Service, Operator’s, & Parts Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF KOHLER OR IT’S SUCCESSORS. KOHLER AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Serv

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11/2 KV, 11/2 KW 2 KW

KO-S-11/2KW

CONTENTS

I NTRO D U CTI ON _____________________________________________________________________________________________ _ 2 ' ....

Warran ty _______________________________ . ______ . _________________________________________________________________ _ 2 General Descri ption ___________________________________________________________________________________ _ 3 Installa tion ___________________________________________________________________________________________________ _ 3 Wiring _______________________________________________________________________________________ ._~ _________________ ~ ___ ; 8

STARTING A NEW PLANT _________________________________________________________________________ _ 9

OPERA TI ON AND CARE _______________________________________________________________________________ _ 10 Inspections After 50 Hours of Operation ______________________________________________ _ 10 Inspections After 200 Hours of Operation _____________________________________________ _ 11 Lubrication System____________ ____________________ __ _____ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ ___________ _ 11 Ignition System ____________________________________ -------__ -------__ ----__ --__ -___ ----_ ----_____ -__________ _ 12

Cooling System ________________________ ------ ------------------- --- ------------ ---- ------_ -____ -_ --_________ ~ 14 Fuel System ____________________________________ --- ----- -- -- --- --------- ------- -----___________________________ _ 14 Thermostatic Choke and Electric Choke _________________________________________________ _ 18 Starting System, A. C. Models __ _______________________________________________________________ _ 20 Starting System, D. C. Models __________________________________________________________________ _ 31

REPAIRS AND AD JUSTM ENT ___________________________________________________________________ _ 38 Specifications, Tolerances. and Clearances ________________________________________________ _ 39 Repairs to Gasoline Engine __ ________________________________________________________________________ . 40 Grinding Val ves _____________________________________________________________________________________________ _ 41 Installing Fan Bel t _______________________________________________________________________________________ _ 43

G EN ERA TOR ________________________ --__ -- ____ ----_ --- __ -- --- ---- --_ --- ___ -----_ --- ___________________________ _ 52

DIAGNOSES OF TROUBLES AND THEIR REMEDIES _________________ _ 60-65

REP AI R PAR TS _________________________________________________ . _________________________________________ _ 66 Parts III ustra tions _____________________ -- -__ -______________ --__ -_________________________________________ _ 67-93 Parts Price List. _____________________________________________________________________________________ .- ____ 94-1 06

ELECTRIC PLANTS

General Description

The 1% KVA Model is a self contained gasoline-engine driven direct connected electric generator designed to generate 115 volts, AC, 60 cycle, 1500 watts. 1 % KW and 2 KW Models are 115 volt DC.

Com.ponent Parts

The gasoline engine is a 4 cyclinder, valve-in-head, 4 cycle type 2 inch bore and 3 inch stroke. It is radiator cooled and employs a high tension magneto.

The generator is self excited, 115 volt, 60 cycle, single phase, AC, 1500 watts, capacity.

Dim.ensions and Weights

The illustration in Fig. 1 indicates the overall dimensions, and the weight of the complete plant is 497 pounds.

INSTALLATION

Introduction

ALL ENGINES are affected by the conditions under which they are in­stalled and operateci. NO ENGINE or electrical apparatus can function prop­erly and give economical and satisfactory service, unless it is properly installed under conditions that are reasonably favorable.

The operation of any electrical generating set driven by any internal com-bustion engine is affected by:

Temperature Dirt Oil

Moisture Ventilation

Grit Dust Grease

IMPORTANT - The plant is known to the factory and at our branch offices by Model and Serial Number only. This information is given on the name plate.

All communications regarding the plant must give the correct Model and Serial Number to insure efficient service and a prompt response.

Tem.peratures Should Be Moderate

An engine must warm up to a running heat before it will function properly, run economically, and operate satisfactorily.

All engines that derive their power from the burning of any fuel-such as the internal combustion engines used in automobiles, tractors, or lighting plants, as well as the steam engine of the locomotive, the steamship, and the' power house-are HEAT ENGINES.

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7 16 ii -----<.-j

NOTE­

TOTAL WEIGHT - 497 LBS.

ELECTRIC PLANTS

122 U 1----15 ~ --+-+---13i 8 __ ---i

t------181~

Ii EXH. PORT

!FUEL LINE

1--------:34 I~ ----------1

t-----------45Fe -----------1

WT. AT EACH FRONT MOUNTING HOLE - 10.5 LBS.

WT. AT EACH REAR MOUNTING HOLE - 238 LBS.

DIMENSIONS FOR .... ODEL

IM21 PLANT - DWG. D-850-"'"

Figure 1

f "'1!2 L()

The carbon monoxide gas discharged by all gasoline internal combustion engines is extremely poisonous when it is allowed to collect in a closed room. Every precaution should be taken to prevent the escape of this gas into the building. All joints must be perfectly tight and where the exhaust pipe passes through the wall care should be taken to prevent the gas from returning along outside of pipe back into the building_

Connecting Exhaust Pipe to Plant

The exhaust pipe should be as short and straight as possible. It is best to avoid a long exhaust pipe and elbows, as these become cogged with carbon and add resistance, thus decreasing the capacity of the plant. If possible, have the outer end of exhaust pipe slant downward slightly from a horizontal position. The moisture which condenses in the exhaust pipe will then run out the end of the pipe instead of into the engine cylinders, where it would cause rusting, make starting difficult, and foul the spark plugs.

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KOHLER OF KOHLER

Figure 2 Carburetor Side of Plant

A - Cleanout Plate B - Starting Crank C - Carburetor Drip Pan D - Governor Operating Lever E - Carburetor Overflow F - Carburetor Screen G - Oil Sight Hole H -Choker

I - Air Cleaner * J - Magneto Ground Switch

K - Field Resistance L - Name Plate

M - Magneto N - Magneto Coupling o - Governor Stop Screw

* On some models this is eliminated and plant is grounded at the magneto

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ELECTRIC PLANTS

• A - Exciter Field Switch B - Radiator Cap C - Thermometer D - Oil Filler Cap E - Exhaust Outlet F - Shielded Spark Plugs G - Fuel Pump Inlet

Figure 3 Exhaust Side of Plant

H -Fuel Pump I - Fuel Pump Priming Lever J - Drain for Cooling System

K - Oil Gauge L - Oil Filter

M - Oil Drain

• This is eliminated on some models.

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KOHLER OF KOHLER

Wiring

To secure the fullest use of the current generated by a Kohler Electric Plant, it is absolutely essential that the wiring be of the right size and properly installed. Too often proper consideration is not given to the possible uses for which power will be wanted in the future. When more current is used than the circuits were designed to take care of, the wires will be overloaded.

115 VOLT

Loads in 100' 200' 300' 400' 500' 600' 700' 800' 900' 1000' 1100' 1500' 2000' 2500' 3000' 4000' Watts at End of Cireui t

100 No. 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 8 250 " 10 10 10 10 10 10 10 10 10 10 10 8 8 6 6 4 500 " 10 10 10 10 10 10 8 8 8 8 6 6 4 4 2 2 750 " 10 10 10 10 8 8 8 6 6 6 4 4 2 2 1 1-0

1000 " 10 10 10 8 8 6 6 6 6 4 4 2 2 1 1-0 2-0 1500 " 10 8 6 6 6 4 4 4 4 2 2 1 1-0 2-0 3-0 4-0 2000 " 10 8 6 4 4 2 2 2 2 1 1-0 2-0 3-0 4-0 4000 " 8 6 6 4 2 2 1 1-0 1-0 2-0 2-0 3-0 4-0 5000 " 8 4 2 2 1 1-0 2-0 2-0 3-0 3-0 4-0 6000 " 6 4 2 1 1-0 2-0 2-0 3-0 3-0 4-0 8000 " 4 2 1 1-0 2-0 3-0 4-0 NOTE:-No. 4-0 wire is the largest

10000 " 4 2 1-0 2-0 3-0 4-0 size commercially practical.

NOTE :-The size of wire to be used depends upon the following factors:-

1st. Load to be carried in watts or amperes.

2nd. Distance between load and power plant.

3rd. Strength of wire to withstand strains imposed by weather conditions.

Not less than No. 10 wire supported every 75 feet should be used for outside leads, while a smaller wire may carry the load, it will not possess sufficient strength to withstand strains imposed by weather conditions. No. 4-0 wire is the largest size commercially practicable. The adjacent table is based on com­mercial annealed copper wire commonly used for lighting circuits. If hard drawn wire is used the voltage drop will be increased about 2%. If this is not permissible use next larger size as shown in table.

Smaller wire may be used for indoor service and in places where it is pro­tected from weather conditions. All wiring should meet the Fire Underwriters' specifications for size of load and insulation.

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