Kohler 4EFRKM, Operation, Page: 29 / 40

TP-6081 4/00 17 Section 4 Troubleshooting
Trouble Symptoms
Probable Causes
Generator
set does not
crank
Generator
set cranks
but does
not start
Generator
set starts
hard
No or low
generator
voltage
Generator
set stops
suddenly
Generator
set lacks
power
Generator
set
overheats
Low/High
oil
pressure
High fuel
consumption
Excessive
or
abnormal
noise
Section/
Publication
Reference
Actions
Air cleaner clogged
x x x x 3.5
Clean or replace.
Engine overload
x x x x I/M
Reduce electrical load. See the installation manual for wattage requirements.
Compression weak
x x x x x x Engine S/M
Check the compression.*
Exhaust system leak
x x 3.6
Inspect the exhaust system. Replace the inoperative exhaust system components.*
e
Exhaust system not securely installed
x 3.6
Inspect the exhaust system. Tighten the loose exhaust system components.*
gine
Governor inoperative
x x x x S/M
Adjust the governor.*
En
g
Valve clearance incorrect
x x x Engine S/M
Adjust the valves.*
Excessive vibration
x
Tighten all loose hardware.
Inadequate cooling
x x x 3.7
Check air intake/cooling areas.
Inoperative or improper gap of spark plug
x x x 3.8
Regap or replace spark plug
be
Incorrect crankcase oil type for ambient temperature
x x x x 3.3.4
Change the oil. Use oil with a viscosity suitable for the operating climate.
Lub
e
Oil level low
x x x 3.3.2
Restore the oil level. Inspect the generator set for oil leaks.
Battery connections loose, corroded, or incorrect
x x 3.9
Verify that the battery connections are correct, clean and tight.
Battery weak or dead
x x 3.9
Recharge or replace the battery.
Starter/starter solenoid inoperative
x x S/M
Replace the starter or starter solenoid. *
cal
Engine harness twist-lock connector not locked tight
x x x
Disconnect the engine harness twist-lock connector then reconnect it to the controller.
ct
ric
a
Loose or inoperative spark plug wire
x x x x x 3.8
Reconnect or replace wire
Ele
c
Fault shutdown
x S/M
Reset the fault switch(es) and troubleshoot the controller. *
Inoperative ignition module
x x x x Engine S/M
Test and/or replace. *
Voltage regulator inoperative or out of adjustment
x x x S/M
Replace the voltage regulator fuse. Excite the main field separately.*
Inoperative controller circuit board
x x x S/M
Replace the controller circuit board. *
ol
Tripped controller circuit breaker, if equipped
x x 2.4.1
Reset the controller circuit breaker.
ontrol
Controller fault
x S/M
Troubleshoot the controller.*
Co
n
Blown controller fuse
x x x S/M
Replace the blown controller fuse. If the fuse blows again, troubleshoot the controller.*
Inoperative controller start/stop switch
x x S/M
Replace the start/stop switch. *
Inoperative choke heater
x x x x Engine S/M
Check operation. *
Fuel tank empty or fuel valve shut off
x x 3.4.1
Add fuel and move the fuel valve to the ON position.
Inoperative electric fuel pump
x x x x S/M
Test the fuel pump. *
F
uel
Fuel old or dirty
x x x 3.4.1
Replace fuel
F
Fuel vapor lock
x
Check the fuel line routing.
Inoperative antidieseling solenoid
x x x S/M
Check operation.*
Open AC output circuit breaker
x 2.4.1
Reset the breaker and check for AC voltage at the generator side of the circuit breaker.
r
Transfer switch main power contacts in the OFF position
x
Turn the switch to the auto position.
rator
Open wiring, terminals, or pin in the exciter field
x S/M
Check for continuity. *
ener
a
Inoperative main field (rotor) (open or grounded)
x S/M
Test and/or replace the rotor.*
G
e
Inoperative stator (open or grounded)
x S/M
Test and/or replace the stator.*
Excessive vibration x
S/M
Tighten loose components.*
*
Have an authorized service distributor/dealer perform this service.