Kohler 4CM21 Service Manual

MODEL

4CM21 4000 WATT- 129 VOillAC, -:RE~:R.EA'il'ONAlVEHIClE

GENERATOR SET OWNER'S MANUAL CONTENTS SUBJECT Service and Adjustment Points Engine General Specifications Fuel Consumption Generator - General Details Pre-Start Instructions ....................•... Starting-Stopping Procedures Preventive Maintenance .. ~ Battery Connection Service Schedule Air Cleaner Service Lubricating Oil Carburetor Adjustment Automatic Choke Adjustment Governor Adj ustment Cooling System Service Ignition System Service

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PAGE SUBJECT 2 Trouble Shooting-Engine 2 Schematic Diagram-Generator Set 2 Generator Service 2 Trouble Shooting-Generator 3 Controller Operation ..•....................... 3 Engine Parts Identification ..........•........ 3 Parts Ordering~nstructions 3 Engi ne Parts ' 4 Mounting Parts 4 Exhaust Parts 4 Generator Parts ..........•.................... 5 Controller Parts 5 Storage Instructions 6 Opt i ona 1 Accessori es 6 Operating Hour-Service Log .......•.•.......... 7 Warranty .................•.........•..........

•

PAGE 7 ~ 8 9 9 9 10 11 11 12 12 13 14 15 15 16 16

SAFETY PRECAUTIONS Safety is built into every engine driven generator; however, like any other electro-mechanical device it can present serious threat to life and limb if imprudently operated and maintained, Remember that the best safeguards against accidents are to keep ever mindful of the potential dangers and to always use good common sense. In the interest of safety, some general precautions are presented below - keep these in mind! WARNING - HIGH VOLT AGE! Remember that the function of a generator set is to produce electricity and wherever electrical energy is present, there is the potential danger of electrocution. Keep everyone, especially children, away from the set while it is running and take precautions to prevent unqualified personnel from tampering with or attempting to operate your generator set. Have the set and electrical circuits serviced only by qualified technicians and make sure that the battery is disconnected before any service is performed to prevent unintentional starting. Wiring should be inspected frequently - replace leads that are frayed or in poor condition. Be especially careful not to come in contact with electrical equipment when standing in water or on wet ground or when your hands are wet. WARNING - LETHAL EXHAUST GAS! The engine powering your generator discharges deadly carbon monoxide as part of the exhaust • gas when operating. Carbon monoxide is particularly dangerous in that it is odorless but keep in mind that it can cause death if inhaled for even a short period of time. Never operate the generator set inside a building unless the exhaust gas is piped safely outside or operate in any area where exhaust gas could accumulate and seep back inside an occupied building. Keep exhaust system tight and in good condition at all times to prevent leakage. Avoid breathing exhaust fumes when working on or near the generator set. WARNING - DANGEROUS FUELS! Use extreme caution when handling, storing and using fuels - they are highly volatile and explosive in vapor state. Store gasoline only in approved red containers clearly marked GASOLINE - store in well-ventilated area out of the reach of children and away from any flame or spark producing equipment. Don't store gasoline inside home or any occupied building. Never add fuel to tank while engine is running to prevent spilled fuel from igniting on contact with hot parts or from ignition spark. With gaseous fuel, make sure the system meets all safety codes and have it serviced only by qualified technicians. WARNING - MOVING, HOT PARTS! Imprudent operation creates hazards to life and limb - never operate with safety guards removed, keep hands, feet, clothing away from moving and hot parts. Remember that an engine gets hot while running, and exhaust system components get extremely hot. Know how to make emergency stops - don't allow inexperienced persons to operate your set. Always disconnect battery or remove spark plug while working on equipment. Never tamper with governor setting to gain more power - the governor establishes safe operating limits. Overspeed not only shortens engine life but can be extremely hazardous. WARNING - GENERAL PRECAUTIONS! Handle starting batteries carefully - they are filled with acid which can eat thru clothing, bum skin, and cause blindness. Keep in mind that a battery gives off highly flammable hydrogen gas while being charged - charge only in well venti~ lated area. While electrical energy produced in an engine ignition system may not be strong enough to cause injury, reaction to shock produced could cause you to pull away and into contact with hot or moving parts - keep away from ignition system while operating. Never operate without adequate muffler or with faulty exhaust system - exposure to excessive noise is not only tiring but can lead to impairment of hearing.

KOHLER CO.,

KOHLER, WIS. 53044

STOP-START SWITCH AIR

CLEANER

FUEL PUMP

T

OIL AND

OIL .DRAIN

FIGURE

1 -- MAIN

COMPONENTS-SERVICE

&

ADJUSTMENT

FILL TUBE DIPSTICK

POINTS

Engine: Kohler 4-stroke cycle, air-cooled single cylinder gasoline Model K321 engine. Kohler patented ACR (Automatic Compression Release) feature for quick, easy starting. specifications are: LUBE OIL CAPACITy SPARK PLUG SIZE (XH-10 or Equivalent) SPARK PLUG GAP BREAKER POINT GAP

1-3/4 l4mm 025" 020"

BATTERY (55 amp. hr. minimum) FUEL (Regular grade gasoline)

APPROXIMATE

Quarts

12 volt 85 Octane Minimum

The following chart is provided to help you calculate set at various load levels.

.46 .575 .74 Gallon FULLGallon LOAD 3/4 1/2 LOAD APPROXIMATE CONSUMPTION

All have the Other general

FUEL

the approximate

fuel consumption

of your

CONSUMPTION

IN GALLONS

(U.S. STD.)

PER HOUR

AT

1/4 LOAD

Generator: Kohler rotating armature (alternating current) type with built-in exciter which functions as a starting motor to crank the engine during starting then switches to its generating function after the engine starts. Exciter cranking permits higher cranking speeds for longer periods of time thus provides better starting under all conditions.

2

OPERATING

INSTRUCTIONS

PRE - START INSTRUCTIONS Before each start,

open the compartment

and make the following checks:

OIL LEVEL: Must be in safe range. AIR INLETS: Must be clear. COMPARTMENT: Keep interior clean.

STARTING - STOPPING

AIR CLEANER: Must be properly installed. FUEL FILTER: Service if needed. ~ Make sure supply is adequate.

PROCEDURE

The START-STOP switches inside the motor home and on the controller are momentary contact switches which means that they must be held in the STAR T position until the set starts running or when stopping, held in the STOP position until the unit comes to a complete halt. Whenever possible, allow a brief cooling period by running the unit at low or no load for a few moments just prior to shutdown.

PREVENTIVE

MAINTENANCE

In addition to the routine services listed in this manual, there are other important steps that Usually, tools and instruments required for should be taken to keep 3. generator set in top condition. these additioClal steps are not available to the generator set owner. For this reason, the set should be returned periodically to an authorized Service Center for complete servicing and tune-up. The benefits of such service will not only be noted immediately in improved performance, but, most important, in continued satisfactory operation during a long, trouble free service life.

A BATTERY RELAY

BATTERY "N"

NEGATIVE

POSITIVE "C"

TO

POSITIVE

(p)

TO

TERMINAL USING FOR

SEPARATE GENERATOR

BATTERY SET

GROUND STRAP

TO VEHICLE FRAME

B BATTERY RELAY

POSITIVE "C"

POSITI

USING AS

VEHI CLE GROUND VEHI CLE

FIGURE

2 -- BATTERY

SAME

VEHICLE

(p)

BATTERY ENGINE

FRAME BATTE RY

STRAP

TO

FRAME

CONNECTIONS-(A)

SEPARATE

3

I

TO VE

BATTERY

(B) SAME

BATTERY

NE GA TI VE

VEHI CLE

FRAME

AS VEHICLE

ENGINE

SERVICE PROCEDURE SERVICE

. II

SCHEDULE

I

OCCURS EVERY FIRST) 200 HOURS OR EVERY YEAR • Check mounti ng bolts and vi bro mounts. genera torpoints. brushes. .Check breaker • 100 HOURS spark (OR plug. 12 MONTHS -- WHICHEVER DAILY EVERY (OR •• Service "Tune BEFORE up" EACH at START authori UP) zed servi ce center. Retighten electrical connections. Replace air cleaner element.

I

I

AIR

I!II I~ !I

CLEANER

Engine is equipped with a dry type air cleaner. Every 50 hours remove element and service by tapping element lightly against flat surface to dislodge loose surface dirt--do not clean in any liquid or blowout with compressed air as this will ruin filter material in element. ~ce (with genuine Kohler conditIons are encountered, replacement element only) after each 100 hours £l' if guod clean operating thlS can be extended up to 200 hours.

LUBRICATING

OIL

To be on the safe side, check oil in engine crankcase daily or before each start to insure that the level is in the safe range between the Land F marks on dipstick. Do not operate set if level exceeds the "F" mark or if b.elow "L" mark.

I CAUTION: quently

CHECK

OIL ONLY

WHEN

SET

IS NOT

IN OPERATION.

I

Change oil at 50 hour intervals or every 6 months--whichever occurs first. Change if operating under dirtv, dusty conditions, If possibl~, drain oil while hot.

more

fre-

OIL CAPACITV-1% GTS. Use only oils having the API Service se classifications. ture is above 32° F., SAE 10W-30 for 0° F. to 32° F. range below 0° F.

Use SAE 30 weight oils when temperaor SAE 5W-20 when temperature falls

BACK

PLA~E~

SEAL ""

COVER

GENUINE

FIGURE

3 -- OIL LEVEL

MARKS

FIGURE

ON DIPSTICK

4

•

4 -- AIR CLEANER

COMPONENTS

-I CARBURETOR

ADJUSTMENT

Lack of power and black sooty exhaust smoke usually indicates that fuel mixture is too rich. An "overrich" mixture may also be caused by a clogged air cleaner--check this before readjusting carburetcH. Fuel mixture nlay be too lean if engine "skips" or backfires. Note that an overrich condition cou1d a1so be caused by an inlproperly adjusted choke. Main Fuel Adjustment: For preliminary setting, turn MAIN FUEL screw in clockwise direction until it bottoms lightly (do not force) then back out Z turns. With engine thoroughly warmed up and running at 1800 RPM· and full load; turn MAIN FUEL screw in until engine slows down (lean setting) then turn screw out until engine regains speed and then starts to slow down (overrich setting). Turn screw back in until it is positioned halfway between lean and overrich settings--when properly adjusted, engine will operate with steady governor action. Idle Adjustrnent: On generator set app1ications, the idle systenl functions only as the engine UHnes up thru idle range to 1800 RPM. For this reason, idle system has o'11y a mo~entary effect. To adjust. stop engine then turn IDLE FUEL screw all the way in (clockwise) until it bottoms lightly (do not force screw), then back out 1-1/4 turns--no further adjustment is needed.

MAIN

MOVE LEVER IN DIRECTION OF ARROW TO INCREASE CHOKE

FUEL #43 DRILL

(2 TURNS) ADJUSTMENT~

(.089")

~

_ ----.........

F1 II

t

-----

LEVER CLAMP

CHOKE LEV ER ARM

BOLT~

CHOKE

IDLE FUEL ADJUSTMENT

PLATE

(1-1/4

FIGURE

5 - CARBURETOR

AUTOMATIC

NOTCH IN

TURNS)

BASE

FIGURE

ADJUSTMENTS

6 - AUTOMATIC

CHOKE

ADJUSTMENT

CHOKE

Chokes are set at the factory but may have to be readjusted to suit local conditions. Remove air cleaner from carburetor to observe position of choke plate. Choke adjustment must be made on cold engine. If starting in extreme cold, choke should be in full closed position before engine is started. A lesser degree of choking may be needed in milder temperatures. If adjustment is required, proceed as follows: . 1. Z. 3. 4.

Move choke arm until hole in cross shaft lines up with slot in bearings. Insert #43 drill (.089) thru hole and push all the way down to engine manifold to engage in notch in base of choke unit (see accompanying figure). Loosen clamp bolt on choke lever, push arm upwardto move choke plate toward closed position for increased choke or away to decrease choking effect. When properly positioned, tighten clamp bolt then remove drill. After replacing air cleaner, check for evidence of binding in linkage--correct if necessary. Be sure choke is fully open when engine is at normal operating temperatures.

5

GOVERNOR

ADJUSTMENT

The governor functions to maintain engine speed a speed limiting device. Governor is set in the factory unless linkage works loose or becomes disconnected. with changing load or if speed drops considerably when

under changing load conditions and also acts as and further adjustment should not be required Readjustment should be made if engine surges a normal load is applied.

Initial Adjustment: With engine stopped, loosen (do not remove) hex. nut securing governor arm to governor cross shaft. Grasp end of cross shaft with pliers and turn shaft as far as possible in counterclockwise direction--tab on shaft will stop internally against governor gear mechanism. Hold shaft in this position, pull governor arm all the way away from carburetor then retighten governor arm nut to complete initial adjustment. Speed Adjustment: This set must be operated at 1800 RPM. If frequency or overspeed condition is suspected, check RPM with hand tachometer and readjust as follows: With constant speed arrangement, loosen speed adjusting nut to decrease speed or tighten to increase speed.

THROTTLE LINKAGE

GOVERNOR

CROSS

ARM

SHAFT

CARBURETOR

SPEED

ADJUSTING

NUTS

ARM RETAINING NUT SPEED

FIGURE

7 - GOVERNOR

COMPONENTS

AND ADJUSTMENT

BRACKET

POINTS

Sensitivity Adjustment: If speed drops considerably when a normal load set for greater sensitivity. If set too sensitive, speed surging will occur sensitivity is adjusted by repositioning governor spring in holes provided brackets. Increase tension on spring (and sensitivity) by moving spring apart--conversely, decrease sensitivity by reducing tension on spring. readjust as needed after changing sensitivity.

COOLING

CONTROL

is applied, governor should be with changing load. Governor on arm and speed control hooks into holes spaced further Recheck engine speed and

SYSTEM

Kohler Air- Vac cooling is used on this set. With this system, cooling air is drawn into the generator set compartment, circulated from the generator end, around the cooling fins and finally ejected as heated air downward thru the Air- Vac scroll at the flywheel end of engine. High-temperature cutout on cylinder head will stop the generator set if overheating occurs. Keep intake louvers, generator cooling openings, cooling fins and scroll work clean and unobstructed at all tiDIes to prevent overheating--do not operate with blower housing, scroll or cooling shrouds removed as this will also cause overheating.

6

FIGURE

8 -- COOLING

IGNITION

AIR

CIRCULATION

FIGURE

9 -- BREAKER

POINT

GAP

SYSTEM

Spark Plug: Every 100 hours remove plug and check condition. Good operating conditions are indicated 1£ plug has light coating of gray or tan deposit. A dead white, blistered coating could indicate overheating. A black (carbon) coating may indicate an "overrich" fuel mixture caused by clogged air cleaner or improper carburetor adjustment. Do not sandblast, wire brush, scrape or otherwise service plug in poor condition--best results are obtained with new plug. Set standard and resistor type spark plug gap at .025". Tighten plug to 22 ft. lbs. torque when installing. Use 14 mm resistor type XH10 plug for suppression of radio noise. Breaker Points: Every 200 hours breaker points should be inspected and serviced. If oxidized, dirty or oily, clean with coarse cloth--do not use emery cloth or- sandpaper. Slightly pitted points can be dressed with point file--replace badly pitted or burned points. The gap must be adjusted after points are serviced or replaced since this setting establishes ignition timing. To adjust, turn engine over by hand until points are at maximum opening--check with feeler gauge. If gap is not. 020", loosen adjusting screw then shift movable plate until. 020" gap is obtained. After retightening screw, recheck to make sure gap is still properly set. ---

TROUBLE SHOOTING - ENGINE If trouble occurs, don't overlook causes fuel tank--check for the simplest causes first. spark and, of course, good compression--keep HARD

STARTING

a.

Faulty ignition. 1. Leads grounded or loose. 2. Breaker points faulty or improperly gapped. 3. Spark plug faulty or improperly gapped. 4. Coil or condenser defective.

b.

c.

that seem too obvious to be considered such as an empty To operate, an engine must have fuel, a good ignition this in mind when trying to pinpoint the cause.

OR LOSS OF POWER

KNOCKING a. Fuel

OPERATING

ERRATICALLY

Clogged fuel line. Water in fuel.

c. d. e. f. g.

Vent in fuel system plugged. Faulty fuel pump. Gasket leaking (carb.-manifold). Governor improperly set. Carburetor improperly adjusted.

d.

Engine

"SKIP" AT HIGH SPEED

a.

Spark plug too wide.

b. c.

Ignition timing wrong. Carburetor improperly adjusted.

fouled,

faulty

or gap

a.

Ai r intake obstructed

b. c.

Oil 1eve 1 too high (or low). Fuel mixture too lean.

d. e. f. g.

Ignition timing wrong. Engine overloaded. Tappet clearance too close. Air vac outlet obstructed.

openi ngs to compartment

BACKFIRING a.

Carburetor Fue 1) .

b.

Breaker points improperly (timing) . Valve sticking.

c.

7

I

overheated.

OV ERHEA II NG

Choke faulty or improperly adjusted. compression. Head loose or gasket leaking. Valves sticking or leaking. Piston rings worn.

a. b.

too low.

Ignition timing wrong. Carbon build-up in combustion chamber.

OCCASIONAL

Faulty carburetion. 1. Fuel line clogged (dirt-gum). 2. Fuel pump faulty. 3. Carburetor dirty or improperly adjusted. 4. Poor 1. 2. 3.

octane

b. c.

set too lean

(Main gapped

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THIS DRAWING IN DESIGN AND DETAIl.. IS OUR PROPERTY AND MUST NOT BE USED EXCEPT

IN CONNECTION WITH auI'! WORI(. ALL RIGHTS OF

DESIGN

OR

INVENTION

ARE

RESE:R ••••ED.

KOH LER CO. KOHLER.

WIS.,

U.S.A.

NAME

DIAGRAM

WIRING

248374 •••

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