Kohler 30RES

TP-6344 4/0930 Section 4 Troubleshooting
4.4 Generator Set Troubleshooting
Figure 4-2 contains generator set troubleshooting,
diagnostic, and repair information. Check for loose
connections before replacing parts.
Problem Possible Cause Corrective Action
The generator
set does not
crank.
Battery weak or dead. Recharge or replace the battery.
Battery connections reversed or poor. Check the connections.
Controller fuse (F3) blown.
Replace the fuse. Contact an authorized Kohler
distributor/dealer for service if fuse blows repeatedly.
Relay interface board fuse (F2) blown.
Engine fuses F4 or F6 blown.
Generator set master switch in the OFF
position.
Move the master switch to the RUN position.
The generator
set cranks but
does not start,
starts hard,
lacks power, or
operates
erratically.
Air cleaner clogged. Clean and/or replace the air cleaner.
Battery weak or dead. Recharge or replace the battery.
Battery connection poor. Clean and tighten the battery connections.
Spark plug wire connection loose. Check the spark plug wires.
Low oil pressure shutdown. Check the oil level.
Fuel pressure insufficient. Check the fuel supply and valves.
Engine fuse F4, F6, or F7 blown. Replace the fuse. If the fuse blows again, contact an
authorized Kohler distributor/dealer.
Engine malfunction. Contact an authorized Kohler distributor/dealer.
No AC output.
AC circuit breaker in the OFF position. Place the circuit breaker in the ON position.
AC circuit breaker tripping because of overload. Reduce the load on the generator set.
AC circuit breaker tripping because of short
circuit.
Contact an authorized Kohler distributor/dealer for
service.
Auxiliary winding fuse (F1) blown.
Replace the fuse. Contact an authorized Kohler
distributor/dealer for service if fuse blows repeatedly.
Engine fuses F6 or F7 blown.
Low output or
excessive drop
in voltage.
Generator set overloaded. Reduce the load.
Generator set
stops suddenly.
Low oil pressure shutdown. Check the oil level. Check for oil leaks.
Outoffuel. Check fuel supply.
Overcrank shutdown. Reset the controller. If the overcrank fault occurs again,
contact an authorized Kohler distributor/dealer.
Controller fuse (F3) blown.
Replace the fuse. If the fuse blows again, contact an
authorized Kohler distributor/dealer.
Engine fuse F6 or F7 blown.
Auxiliary winding fuse (F1) blown. Replace the fuse. Contact an authorized Kohler
distributor/dealer for service if fuse blows repeatedly.
Overspeed shutdown. Reset the controller. If the overspeed fault occurs again,
contact an authorized Kohler distributor/dealer.
Generator set master switch in the OFF/RESET
position.
Move the switch to the correct position (RUN or AUTO).
Remote stop command received from a remote
switch, remote digital gauge, or ATS.
Check the remote switch position.
Engine malfunction. Contact an authorized Kohler distributor/dealer.
Figure 4-2 General Troubleshooting Chart