Kohler gen problems

[Chet Geist]

Jim,

My controller is number 259233 so that may not be of any help to you. I'm afraid your way ahead of me on the trouble shooting. I hope some of our forum experts jump in here with some ideas.

Chet Geist

1981 FC33, Austin, Texas

-----Original Message-----
From: WanderlodgeForum@yahoogroups.com [mailto:WanderlodgeForum@yahoogroups.com]On Behalf Of cortezfenn
Sent: Saturday, January 12, 2008 4:52 PM
To: WanderlodgeForum@yahoogroups.com
Subject: [WanderlodgeForum] Kohler gen problems

Thanks Chet for the advice, so here goes with all I know about the
gen:
The gen had been working fine but on the last trip home we tried
starting the gen while driving and couldn't get it started. I jumped
at throwing a new remote rocker switch in thinking the switch had
stuck closed. The reason I thought this was that the cranking reset
button in the gen compartment control box had tripped and when I
pushed in back in, the gen tried starting without doing anything.
weel, the new rocker switch didn't help. I removed the three wires at
the long connection block that go to the remote switches, still no
solution. I have 5 eleven pin relays in the control box, and saw one
that had burned a hole through the side, and replaced it. I then
visually checked for any other signs og bad wiring, nothing. The
other four relays are all the same number, so I bought one and moved
it around to each relay to find a bad one, nothing. So I think all
five relays are good. With everything hooked up except the positive
battery cable, when I connect it, engine turns over, but no start.
After a short itme, the cranking reset button trips. While it is
cranking, I have power to the fuel solenoid. So I tried a little
ether in the air filter while cranking, nothing. So now I disconnect
the wire on the S side of the starter solenoid, hook up the battery
cable and have a 10A draw on the amp guage on the front of the
control box. One of the 11 pin relays clicks, the round solenoid type
switch on the bottom of the control box also clicks and all stays
like that till the cranking reset button trips. Also, when everything
is connected and I connect the battery, it doesn't matter if the
toggle switch on the control box is in the start or stop position,
it's the same. Not really sure where to turn, I'm not in an area
where I know of a shop that might help. I have been referred to EC
POower Systems in Boise as the nearest Kohler Rep. Eric there has
been very helpful, he's the one that got me a copy of the schematic
that I believe is correct, he got it from Kohler, but it is not all
legible. It has helped some. I have controller A-259677 and the
schematic I have has a Kohler part # 259678. When I run the sequence
of connecting to battery, after the cranking button trips, the
amperage draw is 0 and it will sit forever that way.I'm not that
experienced to figure this out any more, but thought with the right
schematic, I would have something to bring to someone local and try
to get it going. Sorry for the lon message, maybe someone will read
this and know exactly what is wrong!!! Thanks, Jim