Kohler 5ECD Service Manual page 18

Troubleshooting Chart
Problem Possible Cause
Generator
Weak or dead battery
set does d
Battery connections
not crank not crank
Open circuit in engine/controller
connections
Blown fuse F2, controller
Blown fuse F2, relay interface
board (RIB) b d (RIB)
Crank relay on relay interface
board (RIB)
Generator set master switch
Poor ground (--) connection
Starter
Controller
Blown F3 fuse
Blown F6 fuse
Blown F7 fuse
18 Section 3 Troubleshooting
Corrective Action
Recharge or replace battery.
Check for reversed or poor battery connections.
Check for loose connections.
Check the wire harness continuity.
Replace fuse; if fuse blows again, check circuit and
components.
, y Replace fuse.
If fuse blows again, disconnect the board leads one at a
time to identify the cause of the blown fuse:
Lead 70A
Leads FP and FN at the rotor
Repair or replace the component causing the blown
fuse.
If fuse continues to blow and the previous step did not
identify the cause, check the continuity of leads FP and
FN and the leads from the P14 connector. Replace any
bad leads. Use a pin pusher, part #241918 (large) or
241919 (small) to remove leads from the connector, if
necessary. If replacing the leads does not solve the
problem, replace the RIB.
Check connections to the RIB. Check for 12VDC to the
RIB on lead 71N.
Check for a good ground connection (lead N).
Check crank relay K2 operation (LED3). Replace the
RIB if relay does not operate.
Check connections to the master switch on the
ADC 2100.
Test function of switch.
Clean and retighten.
Check starter connections.
Rebuild or replace starter.
Check controller connections and operation. Check for
power to the controller. Move generator set master
switch to OFF/RESET and then to RUN.
Verify line circuit.
Check voltage regulator wiring.
Check wiring for open grounds or loose connections.
Also, check for pushed out pins.
Reference
Generator O/M
—
Section 7
Section 5.12
Section 7
Section 5.12
Section 7
Section 7
Section 4.6
Section 4.6
Section 7
Section 7
Section 4.6
Section 4.3
Section 5.13
Section 5.13
—
Section 7
Engine S/M
Section 4
Section 7
Section 7
Section 7
Section 7
TP-6391 9/08