Generator Set Troubleshooting - Kohler 12RESM1 Manual

4.3 Generator Set Troubleshooting

Figure 4-1 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 crank.
Battery charger fuse blown
Battery connections reversed or poor
Controller fuse (F3) blown
Relay interface board fuse (F2) blown
Generator set master switch in the OFF position
The generator set Air cleaner clogged
cranks but does not
Battery weak or dead
start, starts hard, lacks
power, or operates
Battery connection poor
erratically.
Spark plug wire connection loose
Low oil pressure shutdown
Fuel pressure insufficient
Engine malfunction
AC circuit breaker in the OFF position
No AC output.
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 Fault shutdown, indicated by fault code on the
controller display.
suddenly.
No fuel to generator set
Controller fuse (F3) blown
Generator set master switch in the OFF/RESET
position
Remote stop command received from a remote
switch or ATS
Engine malfunction
Auxiliary winding fuse (F1) blown
No power to the controller because:
Controller LED display
is off.
Controller fuse (F3) is blown.
Battery voltage to controller is low or zero.
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 4-1 General Troubleshooting Chart
28 Section 4 Troubleshooting
Corrective Action
Check power to the battery charger.
Recharge or replace the battery.
Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
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.
Move the master switch to the RUN position.
Clean and/or replace the air cleaner.
Check power to the battery charger.
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.
See Section 2.4.3.
Check fuel supply and piping. Contact your fuel supplier.
Replace the fuse. If the fuse blows 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.
Replace the fuse. If the fuse blows again, contact the
distributor/dealer.
Check connections.
Check generator set battery and battery charger. See
Figure 4-2.
Move generator set master switch to the AUTO or RUN
position.
No action required (see Section 2.2.1). 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.
TP-6398 4/07