Controller Flowcharts - Kohler Decision-Maker 1 Manual

3.5.2

Controller Flowcharts

Engine Will Not Crank
Engine will not crank with generator
set master switch in RUN position.
Is battery fully charged?
Yes
Press lamp test button.
Do lamps light?
Yes
Is controller LED1 lit?
No
Is emergency stop switch (controller
or remote) activated? See emergency
stopping in the generator set
operation manual.
No Yes
Reset emergency stop
switch (controller or remote).
Is LED1 lit?
No
Place test jumper between TB1-1 and
TB1-1A. Is LED1 lit? Remove test
jumper before proceeding.
No
Check for DC voltage at Fuse F2 (3 amp).
See Figure 3-19. Voltage at fuse indicates
fuse is good. Is voltage present?
No
Check fuse. Is
fuse okay?
No
Replace fuse. If fuse blows again,
refer to Section 3.5.1, Fuses.
TP-6356 4/12
No
Is DC voltage available at
No
main circuit board P1-12?
Does fuse F2 checkout okay?
Check P3/P4 harness and
connections. Are connections okay?
Yes
Replace defective indicator
panel circuit board.
Do controller LED2 and LED3 light with
generator set master switch in RUN position?
Was there a fault shutdown?
Yes
No
Replace circuit
board.
Repair/replace defective
Yes
emergency stop switch
(controller or remote.)
Yes
Replace circuit board.
Check P1 connector/harness.
Check if battery connections
Yes
are loose or reversed.
Charge battery and attempt restart.
If engine will not crank, continue
troubleshooting sequence.
No
Yes
No
Yes
Yes
No
(P1 harness, starter, solenoid,
Yes
Correct fault.
Repair defective
component.
Repair/replace
the starter motor
and/or starter
solenoid. See
service manual.
Section 3 Decision-Makerr 3+ Troubleshooting
Correct DC
voltage fault.
Replace fuse.
Replace P3/P4
No
harness.
Yes
Check engine start circuit
battery connections, etc.).
Is start circuit okay?
No Yes
Replace
circuit board.
the engine
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