Alpha COM5 User Manual
Operation and Service
Commercial Generator Sets
Models:
COM5
TP-6482 8/06
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Number
Table of Contents
Product Identification Information 2............................................................
Safety Precautions and Instructions 5........................................................
Introduction 9...............................................................................
Maintenance and Service Parts 10.............................................................
Service Assistance 10........................................................................
Section 1 Specifications 11...................................................................
1.1 System Description 11....................................................
1.2 Generator Set Functional Description 11....................................
1.3 Specifications 11.........................................................
1.4 Service Views 13........................................................
Section 2 Operation 15.......................................................................
2.1 Prestart Checklist 15.....................................................
2.2 Exercising Generator Set 15...............................................
2.3 Controller Operation 16...................................................
2.3.1 Control Connections 16...........................................
2.3.2 Remote Start/Stop Connections 18.................................
2.3.3 Starting Generator Set 18.........................................
2.3.4 Stopping Generator Set 19........................................
2.3.5 Status Indicators 19..............................................
2.3.6 Fault Shutdowns 20..............................................
2.3.7 Control Resetting Procedure (Following Fault Shutdown) 20...........
2.4 Circuit Protection 20......................................................
Section 3 Scheduled Maintenance 21..........................................................
3.1 Routine Maintenance 21..................................................
3.2 Service Schedule 22.....................................................
3.3 Service Access 23.......................................................
3.4 Lubrication System 24....................................................
3.4.1 Oil Check 24....................................................
3.4.2 Engine Oil Recommendation 25....................................
3.4.3 Oil Change Procedure 25.........................................
3.4.4 Low Oil Pressure Shutdown 26....................................
3.5 Air Cleaner Element and Precleaner 26.....................................
3.5.1 Precleaner Service 26............................................
3.5.2 Paper Element Service 27.........................................
3.6 Fuel System 27..........................................................
3.7 Battery 28...............................................................
3.8 Ignition System 29.......................................................
3.8.1 Ignition System Description 29.....................................
3.8.2 Spark Plug 29...................................................
3.9 Cooling System 29.......................................................
3.10 Electronic Governor 30...................................................
3.11 Exhaust System 30......................................................
3.12 Alternator Service 30.....................................................
Section 4 General Troubleshooting 31.........................................................
4.1 Troubleshooting Chart 32.................................................
4.2 Generator Set/Controller System Troubleshooting Flowcharts 34...............
Section 5 Component Testing and Adjustment 41..............................................
5.1 Operating Generator Set Outside Enclosure 41
5.1.1 Test Equipment 41...............................................
5.1.2 Lifting Generator Set 42...........................................
5.2 Circuit Protection 43......................................................
5.3 Voltage Rectifier 43......................................................
..............................
TP-6482 8/06 Table of Contents 3
Table of Contents, continued
5.4 Electronic Governor 43...................................................
5.4.1 Governor Checks 43.............................................
5.4.2 Stepper Motor Check 44..........................................
5.5 Ignition System 45.......................................................
5.5.1 Ignition Trigger 45................................................
5.5.2 Ignition Module 46...............................................
5.5.3 Ignition Coil 47...................................................
5.6 Starter 47...............................................................
5.7 Fuel System 48..........................................................
5.7.1 Fuel Regulators 49...............................................
5.7.2 Fuel Solenoid Valve 50...........................................
5.7.3 Fuel Conversion 50..............................................
5.7.4 Fuel System Recalibration 51......................................
5.7.5 Choke 51.......................................................
5.8 Alternator 52............................................................
5.8.1 Stator 52........................................................
5.8.2 Rotor 53........................................................
5.9 Fault Shutdown Switches 53...............................................
Section 6 Controller Operation and Test 55....................................................
6.1 Sequence of Operation 55................................................
6.1.1 Starting Sequence 55.............................................
6.1.2 Running Sequence 55............................................
6.1.3 Stopping Sequence 55............................................
6.2 Control Connections 56...................................................
6.2.1 Generator Set Master Switch 56...................................
6.2.2 Remote Start/Stop Connections 56.................................
6.2.3 Status Indicators 56..............................................
6.3 Fault Shutdowns 56......................................................
6.3.1 Control Resetting Procedure (Following Fault Shutdown) 57...........
6.4 Fault Shutdown Tests 57..................................................
6.4.1 Low Oil Pressure (LOP) Shutdown 58...............................
6.4.2 High Engine Temperature (HET) Shutdown 58.......................
6.4.3 Overcrank Shutdown 58..........................................
6.4.4 Overspeed Shutdown 58..........................................
6.5 Control Board Tests 59...................................................
6.5.1 Fuel Control Circuit 59............................................
6.5.2 Speed Sensing and Governor (Throttle Control) Circuits 59............
6.5.3 Start Circuits 59..................................................
6.5.4 Ignition Circuits 60...............................................
6.6 Voltage Programming Shunt 60............................................
6.7 Control Board Replacement 60............................................
Section 7 Disassembly/Reassembly 63........................................................
7.1 Disassembly Procedure 63................................................
7.2 Reassembly Procedure 65................................................
Section 8 Diagrams and Drawings 67..........................................................
Appendix A Abbreviations 71................................................................
Appendix B Common Hardware Application Guidelines 73.....................................
Appendix C General Torque Specifications 74.................................................
Appendix D Common Hardware Identification 75..............................................
Appendix E Common Hardware List 76
.......................................................
TP-6482 8/06Table of Contents4
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has severaltypesofsafety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury,death,orsubstantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury,death,or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
equipment connected to the set,
disable the generator set as follows:
(1) Place the generator set start/stop
switch in the STOP position.
(2) Disconnect the power to the battery
charger, if equipped. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolatethe battery charger from
explosive fumes.
Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. Ifbattery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
containerwith4L(1gal.)ofwaterand
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
TP-6482 8/06 5Safety Precautions and Instructions
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
Generator set operation. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid
breathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
building unless the exhaust gas is
piped safely outside. Never operate
the generator set where exhaust gas
could accumulate and seep back inside
a potentially occupied building.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide
poisoning symptoms include but are
not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check the LP vapor gas or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble formation. A successful
test depends on the ability of the
solution to bubble.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
TP-6482 8/066 Safety Precautions and Instructions
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous Voltage/
Electrical Shock
WARNING
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Open the main circuit
breakers of all power sources before
servicing the equipment. Configure the
installation to electrically ground the
generator set and related equipment
and electrical circuits to comply with
applicable codes and standards.
Never contact electrical leads or
appliances when standing in water or
on wet ground because these
conditions increase the risk of
electrocution.
High voltage test. Hazardous
voltage can cause severe injury or
death. Follow the instructions of the
test equipment manufacturer when
performing high-voltage tests on the
rotor or stator. An improper test
procedure can damage equipment or
lead to generator set failure.
Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).
Hot Parts
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
Servicing the alternator. Hot parts
can cause severe injury or death.
Avoid touching the alternator field or
exciter armature. When shorted, the
alternator field and exciter armature
become hot enough to cause severe
burns.
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.
Moving Parts
WARNING
Hazardous voltage.
Can cause severe injury or death.
Only authorized personnel should
open the enclosure.
(600 volts and under)
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.
Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and follow the instructions of the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
Tightening the hardware. Flying
projectiles can cause severe injury
or death. Loose hardware can cause
the hardware or pulley to release from
the generator set engine and can cause
personal injury. Retorque all
crankshaft and rotor hardware after
servicing. Do not loosen the crankshaft
hardware or rotor thrubolt when making
adjustments or servicing the generator
set. Rotate the crankshaft manually in
a clockwise direction only. Turning the
crankshaft bolt or rotor thrubolt
counterclockwise can loosen the
hardware.
TP-6482 8/06 7Safety Precautions and Instructions
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.
Notice
NOTICE
Hardware damage. The engine and
generator set may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads and nuts.
NOTICE
When replacing hardware, do not
substitute with inferior grade
hardware. Screws and nuts are
available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of
markings, and metric hardware uses a
numeric system. Check the markings
on the bolt heads and nuts for
identification.
NOTICE
Electrostatic discharge damage.
Electrostatic discharge (ESD)
damages electronic circuit boards.
Prevent electrostatic discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short,to
ground.
NOTICE
Fuse replacement. Replace fuses
with fuses of the same ampere rating
and type (for example: 3AB or 314,
ceramic). Do not substitute clear
glass-type fuses for ceramic fuses.
Refer to the wiring diagram when the
ampere rating is unknown or
questionable.
TP-6482 8/068 Safety Precautions and Instructions
Introduction
This manual provides operation, troubleshooting, and
repair instructions for model Alpha 5 and COM5
generator sets and controllers.
The generator sets use a Kohlerr CV-14 engine with
modified ignition, governor, and fuel systems. Refer to
the engine service manual for engine information not
covered in this manual.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately
skilled and suitably-trained maintenance personnel
familiar with generator set operation and service.
California Emission Certification
This engine/generator is certified to operate using
natural gas or propane fuel.
This engine is certified with engine modifications made
by the generator set manufacturer.
IMPORTANT ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA PHASE 1 AND
CALIFORNIA 2006 AND LATER EMISSION
CONTROL REGULATIONS FOR SI SORE
FAMILY
DISPL (CC)
MODEL NO.
SPEC. NO.
SERIAL NO.
EMISSION COMPLIANCE PERIOD:
EPA: CARB: EXTENDED
THIS ENGINE IS CERTIFIED TO OPERATE ON:
PROPANE / NATURAL GAS
REFER TO OWNER’S MANUAL FOR SAFETY,
MAINTENANCE SPECS AND ADJUSTMENTS.
FOR SALES AND SERVICE IN US/CANADA,
CALL:
1--800--544 -- 2444
WWW.KOHLERENGINES.COM
N11236
The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the number
of operating hours for which the engine has been shown
to meet CARB emission requirements. The following
table provides the Engine Compliance Period (in hours)
associated with the category descriptor found on the
certification label.
An engine or generator set with one of the following
identification labels is certified to meet Small Off-Road
CARB Moderate, 125 Intermediate, 250 Extended, 500
Emission Compliance Period (hours)
Engine (SORE) emission standards for EPA/CARB.
Refer to certification label for engine displacement.
Exhaust Emission Control System for COM5 (CV14) is
EM.
*
* Spark-Ignited Small Off-Road Engines
TP-6482 8/06 9Introduction
Maintenance and Service Parts
Figure 1 lists some routine maintenance and service
parts for your generator set. Parts Catalog TP-6091
provides a complete list of replacement parts.
Part Description Part Number Part Description Part Number
Maintenance Parts: Test Fixtures:
Air Cleaner Foam Element 12 083 07 Controller board GM17820
Air Cleaner Paper Element 12 083 15 Cover plate GM23579
Exhaust gasket 12 041 03 Exhaust extension with test port GM23580
Fuse, 200 amp (36 volt) GM13492 Extended wiring harness GM23713
Fuse, 150 amp (48 volt) 337123 Silencer GM11509
Oil Filter 12 050 01
Spark Plug 24 132 03
Figure 1 Maintenance and Service Parts
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
D Consult the Yellow Pages under the heading
Generators—Electric
D Visit the Kohler Power Systems website at
KohlerPowerSystems.com
D Look at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product
D Call toll free in the US and Canada 1-800-544-2444
D Outside the US and Canada, call the nearest regional
office
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler Power Systems
ZI Senia 122
12, rue des Hauts Flouviers
94517 Thiais Cedex
France
Phone: (33) 1 41 735500
Fax: (33) 1 41 735501
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131
TP-6482 8/0610 Maintenance and Service Parts
Section 1 Specifications
1.1 System Description
The COM5 generator set provides reliable backup DC
power to cable TV systems or telecommunication sites
in place of, or in addition to, batteries. The COM5 is
available in 36 and 48 VDC models. The generator set
nameplate indicates the unit’s rated voltage.
The system batteries provide power at 36 or 48 volts.
When power fails, the control system signals the
generator set to start. The generator set provides DC
power for continued or reserve operation of the system.
The COM5 generator set has both local and remote
annunciation and control capabilities. The unit runs on
natural gas or LP vapor.
1.2 Generator Set Functional
Description
The COM5 generator set system consists of the
generator set (engine and generator) and the control
system. The generator set provides regulated DC
voltage to the telecommunications power system. The
control system provides complete control of the engine
and generator, accepts remote control commands, and
delivers local and remote annunciation of unit status.
Internal control functions include start and stop logic,
fault monitoring, unit voltage control, engine speed
(rpm) governing, and local LEDs for fault annunciation.
Status indicators include low oil pressure, high
temperature, overspeed, overcrank, and engine
running.
Under very light loads, the generator set operates at low
speed. As loads increase, the control system maintains
constant generator output voltage by increasing the
generator set engine speed.
The Kohler CV14 engine drives a direct-connected,
variable-speed, 3-phase, voltage-specific generator to
produce high-frequency AC power. A 3-phase, fullwave rectifier in the control system rectifies the output to
produce low-ripple, unfiltered DC power. The DC inline
fuse provides protection for downstream devices in
case of overload.
1.3 Specifications
Figure 1-1, Figure 1-2, and Figure 1-3 contain
generator set, alternator, and engine specifications.
Refer to Section 3, Scheduled Maintenance, for service
details.
Item 36 VDC 48 VDC
Manufacturer Kohler
Dimensions,
L x W x H, mm (in.)
Weight,dry,kg(lb.) 68 (150)
Rated kW* 5 3.5 or 5[
Rated voltage (after rectifier) 39 52
Rated amps 128 96
* Derate approximately 3.5% per 300 m (1000 ft.) over 600 m
(2000 ft.) above sea level. Derate 1% for each 5.5°C(10°F)
increase in temperature above 49°C (120°F).
[ Check the generator set nameplate for the kW rating.
Figure 1-1 Generator Set Specifications
Item 36 VDC 48 VDC
Stator resistance, ohms 0.014 0.024
Stator type 3-Phase, 3-Lead,
Excitation method (rotor) Permanent-Magnet,
Coupling type Direct-to-Engine
Insulation (stator) Class 155, Epoxy
Winding material Copper
Stator-to-alternator adapter bolt torque,
Nm (ft. lb.)
Flywheel-to-shaft bolt torque, Nm (ft. lb.) 67 (49.4)
Rotor-to-flywheel bolt torque, Nm (ft. lb.) 38 (28.0)
Fan-to-flywheel bolt torque, Nm (ft. lb.) 25 (18.4)
Figure 1-2 Alternator Specifications
495 x 380 x 514
(19.5 x 15 x 20.24)
Ungrounded
Brushless
Var n ish,
Vacuum-Impregnated
11 (8.1 )
TP-6482 8/06 11Section 1 Specifications
Item
Manufacturer Kohler
Make/model CV14
Cycle 4
Compression ratio 8.5:1
Displacement, cc (cu. in.) 398 (24.3)
Rated horsepower (using natural gas fuel), HP 10.5
Engine speed, rpm 2800--3600
Overspeed shutdown, rpm 3750
Bore,mm(in.) 87 (3.43)
Stroke,mm(in.) 67 (2.64)
Valve train Overhead Valve
Valve material:
Intake Steel
Exhaust Stelliter Face
Cylinders, qty. 1
Cylinder block material Aluminum w/Cast Iron Liners
Cylinder head material Aluminum
Piston rings: qty., type 2 Compression, 1 Oil
Crankshaft material Heat Treated, Ductile Iron Casting
Bearings: qty., type 2, Replaceable Sleeve
Governor Electronic
Starter motor Electric, Solenoid Shift
Lubrication system Full Pressure
Oil capacity (with filter and cooler), L (qt.) 2.0 (2.1)
Oil type (summer/winter) Synthetic 5W-30
Oil pressure, kPa (psi) 172--241 (25--35)
Low oil pressure, kPa (psi) 13.8--34.5 (2--5)
Fuel type Natural Gas or Propane
Fuel pressure, kPa (in. water column) 1.7to2.7(7to11)
Fuel consumption at 5 kW:
Natural gas, 1000 Btu/ft.
m3/hr. ( cfh)
Propane, 2516 Btu/ft.
m3/hr. (cfh)
kg/hr. (lb./hr.)
Lph (gph)
Battery voltage, VDC 12
Battery ground Negative
Battery recommendation (minimum) 425 CCA at -- 18_C(0°F)
Spark plug type (Kohler Part No.) 24 132 03
Spark plug gap, mm (in.) 0.75 (0.030)
Spark plug tightening torque, Nm (ft. lb.) 24.4--29.8 (18--22)
Ignition system Battery/Coil
Cooling system Integrated Air Cooling
High engine temperature, _C(_F)
3
3
Specification
2.3 (80)
1.1 (40);
2.1 (4.66)
4.2 (1.1)
152 (305)
Figure 1-3 Engine Specifications
TP-6482 8/0612 Section 1 Specifications
1.4 Service Views
2
1
12
4
3
5
11
6
21
13
20
+
10
Left Side View
1. Decal, engine serial number
2. Decal, emission
3. Engine interface connector
4. Engine starting battery connector
5. Ignition module
6. Engine oil fill and dipstick
7. Ignition coil
8. Spark plug (not visible)
9. Fuel supply connection (3/4 in. NPT)
10. High engine temperature (HET) sensor
11. DC output connector
12. Muffler
13. Generator set compartment outline
14. Fuel block
15. Secondary fuel pressure regulator
16. Hourmeter location
17. Fuel metering valves (sealed)
18. Oil filter
19. Exhaust pipe connection
20. Generator set control circuit board (location may vary)
21. Fuse
22. Cooling fan (inside)
23. Engine oil cooler
24. Alternator (inside)
25. Low oil pressure (LOP) switch
26. Oil drain (3/8 in. NPT)
27. Carburetor
28. Air cleaner
29. Throttle linkage
30. Governor
7
--
14
8
G
NGLP
15
16
17
9
18
19
30
Front View
22
23
24
29
28
27
25
26
Right Side View
GM14140B-AL
Figure 1-4 COM5 Service Views
TP-6482 8/06 13Section 1 Specifications
123 4
5
9
8
Left Side View
1. Engine interface connector
2. Engine starting battery connector
3. Ignition module
4. Engine oil fill and dipstick
5. Ignition coil
6. Spark plug
7. Fuel supply connection
8. High temperature (HET) sensor
9. DC output connector
10. Fuel block
11. Secondary fuel pressure regulator
12. Hourmeter location
13. Fuel metering valves, sealed
14. Oil filter
15. Exhaust pipe connection
16. Governor
17. Engine oil cooler
18. Alternator (inside)
19. Low oil pressure (LOP) switch
20. Oil drain
21. Carburetor
22. Air cleaner
23. Throttle linkage
6
10
11
12
7
15
14
13
Front View
16
23
22
21
17
18
19
20
Right Side View
ADV-6536-A
Figure 1-5 Alpha 5
TP-6482 8/0614 Section 1 Specifications
Section 2 Operation
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
Combustible materials. A fire can cause severe injury or
death. Generator set engine fuels and fuel vapors are
flammable and explosive. Handle these materials carefully to
minimize the risk of fire or explosion. Equip the compartment
or nearby area with a fully charged fire extinguisher. Select a
fire extinguisher rated ABC or BC for electrical fires or as
recommended by the local fire code or an authorized agency.
Train all personnel on fire extinguisher operation and fire
prevention procedures.
CAUTION
Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering the
engine.
Air Inlets and Outlets. Check for clean and
unobstructed cabinet air inlets and outlets. Check for
obstructions that could block the flow of cooling air.
Keep the air intake area clean. Do not leave rags, tools,
or debris on or near the generator set.
Battery. Check for clean and tight battery connections.
Consult the battery manufacturer’s instructions
regarding battery care and maintenance.
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components (exhaust
manifold, exhaust line, flexible exhaust, clamps,
silencer, and outlet pipe) for cracks, leaks, and
corrosion.
D Check for corroded or broken metal parts and replace
them as needed.
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
2.1 Prestart Checklist
To ensure satisfactory operation, perform the following
checks or inspections before or at each startup, as
designated, and at the intervals specified in the service
schedule. Some checks require verification after the
unit starts.
D Check for loose, corroded, or missing clamps and
hangers. Tighten or replace the exhaust clamps and/
or hangers as needed.
D Check that the exhaust outlet is unobstructed.
D Visually inspect for exhaust leaks. Check for carbon
or soot residue on exhaust components. Carbon and
soot residue indicates an exhaust leak. Replace or
repair leaking parts as needed.
Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
2.2 Exercising Generator Set
Operate the generator set under load weekly. Perform
all of the prestart checks before starting the exercise
procedure. Start the generator set according to the
starting procedure in Section 2.3.3. While the generator
set is operating, listen for a smooth-running engine and
visually inspect the generator set for fluid or exhaust
leaks.
TP-6482 8/06 15Section 2 Operation
2.3 Controller Operation
Microprocessor-based controls provide complete
control of the engine and generator. The control system
accepts remote control inputs for generator start and run
and delivers local and remote annunciation of unit
status. Internal functions of the controls include start
and stop logic, fault monitoring, generator voltage and
engine speed governing, and fault annunciation through
local LEDs.
A three-position generator set master switch on the
control board allows local or remote control of the
generator set. The RUN and STOP positions provide
local control of the generator set. The STOP position
also resets controller faults. The AUTO position allows a
remote device to start and stop the generator set. See
Section 2.3.2 for remote start/stop connection
information.
1
Note: Set the generator set master switch to the AUTO
position to allow remote control of generator set.
1
2
1. Generator set master switch
2. Common fault indicator LED
STOP
AUTO
RUN
FAULT
M-337000C-B
Figure 2-1 Generator Set Controls
TP6076
1. Generator set master switch
Figure 2-2 Generator Set Master Switch Location
2.3.1 Control Connections
Wiring harnesses connect the generator set control
board to the remote controls and the engine. Figure 2-3
shows the wiring harness connections to the control
board. Refer to the wiring diagrams in Section 8 for
connector pin identification. Figure 2-5 defines the
abbreviations used for the pin diagrams.
1
3
1. Cabinet interface harness
2. Generator set control circuit board
3. Engine interface harness
GM14140-AL
Figure 2-3 Generator Set Control Connections
TP-6482 8/0616 Section 2 Operation
2
Figure 2-4 Cabinet Interface Harness Connectors
Abbreviation Definition
70 Run
71 Crank
AC1 Speed sensing
AC2 Speed sensing
DCN DC negative
DCP DC positive
LOP Low oil pressure
M1 Throttle control
M2 Throttle control
M3 Throttle control
M4 Throttle control
N Ground
N/C Not connected
OVC Overcrank
OVS Overspeed
OVT Overtemperature
P Positive
STP Stop
STT Start
GM14245-A
Figure 2-5 Pin Abbreviations
TP-6482 8/06 17Section 2 Operation
Figure 2-6 Engine Interface Harness Connectors
GM14244-B
2.3.2 Remote Start/Stop Connections
To operate the generator set from a remote location, use
a three-wire start/stop switch connected to pins 5, 6, and
7 of connector P6 on the cabinet interface harness. See
the wiring diagrams in Section 8.
Set the generator set master switch to the AUTO
position for remote operation. To start the generator set,
open a contact between pins 6 and 7 and close a contact
between pins 5 and 6 of connector P6. Close the contact
between pins 6 and 7 to stop the generator set.
2.3.3 Starting Generator Set
The following procedures describe the actions required
to start the generator set.
Local Starting. Move the generator set master switch
to the RUN position to immediately start the generator
set.
Remote Starting. Move the generator set master
switch to the AUTO position to allow startup by the
remote start/stop contacts. See Section 2.3.2 for the
remote start/stop switch connections.
At initial startup, the engine’s hydraulic lifters may
produce a metallic clicking sound. This is caused by the
hydraulic lifter leakdown during storage. Run the
generator for 5 minutes. The noise will normally cease
in the first minute. If the noise continues, run the
generator at mid throttle for 20 minutes.
Note: The control board provides up to 70 seconds of
cyclic cranking before overcrank shutdown
occurs.
TP-6482 8/0618 Section 2 Operation
2.3.4 Stopping Generator Set
The following procedures describe the actions required
to stop the generator set.
Local Stopping. Move the generator set master switch
to the STOP position. The generator set stops
immediately.
Remote Stopping. Close a remote contact between
pins 6 and 7 of connector P6 of the cabinet interface
harness. The generator set shuts down regardless of
the generator set master switch position.
LED Indicates
1 Overspeed shutdown Yes
2 Overtemperature shutdown Yes
3 Engine running status indicator Ye s
4 Low oil pressure fault shutdown Yes
5 Overcrank shutdown Yes
6 Ignition energized No
7 Cranking energized No
8 Common fault indicator No
Figure 2-7 Control Board LEDs
Remote
Annunciation
2.3.5 Status Indicators
Eight LEDs on the generator set control board provide
system status and fault annunciation. LEDs indicate the
status or fault shutdowns listed in Figure 2-7.
1
R37
LED6
LED1
LED2
Common fault LED8 is located on the edge of the control
board. Figure 2-8 shows the LED locations.
2
STOP
AUTO
3
RUN
FAULT
LED3
P3
LED8
P2
LED7
P1
LED4
LED5
4
M-337000C-B
1. Control circuit board
2. Generator set master switch
3. Common fault annunciation LED
4. LEDs 1--7
Figure 2-8 Control Board LEDs
TP-6482 8/06 19Section 2 Operation
2.3.6 Fault Shutdowns
The generator set shuts down automatically under the
fault conditions listed in Figure 2-9 and cannot be
restarted until the controls are reset. Reset the
controller by placing either the remote control switch or
the generator set master switch in the STOP position.
The high engine temperature fault automatically resets
when the generator set cools.
2.3.7 Control Resetting Procedure
(Following Fault Shutdown)
Use the following procedure to restart the generator set
after a fault shutdown. Set either the remote control
switch or the generator set master switch to the STOP
position to reset the controls.
1. Move either the generator set master switch or the
remote switch to the STOP position.
Fault Description
High engine
temperature
Low oil
pressure
Overcrank Shuts down after 70 seconds of cyclic cranking.
Overspeed Shuts down immediately if the engine speed
Shuts down 5 seconds after the fault. When the
engine cools, the fault clears and allows generator
set to be started without resetting the controller.
The high engine temperature shutdown does not
function during the first 30 seconds after startup.
Shuts down 5 seconds after fault. The low oil
pressure shutdown does not function during the
first 30 seconds after startup.
Note: The low oil pressure shutdown does not
protect against low oil level.
The factory sets the circuit board for three starting
attempts: crank 20 seconds, rest 5 seconds, crank
20 seconds, rest 5 seconds, crank 20 seconds,
overcrank fault.
Overcrank shutdown also occurs in the case of a
locked rotor. Shuts down 1 second after the fault is
detected.
exceeds 3750 rpm.
Figure 2-9 Fault Shutdowns
2. Correct the cause of the fault shutdown. See the
safety precautions at the beginning of this section
before proceeding.
3. Start the generator set locally by moving the
generator set master switch to the RUN position, or
move the master switch to the AUTO position and
start the generator set using the remote start
switch. Run the generator set to verify that the
cause of the shutdown has been corrected.
4. Move the generator set master switch to the STOP
position to stop the generator set.
5. Move the generator set master switch to the AUTO
position to return to standby operation.
2.4 Circuit Protection
A DC line limiter (fuse) interrupts the generator output in
the event of a 50% overload or a short circuit in the wiring
between the generator and the load. Replace the line
limiter if it blows. See Maintenance and Service Parts in
the Introduction of this manual for the fuse part number.
TP-6482 8/0620 Section 2 Operation
Section 3 Scheduled Maintenance
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
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.
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator
set and related equipment and electrical circuits to comply with
applicable codes and standards. Never contact electrical
leads or appliances when standing in water or on wet ground
because these conditions increase the risk of electrocution.
Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.
Moving rotor.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The
engine and exhaust system components become extremely
hot during operation.
DANGER
Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.
3.1 Routine Maintenance
Refer to the following service schedule and the
hourmeter located on the generator set to schedule
routine maintenance. Perform maintenance on each
item in the service schedule at the designated interval
for the life of the generator set. Service units subject to
extreme weather, long operating hours, or dusty or dirty
conditions more frequently.
Generator set service. Have an authorized Kohler
service distributor/dealer perform all generator set
service. See the Safety Precautions and Instructions at
the beginning of this manual before attempting to
service or repair the generator set.
Engine service. Perform generator set engine service
at the intervals specified by the service schedule in this
section. For additional information contact an
authorized Kohler service distributor/dealer to obtain
engine service literature.
Generator service. Refer to the service schedule for
items that require maintenance.
TP-6482 8/06 21Section 3 Scheduled Maintenance
Tools. Tools and instruments used to perform some
3.2 Service Schedule
maintenance are not generally available to the
generator set owner. It is recommended that service
requiring special tools be performed by an authorized
distributor/dealer.
Perform the service listed in Figure 3-1 at the
designated intervals for the life of the generator set.
Refer to the service views in Section 1.4 for system
component locations.
Procedure
Visually
System Component or Procedure See Section
Fuel 3.6
Inspect flexible lines and connections. Replace
cracked or spongy hoses. *
Check the main LP tank supply level, if used. X M
Inspect fuel piping for damage or corrosion. X Y
Lubrication 3.4
Check the oil level. 3.4.1 X X M or before use
Change the oil and replace the oil filter. 3.4.2, 3.4.3 R Y or 100 hr.
Cooling 3.9
Check that air ducts and louvers are clean and
unobstructed.
Exhaust System 3.11
Check for leakage. Carbon or soot residue
indicates a leak. Repair leaks.
Check for fire hazards. X X X Y
Check for loose or broken hangers and
supports. Tighten or replace as needed.
Battery
Check battery charger operation and charge
rate (if equipped).
Clean and tighten battery terminals. 3.7 X X X Y
Electrical System
Inspect wiring and components for visible wear
or damage.
Check for abrasions where wiring is subject to
motion.
Engine And Mounting
Inspect for visible wear or damage. X M
Inspect the air cleaner element; replace it if
necessary.*
Clean and oil the foam precleaner. 3.5.1 X 100
Inspect the spark plug; replace if necessary.* 3.8.2 X R Y or 500 hr.
Control System
Check remote control operation. Controller
Generator Set
Check items listed in the Prestart Checklist. 2.1 X M
Exercise the generator set. 2.2 X W
General Condition Of Equipment
Check for signs of vibration, leakage, excessive
noise, extreme temperature, or deterioration.
Inspect and clean the cabinet interior. X X Q
* Contact your local distributor/dealer for parts or service. XAction
Battery charger
manual
3.5 X R Y or 500 hr.
manufacturer’s
instructions.
Inspect
R Replace as necessary
Check Change Clean Test
X R Q
X X X M or before use
X X R Y
X X R Y
X X M
X Q
X X S
X X X M
Frequency
X M
W=Weekly
M=Monthly
Q=Quarterly
S=Six Months
Y=Yearly
Figure 3-1 Service Schedule
TP-6482 8/0622 Section 3 Scheduled Maintenance
3.3 Service Access
Use the following procedure to gain access to the
generator set for maintenance or service. See
Figure 3-2 and Figure 3-3.
A key is required to open the enclosure. Obtain the
enclosure key from the equipment owner. Use the
following procedure to gain access to the generator set
for maintenance or service. See Figure 3-3.
Refer to the enclosure manufacturer’s instruction
manual for more information.
Note: Allow the exhaust system to cool before
disconnecting the exhaust pipe. Inspect the
exhaust gasket and replace it if necessary when
reassembling the exhaust system. See the list of
routine service parts in the Introduction of this
manual for the gasket part number.
Generator Set Service Access
1. Remove the front door of the cabinet.
6. Remove the back panel of the cabinet to gain
access to the exhaust connection near the bottom
of the unit.
7. Disconnect the engine exhaust pipe at the location
show in Figure 3-2.
8. Grasp the generator tray at the sides and pull the
generator set forward.
9. Remove the four bolts securing the generator set to
the enclosure rails. Use appropriate lifting
equipment to lift the generator set off the rails. The
generator set weighs approximately 68 kg
(150 lb.).
Note: Service fixtures are required to run the generator
set outside the enclosure. Refer to Section 5.1 for
instructions and precautions.
2. Place the generator set master switch in the STOP
position.
3. Remove the front panel from the generator set
compartment.
4. Disconnect the generator set battery harness,
engine wiring harness, and load leads at the quickdisconnect plugs.
5. Turn off the fuel supply at the upstream valve and
disconnect the fuel line on the right side of the
cabinet. See Figure 3-3.
+
--
+
--
NGLP
1
1
2
5
3
4
GM14140B-AL
1. Load lead connector
1. Exhaust connection
Figure 3-2 Exhaust Connection
2. Battery harness connector
3. Engine harness connector
4. Fuel connection
5. Exhaust pipe connection (not visible in this photo)
Figure 3-3 Generator Set Installed in Cabinet
(door and front panel removed)
TP-6482 8/06 23Section 3 Scheduled Maintenance
TP6076
Return to Operation
Slide the generator set back into the enclosure and
reconnect the exhaust pipe, fuel system, and wiring
harnesses as described below.
10. Reinstall the generator set compartment front
panel.
11. Reinstall the enclosure door.
1. Verify that the generator set master switch is in the
STOP position.
2. Slide the generator set back into the enclosure.
3. Install the exhaust gasket and reconnect the
exhaust pipe.
4. Reinstall the enclosure back panel.
5. Reconnect the fuel line and turn on the fuel supply.
6. Check for fuel leaks.
7. Reconnect the engine wiring harness, load leads,
and battery harness.
8. Reconnect the generator set engine battery
harness.
9. Move the generator set master switch to the center
(AUTO) position to return the generator set to
standby service.
3.4 Lubrication System
See the service schedule in Section 3.2 for oil change
and oil filter replacement intervals. See Figure 3-4 and
Figure 3-5 for the oil drain, oil check, oil fill, and oil filter
locations. The list of routine service parts in the
Introduction of this manual shows the oil filter part
number.
3.4.1 Oil Check
The generator set is shipped with oil. Before operating a
new generator set check the engine oil in the crankcase.
See Figure 3-4 and Figure 3-5. Verify that the oil level is
at the F mark on the dipstick. See Section 3.4.2 for
engine oil recommendations.
Do not check the oil level when operating the generator
set. To obtain the most accurate oil level reading, shut
down the generator set and wait several minutes before
checking the oil.
3
1
5
2
1. Oil check, fill
2. Exhaust pipe connection
3. Oil cooler
4. Oil drain
5. Oil filter
Figure 3-4 Lubrication System, Specification Numbers PA-195023 and PA-195027
4
M-337000B-B
TP-6482 8/0624 Section 3 Scheduled Maintenance
Loading...