Full Product Manual

86 TP-7092 4/23
5.7 Troubleshooting
Figure 69 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before
replacing parts.
Problem
Possible Cause
Corrective Action
Controller display
backlight is off.
Backlight turns off after about 1 minute with no activity.
Backlight will turn on when a button is pressed or the
generator set starts.
Controller display
is off.
Low or no battery voltage.
Check connections.
Check generator set battery. See the Service Views
section.
The generator set
does not crank.
Battery weak or dead.
Recharge or replace the battery. Make sure that the AC
power to the generator set controller is backed up by the
generator set.
Battery connections reversed or poor.
Check the connections.
Emergency stop switch activated.
Verify that it is safe to start the engine and apply load.
Then reset the stop switch or engine shutdown switch.
Fault shutdown.
Check the controller display for fault messages. Correct
the fault condition and reset the controller.
Generator set in the OFF mode.
Press the RUN button to start the engine or press AUTO to
allow remote starting.
Generator thermostat tripped.
Check for obstructed air inlets and outlets. Reset the
thermostat.
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 for oil leaks. Check the oil level and add oil if
necessary.
Fuel pressure insufficient.
Check the fuel supply and valves.
Engine malfunction.
Contact an authorized Kohler dealer.
No AC output.
Line circuit breaker in the OFF position.
Place the circuit breaker in the ON position.
Line circuit breaker tripping because of overload.
Reduce the load on the generator set by unplugging non-
essential appliances.
Line circuit breaker tripping because of short circuit.
Contact an authorized Kohler dealer for service.
Auxiliary winding circuit breaker tripped.
Reset the circuit breaker (located in controller’s service
access area). Contact an authorized dealer for service if
breaker trips repeatedly.
Low output or
excessive drop in
voltage.
Generator set overloaded.
Reduce the load by unplugging non-essential appliances.
Generator set
stops suddenly.
Low oil pressure shutdown.
Check for oil leaks. Check the oil level and add oil if
necessary.
No fuel.
Check fuel valves and fuel supply.
Check enclosure thermostat and reset if tripped. Check
and clear air inlets and exhaust outlets.
Overcrank shutdown.
Reset the controller. If the overcrank fault occurs again,
contact an authorized Kohler dealer.
Auxiliary winding circuit breaker tripped.
Reset the auxiliary winding circuit breaker. Contact an
authorized dealer for service if breaker trips repeatedly.
Emergency stop switch activated.
Verify that it is safe to start the engine and apply load.
Then reset the stop switch or engine shutdown switch.
Fault shutdown.
Check the controller display for fault messages. Correct
the fault condition and reset the controller.
Generator set in the OFF mode.
Press the RUN button to start the engine or press AUTO to
allow remote starting.
Remote stop command received from a remote switch,
ATS, or OnCue
®
Plus.
Check the remote switch position. Check OnCue
®
Plus.
Generator thermostat tripped.
Check for obstructed air inlets and outlets. Reset the
thermostat.
Engine malfunction.
Contact an authorized Kohler dealer.
Figure 69 General Troubleshooting