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Kohler
Portable Generator
4EF
Kohler 4EF Service Manual
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TP-5986
4/03
24
Section
6
Controller
Troubleshooting
No
Is
there
AC
output
when
the
start
button
is
held
and
the
unit
is
running?
Ye
s
Is
there
12
volts
AC
output
at
the
B1/B2
stator
winding?
No
Is
there
approximately
12VDC
at
the
exciter
field?
No
Separately
excite
the
generator
set
to
determine
if
other
components
are
inoperative.
(See
Section
7.1.2,
Separate
Excitation).
Ye
s
No
Is
the
voltage
regulator
functional?
Is
there
AC
output
voltage?
Is
the
stator
and
rotor
functional?
Is
the
voltage
regulator
fuse
functional?
D
No
Ye
s
Replace
the
voltage
regulator
.
Ye
s
Replace
the
fuse.
No
Replace
inoperative
components.
Ye
s
Replace
the
circuit
board.
Is
the
stator
functional?
No
No
Replace
the
stator
.
Ye
s
Replace
the
circuit
board.
Figure
6-6
Troubleshooting
Relay
Controller
Circuit
Board
(4
of
4)
37
39
Table of Contents
Product Identification Information
2
Table of Contents
3
Safety Precautions and Instructions
5
Fuel System
7
Hot Parts
8
Introduction
11
Service Assistance
12
Service Parts/Publications
13
Routine Service Parts
13
List of Related Literature
13
Section 1 Specifications
15
General
15
Engine
15
Fuel
15
Cooling
15
Generator
16
Torque
16
Service Views
17
Section 2 Scheduled Maintenance
19
General
19
Lubrication System
19
Section 3 Intake and Exhaust System
21
Backfire Flame Arrestor
21
Exhaust
21
Section 4 Fuel System
23
General
23
Float Bowl Vent System
23
Fuel Pump and Filter
23
Fuel Pump Troubleshooting
24
Carburetor Troubleshooting
24
Hard Starting
24
Stalling
24
Flooding
25
Hunting
25
Leaking Carburetor
25
Governor 60 Hz to 50 Hz Conversion
25
Section 5 Cooling System
27
General
27
Closed Heat Exchanger
28
Check and Fill Coolant
28
Flush and Clean Cooling System
28
Impeller
29
Siphon Break
30
Anticorrosion Zinc Anode
31
Generator Storage
32
Section 6 Controller Troubleshooting
33
Sequence of Operation
33
Start
33
Run
33
Stop
34
Engine Safety Shutdown Switches
34
Low Oil Pressure (LOP) Shutdown
34
Loss of Coolant Switch (LCS) Shutdown
34
High Engine Temperature Switch
34
(HET) Shutdown
34
Controller Circuit Board
34
Troubleshooting
35
Section 7 Generator Troubleshooting
39
General
39
Troubleshooting
39
Separate Excitation
40
Powerboost IIIE Voltage Regulators
41
Voltage Regulator Test
41
Voltage Regulator Adjustment
42
Rotor
43
Stator
43
Brushes
45
Section 8 Component Troubleshooting
47
Engine/Generator Components
47
Remote Panels (Optional)
49
Section 9 Generator Disassembly/Reassembly
51
Disassembly
51
Collector Ring and Bearing Replacement
53
Reassembly
53
Section 10 Wiring Diagrams and Voltage
55
Reconnection
55
Schematic Wiring Diagram
56
Point-To-Point Wiring Diagram
57
Reconnection Diagram 100--120 V, 60 & 50 Hz
58
Reconnection Diagram 100--120/200--240
58
50 Hz
58
Reconnection Diagram 220--240 V, 50 Hz
58
Remote Start Panel
58
Remote Start and Two-Meter Panel
59
Remote Start and Four-Meter Panel
59
Appendix A Abbreviations
61
Appendix C General Torque
63
Appendix B Common Hardware Application Guidelines
63
Specifications
63
Appendix D Common Hardware Identification
65
Appendix E Common Hardware List
66
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Kohler 4EF Specifications
General
Brand
Kohler
Model
4EF
Category
Portable Generator
Language
English
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