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4.5 ckm21-rv manualBest thing about this new service is that you are never placed on hold and get to talk to real repairmen in the US. Here is another source (recommended by several forum members) for Kohler parts: ASAP (Advanced Service and Parts aka Parts For Techs). They have the control board and the service manual - its TP-5206 for the 4.5 CKM. I am looking for simple service info (like breaker points -where are they?) for my 4.5CKM21-RV Kohler. A service manual would be great. Regarding the failure to continue running when the start button is released, one possibility is a fault in the 12 volt supply to the electric fuel pump. Battery voltage is used View and Download Kohler L654 service manual online.Differences between models are noted throughout the manual. Engine service and parts catalogs are available sep- arately for particular models and specifications. By continuing to use this site you consent to the use of cookies on your device as described in our cookie policy unless you have disabled them. By chatting and providing personal info, you understand and agree to our Terms of Service and Privacy Policy. RV Have RV questions. Ask an RV mechanic online. I am trying to get a manual for the Kohler 4.5CKM21-RV, spec 10162 generator. RV experience including Cummins North West, Country Coach, Monaco Coach - vendor certified. Verified Hi my name is Robert. Click HERE and see if this helps you out, should be what you are looking for. IF you are satisfied with my efforts please feel free to select a rating, it is the only way I get credit for helping, you are NOT getting charged again when you select a rating. Robert Robert, RV Mechanic Category: RV Satisfied Customers: 19,859 Experience: 23 yrs. Verified Robert and 87 other RV Specialists are ready to help you Ask your own question now Customer reply replied 4 years ago that is exactly what I have been looking for. I have been searching for months and you got it within minutes. I will definitely do business again. Thank you.http://www.reichspfarrer.sk/bosch-maxx-wtl-6500-manual.xml
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RV Mechanic: Robert, RV Mechanic replied 4 years ago Glad I could help you on this. Take care. Robert Ask Your Own RV Question Was this answer helpful. The I have a Kohler confidant 7 propane generator in my rv. The unit was running the other day and shut off by itself, and now will start but shut off as soon as I release the start button. I just I just purchased a 1997 Georgi Boy Pursuit with 23000 miles. I've just started trouble shooting issues and needed to replace the converter, now working on generator. The generator will not start. The main circuit board was replaced which i was told was bad and it still will not start. Problem: generator will not start.How many watts do I need to run the AC unit on my RV and other appliances together. Early 90s model with Kohler Generator Won't start or spark. Model number 4.5ckm21-rv. 4500 watts 37.5 amps. Oil level is good. fuel pump is sucking fuel. The controller wiring is messed-up. 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Login to post However, I have been able to find some other things which may help: Installing electric starter in Kohler K181 Kohler K181 wiring I hope this helped, if it did, please feel free to write a testimonial to show your feedback:)Amanda, 11-10-11. I need a wiring diagram for a Coleman evconpresidential model 7956c856.http://superbia.lgbt/flotaganis/1647624079 Need wireing diagram for coleman 3500a916.I assume it is wired right and you have a transfer switch. Are you saying the voltage is fine when the RV isn't plugged in?The wiring diagram is on page 90. Hope this helps! When I idle it down I have to do it very slow to keep it from back firing and as I engage it in gear it pulls down I have to stop let it idle back up and go and stop and go its just a few seconds to idle back up each time. Answer questions, earn points and help others. GET POWERED. I may be able to help if you need to get the manuals. In need of service repair manual for 4 4ckm21-rv generator.. 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Service manual needed kohler 4.5ckm21-rv - smokstak hello I am in need of a service manual for a kohler 4.5ckm21-rv generator i had a pdf a few years back and lost. Kohler Rv Generator Service Manual For 5ckm21 - kohler generator service manuals rv free PDF ebook downloads.Call MPG Service Company in Little Rock, Arkansas. Replacement Onan RV Generator Voltage Regulators and Control Boards and repair services for Onan, Kohler, and Generac RV controls as well as electric steps, furnace. Share on Facebook Share on Twitter Please reload Follow Us. Check fuel filter. Get To Know Your Engine. Whether you're looking for maintenance guidelines or technical specifications, with the proper manual you'll learn more about your KOHLER. Kohler Engine Fuel System parts. Kohler lawn mower Fuel System parts, Replacement Fuel System Parts for Kohler, MTD, Murray, Yard Man, Sears Craftsman, Briggs and. How to Clean Brushes on a Kohler 4.5CKM21-RV Generator. An RV generator helps keep your. Parts in stock and ready to ship - everything from oil filters, air filters to. Download: Kohler 4 5ckm21 at Marks Web of Books and Manuals Kohler 4.5CKM21 - SmokStak - Antique Engines Antique Tractors. Kohler 4 5ckm21 Rv Generator Exhaust System.pdf Full Version How to Clean Brushes on a Kohler 4.5CKM21-RV Generator. An RV generator helps keep your. Air conditioner filters need cleaning regularly because they fill with dust. Kohler Parts online catalog, Early 90s model with. Sebastian Vettel was captured by his on-board camera twice displaying his middle-finger. All text symbols for Facebook ? - fsymbols Many people ask how to do the Myspace heart. SAN FRANCISCO POLICE DEPARTMENT CODES: Division 1 Headquarters: 1-Adam 1 to 20. City of Modesto Modesto Frequencies. City of Ceres. This manual includes the following main sections: Table of Contents. Lists the sections of the manual. Introduction (and other information sections). Find all of the resources you need on the Kohler Engines site. Get the engine you need today. This approach allows you to see the different types of literature that are available for your. The best safeguards against accident are to be ever mindful of the potential dangers and to always use good common sense.Keep these in mind. A WARNNG LETHAL EXHAUST GAS. An engine discharges deadly 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, or any occupied building. Be especially watchful for exhaust accumulation under calm, windless conditions.Exercise reasonable care when working near the battery to avoid electrical connections through tools. Remove wristwatch, rings, and any other jewelry.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.Always wear splash-proof safety goggles when working around the battery.Never add acid to a battery once the battery has been placed in service. Doing so may result in dangerous spattering of electrolyte.a WARNNG EXPLOSVE t3attery GASES. The gases generated by a 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 terminals 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 connections 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 WARNNG HOT PPNG! 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.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 fuel lines with rigid lines. Flexiblesections 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-. 4 terns 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 GASOLNE. Don t store gasoline in.any occupied building. Propane (LP)-Adequate ventilation is mandatory. Propane is heavier than air; install gas detectors low in room.A WARNNG FLASH FRE! 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 WARNNG BACKFRE! A sudden backfire can cause serious burns. Keep hands and face away from the carburetor when the air cleaner is removed.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.Replace guards, covers, and screens (if used) before operating generator set.A transfer switch must be installed in the RV to prevent interconnection of generator and outside source of power. A WARNNG EXPLOSON! Use generator sets specified for RV use in RV installations only. 5 Section 1. ntroduction and Specifications l-l. NTRODUCTON This manual covers operation, scheduled maintenance troubleshooting and corrective maintenance for Kohler gen- erator sets designed and built for recreational six standard vehicles. All models feature Kohler designed and built 4-cycle gasoline engines, rotating field generators and relay controllers. See Table l-l for specifications and model vari- ations, Table 1-2 for dimensions and weight, and Table l-3 for engine specifications. Refer to the wiring diagrams in the back of the manual. -2. MODEL 3.5CM21-RV The 3500 watt generator set is powered by a single cylinder model K181 QS engine. The set produces 120 volt, 29 amp alternating current.A 30 amp circuit breaker protects the set from overload damage. Due to its compact size and lightweight, it is installed in RV s with limited suspension support and compartment 1-3. MODEL 4.5CM21-RV space. See Figure l-l for major components. The 4500 watt generator set is powered by a single cylinder Kohler Model K341QS engine. The set produces 120 volt, 37.5 amp alternating current.A 40 amp line circuit breaker protects generator against damage due to overload. See Figure l-2 for major components MODEL 4.5CKM21-RV The 4500 watt generator set is powered by a two cylinder Kohler Model KT17 engine. The set produces 120 volts, 37.5 amp alternating current.Two 20 amp circuit breakers protect against damage due to overload. See Figure l-3 for major components MODEL 5.5CM21-RV The 5500 watt generator set is powered by a two cylinder Kohler Model K582QS engine. The set produces 120 volt, 46 amp alternating current.A 50 amp circuit breaker (on most models) protects against damage due to overload. See Figure -4for major components MODEL 7CM21-RV The 7000 watt generator set is powdered by a two cylinder Kohler Model K582QS engine. The set produces 120 volt, 58 amp alternating current.A 60amp circuit breaker (on most models) protects against damage due to overload. See Figure -4for major compon- ents. Select viscosity based on the air temperature at the time of operation as shown below: RECOMMENDED SAE VSCOSTY GRADES! 'F-50 6 T 20 1 r t T c TEMPERATURE RANGE EXPECTED BEFORE NEXT OL CHANGE Straight 30 weight oil is preferred.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. On a new engine, change the oil after the first five hours of operation, and thereafter on K181QS and K341 QS change oil every 25 hours. On KT17, K582QS and L654, change oil every 50 hours. -9. FUEL SPECFCATONS 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. n countries using the Research rating method, it should be 90 octane minimum. 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. Gasohol containing no more than 10 ethanol can be used if unleaded gasoline is unavailable. Never use gasohol containing more than 10 ethanol or gasoline containing methanol. Do not add oil to the gasoline. This switch is a momentary contact, three-position, start-run-stop switch.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 PRESTART CHECKLST Refer to Table 2-l for all prestart checks. CHECK REQUREMENT Oil Level Near Full (Not Over) Air nlets Unobstructed Compartment Clean Air Cleaner Clean, Properly nstalled Air Shrouding Tight, Proper Position Exhaust System Unobstructed, Properly lnstal led Electrical Connections Clean and Tight Table 2-. Prestart Checklist 2-3. OPERATON NOTE f 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 position so generator output is transferred to the load. CAUTON n 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.Normally the engine will start within five seconds.This allows the choke to reset in the full choke position. 2. Whenever possible allow a brief cooling period by running 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- 11 Section 3 Scheduled Maintenance 3-l. 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. NOTE - Oil Change On a new engine change the oil after the first five hours of operation, and thereafter on K181QS and K341QS change oil every 25 hours. Perform each function at the indicated time interval. For each function, refer to the applicable paragraph for instructions. NOTE For maintenance work on engine components, refer to the Kohler engine service manual which covers the engine model. Compartment Before Every Every Every Every. Each Function Startup Hours Hours Hours Hours - Remove dirt. Blow dry compressed air through cooling inlets (set running). Air nlet and Outlet - Clean. X Oil Level - Check. Check Exhaust Pipe. X Oil - Change. X X See note above. Oil Filter - Change. X Air Cleaner Element - Clean (change every 200 hrs.). Fuel Sediment Bowl or Filter (if equipped) - Remove and clean. X Clean Electric Fuel Pump Filter - See owner s manual. X Check Coolant Level n Radiator (7.5KW) X Check Fan Belt Tension (7.5KW) X Spark Plug - Clean and regap. Point Contacts - Service or replace. X Brushes and Collector Rings - Check and service.X X X X i: Rectifier - Regulator - Check condition and battery charging. X Alternator Stator - Check leads and connections. Engine External Surface - Clean screen, cooling fins, block, oil fill area. X Valve Clearance - Check and adjust valve stems and tappets. Crankcase Breather - Check valve and gaskets, clean filter, check hoses. X Cylinder Head - Remove, clean and inspect. Electric Fuel Pump - Service filter. X Check Electrolyte 50 hours. Narrow the problem down to a functional 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 components in working order. See Table 4-l for Engine Troubleshooting and Table 4-2 for Generator Troubleshooting RV SYSTEMS CHECK The RV Systems Check is designed to check the electri- cal status of an RV generator set prior to connecting and testing with the controller.CAUTON before proceeding Do not push the V.B.U. button after the GEN ON lamp is on. Voltage regulator damage may resu t. CAUTON Do not use the RV Systems Check as a replacement for the controller. The hi-temp and low oil pressure switches will not shut the machine down in the event of a malfunction.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.Note: May be actuated with ignition switch on or off. Choke - Supplies battery voltage to choke plate solenoid. Note: May only be actuated during cranking. V.B.U. - Voltage Build Up, supplies battery voltage to excite field. VSUAL NDCATORS Pol - Green - ndicates battery polarity correct. GEN. ON -. DOES NOT FUNCTON ON SETS EQUPPED WTH RELAY CONTROLLERS. Crank - Amber - ndicates battery voltage signal present during cranking. Safety Switch - Amber - ndicates safety circuit wiring correct. Green light indicates battery polarity is correct.This indicates the low oil pressure switch is functioning properly. 5. With the GNTON switch in OFF position, press the CRANK button. The CRANK lamp should light and the engine should crank.The amber safety lamp should light, indicating the protective circuit is functioning prop- erly. 11. f all checks are OK, connect the 12 pin connector to the generator set controller.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.Check for generator output voltage.To make engine repairs, refer to the Kohler engine service manual which covers the engine model. A troubleshooting chart cannot cover every possible cause of malfunction. Always consider every possible cause of malfunction. Knowledge of four cycle engines and battery ignition systems can be applied. Refer to Table 4-2 to troubleshoot the genera- tor. Use resistor type plug. 4. mproper timing. 5. Faulty condenser. E. Operating Erratically 1: O. Clogged fuel line. Water in fuel. Faulty choke control.Loose ignition connections. Vacuum leaks in manifold or carburetor connection. Vent in gas cap plugged. Fuel pump faulty. 4CR installed upside down. Solenoid should be to the bottom.Refer to RV 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 switch - OK at controller.Center pole of remote switch must connect to terminal 4 of remote harness plug, Figure Open connection in wiring. Table 4-2. Troubleshooting Generator 16 Section 5 Relay Controller 5-. 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 operator to start and stop the generator set from another location 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 SEQUENCE OF OPERATON The Relay Controller is the controlling point for generator set operation. The following is the sequence of operations controlled by the Relay Controller. 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. La?- 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 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. TRANSFORMER 9. The now closed 3CR contacts in series with the CR relay coil and engine safety cutouts will allow the CR relay to become energized if the safety cutout contacts close. The CR relay also energizes when the start-stop switch is placed in the stop position. 10. Energizing the CR relay, either by the engine safety cutouts or by placing the start-stop switch to the stop position 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. EARLER Y r CEN:: ATOR i t L2 L LO MODELS ONLY Figure 5-7. Sequence of Operation Schematic 7.5kW Pressing the start-stop switch to the start position ener- gizes both the cranking contactor C and the 2CR relay. (Diode RE will prevent this from happening if the battery is connected 5-4 in reverse.) 5-3. FUSES A WARNNG UNT STARTS WTHOUT NOTCE. There is one O 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.See the wiring diagram, t protects the control- ler in the event of a shorted or failed ignition coil, fuel pump, choke heater, shut-down con- trol or engine wiring. NOTE f the 10 Amp in-line fuse is blown the engine will not crank.One relay is located in the generator end bracket (Figure 6-7). The other three relays are mounted inside the controller. Refer to Figure 5-8 when checking or replacing relays. The function of each relay is described below. When replacing the diode, make certain connections are made with the arrow on the diode directing start-stop switch (Figure 5-8). See Figures 6-l and 6-2 for parts identification. grounded. Never touch electrical leadi or appliances with wet hands, when standing in water, or on wet ground as the chance of electrocution is especially prevalent under such conditions TROUBLESHOOTNG 6-3. GENERATOR DSASSEMBLY Refer to Table 4-2 to troubleshoot the generator. Follow the disassembly procedure in Section 6-3 as far as necessary to inspect a component, then start reassembly procedure in Section 6-12 at the point the component is replaced, When a fuse must be replaced, always inspect the related com- ponents and wiring to locate the cause.