Kohler 12RES, 8.5RES manual Introduction, Generator Set Troubleshooting

Page 31

Section 4 Troubleshooting

4.1 Introduction

Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, and recommended corrective actions.

If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/

dealer. Maintain a record of repairs and adjustments performed on the equipment. Use the record to help describe the problem and repairs or adjustments made to the equipment.

4.2 Generator Set Troubleshooting

Figure 4-1 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts.

Problem

Possible Cause

Corrective Action

 

 

 

The generator set

Battery weak or dead

Check power to the battery charger.

does not crank.

 

Recharge or replace the battery.

 

Battery charger fuse blown

Replace the fuse. Contact an authorized distributor/dealer

 

 

for service if fuse blows repeatedly.

 

Battery connections reversed or poor

Check the connections.

 

Controller fuse (F3) blown

Replace the fuse. Contact an authorized distributor/dealer

 

 

for service if fuse blows repeatedly.

 

Relay interface board fuse (F2) blown

Replace the fuse. Contact an authorized distributor/dealer

 

 

for service if fuse blows repeatedly.

 

Generator set master switch in the OFF position

Move the master switch to the RUN position.

 

 

 

The generator set

Air cleaner clogged

Clean and/or replace the air cleaner.

cranks but does not

Battery weak or dead

Check power to the battery charger.

start, starts hard, lacks

power, or operates

 

Recharge or replace the battery.

 

 

erratically.

Battery connection poor

Clean and tighten the battery connections.

 

Spark plug wire connection loose

Check the spark plug wires.

 

Low oil pressure shutdown

Check the oil level.

 

Fuel pressure insufficient

Check the fuel supply and valves.

 

Engine malfunction

Contact the distributor/dealer.

 

 

 

No AC output.

AC circuit breaker in the OFF position

Place the circuit breaker in the ON position.

 

AC circuit breaker tripping because of overload

Reduce the load on the generator set.

 

AC circuit breaker tripping because of short circuit

Contact an authorized distributor/dealer for service.

 

Auxiliary winding fuse (F1) blown

Replace the fuse. Contact an authorized distributor/dealer

 

 

for service if fuse blows repeatedly.

 

 

 

Low output or

Generator set overloaded

Reduce the load.

excessive drop in

 

 

voltage.

 

 

 

 

 

Generator set stops

Low oil pressure shutdown

Check the oil level.

suddenly.

Out of fuel

Check fuel supply.

 

 

Overcrank shutdown

Reset the controller. If the overcrank fault occurs again,

 

 

contact the distributor/dealer.

 

Controller fuse (F3) blown

Replace the fuse. If the fuse blows again, contact the

 

 

distributor/dealer.

 

Overspeed shutdown

Reset the controller. If the overspeed fault occurs again,

 

 

contact the distributor/dealer.

 

Generator set master switch in the OFF/RESET

Move the switch to the correct position (RUN or AUTO).

 

position

 

 

Remote stop command received from a remote switch

Check the remote switch position.

 

or ATS

 

 

Engine malfunction

Contact the distributor/dealer.

 

Auxiliary winding fuse (F1) blown

Replace the fuse. Contact an authorized distributor/dealer

 

 

for service if fuse blows repeatedly.

Figure 4-1 General Troubleshooting Chart

TP-6331 5/04

Section 4 Troubleshooting 19

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Contents Controller Advanced Digital Control ADC ModelsTP-6331 5/04 Engine Identification Product Identification InformationController Identification Generator Set Identification NumbersTable of Contents Table of Contents TP-6331 5/04 Battery Safety Precautions and InstructionsAccidental Starting Exhaust System Engine Backfire/Flash FireHazardous Voltage/ Electrical Shock Fuel System Hazardous NoiseHot Parts Heavy EquipmentMoving Parts 246242 VI Safety Precautions and Instructions TPTPS-6331 5/04 Nameplate IntroductionEPA and California Emission Certification Service Assistance Advanced Digital Control FeaturesSpecifications Generator EngineGenerator Set Components Generator Set ComponentsGenerator Set Operation Prestart ChecklistOperation Exercising Generator SetStarting Generator Set Controls and IndicatorsStopping Generator Set Code Fault Description Check Fault ShutdownsResetting Controller after a Fault Shutdown Continuous Power ModeBattery Charger Operation Battery ChargerOperation TP-6331 5/04 Routine Maintenance Scheduled MaintenanceLubrication Service ScheduleOil Check Oil Change ProcedureLubrication System Low Oil Pressure ShutdownPrecleaner Service Air Cleaner Element and PrecleanerSpark Plugs Air Cleaner Components Paper Element ServiceCooling Air Intake and Exhaust Cooling SystemEZ-273000-J Circuit Protection Storage ProcedureCylinder Lubrication BatteryExterior Preparation Scheduled Maintenance TP-6331 5/04 Generator Set Troubleshooting TroubleshootingIntroduction Battery Charger Troubleshooting Fault CodesTroubleshooting Ansi Appendix a AbbreviationsISO Page By Kohler Co. All rights reserved

12RES, 8.5RES specifications

The Kohler 8.5RES and 12RES generators are known for their robust reliability and efficiency, making them ideal solutions for both residential and light commercial applications. These generators are equipped with advanced technologies that ensure seamless power delivery during outages, giving users peace of mind.

The Kohler 8.5RES, with its 8.5 kW output, is perfect for homeowners who require backup power for essential appliances and systems. It efficiently powers refrigerators, lights, and heating or cooling systems, providing convenience when the grid is down. The 12RES, delivering 12 kW, caters to larger homes or small businesses, accommodating additional loads such as sump pumps and electric dryers.

One of the standout features of these generators is the Kohler Command PRO engine, designed for maximum performance and longevity. This engine operates with low noise levels, ensuring that any power interruption goes unnoticed. Both models come with an innovative digital control panel that simplifies operation and monitoring, allowing users to access critical information at a glance.

The Kohler 8.5RES and 12RES are equipped with the patented Automatic Voltage Regulation (AVR) technology. This feature maintains a steady voltage output to protect sensitive electronics from damage caused by power surges. The modular design of these units facilitates easy maintenance, with service intervals and replacement parts readily available.

For eco-conscious consumers, the Kohler generators meet EPA emission regulations, ensuring a cleaner energy solution. The units also offer a comprehensive sound-attenuated enclosure, resulting in quieter operation, making them suitable for use in suburban environments.

Installation is straightforward, with various connection options for natural gas and propane fueling. Both models come with a fully automatic transfer switch, providing seamless transition from grid to generator power. This ensures that critical systems are always operational during outages.

In summary, the Kohler 8.5RES and 12RES generators stand out for their reliability, advanced technology, and user-friendly features. Their powerful engines, efficient performance, and low emissions make them an excellent choice for anyone looking to invest in a dependable backup power solution. Whether for home use or light commercial needs, these generators provide the essential peace of mind that comes with knowing you have power when you need it most.
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