3. Remove the
12 pin connector
plug it into the
tester.
from the controller and NOTE
4. Observe the POL (polarity) lamp. Green light indicates
battery polarity is correct. If lamp does not light, check for
correct battery connection to the generator set.
NOTE
On 5.5kW, 7kW and 7.5kW sets the SAFETY
lamp will also be on. This indicates the low oil
pressure switch is functioning properly.
5. With the IGNITION switch in OFF position, press the
CRANK button. The CRANK lamp should light and the
engine should crank. If the lamp does not light, no voltage
from the battery is present.
On 5.5kW, 7kW and 7.5kW sets, the SAFETY
lamp will go off after the engine has reached
sufficient operating oil pressure.
IO. To check the high temperature cutout, low oil pressure
cutout and/or the oil level cutout for proper operation,
start the generator set and connect a jumper wire from the
cutout device to ground. The “amber” safety lamp should
light, indicating the protective circuit is functioning prop-
erly.
11. If all checks are OK, connect the 12 pin connector to
the generator set controller.
If the 15 amp fuse blows, check for defective cranking
solenoid, fuel pump or fuel solenoid, ignition coil, choke
heater, fuel shutdown control or shorted wiring.
6. Remove the air cleaner cover to observe the choke plate
during the next step.
If the 1 amp fuse blows, check for defective choke sol-
enoid or wiring.
7. Again, with the IGNITION switch in OFF position press
the crank button. While the engine is cranking, press the
CHOKE button to supply battery voltage to the choke
plate solenoid. Make sure the choke plate is functioning
properly. If not, see Section 7. Release the CRANK and
CHOKE buttons.
If the 3 amp fuse blows, check for shorted or grounded
generator rotor or defective voltage regulator.
8. With the IGNITION switch ON, start the engine, using
CRANK and CHOKE buttons as needed. If engine does not
start, see Engine Troubleshooting, Table 4-l. With engine
at operating speed, press V.B.U. (voltage build-up) button
momentarily. Check for generator output voltage. If no
output voltage is available, see Troubleshooting Gen-
erator., Table 4-2.
9. Turn the IGNITION switch to OFF position to stop the
engine.
4-3. TROUBLESHOOTING
Refer to Table 4-l for engine troubleshooting. To make
engine repairs, refer to the Kohler engine service manual
which covers the engine model. A troubleshooting chart
cannot cover every possible cause of malfunction. Always
consider every possible cause of malfunction. Knowledge
of four cycle engines and battery ignition systems can
be applied. Refer to Table 4-2 to troubleshoot the genera-
tor. The table refers to applicable paragraphs in the manual.
4-2
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