Perkins Genset Engine & Kohler Manuals and Information

FILES RELATED TO VARIOUS INFORMATION ABOUT THE PERKINS DIESEL ENGINE USED IN A GENSET APPLICATION ON 'BIRDS

• KOHLER DRAWINGS

SOME HAVE THE CONTROLLER MODEL NUMBER LISTED ON THE DRAWINGS AND THE DATE OF THE DRAWING, THERE ARE ALSO DRAWING CONTAINED IN THE FOLLOWING MANUALS. THANKS TO BILL SCHREURS FOR THE REDRAWN FILES.

• KOHLER DRAWINGS/ 06-Feb-2010 03:53

1984-055.jpg 06-Feb-2010 03:34 1.4M

1984-055A.jpg 06-Feb-2010 03:34 1.9M

1984-055B.jpg 06-Feb-2010 03:34 1.5M

1984-055C.jpg 06-Feb-2010 03:34 1.3M

KOHLER DRAWING.jpg 06-Feb-2010 03:34 619k

KOHLERCOGEN1981-1A.jpg 06-Feb-2010 03:35 657k

KOHLERCOGEN1981-2A.jpg 06-Feb-2010 03:35 1.1M

KOHLERCOGEN1981-3A.jpg 06-Feb-2010 03:36 1.8M

Perkins_125KW_side_1..> 06-Feb-2010 03:53 229k

Perkins_125KW_side_2..> 06-Feb-2010 03:53 357k

• Kohler Troubleshooti..> 16-Jun-2009 19:12 948k
• Kohler Installation ..> 16-Jun-2009 19:12 3.6M
• Kohler_7_5Gas_TP5045..> 11-Dec-2009 19:48 2.0M
• Tom Warners Kohler Control Box Rebuild an excellent detailed with pictures guide to rebuoil;ding the Kohler Control Box.
• ENGINE NUMBER LOCATION ON PERKINS DIESEL ENGINE & PARTS Numbers.pdf
  A PDF file showing how to locate the engine number on your Perkins genset engine, plus a list of accessory parts numbers, such as hoses, belts, shutdown sending units and more.
• NEWER 'BIRD STYLE DOWNDRAFT RADIATOR FAN INSTALLATION.jpg
  Check out the modifications that I have done to my genset, from the newer 'Bird style downdraft radiator fan shown here, there is a total of 30 pages of modifications starting at http://www.pbase.com/iamflagman/image/52361793 copy and paste that URL into your web browser to see the first of the 30 pages of the modifications, including a larger version of this photo.
• Oil bath air filter - generator
• PerkensBleedpoints.pdf
  DESCRIPTION OF BLEED POINTS FOR PERKINS GENSET ENGINE FROM MY COPY OF THE ORIGINAL WANDERLODGE FORUM FILE

http://www.pbase.com/iamflagman/image/108041738

• PerkensWiring.pdf
  WIRING DIAGRAM FOR PERKINS GENSET ENGINE ON A '85 FC35
• PERKINS STARTER SOLENOID REPAIR
• PERKINS FUEL FILTER REPLACEMENT.pdf
  A PDF file article by George Witt, detailing how to change the fuel filter on a Perkins generator engine. Plus a photo tip on priming the fuels system on the Perkins engine.
• PERKINS MANUALS found in the Database, notice engine designations 4.108 and 4.108M either model can be found on some Wanderlodges, it is suggested that you download all of the manuals and use them as a reference for your model Perkins.
  PERKINS 4.108 Operat..> 28-Jan-2009 03:20 814k
  PERKINS 4.108 Worksh..> 28-Jan-2009 03:30 14.5M
  PERKINS 4.108M Parts..> 28-Jan-2009 03:23 3.5M
  PERKINS 4.108M Works..> 28-Jan-2009 03:30 8.8M
• PERKINS-KOHLER DUPLI-COLOR ENGINE PAINT.jpg
  PERKINS/KOHLER GENSET DUPLI-COLOR PAINT SPRAY CAN LABEL WITH THE PART NUMBER, PROVIDED BY STEPHEN H.
• SHANE FEDELI FAN THERMOSTAT.pdf
  A PDF file with detailed photos and a description of how Shane Fidelli modified the fan circuit on his Perkins/Kohler genset radiator, to incorporate a thermostat that regulates the operation of the fan, so that it does not run all of the time.
• PERKINS OIL BATH AIR CLEANER
• How it works and how to service
• Using Your 'Birds Generator For Emergency Power
• PERKINS ENGINE PARTS, BELTS AND FILTERS

High Water Temperature Shut Down Sending unit (Perkins Generator Engine)

BLUEBIRD #4176483 $88.00
NIXON POWER #241308 (KOHLER PART) $45.72
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Low Oil Pressure Shut Down sending unit (Perkins Generator Engine)
BLUEBIRD #4176491 $41.49
NIXON POWER #271662 (OLD) REPLACED BY #328309 (NEW STYLE KOHLER PART**) $21.36
**FOR INSTALLATION TIP GO TO;
http://www.pbase.com/iamflagman/image/50053227

***Nixon Power Services 800-766-4966***
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Thermostat
NAPA #382-190
Gasket
1038-ST
The thermostat is made by VW-AUDI and has these numbers inscribed on it;
BTT
050 121 113C
1.180
87 degrees Celsius (that converts to 188.6 Fahrenheit)

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UPDATE;

Had to replace the water pump and thermostat was running a little hot. Went to NAPA and they looked up a Perkins 4.108 in their parts book and it gave them a thermostat with a part number of simply #170. This appears to be a widely used one. I pulled the 382-190 that you listed on the site (which was running around 200 degrees) and installed the 170 (which is fully open at 180 degrees) Temps are a lot cooler- running around 185 now. They also have a part number 70. This thermostat is rated at 160 degrees.

I just noticed that the 382-190 is rated to open at 195 degrees, not 190- that may have been my problem. There is also a note in the Perkins Manual about needing a thermostat with "bypass blanking valve" ??? Not sure if we need that or not.

Also forgot to mention that the thermostat has to have a diameter of 2.125 inches. Mine had 54 MM stamped on it, so I'd assume that is the metric dimension.

Shane Fedeli
85PT40
Hershey, PA

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Perkins "V" Belt 40 inches long
Autozone and Advance Auto part DAYCO #15400 (11A1015)
NAPA PREMIUM XL 25-10153 (not positive on this number, be sure to measure)
RADIATOR CAP 7# CARQUEST #33029
OIL PRESSURE SENDING UNIT FOR GAUGE NAPA #OP6622
These are the dimensions of the radiator on my Perkins genset;
20 1/4" wide
22" high
2 1/2" deep
The inlet and outlet sizes are hard to measure without draining the radiator and removing the hoses, but the hose part numbers are listed next and the sizes can be determined by measuring the hose interior diameters.
These are the part numbers that you need to replace all the hoses on your
> Kohler/Pekins 12.5 KW . All are available from Auto Zone.
>
2ea. M-248 (1) thermostat housing to exhaust manifold cooler inlet
(1) exhaust manifold cooler outlet to inflow tube to radiator
1ea M-049 top radiator inlet hose from inflow tube
1ea L-326 bottom radiator outlet hose to outflow tube inlet (this tube is reduced down in size directly after the hose connection)
1ea L-978 radiator outflow tube outlet to engine block (SEE NOTE)
This is a Cut and Fit project. The Molded hose (L-978) has two different end diameters, make sure that you use the smaller diameter end trimmed down to the block side and cut the larger diameter end off, just before the bend.

PERKINS FILTERS
OIL NAPA GOLD 1806 PH4403(LUBERFINER)
FUEL NAPA 3166 L296F(LUBERFINER) WIX 33166

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Check out;

Wanderlodge Owners Group > Mechanic's Corner > Generators > No fuel

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#399

gcyeaw
Gardner
Join Date: Dec 2007
Location: Ridgewood
Posts: 5,724



Quote:
Originally Posted by jim11dd
Thanks Randy, the genny will run for approx 30 seconds and then it shuts down. You can keep it running by holding the switch, however once you start it you can't shut it down with switch.[/quote]

In my Perkins/kohler control box there is a relay called the CR relay. It is a three poll double throw clear plastic relay. When there is AC voltage generated it picks this relay. One of the sets of points enables the stop switch circuit. So if the CR relay does not pick (bad relay or no AC) the stop switch will not work.

The stop switch grounds the same circuit that the over temp and low oil pressure switch ground, so if the stop switch doesn't work it is likely the CR relay did not pick and the over temp and low oil pressure switch can't cause the shutdown.

You stated that the fan runs, so there is AC being generated. Is it possible the CR relay has failed or the wiring is loose or broken. The voltage regulators are very expensive, and not returnable

30 seconds is a long time for the engine to run with no AC present, normally it will quit as soon as the start switch is released. I would look at the CR relay points to see if they are burned and not working consistently. I had an issue with burned points on the CR relay and did some magic with a bosch relay to compensate.

Another set of points in the CR relay supply 12 volts to the B terminal of the voltage regulator. This gives the generator voltage to start generating power. Once it is generating power and the CR relay picks, the 12 volts is routed to the switch light. So if the switch light doesn't come on, the relay either failed or did not get AC to pick it.

I know this is complicated,, and I have moments of lucid thinking so I can sometimes figure this stuff out, but it passes quickly.
__________________
Gardner Yeaw
83FC35 SB $IXTEEN TON$
Ridgewood, New Jersey
Travel Blog http://newdealblog.com/archives/category/trek-2012