Kohler KS540 [42/92] Electrical system
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Kohler KS540 [42/92] Electrical system

Kohler KS540 [42/92] Electrical system
42
Electrical System
KohlerEngines.com 22 690 01 Rev. --
BATTERY CHARGING SYSTEM
CAUTION
Electrical Shock can cause injury.
Do not touch wires while engine is running.
NOTE: Observe following guidelines to avoid damage to
electrical system and components:
● Make sure battery polarity is correct. A negative (-)
ground system is used.
● Disconnect rectifi er-regulator plug and/or wiring
harness plug before doing any electric welding on
equipment powered by engine. Disconnect all other
electrical accessories in common ground with engine.
● Prevent stator (AC) leads from touching or shorting
while engine is running. This could damage stator.
These engines are equipped with either a 12 or 15 amp,
regulated battery charging system.
Ignition System Components
A
D
E
F
B
F
H
G
C
A
Kill Switch/Off Position
of Key Switch
B Air Gap
C Flywheel D Magnet
E Spark Plug F Ignition Module
G Kill Terminal H Spark Plug Boot
There is 1 type of ignition system used on these engines.
This system uses an ignition module which energizes
spark plug.
This ignition system is designed to be trouble free for
life of engine. Other than periodically checking/replacing
spark plugs, no maintenance or timing adjustments
are necessary or possible. Mechanical systems do
occasionally fail or break down. Refer to Troubleshooting
to determine root of a reported problem.
Reported ignition problems are most often due to poor
connections. Before beginning test procedure, check
all external wiring. Be certain all ignition-related wires
are connected, including spark plug leads. Be certain all
terminal connections fi t snugly. Make sure ignition switch
is in run position.
Fixed Ignition System
This system uses an inductive discharge (ID) coil.
Ignition timing and spark remains constant regardless of
engine speed. Timing of spark is controlled by location of
fl ywheel magnet group as referenced to engine TDC. A
typical fi xed ignition system consists of:
● 1 magnet assembly which is permanently affi xed to
fl ywheel.
● 1 electronic inductive-discharge ignition module which
mounts on engine crankcase.
● 1 kill switch (or key switch) which grounds module to
stop engine.
● 1 spark plug.
BATTERY
A 12-volt battery with 250 cold cranking amps (cca) is
generally recommended for starting in all conditions.
A smaller capacity battery is often suffi cient if an
application is started only in warmer temperatures.
Actual cold cranking requirement depends on engine
size, application, and starting temperatures. Cranking
requirements increase as temperatures decrease and
battery capacity shrinks. Refer to equipment's operating
instructions for specifi c battery requirements.
Battery Size Recommendations
If battery charge is insuffi cient to turn over engine,
recharge battery.
Battery Maintenance
Regular maintenance is necessary to prolong battery
life.
Battery Test
To test battery, follow manufacturer's instructions.

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