Kohler 12RES, Service

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TP-6196 10/09 29 Section 3 Troubleshooting
Troubleshooting Chart, continued
Problem Reference Corrective Action Possible Cause
Cranks but
does not
start,
continued
Air cleaner clogged Clean or replace. Section 2.4
Magnetic pickup Check for 1.75 volts or higher from the magnetic pickup during
cranking. A lower signal will cause the stepper motor to open
and close during cranking. Section 6.9.4
Incorrect controller
configuration Check for correct controller configuration settings. Section4.5 or
5.5
Ignition system spark
control or ignition coil Test and/or replace components. Engine S/M
Digital spark advance
ignition (DSAI)
connections
(12kW only) Connect for natural gas. Disconnect for LP.
Check for loose connections. Section 6.12.5
No engine rotation
sensed (check for an
overcrank fault
shutdown)
Check mag pickup connections, mag pickup gap, and operation. Section 6.9.4
Check for locked rotor. Section 6.4
Starts hard Low battery voltage Check battery voltage and battery charger connections, power
supply, and operation. Generator Set
O/M
Air cleaner clogged Replace element. Section 2.4
Fuel mixture adjustment
incorrect Adjust fuel valve. Section 6.12
DSAI leads incorrectly
connected or
disconnected
(12kW only) Connect for natural gas. Disconnect for LP. Section 6.12.5
Spark plug(s) Replace or regap spark plug(s). Section 2.3
Spark plug wire(s) Check spark plug wires and connections. Replace spark plug
wires. Engine S/M
Ignition components
(spark control or ignition
module) Test/replace ignition components. Engine S/M
Insufficient fuel pressure Check fuel pressure. Section 6.12.3
Worn piston rings, valves Check compression. Engine S/M
Starts but
shuts down Fault shutdown Check for a fault shutdown code on the controller’s LED display.
Correct the fault and then move the generator set master switch
to OFF/RESET to reset the controller. Section 4.4 or
5.4
Section 6.11
Stops
suddenly Fault shutdown Check for a fault shutdown code on the controller’s LED display.
Correct the fault and then move the generator set master switch
to OFF/RESET to reset the controller. Section 4.4 or
5.4
Section 6.11
No fuel Turn on fuel supply. —
Fuel line restriction Inspect fuel lines. —
Fuel lines too long Check fuel line length. Section 6.12.1
Air cleaner clogged Replace element. Section 2.4
Blown fuse Check fuses F1, F2 and F3. Replace any blown fuses. If fuse
blows again, test generator components. Section 6.13
Spark plug(s) Replace and regap plug(s). Engine S/M
Engine overheated
(hot engine only) Check air intake, fuel adjustment, oil level, air inlet/ outlet. Section 2.5
Section 2.2
Section 6.12
Low oil pressure (LOP)
switch Attempt startup. If unit shuts down, remove lead from LOP switch
and reset controller. A successful restart attempt indicates a
faulty LOP shutdown switch.
Note: Check engine oil pressure before performing test and/or
replacing LOP shutdown switch.
Section 2.2.1
Section 6.11.2