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Service Manual, 3.5-7.5 kW RV (TP-5014)

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Contents

1. Battery Voltage 12V 12V 12V 12V Battery Amp Hr 32 to 45 32 to 45 32 to 45 32 to 45 Battery Ground Negative Negative Negative Negative Battery Cranking Current 40 amps 76 amps 98 amps 98 amps Battery Charging Current 15 amps 7 amps 7 amps 7 amps Engine Model 18105 K3410S 58205 58205 Point 0 020 0 016 to 0 020 0 020 0 020 Number of Cylinders 1 1 2 2 Cylinder Block Cast Iron Cast Iron Cast Iron Cast Iron Rated Horsepower 8 9 2 13 8 13 8 RPM 3600 1800 1800 1800 Bore 2 94 3 50 3 50 3 50 Stroke 2 75 3 25 3 Valve Material Intake Forged Steel Forged Steel Forged Steel Forged Steel Exhaust Stellite Stellite Stellite Stellite Exhaust Valves Aluminum Alloy Exhaust Valves Aluminum Alloy 2 Compression Exhaust Valves Aluminum Alloy Valve Rotators Cylinder Head Piston Rings Exhaust Valves Alluminum Alloy 2 Compression 2 Compression 2 Compression 1 Oil 1 Oil 1 Oil 1 Oil Crankshaft Ductile Iron Ductile Iron Ductile Iron Ductile Iron Bearings Anti Friction Anti Friction Steel Backed Steel Backed Bearing Ball Bearing Sleeve Type Sleeve Type Connecting Rod Tin Plated Tin Plated Tin Plated Tin Plated Aluminum Alloy Aluminum Alloy Aluminum Alloy Aluminum Alloy Governor Oil Bathed Oil Bathed Oil Bathed Oil Bathed Flyweight Flyweight External Flyweight
2. 35 30 8345 2 _ NOILINS yOLVLS YOIVNYSL IV AAS TOY NOD dW3L SLNIOd OL 3xOHD dmnd 3 3 lt gt 8 3 1 9 LINDYID y2O1831NI 8 YOLV 1N93Y OV 6 q LINDYID TOYLNOD 31 15 1105 1 Wiring Diagram 5 5CM21 7CM21 Generator Sets RV AOC i SLNIOd LOA 21 ENGINE ALTERNATOR STATOR CRANKING AC SOLI BAT CHG VOLT REG GRE GRN ORNG PURPLE a NG HI CONDENSER CUTOUT EOR 55 amp 7 21 LOW OIL PRESS CUTOUT ae HARNESS PLUG TO DECISION MAKER CONTROLLER 7 SHUT DOWN CONTROL V lt 3 5 8 4 5CM2I L ONLY 4 5 21 FUEL VALVE 3 5 5 5 7 21 FUEL PUMP TO IGNITION POINTS Engine Electrical Wiring Diagram 8 4 5014 11 87 Kohler Co 1987 All rights reserved KOHLER POVVER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Web site www kohlergenerators com Fax 920 459 1646 U S A Sales Fax 920 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444
3. KOHLER BOWER SYSTEMS Service Manual RV Generator Sets Models 3 5CM21 3 5CM61 3 5CFM21 3 5CFM61 4 5CM21 4 5CM61 4 5CFM21 4 5CFM61 5 5CM21 5 5CM61 5 5 21 5 61 21 7 61 TABLE OF 5 Page Safety Page SECTION 1 INTRODUCTION AND SPECIFICATIONS SECTION 5 DECISION MAKER CONTROLLER 1 1 Introduction 1 1 5 1 Description 5 1 1 2 Model 3 5 21 1 1 5 2 Sequence of Operation 5 1 1 3 Model 4 5CM21 RV 1 1 5522 PUSCS su pampam 5 3 1 4 Model 5 5CM21 RV 1 1 5 4 6 2524 5 3 1 5 Model 7 21 1 1 5 5 Circuit Board Foil Repair 5 3 1 6 Specifications 1 4 1 7 Fuel Specifications 1 4 SECTION 6 GENERATOR ee 6 1 SECTION 2 OPERATION 6 2 Troubleshooting 6 1 6 3 Generator Disassembly 6 2 2 1 2 1 6 4 Build Up 6 5 2 2 Prestart 151 2 1 6 5 6 5 2 3 Operation 2 1 6 6 Collector Rings 6 5 6 7 Exciter Voltage Regula
4. DECISION INLINE MAKER FUSE BATTERY CONTROLLER CHARGING RECTIFIER RESET N REGULATOR BUTTON GENERATOR ON LAMP FUEL INLET SHUT DOWN FUEL PUMP WARNING 3500 5 i LAMP 5 i AIR j START STOP 7 INTAKE SWITCH e TIMING AIR OIL FILL SIGHT INTAKE TUBE AND HOLE POSITIVE CONNECTION GROUND STRAP Figure 1 1 Service Side View of a Kohler 3 5CM21 RV Generator Set QUIET AIR RESISTOR TYPE COOLING SHROUD Le SPARK PLUG DRY ELEMENT CIRCUIT AIR CLEANER PROTECTOR GOVERNOR REMOTE CONTROL RECEPTACLE DECISION BREAKER POINT MAKER COVER CONTROLLER AIR INTAKE GENERATOR GN a SCREEN TIMING LIGHT KOHLER HOLE WARNING 4500 LIGHT SPRING SNUBBER MOUNT 0 FUEL START STOP SWITCH _ SOLENOID AND DIPSTICK POSITIVE CONNECTION GROUNDING STRAP AIR DISCHARGE OIL DRAIN UNDER UNIT Figure 1 2 Service Side View of a Kohler 4 5CM21 RV Generator Set 1 3 DRY ELEMENT AIR _ ELECTRIC FUEL PUMP ile BREAKER POINT COVER ON ms GOVENOR BATTERY CHARGING REGULATOR GOVERNOR FULL FLOW OIL FILTER ONUER5a CARBURETOR SPARK PLUG IGNITION COIL GENERATOR FRAME EXHAUST CIRCUIT PROTECTOR REMOTE CONTROL RECEPTACLE SAFETY TRIP RESET BUTTON CONTROLLER 5 SAFETY lt TRIP LAMP
5. See Carburetor Adjustment 7 4 GOVERNOR 3 5KW 4 5KW 7 4 1 General All Kohler Single Cylinder Engines are equipped with centrifugal flyweight mechanical type gov ernors The governor gear flyweight mechanism is mounted within the crankcase and driven off 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 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 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 of the cross shaft is transmitted to the throttle or butter fly valve in the carburetor When the engine is at rest the tension of the governor spring should hold the throttle valve in open position 7 4 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 normal load is applied initial Governor Adjustment Figure 7 4 or 7 5 1 With engine
6. The brushes transfer current from the vol tage regulator to collector rings The brushes carry a very low current approximately 2 amps and should last the life of the generator set Abrasive dust on the collector rings could however shorten the life of the brushes Excessive arcing at the brushes could damage the voltage regulator Arcing could be caused by weak springs damaged collector rings sticking brushes loose holder or poor brush contact 6 5 2 Maintenance sere 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 posi tioned spring pressure on the brush surface will cause the brush to wear evenly Figure 6 21 shows normal brush wear 3 Replace the brushes if worn excessively or unevenly 4 Replace the springs if damaged or discolored Figure 6 18 Rotor Bearing 5 Be sure to use original or identical screws 1 2 inch when reinstalling the brush holder Longer screws will break the holder when tightened 6 To install the brushes and holder insert a wire as shown in Figure 6 22 to hold the brushes in Position the brushes on the collector 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 Is started 6 6 COLLECTOR RINGS Collector rings acquire a glossy brown fi
7. carbon monoxide as part of the exhaust when operating Carbon monoxide is particularly dangerous in that it is an odorless tasteless and nonirritating gas but be ever mindful that it can cause death if inhaled for even a short period of time Have only qualified specialists install and replace exhaust system components and have the system inspected frequently Be careful when parking your coach to avoid obstructing the exhaust outlet The exhaust gasses must discharge freely otherwise carbon monoxide may deflect under and into the vehicle or enter through open doors windows or vents Also make sure that your exhaust cannot be discharged toward neighboring RV s campers orany occupied building Be especially watchful for exhaust accumulation under calm windless condi tions 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 A warnine HIGH VOLTAGE Remember that the function of a genera tor set is to produce electricity and that wherever electric ity is present there is the potential danger of electrocu tion 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 the set is running and have electrical service performed only by qualified electricians Make
8. 3 Completely disconnect 120V AC source from primary power source before connecting across regulator CAUTION When AC pins become hot there is danger of electrocution 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 110 120 AC source Figure 6 25 Con nect other AC terminal to 110 120V AC source 5 Turn 110 120V AC source 6 With multimeter connected across light bulbs turn on switch Bulbs should light immediately DC voltmeter should register 10 to 50V DC NOTE If bulbs flash momentarily and extinguish flicker dimly or glow steadily the regulator is functioning properly These conditions are caused by the amplitude of the AC supply voltage used A momentary flash results when supply voltage is above the regulating voltage or regulator under test Flickering results when supply voltage and regulating voltage are with in a few volts If a variable transformer is available it should be used to adjust the AC supply until the bulbs glow steadily The vari able transformer will adjust the voltage to coin cide with the approximate regulating voltage of the regulator 7 Test field build up circuit by connecting one end of jumper to either AC terminal Touch the other end of jumper to B terminal Bulbs should glow brighter Volt meter should indicate 50 75 volts DC A warnine HIGH VOLTAGE Whe
9. 60 40 composition resin core c Soldering iron 24 to 40 watt rating d Wire cutters e Pocket knife 2 Use the following procedure to repair the foil a Disconnect the wiring harness from the connectors on top of the Decision Maker Controller Remove the cover of the Decision Maker control box and disconnect the cover circuit plug b Remove the two screws holding the fuse block to the side of the control box Also remove the four corner hold down screws on the main circuit board circuit board in back of box c Remove both wiring harness connectors by pressing on expander clips and pushing them into the box d Visually inspect all foil runs on the solder side of the circuit board for burnt foil e To remove burnt foil cut around the burn with a pocket knife 1 8 into the undamaged foil and lift off the board f Cut a piece of tinned copper wire 1 8 longer than the section just removed from the circuit board g Solder the piece of wire across gap into the foil run DO NOT allow solder to flow into adjoining foil runs h Reattach the circuit board to the control box with the hold down screws Reinsert both connectors Make sure they are locked in place Refasten the fuse block to the control box with the two screws i Replace the control box cover and the four corner screws Reconnect the wiring harness to the top of the Decision Maker Controller 5 3 V 9nd NI 2 OL 0 907184 NI
10. 7 FUEL SPECIFICATIONS For best results use only clean fresh regular grade unleaded gasoline with a pump sticker octane rating of 87 or higher in the U S A In countries using the Research rating method it should be 90 octane minimum Unleaded is recommended since it leaves less combustion chamber deposits Regular grade leaded gasoline may also be used however be aware that the combustion chamber and cylinder head will require more frequent service Use fresh gasoline to ensure it is blended for the season and to reduce the possibility of gum deposits forming which could clog the fuel system Do not use gasoline left over from the previous season Do not add oil to the gasoline SECTION 2 OPERATION 2 1 GENERAL Operation of the generator set is controlled by a single switch on the Kohler Decision Maker Controller Figure 2 1 This switch is a momentary contact three position start run stop switch The controller has two indicating lamps and a safety reset button The GENERATOR ON lamp lights up green when AC output is available The SAFETY TRIP lamp lights up red when the generator set automatically stops due to the engine overheating On the 5 5KW and 7KW low oil pressure will cause red light If this happens the cause of overheating or low oil pressure must be eliminated and the SAFETY RESET button pressed before the set can be restarted The controller in cludes a keyed connector for installing a remote s
11. External Flyweight Lubrication System Splash Splash Pressure Pressure Fuel System Choke Automatic Automatic Automatic Automatic Thermal Electric Thermal Electric Thermal Electric Thermal Electric Fuel Pump Anti Vapor Anti Vapor Anti Vapor Anti Vapor Lock Electric 12V 2 75 to 3 50 psi Lock Electric 12V 2 75 to 3 50 psi Lock Electric 12V 2 75 to 3 50 psi Lock Mechanical 0 29 to 0 65 psi Fuel Pump Outlet Pressure Ignition Type Battery Battery Battery Battery Spark Plug Type Resistor Resistor Resistor Resistor Spark Plug Size 3 8 Reach 3 8 Reach 7 16 Reach 7 16 Reach 14mm 14mm 14mm 14mm Spark Plug Gap 0 035 0 035 0 035 0 035 Starter Motor Bendix Auto Bendix Auto Bendix Auto Bendix Auto motive Type motive Type motive Type motive Type Air System Combustion 16 16 cfm 25 cfm 25 cfm Cooling 360cfm 380cfm 650cfm 650cfm Total Air Requirements 376cfm 396cfm 675cfm 675cfm Frequency Regulation 5 5 5 5 Fuel Consumption 259 Load 0 35 gal hr 0 52 gal hr 0 55 gal hr 0 56 gal hr 50 Load 0 46 gal hr 0 60 gal hr 0 61 gal hr 0 66 gal hr 75 Load 0 57 gal hr 0 73gal hr 0 73 gal hr 0 84 gal hr 100 Load 0 75 gal hr 0 92 gal hr 0 88 gal hr 1 08 gal hr Table 1 3 Engine Specifications AIR COOLING SPARK SHROUD PLUG REMOTE CIRCUIT ka CLEANER CONTROL PROTECTOR PLUG HARNESS PLUG
12. INTERLOCK CIRCUIT BOARD 6 10 1 General The interlock circuit board Figure 6 29 is located in the end bracket assembly Its function is to prevent the starter motor from reengaging the ring gear if the start switch is activated while the engine is running It performs this function by sensing generator output voltage and sending a signal to the Decision Maker Controller when ever this voltage is present If no voltage is present the Deci tion Maker will shut the engine down COLLECTO 6 10 2 Removal and Inspection RINGS 1 Remove generator end panels 2 Disconnect plug and remove mounting screws holding circuit boards to the end bracket 3 Examine front and back of circuit board for burnt components or damaged foil BEARING 6 10 3 Testing Figure 6 28 Four Pole Rotor 1 Connecting an ohmeter across the interlock board pins and rectifier terminals perform the following resistance tests with the meter set on R x 1000 ohm scale SCHEMATIC KOHLER PART NO A 269150 I D CORNELL DUBLIER IOOMFD SOW V D C Cx L W 100 50 R22 5 5 tio Pw 5 DESCRIPTION IN4Z755A 43 ZENER DIODE 8 DUAL INLINE BRIDGE KOHLER PART NO B 269150 Figure 6 29 Generator Interlock Circuit Board 6 9 PINITOIPIN METER COMMON LEAD READING SHOULD BE 5 3 2 200 ohms 5 1 2 200 ohms 3 Terminal on Rectifier 1C2 2 200 ohms 1 Terminal on Rectifier 1C2 2 200
13. Operating Erratically Faulty choke control Improper fuel mixture Loose ignition connections Air leaks in manifold or carburetor connections Vent in gas cap plugged Fuel pump faulty CON OO Q N Table 4 1 Engine Troubleshooting Refer to Kohler Service Manual for Repair Refer to Generator Owner s Manual for Adjustments 4 3 CONDITION POSSIBLE CAUSE CORRECTION No AC output green lamp off Fuse in controller blown 5 3 Engine starts then stops when start switch 10 amp fuse blown 5 3 is released If blows after replacement check for defective wiring generator and generator voltage regulator Engine runs AC voltage is present but green 1 amp fuse blown 5 3 lamp does not come on Engine will not crank Defective switch circuit board 5 4 Loose pin in electrical connector Open in foil pattern of Main Circuit Board Engine cranks but will not start Defective main circuit board 5 4 Foil burnt 5 5 Defective choke In line fuse to ignition coil blown Q N I G N gt Engine shuts down e 10 amp in line fuse blown 5 3 Radiated electrical noise from ignition circuit affecting logic circuitry in the controller N No AC output green lamp on Circuit protector left in OFF position Reset ON position If the breaker trips after starting reduce the load on the generator set Short circuit Check a
14. any equipment connected to generator 5 3 1 Two fuses are located inside the controller Figure 5 3 The pink leads are connected to a 10 Amp fuse The gray leads are connected to a 1 Amp fuse See Generator Wiring Diagram Fuse identification is labeled on the inside of the controller The 1 Amp fuse protects the controller from damage if a short develops in the wiring harness to the remote control option The 10 Amp fuse protects the Decision Maker in case a short circuit or malfunction occurs within the generator buildup circuitry 5 3 2 A 10 Amp in line fuse later models only is mounted in the lead from pin number 2 in harness plug to ignition coil positive terminal It protects the controller in the event of a shorted or faulty ignition coil choke heater fuel pump shut down control or engine wiring Figure 5 3 Decision Maker Controller Cover Removed 5 4 CIRCUIT BOARDS Figures 5 4 and 5 5 show the circuit board components and wiring Replace a circuit board if any parts are burned or damaged The foil can be repaired by soldering Refer to Paragraph 5 5 5 5 CIRCUIT BOARD FOIL REPAIR 5 5 1 General On later models sets the controller is protected by a 10 Amp in line fuse However the foil could be burnt as a result of a pinched wire or short in the controller 5 5 2 Foil Repair 1 For field repair of the board the following equipment is required a Tinned copper wire 16 20 b Solder
15. fuel lines with rigid lines Flexible sections are used to avoid breakage due to vibration Should any fuel leakage fuel accumulation or electrical sparks be noted DO NOT OPERATE GENERATOR SET Have sys tems repaired by qualified specialists before resuming generator operation Additional precautions should be taken when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Don t store gasoline any occupied building Propane LP Adequate ventilation is mandatory Pro pane is heavier than air install gas detectors low in room Inspect detectors often A WARNING UNINTENTIONAL STARTING To prevent accidental starting when checking choke operation remove spark plug lead s at spark plug s A warninc 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 fuel filter fuel pump or other potential sources of spilled fuel or fuel vapors A WARNING ELECTROCUTION Your RV generator set must not be used to backfeed by connecting it to building camp ground electrical circuits Doing so can cause serious injury or death to utility personnel working on utility transmission lines may also seriously injure persons your household Unauthorized connection may be unlawful in some states and or localities A transfer switch must be insta
16. is turned on Tension of the thermostatic spring is set to allow full choke at starting Current through a heating element furnishes heat which releases the spring tension and allows the choke plate to return to the open position 7 2 2 Inspection 1 Disconnect the high tension leads from both 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 Decision Maker Controller to the start position and hold for five seconds The choke should fully close and release when the start switch is re leased If the choke does not function properly Step 3 see troubleshooting Table 7 2 7 2 3 Adjustment The choke unit Figure 7 2 is set at the factory for average conditions To readjust for local conditions loosen the cover retaining screws and shift the cover in clockwise direction for richer setting or counter clockwise direction for leaner setting Tighten the cover retainer screws 7 3 POSITIVE SHUTDOWN CONTROL 7 3 1 General If an engine has been working under load it tends to continue running or diesel after the switch is moved to the stop position This is prevented on these generator sets by a solenoid and plunger which positively stops all flow of fuel when the switch is moved to the stop position See Figure 7 1 or Figure 7 3 The solenoid is mounted on the carburetor When the switch is in the Figure 7 2 Choke 5 5KW 7KW Sta
17. stopped loosen do not remove the arm retaining nut which secures the governor arm to the cross shaft 7 4 RETAINING NUT SPEED ADJUSTING NUT Figure 7 4 Governor Components and Adjustment Points 3 5KW ADJUSTING NUT Figure 7 5 Governor Components and Adjsutment Points 4 5KW 2 Grasp the end of the shaft with pliers and turn the shaft as far as possible in counterclockwise direction until the internal tab on the shaft stops against the qovernor gear mechanism Hold shaft in this position pull governor arm all the way from the carburetor then retighten the arm retaining nut B Governor Speed Adjustment 1 If overspeed or underspeed condition is suspected check speed with a tachometer or frequency meter at rated load 2 Loosen speed adjusting nuts to decrease speed and tighten speed adjusting nuts to increase speed C Sensitivity Adjustment If the speed drops considerably when a normal load is applied the governor may not be sensitive enough If speed surging occurs with changing load the governor may be too sensitive 1 To make the governor MORE sensitive increase the spring tension by moving the spring hooks into holes spaced further apart 2 To make the governor LESS sensitive decrease the spring tension by moving the spring hooks into holes spaced closer together 7 5 GOVERNOR HUNTING CHECKS 4 5KW ONLY Governor hunting is a periodic frequency variation If the varia
18. sure unqualified persons especially children cannot gain access to your set keep the compartment door locked or securely latched at all times Be sure that generator is properly grounded Never touch electrical leads or appliances with wet hands when standing in water or on wet ground as the chance of electrocution is especially prevalent under such con ditions A WARNING UNIT STARTS WITHOUT NOTICE To prevent accidental starting on units with a remote start stop switch always disconnect battery remove negative lead first and recon nect it last to disable generator set before working on any equipment connected to generator A wARNING DANGEROUS ACID Avoid contact with battery electro lyte It contains acid which can eat holes in clothing burn skin and cause permanent damage to eyes Always wear splash proof safety goggles when working around the battery If battery electrolyte is splashed in the eyes or on skin immediately flush the affected area for 15 minutes with large quantities of clean water In the case of eye contact seek immediate medical aid Never add acid to a battery once the battery has been placed in service Doing so may result in dangerous spattering of electrolyte A WARNING EXPLOSIVE BATTERY GASES The gases generated bya battery being charged are highly explosive Do not smoke or permit flame or spark to occur near a battery at any time particularly when it is being charged Avoid contact ing t
19. the brush holder it will be necessary to retain the brushes with a wire Figure 6 33 Remove the wire when the brushes are installed 7 Install the generator to the base 8 Install the inside housings 9 Install the exhaust tube Install the side housings and top housing 10 Install the interlock circuit board and plug See Genera tor Wiring Diagram for connections 11 Install the safeguard breaker and end panels Figure 6 34 12 Connect the generator ground strap to the base 13 Connect the battery positive lead to the generator Figure 6 33 Brush Retaining Wire positive stud SAFEGUARD INTERLOCK 75 CIRCUIT HOLDER Figure 6 34 End Panels Removed 4 5KW Shown 6 11 SECTION 7 CHOKE SHUTDOWN CONTROL AND GOVENOR 7 1 CHOKE TESTING AND ADJUSTMENTS 3 5kW 4 5kW 7 1 1 General When the engine start switch is activated battery current activates the rotary solenoid in the electric choke unit Figure 7 1 The choke lever pushes the choke plate into full choke position A timer inside the Decision Maker controller de energizes the solenoid after five seconds When the solenoid de energizes the choke plate opens to a position determined by a thermostatic spring and the ambient temperature As the engine warms and less choking is needed the thermostatic spring allows the choke plate to gradually move to full open position A WARNING BACKFIRE A sudden backfire can cause s
20. 8 01 V 9 8 90d NI OL 9NId 2 01 NI OL g nTd S OL NI 01 g 9n1g 9 9nnd 6 01 6 V OL 9 4 2 Q NOILYASNI 107 69 8 ON MIGN3SSY YJIHOY e IVNIAH3 L O 90 Oo O 50 gO sO 20 O rO Oa 6 90 lt 8 tv NI OY Q 1 v n1d NI v 9 9n1d NI S 01 01 01 OL 01 Figure 5 4 Main Circuit Controller 5 4 DESCRIPTION 560 1 2 W 10 CARBON FILM 2 390 1 2 W 10 CARBON FILM 560 1 2 W 10 CARBON FILM 7105 0 30 0 8 K 4 8121 C V3 W 8004 susnne Figure 5 5 Switch Circuit Board SECTION 6 GENERATOR 6 1 GENERAL This chapter covers disassembly inspection and testing of the generator components See Figures 6 1 and 6 2 for parts identification 6 2 TROUBLESHOOTING Refer to Table 4 2 to troubleshoot the generator Follow the disassembly procedure in Paragraph 6 3 as far as neces sary to inspect a component then start reassembly proce dure in Paragraph 6 10 at the point the component is re placed When a fuse must be replaced always inspect the related components and
21. NITION switch ON start the engine using CRANK and CHOKE buttons as needed If engine does not start see Troubleshooting Table 4 1 With engine at opera 4 2 ting speed press V B U voltage build up button momen tarily Observe GEN ON lamp Green light indicates genera tor output voltage is available If no output voltage is available see Generator Troubleshooting Table 4 2 9 Turn the IGNITION switch to OFF position to stop the engine NOTE On 5 5KW and 7KW sets the SAFETY lamp will go off after the engine has begun operating and oil pressure rises above 15 psi 10 To check the high temperature cutout and or the low oil pressure cutout For proper operation start the genera tor set and connect a jumper wire from the cutout device to ground The amber safety lamp should light indi cating the protective circuit is functioning properly 11 If all checks are OK connect the 12 pin connector to the generator set controller If the 15 amp fuse blows check for defective cranking solenoid fuel pump or fuel solenoid ignition coil choke heater fuel shutdown control or shorted wiring If the 1 amp fuse blows check for defective choke solenoid or wiring If the 3 amp fuse blows check for shorted or grounded generator rotor or defective voltage regulator 4 3 TROUBLESHOOTING cannot cover every possible cause of malfunction Always consider every possible cause of malfunction Knowledge Refer to Table 4 1 f
22. OD 1 201 IVA 7373 gt z eo vO 1 W3SSV 39 V AOC 22 18 17 OL N33Y9 JN O QuvzVH Ee ene 1700172 awa Ooo 3SN30N09 YOLVLS YOLWNYSL TV UNid 835 gt u NIA 3015 NOMUISNI NI WOud NMOHS 580123 XB 2 LHM 30156 1 1 2 7302 5 9 gt uso 3MOH2 aava Adi OL a 310118 Ya THOW a LINDYID yDO 1d3LNI I 3 Sv uJ O 4 0 5 L dOLS v 4 6 5 gt LINDID TOdLNO2 2 77 wy 3LviS 1105 26016 Wiring Diagram 4 5CM21 Generator Set RV 8 2 3AOD O 6 O N AQ W3SSV YOLVY3N39 269150 3389 QudYZVYH avol 21 OW 10d Aer bang 1 3015 35 Nid INouad NMOHS SYOLDINNOD JLIHM N3389 ame WVG Nodd M NMOHS 3NYvd VW3NVd 3LOW38 831 x 1 3138 AOT ONO TOYLNOD LHM VOI 0 n G S 9 v Ol K Vv
23. OIL FILL TUBE amp DIPSTICK BLOWER HOUSING STARTING MOUNTING TRAY MOTOR START STOP SWITCH CRANKING SOLENOID GROUNDING STRAP DIRECT AIR DISCHARGE SHROUD BATTERY POSITIVE CONNECTION OIL DRAIN LOCATED UNDER UNIT Figure 1 3 Service Side View of a Kohler 5500 or 7000 Watt RV Generator Set 1 6 OIL SPECIFICATIONS Use high quality detergent oil of API American Petroleum Institute service class SF Select viscosity based on the air temperature at the time of operation as shown below RECOMMENDED SAE VISCOSITY GRADES SW 20 SW 30 F 20 0 C 30 20 10 Straight 30 weight oil is preferred If multi viscosity is used be aware of the resulting increase in oil consump tion and combustion deposits when used in temperatures above 32 F 0 C Using other than service class SF oil or extending oil change intervals longer than recommended could cause engine damage which is not covered by the engine warranty For Overhauled Engines Or Those Rebuilt With A New Short Block or Miniblock Use straight SAE 30 SF quality oil for the first 5 hours of operation Change the oil after this initial run in period Refill with SF quality oil as specified 1 4 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE 1 Quart 2 Quarts 4 Quarts Additional 1 2 quart when filter is replaced 4 Quarts Additional 1 2 quart when filter is replaced Table 1 5 Oil Capacity 1
24. R CONTROLLER 5 1 DESCRIPTION All generator set functions are dependent upon the Deci sion Maker Controller See Figure 5 1 for parts identifica tion 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 operator to start and stop the generator set from another location in the vehicle The hour meter records the hours of generator set operation The controller can be removed by removing the two snap connectors and two cap screws underneath the controller This section cov ers troubleshooting fuse replacement inspection of the circuit boards and controller foil repair Controller Assembly Box Main Circuit Board Figure 5 4 Cover Fuse Quantity 2 Fuse Block Switch Circuit Figure 5 5 Switch Circuit Plug Wiring Harness Connectors 1 2 3 4 5 6 7 8 9 Figure 5 1 Decision Maker Controller 5 2 SEQUENCE OF OPERATION The Decision Maker is the controlling point for generator set operation The following is the sequence of operations controlled by the Decision Maker Refer to Figure 5 2 1 Pressing the start stop switch to the start position allows battery current to flow through a set of normally closed 1CR contacts main circuit board to the coil of the crank ing solenoid through the switch and return to ground This energizes the cranking solen
25. ature Kohler designed and built 4 cycle air cooled gasoline engines rotating field generators and Decision Maker Controllers See Table 1 1 for specifications and model variations Table 1 2 for dimensions and weight and Table 1 3 for enigne specifications Refer to the wiring diagrams in the back of the manual 1 2 MODEL 3 5CM21 RV This 3500 watt generator set is powered by a single cylinder model K181OS engine The set produces 120 volt 29 amp alternating current It has a rotor with two magnetic poles and operates at 3600 R P M producing 60 hertz or 3000 R P M producing 50 hertz 13 amp current A 30 amp cir cuit breaker protects the set from overload damage Due to its compact size and lightweight it is installed RV s with limited suspension support and compartment space See Figure 1 1 for major components 1 3 MODEL 4 5CM21 RV This 4500 watt generator set is powered by a single cylinder Kohler Model 4105 engine The set produces 120 volt 37 7 amp alternating current It has a rotor with four mag netic poles and operates at 1800 R P M producing 60 hertz A 40 amp line circuit breaker protects generator against damage due to overload See Figure 1 2 for major components 1 4 MODEL 5 5CM21 RV The 5500 watt generator set is powered by a two cylinder Kohler Model 58205 engine The set produces 120 volt 46 amp alternating current It has a rotor with four magne tic poles and operates at 1800 R P M produci
26. e plate will close more at lower temperatures The choke will remain closed only 5 to 10 seconds as determined by controller PROBLEM CAUSES SOLUTIONS Choke won t close when cranking Faulty solenoid Faulty Decision Maker or ground in Decision Maker Choke lever lacks sufficient travel or smooth movement Choke will not fully open adjusted Choke shaft fails to move freely Faulty choke adjustment Faulty heater Faulty lead wires or terminals Air cleaner gasket interference with choke shaft lever 4 5KW only Choke spring not properly Change lead wires or replace choke Reposition flat of gasket to provide clearance for choke shaft lever Test solenoid Replace lead to Decision Maker with a jumper wire to ground If choke functions properly check Decision Maker Manually move the choke lever until the choke plate is fully closed Re place the choke unit if it does not move freely Remove spring retainer and with choke wide open wind up spring 1 2 turn replace spring retainer Replace choke shaft Adjust choke Test heater resistance Table 7 1 Troubleshooting Choke 3 5KW 4 5KW 7 2 7 2 CHOKE TESTING AND ADJUSTMENTS 5 5KW 7KW 7 2 1 General The choke on the 5 5KW and 7KW models is an integral part of the carburetor The electrical lead to the choke is connected so that current flows to the thermo static element only when the ignition
27. en the engine is operating at its rated speed it is important that the starter motor is not again energized If this should occur the teeth on the starter or ring gear would be damaged or the starter motor itself could be ruined 8 To prevent this from happening a cranking interlock is provided This consists of a circuit which provides a for ward bias to transistor Q10 allowing the 1CR relay to be energized as long as AC is available from generator stator terminals 33 and 44 When the 1CR relay is energized the normally open 1CR contacts close to provide a holding supply to B for the 1CR relay after the contacts open 9 Normally closed 1CR contacts in series with the solenoid will open when is present preventing the C coil from being energized This prevents the possibility of cranking when the engine is running 10 The 1CR contacts supplying initial field flashing current to the B terminal of the regulator also open when AC is present engine running Note that the Q10 transistor also provides the ground path for the green on LED 5 1 11 If no signal to the bias circuit of the transistor is received from the interlock circuit the engine will remain running only as long as the start switch is held in the start position 12 If a reverse bias is furnished to the Q1 transistor it will cease to conduct and allow the 2CR relay to become de energized removing battery suppl
28. er of electrocu tion 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 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 locked or securely latched at all times Be sure that generator is properly grounded Never touch electrical leads or appliances with wet hands when standing in water or on wet ground as the chance of electrocution is especially prevalent under such con ditions Since this test is designed for use in the field it only checks regulator output when cold and does not check voltage build up To complete the test you ll need the following equipment Two 120V 100 watt bulbs and sockets 110 120V AC power source or variable transformer Switch SPST 120V 2 amp minimum Fuse 2A in holder Jumpers Multimeter Figure 6 24 shows the typical voltage regulator terminal identifications Figure 6 24 Terminal Identification 1 Connect two 100 watt light bulbs across terminals of regulator See Figure 6 25 2 Set multimeter range to 100 volts DC Connect meter across light bulbs Check for correct polarity refer to Fig ure CAUTION Do not touch electrical equipment when stand ing in water or when your hands are wet
29. erious burns Keep hands and face away from the carburetor when the air cleaner is removed ONE LEAD TO STARTER RELAY THE OTHER LEAD TO DECISION MAKER HEATER THERISTOR TERMINAL LOCKWASHER FLAT WASHER AUTOMATIC ELECTRI CHOKE UNIT CHOKE SLOT LEVER ADJUSTING A WARNING UNINTENTIONAL STARTING To prevent accidental starting when checking choke operation remove spark plug lead s at spark plug s NOTE Defective choke may cause failure of the Deci sion Maker Controller 7 1 2 Inspection 1 Disconnect the high tension lead from the spark plug so the engine will not start 2 Remove the air cleaner cover element and base plate CHOKE SHAFT SHUT DOWN SOLENOID PLUNGER SPRING RETAINER 0 _ CHOKE 1 2 TURN TENSION Figure 7 1 Choke and Carburetor 3 5KW 4 5KW 7 1 3 Push the start switch on the Decision Maker Controller to the start position and hold for five seconds The choke plate should close a minimum of 45 at an ambient temper ature of about 75 F The plate will close more at lower temperatures The choke plate should open when the switch is released 4 During cranking the choke will remain closed only five to ten seconds as closing time is controlled by the Deci sion Maker Controller 5 If the choke does not function properly refer to Choke Troubleshooting Table 7 1 7 1 3 Testing Choke Solenoid 3 5 4 5KW 1 Disconnect
30. erminals with tools etc to prevent burns and to prevent sparks that could cause an explosion Remove wristwatch rings and any other jewelry before handling battery Any compartment containing batteries should be well ventilated to prevent accumulation of explosive gases To avoid sparks do not disturb battery charger connec tions while battery is being charged and always turn charger off before disconnecting battery connections Turn automotive test equipment off when connecting or removing battery clips When removing or reconnecting battery cables make sure ignition switch and all accesso ries are turned off A WARNING EXCESSIVE NOISE Never operate without adequate muffler or with faulty exhaust system exposure to excessive noise is not only tiring but can lead to impair ment of hearing A warnine HOT PIPING An engine gets hot while running and exhaust system components get extremely hot Do not work on generator set until unit is allowed to cool A warnine DANGEROUS FUELS Use extreme caution when hand ling storing and using fuels all fuels are highly explosive in a vapor state Store fuel in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running to prevent spilled fuel from igniting on contact with hot parts or from ignition spark Keep fuel lines and connections tight and in good condition don t replace flexible
31. eyebolt down ward 2 To make the governor less sensitive loosen the lower nut and tighten the upper nut to draw the eyebolt upward 3 Retighten the nut that was loosened to lock the eyebolt at the new setting 7 5 7 6 UPPER THROTTLE LINKAGE SENSITIVITY ADJUSTING EYE BOLT GOVERNOR ARM GOVERNOR SPRING SPEED ADJUSTING EYE BOLT INCREASE SPEED OUTSIDE NUT BRACKET INCREASE SENSITIVITY Figure 7 7 Governor Components and Adjustments 5 5KW 7KW 93d 1692 17 201 qg LIANDYID gt 1 2 N 266 1303 188 HD 2 HID 061692 W3SSV 01 w A Oz ee a h wae QHVZYR LINDYID TOYLNOD 9 311916 1705 I T YOLVLS Lnoln2 a YOLVNYSLIV IH 2 J JSNJONOD Nde 134 15 4 2 3n 18 ofp BES EE KA 4 adand 2015 NOILYISN WOt3 NMOHS 580123 ym amp NMOGI NHS AWN y 5 z s NMOG LOHS 7303 N 2 gt o J Qau LHM A 4 341038 LION 21 Wiring Diagram 3 5CM21 Generator Set RV 8 1 3A09 661692 NOYLN
32. leads from the solenoid tabs Figure 7 1 2 Check the resistance of the solenoid by connecting an ohmeter or multimeter across the solenoid tabs Solenoid resistance should be approximately 23 ohms or higher 7 1 4 Testing Choke Heater 3 5 4 5KW 1 Remove the lead from the heater terminal 2 Check heater resistance Connect one lead of an ohmeter or multimeter to the heater terminal Connect the other lead to the curburetor body ground 3 The resistance should read at least three ohms If not replace the choke 7 1 5 Replacement and Adjustment NOTE When installing the choke make sure the choke plate arm goes under the choke lever 1 Position the choke with the two mounting screws slightly loose 2 Push the choke unit all the way down then keeping slight pressure on it move the chokeplate in carburetor into the full open position allowing the choke unit to rise 3 Rotate the choke unit clockwise viewed from choke side with a slight pressure Continue to rotate the choke until it can no longer be rotated without closing the choke plate An internal spring will be wound up in the last 5 to 15 degrees of rotation before internal stop is reached 4 When the choke plate is full open tighten the bracket screws and install the three leads 5 Check choke function by removing the spark plug lead and cranking the engine The choke plate should close a minimum of 45 at a temperature of about 75 Th
33. ll wiring and voltage regulator Low output or excessive drop in voltage Set overloaded Reduce the load green lamp Defective voltage regulator Replace Low AC voltage Below 110V Worn brushes 6 5 Defective voltage regulator 6 7 replace NOTE Before installing use thermal compound 287945 and apply thin coat on base of regulator Low engine speed High AC voltage Defective voltage regulator 6 7 replace NOTE Before installing use thermal compound 287945 and apply thin coat on base of regulator High engine speed Engine starts then stops when start Check the 110 Volt AC output at available outlet while the start button switch is released no red or green light is being held on If AC output is present replace AC interlock board 6 10 If no 110 Volt AC output is present Check for open or short circuit Check brushes 6 5 for cracks or broken leads and make sure they are making proper contact on the slip rings Check rotor 6 9 and stator 6 8 resistance Check voltage regulator 6 7 If defective replace voltage regulator NOTE Before installing apply thermal compound thin coat on base of regulator e Check stator 6 8 for grounded open or shorted windings Engine runs AC voltage is present Faulty exciter voltage regulator 6 7 engine stops running after a short time Table 4 2 Troubleshooting Generator 4 4 SECTION 5 DECISION MAKE
34. lled in the RV to prevent interconnection of generator and outside source of power A WARNING BACKFIRE A sudden backfire can cause serious burns Keep hands and face away from the carburetor when the air cleaner is removed A warninc FIRE HAZARD Keep the compartment and generator set clean and free of debris to minimize chances of fire Also remember that hot exhaust gases and exhaust system parts could start grass fires Keep away from hot engine and generator parts to avoid burning yourself A WARNING MOVING PARTS Do not open generator set compartment door when unit is running except for servicing by quali fied specialists Replace guards covers and screens if used before operating generator set A warnine HIGH VOLTAGE When the power cord is plugged in during voltage regulator test the pins become hot and there is danger of electrocution A WARNING EXPLOSION Use generator sets specified for RV use RV installations only SECTION 1 INTRODUCTION AND SPECIFICATIONS 1 1 INTRODUCTION This manual covers operation scheduled maintenance troubleshooting and corrective maintenance for Kohler gen erator sets designed and built for recreational vehicles The four standard models the 3 5CM21 RV 4 5CM21 RV 5 5CM21 RV 7CM21 RV These models are referred to by their kilowatt output 3 5KW 4 5KW 5 5KW and 7KW Differences between models are noted throughout the man ual All models fe
35. locks under the generator adapter 12 Lift the brushes by the leads and lock in this position by inserting a retainer wire as shown in Figure 6 12 13 Remove the four long over bolts Figure 6 13 and 6 14 and remove the end bracket to reveal the exciter voltage regulator Figure 6 14 Disconnect the stator leads from Figure 6 9 Exhaust Tube the regulator Figure 6 14 Exciter Voltage Regulator NOTE Voltage regulators will appear as shown in Figure 6 14 or 6 15 Terminal connections and testing will be the same for both 14 The stator Figure 6 16 can be tested at this time Paragraph 6 7 Remove the stator by guiding it to the rear NOTE The rotor is threaded on the crankshaft right hand threads on the 3 5KW only Remove with a strap wrench 15 Loosen thru bolt one or two turns and bump the thru bolt with a lead mallet to break the rotor loose 4 5KW 5 5KW 7KW only to remove the rotor Figure 6 17 If the bearing Figure 6 18 turns freely and has no sign of damage do not remove The fan will be removed with the rotor Figure 6 19 Figure 6 15 Exciter Voltage Regulator 3 5KW Shown Figure 6 16 Stator 6 4 BUILT UP CIRCUIT This circuit magnetizes the rotor during cranking When the switch on the Decision Maker Controller is moved to the start position DC current flows from the battery to brushes and collector rings on the rotor See Figure 6 20 6 5 BRUSHES 6 5 1 General
36. n the power cord is plugged in during voltage regulator test the AC pins become hot and there is danger of electrocution NOTE If voltage readings coincide with above recom mended test results regulator may be used in generator set CAUTION Completely disconnect 120V AC source from primary power source before disconnecting from regulator 6 7 110 120 VAC OR VARIABLE TRANSFORMER See Note After Step 7 JUMPER Figure 6 25 Wiring Diagram Voltage Regulator Field Test 6 8 STATOR 6 8 2 Inspection The stator should have 0 25 ohms resis tance across each winding To test connect ohmeter 6 8 1 General The stator Figure 6 26 consists of a series between leads 1 and 2 3 and 4 and then 33 and 44 The coils of wire laid in a laminated steel frame The stator leads leads are tagged with the lead number see generator wiring diagram supply voltage to the AC load and exciter regulator 6 9 ROTOR The function of the rotor is to create a magnetic field The 3 5KW has a rotor with two electromagnetic field poles Figure 6 27 The 4 5KW 5 5KW and 7KW each have a rotor with four electromagnetic field poles Figure 6 28 Rotor resistance readings are given in Table 6 1 Measure resistance ohms between the two collector rings 9 to 11 ohms 8 to 10 ohms 8 to 10 ohms 8 to 10 ohms Table 6 1 Rotor Resistance COLLECTOR Figure 6 26 Stator Figure 6 27 Two Pole Rotor 6 8 6 10
37. ng 60 hertz A 50 amp circuit breaker on most models protects against damage due to overload See Figure 1 3 for major compon ents 1 5 MODEL 7CM21 RV The 7000 watt generator set is powered by two cylinder Kohler Model K582QS engine The set produces 120 volt 58 amp alternating current It has a rotor with four magne tic poles and operates at 1800 R P M producing 60 hertz A 60 amp circuit breaker on most models protects against damage due to overload See Figure 1 3 for major compon ents Amps Per Volts Terminal 3 5CM21 RV 120 3 5CM61 RV 120 240 3 5CFM21 RV 120 3 5CFM61 RV 120 240 4 5CM21 RV 120 4 5CM61 RV 120 240 4 5CFM21 RV 120 4 5CFM61 RV 120 240 5 5CM21 120 5 5CM61 120 240 5 5CFM21 120 5 5CFM61 120 240 7 21 120 7CM61 120 240 oD 2 3 2 3 2 3 2 3 2 3 2 3 2 3 Table 1 1 Generator Specifications Weight approximate 146 lb 237 Ib 315 Ib 350 Ib Length Overall 22 23 13 16 26 27 1 2 Width Overall 13 3 4 18 3 16 21 1 2 21 1 2 Height Overall 15 3 4 19 1 16 20 3 8 20 3 8 Earlier Models 250 Ib Table 1 2 Dimensions and Weight 1 1 Fuel Inlet Connection Size 1 4 I D 1 4 1 D 1 4 1 D 1 4
38. nish in normal operation Do not attempt to maintain a bright newly machined appearance Ordinary cleaning with a dry lint free cloth is usually sufficient Very fine sandpaper 00 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 Figure 6 19 Removing Rotor some of the surface material by using a lathe SS Z 2 GENERATOR ROTOR BRUSHES amp COLLECTOR RINGS GENERATOR REGULATOR STARTER 12 VOLT BATTERY SOLENOID DECISION MAKER Figure 6 20 Buildup Circuit Figure 6 21 Brushes BRUSH aa WIRE RETAINER Figure 6 22 Brush Holder 6 7 EXCITER VOLTAGE REGULATOR 6 7 1 General The voltage regulator assembly Figure 6 23 includes a bridge rectifier and a voltage regulating circuit AC from the stator is received at the AC termin als on the regulator This current is rectified to DC by the bridge rectifier and supplied to the rotor from terminals and through the brushes and collector rings This AC is constantly monitored by the regulator to maintain 2 variation of the stator output Figure 6 23 Exciter Voltage Regulator WARNING HIGH VOLTAGE Remember that the function of a genera tor setis to produce electricity and that wherever electric ity is present there is the potential dang
39. nnecting and testing with the controller If the generator does not check out in each step correct the malfunction before proceeding to the next step CAUTION Do not push the CRANK button after the en gine is running Starter damage will result SYSTEMS CHECK GEN POL CRANK ON SAFETY IGNITION ON OFF CRANK CHOKE V B U CAUTION Do not push the V B U button after the GEN ON lamp is on Voltage regulator damage may result CAUTION Do not use the RV Systems Check as a replace ment for a Decision Maker The hi temp and low oil pressure switches will not shut the machine down in the event of a malfunction Generator damage will result 1 Make sure the battery is properly connected and oil is at proper level 2 Check the three fuses the in RV Systems Check tester Figure 4 1 Replace any blown fuses RV SYSTEMS CHECK CONNECT TO RV GENERATOR WIRING HARNESS PLUG SWITCHES gnition Supplies battery voltage to ignition coil choke heater fuel control solenoid fuel valve and fuel pump Crank Supplies battery voltage to starter relay Note May be actuated with ignition switch on or off Supplies battery voltage to choke plate solenoid Note May only be actuated during cranking V B U Voltage Build Up supplies battery vol tage to excite field VISUAL INDICATORS Pol Green Indicates battery
40. ohms 2 Terminal on Rectifier 102 12 500 ohms 2 Connect a 100 or 1000 ohm resistor across pins 2 and TORQUE 5 with jumpers 100 to 125 in Ibs 3 Set a multimeter at 60 volt DC range Connect the meter 175 to 200 in Ibs across the resistor 40 to 55 ft Ibs 4 Apply 110 120 volt AC source between pins 3 and 4 Table 6 2 Generator Thru Bolt Torque Using a 100 ohm resistor voltage drop reading should be 1 15 to 1 55 volts DC With a 1000 ohm resistor the reading should be 11 5 to 12 5 volts DC If these voltages are present interlock board B 269150 is functioning correctly 6 11 GENERATOR REASSEMBLY 1 On the 3 5KW apply antiseize compound to the rotor threads Figure 6 30 Thread the rotor onto the drive shaft and tighten with a strap wrench Figure 6 31 Driveshaft 4 5KW Shown 3 Slide the stator into position making sure the leads are at 12 o clock position Figure 6 32 THREADS Figure 6 30 Rotor 3 5KW 2 On the 4 5KW 5 5KW or 7KW apply antiseize to the crankshaft stub Figure 6 31 Install the rotor onto the crankshaft with the thru bolt See Table 6 2 for torque value Figure 6 32 Stator and Rotor 6 10 4 Install the exciter voltage regulator onto the end brac 5 Install the end bracket with the four long over bolts ket Refer to Generator Wiring Diagram to connect leads 6 Position the brush holder on the collector rings and install the two brush holder screws To install
41. oid C 2 When these contacts are closed battery current of approximately 90 amperes can flow to the engine cranking starter motor Current can now also flow to the choke solenoid through transistor Q6 main circuit board to ground After approximately 5 seconds Q6 turns off de energizing the choke 3 With the contacts still closed current can also flow through normally closed contacts 1CR and the 10 amp fuse to terminal B of the voltage regulator This supplies field flashing to the generator via the brushes and rotor collector rings This is called the build up circuit 4 Transistor Q1 also receives a forward bias when the contacts close and allows current to flow through the coil of the 2CR relay Energizing of the 2CR relay provides a path of current which flows to the ignition coil engine choke fuel solenoid etc 5 With battery current being supplied to the ignition and fuel circuit the engine should run driving the generator This completes the cranking and ignition portion of the Decision Maker s function 6 With the engine driving the generator at the specified speed AC voltage from the stator terminals 33 and 44 is furnished to the AC terminals input of the voltage regula tor The regulator rectifies this AC to DC and furnishes the rotating field with a regulated current supply from the and terminals of the regulator via the brushes and collec tor rings 7 Wh
42. or engine troubleshooting To make of four cycle engines and battery ignition systems can engine repairs refer to the Kohler engine service manual be applied Refer to Table 4 2 to troubleshoot the genera which covers the engine model A troubleshooting chart tor The table refers to applicable paragraphs in the manual CONDITION POSSIBLE CAUSE A Hard Starting or Loss of Power 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 2 Faulty Fuel System a Gasoline not getting to carburetor 1 Dirt or gum in fuel line 2 Fuel pump faulty b Dirt in carburetor c Carburetor improperly adjusted d Choke faulty or improperly adjusted B Overheating Insufficient available cool air Dirty air intake screen shroud or cooling fins Improper fuel Fuel mixture too lean Improper ignition timing Engine overloaded Tight tappet clearance Insufficient hot air discharge opening OOF Q N Backfiring Fuel mixture too lean 2 Improper timing Valve Sticking 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 Clogged fuel line Water in fuel E
43. polarity correct Gen On Green Indicates generator output voltage Crank Amber Indicates battery voltage signal present during cranking Safety Switch Amber Indicates safety circuit wiring correct Operator must manually short temperature switch to ground to obtain this indication Check Tester Fuses First In Case Of Malfunction FUSES 15 AMP IGN CRK 1 AMP CHOKE 3 AMP V B U Figure 4 1 RV Systems Check 3 Remove the 12 pin connector from the Decision Maker controller and plug it to the tester 4 Observe the POL polarity lamp Green light indicates battery polarity is correct If lamp does not light check for correct battery connection to the generator set NOTE On 5 5KW and 7KW sets the SAFETY lamp will also be on This indicates the low oil pres sure switch is functioning properly 5 With the IGNITION switch in OFF position press the CRANK button The CRANK lamp should light and the engine should crank If the lamp does not light no voltage from the battery is present 6 Remove the air cleaner cover to observe the choke plate during the next step 7 Again with the IGNITION switch in OFF position press the crank button While the engine is cranking press the CHOKE button to supply battery voltage to the choke plate solenoid Make sure the choke plate is functioning properly If not see Section 7 Release the CRANK and CHOKE buttons 8 With the IG
44. release the switch and wait a few seconds before mov ing back to START position This allows the choke to reset in the full choke position 2 Whenever possible allow a brief cooling period by run ning the set at low or no load for a few minutes just prior to shutdown To stop move the switch to STOP position and hold until the set comes to a complete halt 2 1 SECTION 3 SCHEDULED MAINTENANCE 3 1 GENERAL Scheduled maintenance is preventive maintenance Major repair can be avoided by correcting problems when they are small When performing maintenance always look for signs of potential trouble such as loose connec tions or dirty components When running the set listen for any unusual noises Before Each Function Startup ae Compartment Remove dirt Blow dry compressed air through cooling inlets set running Air Inlet and Outlet Clean Oil Level Check Check Exhaust Pipe Oil Change Oil Filter Change Air Cleaner Element Clean change every 200 hrs Fuel Sediment Bowl or Filter if equipped Remove and clean Clean Electric Fuel Pump Filter See owner s manual Spark Plug Clean and regap Point Contacts Service or replace Brushes and Collector Rings Check and service Ignition Timing Check and correct Rectifier Regulator Check _ condition and battery charging Alternator Stator Check lead
45. rt position battery current thru the solenoid holds the plunger and continues to hold it while the engine is run ning When the switch is moved to the stop position the solenoid de energizes and drops the plunger into porting in the carburetor to stop all flow of fuel 7 3 2 Inspection and Repair 1 Make sure the solenoid has a secure electrical connection and good contact with the hold down bracket ground 2 Check for stuck plunger Replace if damaged 3 Check for defective solenoid with an ohmeter or multi meter Solenoid resistance is approximately 20 ohms 7 3 3 Temporary Field Fix 1 Turn the main fuel adjusting needle out then shift the solenoid retaining bracket PROBLEMS CAUSES SOLUTIONS Choke won t close during Faulty lead to choke cranking Faulty lead to ground Poor adjustment Choke will not fully open 1 Poor adjustment 2 Faulty choke Check for secure lead connections Make continuity check on lead Re place if no continuity Check for secure lead connections Make continuity check on lead Re place if no continuity Adjust choke Repair with kit or replace choke Adjust choke Repair with kit or replace choke Table 7 2 Troubleshooting Choke 5 5KW 7KW 7 3 SHUTDOWN CONTROL SOLENOID ON Figure 7 3 Shutdown Control Solenoid 2 Lift the solenoid and remove the plunger 3 Replace the solenoid and retaining bracket and readjust the main fuel needle
46. s and connections Starting Motor Check brushes amp commutator Engine External Surface Clean screen cooling fins block oil fill area Valve Clearance Check and adjust valve stems and tappets Crankcase Breather Check valve and gaskets clean filter check hoses Cylinder Head Remove clean and inspect Electric Fuel Pump Service filter 3 2 SCHEDULED MAINTENANCE Refer to Table 3 1 for scheduled maintenance requirements Perform each function at the indicated time interval For each function refer to the applicable paragraph for instruc tions IMPORTANT For maintenance work on engine components refer to the Kohler engine service manual which covers the engine model Every Every 25 50 Hours Hours Table 3 1 Scheduled Maintenance 5 SECTION 4 TROUBLESHOOTING 4 1 GENERAL When troubleshooting a generator set always consider the simplest causes first Narrow the problem down to a func tional system such as fuel or ignition To operate efficient 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 all parts must be clean all connections tight and all com ponents in working order See Table 4 1 for Engine Trou 4 2 RV SYSTEMS CHECK The RV Systems Check is designed to check the electri cal status of an RV generator set prior to co
47. s too great over 90 PRM 3 CPS the governor spring can be moved up one hole in the governor lever 7 6 GOVERNOR 5 5KW 7KW 7 6 1 General These models are equipped with centrifu gal flyweight type mechanical governors which are exter nally mounted See Figure 1 3 for location The governor drive gear is driven by the camshaft gear Lubrication is provided through an external oil line which connects to the engine lubrication system 7 6 2 Speed Adjustment The throttle shaft is fixed at a definite length to establish a load speed of 1800 RPM variation in speed frequency changes the output of the generator For this reason only slight readjustment of speed is possible Proceed as follows 1 To increase speed loosen the inside speed adjusting nut Figure 7 7 and tighten the outside nut to draw the eyebolt closer to the bracket which is mounted on the governor This will pull the throttle open 2 To decrease speed loosen the outside nut and tighten the inside nut to force the eyebolt away from the bracket 3 When speed is correct tighten the nut that was loosened to lock the eyebolt at the new setting 7 6 3 Sensitivity Adjustment If the governor is too sensi tive speed surging will occur with change in load If the governor is not sensitive enough a big drop in speed will occur when normal load is applied 1 To make the governor more sensitive loosen the upper nut and tighten and lower nut to force the
48. t Board 9 1 Bearing 1 2 Wiring Harness 10 Collector Ring 3 Spring 11 Fan 4 Brush 12 Adapter 5 Brush Holder 13 Stator 6 Panel 14 End Bracket 7 Tolerance Ring 15 Exciter Voltage Regulator 8 Rotor 2 Pole Shown 16 Circuit Breaker 6 3 GENERATOR DISASSEMBLY NOTE Tag leads to ease re installation Scratch align ing marks on parts before removing to aid reassembly 1 Disconnect the battery positive lead from the generator positive stud Figure 1 1 1 2 or 1 3 Remove the stud from the generator mounting 2 Disconnect the generator ground strap at the tray Fig ure 6 3 or 6 4 GROUND STRAP Figure 6 4 Generator Ground Strap 5 5KW 7KW 3 Remove the center panel Figure 6 5 or 6 6 The safe guard breaker can be removed 4 Remove the side panels Figure 6 5 4 5 5 5 7KW 5 Remove the plug from the interlock circuit board Fig ure 6 7 The circuit board can now be removed 6 Remove the top housing Figure 6 8 6 2 1 Center Panel 2 Brush Holder 3 Side Panels 4 Circuit Protector CIRCUIT PROTECTOR BRUSH HOLDER Figure 6 6 End Panel Removed 3 5KW 7 Remove the exhaust tube Figure 6 9 8 Remove the side housings 9 Remove the inside housings Figure 6 10 10 Loosen the vibro mounts Figure 6 11 lift the generator from the base INTERLOCK CIRCUIT BOARD Figure 6 11 Vibro Mounts 11 Tilt the generator end up and place b
49. tion hunting is audible to the unaided ear it is not acceptable Use the checklist below to help maintain proper governor operation The items in this list may be used singly or in combination to achieve smoothest pos sible operation 1 Set the point gap to 0 020 with a feeler gauge and ad just the carburetor for peak performance 2 With the engine not running check for free governor linkage movement from idle to full throttle Note Remove excess paint from governor spring and damper and make sure choke wires do not inferfere 3 With the engine shut down the throttle will be in wide open position Adjust the governor linkage so that approxi mately 1 32 space exists between the throttle lever and carburetor body Note This can be done by sight no fine measurement is necessary GOVERNOR LINKAGE CARBURETOR IDLE STOP SCREW Figure 7 6 Carburetor 4 5KW 4 Check idle speed at no load with the throttle lever against the idle speed screw and set speed to approximately 1680 RPM 56 CPS 5 Reposition the governor spring in the governor lever On most units the 2nd hole from the bottom provides the best operation Whenever the governor spring is moved in the governor lever the governor speed control must be adjusted at no load to approximately 1890 RPM 63 CPS 6 If poor governing remains the spring may be moved to the bottom hole If the governing is good but the speed drop from no load to full load i
50. tor 6 6 See 6 8 Rotor 6 8 6 10 Interlock Circuit Board 6 9 SECTION 3 SCHEDULED MAINTENANCE 6 11 Generator Reassembly 6 10 3212 General bo eae 3 1 3 2 Scheduled Maintenance 3 1 SECTION 7 CHOKE SHUTDOWN CONTROL AND GOVERNOR 7 1 Choke Testing and Adjustments SECTION 4 TROUBLESHOOTING 3 5 4 5 7 1 7 2 Choke Testing Adjustments 4 1 4 1 5 5KW TKW 7 3 4 2 RV Systems Check BV 4 1 7 3 Positive Shutdown Control 7 3 4 3 Troubleshooting pp 4 3 7 4 Governor 3 5 4 5KW 7 4 7 5 Governor Hunting Checks 4 5kW Only 7 5 7 6 Governor 5 5KW 7 7 5 SECTION 8 WIRING DIAGRAMS Safety Precautions A Generator Set like any other electro mechanical device can pose potential dangers to life and limb if improperly maintained or imprudently operated The best safeguards against accident are to be ever mindful of the potential dangers and to always use good common sense In the interest of safety some general precautions relating to operating of a Generator Set are presented below Keep these in mind Awarnine LETHAL EXHAUST GAS An engine discharges deadly
51. wiring to locate the cause Refer to the wiring diagrams in the back of the manual fom ww A warnine HIGH VOLTAGE Remember that the function of a genera tor set is to produce electricity and that wherever electric ity is present there is the potential danger of electrocu tion 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 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 locked or securely latched at all times Be sure that generator is properly grounded Never touch electrical leads or appliances with wet hands when standing in water or on wet ground as the chance of electrocution is especially prevalent under such con ditions 15 1 End Bracket 7 Panel Center 13 Interlock Circuit Board 19 Washer 2 Stator 8 Circuit Breaker 14 Thru Bolt 20 Tolerance Ring 3 Rotor 9 Junction Panel 15 Over Bolt 21 Brush 4 Adapter 10 Generator Fan 16 End Bracket 22 Brush Holder 5 Guard Fan 11 Bearing Cap 17 Collector Ring 6 Junction Panel 12 Regulator 18 Ball Bearing Figure 6 1 Generator Cross Sectional View Figure 6 2 Generator Parts Identification Interlock Circui
52. witch Operating procedure is the same for the Decision Maker Controller and the optional remote switch 2 2 PRESTART CHECKLIST Refer to Table 2 1 for all prestart checks HECK REQUIREMENT Oil Level Near Full Not Over Air Inlets Unobstructed Compartment Clean Air Cleaner Clean Properly Installed Tight Proper Position Unobstructed Properly Installed Clean and Tight Air Shrouding Exhaust System Electrical Connections Table 2 1 Prestart Checklist If the engine shuts itself down due to high en gine temperature overload or other reasons press the reset switch on the Decision Maker Controller before attempting restart Also make sure the circuit protector is in the on position so generator output is transferred to the load CAUTION In the event of a false start that is the en gine gets up sufficient speed to disengage the starter but fails to continue running allow the engine to come to a complete halt before making a restart attempt If the flywheel is still rotating when the starter is engaged the startet pinion ring gear will clash which may damage the ring gear teeth REMOTE CONTROL CONNECTOR Figure 2 1 Decision Maker Controller 1 Move the START STOP button on the Controller to START position and hold until the engine is running but not more than 10 seconds Normally the engine will start within five seconds If the engine does not start in 10 sec onds
53. y to the ignition coil fuel pump etc therefore shutting down the engine 13 Reverse biasing of the Q1 occurs when 1 The start stop switch is moved to the stap position 2 The engine safety cutouts are activated 3 Forward bias is removed by opening of both the C and 1CR contacts disconnecting battery and source from the bias circuit 14 The red safety trip LED will light if the circuit was shut down by a reverse bias signal to the Q1 transistor other than from the stop switch This signal could be caused by the hi temp or low oil pressure switch An SCR in this cir cuit maintains this bias 15 Pressing the reset button opens the circuit of the SCR which allows the system to reset VOLT STARTING BATTERY CHOKE 06 7 CRANKING TIMER c A SOLENOID CONTACTS A 6 HOURS Z L ICR IO AMP AMP SOLENOID 2 D2 STARTER FOR FIELD START STOP ROTATING GENERATOR FIELD 4 L 2 CRANKING INTERLOCK CIRCUIT BOARD GENERATOR STATOR x LOW OIL PRESSURE _ CUTOUT IGNITION POINTS Figure 5 2 Sequence of Operation Schematic 5 2 5 3 FUSES A WARNING UNIT STARTS WITHOUT NOTICE To prevent accidental starting on units with a remote start stop switch always disconnect battery remove negative lead first and recon nect it last to disable generator set before working on

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