Kohler — Procedure to Disconnect the Engine Start Bypass Circuit
Repair & overhaul · engine start bypass circuit leads 4B and 4D
From a Kohler service manual — check it applies to your exact model before use.
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Before you start
- Hazardous voltage. Only authorized personnel should open the enclosure.
- Accidental starting. Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first.
Procedure
- Prevent the generator set from starting: press OFF on the generator controller.
- Disconnect power to the generator engine starting battery charger, if installed.
- Disconnect all generator engine start battery cables, negative (--) leads first.
- Perform the service disconnect procedure and the control circuit isolation procedure to remove power from the ATS controller.
- Open the ATS enclosure door and find the programmable output connections to TB1 on the back of the controller.
- Disconnect leads 4B and 4D from programmable output #1, terminals TB1-5 and TB1-6.
- Connect leads 4B and 4D together and tape securely.
- Use cable ties to secure the leads out of the way.
- Reconnect power to the control circuit.
- Use SiteTech to change the service disconnect position setting to Emergency.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Source: Kohler service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.