Kohler 5ECD Service Manual page 21

Troubleshooting Chart, continued
Problem Possible Cause
Light Voltage stability (gain) setting
flicker
High
Incorrect controller configuration
output p
voltage lt
Incorrect controller voltage
settings
Loose voltage sensing
connections
SCR module
Controller
No output
AC output circuit breaker open
voltage
Alternator or control system
Aux. winding F1 fuse blown
SCR module
Controller
Open wiring, terminal, or pin in
buildup circuit or SCR module
circuit
Brushes
Rotor connections
Rotor slip rings dirty or corroded
Rotor (open, grounded, or
shorted windings)
Stator (open, grounded, or
shorted windings)
Flash relay (K3) on relay
interface board (RIB)
Blown F2 fuse
Blown F5 fuse
TP-6391 9/08
Corrective Action
Check and adjust the voltage stability (gain) setting
using the ADC 2100.
Check and adjust the controller configuration
parameters.
Check and adjust the controller voltage settings.
Check connections: stator leads 11 and 44 and P15
controller connection.
Check wiring and connections to the SCR module.
Check auxiliary winding fuse F1 (lead 55).
Replace SCR module and recheck voltage.
Check fuses, wiring and connections. Before replacing
controller, replace SCR module and test voltage.
Check for AC voltage on the generator side of circuit
breaker. If there is AC voltage on the generator side of
the breaker, then a problem in the load circuits is
causing the line circuit breaker to trip. Check for and
correct short circuits or overloading on the load side
before resetting the circuit breaker.
Perform separate excitation procedure to isolate the
problem to the alternator or the control system. Then
troubleshoot the alternator or control system
components as follows.
Replace blown fuse. If fuse blows again, check stator.
Check auxiliary winding fuse F1 (lead 55).
Replace SCR module and test voltage.
Check controller settings. Check wiring and
connections. Before replacing controller, replace SCR
module and check voltage.
Check continuity.
Inspect brushes and replace if worn.
Check for brushes sticking in brush holder or broken
brush spring.
Check for open circuit in rotor connection circuit (leads
FN and FP to SCR and RIB).
Check slip ring condition.
Check voltage and continuity.
Check voltage and continuity.
Check flash LED on RIB.
Check fuse F2 and troubleshoot RIB.
Replace fuse If fuse blows again, check circuit and
components.
Check ECM ground connection pin 14.
Reference
Section 5.7
Section 4.11.2
Section 5.7
Section 7
Section 4.9
Section 5.12
Section 4.9
Section 4.10
—
Section 5.2
Section 5.3
Section 5.12
Section 4.9
Section 4.11.2
Section 4.10
Section 5.13
Section 7
Section 5.6
Section 5.6
Section 7
Section 5.4
Section 5.4
Section 5.3
Section 4.6
Section 5.12
Section 7
Section 7
Section 3 Troubleshooting 21