Fault Codes; Controller Troubleshooting; Battery Charger Troubleshooting - Kohler 8.5RES Operation And Installation

4.3 Fault Codes

The Advanced Digital Control displays fault codes to aid
in troubleshooting. Fault codes, descriptions, and
recommended actions are listed in Figure 2-3.
Identify and correct the cause of the fault condition.
Then reset the controller after a fault shutdown. See
Section 2.3.5.

4.4 Controller Troubleshooting

Figure 4-2 contains troubleshooting, diagnostic, and
repair information for the Advanced Digital Control.
Problem Possible Cause
Controller LED display No power to the controller:
is off
Continuous power mode jumper is disconnected
and the generator set has not run for 48 hours or
longer.
Controller fuse (F3) is blown.
Low or no battery voltage.
Generator set master switch is in the OFF/RESET
position.
Generator set master switch in AUTO but no start
command has been received since last controller
reset.
Figure 4-2 Controller Troubleshooting Chart
Problem Cause
Red LED stays y One or more defective or damaged cells.
on for more than f th
Battery charger has reduced its output voltage below
24 hours
the normal level due to a DC overload or a DC short.
Onboard DC systems are drawing more current than
the battery charger can replace.
Red and green Onboard DC systems are drawing between 1.5 and
LEDs stay on for y
5 amps.
more than th
One or more defective or damaged cells.
24 hours 24 hours
Extremely low AC voltage at the battery charger.
Green LED stays y
Open DC output fuse.
on when the h th
Faulty or contaminated terminal connections.
battery is known battery is known
to be low
One or more defective or damaged cells.
Neither of the No AC power available at the battery charger.
LEDs turn on LEDs turn on
when the AC
Component failure.
power is applied
Figure 4-3 Battery Charger Troubleshooting
20 Section 4 Troubleshooting
4.5 Battery Charger
Troubleshooting
Use the battery charger's LED indicators and the table in
Figure 4-3 to troubleshoot battery charger operation
problems.
Corrective Action
Controller display will automatically activate when a remote
start command is received or the generator set master
switch is moved to the RUN position. Connect the jumper
to maintain continuous power to the controller, if desired.
See Sections 2.3.6 and 6.9.3.
Replace the fuse. If the fuse blows again, contact the
distributor/dealer.
Check connections.
Check generator set battery and battery charger. See
Figure 4-1.
Move generator set master switch to the AUTO or RUN
position.
No action required (see Section 2.3.1). Controller display
will activate when a remote start command is received or
the generator set master switch is moved to the RUN
position. Use the remote switch to start generator set and
activate the controller display, if desired.
Solution
Load test the battery and replace, if necessary
Remove the source of the overload or short. Disconnect the
battery charger's black (NEGATIVE) ring terminal from the
battery. Reapply AC power and the green LED only should now
light.
Turn off all DC equipment while charging.
Turn off all DC equipment while charging.
Load test the battery and replace, if necessary
Apply a higher AC voltage source or reduce the length of the
extension cord.
Replace AGS-10 fuse.
Clean and tighten or repair all terminal connections.
Load test the battery and replace, if necessary.
Connect AC power or reset the AC breaker on the main panel.
Replace battery charger.
TP-6195 1/04