Section 3 General Troubleshooting - Kohler COM7.5 Service Manual

This section contains generator set troubleshooting and
diagnostic information.
Use the following charts to diagnose and correct
common problems. First check for simple causes such
as a dead engine starting battery or loose connections.
Disconnect the generator set control board from the
system controller and use the generator set master
switch to operate the generator set. If the problem
persists after the system controller is disconnected, use
the troubleshooting procedures in this manual to
diagnose the problem. If the generator set operates
normally when the system controller is disconnected,
the system controller may have sent a remote stop
command or there may be a problem with the system
controller. Instruct the customer to contact the system
controller manufacturer for service information.
Note: Use an ohmmeter or continuity tester to check for
shorts or open leads in the wiring harnesses
before replacing the controller circuit board or
other system components.
Follow the enclosure manufacturer's instructions to
open or remove the enclosure, if necessary.
Maintain a record of repairs and adjustments performed
on the equipment.
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set.
cause severe injury or death.
generator set or equipment connected to the set, disable the
generator set as follows: (1) Place the generator set start/stop
switch in the STOP position. (2) Disconnect the power to the
battery charger, if equipped. (3) Remove the battery cables,
negative (--) lead first. Reconnect the negative (--) lead last
when reconnecting the battery. Follow these precautions to
prevent the starting of the generator set by the remote
start/stop switch.
TP-6120 5/02
generator set.
Accidental starting can
Before working on the

Section 3 General Troubleshooting

Hazardous voltage.
Can cause severe injury or death.
Only authorized personnel should
open the enclosure.
(600 volts and under)
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present.
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator
set and related equipment and electrical circuits to comply with
applicable codes and standards. Never contact electrical
leads or appliances when standing in water or on wet ground
because these conditions increase the risk of electrocution.
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it
cools.
Servicing the exhaust system.
severe injury or death. Do not touch hot engine parts. The
engine and exhaust system components become extremely
hot during operation.
WARNING
WARNING
Moving rotor.
Open the main circuit
WARNING
Hot parts can cause
Section 3 General Troubleshooting 13