Kohler 4.5 CKM Generator Set

Tools: screwdriver

1. Loosen the screws securing the choke bracket to the carburetor.
2. Shift the position of the choke assembly.
3. When properly set, choke plate will be within 5 to 10 degrees of full open at approximately 70°F (21°C).

⚠ Accidental starting can cause death or serious personal injury. Disconnect battery cables before working on generator.

Tools: feeler gauge, 3/4 in. socket wrench, offset screwdriver or allen wrench, screwdriver, timing light

1. Disconnect battery (negative lead first) and remove spark plug leads to prevent unintentional starting.
2. Remove the breaker point cover.
3. Remove the rotor end cap. With 3/4 in. socket wrench, rotate rotor bolt clockwise until points reach maximum opening.
4. Measure the gap with a feeler gauge; gap at full open should be .017/.023 inch (.432/.580 mm).
5. If not, loosen point gap adjustment screw; adjust by inserting screwdriver blade in adjusting notch and shifting movable plate.
6. Securely tighten the adjusting screw after setting the gap.
7. Replace the breaker point cover.
8. Reconnect battery (negative lead last) and reconnect spark plug leads.
9. Follow up with final or precision adjustment using a timing light.

Tools: screwdriver

1. Stop the engine.
2. Turn the IDLE FUEL needle all the way in (clockwise) until it bottoms lightly (do not force), then back out 1-1/2 to 1-3/4 turns.
3. No further adjustment is needed.

⚠ Always check the air cleaner before readjusting the choke or carburetor.

Tools: screwdriver

1. Turn MAIN FUEL screw clockwise until it bottoms lightly (do not force), then back out 2-3/4 to 3 turns.
2. With engine thoroughly warmed up and running at rated rpm under full load, turn MAIN FUEL screw in until engine slows down (lean setting).
3. Turn screw out until engine regains speed then starts to slow down (overrich setting).
4. Turn screw back in to halfway between lean and overrich settings.
5. When properly adjusted, engine operates with steady governor action.

1. Reposition the governor spring in the governor arm holes.
2. To make governor control more sensitive, move the spring in.
3. To make control less sensitive, move the spring out.
4. Recheck speed after making sensitivity adjustment.

Tools: wrench

1. Loosen the outside locking nut.
2. To increase speed, tighten the inside speed adjusting nut to draw back the speed adjusting arm.
3. To decrease speed, loosen the speed adjusting nut.
4. After speed is correct, secure at the new setting by tightening the outside locking nut.

1. Run the generator set at no load.
2. Push the throttle lever counterclockwise until it hits the idle speed screw.
3. Holding throttle lever against the screw, adjust idle speed until it runs at 55 Hertz (1650 rpm).

⚠ Breaker point cover screws must be screwed back into mounting pad after cover is removed to keep engine oil from spurting out crankcase.

Tools: timing light

1. Rotate engine until S mark is visible; chalk S line for easy reading.
2. Start unit and operate at 1800-1920 rpm.
3. Aim timing light into sight hole; light should flash as S mark is centered.
4. If light flashes before mark centered, timing is overadvanced; after, retarded.
5. If timing is off, remove breaker point cover, loosen gap adjusting screw, shift breaker plate until mark is exactly centered.
6. Retighten adjusting screw and recheck timing before replacing breaker point cover.

⚠ Gas and supply pressure should not exceed six ounces.

Tools: ounce pressure gauge or manometer

1. Turn load block fuel adjustment screw in until it bottoms lightly.
2. From the closed position back the screw out three complete turns.
3. Check inlet pressure by removing plug on fuel inlet of gas regulator; insert ounce pressure gauge or manometer.
4. Adjust pressure to 4-6 ounces or 7-11 inches water column on primary regulator.

⚠ Battery gases can cause an explosion. Do not smoke or permit flame or spark near battery.

Tools: Ammeter, 12-Volt automotive battery

1. Disconnect all leads from voltage regulator.
2. Connect an ammeter and a 12-Volt automotive battery to the positive (+) and negative (-) brush leads.
3. Ammeter reading should approximate battery voltage divided by specified rotor resistance.
4. Start engine and check that ammeter remains stable; increasing reading indicates shorted rotor.
5. Check for AC output across stator leads and compare to Table 6-2.

⚠ Wiring should be inspected at the interval recommended in the service schedule.

Tools: ohmmeter

1. Set ohmmeter on Rx1 scale; contact leads and adjust to zero ohms.
2. Check continuity between leads 1 and 2.
3. Check continuity between leads 3, 4, 33, and 44.
4. Check continuity between leads 55 and 66.
5. Check continuity between leads B1 and B2.
6. Verify no continuity between lead 1 and leads 3, 4, 33, 44.
7. Verify no continuity between lead 1 and leads 55, 66, B1, B2.
8. Verify no continuity between lead 4 and leads 55, 66, B1, B2.
9. Verify no continuity between lead 55 and leads B1 and B2.
10. Verify no continuity between any stator lead and ground.

⚠ Heat sink of the voltage regulator contains high voltage. Do not touch heat sink when testing.

⚠ Unplug power cord from AC power source before connecting or disconnecting wires.

Tools: Variable Transformer 0-140 Volts (.5 Amp Min.), 1 to 1 Isolation Transformer (.6 Amp Min.), 120 Volt AC Plug (60 Hz), Double Pole, Single Throw Switch, 120 Volt, 100 Watt Lamp, 2 Amp Fuse and Fuse Holder, AC Voltmeter, #14 AWG copper wire (minimum)

1. Connect components as shown in Figure 7-1.
2. Plug in variable transformer and AC plug.
3. Turn switch S1 on. Lamp should be on. If lamp does not go on, regulator is faulty; replace.
4. Turn variable transformer on and slowly increase; lamp should go out at approximately 120 Volts and remain out.
5. If lamp does not go out or stays at a dull glow, regulator is faulty and should be replaced.
6. Turn switch S1 off and unplug AC cords.