Generator Set Troubleshooting - Kohler 38RCL Manual

5.9 Generator Set Troubleshooting

The following tables
troubleshooting, diagnostic, and repair information.
Check for loose connections and incorrect controller
settings before replacing parts.
For problems with
speed/governing, or stopping, refer to the engine
Problem Possible Cause
Weak or dead battery.
Generator set
engine does not
Weak or dead battery due to
crank.
battery charging malfunction.
Reversed or poor battery
connections.
Inoperative controller.
Controller's internal circuit
protection has tripped.
Open circuit in engine or controller
connections.
Poor ground (--) connection.
Generator set is OFF.
Engine problem.
Generator set Air cleaner clogged.
engine cranks
Weak battery.
but does not
start.
Poor battery connection.
Spark plugs.
Spark plug connections.
No fuel or low fuel pressure.
Loose connections or faulty
wiring.
No engine rotation sensed.
Engine fuse blown.
Engine problem.
Note: I/M = generator set installation manual; O/M = generator set Operation Manual; S/M = service manual; W/D = wiring diagram.
70 Section 5 Troubleshooting
contain generator
engine starting, operation,
set service manuals. For issues with generator output
voltage, refer to the alternator service manual in addition
to the items mentioned in the tables below. See the List
of Related Materials in the Introduction section of this
manual for engine and alternator service manual part
numbers.
Corrective Action
Recharge or replace the battery.
Check for DC voltage on lead CHO to the
battery.
Check for 120 VAC on the black and white
leads to controller P5-1 and P5-3 for battery
charging.
Check 120 VAC utility power connection to the
generator set.
Check the battery connections and ground
connection.
Check power to the controller.
Troubleshoot the controller.
Press the OFF button to reset the controller.
Check for loose connections.
Check the wire harness continuity.
Clean and tighten.
Press the RUN button to start the engine or
press AUTO to allow remote starting.
Troubleshoot/service the engine.
Clean and/or replace the air cleaner.
Recharge or replace the battery.
Check for DC voltage on lead CHO to the
battery.
Check for 120 VAC on the black and white
leads to controller P5-1 and P5-3 for battery
charging.
Check 120 VAC utility power connection to the
generator set.
Clean and tighten the battery connections.
Check the spark plugs. Regap or replace if
necessary.
Tighten connections. Replace spark plug wires
if necessary.
Check the fuel supply, regulators, fuel supply
lines, and valves.
Check connections to fuel solenoid valves.
Check the engine/controller connections and
wiring.
Check for locked rotor shutdown.
Replace the fuse. If the fuse blows again,
troubleshoot/service the engine.
Troubleshoot/service the engine.
Reference
—
W/D Section 8
W/D Section 8
Section 5.10
—
W/D Section 8
W/D Section 8
Engine S/M
Section 2.4
W/D Section 8
Section 2.6
Section 2.6
Section 5.5
Section 6.8, Fuel
System
W/D Section 8
Section 5.7 and
Alternator S/M
Engine S/M
Engine S/M
TP-6811 7/16