TP-5737 5/01 53Section 6 Decision-Makert 1 Controller Troubleshooting
E-254717-A
12 34
56789
1. LED1
2. K1 relay (fault)
3. K3 relay (crank/run)
4. LED3
5. LED4
6. K4 relay (crank)
7. P1 connector
8. K2 relay (run)
9. LED2
Figure 6 -9 Relay Controller Circuit Board E-254717
(COZ/CFOZ Models)
F-254717-
12 34
56789
1011
1. K5 relay (fault latch)
2. K1 relay (fault)
3. K3 relay (crank/run)
4. LED3
5. LED4
6. K4 relay (crank)
7. P1 connector
8. K2 relay (run)
9. LED2
10. LED1
11. LED5
Figure 6 -10 Relay Controller Circuit Board F-254717
(EOZ/EFOZ Models)
6.2.1 Relay Controller Flowchart
Move the
generator
set master
switch to
the RUN
position
Does the
engine crank?
Is the K2 relay
LED2 lit?
No Yes
Replace
the fuse
D Check the condition/
connections of the
start/stop switch
(N, 4, and 47). See
Wiring Diagrams
D Check the battery
condition and
connections
Do the above items
check out okay?
Yes
Is the 10-amp
fuse functioning?
Is the K4 relay
LED4 lit?
TheK2orK4relayis
inoperative. Replace
the circuit board
Verify that the K4 relay
is energized by
checking for DC
voltage at the K20
relay coil when the
start switch is in the
RUN position. Is
voltage present at the
K20 relay?
TheK4relayis
faulty—replace
the circuit
board
D Check the starter and K20
relay. See Wiring
Diagrams and the engine
service manual
D Check battery(ies). Load
test the battery(ies)
Yes
Go to
A
No
Yes
No
Yes
No
Is diode D5
open?
TheK2relayis
faulty—replace
the board
Replace
board
Yes
Repair/replace
the components
Yes
No
No
No
Is voltage present
at the starter
motor?
Yes
Check battery(ies).
Load test battery(ies).
Repair/replace the
starter motor. See
the engine service
manual.
No
Replace
the K20
relay
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