Kohler 8.5RMY Service Manual page 29

Problem Possible Cause
Generator set
Loss of generator output voltage
stops
to K1 relay (LED1 not lit)
suddenly, y,
continued ti d
Defective ignition module
Defective K3 relay (field flashing)
Generator set
Air cleaner clogged
operates p
erratically
Faulty spark plug(s)
Fuel mixture adjustment incorrect
Governor adjustment incorrect
Carbon buildup in engine
Engine valves not seating
correctly
Defective ignition system
Defective spark plug wire(s)
Incorrect cooling (hot engine only) Inspect air inlet and outlet.
Fuel line restriction
Carburetor adjustment incorrect
Generator set
Air intake restriction
lacks power p
Generator overloaded
Faulty spark plug(s)
Faulty spark plug wire(s)
Engine not running at rated rpm
Governor defective or misadjusted Test/readjust governor.
Incorrect cooling
Defective ignition system
Insufficient fuel pressure
Fuel line restriction
Defective fuel regulator
Generator set Incorrect cooling
overheats
Air cleaner clogged
Fuel mixture adjustment incorrect
Generator set Exhaust system leaks
is noisy i i
Engine not running smoothly
Broken or damaged vibromount(s) Check and replace as necessary.
Loose or vibrating sheet
metal/housing
Exhaust piping or air inlets/outlets
not securely installed
Excessive engine/generator
vibration
TP-5867 11/02
General Troubleshooting Chart, continued
Corrective Action
Check AC voltage at rectifier
(BR1). Check continuity of B1/B2
stator leads.
Test and/or replace.
Test/replace controller circuit
board.
Replace element.
Replace and regap plugs.
Check and/or adjust.
Adjust electronic governor.
Clean cylinder head.
Inspect valves and valve seats.
Test and/or replace components.
Replace spark plug wires.
Check fuel lines.
Adjust carburetor.
Check air cleaner, air intake.
Reduce load.
Replace and regap plug(s).
Replace spark plug wires.
Adjust governor.
Inspect cooling system for
obstructions.
Test and/or replace.
Check fuel pressure at carburetor
outlet.
Check fuel pipe size.
Check function of fuel regulator.
Inspect cooling system for
obstructions.
Replace element.
Readjust fuel mixture.
Check and replace as necessary.
See "Generator set operates
erratically," this table
Retighten screws, replace rivets.
Inspect for loose parts and secure
if necessary.
Check, rotor, crankshaft, bearing,
etc. (disassembly of engine and/or
alternator may be required).
Reference
Sections 6, Component Testing
and Adjustment, and 9, Wiring
Diagrams
Engine S/M
Section 4, Controller
Troubleshooting
Section 2.4, Air Cleaner Element
and Precleaner
Section 2.3, Spark Plugs
Section 6.11, Fuel Systems
Section 6.9, Electronic Governor
Engine S/M
Engine S/M
Engine S/M
Engine S/M
Section 2.5, Cooling System
Section 6.11.1, Gas Piping
Section 6.9.3, Hunting/Surging
Section 2.4, Air Cleaner Element
and Precleaner
O/M
Section 2.3, Spark Plugs
Engine S/M
Section 6.9, Electronic Governor
Section 6.9, Electronic Governor
Section 2.5, Cooling System
Engine S/M
Section 6.11,Fuel Systems
Section 6.11, Fuel Systems
Section 6.11, Fuel Systemss
Section 2.5, Cooling System
Section 2.4, Air Cleaner Element
and Precleaner
Section 6.11, Fuel Systems
Section 2.6, Exhaust System
See "Generator set operates
erratically," this table
Section 8, Disassembly/
Reassembly
—
Section 2.6, Exhaust System
Section 8, Disassembly/
Reassembly and Engine S/M
Section 3 Troubleshooting 19