ............... 6-12
2-1. General. ......................... 2-1
2-2. Prestart Checklist ................... 2-1
2-3. Operation ........................ 2-l
Section 7. Choke, Shutdown Control and
Section 3. Scheduled Maintenance Governor

3-1. General. ......................... 3-1 7-1. Choke Testing and Adjustments

3-2. Scheduled Maintenance ............... 3-I (3.5kW,4.5kW). . . . . . . . . . . . . . . . . . . . 7-1
7-2. Choke Testing and Adjustments
Section 4. Troubleshooting (4.5 twin, 5.5,7, ..........
7.5kW) . . . 7-3
7-3. Positive Shutdown Control .
(3.5kW-7kW) . . . 7-3
4-l. General. ........................ .4-l 7-4. Crankcase Breather (3.5kW, 4.5kW) . . . . . . . 7-4
4-2. RV Systems Check .................. 4-1 7-5. Governor (3.5kW, 4.5kW single). . . . . . . . . . 7-4
4-3. Troubleshooting .................... 4-2 7-6 Governor Hunting Checks (4.5kW Only) . . . . 7-5
7-7. Governor (4.5kW twin). . . . . . . . . . . . . . . . 7-6
Section 5. Relay Controller 7-8. Governor (5.5kW, 7kW) . . . . . . . . . . . . . . . 7-6
7-9. Governor (7.5kW) . . . . . . . . . . . . . . . . . . . 7-7
5-l. Description ....................... 5-1
5-2. Sequence of Operation ............... 5-l Section 8. Wiring Diagrams
5-3. Fuses ........................... 5-4
5-4. REl Diode ....................... 5-5 Appendix
5-5. Relays .......................... 5-5
Radio Frequency Interference Kit.. . . . . . . . . A-l
 Safety Precautions

A Generator Set, like any other electro-mechanical device A WARNING

can pose potential dangers to life and limb if improperly
DANGEROUS ACID! Avoid contact with battery electro-
maintained or imprudently operated. The best safeguards
lyte. It contains acid which can eat holes in clothing, burn
against accident are to be ever mindful of the potential
skin, and cause permanent damage to eyes. Always wear
dangers and to always use good common sense. In the
splash-proof safety goggles when working around the
interest of safety, some general precautions relating to
battery. If battery electrolyte is splashed in the eyes or on
operating of a Generator Set are presented below. Keep
skin, immediately flush the affected area for 15 minutes
these in mind.
with large quantities of clean water. In the case of eye

A WARNING contact, seek immediate medical aid. Never add acid to a

battery once the battery has been placed in service. Doing
LETHAL EXHAUST GAS! An engine discharges deadly so may result in dangerous spattering of electrolyte.
carbon monoxide as part of the exhaust when operating.
Carbon monoxide is particularly dangerous in that it is an .A WARNING
odorless, tasteless, and nonirritating gas, but be ever
EXPLOSIVE t3ATTERY GASES! The gases generated by a
mindful that it can cause death if inhaled for even a short
battery being charged are highly explosive. Do not smoke
period of time. Have only qualified specialists install and
or permit flame or spark to occur near a battery at any
replace exhaust system components and have the system
time, particularly when it is being charged. Avoid contact-
inspected frequently. Be careful when parking your coach
ing terminals with tools, etc., to prevent burns and to
to avoid obstructing the exhaust outlet. The exhaust
prevent sparks that could cause an explosion. Remove
gasses must discharge freely, otherwise carbon monoxide
wristwatch, rings, and any other jewelry before handling
may deflect under and into the vehicle or enter through
battery. Any compartment containing batteries should be
open doors, windows, or vents. Also make sure that your
well ventilated to prevent accumulation of explosive gases. ...
exhaust cannot be discharged toward neighboring RV’s,
To avoid sparks, do not disturb battery charger connec-
campers, or any occupied building. Be especially watchful
tions while battery is being charged and always turn
for exhaust accumulation under calm, windless condi-
charger off before disconnecting battery connections.
tions.
Turn automotive test equipment off when connecting or

A WARNING removing battery clips. When removing or reconnecting

battery cables, make sure ignition switch and all accesso-
ELECTRICAL SHOCK! Battery can cause electrical burns ries are turned off.
and shocks. Exercise reasonable care when working near
the battery to avoid electrical connections through tools. A WARNING
Remove wristwatch, rings, and any other jewelry.
EXCESSIVE NOISE! Never operate without adequate

A WARNING muffler
excessive
or with faulty exhaust system - exposure to
noise is not only tiring but can lead to impair-
HIGH VOLTAGE! Remember that the function of a genera- ment of hearing.
tor set is to produce electricity and that wherever electric-
ity is present, there is the potential danger of electrocu- A WARNING
tion. Take the same precautions with electrical appliances
HOT PIPING! An engine gets hot while running and
in your coach that you would observe in your home. Keep
exhaust system components get extremely hot. Do not
away from electrical circuits and wiring while the set is
work on generator set until unit is allowed to cool.
running and have electrical service performed only by
qualified electricians. Make sure unqualified persons,
especially children, cannot gain access to your set - keep A WARNING
the compartment door locked or securely latched at all
DANGEROUS FUELS! Use extreme caution when hand-
times. Be sure that generator is properly grounded. Never
ling, storing, and using fuels - all fuels are highly
touch electrical leads or appliances with wet hands, when
explosive in a vapor state. Store fuel in a well-ventilated
standing in water, or on wet ground as the chance of
area away from spark producing equipment and out of the
electrocution is especially prevalent under such con-
reach of children. Never add fuel to the tank while the
ditions.

A WARNING
engine is running to prevent spilled fuel from igniting on
contact with hot parts or from ignition spark. Keep fuel
UNIT STARTS WITHOUT NOTICE! To prevent accidental lines and connections tight and in good condition - don’t
starting on units with a remote start/stop switch, always replace flexible fuel lines with rigid lines. Flexiblesections
disconnect battery (remove negative lead first and recon- are used to avoid breakage due to vibration. Should any
nect it last) to disable generator set before working on any fuel leakage, fuel accumulation, or electrical sparks be
equipment connected to generator. noted, DO NOT OPERATE GENERATOR SET. Have sys-
terns repaired by qualified specialists before resuming A WARNING
generator operation. Additional precautions should be
BACKFIRE! A sudden backfire can cause serious burns.
taken when using the following fuels:
Keep hands and face away from the carburetor when the
Gasoline-Store gasoline only in approved red containers air cleaner is removed.
clearly marked GASOLINE. Don’t store gasoline in .any
occupied building. A WARNING
Propane (LP)-Adequate ventilation is mandatory. Pro- FIRE HAZARD! Keep the compartment and generator set
pane is heavier than air; install gas detectors low in room. clean and free of debris to minimize chances of fire. Also
Inspect detectors often. remember that hot exhaust gases and exhaust system
parts could start grass fires. Keep away from hot engine
A WARNING and generator parts’to avoid burning yourself.

UNINTENTIONAL STARTING!
starting when checking choke
To prevent
operation,
accidental
remove spark
A WARNING
plug lead(s) at spark plug(s). MOVING PARTS! Do not open generator set compartment
door when unit is running, except for servicing by quali-
A WARNING fied specialists. Replace guards, covers, and screens (if
used) before operating generator set.
FLASH FIRE! A sudden flash fire can cause serious burns.
To avoid the possibility of a flash fire, do not smoke or
permit flame or spark to occur near carburetor, fuel line,
A WARNING
fuel filter, fuel pump, or other potential sources of spilled HIGH VOLTAGE! When the power cord is plugged in
fuel or fuel vapors. during voltage regulator test, the AC pins become “hot”
and there is danger of electrocution.

A WARNING A WARNING
ELECTROCUTION! Your RV generator set must not be EXPLOSION! Use generator sets specified for RV use in RV
used to “backfeed” by connecting it to building/camp- installations only.
ground electrical circuits. Doing so can cause serious
injury or death to utility personnel working on utility
transmission lines and may also seriously injure persons in
your household. Unauthorized connection may be unlawful
in some states and/or localities. A transfer switch must be
installed in the RV to prevent interconnection of generator
and outside source of power.
 Section 1.
Introduction and Specifications

l-l. INTRODUCTION 120 volt, 37.5 amp alternating current. It has a rotor with
four magnetic poles and operates at 1800 R.P.M., produc-
This manual covers operation, scheduled maintenance ing 60 hertz. A 40 amp line circuit breaker protects
troubleshooting and corrective maintenance for Kohler gen- generator against damage due to overload. See Figure l-2
erator sets designed and built for recreational vehicles. The for major components.
six standard models are the 3.5CM21 -RV, 4.5CM21-RV, 1-4. MODEL 4.5CKM21-RV
4.5CKM21 -RV, 5.5CM21 -RV, 7CM21 -RV and 7.5C21 -RV.
These models are referred to by their kilowatt output, The 4500 watt generator set is powered by a two cylinder
3.5kW, 4.5kW (single), 4.5kW (twin), 5.5kW, 7kW and Kohler Model KT17 engine. The set produces 120 volts,
7.5kW. Differences between models are noted throughout 37.5 amp alternating current. It has a rotor with four mag-
the manual. All models feature Kohler designed and built netic poles and operates at 1800 R.P.M., producing 60
4-cycle gasoline engines, rotating field generators and relay hertz. Two 20 amp circuit breakers protect against damage
controllers. See Table l-l for specifications and model vari- due to overload. See Figure l-3 for major components.
ations, Table 1-2 for dimensions and weight, and Table l-3
for engine specifications. Refer to the wiring diagrams in 1-5. MODEL 5.5CM21-RV
the back of the manual. The 5500 watt generator set is powered by a two cylinder
Kohler Model K582QS engine. The set produces 120 volt,
I-2. MODEL 3.5CM21-RV
46 amp alternating current. It has a rotor with four magne-
The 3500 watt generator set is powered by a single tic poles and operates at 1800 R.P.M., producing 60 hertz.
cylinder model K181 QS engine. The set produces 120 volt, A 50 amp circuit breaker (on most models) protects against
29 amp alternating current. It has a rotor with two damage due to overload. See Figure I-4for major compon-
magnetic poles and operates at 3600 R.P.M., producing 60 ents.
hertz or 3000 R.P.M., producing 50 hertz, 13 amp current.
1-6. MODEL 7CM21-RV
A 30 amp circuit breaker protects the set from overload
damage. Due to its compact size and lightweight, it is The 7000 watt generator set is powdered by a two cylinder
installed in RV’s with limited suspension support and Kohler Model K582QS engine. The’set produces 120 volt,
compartment space. See Figure l-l for major components. 58 amp alternating current. It has a rotor with four magne-
1-3. MODEL 4.5CM21-RV tic poles and operates at 1800 R.P.M., producing 60 hertz.
A 60amp circuit breaker (on most models) protects against
The 4500 watt generator set is powered by a single damage due to overload. See Figure I-4for major compon-
cylinder Kohler Model K341QS engine. The set produces ents.

Amps Per ..
Model Volts Term in al Watts Freq. (HZ) RPM Wires, I Phase

3.5CM21-RV 120 29 3500 60 3600 2 1

3.5CM61-RV 120/240 14.5 3500 60 3600 3 1
3.5CFM21-RV 120 26.6 3200 50 3000 ‘2 1
3.5CFM61-RV 120/240 13.3 3200 50 3000 3 1
4.5CM21:RV 120 37.5 4500 60 1800 2 1
4.5CM61 -RV 120/240 18.8 4500 60 * 1800 3 1
4.5CFM21-RV 120 30 3600 50 1500 2 1
4.5CFM61-RV 120/240 15 3600 SO 1500 3 1

4.5CKM21 -RV 120 37.5 4500 60 1800 2 1

4.5CKM61 -RV 1201240 18.8 4500 60 1800 3 1
5.5CM21 120 46 5500 60 1800 2 1
5.5CM61 120/246 23 5500 . 60 1800 3 1
5.5CFM21 120 37.5 4500 50 1500 2 1
5.5CFM61 120/240 18.8 4500 ,50 1500 3 1
7CM21 120 58 7000 60 1800 2 1
7CM61 120/240 26 7000 60 ’ 1800 3 1
7.5C21 120 62.5 7500 60 1.800 2 1
7.5C61 120/240 31.3 7500 60 1800 3 1

Table l-l. Generator Specifications

l-l
1-7. MODEL 7.5CZl-RV

The 7500 watt generator set is powered by a four cylinder torfrom overload. On the 7.X21 model-s, the set produces
Kohler Model L654 liquid-cooled engine. Two 30 Amp 120 volt, 62.5 amp alternating current. On the 7.5661
circuit breakers protect the rotating field 60 Hertz genera- models, 120/240 volt, 31.3 Amp alternating current is
produced. See Figure 1-5 for major components.

,
Specification 3.5 Model 4.5 Model 4.5 Model 5.5 Model 7.0 Model 7.5 Model
(Single) KT17 Series II
4
Weight (approximate) 150 lb. 235 lb.* 230 lb.** 315 lb. 334 lb. 470 lb.
(68.0 kg) (106.6 kg) (104.3 kg) (142.9 kg) (151.5 kg) (213.2 kg)
Length - Overall 22” 23- 13/26” 28-5/l 6” 26” 27-l/2” 43-l /4”
(55.9cm) (60.5cm) (71.9 cm) (66.Ocm) (69.8cm) (109.8cm)
Width - Overall 13-3/4” 18-3/l 6” 1 20-3/4” 21-l/2”
(34.9cm) (46.2cm) 1 (52.7 cm) (54.6cm)

Height - Overall 15-314” 19-l /I 6” 17-9/l 6” 20-3/8” 20-3/8” 25-l /4”

(40.0cm) (48.4cm) (44.6 cm) (51.8cm) (51.8cm) (64.1cm)
A A
**KT17 Series I *Earlier Models 250 Ib.
235 lb. (106.3 kg) (113.4 kg)

Table l-2. Dimensions and Weight

.
4.5 Model 4.5 Model
Specifications 3.5 Model 5.5 Model 7.0 Model 7.5 Model
(Single) (Twin)
Fuel Inlet Connection l/4” I.D. l/4” I.D. 7/l 6-20 l/4” I.D. l/4” I.D. 7/l 6-20
Size U.N.F. U.N.F.

Battery Voltage 12v 12v 12v 12v 12v 12v

Battery Amp Hr. 55 55 55 55 55 90

Battery Ground Negative Negative Negative Negative Negative Negative

Battery Cranking 40 amps 76 amps 76 amps 98 amps 98 amps 120 amps

Current

Battery Charging 15 amps 7 amps 7 amps 7 amps 7 amps 4 amps

Current

Engine Model K181QS K34 1QS KTI 7 K582QS K582QS L654

Breaker Point Gap 0.020” 0.016” to 0.012” to 0.020” 0.020” 0.015”

(0.51 mm) 0.020” 0.018” (0.51 mm) (0.51 mm) (.381mm)
(0.41 mm to (0.30mm to
0.51 mm) 0.45mm)

RPM 3600 1800 1800 1800 1800 1800

Fuel System Choke Automatic Automatic Automatic Automatic Automatic Automatic

Thermal/Electric Thermal/Electric Thermal/Electric Thermal./Electric Thermal/Electric Thermal/Electric

Spark Plug Gap 0.035” 0.035” 0 -025” 0.035” 0.035” .0.025”

(0.89mm) (0.89mm) (0.64mm) (0.89mm) (0.89mm) (0.64mm)

Total Air 376cfm 396cfm 417cfm 675cfm 675cfm 1777cfm

Requirements (10.7m3/min.) (11.2m3/min.) (11 .7m3/min.) (19.1m3/min.) (19.1 m3/min.) (49.75m3/min.)

Frequency Regulation 5% 5% 5% 5% 5% 5%

25% Load 0.35 gal/hr 0.52 gal/hr 0.40 gal/hr 0.55 gal/hr 0.56 gal/hr 0.7 gal/hr
(1.3 lts/hr) (2.0 lts/hr) (1.5lts/hr) (2.1 lts/hr) (2.1 lts/hr) (2.6 lts/hr)
._g
‘; 50% Load 0.46 gal/hr 0.60 gal/hr 0.50 gal/hr 0.61 gal/hr 0.66 gal/hr 0.8 gal/hr
5v) (1.7lts/hr) (2.3 lts/hr) (1 .9lts/hr) (2.3 lts/hr) (2.5 lts/hr) (3.0 lts/hr)
c
s 75% Load 0.57 gal/hr 0.73 gal/hr 0.60 gal/hr 0.73 gal/hr 0.84 gal/hr 1.1 gal/hr
z (2.2 lts/hr) (2.8 lts/hr) (2.3lts/hr) (2.8 lts/hr) (3.2 Its/h r) (4.2 Its/hr)
l? .
100% Load 0.74 gal/hr 0.92 gal/hr 0.80 gal/hr 0.88 gal/hr 1.08 gal/hr 1.4 gal/hr

I I (2.8 Itslhr) I (3.5 Its/hr)

I (3.0lts/hr) I (3.3 lts/hr) , (4.1 lts/hr) , (5.3 lts/hr) ,

Table 1.3 Engine Specifications

1-2
 AIR COOLING SPARK
SHROUD
AIR
REMOTE CIRCUIT CL EANER
CONTROL PROTECTOR

BATTERY
CHARGING
CONTROLLER
RECTIFIER
REGULATOR

(HIDDEN) I

INTAKE

TIMING
SIGHT
INTAKE HOLE
BATTERY -+@ /
POSITIVE
CONNECTION

GROUND STRAP

Figure 1-1. Service Side View of a Kohler 3500 Watt RV Generator Set

AIR SPARK PLUG

COOLING SHROUD

DRY ELEMENT
AIR CLEANER
CIRCUIT _ GOVERNOR
PROTECTORS\ REGULAT(

REMOTE FUEL
CONTROL PUMP
EC EPTAC L HARNESS PLUG

BREAKER POINT

iONTROLLER AIR INTAKE

/ SCREEN

TIMING
SIGHT
HOLE

START-STOP
SWITCH

OIL FILL TUBE

BATTERY AND DIPSTICK
POSITIVE ,
CONNECTION
I STRAP

AIR DISCHARGE
0lL DRAIN (UNDER UNIT)

Figure l-2. Service Side View of a Kohler 4500 Watt Single Cylinder RV Generator Set
 BREATHER_ AIR DUCT

/ IGNITION

thtMtNT

EXHAUST .d ~.
..”
TUBE

FUEL
LINE

i OIL FILL
CIRCUIT
?OTECTOR

VOLTAGE / FINS
c
EGULATOR
&j \ FUEL
PUMP

COOLING SLOTS /
$p”
:i:::::
,;:z> r..
“’
.:’
,:*.
:
,::. : ,, :.:::::,A~
./:
..,,,,,.
>::: ;,..1’

’ CONTROLLER
EQUIPMENT
GROUND

Figure 1-3. Service Side View of a Kohler 4500 Watt Twin Cylinder RV Generator Set

AIR CLEANER
. CARBURETOR

UST CIRCUIT PROTECTORS

BREAKER POINT ES
COVER (ON / b=AA9TE CONTROL
GOVENOR) ICEPTACLE

BATTERY
CHARGING VOLTAGE
REGULATOR EGULATOR
GOVERNOR

FULL-FLOW
CONTROLLER
OIL FILTER

OIL FILL TUBE

& DIPSTICK
‘OP
BLOWER , Ah I I SWITCH
HOUSING
/

GROUNDING

AIR I
MOUNTI “ISCHARGE
Y
BATTERY POSITIVE
CONNECTION
OIL DRAIN LOCATED
UNDER UNIT

Figure I-4. Service Side View of a Kohler 5500 or 7000 Watt RV Generator Set

I-4
l-8 OIL SPECIFICATIONS
MODEL CAPACITY
Use high quality detergent oil of API (American Petroleum
Institute) service class SF. Select viscosity based on the 35kW 1 Quart (0.95 Iitres)
air temperature at the time of operation as shown below: 4.5kW (Single) 2 Quarts (1.89 litres)

RECOMMENDED SAE VISCOSITY GRADES 4.5kW (KT17

I Series I) 3.8 Quarts (3.6 litres)
!
4.5kW (KT17
Series II) 1.5 Quarts (1.4 litres)

I
5.5kW 4 Quarts (3.78 litres) (Additional
I
I 1 I
I
l/2 quart (0.47 litres) when filter
I
T 1 r I I
'F-50 6 20 32 40 60 80 100 is replaced)
t I I T I I I I
c-30 -20 -10 0 10 20 30 40
7kW 4 Quarts (3.78 litres) (Additional
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
l l/2 quart (0.47 litres) when filter

Straight 30 weight oil is preferred. If multi-viscosity is is replaced)

used, be aware of the resulting increase in oil consump- 7.5kW 5 U.S. Quarts (4.73 Iitres)
tion and combustion deposits when used in temperatures
above 32’ F (0” C). Table 1-5. Oil Capacity
Using other than service class SF oil, or extending oil Unleaded is recommended since it leaves less combus-
change intervals longer than recommended could cause tion chamber deposits. Regular grade leaded gasoline
engine damage which is not covered by the engine may also be used; however, be aware that the combustion
warranty. chamber and cylinder head will require more frequent
On a new engine, change the oil after the first five hours of service.
operation, and thereafter on K181QS and K341 QS change Use fresh gasoline to ensure it is blended for the season,
oil every 25 hours. On KT17, K582QS and L654, change and to’ reduce the possibility of gum deposits forming
oil every 50 hours. which could clog the fuel system. Do not use gasoline left
I-9. FUEL SPECIFICATIONS over from the previous season.
For best results, use only clean, fresh, regular grade Gasohol containing no more than 10% ethanol can be
unleaded gasoline with a pump sticker octane rating of 87 used if unleaded gasoline is unavailable. Never use gas-
or higher in the U.S.A. In countries using the Research ohol containing more than 10% ethanol or gasoline con-
rating method, it should be 90 octane minimum. taining methanol. Do not add oil to the gasoline.
SPARK
RADIATOR FILL CRANKCASE
PLUGS
\ A BREATHER

\ /I\\ (HIDDEN)
I
CIjRBURETOR

VALVE
TAPPET,
COVER
REMO’ TE
CONTR OL

BELTTENSION
C:ONNEC TOR
ADJUSTMENT

GOVERNOR
ADJUSTMEN

OIL PRE
GAUGE / OIL PRESSURE \
OIL CONTROLLER
ADJUSTMENT \
/ FILL/CHECK \ GROUN
I /
OIL
MOUNTING FUEL FUEL STRAF
DRAIN
TRAY SOLENOID PUMP

Figure 1-5. Service Side View of Kohler 7500 Watt RV Generator Set c

l-5
 Section 2
Operation

2-l. GENERAL

Operation of the generator set is controlled by a single

switch on the controller (Figure 2-l). This switch is a
momentary contact, three-position, start-run-stop switch.
It is spring loaded to return to the center (run) position
when released from either the start or stop position. This
switch must be held in the desired position until the unit
is running or has come to a complete stop. The controller
includes a keyed connector for starting and stopping the
set at an optional remote switch located inside the vehicle.

2-2. PRESTART CHECKLIST

Refer to Table 2-l for all prestart checks.

CHECK REQUIREMENT

Oil Level Near Full (Not Over)

Air Inlets Unobstructed
Compartment Clean
Air Cleaner Clean, Properly Installed
Air Shrouding Tight, Proper Position
Exhaust System Unobstructed, Properly
lnstal led
Electrical Connections Clean and Tight

Table 2-I. Prestart Checklist

2-3. OPERATION

NOTE
Figure 2-I. Controller
If the generator set shuts itself down due to
high engine temperature or low oil pressure,
the cause must be located and eliminated
before the set can be restarted. Also, make
sure the circuit breaker(s) is in the “on” posi-
tion so generator output is transferred to the ‘I. Move the START-STOP switch on the controller to
load. START position and hold until the engine is running but
not more than 10 seconds. Normally the engine will start
CAUTION within five seconds. If the engine does not start in 10 sec-
onds, release the switch and wait a few seconds before mov-
In the event of a “false start”, that is, the en- ing back to START position. This allows the choke to reset
gine gets up sufficient speed to disengage the in the full choke position.
starter but fails to continue running, allow the
engine to come to a complete halt before
making a restart attempt. If the flywheel is 2. Whenever possible allow a brief cooling period by run-
still rotating when the starter is engaged, the ning the set at low or no load for a few minutes just prior
starter pinion and ring gear will clash which to shutdown. To stop, move the switch to STOP position
may damage the ring gear teeth. and hold until the set comes to a complete halt.

2-I
 Section 3
Scheduled Maintenance
3-l. GENERAL 3-2. SCHEDULED MAINTENANCE
Scheduled maintenance is “preventive” maintenance. Refer to Table 3-1 for scheduled maintenance requirements.
Major repair can be avoided by correcting problems when Perform each function at the indicated time interval. For
they are small. When performing maintenance, always each function, refer to the applicable paragraph for instruc-
look for signs of potential trouble, such as loose connec- tions.
tions or dirty components. When running the set, listen for
any unusual noises.
NOTE
NOTE - Oil Change
On a new engine change the oil after the first For maintenance work on engine components,
five hours of operation, and thereafter on refer to the Kohler engine service manual
K181QS and K341QS change oil every 25 which covers the engine model.
hours. On KT17, K582QS & L654 change oil
every 50 hours.
1

Before Every Every Every Every

.
Each 25 50 100 500
Function Startup Hours Hours Hours Hours
.
Compartment - Remove dirt. Blow dry
compressed air through cooling inlets
(set running). X
I
Air Inlet and Outlet - Clean. X

Oil Level - Check. X

Check Exhaust Pipe. X

I
Oil - Change. See note above.

. Oil Filter - Change. X

Air Cleaner Element - Clean

(change every 200 hrs.). X

Fuel Sediment Bowl or Filter

(if equipped) - Remove and clean. X

Clean Electric Fuel Pump Filter -

See owner’s manual. X

Check Coolant Level In Radiator (7.5KW) X

Check Fan Belt Tension (7.5KW) X

Spark Plug - Clean and regap. X

Point Contacts - Service or replace. X

Brushes and Collector Rings -

Check and service. X

Ignition Timing - Check and correct. X

Rectifier - Regulator - Check

condition and battery charging. X

Alternator Stator - Check leads and

connections. X

Starting Motor - Check brushes &

commutator. X

Engine External Surface - Clean screen,

cooling fins, block, oil fill area. X

Valve Clearance - Check and adjust

valve stems and tappets. X
I
Crankcase Breather - Check valve and
gaskets, clean filter, check hoses. X

Cylinder Head - Remove, clean

and inspect. X
.
Electric Fuel Pump - Service filter. X
Check Electrolyte Level in Battery
1-i: 50 hours. ---_--.-_ . ..-__
Table 3-1. Scheduled Maintenance

3-1
 Section 4
Troubleshooting
4-l. GENERAL CAUTION

When troubleshooting a generator set, always consider the Do not push the V.B.U. button after the “GEN
simplest causes first. Narrow the problem down to a func- ON” lamp is on. Voltage regulator damage may
tional system, such as fuel or ignition. To operate efficient- resu It.
ly, an engine must have sufficient fuel, a good ignition
spark and good compression. All adjustments must be
correct. For a generator to produce the required electricity,
CAUTION
all parts must be clean, all connections tight, and all com-
ponents in working order. See Table 4-l for Engine Trou-
bleshooting and Table 4-2 for Generator Troubleshooting. Do not use the RV Systems Check as a replace-
ment for the controller. The hi-temp and low
4-2. RV SYSTEMS CHECK oil pressure switches will not shut the machine
down in the event of a malfunction. Generator
The “RV Systems Check” is designed to check the electri- damage will result.
cal status of an RV generator set prior to connecting and
testing with the controller. If the generator does not check
out in each step, correct the malfunction before proceeding 1. Make sure the battery is properly connected and oil is
to the next step. at proper level.
CAUTION

Do not push the CRANK button after the en- 2. Check the three fuses in the RV Systems Check tester
gine is running. Starter damage will result. (Figure 4-l). Replace any blown fuses.

“RV SYSTEMS CHECK”

CONNECT TO RV GENERATOR
*WIRING HARNESS PLUG
SWITCHES
“Ignition” - Supplies battery voltage to ignition coil,
choke heater, fuel control solenoid, fuel valve
and fuel pump.
“Crank” - Supplies battery voltage to starter relay.

RV
Note: May be actuated with ignition switch on
‘II I or off.
SYSTEMS CHECK “Choke” - Supplies battery voltage to choke plate
solenoid. Note: May only be actuated during
GEN cranking.
POL. CRANK ON’ SAFETY “V.B.U.” - Voltage Build Up, supplies battery vol-
tage to excite field.
VISUAL INDICATORS
“Pol” - Green - Indicates battery polarity correct.
IGNITION “GEN. ON” -. DOES NOT FUNCTION ON SETS
EQUIPPED WITH RELAY CONTROLLERS.
ON OFF
“Crank” - Amber -’ Indicates battery voltage signal
present during cranking.
“Safety Switch” - Amber - Indicates safety circuit
CRANK CHOKE V. B.U. wiring correct. Operator must manually short
temperature switch to ground to obtain this
indication.

[Check Tester Fuses First In Case Of Malfunction 1

FUSES
15 AMP - IGN/CRK 3 AMP - V.B.U.
1 AMP -CHOKE

Figure 4-1. RV Systems Check

4-1
3. Remove the 12 pin connector from the controller and NOTE
plug it into the tester.
On 5.5kW, 7kW and 7.5kW sets, the SAFETY
4. Observe the POL (polarity) lamp. Green light indicates lamp will go off after the engine has reached
battery polarity is correct. If lamp does not light, check for sufficient operating oil pressure.
correct battery connection to the generator set. IO. To check the high temperature cutout, low oil pressure
cutout and/or the oil level cutout for proper operation,
NOTE start the generator set and connect a jumper wire from the
cutout device to ground. The “amber” safety lamp should
On 5.5kW, 7kW and 7.5kW sets the SAFETY light, indicating the protective circuit is functioning prop-
lamp will also be on. This indicates the low oil erly.
pressure switch is functioning properly.
11. If all checks are OK, connect the 12 pin connector to
5. With the IGNITION switch in OFF position, press the the generator set controller.
CRANK button. The CRANK lamp should light and the
engine should crank. If the lamp does not light, no voltage If the 15 amp fuse blows, check for defective cranking
from the battery is present. solenoid, fuel pump or fuel solenoid, ignition coil, choke
heater, fuel shutdown control or shorted wiring.
6. Remove the air cleaner cover to observe the choke plate
during the next step. If the 1 amp fuse blows, check for defective choke sol-
enoid or wiring.
7. Again, with the IGNITION switch in OFF position press
the crank button. While the engine is cranking, press the If the 3 amp fuse blows, check for shorted or grounded
CHOKE button to supply battery voltage to the choke generator rotor or defective voltage regulator.
plate solenoid. Make sure the choke plate is functioning
properly. If not, see Section 7. Release the CRANK and
CHOKE buttons.

4-3. TROUBLESHOOTING
8. With the IGNITION switch ON, start the engine, using
CRANK and CHOKE buttons as needed. If engine does not
Refer to Table 4-l for engine troubleshooting. To make
start, see Engine Troubleshooting, Table 4-l. With engine
engine repairs, refer to the Kohler engine service manual
at operating speed, press V.B.U. (voltage build-up) button
which covers the engine model. A troubleshooting chart
momentarily. Check for generator output voltage. If no
cannot cover every possible cause of malfunction. Always
output voltage is available, see Troubleshooting Gen-
consider every possible cause of malfunction. Knowledge
erator., Table 4-2.
of four cycle engines and battery ignition systems can
be applied. Refer to Table 4-2 to troubleshoot the genera-
9. Turn the IGNITION switch to OFF position to stop the tor. The table refers to applicable paragraphs in the manual.
engine.

4-2
 CONDITION POSSIBLE CAUSE

A. Hard Starting or Loss of Power 1. Faulty Ignition.

a. Loose or grounded high tension or breaker point leads.
b. Improper breaker point gap and timing.
c. Defective breaker points.
d. Faulty spark plug or improper gap.
e. Faulty condenser or coil.
f. Weak battery.
2. Faulty Fuel System.
a. Gasoline not getting to carburetor.
A. Dirt or gum in fuel line.
B. Fuel pump faulty.
b. Dirt in carburetor.
c. Carburetor improperly adjusted.
d. Choke faulty or improperly adjusted.
e. Stale fuel.
f. Carbon build up.
g. Possible intake manifold vacuum leak.
3. Valve maintenance.
4. Defective Automatic Compression Release (ACR).

B. Overheating 1. Insufficient available cool air.

2. Dirty air intake screen, shroud or cooling fins.
3. Stale fuel.
4. Fuel mixture too lean.
5. Improper ignition timing.
6. Engine overloaded.
7. Tight tappet clearance.
8. Insufficient hot-air discharge opening.
9. Loose or broken fan belt (7.5kW).
10. Low coolant level (7.5kW).
11. Too much lube oil.
12. Summer/Winter air baffle in wrong position.

C. Backfiring ‘I. Fuel mixture too lean.

2. Improper timing.
3. Valve “sticking”.
4. Possible intake manifold vacuum leak.

D. Occasional “skip” at High Speed 1. Spark plug gap too wide.

2. Improper carburetor setting or lack of fuel.
3. Wrong type spark plug. Use resistor type plug.
4. Improper timing.
5. Faulty condenser.

E. Operating Erratically 1: Clogged fuel line.

2. Water in fuel.
3. Faulty choke control.
4. Improper fuel mixture.
5. Loose ignition connections.
6. Vacuum leaks in manifold or carburetor connection.
7. Vent in gas cap plugged.
8. Fuel pump faulty.
9. 4CR installed upside down. Solenoid should be to the bottom.
IO. Improper ground on anti-dieseling device.

Table 4-1. Engine Troubleshooting

Refer to Kohler Engine Service Manual for Repair. 4-3

defer to Generator Owner’s Manual for Adjustments.
 CONDITION POSSIBLE CAUSE/CORRECTION (SECTION)

1. Engine will not crank. 1. Battery cable connections reversed. (Must be negative ground.)
2. 10 amp fuse in controller blown (5-3).
3. Defective start switch or “C” relay (5-2).
4. Open circuit in wiring harness or connector.
5. Faulty starter motor.
6. Open circuit in REI diode (5-4).
7. Normally closed 3CR contacts, open (5-5).
8. Busted or loose ground strap.

2. Engine cranks but will not start. 1. Choke not operating or out of adjustment (7-1, 7-2).
2. Check fuel supply to carburetor.
3. Faulty fuel shut-down control (7-3).
4. Faulty fuel pump.
5. Dirty or stuck ignition points.
6. Faulty condenser.
7. Faulty spark plug.
8. 2CR relay not functioning. Must have battery voltage on positive
connection of ignition coil (5-5).
9. Fuel mixture. Replace.

3. Engine starts, then stops when 1. No AC generator output.

switch is closed. 2. Faulty 3CR interlock relay (5-5).
3. Faulty 4CR voltage sensing relay (5-5).
4. Faulty exciter voltage regulator (6-7).

4. No AC output. 1. Circuit breakers in the off position (2-3).

2. Generator brushes not making contact on slip rings (6-5).
3. Faulty build-up circuit. Battery voltage must be present at terminal
“B” of regulator during cranking (6-7).
4. Open connection in wiring harness or plug connector (5-2).
5. Faulty exciter voltage regulator (6-7).
6. Circuit protector tripping due to overload, reduce load.

5. Low output or excessive drop in 1. Generator set overloaded.

voltage (below 1 IO volts). 2. Engine rpm set too low (7-5 thru 7-9).
3. Faulty exciter voltage regulator (6-7).
4. Poor stator coil connections, use a clamp-on ammeter and check
each connection. .

6. High AC voltage (above 125 volts AC). 1. Faulty exciter voltage regulator.
2. Stator reconnected improperly.

7. Engine shuts down for no apparent

1. Generator set overheated - improper installation. Refer to RV
reason.
installation manual or 75kW Owner’s Manual.
2. No fuel.
3. Oil level or oil pressure system failure.
4. Faulty shutdown solenoid.

8. Unit will not operate with remote I. Incorrect wiring of remote switch to remote plug assembly. Center
switch - OK at controller. pole of remote switch must connect to terminal 4 of remote harness
plug, Figure 5-2.
2. Open connection in wiring.

Table 4-2. Troubleshooting Generator

 Section 5
Relay Controller
5-I. DESCRIPTION REMOTE CONTROL WIRING HARNESS
CONNECTOR / PLUG
All generator set functions are dependent upon the control-
ler. See Figure 5-l for parts identification. For operation
instructions refer to Section 2. The controller includes a
keyed connector for installing a remote switch and hour-
meter panel. This optional remote switch allows the oper-
ator to start and stop the generator set from another loca-
tion in the vehicle. The hourmeter records the hours of
generator set operation (Figure 5-2). The controller can be
removed by removing the two snap connectors and two
capscrews underneath the controller. This section covers
sequence of operation, and fuse, diode, and relay replace-
ment.

5-2. SEQUENCE OF OPERATION

The Relay Controller is the controlling point for generator

set operation. The following is the sequence of operations IGNITION RELAY REI 3CR
controlled by the Relay Controller. See Figures 5-3 DIODE INTERLOCK RELAY
.
through 5-7.
Figure 5-1. Controller

12 VOLT
GENERATOR
“ON” LIGHT

12 VOLT
HOURMETER

Lead Designation SPRING LOADED

. . START-STOP
Pin No. Color Gauge of Wire

1 Red 18
2 White 22
3 Brown 22
4 Black 18
5
6 Blue 22

REMOTE CONTROL CONNECTOR HARNESS

(ON CONTROLLER) PLUG
/

APPLIES TO SWITCH A-269299 ONLY KOHLER PART NO. PA-269966

Figure 5-2. Remote Control Connections

5-l
 llO AMP
lN.LINE
FUSE

I
CHOKE HTR.

d
\;/-
.
2CR
8 /

ZCR I I

*EARLIER MODELS ONLY *EARLIER MODELS ONLY

238760 238749

Figure 5-3. Sequence of Operation Figure 5-4. Sequence of Operation

Schematic 3.5kW Schematic 4.5kW (Single)

52
 5 II
-STARTER 1

REuOTE SW.

+
YLL
2CR EINTS
2 + ICN -
OIL e II

LIITLUI I

BREAKER

STD. ON 7kW
OPTION 5.5kW

. :
Q%. Qb +O-.
. I, 1 .
.

“EARLIER MODELS ONLY 277948 *EARLIER MODELS ONLY 277931

Figure 5-5. Sequence of Operation Figure 5-6. Sequence of Operation

Schematic 4SkW (KT17 Series I) Schematic 5.5 & 7kW

5-3
 2. Energizing the 2CR relay will allow current to flow
I2 VOLT
through the 10 Amp in-line fuse to the ignition coil, choke
heater, carburetor shut-down solenoid and electric fuel
pump (if equipped).

3. Energizing cranking contactor “C” will allow current to

flow to the starter motor and crank the engine. The car-
buretor choke solenoid will also be energized and current
can flow through the normally closed 4CR contacts to the
“B” terminal of the aenerator voltage regulator for the
initial voltage build-up.

4. When the engine starts and the generator is producing

AC output, the 4CR relay (mounted in the generator end
bracket) will energize.

3CRT 5. The
. . normally CLOSED contacts in the V.B.U. (voltage
bui,ld-up) circuit will then open and disconnect the battery
supply from the generator voltage regulator.

6. The normally OPEN 4CR contacts will close and allow

the 3CR relay to become energized. All the 3CR contacts
will then change positions, the normally open contacts
La?-
will close and the normally closed contacts will open.

FUEL ‘PUMP
7. The normally closed 3CR contacts in series with the
“C” cranking contactor will open deenergizing the “C”
contactor. This offers protection from engaging the starter
motor while the unit is operating.

.
8. The 3CR contacts in series with the 2CR relay coil will
close, maintaining current flow to the 2CR relay coil.
The 2CR relay controls current flow to the engine ignition
circuit.

9. The now closed 3CR contacts in series with the ICR

I relay coil and engine safety cutouts will allow the ICR relay
TRANSFORMER
to become energized if the safety cutout contacts close.
The ICR relay also energizes when the start-stop switch is
placed in the stop position.

10. Energizing the ICR relay, either by the engine safety

cutouts or by placing the start-stop switch to the stop posi-
tion will disrupt current flow to the 2CR relay coil and in
turn prevent current flow to the ignition circuit when the
2CR contacts in this circuit open.

Y
i
L2 LI
r
t
CEN:: ATOR

LO
5-3. FUSES

UNIT STARTS WITHOUT

A WARNING
NOTICE! To prevent accidental
starting on units with a remote start/stop switch, always
disconnect battery (remove negative lead first and recon-
“EARLIER MODELS ONLY
241753 nect it last) to disable generator set before working on any
equipment connected to generator.
Figure 5-7. Sequence of Operation
Schematic 7.5kW There is one IO Amp fuse inside the controller (Figure 5-l).
This fuse protects the controller against damage in the
event a short develops in the engine wiring. If this fuse
“blows” the set will stop. If the set has stopped due to
1. Pressing the start-stop switch to the start position ener- causes other than lack of fuel, engine malfunction, or low
gizes both the cranking contactor “C” and the 2CR relay. oil pressure, remove the cover of the controller and check
(Diode REI will prevent this from happening if the battery the fuse. If blown, replace the fuse then attempt to restart
is connected in reverse.) the generator set. If the set will not start, or if the fuse
blows again, locate and correct the cause.
5-4
 NOTE 5-5. RELAYS

On earlier models a 10 Amp fuse is mounted in-

There are four relays in the generator set. One relay is lo-
line between the controller and ignition coil.
cated in the generator end bracket (Figure 6-7). The other
See the wiring diagram, It protects the control-
three relays are mounted inside the controller. Refer to
ler in the event of a shorted or failed ignition
Figure 5-8 when checking or replacing relays. The function
coil, fuel pump, choke heater, shut-down con-
of each relay is described below.
trol or engine wiring.

. ICR (STOP RELAY) - When energized, deenergizes

NOTE
the 2CR relay.
If the 10 Amp in-line fuse is blown the engine
l 2CR (IGNITION RELAY) - When energized, pro-
will not crank. If the 10 Amp fuse inside the
vides battery supply to the engine electrical system.
controller is blown the engine will crank but
not start. If either fuse blows while the engine l 3CR (INTERLOCK RELAY) - When energized, de-
is running, the set will stop. energizes the “C” cranking contactor, and provides
current to energize the ICR relay upon closing of the
engine safety cutouts.
NOTE
l 4CR (VOLTAGE SENSING RELAY) - When ener-
On 4.5 (twin) & 7.5kW models, a self-resetting gized, disconnects excitation current from battery to
circuit breaker located in the generator end regulator and field (V.B.U.), and energizes the 3CR
bracket protects the battery charging circuit. relay. (The 4CR relay is located inside the generator
The 7.5kW model uses an 8 Amp circuit break- end bracket.)
er. The 4.5kW (twin) and early 7.5kW models
use a 5 Amp circuit breaker. STARTING 1 RUNNING 1 STOPPING

5-4. REl DIODE “C” contactor 4CR relay ’ 1CR relay

energized energized energized
A diode is located in-line between the start-stop switch and
2CR relay 3CR relay
the 2CR relay to protect against reverse battery polarity.
energized energized
When replacing the diode, make certain connections are
made with the arrow on the diode directing away from the 2CR relay
start-stop switch (Figure 5-8). energized

5-5
 THE SCHEMATIC BELOW SERVES AS
A GUIDE TO LOCATING PROPER
TERMINAL CONNECTIONS.

0 0
- COVER

TERMINAL CONNECTIONS AS
SHOWN ON WIRING DIAGRAM
0 0

START

I STOP
SWITCH

CONTROLLER

CONNECTORS SHOWN
FROM PIN INSERTION
SIDE -lr

---
r l
1
I
I
I
c
I I
I I I
I IOAMPFUSE I I
I I I
I ! I
I I I I
I I
I I
I I
I I
I I
I .I
I I
-m----- ~~~~~~--~~-----~

LOCAL CONTROL BOX A-241752 COVER

(SHOW FROM RcAR)
277947

I
I
I
I
I
I
.I
~~~~,~~~ w-&-w------ --e,u#
I
- - - - - LOCAL CONTROL
801 A-241939 WUCR
&W@J fROu RUR)

277932

Figure 5-8. Relay Terminal Connections

 Section 6
Generator

6-1. GENERAL grounded. Never touch electrical leadi or appliances with

This chapter covers disassembly, inspection, and testing of wet hands, when standing in water, or on wet ground as
the generator components. See Figures 6-l and 6-2 for the chance of electrocution is especially prevalent under
parts identification. such conditions.

6-2. TROUBLESHOOTING 6-3. GENERATOR DISASSEMBLY

Refer to Table 4-2 to troubleshoot the generator. Follow NOTE

the disassembly procedure in Section 6-3 as far as necessary
to inspect a component, then start reassembly procedure in Tag leads to ease re-installation. Scratch align-
Section 6-12 at the point the component is replaced, When ing marks on parts before removing to aid
a fuse must be replaced, always inspect the related com- reassembly.
ponents and wiring to locate the cause. Refer to the wiring
diagrams in the back of the manual, 7. Disconnect battery of generator set, negative lead first.

A WARNING
2. Disconnect the generator ground strap at the tray (Fig-
HIGH VOLTAGE! Remember that the function of a gen-
gure 6-3 or 6-4). On the 3.5kW and 4.5kW (single), remove
erator set is to produce electricity and that wherever
the battery positive lead from the generator positive stud
electricity is present, there is the potential danger of
and remove stud remove stud from the generator mounting.
electrocution. Take the same precautions with electrical
appliances in your coach that you would observe in your
home. Keep away from electrical circuits and wiring while 3. Remove the center panel (4.5, 5.5, 7, 7.5kW), see Fig-
the set is running and have electrical service performed ure 6-5; or remove the end panel (3.5kW), see Figure 6-6.
only by qualified electricians. Make sure unqualified
persons, especially children, cannot gain access to your
set-keep the compartment door locked or securely 4. Remove the plug from the voltage sensing relay Figure
latched at all times. Be sure that generator is properly 6-7). The relay can now be removed.

‘j 12b

1. End Bracket 7. Panel, Center 12b. Voltage Regulator (7.5KW) 18. Ball Bearing
2. Stator 8. Circuit Breaker(s) 13. Voltage Sensing Relay (VSR) 19. Washer
3. Rotor 9. Junction Panel 14. Thru Bolt 20. Tolerance Ring
4. Adapter IO. Generator Fan 15. Over Bolt 21. Brush
5. Guard, Fan 11. Bearing Cap 16. End Bracket 22. Brush Holder
6. Junction Panel 12a. Voltage Regulator (3.5kW-7kW) 17. Slip Ring

Figure 6-l. Generator, Cross Sectional View

6-1
 3 13
1 2I \ --.- /

1. Voltage Sensing Relay 11. Fan

(VSR) 12. Adapter
2. Wiring Harness 13. Stator
3. Spring 14. End Bracket
16- 19’ i?y- 4. Brush 15. Exciter / Voltage Regulator
5. Brush Holder 16. Circuit Breaker
6. Panel 17. Transformer
7. Tolerance Ring 18. Transformer Bracket
8. Rotor (2 Pole Shown) 19. Circuit Breaker
20. Bridge Rectifier
9. Ball Bearing
10. Slip Ring

Figure 6-2. Generator Pa es Identification

,:::;
GROUND STRAF

Figure 6-3. Generator Ground Strap (3.5kW Shown)

Figure 6-5. Center Panel Removal (4.5, 5.5, 7, 7.5kW)

Figure 6-4. Generator Ground Strap

(4.5 Twin, 5.5, 7, 7.5kW)

Figure 6-6. End Panel Removed (3.5kW)

6-2
 Figure 6-9. Exhaust Tube

Figure 6-7. Removing Plug from Voltage

Sensing Relay (VSR) (4.5kW-7kW)

5. Remove the top housing (Figure 6-8) (3.5 and 4.5kW

single).

6. Remove the exhaust tube (Figure 6-9) (3.5kW-7kW).

7. Remove the side housings (3.5kW-7kW).

8. Remove the inside housings (Figure 6-10) (3.5 and 4.5

kW single).

9. Loosen the vibro-mounts (Figure 6-11) and lift the gen-

Figure 6-10. Inside Housing Removal
erator from the base.

10. Tilt the generator end up and place blocks under the
generator adapter.

Figure 6-8. Top Housing Removal Figure 6-l I. Vibro-Mounts

6-3
 Figure 6-14. Exciter / Voltage Regulator

Figure 6-13. Over Bolt Removal (Two Shown)

11. Lift the brushes by the leads and lock in this position
by inserting a retainer wire as shown in Figure 6-12.

12. Remove the end bracket by removing four long over

bolts. See Figure 6-13.

13. Disconnect the stator leads from the regulator.

NOTE Figure 6-15. Exciter / Voltage Regulator (3.5KW)

The voltage regulators on 4.5, 5.5, 7 and 7.5kW

generator sets are located inside the end bracket.
14. The stator (Figure 6-16) can be tested at this time (Sec-
On the 3.5kW, the voltage regulator is located
tion 6-8). Remove the stator by guiding it to the rear,
outside the end bracket. See Figures 6-14 and
6-15. Terminal connections and testing will be 15.1 l Four-Pole Removal (4.5, 5.5,7,7.5kW). Remove thru
the same for all. bolt and detach washers. Re-insert thru bolt leaving a l/8

6-4
inch gap between bolt and rotor. Bump the thru bolt with
a lead mallet to break the rotor loose (4.5, 5.5, 7, 7.5kW
only) for removal (Figure 6-l 7). If the bearing turns freely
and has no sign of damage do not remove, the fan will be
removed with rotor (Figure 6-18).

NOTE
On 7.5kW, if the rotor seems loose but can not
be removed, see Section 6-3.2.

Figure 6-18. Removing Rotor (4.5,5.5, 7kW)

CAUTION

Do not attempt to remove rotor by blocking

Figure 6-16. Stator
engine cooling fan and turning rotor with any
kind of wrench. Damage to fan blades and rotor
may result.

Figure 6-17. Rotor Thru Bolt

15.2. Two-Pole Removal (3.5kW). On the 3.5kW, the rotor

is held to the engine crankshaft by right-hand threads on
the crankshaft and in the rotor shaft (engine rotates coun-
terclockwise when viewed from drive side). These threads
have been coated with antiseize compound to aid disassem-
bly. To remove rotor, place a wood block in a trailing edge
of one rotor pole. A sharp, medium force hammer blow to
wood block’s end will free the rotor, allowing it to be
turned off by hand (Figure 6-19). Figure 6-19. Removing Rotor (3.5kW)

6-5
 Insulator
Sleeve

YL-J
Notch Must Be
On Bottom

Figure 6-22. Oil Level Switch Mounting

Figure 6-20. Removing Oil Tank

d. With gasket surfaces clean, install oil tank cover

using a new gasket. Torque bolts to 70 in/lbs. (7.9Nm)
using torque sequence shown in Figure 6-23.

NOTE
Cut one wire from switch so that it reaches
screw shown in Figure 6-23, strip 250 in.
(6.4mm) of insulation and crimp-on l/4” eye-
let term inal. Place terminal between lockwasher
and cover.

e. Plug end of ventilation fitting. Below compressed air,

about 30 psi (207kPa), into oil tank bore and check for
leaks at gasket surfaces, switch connection and ventila-
tion fitting using a soap solution. Repair any leaks.

CAUTION
Figure 6-21. Oil Tank Removed
Any air leak in the ventilation line system could
cause the engine oil to be drawn from the reser-
voir into the crankcase, resulting in engine blow-
6-3.1. Removal of Oil Tank 4.5kW (KT17 Series I only)
by and a low oil level shutdown.
1. Drain oil from oil tank assembly. f. Cut the other wire from switch so that it reaches #I2
(purple) lead, strip .250 in. (6.4mm) of insulation and
2. Detach nut from eyebolt. Remove the bolt attaching the connect together using an insulink.
oil tank to engine leg. Detach ventilation line (Figure 6-20).

3. Pull the tank off, making sure it is removed squarely

(Figure 6-21).

4. Oil Level Switch Replacement.

does not need replacement,
(If the oil level switch
omit Step 4.) w\ .+
a. Remove oil tank cover by removing six screws. Be Ground
careful not to damage gasket surface when prying Lead
apart.

b. Remove switch at coupling connection. It will be

necessary to cutoff eyelet terminal and insulink to
remove switch.

c. Apply pipe thread compound to new switch, slide

leads through insulator sleeve and thread switch into
coupling. Tighten switch so that distance between
bottom of switch and inside of cover is 3.0 in. (76.2mm).
See Figure 6-22. Figure 6-23. Torque Sequence

6-6
5. When installing the oil tank, make sure O-rings are not 5. The flywheel and adapter can now be removed (Figure
damaged. Apply grease to the O-rings, fitting and the oil 6-26).
tank bore. Push tank on squarely.
6. Strike downward on corner of stub shaft with a lead
6-3.2 On the 7.5kW generator set, if the rotor seems loose mallet as shown in Figure 6-27.
but cannot be removed, the flywheel has become free of
the crankshaft taper. To separate rotor from flywheel, 7. The stub shaft can now be removed.
adapter, and stub shaft proceed as follows.

I. Remove eight bolts fastening generator adapter to bell

housing (Figure 6-24).

2. Pull rotor, adapter, and flywheel away from engine.

3. Slide adapter over generator fan as far as possible. - .

4. Remove four bolts fastening stub shaft to flywheel

(Figure 6-25).

Figure 6-26. Remove Flywheel and Adapter

Figure 6-24. Adapter Removal

Stub

Figure 6-27. Stub Shaft Removal

6-4. BUI LD-UP Cl RCUIT

Flywheel
This circuit magnetizes the rotor during cranking. When
Figure 6-25. Separating Stub Shaft and Flywheel the switch on the controller is moved to the start position,

6-7
DC current flows from the battery to brushes and sl ip rings
on the rotor. See Figure 6-28.

6-5. BRUSHES

6-5.1 General. The brushes transfer current from the volt-

age regulator to slip rings. The brushes carry a very low cur-
rent (approximately 2 Amps) and should last the life of the
generator set. Abrasive dust on the slip rings could, how-
ever, shorten the life of the brushes. Excessive arcing at the
brushes could damage the voltage regulator. Arcing could
be caused by weak springs, damaged slip rings, sticking
brushes, loose holder, or poor brush alignment.

6-5.2. Maintenance.

1. Remove the end bracket panel to gain access to the

brushes.

2. The brushes must be free to move within the holder and

held in proper contact by the springs. When properly
positioned, spring pressure on the brush surface will
Figure 6-29. Brushes
cause the brush to wear evenly. Figure 6-29 shows normal
brush wear.

3. Replace the brushes if worn excessively or unevenly.

4. Replace the springs if damaged or discolored.

5. Be sure to use original or identical l/2 inch (12.7mm)

screws when reinstalling the brush holder. Longer screws
will break the holder when tightened.
WIRE
6. To install the brushes and holder insert a wire as shown
in Figure 6-30, to hold the brushes in. Position the brushes
on the slip rings and install the two screws. Remove the
wire.

CAUTION

If the retainer wire is not removed, the voltage

regulator will be damaged when the generator
Figure 6-30. Brush Holder
is started.

STARTER

12 VOLT
GENERATOR BATTERY
ROTOR

/
BRUSHES &
SLIP RINGS

4CR
GENERATOR
REGULATOR

Figure 6-28. Buildup Circuit

6-8
 6-6. SLIP RINGS

Slip rings acquire a glossy brown finish in normal operation.

Do not attempt to maintain a bright, newly-machined ap-
pearance. Ordinary cleaning with a dry, lint free cloth is
usually sufficient. Very fine sandpaper (#OO) may be used
to remove roughness. Use light pressure on the sandpaper.
Do not use emery or Carborundum‘ paper or cloth. Clean
out all carbon dust from the generator. If the rings are
black or pitted, remove the rotor and remove some of the
surface material by using a lathe.

6-7. EXCITER / VOLTAGE REGULATOR

6-7.1. General. The voltage regulator assembly (Figure

6-31) includes a bridge rectifier and a voltage regulating
circuit. AC from the stator is received at the “AC” termin-
als on the regulator. Thi’s current is rectified to DC by the
bridge rectifier and supplied to the rotor from terminals
(+) and (-) through the brushes and slip rings. This AC is
constantly monitored by the regulator to maintain +2%
variation of the stator output.

NOTE
Although the physical appearance of your Figure 6-31. Exciter / Voltage Regulator
voltage regulator may differ from the one pic-
tured, its fu tiction is identical.

NOTE To complete the test you’ll need the following equipment:

When replacing regulators apply a light coating Two 12OV/lOO watt bulbs and sockets.
of thermal compound between the regulator 11 O/l 20V AC power source or variable transformer.
and end bracket. This compound aids in dissi- Switch, PST, 12OV, 2 Amp. minimum
pating heat from regulator to end bracket. For
Fuse, 2A (in holder)
regulators with two mounting screws tighten to
Jumpers
20 in. Ibs. (2.3Nm) maximum. For center
mount-type regulators, tighten screw to 15 in. Multimeter
Ibs. (1.7Nm) maximum.
Figure 6-32 shows the typical voltage regulator terminal
identification:

67.2. Exciter / Voltage Regulator Test.

A’ WARNING
HIGH VOLTAGE! Remember that the function of a gen-
erator set is to produce electricity and that wherever
electricity is present, there is the potential danger of
electrocution. Take the same precautions with electrical OR AC +
appliances in your coach that you would observe in your 0
home. Keep away from electrical circuits and wiring while
AC
the set is running and have electrical service performed
only by qualified electricians. Make sure unqualified
persons, especially children, cannot gain access to your
set-keep the compartment door Iock,ed or securely
latched at all times. Be sure that generator is properly
grounded. Never touch electrical leads or appliances with Figure 6-32. Terminal Identification
wet hands, when standing in water, or on wet ground as
the chance of electrocution is especially prevalent under
such conditions.

Since this test is designed for use in the field, it only

checks regulator output when “cold” and does not check
voltage build-up.

6-9
1. Connect two 100 watt light bulbs across “+” and ‘I-” NOTE
terminals of regulator. See Figure 6-33.
If bulbs flash momentarily and extinguish,
2. Set multimeter range to 100 Volts DC. Connect meter flicker dimly or glow steadily the regulator is
across light bulbs. Check for correct polarity (refer to functioning properly. These conditions are
Figure 6-33). caused by the amplitude of the “AC” supply

A WARNING voltage used. A momentary flash results when

supply voltage is above the regulating voltage
HIGH VOLTAGE! Remember that the function of a gen- or regulator under test. Flickering results when
erator set is to produce electricity and that wherever supply voltage and regulating voltage are with-
electricity is present, there is the potential danger of in a few volts. If a variable transformer is
electrocution. Take the same precautions with electrical available, it should be used to adjust the AC
appliances in your coach that you would observe in your supply ‘until the bulbs glow steadily. The vari-
home. Keep away from electrical circuits and wiring while able transformer will adjust the voltage to coin-
the set is running and have electrical service performed cide with the approximate regulating voltage of
only by qualified electricians. Make sure unqualified the regulator.
persons, especially children, cannot gain access to your
set-keep the compartment door locked or securely
7. Test field build-up circuit by connecting one end of
latched at all times. Be sure that generator is properly
jumper to either “AC” terminal. Touch the other end of
grounded. Never touch electrical leads or appliances with
jumper to “B” terminal. Bulbs should glow brighter. Volt-
wet hands, when standing in water, or on wet ground as
meter should indicate 50-75 Volts DC.
the chance of electrocution is especially prevalent under
such conditions. A WARNING
3. Completely disconnect IZOV AC source from primary HIGH VOLTAGE! When the power cord is plugged in
power source before connecting across regulator. during voltage regulator test, the AC pins become “hot”
and there is danger of electrocution.
A WARNING NOTE
HIGH VOLTAGE! When the power cord is plugged in
during voltage regulator test, the AC pins become “hot” If voltage readings coincide with above recom-
and there is danger of electrocution. mended test results, regulator may be used in
generator set.
4. Connect one pole of (on-off) switch and the fuse to one
of the “AC” terminals on the regulator. Connect other pole
of switch to the 110/l 20 AC source (Figure 6-33). Connect CAUTION
other “AC” terminal to 110/12OV AC source. Completely disconnect IZOV AC source from
primary power source before disconnecting
5. Turn on 1 IO/l 20V AC source.
from regulator.
6. With multimeter connected across light bulbs, turn on
switch. Bulbs should light immediately, DC voltmeter
should register 10 to 50V DC.

Fl
2A

110/120 AC B +
VAC OR
VARIABLE
TRANSFORMER’+

* See Note After Step 7.

Figure 6-33. Wiring Diagram -Voltage Regulator Field Test

6-10
 Figure 6-35. Two Pole Rotor
.:

Figure 6-34. Stator

6-8. STAT0 R

6-8.1. General. The stator (Figure 6-34) consists of a series

of coils of wire laid in a laminated steel frame. The stator
leads (see Generator Wiring Diagram) supply voltage to the
AC load and exciter / voltage regulator.
Figure 6-36. Four Pole Rotor
6-8.2. Testing. The stator should have 0.25 ohms resistance
across each winding. To test, connect an ohmmeter between A WARNING
leads 1 and 2, 3 and 4, and then 33 and 44. The leads are
DANGEROUS ACID! Avoid contact with battery electro-
tagged with the lead number,
lyte. It contains acid which can eat holes in clothing, burn
skin, and cause permanent damage to eyes. Always wear
6-9. ROTOR splash-proof safety goggles when working around the
battery. If battery electrolyte is splashed in the eyes or on
The function of the rotor is to create a magnetic field. The
skin, immediately flush the affected area for 15 minutes
3.5kW has a rotor with two electromagnetic field poles
with large quantities of clean water. In the case of eye
(Figure 6-35). The +5kW, 55kW, 7kW and 7.5kW each
contact, seek immediate medical aid. Never add acid to a
have a rotor with four electromagnetic field poles (Figure
battery once the battery has been placed in service. Doing
6-36). Rotor resistance readings are given in Table 6-1.
so may result in dangerous spattering of electrolyte.
Measure resistance (ohms) between the two slip rings.
s c l A WARNING
MODEL RESISTANCE
EXPLOSIVE BATTERY GASES! The gases generated by a
3.5KW 9 to 11 ohms battery being charged are highly explosive. Do not smoke
4.5KW 8 to 10 ohms or permit flame or spark to occur near a battery at any
time, particularly when it is being charged. Avoid contact-
5.5KW 8 to 10 ohms
ing terminals with tools, etc., to prevent burns and to
7KW 8 to 10 ohms.
prevent sparks that could cause an explosion. Remove
Table 6-l. Rotor Resistance wristwatch, rings, and any other jewelry before handling
battery. Any compartment containing batteries should be
6-10. SEPARATE FIELD EXCITATION well ventilated to prevent accumulation of explosive gases.
To avoid sparks, do not disturb battery charger connec-
As a preliminary aid to troubleshooting, the generator field tions while battery is being charged and always turn
(rotor) may be excited (magnetized) using an outside power charger off before disconnecting battery connections.
source and the following procedure: Turn automotive test equipment off when connecting or
removing battery clips. When removing or reconnecting
1. Disconnect brush leads from voltage regulator. battery cables, make sure ignition switch and all acces-
sories are turned off.
6-11
2. Connect brush leads in series with 12-Volt battery and erator output, and disconnect excitation current from the
DC ammeter as shown in Figure 6-37. battery to the regulator and field (V.B.U.), and energize the
3CR (interlock relay). If there is no AC output; the relay
3. Ammeter reading should approximate battery voltage will not energize, and the unit will shut down when the
divided by specified rotor resistance (Table 6-1). start-stop switch is released from the start position.

4. Record ammeter reading.

6-12. GENERATOR REASSEMBLY

5. Start generator set and run at NO load. 1. On the 3.5kW, apply antiseize compound to the rotor
threads (Figure 6-39). Thread the rotor onto the drive
6. Observe ammeter with unit running. If current increases shaft, and tighten by hand.
considerably, a running short in the rotor has been detected.
2. On the 4SkW, 55kW, 7kW or 7.5kW, apply antiseize
EXCITER / compound to the crankshaft stub (Figure 6-40). Install the
VOLTAGE r 1 rotor onto the crankshaft with the thru bolt. See Table 6-2
REGULATOR ,-‘&I; DC for torque value.

I SIZE I TORQUE I
5116 100 to 125 in. Ibs. (11.3-14.1Nm)

3/8 175 to 200 in. Ibs. (19.8-22.6Nm)

l/2 40 to 55 ft. Ibs. (54.2-74.6Nm)

BATTERY
Table 6-2. Generator Thru Bolt Torque

SLIP RINGS J BRUSHES

3. Slide the stator into position making sure the leads are
at 12 o’clock position (Figure 6-41).
Figure 6-37. Separate Excitation Connections
4. Install the end bracket with the four long over bolts.

6-l 1. VOLTAGE SENSING RELAY 5. Position the brush holder and install the two brush
holder screws. To install the brush holder, it will be
The voltage sensing relay (Figure 6-38) is located in the necessary to retain the brushes with a wire (Figure 6-42).
end bracket assembly. Its function is to sense AC gen- Remove the wire when the brushes are installed.

TO PIN “4” OF ’
PI CONNECTOR

TO LEAD FROM “B”

TERMINAL OF
VOLTAGE REGULATOR

I I COIL RESISTANCE = 4000 OHMS

COIL VOLTAGE = 120 VOLTS AC

Figure 6-38. Generator Voltage Sensing Relay (VSR)

6-12
 Figure 6-41. Stator and Rotor
).A:::‘; ::,..:, :,<4y:.:

THREADS
,. ..::

Figure 6-39. Rotor (3.5kW)

6. Install the generator to the base.

Figure 6-42. Brush Retaining Wire

Figure 6-40. Driveshaft (4.5kW Shown)

9. Install the circuit breaker(s) and end panels (Figures
6-43 and 6-44).

7. Install the exhaust tube. Install the side housings and

10. Reconnect the generator ground strap to the tray, On
top housing.
the 3.5kW and 4.5kW (single), reinstall the generator posi-
tive stud and reconnect battery positive lead to stud.
8. Install the voltage sensing relay and plug. See Genera-
tor Wiring Diagram for connections. 11. Reconnect battery of generator set, negative lead last.

6-13
 .A.. .: ,...

Figure 6-43. End Bracket, Panels Removed (4.5kW Single Shown)

BREAKER :

Figure 6-44. Lower End Bracket (4.5 Twin, 7SkW)

6-14
 Section 7
Choke, Shutdown Control and Governor
7-1. CHOKE TESTING AND ADJUSTMENTS (3.5kW,
A WARNING
BACKFIRE! A sudden backfire can cause serious burns.
4.5kW SINGLE)
Keep hands and face away from the carburetor when the
air cleaner is removed.
7-1.1 General. When the engine start switch is activated,
battery current activates the rotary solenoid in the electric A WARNING
choke unit (Figure 7-l). The choke lever pushes the choke FLASH FIRE! Asudden flash fire can cause serious burns.
plate into the full choke position. The solenoid deenergizes To avoid the possibility of a flash fire, do not smoke or
immediately after the switch is released from the start posi- permit flame or spark to occur near carburetor, fuel line,
tion. When the solenoid deenergizes, the choke plate opens fuel filter, fuel pump, or other potential sources of spilled
to a position determined by a thermostatic spring and the fuel or fuel vapors.
ambient temperature. As the engine warms and less choking
7-1.2. Inspection.
is needed, the thermistor circuit allows the choke plate to
1. Disconnect the high tension lead from the spark plug
gradually move to full open position.
sothe
A
engine will not start.
WARNING
2. Remove the air cleaner cover, element and base plate.
UNINTENTIONAL STARTING! To prevent accidental
3. Push the start-stop switch on the controller to the start
starting when checking choke operation, remove spark
position and hold for five seconds. The choke plate should
plug lead(s) at spark plug(s).

CHOKE
SHAFT

ONE LEAD TO
/
STARTER RELAY
THE OTHER LEAD
TO CONTROLLER

HEATER
(THERMISTOR)
TERMINAL

LOCKWASHER

IDLE FUEL
ADJUSTMENT

SOLENOID
TABS

SPRING
AUTOMATIC
ELECTRI-CHOKE UNIT I

LEVER
l/2 TURN TENSION

Figure 7-1. Choke and Carburetor (3.5KW, 4.5KW)

7-l
 close a minimum of 45’ at an ambient temperature of 7-1.5. Replacement and Adiustment.
about 75’F (24’C). The plate will close more at lower tem- NOTE
peratures. The choke plate should open when the switch is
released. When installing the choke, make sure the choke
plate arm goes under the choke lever.
, , 4; During cranking the choke will remain closed as long as
t the start-stop switch is held in the start position.
1. Position the choke with the two mounting screws
5. If the choke does not function properly, refer to Choke slightly loose.
Troubleshooting, Table 7-l.
2. Push the choke unit all the way down, then, keeping
7-l .3. Testing - Choke Solenoid (3.5,4.5kW Single) slight pressure on it, move the chokeplate (in carburetor)
into the full open position allowing the choke unit to rise.
1. Disconnect leads from the solenoid tabs (Figure 7-l).

3. Rotate the choke unit clockwise (viewed from choke

2. Check the resistance of the solenoid by connecting an
side) with a slight pressure. Continue to rotate the choke
ohmmeter or multimeter across the solenoid tabs. Sole-
until it can no longer be rotated without closing the choke
noid resistance should be approximately 23 ohms or
plate. (An internal spring will be wound up in the last 5 to
higher.
15 degrees of rotation before internal stop is reached).

7-1.4. Testing - Choke Heater (3.5,4.5kW Single)

4. When the choke plate is full open, tighten the bracket
screws and install the three leads.
1. Remove the lead from the heater terminal.

2. Check heater resistance. Connect one lead of an ohm- 5. Check choke function by removing the spark plug lead
meter or multimeter to the heater terminal. Connect the and cranking the engine. The choke plate should close
other lead to the carburetor body (ground). a minimum of 45’ at a temperature of about 75’F (24’C).
The plate will close more at lower temperatures. The choke
3. The resistance should read at least three ohms. If not, will remain closed as long as the start-stop switch is held in
replace the choke. the start position.

PROBLEM CAUSES SOLUTIONS

Choke won’t close when 1. Faulty lead wires or terminals. 1. Change lead wires or replace choke.
cranking. 2. Air cleaner gasket interference with 2. Reposition flat of gasket to provide
choke shaft lever. (4.5kW only.) clearance for choke shaft lever.
3. Faulty solenoid. 3. Test solenoid.
4. Faulty controller or ground 4. Replace lead to controller with
in controller. a jumper wire to ground. If choke
functions properly check con-
troller.
5. Choke lever lacks sufficient travel 5. Manually move the choke lever until
or smooth movement. the choke plate is fully closed. Re-
place the choke unit if it does not
move freely.

Choke will not fully open. 1. Choke spring not properly 1. Remove spring retainer and with
adjusted. choke wide open wind up spring l/2
turn, replace spring retainer.
2. Choke shaft fails to move freely. 2. Replace choke shaft.
3. Faulty choke adjustment. 3. Adjust choke.
4. Faulty heater. 4. Test heater resistance.

Table 7-1. Troubleshooting Choke (3.5KW, 4.5KW)

7-2
7-2, CHOKE TESTING AND ADJUSTMENTS (4.5 TWIN,
5.5, 7, 7.5kW)

7-2.1. General. The choke on the 4.5 (twin), 5.5, 7 and

7.5kW models is an intergral part of the carburetor. The
choke wit1 close automatically from ambient air. Upon
starting, the engine vacuum will partially open the choke.
The bi-metal spring in the choke is e&trically connected to
the ignition coil and the current flowing thrbugh the bi-
metal spring will heat to a point that the choke will open
fully.

7-2.2. Inspection.

1. Disconnect the high tension leads from spark plugs so

the engine will not start.

2. Remove the air cleaner cover, element and base plate.

3. Push the start switch on the controller to the start posi-

tion and hold for five seconds. The choke should fully close Figure 7-2. Choke (4.5 Twin, 5..5,7,7.5 kW)
and release when the start switch is released.
start position, battery current thru the solenoid holds the
plunger and continues to hold it while the engine is run-
4. If the choke does not function properly (Step 3), see ning. When the switch is moved to the stop position the
troubleshooting, Table 7-2.
solenoid de-energizes and drops the plunger into a porting
in the carburetor to stop all flow of fuel.
7-2.3. Adjustment. The choke unit (Figure 7-2) is set at
the factory for average conditions. To readjust for local 7-3.2. Inspection and Repair.
conditions, loosen the cover retaining screws and shift the
cover in clockwise direction for richer setting or counter-
1. Make sure the solenoid has a secure electrical connection
clockwise direction for leaner setting. Tighten the cover
and good contact with the hold down bracket (ground).
retainer screws.
7-3. POSITIVE SHUTDOWN CONTROL (3.5kW-7kW) 2. Check for stuck plunger. Replace if,.damaged.

7-3.1. General. If an engine has been working under load, 3. Check for defective solenoid with an ohmmeter or multi-
it tends to continue running or “diesel” after the switch is meter. Solenoid resistance is approximately 20 ohms.
moved to the stop position. This is prevented on these
generator sets by a solenoid and plunger which positively 7-3.3. Temporary Field Fix.
stops all flow of fuel when the switch is moved to the stop
position. See Figure 7-I or Figure 7-3. The solenoid is 1. Turn the main fuel adjusting needle out then shift the
mounted on the carburetor. When the switch is in the solenoid retaining bracket.

PROBLEMS CAUSES SOLUTlONS

Choke won’t close during Faulty lead to choke. 1. Check for secure lead connections
cranking. 2. Make continuity check on lead. Re-
place if no continuity.

Fau ty lead to ground. 1. Check for secure lead connections.

2. Make continuity check on lead. Re-
place if no continuity.

PO0 rsadjustment. 1. Adjust choke.

2. Repair with kit or replace choke.

Choke will not4ully open. 1. Poor adjustment. 1. Adjust choke.

2. Faulty choke. 2. Repair with kit or replace choke.

Table 7-2. Troubleshooting Choke (4.5 Twin, 5.5, 7, 7.5kW)

7-3
 BREATHER PLATE

VALVE COVER

COVER GASKET
BREATHER
HOSE
Figure 7-5. Crankcase Breather Assembly (4.5kW Single)

Figure 7-3. Shutdown Control Solenoid (3.5kW-7kW)

2. Lift the solenoid and remove the plunger.

COVER GASKET
3. Replace the solenoid and retaining bracket and readjust
the main fuel needle. (See Carburetor Adjustment).

7-4. CRANKCASE BREATHER (3.5kW, 4.5kW)

7-4.1. General. Reed type breathers are used to maintain a

slight vacuum in the crankcase. A clogged or pinched crank-
case breather, or faulty reed assembly can cause positive
pressures to build up in the crankcase resulting in unseating
of the dipstick and oil leakage thru the oil fill tube. See
BREATHER PLATE
Figure 7-4, 7-5 or 7-6.

GASKET -

STUD
FILTER GASKET \ ,

Figure 7-6. Breather Assembly (4.5kW Twin)

ernors. The governor gear flyweight mechanism is mounted

within the crankcase and driven off a gear on the camshaft.
In operation, centrifugal force causes the flyweights to
move outward with increase in speed and inward with de-
creasing speed. As the flyweights move outward, they force
VALVE COVER the rod portion of the assembly to push outward. Tension
of the governor spring pulls the flyweights back inward
with decrease in engine speed. The rod, in turn, contacts
Figure 7-4. Crankcase Breather Assembly (3.5kW) a tab on the governor cross shaft causing it to rotate with
changing speed. One end of the cross shaft protrudes thru
the side of the crankcase. Thru external linkage, the action
7-5. GOVERNOR (3.5kW, 4.5kW) of the cross shaft is transmitted to the throttle (or butter-
fly) valve in the carburetor. When the engine is at rest, the
7-5.1. General. All Kohler Single Cylinder Engines are tension of the governor spring should hold the throttle
equipped with centrifugal flyweight mechanical type gov- valve in open position.

7-4
7-5.2. Adjustments. The governor maintains engine speed
when changing loads and limits the engine speed. Initial
adjustment is made at the factory and should not be re-
quired in the field unless the linkage works loose or becom-
es disconnected. Speed adjustment should be made if the
engine surges when changing loads or if speed drops consid-
erably when a normal load is applied.

A. Initial Governor Adjustment (Figure 7-7 or 7-8).

1. With engine ‘stopped, loosen (do not remove) the arm

retaining nut which secures the governor arm to the cross

Figure 7-8.
Governor Components and Adjustment Points
(4.5kW Single)

2. To make the governor LESS sensitive, decrease the

spring tension by moving the spring hooks into holes
spaced closer together.
Figure 7-7.
Governor Components and Adjustment Points (3.5kW) 7-6. GOVERNOR HUNTING CHECKS (4.5 kW SINGLE
ONLY).

Governor hunting is a periodic frequency variation. If the

2. Grasp the end of the shaft with pliers and turn the shaft variation (hunting) is audible to the unaided ear, it is not
as far as possible in counterclockwise direction until the acceptable. Use the checklist below to help maintain
internal tab on the shaft stops against the governor gear proper governor operation. The items in this list may be
mechanism. Hold shaft in this position, pull governor used singly or in combination to achieve smoothest pos-
arm all the way from the carburetor then retighten the arm sible operation.
retaining nut.
NOTE

Due to variances in generator output wave

B. Governor Speed Adjustment. shape, not all pointer type frequency meters are
compatible.
1. If overspeed or underspeed condition is suspected, check
speed with a tachometer or frequency meter at rated load.
1. Set the point gap to 0.020 in. (0.51 mm) with a feeler
gauge and adjust the carburetor for peak performance.
2. Loosen speed adjusting nuts to decrease speed and
tighten speed adjusting nuts to increase speed. 2. With the engine not running check for free governor
linkage movement from idle to full throttle. (Note: Remove
C. Sensitivity Adjustment. If the speed drops considerably excess paint from governor spring and dampening spring
when a normal load is applied, the governor may not be and make sure choke wires do not interfere.)
sensitive enough. If speed surging occurs with changing
load, the governor may be too sensitive. 3. With the engine shut down the throttle will be in wide
open position. Adjust the governor linkage so that approxi-
1. To make the governor MORE sensitive, increase the mately l/32” (0.79mm) space exists between the throttle
spring tension by moving the spring hooks into holes spaced lever and carburetor body. (Note: This can be done by
further apart. sight, no fine measurement is necessary.)

7-5
 GOVERNOR
LINKAGE

\ CARBURETOR
DAMPENING BODY

IDLE STOP
SCRE

Figure 7-10. Installing Air Intake Tube

(3.5kW, 4.5kW Single)

Figure 7-9. Carburetor (4.5kW Single)

1. First loosen the outside locking nut.

4. Check idle speed, at no load, with the throttle lever

2. To increase speed, tighten the inside speed adjusting nut
against the idle speed screw and set speed to approxi-
to draw back the speed adjusting arm.
mately 1680 RPM (56 Hz).
3. To d’;e’ccr”ease
speed, loosen the speed adjusting nut.
5. Reposition the governor spring in the governor lever.
On most units the 2nd hole from the bottom provides the
4. Securenew setting by tightening outside locking nut.
best operation. Whenever the governor spring is moved in
the governor lever, the governor speed control must be
7-7.3 Sensitivity Adjustment. If the governor is too sensi-
adjusted at no load, to approximately 1890 RPM (64 Hz).
tive, speed surging will occur with change in load. If the
governor is not sensitive enough, a big drop in speed will oc-
6. If poor governing remains, the spring may be moved to
cur when normal load is applied.
the bottom hole. If the governing is good but the speed
drop from no load to full load is too great (over 90 RPM
1. To make *the governor more sensitive, move the governor
(3 Hz)) the governor spring can be moved up one hole in
spring in togards the governor shaft.
the governor lever.

2. To make the governor less sensitive move the governor

7. After making choke and governor adjustments reinstall
the air cleaner base. Thread the crankcase breather hose spring out.
back thru the hole in the base plate. Align the three small
3. Recheck speed after making sensitivity adjustment (Fig-
holes with the threaded holes in the carburetor.
ure 7-11).

NOTE
7-8. GOVERNOR (5.5kW, 7kW).
When placing the base plate on the carburetor,
be sure to install the air intake tube into the 7-8.1. General. These models are equipped with centrifu-
blower housing as shown in Figure 7-10 (long gal flyweight type mechanical governors which are exter-
side down). nally mounted. See Figure l-4 for location. The governor
drive gear is driven by the camshaft gear.
7-7. GOVERNOR (4.5kW TWIN)
7-8.2. Speed Adjustment. The throttle shaft is fixed at a
7-7.1. General. This model is equipped with a centrifugal definite length to establish a load speed of 1800 RPM
flyweight mechanical governor. The governor gear/fly- (1500 RPM, 50 H z models). Any variation in speed fre-
weight mechanism is mounted within the crankcase and quency changes the output of the generator. For this rea-
driven off a gear on the camshaft. son only slight readjustment of speed is possible. Proceed as
follows:
7-7.2. Speed Adjustment. The throttle shaft is fixed at a
NOTE
definite length to establish a load speed of 1800 RPM. Any
variation in speed frequency changes the output of the gen- Due to variances in generator output wave-
erator. For this reason only slight re-adjustment of speed is shape, not all pointer type frequency meters are
possible. Proceed as follows: compatible.

7-6
 Figure 7-11. Governor Sensitivity Adjustment (4.5kW Twin)

1. To increase speed, loosen the inside speed adjusting 2. To make the governor less sensitive, loosen the lower
nut (Figure 7-12) and tighten the outside nut to draw the nut and tighten the upper nut to draw the eyebolt upward.
eyebolt closer to the bracket which is mounted on the
governor. This will pull the throttle open. 3. Retighten the nut that was loosened to lock the eyebolt
at the new setting.
2. To decrease speed, ~Ioosen the outside nut and tighten
the inside nut tovforce the eyebolt away from the bracket. 7-8.4. Anti-Dieseling Control Adjustment. Used with car-
buretor assembly 48 053 29. See Figure 7-13 for dimen-
.3. When speed is correct, tighten the nut that was loosened
sions.
to lock the eyebolt at the new setting.
1. With anti-dieseling control dimensions correct, hold
SPEED ADJUSTING governor arm in fully closed position. See Figure 7-13 (bot-
EYE BOLT tom view).
UPPER NUT
CRANKCASE 2. With solenoid plunger fully in solenoid, adjust solenoid
BREATHER INCREASE SPEED coil so chain is taut. Tighten solenoid hold-down clamp.
\
3. With governor arm fully closed, adjust carburetor idle
stop screw one-turn in after screw makes contact with stop
spring.
DE NUT
THROTTLE /I-VI NOTE
LINKAGE
Solenoid is energized only when stop button is
~-??5lll held in stop position.
SENSITIVITY

7-9. GOVERNOR (7.5kW)

BRACKET

7-9.1 General. This model is equipped with a constant

GOVERNOR’
speed type governor. The governor drive gear is driven by
the cam gear. Lubrication is provided through an external
GOVERNOR oil line which connects to the engine lubrication system.
SPRING

79.2. Speed Adjustment. The throttle shaft is fixed at a

definite length to establish a load speed of 1800 RPM
INCREASE SENSITIWITY
(1500 RPM, 50 Hz models). Any variation in speed fre-
Figure 7-12. Governor Components quency changes the output of the generator. For this reason
and Adjustments (5.5kW, 7kW) only slight readjustment of speed is possible. Proceed as
follows:
7-8.3. Sensitivity Adjustment. If the governor is too sensi- NOTE
tive, speed surging will occur with change in load. If the Due to variances in generator output wave-
governor is not sensitive enough, a big drop in speed will shape, not all pointer type frequency meters are
occur when normal load is applied. compatible.

1. To make the governor moresensitive, loosen the upper

1. To increase speed, loosen locking nut on speed adjusting
nut and tighten the lower nut to force the eyebolt down-
screw (Figure 7-14), and turn screw in clockwise direction.
ward.

7-7
 -50 in_ -88 in.
(12.7mm) (22.4mm)

TO PIN 5 OF
A-241 939 CONTROLLER

.I25 in. \
(3.2mm) 3.38 in.
(85.9mm) IDLE STOP SCREW

NOTE
____-
Dimensions are approximate.

GOVERNOR
ARM

v
SOLENOID

Figure 7-13. Anti-Dieseling Control Adjustment

2. To decrease speed, loosen locking nut on speed adjusting

SPEED ADJUSTMENT THROTTLE
screw, and turn screw in counterclockwise direction.
w LINKAGE
3. When the speed is correct, tighten the locking nut at the
new setting. OR

7-9.3. Sensitivity Adjustment. If the governor is too sensi-

I
tive, speed surging will occur with change in load. If the
governor is not sensitive enough, a big drop in speed will oc- SENSITIVITY
cur when normal load is applied. ADJUSTMENT

I. To make the governor more sensitive, loosen the nut at

bottom of adjusting eyebolt and tighten the top nut there-
PIVOT
by drawing the head of the eyebolt closer to the governor POINT
arm pivot point.

2. To make the governor less sensitive, loosen the top nut

and tighten the bottom nut to move the head of the eye-
bolt away from the pivot point. EYEBOL;i&AD - MOVE HEAD
CLOSER TO PIVOT POINT FOR
GREATER SENSITIVITY - AWAY
3. After sensitivity is correct, tighten the nut that was pre-
&ES SENSITIVITY
viously loosened to lock the eyebolt at the new setting. Re-
check speed after sensitivity adjustment since changing this Figure 7-14. Governor Components and
will also affect speed. Adjustments (7.5kW)

7-8
 -a---LB-
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Wiring Diagram - 3SCM21 1200volt

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Wiring Diagram - 4.5CKM61 (KTI 7 Series I) 120/240-Volt/GSA

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Wiring Diagram - 5.5CM21, 7CM21 120-volt
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Wiring Diagram - 7SCF41 240 Volt, 50 Hz

With Leads 2 and 3 Grounded (early models only)

8-15
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Wiring Diagram - 7.5CF61 240+olt, 50 Hz

8-l 7
 APPENDIX
Radio Frequent nterference Kit
A-2: 366
This kit can be installed to filter out electrical noise emit- 8. Remount regulator mounting plate to generator end
ted at radio frequencies. bracket.

9. Reconnect battery, negative lead last.

A WARNING
UNIT STARTS WITHOUT NOTICE! To prevent accidental
starting on units with a remote start/stop switch, always
disc,onnect battery (remove negative lead first and recon-
nect it last) to disable generator set before working on any
equipment connected to generator.

A WARNING
ELECTRICAL SHOCK! Battery can cause electrical burns
and shocks. Exercise reasonable care when working near
the battery to avoid electrical connections through tools.
Remove wristwatch, rings, and any other jewelry.

1. Disconnect battery, negative lead first.

2. Unscrew regulator mounting plate from generator end
bracket. See Figure 1. A-238888
X-49-6
X-25-58
X-22-7( 2)
X-71 -2

Assemble As Shown When Using

Gentron Regulator

Figure 1. Removing Reguiatar from End Bracket

3. Disconnect AC leads from regulator.

X-71 2-2
4. Mount capacitor assembly to regulator mounting plate X-49-6
as shown in Figure 2. X-25-58
5. Connect blue and gray leads from capacitor assembly X-22-7( 2)
to AC terminals on regulator. X-71 -2

6. Connect one AC lead to gray lead on capacitor as- Assemble As Shown When Using
sem bly. Omnetics Regulator
7. Connect the other AC lead to lead on capacitor as- Figure 2. To Mount Capacitor Assembly
sembly with pink terminal.

A-l
 KOHLER
GENERATORS
TP-5024 g/89 KOHlER CO.KOHLER,WISCONSIN 53044
PRINTED IN U.S.A.