Troubleshooting Chart - Kohler 6VSG Service Manual

4.9 Troubleshooting Chart

Use Figure 4-4 as a reference in troubleshooting
individual problems. Generator set faults are listed in
groups and include likely causes and remedies. The
simplest and most likely causes of the problem are
listed first; follow the recommendations in the order
Problem Possible Cause
Generator Battery
set engine connections
does not
Weak or dead
crank
battery
Open circuit in
engine/controller
connections
Poor ground (–)
connection
Starter relay
Starter
Controller
W/D = Wiring Diagram(s) (Section 7)
I/M = Generator Set Installation Manual
S/S = Generator Set Specification Sheet
TP-6844 1/13
Test
Check for reversed or poor battery
connections.
Check the battery voltage.
Test battery according to battery
manufacturer's recommendations.
Check battery charger
connections and power
connection to the generator set.
Check for loose connections.
Check the wire harness continuity. Replace harness or harness leads
Test ground connection.
Check connections to the starter
relay.
Check continuity of circuit.
Check that the starter relay picks
up when 12 VDC is applied at lead
71 connection.
Check starter connections.
Troubleshoot the starter. See the
engine service manual for
instructions.
Check for 12 VDC to the controller. Check battery and connections.
Check the genset model, engine
model, and other controller
settings.
Troubleshoot the controller as
described in Section 4.10.
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
shown. The reference column provides additional
sources of information in this and related manuals
regarding the problem and solution.
Figure 4-4
Corrective Action
Correct and tighten battery
connections.
Recharge or replace battery.
Tighten connections. Connect
120VAC power to the genset
terminal block.
Tighten connections.
if damaged.
Clean and retighten.
Tighten connections.
Replace wiring if damaged.
Replace harness or harness leads
if damaged.
Replace starter relay.
Tighten connections.
Replace wiring if damaged.
Rebuild or replace starter.
Adjust controller settings, if
necessary.
See Section 4.10.
Reference
—
O/M
I/M
Section 5.8
Section 5.10
Section 7
—
Section 5.9
W/D Section 7
Section 5.10
W/D Section 7
W/D Section 7
W/D Section 7
Engine S/M
W/D
Section 3.3
Section 4.10
Section 4 Troubleshooting 57