Generator Set/Controller System Troubleshooting Flowcharts - Kohler COM7.5 Service Manual

3.2 Generator Set/Controller System Troubleshooting Flowcharts

Move master switch to STOP
position to reset controller faults.
Unplug controller interface
connector to disconnect
remote control system.
Move master switch to
RUN position.
Connect the
battery.
Replace the fuse.
See Maintenance
and Service Parts.
Charge or replace the
battery and attempt to
restart. If engine does
not crank, continue
troubleshooting
sequence.
Move master switch
to the OFF position.
Check wiring
harnesses and
connections.
Reconnect, repair, or
replace wiring if
loose or damaged.
16 Section 3 General Troubleshooting
Does
engine
crank?
No
Is the battery
No
connected?
Yes
Check for a blown
No
controller fuse. See
Section 5.1. Is the
fuse good?
Yes
Check the battery
voltage. Is battery
No
fully charged?
Yes
Move master switch
to RUN position.
Does
Yes
engine
start?
Yes
Does unit stop
while master
switch is still in
AUTO?
Yes
Did a fault
Yes
shutdown
occur?
No
Go to
B
Does engine start
and run normally?
No
Check starter wiring, relay, and
motor. Check voltage to starter
relay on lead 71. See Section
4.3. Is the starter okay?
No
Repair/replace starter.
See the Engine Service
Manual.
Go to
No
A
No
Generator set is okay. The system
may have been sent a remote stop
command, or there may be a problem
with the system controller. Refer to
the system controller manufacturer's
service information.
Correct fault, reset
controller, and
continue
troubleshooting from
top of page.
Yes
Unit is okay.
Replace
controller
Yes
board.
TP-6120 5/02