Kohler 30RES Manual - Page 26

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Battery short circuits. Explosion can cause severe injury

or death.

Short circuits can cause bodily injury and/or

equipment damage. Disconnect the battery before generator

set installation or maintenance. Remove all jewelry before

servicing the equipment. Use tools with insulated handles.

Remove the negative (--) lead first when disconnecting the

battery.

Reconnect the negative (--) lead last when

reconnecting the battery. Never connect the negative (--)

battery cable to the positive (+) connection terminal of the

starter solenoid. Do not test the battery condition by shorting

the terminals together.

3.10 Ignition System

Service the spark plugs at the interval specified in the

service schedule using the following procedure.

Spark Plug Service Procedure

1. Place the generator set master switch in the OFF

position.

2. Disconnect the power to the battery charger, if

equipped.

Problem/Condition

Means of Identification

Gap-bridged spark

Built-up deposits and gap between electrodes

plug

closing.

Oil-fouled spark plug

Wet, black deposits on the insulator shell, bore,

and electrodes.

Carbon-fouled spark

Black, dry, fluffy carbon deposits on insulator

plug

tips, exposed shell surfaces and electrodes.

Lead-fouled spark plug Dark gray, black, yellow, or tan deposits; or a

glazed coating on the insulator tip.

Pre-ignition damaged

Melted electrodes and possibly blistered

spark plug

insulator. Metallic deposits on insulator suggest

internal engine damage.

Overheated spark plug White or light gray insulator with small black or

gray/brown spots with bluish (burned)

appearance on electrodes.

Worn spark plug

Severely eroded or worn electrodes.

Figure 3-9 Engine Evaluation Using Spark Plug Condition

Section 3 Scheduled Maintenance

3. Disconnect the generator set engine starting

battery, negative (--) lead first.

4. Remove spark plug wires by grasping the spark

plug boot and turning slightly while pulling. Do not

pull the wire. Pulling on the wire rather than the

boot may damage the wire or terminal.

5. Loosen the spark plug with a ratchet and 5/8-in.

spark plug socket with a rubber insert to prevent

spark plug damage.

6. Use compressed air to remove dirt from around

each spark plug to prevent dirt particles from falling

into the combustion chamber.

7. Remove spark plugs, one at a time, and examine.

Identify a normal spark plug in good operating

condition by observing a light tan or gray deposit on

firing tip.

See Figure 3-9 to evaluate engine

condition by color/condition of a problem spark plug.

Possible Cause/Solution

Oil or carbon fouling. Clean and regap the spark

plug.

Excessive oil entering combustion chamber

through worn rings and pistons, excessive

clearance between valve guides and stems, or

worn or loose bearings. Replace the spark plug.

Incorrect spark plug, weak ignition, clogged air

intake, overrich fuel mixture, or excessive

no-load operation. Clean and regap the spark

plug.

Caused by highly leaded fuel. Replace the

spark plug.

Wrong type of fuel, incorrect timing or advance,

too hot a plug, burned valves, or engine

overheating. Replace the spark plug.

Engine overheating, wrong type of fuel, loose

spark plugs, too hot a plug, low fuel pressure or

incorrect ignition timing. Replace the spark plug.

Caused by normal wear and failure to replace

spark plug at prescribed interval. Replace the

spark plug.

TP-6344 4/09