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

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Kohler 48RCL, 38RCL, 60RCL manual Generator Set Troubleshooting, Problem Possible Cause Corrective Action
Page 57 Page 59

38RCL, 48RCL, 60RCL specifications

The Kohler RCL series of generators, particularly the 60RCL, 48RCL, and 38RCL models, represents a premium choice for those seeking reliable power solutions for residential and light commercial applications. Each model is tailored to meet diverse power needs, ensuring uninterrupted electricity supply during outages.

The 60RCL is engineered for maximum performance, offering 60 kW of power. This model is ideal for larger homes or small businesses that require dependable backup power. Its powerful Kohler engine is designed to deliver a quiet, smooth performance, while the advanced sound-dampening features keep noise levels to a minimum. The 48RCL offers a slightly lower output at 48 kW, making it suitable for medium-sized homes. Its compact design allows for flexible installation options, whether it’s outdoors or in a utility area, while still providing robust power during critical times.

The 38RCL, while the smallest of the series with 38 kW output, is perfect for homes that need a reliable backup generator without the bulk. Its streamlined design does not compromise on performance, making it an excellent choice for energy-efficient homes. All models in the RCL series come equipped with Kohler's Command Pro commercial-grade engine, ensuring longevity and reliability even in the harshest conditions.

A standout feature of the RCL series is the integrated KOHLER® 2.4-inch color display, which allows users to monitor generator performance in real-time. This user-friendly interface provides vital information such as operational status, run time, and maintenance notifications. Additionally, the series is designed with automatic transfer switches that allow for seamless switching between utility and generator power.

Moreover, these generators incorporate advanced control systems with remote monitoring capabilities, enabling users to check the status of their power supply from a smartphone or tablet. Designed with efficiency in mind, the RCL series boasts a fuel-efficient operation that supports both natural gas and propane, catering to diverse energy preferences.

In summary, the Kohler 60RCL, 48RCL, and 38RCL generators combine high performance, advanced technology, and user-friendly features. They are reliable solutions for anyone looking to safeguard their power needs, ensuring peace of mind when it matters most.
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