I have a Kohler 12RESM1 whole-house generator with a 200AMP RDT, MPAC 500 Automatic transfer switch (ATS) in my home. The system was installed in 2006 and has been working great since. Several weeks ago I began noticing that the weekly tests weren't occurring on schedule and that the generator would initiate a starting crank for a couple seconds several time a day. The false starts began occurring more frequently as time progressed. (BE very careful!! You will be killed if you are not careful!! ) In order to isolate the trouble between the ATS and the generator, I disconnected the 2 start circuit wires from the ATS controller (2 wires on green connector). The problem stopped, which led me to believe the problem was the ATS controller board. The controller board in my ATS is a GM35950. After removing the board (BE very careful!! You will be killed if you are not careful!! ) and doing a little troubleshooting, I determined the trouble was the set of .47F 5V super-capacitors. These are the 2 black oval-shaped cans behind the relays that appear hot-glued together. I ordered 2 new caps from Digi-key (approx. $4.00 ea). The P/N is PB-5R0V474-R. Replacing the supercaps cured the problem. Don't be fooled, these capacitors are .47 farads, not .47 microfarads, thus the reason they're called Supercaps. They function similar to a battery in this application. Oh by the way, I ordered a couple extra Caps. They have a 1000 hour life expectancy, so I suspect I'll need to replace them again in 6-7 years. Good Luck, I wouldn't advise attempting this job unless you have the proper soldering equipment and are experienced with electronic repair. There's a company that will repair the board for $170. Try googling "Kohler GM35950 repair".
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I have a Kohler 12RESM1 whole-house generator with a 200AMP RDT, MPAC 500 Automatic transfer switch (ATS) in my home. The system was installed in 2006 and has been working great since. Several weeks ago I began noticing that the weekly tests weren't occurring on schedule and that the generator would initiate a starting crank for a couple seconds several time a day. The false starts began occurring more frequently as time progressed. (BE very careful!! You will be killed if you are not careful!! ) In order to isolate the trouble between the ATS and the generator, I disconnected the 2 start circuit wires from the ATS controller (2 wires on green connector). The problem stopped, which led me to believe the problem was the ATS controller board. The controller board in my ATS is a GM35950. After removing the board (BE very careful!! You will be killed if you are not careful!! ) and doing a little troubleshooting, I determined the trouble was the set of .47F 5V super-capacitors. These are the 2 black oval-shaped cans behind the relays that appear hot-glued together. I ordered 2 new caps from Digi-key (approx. $4.00 ea). The P/N is PB-5R0V474-R. Replacing the supercaps cured the problem. Don't be fooled, these capacitors are .47 farads, not .47 microfarads, thus the reason they're called Supercaps. They function similar to a battery in this application. Oh by the way, I ordered a couple extra Caps. They have a 1000 hour life expectancy, so I suspect I'll need to replace them again in 6-7 years. Good Luck, I wouldn't advise attempting this job unless you have the proper soldering equipment and are experienced with electronic repair. There's a company that will repair the board for $170. Try googling "Kohler GM35950 repair".