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Kohler TP 4.0 D Generator Set

Kohler TP 4.0 D generator set: . Specifications, engine details, filters, oil capacity and 3 document types.

3
Document types

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Specifications

Ratings spec sheet not in our library yet — see the documents below.

Filters & service parts

model family
ItemSpecCapacityPart #Interval
Air filterClean or replace; paper element cannot be blown out with compressed air—250 hr
Fuel filter—500 hr
Oil filter—250 hr
OilAPI service class CH-4 or higher; see viscosity chart (5W-30 synthetic, 15W-40, SAE 30)1.2 L—250 hr
Spark plug—500 hr

Compiled from this model's family documentation — may include parts for closely-related variants. Confirm the exact part for your serial number.

Service intervals

10
ItemActionHoursMonthsNotes
air cleanerClean250 hrClean or replace air cleaner; more frequently under severe conditions
oil and filterChange250 hrFirst service — Every 250 hours; more frequently under severe, dusty, dirty conditions
pumpClean250 hrEvery 250 hours
fuel filterReplace500 hr12 moEvery 500 hours or annually
fuel filter (E)Replace500 hr12 moEvery 500 hours or annually
fuel tankClean500 hr12 moEvery 500 hours or annually
injectorsAdjust500 hrSet and clean; have a Kohler portable dealer perform this service
injectorsClean500 hrSet and clean injectors; have a Kohler portable dealer perform this service
spark arresterClean500 hr12 moEvery 500 hours or annually
valve lashAdjust500 hrHave valve lash checked/adjusted; have a Kohler portable dealer perform this service

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Service specifications

60
TypeItemValueUnitCondition
ClearanceDistance between shaft shoulder and rotating seal on shaft19.1/19.5mm (0.7520/0.7677 in.)with impeller removed
ClearanceDistance from back plate to outer surface of impeller86.0/86.4mm (3.3858/3.4016 in.)impeller threaded back on shaft
OtherMaximum angle of operation25degreesat full oil level
PressureVacuum reading at pump (Testing Pump)20 to 25lbsat sea level, obtained within 5 seconds, engine at full throttle
Torque1/2-13 fastener, Grade 2 into cast iron or steel67.8 (50)N·m (ft. lb.)± 20%
Torque1/2-13 fastener, Grade 5 into cast iron or steel108.5 (80)N·m (ft. lb.)± 20%
Torque1/2-13 fastener, Grade 8 into cast iron or steel155.9 (115)N·m (ft. lb.)± 20%
Torque1/2-20 fastener, Grade 2 into cast iron or steel94.9 (70)N·m (ft. lb.)± 20%
Torque1/2-20 fastener, Grade 5 into cast iron or steel142.4 (105)N·m (ft. lb.)± 20%
Torque1/2-20 fastener, Grade 8 into cast iron or steel223.7 (165)N·m (ft. lb.)± 20%
Torque1/4-20 fastener into aluminum7.9 (70)N·m (in. lb.)± 20%
Torque1/4-20 fastener, Grade 2 into cast iron or steel7.9 (70)N·m (in. lb.)± 20%
Torque1/4-20 fastener, Grade 5 into cast iron or steel13.0 (115)N·m (in. lb.)± 20%
Torque1/4-20 fastener, Grade 8 into cast iron or steel18.7 (165)N·m (in. lb.)± 20%
Torque1/4-28 fastener, Grade 2 into cast iron or steel9.6 (85)N·m (in. lb.)± 20%
Torque1/4-28 fastener, Grade 5 into cast iron or steel15.8 (140)N·m (in. lb.)± 20%
Torque1/4-28 fastener, Grade 8 into cast iron or steel22.6 (200)N·m (in. lb.)± 20%
Torque10-24 fastener into aluminum3.6 (32)N·m (in. lb.)± 20%
Torque10-24 fastener, Grade 2 into cast iron or steel3.6 (32)N·m (in. lb.)± 20%
Torque10-24 fastener, Grade 5 into cast iron or steel4.5 (40)N·m (in. lb.)± 20%
Torque10-32 fastener, Grade 2 into cast iron or steel3.6 (32)N·m (in. lb.)± 20%
Torque10-32 fastener, Grade 5 into cast iron or steel4.5 (40)N·m (in. lb.)± 20%
Torque3/4-10 fastener, Grade 2 into cast iron or steel199.3 (147)N·m (ft. lb.)± 20%
Torque3/4-10 fastener, Grade 5 into cast iron or steel332.2 (245)N·m (ft. lb.)± 20%
Torque3/4-10 fastener, Grade 8 into cast iron or steel474.6 (350)N·m (ft. lb.)± 20%
Torque3/4-16 fastener, Grade 2 into cast iron or steel271.2 (200)N·m (ft. lb.)± 20%
Torque3/4-16 fastener, Grade 5 into cast iron or steel440.7 (325)N·m (ft. lb.)± 20%
Torque3/4-16 fastener, Grade 8 into cast iron or steel637.3 (470)N·m (ft. lb.)± 20%
Torque3/8-16 fastener, Grade 2 into cast iron or steel29.4 (260)N·m (in. lb.)± 20%
Torque3/8-16 fastener, Grade 5 into cast iron or steel47.5 (35)N·m (ft. lb.)± 20%
Torque3/8-16 fastener, Grade 8 into cast iron or steel67.8 (50)N·m (ft. lb.)± 20%
Torque3/8-24 fastener, Grade 2 into cast iron or steel33.9 (300)N·m (in. lb.)± 20%
Torque3/8-24 fastener, Grade 5 into cast iron or steel54.2 (40)N·m (ft. lb.)± 20%
Torque3/8-24 fastener, Grade 8 into cast iron or steel81.4 (60)N·m (ft. lb.)± 20%
Torque5/16-18 fastener into aluminum17.0 (150)N·m (in. lb.)± 20%
Torque5/16-18 fastener, Grade 2 into cast iron or steel17.0 (150)N·m (in. lb.)± 20%
Torque5/16-18 fastener, Grade 5 into cast iron or steel28.3 (250)N·m (in. lb.)± 20%
Torque5/16-18 fastener, Grade 8 into cast iron or steel39.6 (350)N·m (in. lb.)± 20%
Torque5/16-24 fastener, Grade 2 into cast iron or steel18.7 (165)N·m (in. lb.)± 20%
Torque5/16-24 fastener, Grade 5 into cast iron or steel30.5 (270)N·m (in. lb.)± 20%
Torque5/16-24 fastener, Grade 8 into cast iron or steel40.7 (30)N·m (ft. lb.)± 20%
Torque5/8-11 fastener, Grade 2 into cast iron or steel149.5 (110)N·m (ft. lb.)± 20%
Torque5/8-11 fastener, Grade 5 into cast iron or steel244.1 (180)N·m (ft. lb.)± 20%
Torque5/8-11 fastener, Grade 8 into cast iron or steel352.6 (260)N·m (ft. lb.)± 20%
Torque5/8-18 fastener, Grade 2 into cast iron or steel189.8 (140)N·m (ft. lb.)± 20%
Torque5/8-18 fastener, Grade 5 into cast iron or steel311.9 (230)N·m (ft. lb.)± 20%
Torque5/8-18 fastener, Grade 8 into cast iron or steel447.5 (330)N·m (ft. lb.)± 20%
Torque7/16-14 fastener, Grade 2 into cast iron or steel47.5 (35)N·m (ft. lb.)± 20%
Torque7/16-14 fastener, Grade 5 into cast iron or steel74.6 (55)N·m (ft. lb.)± 20%
Torque7/16-14 fastener, Grade 8 into cast iron or steel108.5 (80)N·m (ft. lb.)± 20%
Torque7/16-20 fastener, Grade 2 into cast iron or steel61.0 (45)N·m (ft. lb.)± 20%
Torque7/16-20 fastener, Grade 5 into cast iron or steel101.7 (75)N·m (ft. lb.)± 20%
Torque7/16-20 fastener, Grade 8 into cast iron or steel142.5 (105)N·m (ft. lb.)± 20%
Torque8-32 fastener into aluminum2.3 (20)N·m (in. lb.)± 20%
Torque8-32 fastener, Grade 2 into cast iron or steel2.3 (20)N·m (in. lb.)± 20%
Torque8-32 fastener, Grade 5 into cast iron or steel2.8 (25)N·m (in. lb.)± 20%
Torque9/16-12 fastener, Grade 2 into cast iron or steel101.7 (75)N·m (ft. lb.)± 20%
Torque9/16-12 fastener, Grade 5 into cast iron or steel169.5 (125)N·m (ft. lb.)± 20%
Torque9/16-12 fastener, Grade 8 into cast iron or steel237.3 (175)N·m (ft. lb.)± 20%
Torque9/16-18 fastener, Grade 2 into cast iron or steel135.6 (100)N·m (ft. lb.)± 20%

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Recommended fluids

FluidGradeStandardAmbientCapacityNotes
Engine oil5W-30 (synthetic base oil), 15W-40, SAE 30API service class CH-4 or higher-30°C to 40°C1.2 LKohler oils recommended; other high-quality detergent oils (including synthetic) acceptable
FuelClean, fresh, commercial-grade diesel fuelASTM D-975 - 1D or 2D, EN590, or equivalent; biodiesel less than 20% methyl ester or B20 acceptable (BQ-9000, EN 14214 or equivalent recommended)4.3 LAviation fuels include JP5, JP4, JP8 and JET-A (if 5% oil is added)
FueldieselASTM D-975 - 1D or 2D, EN590, or equivalent; biodiesel <20% methyl ester or B20 acceptable; BQ-9000, EN 14214 recommended4.3 LAviation fuels JP5, JP4, JP8, JET-A (if 5% oil added). Do not overfill.
OtherDish washing soap / liquid detergentA few drops on shaft to help remove/install the mechanical seal
OtherLoctite® 5770™ High Temperature Thread Sealant or equivalentApplied to outlet flange screws before assembly
OtherLoctite® 587™ Ultra Blue or equivalentThread sealant applied to back plate screws and inlet flange screws before assembly

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

12
Testing Pump diagnostic

Tools: retractable starter, vacuum tester

  1. Before running, check oil and pull engine over with retractable starter to make sure nothing is binding in pump.
  2. Fill with prime water and start engine.
  3. After warm up, run engine at full throttle and check vacuum with vacuum tester to make sure no leaks developed.
  4. A vacuum of 20 to 25 lbs at sea level should be read within 5 seconds.
Assembly of Pipes installation

Tools: strap pipe wrench

  1. Place an airtight band around thread of half-couplings.
  2. With a strap pipe wrench, screw suction and discharge half-couplings (G) into pump suction (A) and discharge (B) ports.
  3. Using collars, secure pipes onto straight suction half-coupling (J) and discharge coupling elbow (H).
  4. Install suction strainer (I) into end of suction pipe.
Install Back Plate installation

Tools: torque wrench

  1. Apply Loctite® 587™ Ultra Blue or equivalent to screws.
  2. Replace back plate and hold in position.
  3. Secure with screws and washers.
  4. Torque back plate screws to 17.6-20.3 N·m (13-15 ft. lbs.).
Install Impeller installation

Tools: rubber mallet

  1. Install rotating seal onto shaft and press against back plate.
  2. Turn impeller on by hand clockwise until tight.
  3. Hit 1 blade clockwise to tighten impeller until resistance is observed.
Install Inlet Flange and Check Valve installation

Tools: torque wrench

  1. Apply Loctite® 587™ Ultra Blue or equivalent to inlet flange screws.
  2. Install inlet flange and check valve to pump case with screws and washers.
  3. Torque screws to 4.1-5.4 N·m (36-48 in. lbs.).
Install Mechanical Seal installation
  1. Put drops of liquid detergent on shaft to help install mechanical seal.
  2. Using thumbs, push mechanical seal into place.
Install Mobility Kit installation

⚠ Place blocks underneath to raise pump to install wheels and legs.

Tools: torque wrench

  1. Insert rubber bumper into cross member hole at center; place axle brace onto cross member and bumper, angled up.
  2. Insert washer and thread nut to rubber bumper; tighten loosely.
  3. Assemble cross member assembly to frame; install screws through frame and cross member with washer and locking nut; tighten loosely.
  4. Align middle hole in axle to axle brace; install screw through axle and axle brace with washer and locking nut; tighten loosely.
  5. Align holes in axle to frame; install screws through frame and axle with washer and locking nut; tighten loosely.
  6. Torque all nuts to 120 in. lb. (13.6 N.m); tighten axle and axle brace locking nut first.
  7. Install wheels onto axle, push retaining rings onto axle.
  8. Align handle with holes on frame; install screw with washers through handle into frame.
  9. Place curved spacer on opposite side of frame; place another washer outside handle and thread nut on.
  10. Tighten screws enough to allow handle to move free.
Install Outlet Flange installation

Tools: torque wrench

  1. Apply Loctite® 5770™ High Temperature Thread Sealant or equivalent to screws.
  2. Install outlet flange and rubber gasket with screws and washers.
  3. Torque screws to 4.1-5.4 N·m (36-48 in. lbs.).
Install Pump Case installation

Tools: torque wrench

  1. Place a new gasket on back plate.
  2. Install pump case to back plate and loosely tighten screws, making sure gasket is seated correctly.
  3. Torque screws to 36.6 N·m (27 ft. lb.).
Air Cleaner Service maintenance

⚠ Paper element (M) cannot be blown out with compressed air.

  1. Loosen air cleaner cover nut (K) and remove air cleaner cover (O).
  2. Precleaner: remove precleaner (N) from paper element (M).
  3. Replace or wash precleaner (N) in warm water with detergent; rinse and air dry.
  4. Saturate precleaner (N) with new engine oil; squeeze out excess oil.
  5. Reinstall precleaner (N) over paper element (M).
  6. Paper element: clean area, remove wing nut (L) and paper element (M) with precleaner (N).
  7. Separate precleaner (N) from paper element (M); replace paper element (M).
  8. Check condition of rubber seal (X) and replace if necessary.
  9. Install new paper element (M) on base; install precleaner (N); secure with wing nut (L).
  10. Reinstall air cleaner cover (O) and secure with cover nut (K).
Change Oil and Filter maintenance

⚠ Drain engine oil into an approved container. Never drain or spill engine oil onto floor.

Tools: hex key

  1. Change oil while engine is warm; clean area around oil fill cap (C).
  2. Remove oil drain plug (T) and oil fill cap (C); allow oil to drain completely.
  3. Reinstall oil drain plug (T).
  4. With a hex key, remove oil filter holder screws (U); remove oil filter and discard.
  5. Clean oil filter holder and apply clean engine oil onto oil filter joint.
  6. Install new oil filter; thread holder screws (U) and tighten.
  7. Fill crankcase with new oil to top of indicator on dipstick (R).
  8. Reinstall oil fill cap (C) and tighten securely.
  9. Start engine, check for oil leaks; stop, correct leaks, recheck level.
  10. Dispose of used oil per local ordinances.
Check Fuel Level maintenance

⚠ Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running.

  1. Ensure engine is cool; clean area around fuel cap (D).
  2. Remove fuel cap (D); fill to base of filler neck. Do not overfill; leave room for fuel to expand.
  3. Reinstall fuel cap (D) and tighten securely.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Repair guides

24

Step-by-step procedures compiled from the Kohler service manual for this model.

Available documents

Reference (Kohler)Reference — 25 590 19 (Kohler)Reference — tp7034 (Kohler)Reference — tri-fuel accessory launch uspec update (Kohler)Owner's manual — 39 590 01 (Kohler)Owner's manual — 39 590 01 rev 7 14 (Kohler)Service manual — 39 690 01 (Kohler)

This page was generated from the 7 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.