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

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