Troubleshooting Chart - Kohler Power Systems 8RESV Service Manual

4.11 Troubleshooting Chart

Use the following table as a reference in troubleshooting
individual problems. Generator set faults are listed in
groups and include likely causes and remedies. The
Problem Possible Cause
Battery connections Check for reversed or poor
Generator
set engine
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
* RDC2 controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech
software. DC2 controller settings can only be changed using SiteTech.
66 Section 4 Troubleshooting
Test
battery connections.
Check the battery voltage.
Test battery according to battery
manufacturer's recommendations.
Check battery charger
connections and utility power
connection to the generator set.
Check for loose connections.
Check the wire harness continuity.
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 the genset model, engine
model, and other controller
settings.
Troubleshoot the controller as
described in Section 4.12.
S/S = Generator Set Specification Sheet
Engine S/M = Engine Service Manual
simplest and most likely causes of the problem are listed
first; follow the recommendations in the order shown.
The reference column provides additional sources of
information in this and related manuals regarding the
problem and solution.
Corrective Action
Correct and tighten battery
connections.
Recharge or replace battery.
Tighten connections. Connect
120VAC power to the genset
terminal block.
Tighten connections.
Replace harness or harness leads
if damaged.
Clean and retighten.
Tighten connections.
Replace wiring if damaged.
Replace starter relay.
Tighten connections.
Replace wiring if damaged.
Rebuild or replace starter.
Check battery and connections.
Adjust controller settings, if
necessary.
See Section 4.12.
O/M = Generator Set Operation Manual
Reference
—
O/M
I/M
Section 5.16,
W/D Section 7
—
Section 5.15
W/D Section 7
Section 5.16
W/D Section 7
W/D Section 7
W/D Section 7
Engine S/M
W/D Section 7
Section 3.3
Section 4.12
TP-6881 7/15