Kohler 48RCL, 38RCL, 60RCL Generator Set Troubleshooting, Problem Possible Cause Corrective Action

5.5 Generator Set Troubleshooting

Figure 5-1 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts.

Problem	Possible Cause	Corrective Action
The generator	Battery weak or dead.	Recharge or replace the battery.
set does not
	Battery connections reversed or poor.	Check the connections.
crank.
	Blown fuse(s).	Replace the fuse. Contact an authorized Kohler
		distributor/dealer for service if fuse blows repeatedly.
	Generator set is OFF.	Press the RUN button to start the engine or press AUTO
		to allow remote starting.
The generator	Air cleaner clogged.	Clean and/or replace the air cleaner.
set cranks but
	Battery weak or dead.	Recharge or replace the battery.
does not start,
	Battery connection poor.	Clean and tighten the battery connections.
starts hard,
lacks power, or	Spark plug wire connection loose.	Check the spark plug wires.
operates
	Low oil pressure shutdown.	Check for oil leaks. Check the oil level and add oil if
erratically.
		necessary.
	Fuel pressure insufficient.	Check the fuel supply and valves.
	Engine fuse blown.	Replace the fuse. If the fuse blows again, contact an
		authorized Kohler distributor/dealer.
	Engine malfunction.	Contact an authorized Kohler 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	Contact an authorized Kohler distributor/dealer for
	circuit.	service.
	Engine fuse blown.	Replace the fuse. Contact an authorized Kohler
		distributor/dealer for service if fuse blows repeatedly.
Low output or	Generator set overloaded.	Reduce the load.
excessive drop
in voltage.
Generator set	Low oil pressure shutdown.	Check for oil leaks. Check the oil level and add oil if
stops suddenly.		necessary.
	Out of fuel.	Check fuel supply.
	Overcrank shutdown.	Reset the controller. If the overcrank fault occurs again,
		contact an authorized Kohler distributor/dealer.
	Blown fuse(s).	Replace the fuse. If the fuse blows again, contact an
		authorized Kohler distributor/dealer.
	Overspeed shutdown.	Reset the controller. If the overspeed fault occurs again,
		contact an authorized Kohler distributor/dealer.
	Generator set is OFF.	Press the RUN button to start the engine or press AUTO
		to allow remote starting.
	Remote stop command received from a remote	Check the remote switch position.
	switch, ATS, or OnCuer.
	Engine malfunction.	Contact an authorized Kohler distributor/dealer.
Fans run after	The fans continue to run for 2 minutes after the	None.
engine shuts	engine shuts down to evacuate the engine
down.	compartment.

Figure 5-1General Troubleshooting Chart

58 Section 5 Troubleshooting TP-6810 11/13