Section 3 Troubleshooting; Introduction; Initial Checks; Troubleshooting Chart - Kohler 8.5RES Service Manual

3.1 Introduction

Corrective action and testing in many cases requires
knowledge of electrical systems and electronic circuits.
Have an authorized distributor/dealer or trained service
technician perform testing and service.
Refer to the engine service manual for engine service
information. See List of Related Materials for the
document part number.
If the troubleshooting procedures in this section identify
a bad part, refer to the parts catalog for replacement part
numbers. See the List of Related Materials in the
Introduction for the parts catalog number.

3.2 Initial Checks

When troubleshooting, always check for simple
problems first. Check for the following common
problems before replacing parts:
D Loose connections or damaged wiring.
D Dead battery.
Fault shutdown. Check for a fault code on the
D
controller display. Section 4.4 describes the warning
and shutdown fault codes.

Troubleshooting Chart

Problem Possible Cause
Generator Weak or dead battery
set does not
crank
Battery connections
Open circuit in
engine/controller
connections
Blown fuse F3, controller Replace fuse; if fuse blows again, check circuit and components. Section 6.13
Blown fuse F2, relay
interface board (RIB)
TP-6196 10/09
D
D
D
3.3 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
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
Recharge or replace battery.
If battery is weak or dead, check battery charger fuse, power
supply, and operation.
Check for reversed or poor battery connections.
Check for loose connections.
Check the wire harness continuity.
Replace fuse.
If fuse blows again, disconnect the board leads one at a time to
identify the cause of the blown fuse:
Lead 70A at the fuel valve
Lead IGN at the ignition module
Lead 71A at the starter relay
Leads FP and FN at the rotor
Repair or replace the component causing the blown fuse.
If fuse continues to blow and the previous step did not identify
the cause, check the continuity of leads FP and FN and the
leads from the P14 connector. Replace any bad leads. Use a
pin pusher to remove leads from the connector, if necessary. If
replacing the leads does not solve the problem, replace the RIB.

Section 3 Troubleshooting

Blown fuses. Fuses in the wiring harness protect the
controller, SCR module, and relay interface board. A
battery charger fuse is located in the positive battery
lead. Always check and replace the fuses before
replacing other components.
Incorrect controller settings. Always check the
controller configuration settings before replacing the
controller. Section 4.5 contains the instructions for
checking and changing the controller configuration.
Inadequate fuel supply.
primary or secondary
connections to the fuel solenoid valve, a damaged or
closed fuel shutoff valve, an empty LP fuel tank, or
other problems with the fuel supply. Check the fuel
supply pressure to the generator set.
Section 6.12, Fuel Systems.
Check for damaged
fuel regulators, loose
See
Reference
Generator Set
O/M
—
Section 6.15
Section 8
Section 8
Section 6.13
Section 8,
ADV-6835
Section 8,
ADV-6835
Section 4.8 or
5.7
Section 3 Troubleshooting 27