Controller Replacement - Kohler 15/30RES Service Manual

9. Connect the positive (+) lead from the DC power
source, with the lamp in series, to terminal AC1 on
the SCR module. The lamp should not glow.
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.

4.8 Controller Replacement

WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set.
cause severe injury or death.
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
If the troubleshooting procedures in Section 3 identify a
bad controller, use the procedure in this section for
controller replacement. Always check the controller
TP-6198 3/15
the generator set.
Accidental starting can
Before working on the
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 4.9 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 4.9.
ADC 2100 Controller Replacement Procedure
1. Place the generator set master switch in the OFF
position.
2. Disconnect power to the battery charger.
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 4-11.
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.
Section 4 Controller 39