Kohler 36VDC, 6VSG, 24VDC, 48VDC manual 2 General Troubleshooting Chart

5.5 Troubleshooting

Figure 5-2contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts.

Problem	Possible Cause	Recommended Action
Controller	Backlight turns off after about 1 minute with no	Backlight will turn on when a button is pressed or the
display backlight	activity.	generator set starts.
is off.
Controller	Low or no battery voltage.	Check connections.
display is off.		Check generator set battery. See Figure 1-2.
The generator	Battery weak or dead.	Recharge or replace the battery.
set does not
	Battery connections reversed or poor.	Check the connections.
crank.
	Fault shutdown.	Check the controller display for fault messages. See
		Section 2.6. Correct the fault condition and reset the
		controller.
	Generator set in the OFF mode.	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,
starts hard,	Battery connection poor.	Clean and tighten the battery connections.
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 malfunction.	Contact an authorized Kohler distributor/dealer.
No DC output.	Line circuit breaker in the OFF position.	Place the circuit breaker in the ON position.
	Line circuit breaker tripping because of overload.	Reduce the load on the generator set.
	Line circuit breaker tripping because of short	Contact an authorized Kohler distributor/dealer for
	circuit.	service.
	Rectifier has failed.	Verify that the generator is providing AC voltage.
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.
	Auxiliary winding circuit breaker tripped.	Reset the circuit breaker (located in controller’s service
		access area). Contact an authorized Kohler
		distributor/dealer for service if breaker trips repeatedly.
	Fault shutdown.	Check the controller display for fault messages. See
		Section 2.6. Correct the fault condition and reset the
		controller.
	Generator set in the OFF mode.	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. Check OnCue®.
	switch, or OnCue®.
	Engine malfunction.	Contact an authorized Kohler distributor/dealer.

Figure 5-2General Troubleshooting Chart

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