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6.2.5
Troubleshooting
Use the following flowchart as an aid in troubleshooting
the main circuit board and the entire generator set. If the
prescribed remedy does not correct the problem, the
Press the start switch
(local or remote).
Does the K2 relay LED
light while cranking?
No
Is 10-amp controller
fuse functional?
No
Yes
Replace the fuse.
Replace the circuit
board.
Figure 6-3 Troubleshooting Relay Controller Circuit Board (1 of 4)
TP-5986 4/03
Does the engine crank?
Check the battery
condition and
connections.
Yes
No
The K2 relay is
faulty. Replace
the circuit board.
Is there continuity between
N and 47 while pressing
the start/stop switch?
Yes
Is there 12 volts
at P1--14?
Yes
No
Replace or repair
the wiring harness.
Replace the
K20 relay.
circuit board may have to be replaced. Use this chart for
component testing only. Always check the continuity of
the wires between components.
Yes
No
Is the K3 relay LED lit?
Is voltage present at the K20 relay coil
(P1-4 connector)?
The K2 relay is
faulty. Replace
the circuit board.
No
Replace or repair
the wiring harness.
Is voltage present
at the starter relay?
No
Go to A
(next page).
Yes
No
Yes
Is voltage present at
the starter?
No
Replace or
Replace the starter
repair the
relay.
starter motor.
Section 6 Controller Troubleshooting
Yes
Yes
21
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Table of Contents
Troubleshooting
Need help?
Do you have a question about the 5E and is the answer not in the manual?
Questions and answers
My Kohler 5E genset will start and run when switching on the batteries. The remote start stop switch light is always on. The switch will shut off the generator but not start it. If I cycle the battery switch off then on the generator will start again. Shuts off with remote switch.
The remote start/stop switch light staying on and preventing the Kohler 5E generator from starting could be caused by several issues:
1. Faulty Switch or Wiring – A stuck or malfunctioning remote start/stop switch could keep the circuit engaged, preventing the generator from starting.
2. Low Oil Pressure Shutdown – If the low oil pressure shutdown circuit remains engaged, it could keep the generator from starting.
3. Tripped Circuit Breaker or Blown Fuse – A tripped circuit breaker or a blown fuse in the controller, battery charging, or voltage regulator circuits could prevent proper operation.
4. K20 Relay Malfunction – If the K20 relay remains energized improperly, it could keep the starter relay engaged or prevent normal starting operation.
5. Seawater Ingress – If the seacock was not closed after a failed start, seawater might have entered the exhaust system, causing additional electrical or mechanical issues.
Checking the switch functionality, relays, circuit breakers, and oil pressure circuit should help diagnose the issue.
This answer is automatically generated