Kohler 20RESAL Troubleshooting Manual - Page 5

Browse online or download pdf Troubleshooting Manual for Portable Generator Kohler 20RESAL. Kohler 20RESAL 8 pages. Residential/commercial generator sets
Also for Kohler 20RESAL: Installation Instructions (2 pages), Operation (20 pages)

Print Page

8. Energize the fuel solenoid valve to verify that it is

opening and closing properly. You should hear an

audible click if the solenoid is operating. Is it

operating correctly?

a. No? Replace the fuel solenoid valve.

b. Yes? Proceed to next step.

9. Monitor voltage at the fuel solenoid valve to verify

that battery voltage is present when running and

absent when not running.

10. Are the carburetor or intake bolts loose, allowing

movement and excess air to be introduced into the

system?

a. Yes? Reposition the carburetor so that the

throttle plate will not touch the carburetor

gasket. Apply Loctiter to the bolt threads and

tighten as needed.

b. No? Proceed to the next step.

11. Do the throttle plate, linkage between throttle and

stepper motor, and stepper motor itself move

freely?

a. No? Check for restrictions including:

Linkage. Go to step 12.

Worn bushings. Go to step 13.

Carburetor gasket. Go to step 14.

b. Yes? Proceed to step 15.

12. On the linkage, is the bias spring in place, around

both bushings and/or connected to the holes the

bushings are inserted in?

a. No? Replace bias spring.

b. Yes?

Try different positions on the throttle

linkage plate. If it has no effect, replace bias

spring to original position and proceed to the

next step.

13. Are the bushings worn, causing excessive

movement of the linkage?

a. Yes? Replace the bushings.

b. No? Proceed to the next step.

14. Is the carburetor gasket interfering with the throttle

plate or linkage?

a. Yes? Always trim the carburetor gasket and

test the operation before replacing the

carburetor. See Figure 3.

Note: Engines with serial numbers 4223605221 or

higher have a new carburetor gasket that

does not require trimming.

b. No? Proceed to the next step.

SB-722

1/13

15. While running the unit with no load, unplug the

stepper motor harness. Does hunting continue?

a. Yes? Then it is not a controller or governor

issue. We can now narrow it down to these

possibilities:

Regulator replacement

Fuel solenoid replacement

Spark plug condition check/replacement

Perform a cylinder leak-down test. See the

engine service manual for instructions.

If none of these procedures remedy the

hunting, contact your Kohler distributor.

b. No?

Controller issue.

controller software to version 4.09 or higher.

Note: For the Model 20RES with RDC controller only,

test the magnetic pickup as described below.

Is the magnetic pickup operating correctly?

Measure

output

disconnects. Should be a minimum of 3 VAC

while cranking.

Monitor

the

magnetic

measurement while manually holding the engine

RPM steady. The frequency should remain

constant. If it is erratic, check the wiring and

crimp connections. Check that the mag pickup

air gap is 0.5 mm (0.020 in.) and adjust if

necessary. If measurements are still erratic,

replace the magnetic pickup.

16. Reconnect the ATS by connecting PWR and COM

(RXT) or engine start leads 3 and 4 (RDT).

17. Verify the generator set operation.

generator set Operation Manual for instructions.

Note: If the generator set still hunts after performing

these procedures, please contact your Kohler

distributor for additional information.

1. Trim this edge if necessary

2. Trim 0.75 mm (0.03 in.) from the edge of each opening

Figure 3 Trimming the Carburetor Gasket

Loctiter is a registered trademark of the Henkel-Loctite

Corporation.

Update the RDC2

voltage

the

quick

pickup

frequency

See the

tp6806