Section 4 Troubleshooting; Introduction; Generator Set Troubleshooting - Kohler 8.5RES Operation And Installation

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/
Problem Possible Cause
The generator set Battery weak or dead
does not crank.
Battery charger fuse blown
Battery connections reversed or poor
Controller fuse (F3) blown
Relay interface board fuse (F2) blown
Generator set master switch in the OFF position
The generator set g Air cleaner clogged
cranks but does not k b d
Battery weak or dead
start, starts hard, lacks
power, or operates power or operates
erratically. y Battery connection poor
Spark plug wire connection loose
Low oil pressure shutdown
Fuel pressure insufficient
Engine malfunction
No AC output. p AC circuit breaker in the OFF position
AC circuit breaker tripping because of overload
AC circuit breaker tripping because of short circuit
Low output or Generator set overloaded
excessive drop in
voltage.
Generator set stops p Low oil pressure shutdown
suddenly. dd l
Out of fuel
Overcrank shutdown
Controller fuse (F3) blown
Overspeed shutdown
Generator set master switch in the OFF/RESET
position
Remote stop command received from a remote switch
or ATS
Engine malfunction
Auxiliary winding fuse (F1) blown
Figure 4-1 General Troubleshooting Chart
TP-6195 1/04

Section 4 Troubleshooting

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.
Corrective Action
Check power to the battery charger.
Recharge or replace the battery.
Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Check the connections.
Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Move the master switch to the RUN position.
Clean and/or replace the air cleaner.
Check power to the battery charger.
Recharge or replace the battery.
Clean and tighten the battery connections.
Check the spark plug wires.
Check the oil level.
Check the fuel supply and valves.
Contact the distributor/dealer.
Place the circuit breaker in the ON position.
Reduce the load on the generator set.
Contact an authorized distributor/dealer for service.
Reduce the load.
Check the oil level.
Check fuel supply.
Reset the controller. If the overcrank fault occurs again,
contact the distributor/dealer.
Replace the fuse. If the fuse blows again, contact the
distributor/dealer.
Reset the controller. If the overspeed fault occurs again,
contact the distributor/dealer.
Move the switch to the correct position (RUN or AUTO).
Check the remote switch position.
Contact the distributor/dealer.
Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Section 4 Troubleshooting 19