Controller Replacement - Kohler 5ECD Service Manual

10. Connect the jumper, with the resistor in series, from
the positive lead of the DC power source to terminal
G1 on the SCR module. The lamp should glow.
11. Repeat steps 9 and 10, with the positive (+) lead
and lamp connected to terminal AC2 on the SCR
module, and connecting the jumper with resister to
terminal G2.
12. If any of the above checks indicates a bad SCR
module, replace the module.

4.10 Controller Replacement

If the troubleshooting procedures in Section 3 identify a
bad controller, use the procedure in this section for
controller replacement. Always check the controller
configuration, fuse, wiring, and connections before
replacing the controller. For output voltage problems,
replace the SCR module and check the operation again
before replacing the controller.
After replacing the controller, verify that the new
controller's configuration settings match the generator
set system voltage and frequency, unit configuration,
engine type, engine data input types, battery voltage,
and communications settings. Refer to Section 4.11 for
instructions to check the controller configuration and to
change the settings, if necessary.
After the controller configuration has been checked and
set to match the generator set, use a voltmeter to check
the generator set output voltage. If the output voltage
needs adjustment, use the Voltage Adjustment
Procedure in Section 5.7.2 and the controller voltage
adjustment instructions in Section 4.11.
ADC 2100 Controller Replacement Procedure
1. Place the generator set master switch in the OFF
position.
2. Disconnect power to the battery charger, if
equipped.
3. Disconnect the generator set engine starting
battery, negative (--) lead first.
4. Remove four mounting screws from the front of the
controller.
5. Carefully pull the controller forward, angling it so
that the P1 connector on the right side clears the
opening in the mounting plate.
6. Disconnect plugs P1, P15, and P16 from the ADC
controller. See Figure 4-14.
TP-6391 9/08
7. Attach plugs P1, P15, and P16 to the new
controller.
8. Place the new controller into position and install the
four mounting screws.
9. Verify that the generator set master switch is in the
OFF position.
10. Reconnect the engine starting battery, negative (--)
lead last.
11. Reconnect power to the battery charger, if
equipped.
12. Follow the instructions in Section 4.11 to change
the new controller's configuration settings to match
the generator set system voltage and frequency,
unit configuration, engine type, engine data input
types, battery voltage, and communications
settings.
13. Use a voltmeter to check the output voltage. Follow
the instructions
Adjustment, to adjust the output voltage and
stability.
14. Place the generator set master switch in the AUTO
position if an ATS or remote start/stop switch is
used.
1
1. Engine wiring harness connector plug (P1)
2. J15 connector
3. J16 connector
Figure 4-14 Controller Connections
in Section 5.7.2, Voltage
3 2
Section 4 Controller
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