Section 4 Troubleshooting; Introduction; Generator Set Troubleshooting - Kohler 15RYG Operation

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.
Problem Possible Cause
The generator set
Battery weak or dead
does not crank
Battery connections reversed or poor
Controller fuse (F3) blown
Relay interface board fuse (F2) blown
Generator set master switch in the OFF position Move the master switch to the RUN position.
The generator set Air cleaner clogged
cranks but does not
Battery weak or dead
start, starts hard,
Battery connection poor
lacks power, or
Spark plug wire connection loose
operates erratically
Low oil pressure shutdown
Fuel pressure insufficient
Engine malfunction
No AC output
AC circuit breaker in the OFF position
AC circuit breaker tripping because of overload
AC circuit breaker tripping because of short
circuit
Auxiliary winding fuse (F1) blown
Low output or Generator set overloaded
excessive drop in
voltage
Generator set stops Low oil pressure shutdown
suddenly
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, remote digital gauge, or ATS
Engine malfunction
Auxiliary winding fuse (F1) blown
Figure 4-1 General Troubleshooting Chart
TP-6197 3/06

Section 4 Troubleshooting

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.
Corrective Action
Recharge or replace the battery.
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.
Clean and/or replace the air cleaner.
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.
Replace the fuse. Contact an authorized distributor/
dealer for service if fuse blows repeatedly.
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 31