Generator Set Troubleshooting - Kohler 15RES Manual

4.4 Generator Set Troubleshooting

Figure 4-2 contains generator set troubleshooting,
diagnostic, and repair information. Check for loose
connections before replacing parts.
Problem Possible Cause
Battery weak or dead.
The generator
set does not
Battery connections reversed or poor.
crank.
Controller fuse (F3) blown.
Relay interface board fuse (F2) blown.
Engine fuses F4 or F6 blown.
Generator set master switch in the OFF
position.
Air cleaner clogged.
The generator
set cranks but
Battery weak or dead.
does not start,
Battery connection poor.
starts hard,
lacks power, or Spark plug wire connection loose.
operates
Low oil pressure shutdown.
erratically.
Fuel pressure insufficient.
Engine fuse F4, F6, or F7 blown.
Engine malfunction.
AC circuit breaker in the OFF position.
No AC output.
AC circuit breaker tripping because of overload. Reduce the load on the generator set.
AC circuit breaker tripping because of short
circuit.
Auxiliary winding fuse (F1) blown.
Engine fuses F6 or F7 blown.
Low output or Generator set overloaded.
excessive drop
in voltage.
Low oil pressure shutdown.
Generator set
stops suddenly.
Out of fuel.
Overcrank shutdown.
Controller fuse (F3) blown.
Engine fuse F6 or F7 blown.
Auxiliary winding fuse (F1) 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.
Figure 4-2 General Troubleshooting Chart
30 Section 4 Troubleshooting
Corrective Action
Recharge or replace the battery.
Check the connections.
Replace the fuse. Contact an authorized Kohler
distributor/dealer for service if fuse blows repeatedly.
Move the master switch to the RUN position.
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.
Replace the fuse. If the fuse blows again, contact an
authorized Kohler distributor/dealer.
Contact an authorized Kohler distributor/dealer.
Place the circuit breaker in the ON position.
Contact an authorized Kohler distributor/dealer for
service.
Replace the fuse. Contact an authorized Kohler
distributor/dealer for service if fuse blows repeatedly.
Reduce the load.
Check the oil level. Check for oil leaks.
Check fuel supply.
Reset the controller. If the overcrank fault occurs again,
contact an authorized Kohler distributor/dealer.
Replace the fuse. If the fuse blows again, contact an
authorized Kohler distributor/dealer.
Replace the fuse. Contact an authorized Kohler
distributor/dealer for service if fuse blows repeatedly.
Reset the controller. If the overspeed fault occurs again,
contact an authorized Kohler distributor/dealer.
Move the switch to the correct position (RUN or AUTO).
Check the remote switch position.
Contact an authorized Kohler distributor/dealer.
TP-6344 4/09