Kohler 5ECD Service Manual page 20

Troubleshooting Chart, continued
Problem Possible Cause
Stops Blown F3 fuse
suddenly suddenly
(continued) Blown F5 fuse
Operates p Backfire flame arrestor clogged
erratically i ll
Spark plug(s)
Spark plug wire(s)
Fuel line restriction
Ignition system
Inadequate cooling (hot engine
only)
Carbon buildup in engine
Engine valves not seating
correctly
Lacks
Air intake restriction, inadequate
power
cooling
Generator overloaded
Spark plug(s)
Spark plug wire(s)
Engine not running at rated rpm
Engine power loss
Ignition system
Blown F5 fuse
Overheats Inadequate cooling
Backfire flame arrestor clogged
Low output Generator overloaded p
or
Incorrect controller configuration
excessive
drop in drop in
Incorrect controller voltage
voltage
settings
Alternator or control system
SCR module
Controller
Rotor (open, grounded, or
shorted windings)
Stator (open, grounded, or
shorted windings)
Brush connection
Low engine speed causing
voltage roll-off
20 Section 3 Troubleshooting
Corrective Action
Verify line circuit.
Check ECM ground connection pin 14.
Clean or replace.
Replace and regap plugs.
Replace spark plug wires.
Check fuel lines.
Test and/or replace components.
Inspect air inlet and outlet.
Clean cylinder head.
Check cylinder pressures with leakdown test. Inspect
valves and valve seats.
Inspect air intakes and exhaust for obstructions.
Check air cleaner.
Reduce load.
Replace and regap plug(s).
Replace spark plug wires.
Check controller settings for unit configuration (UC) and
engine type (EC).
Refer to the Engine Service Manual for troubleshooting
and repair instructions.
Test and/or replace.
Check ECM ground connection pin 14.
Inspect cooling system for air intake obstructions.
Clean or replace.
Reduce load.
Check and adjust the controller configuration
parameters.
Check and adjust the controller voltage settings.
Perform separate excitation procedure to isolate
problem to the alternator or the control system.
Check wiring and connections to the SCR module.
Check auxiliary winding fuse F1 (lead 55).
Replace SCR module and test voltage.
Check controller settings. Check controller fuse, wiring
and connections.
Before replacing controller, replace SCR module and
test voltage.
Test and/or replace.
Test and/or replace.
Check for loose brush connections.
Check the resistance through the brushes. Resistance
through the brushes should be low, 0.1--0.2 ohms
without meter lead resistance.
Check system voltage/frequency (Uu) and engine type
(Ec) parameters.
Troubleshoot the engine.
Reference
Section 7
Section 7
O/M
O/M
Engine S/M
—
Engine S/M
—
Engine S/M
Engine S/M
—
—
O/M
Engine S/M
Section 4.11.2
Engine S/M
Engine S/M
Section 7
—
O/M
—
Section 4.11.2
Section 4.11.2
Section 5.2
Section 5.12
Section 4.9
Section 4.11.2
Section 4.10
Section 5.4
Section 5.3
Section 5.6
Section 4.11.2
Engine S/M
TP-6391 9/08