TP-6344 4/09 29Section 4 Troubleshooting
Section 4 Troubleshooting
4.1 Introduction
Use the troubleshooting charts in this section to
diagnose and correct common problems. First check for
simple causes such as a dead engine starting battery,
loose connections, or an open circuit breaker. The
charts include a list of common problems, possible
causes of the problem, and recommended corrective
actions.
If the procedures in this manual do not explain how to
correct the problem, contact an authorized Kohler
distributor/dealer. Maintain a record of repairs and
adjustments performed on the equipment. Use the
record to help describe the problem and repairs or
adjustments made to equipment.
4.2 Fault Codes
The Advanced Digital Control displays fault codes to aid
in troubleshooting. Fault codes, descriptions, and
recommended checks are listed in Figure 2-4.
Identify and correct the cause of the fault condition.
Then reset the controller after a fault shutdown. See
Section 2.4.5.
4.3 Circuit Protection
If the generator set circuit breaker trips or the fuses blow
repeatedly, contact an authorized Kohler distributor/
dealer for service.
4.3.1 Line Circuit Breaker
A line circuit breaker interrupts the generator output in
the event of a fault in the wiring between the generator
and the load. The line circuit breaker location is shown
in Figure 1-1. If the circuit breaker trips, reduce the load
and switch the breaker back to the ON position.
4.3.2 Fuses
Three 10-amp fuses are located on the junction box
near the circuit breaker panel. Four additional fuses are
located inside the junction box. See the service views in
Section 1 for the fuse locations and Figure 4-1 for
replacement fuse part numbers.
Always identify and correct the cause of a blown fuse
before restarting the generator set. Refer to Figure 4-2,
Troubleshooting Chart, for conditions that may indicate
a blown fuse. Obtain service from an authorized Kohler
distributor/dealer.
F1 Auxiliary Winding Fuse. A replaceable 10-amp
fuse protects the alternator.
F2 Relay Fuse. A replaceable 10-amp fuse protects the
engine relays. If the generator set does not crank, check
the battery and battery connections and then check the
relay fuse.
F3 Controller Fuse. A replaceable 10-amp fuse
protects the controller circuitry. If the controller display is
dark, check the battery and battery connections and
then check the controller fuse.
F4--F7 Engine Fuses. See Figure 4-1 and the
Generator Set Wiring Diagram Manual, TP-6437.
Fuse Description Part Number
F1 10 Amp Auxiliary Winding 358337
F2 10 Amp Relay Interface Board 223316
F3 10 Amp Controller 223316
F4 15 Amp Battery Charging
Alternator
283645
F5 Not used —
F6 20 Amp Main Power Relay GM39266
F7 5 Amp ECM Power, Switched 239298
Figure 4-1 Fuses
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