Kohler EKOZD Series Service page 185

Generator makes
low voltage
Are both LEDs on
activator board
illuminated?
Yes
Remove fast-on connectors
for 60 and 62 where they enter
the harness to the to the
14-pin connector. Start the
generator set while measuring
the voltage on the 60 and 62
wires that come from the
alternator (Aux. Voltage).
Is aux voltage >25 VAC
when the generator set
is running?
Yes
With generator set off, reconnect 60
and 62. Disconnect FP and FN at the
fast-on terminals between the activator
board and the exciter field and connect
a 12-volt battery between FP and FN of
the activator board.
Is the alternator AC
output voltage above
rated voltage when
running?
Yes
Is voltage between
aux. windings 60
and 62 >40 VAC
when running?
Yes
Remove the 12-volt battery from FP
and FN to the activator board
harness. Remove 14-pin connector
from the activator board and connect
a multimeter configured for mADC
between pins (1(-) and 6 (+) of the
connector, measuring LED current.
Yes
Is LED current
>50 mA when
generator set is
running at low
voltage?
TP-6953 7/19
No
Are both LEDs on
No
the activator
board still
illuminated?
Yes
Is the AC output
of the generator
>60 VAC ?
No
No
Note: Some multimeters have a single
position on the selection dial for
measuring mA (both for AC and DC).
These meters require selection of DC by
pressing an additional button or switching
a selection switch. Make sure that the
multimeter is set to read DC current.
No
Yes
No
No
Yes
Section 10 Alternator Component Testing and Adjustment
Remove 14-pin connector
and check for battery voltage
on pins 7 and 8 when the
generator set is running. If
voltage is present, activator
board may be faulty.
Verify wiring to flash
relay for broken,
disconnected, or short
circuited wiring.
Check for loose connections
on FP and FN. Check exciter
field resistance. All models
except 4D8.3/4E8.3: 6.0 Ω
and 4D8.3/4E8.3: 7.2 Ω.
Check for loose
connections on 60, 61,
and 62.
Verify that exciter field is
connected (check wiring for
broken or disconnected wires,
field windings for dark coloring).
Remove and visually inspect
rotating rectifier module.
Check for loose
connections on 60, 61,
and 62.
Verify wiring from the
controller on 3B and 5B for
broken, disconnected, or
short circuited wiring. Verify
that controller is outputting
>50 mA at the controller
harness.
Verify that all pins are seated
in the 14-pin connector
correctly. Activator may be
damaged if receiving a target
current and supply voltage
without driving the field.
185