Alpha COM5 User Manual

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Page 1

Operation and Service

Commercial Generator Sets

Models:

COM5

TP-6482 8/06

Page 2

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

Page 3

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

Page 4

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

Page 5

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

Page 6

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

Page 7

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

Page 8

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

Page 9

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

Page 10

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

Page 11

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

Page 12

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)

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

Page 13

1.4 Service Views

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

NGLP

Front View

Right Side View

GM14140B-AL

Figure 1-4 COM5 Service Views

TP-6482 8/06 13Section 1 Specifications

Page 14

123 4

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

Front View

Right Side View

ADV-6536-A

Figure 1-5 Alpha 5

TP-6482 8/0614 Section 1 Specifications

Page 15

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

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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.

Note: Set the generator set master switch to the AUTO

position to allow remote control of generator set.

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. 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

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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

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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.

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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.

R37

LED6

LED1

LED2

Common fault LED8 is located on the edge of the control board. Figure 2-8 shows the LED locations.

STOP

AUTO

RUN

FAULT

LED3

LED8

LED7

LED4

LED5

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

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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.

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Section 3 Scheduled Maintenance

WARNING

Accidental starting. Can cause severe injury or death.

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

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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 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

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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

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)

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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.

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

M-337000B-B

TP-6482 8/0624 Section 3 Scheduled Maintenance

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1. Oil check, fill

2. Exhaust pipe connection

3. Oil cooler

4. Oil filter

5. Oil drain

Figure 3-5 Lubrication System, Specification Numbers GM14140-GA1 and above

3.4.2 Engine Oil Recommendation

b. Remove the oil filter by rotating it

counterclockwise with an oil filter wrench.

Kohler Co. recommends API (American Petroleum Institute) Service Class SG, SH, or SJ 5W-30 synthetic oil. Synthetic oil oxidizes and thickens less than other

c. Clean the gasket sealing surface of the oil filter

adapter. oils and leaves fewer deposits on the engine intake valves and pistons.

3.4.3 Oil Change Procedure

d. Apply a light coat of clean oil to the rubber seal

of the new oil filter.

e. Install the new oil filter following the instructions

provided with the filter. Hand-tighten the filter. Allow the oil to cool to a safe temperature before

changing.

Note: Dispose of all waste materials (engine

oil, fuel, filter, etc.) in an environmentally

1. Follow the instructions in Section 3.3 to access the

safe manner.

generator set oil drain plug, filter, and fill tube. See Figure 3-4 and Figure 3-5.

4. Fill with oil.

M-337000B-B

2. Drain the oil.

a. Remove the oil fill cap and fill the engine to the F

mark on the dipstick. The engine oil capacity is

a. Place an oil collection container below the oil

drain and remove the oil drain plug.

b. Allow the engine oil to drain completely.

c. Replace the oil drain plug.

3. Replace the oil filter.

a. Place an oil collection container below the oil

2.0 L (2.1 qt.). See Section 3.4.2 for oil

selection.

b. Reinstall the dipstick and the oil fill cap.

5. Slide the generator set back into the cabinet and reconnect the exhaust pipe and wiring harnesses as described in Section 3.3. Do not replace the compartment front panel.

filter.

TP-6482 8/06 25Section 3 Scheduled Maintenance

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6. Check for leaks.

a. Start and run the generator set to allow the oil

pressure to reach the operating range.

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with

the air cleaner removed.

b. Check for oil leaks around the oil filter and oil

drain plug.

c. Stop the generator set and recheck the oil level.

Tighten the oil filter to stop any leaks. Add oil to bring the level up to the F mark on the dipstick.

7. Replace the generator set compartment front panel.

8. Move the generator set master switch to the AUTO position to return the unit to standby service.

9. Reinstall the cabinet door.

3.4.4 Low Oil Pressure Shutdown

The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops below a safe operating level because of oil pump failure or other malfunction. This shutdown feature does not protect against damage caused by operating with the oil level below the safe range—it is not a low oil level shutdown. Check the oil level regularly and add oil as needed.

3.5 Air Cleaner Element and Precleaner

The engine has a replaceable high-density paper air cleaner element with an oiled-foam precleaner. See Figure 3-6. Refer to the service views in Section 1.4 for the air cleaner location.

Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean.

Note: Operating the engine with loose or damaged air

cleaner components could allow unfiltered air into the engine causing premature wear and failure.

WARNING

Fire. Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

TP2974

1. Cover with knob

2. Foam precleaner

3. Short seal

4. Wing nut

5. Air cleaner element

6. Long seal

7. Stud

8. Screw (2)

9. Air cleaner base

10. Gasket

Figure 3-6 Air Cleaner Components

3.5.1 Precleaner Service

Wash and reoil the precleaner at the intervals shown in the service schedule. Wash and reoil the precleaner more often if the generator set operates in extremely dusty or dirty conditions.

1. Follow the instructions in Section 3.3 to access the air cleaner.

TP-6482 8/0626 Section 3 Scheduled Maintenance

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2. Loosen the cover retaining knob and remove the cover. Remove the precleaner from the paper element. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry.

3. Saturate the precleaner with new engine oil. Squeeze out all of the excess oil.

4. Reinstall the precleaner over the paper element.

5. Reinstall the air cleaner cover. Secure the cover with the cover retaining knob.

7. Replace all damaged air cleaner components. Check the condition of the rubber seals and replace, if necessary.

8. Clean and oil the precleaner as described in Section 3.5.1.

9. Reinstall the paper element, precleaner, and wing nut. Replace the short seal and the air cleaner cover. Secure the cover with the cover retaining knob.

10. Follow the instructions in Section 3.3 to return the generator set to service.

6. Follow the instructions in Section 3.3 to return the generator set to service.

3.5.2 Paper Element Service

Replace the paper element at the intervals specified in the service schedule. Replace the paper element more often if the generator set operates in extremely dusty or dirty conditions. Refer to Maintenance and Service Parts in the Introduction section of this manual for replacement part numbers.

1. Follow the instructions in Section 3.3 to access the air cleaner.

2. Loosen the cover retaining knob and remove the cover.

3. Remove the short seal, wing nut, and paper element with precleaner.

4. Remove the precleaner from the paper element.

Note: Do not wash the paper element or clean it

with pressurized air, as this will damage the element.

5. Replace the paper element if it is dirty, bent, or damaged.

6. Check the air cleaner base. Make sure it is secure and not bent or damaged. Remove any loose dirt or debris from the air cleaner base. Wipe the base carefully so that no dirt drops into the intake throat.

3.6 Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

A fuel solenoid valve turns the fuel supply to the fuel pressure regulator on and off. The regulator then reduces fuel pressure for delivery to the fuel metering (fuel mixture adjustment) valve. The fuel flows from the metering valve to the carburetor in a gaseous state. The carburetor mixes the fuel with intake air for consumption by the engine.

Two fuel metering valves allow field-conversion between natural gas and LP vapor. The fuel metering valves are factory-sealed to comply with applicable emission standards and to provide the best possible hot and cold starting. Do not adjust the fuel metering valves.

Have the fuel conversion procedure performed by trained and qualified personnel.

TP-6482 8/06 27Section 3 Scheduled Maintenance

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The manufacturer ships the generator set with the fuel system set for natural gas. To convert to LP gas, use the following procedure to move the fuel line from the natural gas inlet port to the LP inlet port in the fuel block (or from the LP inlet to the natural gas inlet to convert from LP to natural gas). See Figure 3-7 for the LP and natural gas fuel connection and fuel block locations. Also see the service views in Section 1.4.

7. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant, and install it into the LP (or natural gas) metering valve inlet. Do not adjust the fuel metering valves.

8. Slide the hose onto the hose fitting and secure it with the clamp.

9. Turn on the fuel supply and check for leaks using a gas leak detector.

10. Reconnect the battery harness.

11. Install the generator compartment front panel. Set the generator set master switch to AUTO position to return the generator set to standby service.

1. Battery harness connector

2. Fuel block

3. LP and natural gas metering valves

4. LP and natural gas inlet ports

Figure 3-7 Fuel System Conversion

Fuel Conversion Procedure

1. Remove the cabinet front door and the generator compartment front panel to access the fuel system.

2. Disconnect the battery at the quick-disconnect plug.

TP6076

12. Replace the cabinet door.

3.7 Battery

Use a 12-volt battery with a minimum rating of 425 cold cranking amps at --18_C(0_F). The wiring diagrams in Section 8 show the battery connections. The generator set uses a negative ground system. Make sure that the battery is connected correctly and the terminals are tight.

Note: The generator set will not start and circuit board

damage may result if the battery is connected in reverse.

Generator sets that are not used regularly require an external battery charger to keep the starting battery fully charged. Observe the battery polarity when connecting the battery charger.

All generator set models use a negative ground with a 12-volt engine electrical system. See Figure 3-8 for the location of the ground connection.

3. Turn off the fuel supply by closing the upstream valve outside of the cabinet.

4. Remove the hose clamp and fuel line hose from the fuel inlet.

5. Remove the hose fitting from the natural gas (or LP) inlet in the fuel metering valve.

6. Remove the plug from the LP (or natural gas) metering valve. Clean the plug with a dry cloth or brush, apply fresh pipe sealant, and install it into the natural gas (or LP) inlet.

1. Ground connection on chassis frame

Figure 3-8 Ground Connection

tp6092

TP-6482 8/0628 Section 3 Scheduled Maintenance

Page 29

Refer to the cabinet manufacturer’s operation and maintenance manual for battery maintenance instructions.

3.8 Ignition System

3.8.1 Ignition System Description

The generator set uses a battery-powered coil ignition system. Ignition system components include the ignition module, ignition coil, wiring, and spark plug. See the service views in Section 1.4 for ignition system component locations.

Maintain the spark plug using the instructions in Section

3.8.2. The other ignition system components do not require routine maintenance.

3.8.2 Spark Plug

Reset the spark plug gap or replace the plug with a new plug if necessary. Replace the plug at the intervals shown in the service schedule in Figure 3-1.

1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.

2. Remove the spark plug and check its condition. Verify that the insulator is a light tan or gray color. Replace the spark plug if the insulator is discolored, the plug is coated with deposits, or the electrodes are pitted or worn.

1--511

Figure 3-10 Adjusting the Spark Plug Gap

3.9 Cooling System

The air inlet and outlet vents are located near the top of the cabinet. To prevent generator set damage caused by overheating, keep the housing cooling inlets and outlets clean and unobstructed at all times.

Note: Do not block the generator set cooling air inlet or

mount other equipment above it. Overheating and severe generator damage may occur.

Figure 3-11 shows the flow of air through and around the generator set. Ducts inside the cabinet, which are not shown in this figure, direct the flow of cooling air. The generator fan draws cooling air through the opening in the back of the cabinet. The air flows into the alternator at the top of the unit and down over the engine. The air then flows up over the exhaust piping and muffler, mixes with the engine exhaust, and discharges at the cabinet outlet in the front of the cabinet.

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 in.) by carefully bending the ground electrode. See Figure 3-9 and Figure 3-10.

Figure 3-9 Checking the Spark Plug Gap

1--514

M337000B-B

Figure 3-11 Cooling Air Flow

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3.10 Electronic Governor

The governor system consists of an electronic governor control and an electromechanical actuator. The system regulates engine speed to achieve specified DC output voltage. The generator supplies a speed signal to the governor control unit in the form of AC electrical pulses. The control unit compares the frequency of these pulses to a preset reference in the speed command and provides a control signal to the actuator. The actuator controls the carburetor and hence the engine speed.

Periodically inspect the exhaust system components (exhaust manifold, exhaust line, flexible exhaust, clamps, silencer, and outlet pipe) for cracks and corrosion.

D Check for corroded or broken metal parts and replace

as needed.

D Check for loose, corroded, or missing clamps and

hangers. Tighten or replace clamps and/or hangers as needed.

Note: Do not touch or move the throttle linkage between

the actuator and carburetor while the engine is running. Manually increasing the engine speed

(rpm) can raise the output voltage high enough to damage generator and connected equipment.

3.11 Exhaust System

Remove all combustible materials from the exhaust location. Combustible materials include building materials as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material away from the exhaust outlet.

D Check for and remove loose insulation in the exhaust

duct.

D Check that the exhaust outlet is clear.

3.12 Alternator Service

Under normal operating conditions, routine alternator maintenance is not required.

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Section 4 General Troubleshooting

This section contains generator set troubleshooting and diagnostic information.

Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery or loose connections.

The generator set may be connected to a customersupplied remote control system. Disconnect the generator system from the remote control system at plug P6 and use the generator set master switch to operate the generator set. If the problem persists after P6 is disconnected, use the troubleshooting procedures in this manual to diagnose the problem. If the generator set operates normally when P6 is disconnected, the remote controller may have sent a remote stop command or there may be a problem with the remote control system. Refer to the instructions for the remote control system.

Note: Use an ohmmeter or continuity tester to check for

shorts or open leads in the wiring harnesses before replacing the controller circuit board or other system components.

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.

WARNING

Hazardous voltage. Can cause severe injury or death.

Only authorized personnel should open the enclosure.

(600 volts and under)

WARNING

Follow the instructions in Section 3.3 to remove the generator set from the enclosure, if necessary. Service fixtures are required if it is necessary to run the generator set outside of the enclosure. See Section 5.1.

Maintain a record of repairs and adjustments performed on the equipment.

WARNING

Accidental starting. Can cause severe injury or death.

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

Moving rotor.

TP-6482 8/06 31Section 4 General Troubleshooting

Page 32

WARNING

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.

Hot engine and exhaust system. Can cause severe injury or death.

Do not work on the generator set until it cools.

4.1 Troubleshooting Chart

The chart includes a list of common problems, possible causes, and recommended corrective actions.

Problem Possible Cause Corrective Action Reference

Unit does not crank Weak or dead battery Recharge or replace battery. —

Unit cranks but does not start

Engine harness connector not fully locked tight

Start switch not in the Auto position Move switch to Auto. —

Remote start cable disconnected Reconnect start cable. —

Generator set controls are not receiving the remote start command

Starter problem Test starter. Section 5.6 and

Battery connections loose, dirty or incorrect

Fault shutdown Identify and correct the cause of the fault. Reset

Controller board problem Test the board as described in Section 6.5.

Air cleaner clogged Clean or replace air cleaner. Section 3.5

Fuel problem Check fuel supply and replenish if necessary. —

Choke spring disconnected (if equipped with choke assembly)

Disconnect and reconnect. —

Check remote start cable connections and continuity. Troubleshoot remote control system.

Correct, clean, or tighten battery connections. —

the controller

Connect a spare control board to verify that the board needs to be replaced.

Verify that the fuel valve is open. —

Check that the fuel regulator opens. Section 5.7.1

Check that the throttle linkage moves freely and opens at start.

Check the fuel adjustment (oxygen sensor required for this test).

Check for the correct fuel and fuel block connection.

Connect the choke spring and check that it holds the choke open. (Many units have no choke and do not require the spring.)

—

the Engine Service Manual, TP-2339-C

Section 2.3.6

Sections 6.5 and 6.6.

Section 5.4

Section 5.7.4

Section 5.7

Section 5.7.5

TP-6482 8/0632 Section 4 General Troubleshooting

Page 33

Troubleshooting Chart (continued)

Problem Possible Cause Corrective Action Reference

Unit cranks but does not start, continued

Unit starts hard Air cleaner clogged Clean or replace air cleaner element. Section 3.5

Unit stops suddenly Air cleaner clogged Clean or replace air cleaner element. Section 3.5

Unit lacks power or operates erratically

Unit does not supply load Fuel supply problem Check for the correct fuel and fuel block

Engine noise Hydraulic lifter leakdown Run unit 5--10 minutes under load. —

Unit overheats Air openings clogged Clean intake and outlet openings. Section 3.9

Faulty spark plug Replace or regap spark plugs. Section 3.8.2

Loose spark plug wire connection Reconnect and/or tighten spark plug wire. —

Ignition system problem Test ignition system. Replace ignition module if

Weak or dead battery Recharge or replace battery. Section 3.7

Faulty spark plug Replace or regap spark plugs. Section 3.8.2

Weak or intermittent ignition module(s) Test the ignition system and replace faulty

Faulty spark plug Replace or regap spark plugs. Section 3.8.2

Fuel starvation Replenish fuel. —

Engine harness connector not fully locked tight

Fault shutdown Check controller LEDs. Correct fault and reset

Faulty shutdown switch Test switches and replace if necessary. Section 5.9

Engine harness connector not fully locked tight

Air cleaner clogged Clean or replace air cleaner element. Section 3.5

Insufficient cooling Inspect and clean cooling system. Section 3.9

Engine overload Reduce load on generator set. —

Faulty spark plug Replace or regap spark plugs. Section 3.8.2

Fuel supply problem Check valves and fuel pressure. Section 5.7

Governor system problem Check governor and throttle linkage. Section 5.4

Excessive load Check that load does not exceed rating, 3.5 or

Throttle linkage binding Check that throttle linkage is free to move and

Undervoltage Check that voltage with no load is 52 volts (48 V

Air cleaner clogged Clean or replace air cleaner element. Section 3.5

Overload Verify that load is within the specified range.

faulty.

components.

Disconnect and reconnect. —

controller. Test shutdown operation.

Disconnect and reconnect. —

connection.

5kW.

open while engine is running.

models) or 39 volts (36 V models).

Reduce load.

Sections 6.5.4 and 5.5

Section 5.5

Sections 6.2.3,

2.3.6 and 6.4

Section 5.7

—

Section 5.4

Section 5.3

Section 1.3

TP-6482 8/06 33Section 4 General Troubleshooting

Page 34

4.2 Generator Set/Controller System Troubleshooting Flowcharts

Move master switch to STOP

position to reset controller faults.

Unplug cabinet interface

connector (P6) to disconnect

remote control system.

Move master switch to

RUN position.

Connect the

battery.

Charge or replace the battery and attempt to restart. If engine does

not crank, continue

troubleshooting

sequence.

Move master switch to the OFF position.

Check wiring

harnesses and

connections.

Reconnect, repair, or

replace wiring if

loose or damaged.

Check the battery

voltage. Is battery

Does engine crank?

Is the battery

connected?

Yes

fully charged?

Yes

Does

engine

start?

Yes

Does unit stop

while master

switch is still in

AUTO?

Yes

Didafault

shutdown

occur?

Go to

Generator set is okay. The system may have been sent a remote stop

command, or there may be a

problem with the remote control

system. Refer to the instructions

for the remote control system.

Correct fault, reset

controller, and

Yes

troubleshooting from

top of page.

Go to

continue

Move master switch

to RUN position.

Does engine start and run normally?

Check starter wiring, relay, and

motor. Check voltage to starter

relay on lead 71. See Section

5.6. Is the starter okay?

Repair/replace starter.

See the Engine Service

Manual.

Yes

Unit is okay.

Replace

controller

board.

TP-6482 8/0634 Section 4 General Troubleshooting

Page 35

Is fuel supply

turned on?

Yes

Is fuel supply

low?

Yes

Check/replenish fuel

supply.

Turn on fuel supply.

Is gas pressure to system

within specifications?

Yes

Has the air been purged

from the fuel lines?

Yes

Is there an audible click

indicating fuel solenoid opening

when the unit starts to crank?

Yes

Is the fuel hose

pinched?

owner correct fuel

pressure problem.

Have the fuel supply

Have gas provider or

installer purge the fuel

lines.

Check/repair wiring.

Yes Correct the problem.

Does unit start?

Is there a spark?

Yes

Is the air cleaner

dirty or plugged?

Yes

Clean/replace air cleaner elements

Yes

Didafault

shutdown

Go to

occur?

Yes

Correct the fault and reset the

controller.

Ignition system problem.

Refer to Section 5.5.

Engine problem. See the

engine service manual.

TP-6482 8/06 35Section 4 General Troubleshooting

Page 36

Does unit stop

Does unit lack power

or operate erratically?

Yes

while master switch

is in AUTO and

remote control

system is

disconnected?

Yes

Disconnect and

reconnect the harness

to verify a good

connection.

Repair/replace

harness.

Go to

Unit is okay

Does unit stop after

running normally?

Yes

Go to

TP-6482 8/0636 Section 4 General Troubleshooting

Page 37

Ensure that the main connector is tightly connected.

Lacks Power or Runs Erratically

Is any controller fault LED

lit?

Yes

Correct fault

and resume

troubleshooting.

Check the battery charging

Has air

been purged

from fuel

Have fuel supply

installer purge air.

system.

lines?

Is fuel

Yes

pressure 7-11

in. water?

Yes

Aresparkplugwire

connections okay?

Yes

Are spark plugs okay?

See Section 3.8.2.

Yes

Does the battery lose

charge while the

system is running?

Have fuel supply installer

correct fuel pressure

problem.

Reconnect and/or

tighten.

Regap or replace.

Possible generator set

Reduce the load to keep it within the rated range.

TP-6482 8/06 37Section 4 General Troubleshooting

Yes

overload. Does reducing

load solve problem?

(Open circuit breaker to

reduce load.)

Go to

Clean or replace air

cleaner elements.

Is air cleaner

plugged?

Yes

Page 38

Lacks Power or Runs Erratically, continued

Is fuel solenoid and wiring okay?

Yes

Is fuel pressure regulator okay?

Verify that output pressure to

engine is at zero—the engine

must draw gas from regulator.

Yes

Check the fuel adjustment using

an oxygen sensor. See Section

5.7. Is the fuel adjustment correct?

Yes

Test the ignition system. See

Section 5.5. Ignition problem?

Yes

Repair/replace faulty components.

Replace pressure regulator.

Adjust fuel

metering valve.*

Repair/replace ignition

components as needed.

Check the throttle linkage.

See Section 5.4. Throttle

linkage binding?

Yes

Repair throttle linkage.

Check carburetor. See the

engine service manual for

carburetor service

information.

* Adjusting the fuel system may void the emissions certification. Only trained and authorized service technicians should

adjust the fuel system. Use the test equipment specified in the test procedure in Section 5.7.

TP-6482 8/0638 Section 4 General Troubleshooting

Page 39

Unit Stops After Normal Operation

Possible intermittent wiring

problem or control board

malfunction. Check all

wiring and components.

Start the unit. Does it stop

after normal operation?

Yes

Is controller

fault LED lit?

Are alternator output leads

connected to AC terminals

on the rectifier?

Yes

Is air cleaner

plugged?

Are spark plug and

wires okay?

Yes

Done.

Correct the fault and reset

the controller.

Connect/repair/replace

alternator output leads.

Clean/replace

air cleaner

elements.

Replace or regap spark

plugs. See Section 3.8.2.

Are fuel solenoid and wiring okay?

Repair/replace

fuel solenoid

and/or wiring.

Yes

Is fuel adjustment

correct? See Section

5.7.4.

* Adjusting the fuel system may void the emissions certification. Only trained and authorized service technicians should

adjust the fuel system. Use the test equipment specified in the test procedure in Section 5.7.4.

TP-6482 8/06 39Section 4 General Troubleshooting

Adjust the fuel

metering

valve.*

Page 40

Notes

TP-6482 8/0640 Section 4 General Troubleshooting

Page 41

Section 5 Component Testing and Adjustment

Use the troubleshooting procedures in Section 4 and the wiring diagrams in Section 8 to diagnose problems with the generator set operation. For controller operation and test, refer to Section 6 of this manual and to the remote control manual. Use the procedures in this section to check generator components for proper operation and adjust components when necessary. See the service views in Section 1.4 for component locations.

DANGER

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

5.1 Operating Generator Set Outside Enclosure

CAUTION

Hazardous noise. Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

WARNING

Fire. Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with

the air cleaner removed.

The generator set is mounted on rails inside the enclosure. Follow the instructions in Section 3.3 to open the enclosure, disconnect the generator set, and slide it out for removal or service.

5.1.1 Test Equipment

The following test equipment, available from Kohler Co., is required to run the generator set outside the enclosure:

D Cover plate D Exhaust pipe extension with test port D Oxygen sensor (for testing the fuel system) D Silencer D Control board D Extended wiring harness

See Maintenance and Service Parts in the Introduction section of this manual for the part numbers for the test equipment.

Before running the generator set outside the enclosure:

WARNING

D Set the generator set on the fixture, aligning the

generator set mounting holes with the four pins on the fixture.

D Place the cover over the top of the generator to

prevent contact with rotating parts. Tie the cover to

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

TP-6482 8/06 41Section 5 Component Testing and Adjustment

Moving rotor.

the generator set’s lifting eye and one of the bolts that secure the rectifier cover.

Page 42

D Attach the exhaust pipe extension to the silencer.

Verify that the test port is plugged or install the oxygen sensor in the port if needed for fuel adjustments. See Figure 5-1.

tp6092

1. Oxygen sensor

2. Exhaust tube GM23580

Figure 5-1 Exhaust Tube and Oxygen Sensor

D Connect a starting battery to the terminals shown in

Figure 5-2. Connect the negative lead last.

5.1.2 Lifting Generator Set

The generator set weighs approximately 68 kg (150 lb.). Use adequately rated equipment to lift the generator set. The generator set has two lifting eyes. Connect lifting hooks to the two lifting eyes and use a strap to support the other end of the generator set. Thread the strap under the wiring harnesses and over the hoses as shown in Figure 5-3 and Figure 5-4, taking care not to damage the throttle linkage.

D Connect a silencer to the output end of the exhaust

pipe extension.

D Connect the engine/controls interface connector P4

to the control board. Use the extension harness if the extra length is needed. See Figure 5-2.

tp6092

1. Straps

2. Lifting eye 3. Throttle linkage location

Figure 5-3 Lifting Generator Set, Air Cleaner Side

1. Battery negative (--) connection to ground

2. Engine/controls interface connector P4

3. Battery positive (+) connection to starter relay

Figure 5-2 Connections

GM14140B-V

tp6092

1. Lifting straps 2. Wiring harnesses 3. Lifting eye

Figure 5-4 Lifting Generator Set, Starter Side

TP-6482 8/0642 Section 5 Component Testing and Adjustment

Page 43

5.2 Circuit Protection

A fuse on the output (DC) side of the voltage rectifier interrupts the generator output in the event of a 50% overload or a short circuit in the wiring between the generator and the load. See Figure 5-5. Replace the fuse if it blows. See Maintenance and Service Parts in the Introduction of this manual for the fuse part number.

1. Voltage rectifier

2. AC input side (stator leads)

3. DC output side (output leads)

4. Output fuse

6092-33

Figure 5-5 Voltage Rectifier and Fuse

5.3 Voltage Rectifier

The microprocessor controller monitors the DC output voltage. To verify accurate voltage control, increase and decrease loads while measuring DC output voltage at the output connector. The output voltage should remain fairly steady at the rated voltage as the engine speed increases or decreases in response to load changes.

If voltage falls below the rated value as load increases or decreases, check for the following problems:

D Inadequate fuel supply D Fuel solenoid malfunction D Fuel metering valve malfunction D Stepper motor/throttle linkage binding

5.4 Electronic Governor

The system uses a variable-speed generator to maintain the rated output voltage with varying loads. The governor system regulates the engine speed with changing loads.

The governor system consists of an electronic governor control and an electromechanical actuator. Leads AC1 and AC2 provide a speed (frequency) signal from the AC side of the voltage rectifier (terminals E and C) to the control board. The control board signals the actuator, which controls the throttle and hence the engine speed, to maintain the generator nominal output voltage.

The voltage rectifier converts AC voltage from the alternator into DC voltage. Figure 5-6 shows the rectifier schematic.

Figure 5-6 Rectifier Schematic

If there is no DC voltage at the output connector, check the fuse (see Figure 5-5). Test for output at the rectifier to check the output leads. Check for AC voltage into the rectifier. If there is AC voltage coming into the rectifier, but no DC output, replace the rectifier. The voltage rectifier has no adjustments.

5.4.1 Governor Checks

The factory-set electronic governor does not normally require adjustment. If the engine operates erratically, check the following connections and conditions before adjusting the governor:

D Check the electrical connections and wire harnesses

for clean, tight connections.

D Check the speed-sensing connections at rectifier

terminals C and E. Poor connections may cause an erratic signal, which could cause the unit to shut down.

D Check the electrical ground connections.

D Check the battery connections. Verify that the

connections are clean and tight.

D Check for a good positive 12-volt DC supply. Also

check if the positive voltage supply is unstable or

TP-6482 8/06 43Section 5 Component Testing and Adjustment

Page 44

below 8 volts DC making the control unit function erratically.

D Check for stepper motor/throttle shaft linkage binding

or wear. The linkage arm and lever arms must not bind or rub against other components while moving.

D Verify that the governor stepper motor operates with

steady and smooth movement. If the movement of the stepper motor is erratic or large changes in movement occur, check for shaft misalignment, linkage binding, or loose or broken wiring or plug connections.

D Check carburetor for dirt, grime, or misadjustment.

Also, check the idle-adjustment screw. The screw should not prevent the throttle plate from completely closing. Also, check the throttle linkage for any binding, dirt, damage, etc.

Note: Often hunting/surging problems thought to be

caused by the governor are actually linked to carburetor adjustment. Check the carburetor adjustment before adjusting the governor.

The fuel shutoff solenoid deenergizes and generator set shuts down with the following electronic governor faults:

D If the throttle linkage binds or otherwise does not

operate smoothly, check the bushing shown in Figure 5-7 and Figure 5-8. The bushing has a longer slot on one side that must be oriented as shown in Figure 5-7.

tp6092

1. Bushing in the correct orientation, with long slot facing the viewer

D Loss of pickup while running (throttle moves to closed

position)

D Engine overspeed D Break of fuel shutoff solenoid lead D Loss of DC power to governor assembly D Break of stepper motor leads (erratic performance) D Actuator linkage failure (erratic performance)

If none of the above conditions exist, proceed to Section 5.4.2, Stepper Motor Check.

5.4.2 Stepper Motor Check

Use the following procedure to test the operation of the governor stepper motor.

Stepper Motor Test Procedure

1. Stop the generator set and disconnect the battery.

2. Manually move the governor linkage fully counterclockwise (open throttle). See Figure 5-9.

Figure 5-7 Correct Bushing Rotation

1. Bushing in the wrong orientation

Figure 5-8 Incorrect Bushing Rotation

tp6092

1. Electronic governor stepper motor

2. Carburetor throttle linkage

TP5632721

Figure 5-9 Stepper Motor Throttle Linkage

TP-6482 8/0644 Section 5 Component Testing and Adjustment

Page 45

3. Reconnect the battery. The stepper motor should move clockwise to the closed-throttle position with a noticeable clicking sound. If the stepper motor does not stay in the closed-throttle position, replace the stepper motor.

Only two stepper motor leads of each coil group are utilized (BLACK-YELLOW and RED-WHITE). The resistance per phase is 38.5 ohms. See Figure 5-10.

BLK

YEL

GRN

Check the continuity of the spark plug lead. Check the condition of the lead insulation and spark plug boot. Refer to Section 3.8.2 for additional spark plug information.

Figure 5-12 shows some ignition specifications.

Item Specification

Trigger gap 1.02 mm (0.040 in.)

Trigger coil resistance:

Part no. GM17721 Part no. GM23592

Timing 28° BTDC

Spark plug gap 0.76 mm (0.030 in.)

190--205 ohms 320--360 ohms

RED

WHT BLU

SB555

Figure 5-10 Actuator Coil Group

5.5 Ignition System

The breakerless ignition system includes a battery ignition coil, electronic ignition module, and an ignition trigger coil. See Figure 5-11. The ignition module electronically interrupts battery voltage to the primary coil winding, inducing high voltage in the secondary winding and producing the spark at the spark plug.

BLK

Figure 5-12 Ignition System Specifications

5.5.1 Ignition Trigger

Two types of trigger coils are used. One type, part number GM17721, has a resistor connected to the trigger coil cable. See Figure 5-13. Use trigger coil GM17721 only with ignition module 278903. The other coil, GM23592, has no resistor in the wiring. The ignition module part number is stamped on the back of the module. Use coil GM23592 only with ignition module GM23591, which has an internal resistor. See Section 5.5.2 for more information on ignition modules.

BATT

1. Resistor, used on GM17721 only.

Figure 5-13 Trigger Coil GM17721 (use with ignition

module 278903)

tp6092

1. Flywheel magnet

2. Ignition trigger

3. Ignition module

4. Run relay (not replaceable)

5. Spark plug

6. Ignition coil

Use an ohmmeter to check trigger coil resistance and compare the measured value to resistances shown in Figure 5-12. An open coil will produce a reading of 470 ohms. If trigger coil is open or shorted, replace it.

Figure 5-11 Ignition System

TP-6482 8/06 45Section 5 Component Testing and Adjustment

tp6092

Page 46

Use a feeler gauge to check gap between ignition trigger coil and flywheel. See Figure 5-14 and Figure 5-15. Verify that the gap is set to 1.02 mm (0.040 in.).

Note: The ignition module must be matched with the

appropriate trigger coil. See Section 5.5.1 for information.

1. Ignition trigger

Figure 5-14 Ignition Trigger

1. Ignition trigger

Figure 5-15 Ignition Trigger Adjustment

TP6092

1. Ground connection

2. Ignition module

3. Ignition coil

Figure 5-16 Ignition Components

Terminals Ohmmeter Indication Part Number 278903

W--G 10 kOhms

B--Ground 850 ohms

C--Ground Diode check: Open circuit in one direction,

Part Number GM23591

W--G 450 Ohms

B--Ground 850 ohms

C--Ground Diode check: Open circuit in one direction,

approximately 2.7 mOhms with the test leads reversed.

GM14140B-V

5.5.2 Ignition Module

Use an ohmmeter to measure the resistances across the ignition module terminals. See Figure 5-16 and Figure 5-17. The ignition module part number is stamped on the back of the module. If the measured resistances do not match those shown in Figure 5-17, replace the module.

Figure 5-17 Ignition Module Resistances

Apply a thin coating of thermal compound between the mounting pad and the module to ensure good heat transfer. Connect the ground wire to the system ground.

TP-6482 8/0646 Section 5 Component Testing and Adjustment

Page 47

5.5.3 Ignition Coil

5.6 Starter

Use an ohmmeter or a test lamp to check the ignition coil primary winding. Measure the resistance across the positive (+) and negative (--) terminals and from one terminal to ground. If the test shows that the winding is open or grounded, replace the ignition coil.

Disconnect the high tension lead from the engine spark plug and connect it to a test spark plug. Disconnect lead C from the ignition module. Move the generator set master switch to START. Ground lead C and watch the test plug for sparks. If no sparks are produced the ignition coil secondary winding is faulty. Replace the ignition coil.

R37

Check the starter if the generator set engine does not crank.

Check the battery voltage and connections before proceeding. Check for a locked rotor or other fault condition that may have shut down the unit. Correct the fault condition and reset the controller to clear a fault shutdown.

Note: Always check the wiring and connections before

replacing components.

The crank cycle attempts to start three times, cranking for 20 seconds and then resting for 5 seconds between attempts. LED 7 on the control board lights to indicate that cranking is energized. LED 5 indicates an overcrank shutdown; reset the controller if LED 5 lights during these tests. See Figure 5-18.

LED8

STOP

AUTO

RUN

FAULT

1. Control circuit board

2. LED locations

3. Voltage adjustment pot

Figure 5-18 Controller Board

LED7

LED6

LED1

LED3

LED4

LED2

LED5

4. Generator set master switch, 3-position

5. Common fault indicator, LED8

M-337000C-B

TP-6482 8/06 47Section 5 Component Testing and Adjustment

Page 48

Move the generator set master switch to Start and check for 12 VDC to the starter relay on lead 71 during the crank attempt. See Figure 5-19. If there is no voltage to the starter during the crank cycle, check the connections. Then check for voltage from the controller at J4-1 and P2-1 (see the wiring diagram, Section 8). If there is no voltage at P2-1 during cranking, replace the control board.

If there is voltage to the starter motor but the starter motor does not crank the engine, refer to the Engine Service Manual for starter service information. The generator set engine uses an inertia-drive electric starter.

5.7 Fuel System

1 2 3

tp6092

1. Starter motor

2. Lead 71 (energized during cranking)

3. Starter relay (crank relay)

Figure 5-19 Starter Components

To test the starter relay, check for 12 VDC to the starter motor during the crank attempt. If there is voltage to the relay but not to the starter motor, check the connection between the relay and the starter motor. If the connection is good, replace the relay.

Generator sets with serial numbers above 2094977 use a waterproof starter solenoid. Use service kit GM40989 to replace the starter solenoid on earlier units. See TT-1437.

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

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

TP-6482 8/0648 Section 5 Component Testing and Adjustment

Page 49

5.7.1 Fuel Regulators

The typical gaseous fuel system uses two regulators. The primary regulator reduces the line pressure to an allowable inlet pressure for the secondary regulator. The fuel supplier provides and maintains the primary regulator. The secondary regulator is factory-installed on the generator set and is designed for a maximum inlet pressure of 2.7 kPa (6 oz./in. column).

Do not try to adjust the fuel pressure, fuel mixture, or engine speed using the fuel lock-off. See Figure 5-20 for the location of the fuel lockoff. The fuel lock-off prevents fuel flow when the engine is not operating.

) or 280 mm (11 in. water

Checking the Fuel Pressure

Use a gauge or manometer to check the fuel pressure at the secondary regulator inlet. See Figure 5-20. Measure the fuel pressure with the generator set running at full load. The fuel pressure should be 178--280 mm (7--11 in. water column) or 1.7--2.7 kPa (4--6 oz./in.

). Contact the fuel supplier if the inlet

pressure is not within the specified range.

Note: Do not attempt to adjust the fuel mixture or engine

speed by adjusting the regulators.

1. Secondary pressure regulator

2. Dual-fuel block

3. Carburetor

4. Inlet pressure check location (plug)

5. Fuel inlet

6. Fuel metering valves

7. Fuel lockoff (Do not adjust.)

Side View

Top V i e w

End View

Side View

GM14140B-K

Figure 5-20 Fuel System

TP-6482 8/06 49Section 5 Component Testing and Adjustment

Page 50

5.7.2 Fuel Solenoid Valve

Fuel Conversion Procedure

The fuel solenoid valve is located on the outside of the enclosure. It is a 12 VDC valve energized by lead 70 when the generator set controller is in the crank or the run mode. The fuel solenoid valve is supplied with the enclosure.

tp6092

Figure 5-21 Fuel Solenoid Valve

1. Remove the enclosure front door and the generator compartment front panel to access the fuel system.

2. Move the generator set master switch to the STOP position.

5.7.3 Fuel Conversion

Two fuel metering valves allow field-conversion between natural gas and LP vapor. Have the fuel conversion procedure performed by trained and qualified personnel.

Note: Do not adjust the fuel metering valves. The fuel

metering valves are factory-sealed to comply with applicable emission standards and to provide the best possible hot and cold starting.

The manufacturer ships the generator set with the fuel system set for natural gas. To convert to LP gas, use the following procedure to move the fuel line from the natural gas inlet port to the inlet port in the LP fuel metering valve (or from the LP inlet to the natural gas inlet to convert from LP to natural gas). See Figure 5-22 for the LP and natural gas fuel connection and fuel block locations. Also see the service views in Section 1.4.

TP6076

1. Battery harness connector

2. Fuel metering valves

3. LP and natural gas inlet ports

Figure 5-22 Fuel System Conversion

3. Disconnect the battery at the quick-disconnect plug.

4. Turn off the fuel supply by closing the upstream valve outside of the enclosure.

5. Remove the hose clamp and fuel line hose from the fitting in the fuel metering valve.

6. Remove the hose fitting from the natural gas (or LP) inlet in the fuel metering valve.

7. Remove the plug from the LP (or natural gas) inlet. Clean the plug with a dry cloth or brush, apply fresh pipe sealant, and install it into the natural gas (or LP) inlet.

TP-6482 8/0650 Section 5 Component Testing and Adjustment

Page 51

8. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant, and install it into the LP (or natural gas) inlet.

9. Slide the hose onto the hose fitting and secure it with the clamp.

10. Turn on the fuel supply and check for leaks using a gas leak detector.

11. Reconnect the battery harness.

12. Install the generator compartment front panel. Set the generator set master switch to the AUTO or center position to return the generator set to standby service.

13. Replace the enclosure door.

5.7.4 Fuel System Recalibration

The fuel metering valves are factory-set to meet emissions requirements and sealed to discourage field adjustments. If the fuel system requires recalibration, only trained, authorized service technicians may adjust the fuel metering valves. Always use an oxygen sensor and an exhaust tube with an oxygen sensor port, available from the generator set manufacturer, when adjusting the fuel metering valves.

Note: Changing the fuel system adjustments may void

the emissions certification.

1. Oxygen sensor

2. Exhaust tube GM23580

tp6092

Figure 5-23 Exhaust Tube and Oxygen Sensor

5.7.5 Choke

Some engines are equipped with a choke, which is held open at all times by the choke spring shown in Figure 5-24.

If the engine is equipped with a choke, identified by the knob shown in Figure 5-24, check that the spring is attached and holding the choke open.

Fuel system recalibration requires the following equipment, which is available from Kohler Co.:

D Oxygen sensor D Test exhaust pipe with oxygen sensor port

See Maintenance and Service Parts in the Introduction section of this manual for the equipment part numbers.

Follow the instructions in Section 5.1 to remove the generator set and operate outside the enclosure.

Fuel System Recalibration Procedure

1. Run the generator set at full load and check the oxygen sensor reading. At full load, the oxygen sensor output voltage should be between

0.75 VDC and 0.85 VDC.

2. If adjustment is required, remove seal on the fuel metering valve and adjust the valve to obtain an oxygen sensor reading between 0.75 VDC and

0.85 VDC. See Figure 5-20 for the fuel metering valve location.

3. Reseal the valve after adjustment.

1. Choke spring

2. Choke knob

TP5632721

Figure 5-24 Choke Assembly (not included on all

engines)

Generator sets built after June, 2001, do not have a choke assembly and, therefore, do not require the spring. Choke solenoid service kit GM42302 can be installed to improve engine starting in cold weather. See TT-1422 for more information.

TP-6482 8/06 51Section 5 Component Testing and Adjustment

Page 52

5.8 Alternator

The alternator is connected directly to the engine. The alternator uses a permanent magnet rotor and a 3-lead 3-phase stator. See Figure 5-25.

243

Stator Test Procedure

1. Disconnect the power to the battery charger, if equipped.

2. Disconnect the generator set engine starting battery, negative (--) lead first.

3. Disconnect output connector P8 from the load. See Figure 5-27.

4. Disconnect the stator leads from the voltage rectifier. See Figure 5-27.

Note: Disconnect all stator leads from the voltage

rectifier before performing the test.

5. Set the ohmmeter on R x 1 scale. Touch the red meter lead to the black lead and adjust the ohmmeter to show zero ohms.

TP--6092

1. Stator

2. Rotor

3. Flywheel taper

4. Spacer

Figure 5-25 Alternator (shroud and fan removed to

show components)

5.8.1 Stator

The stator contains coils of wire laid in a laminated steel frame. The three stator leads are connected together in a wye configuration. See Figure 5-26.

GM11539

Figure 5-26 Stator Windings

The stator leads supply voltage to the voltage rectifier and the speed-sensing circuit. Before testing, inspect the stator for heat discoloration, visible damage to housing lead wires, exposed coil windings, or exposed areas of frame laminations. Use an ohmmeter to check the continuity of the stator windings using the following procedure.

1. Output connector P8

2. Voltage rectifier

3. Stator leads (AC Side)

M-337000B

Figure 5-27 Stator Lead Connections to Rectifier

TP-6482 8/0652 Section 5 Component Testing and Adjustment

Page 53

6. Check the cold resistance of the stator windings by connecting the meter leads to stator leads 1 and 2, 1 and 3, and 2 and 3. See Figure 5-28 for stator winding resistance values. Replace the stator if any of the resistance checks reveal an open winding. If the resistance test is not conclusive, perform a megohmmeter test on the stator as described in step 7.

5.9 Fault Shutdown Switches

Check the continuity of the high engine temperature (HET) and low oil pressure (LOP) switches. Check for loose connections and open or short circuits in the connecting wires before replacing the switches.

High Engine Temperature (HET) Switch

Note: Most ohmmeters do not measure very small

resistance values accurately. Check for continuity of the windings with no shorts to ground. The stator is functional if the resistance reading (continuity) is low and there is no evidence (heat discoloration) of shorted windings.

Generator Set Voltage

Rating, VDC

36 0.014

48 0.024

Stator Resistance, Ohms

Figure 5-28 Stator Resistance

7. If the resistance test in the previous step is not conclusive, perform a megohmmeter test to determine whether the stator is shorted to ground.

a. Use a megohmmeter to apply 500 volts DC to

any stator lead and the stator’s frame. Follow the instructions of the megohmmeter’s manufacturer when performing this test. A reading of approximately 500 kOhms (1/2 MOhm) or higher indicates that the stator is in good condition. A reading of less than approximately 500 kOhms (1/2 MOhm) indicates deterioration of the winding insulation and possible current flow to ground.

The HET switch is normally open. Shut down the generator set and allow the engine to cool. Use an ohmmeter to measure the resistance from pin P4-12 to ground. The ohmmeter should indicate an open circuit. Any other reading indicates a short; replace the HET switch.

Low Oil Pressure (LOP) Switch

The normally closed LOP switch opens when the engine oil pressure reaches the normal operating level and closes if the oil pressure drops below a preset minimum. Use an ohmmeter to check the continuity between pin P4-13 and ground. Verify that the switch is closed while the engine is stopped. Start the generator set and check that the switch opens approximately 5 seconds later. If the switch does not open after the engine reaches normal operating speed, check the oil level and test for leaks in the lubrication system before replacing the LOP switch.

b. If the megohmmeter reading is less than

500 kOhms, replace the stator.

5.8.2 Rotor

The rotor uses permanent magnets. There are no tests or field adjustments for the rotor.

TP-6482 8/06 53Section 5 Component Testing and Adjustment

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Notes

TP-6482 8/0654 Section 5 Component Testing and Adjustment

Page 55

Section 6 Controller Operation and Test

This section describes troubleshooting procedures for the generator set control board, shown in Figure 6-1. Refer to the operation manual for operating instructions. Refer to the remote controller manufacturer’s instructions for troubleshooting and servicing remote controllers connected to the generator set.

Control circuit boards GM11783 and GM14243 are not interchangeable. However, control circuit board GM17820 can be used to replace either GM11783 or GM14243.

6.1 Sequence of Operation

The following sections describe the controller sequence of operation during generator start, run, stop, and fault shutdown modes. Use this as a starting point for controller fault identification. Use the LEDs on the controller circuit board to assist in the troubleshooting process. Refer to the wiring diagrams in Section 8 to assist in the troubleshooting procedure.

6.1.1 Starting Sequence

Placing the generator set master switch in the RUN position starts the generator set locally. With the

generator set master switch in the AUTO position, momentarily closing contacts P6-5 and P6-6 starts the generator set remotely.

The crank relay energizes, activating the starter motor, SM. The hourmeter, ignition module, coil, and gas valve receive power.

When the engine comes up to speed, the low oil pressure switch contacts open.

6.1.2 Running Sequence

Leads AC1 and AC2 from the AC side of the voltage rectifier provide speed sensing signals to the control board.

Note: The generator set shuts down if the controller

does not obtain AC output within 1 second after engine start (locked rotor shutdown).

6.1.3 Stopping Sequence

Moving the generator set master switch to the stop position or closing a remote contact between pins P6-6 and P6-7 (and opening P6-5 and P6-6) deenergizes the run relay and stops the generator set.

1. Control circuit board

2. LED locations

3. Voltage adjustment pot

Figure 6-1 Controller Board

R37

LED8

LED7

LED6

LED1

LED3

LED4

LED2

LED5

4. Generator set master switch, 3-position

5. Common fault indicator, LED8

STOP

AUTO

RUN

FAULT

M-337000C-B

TP-6482 8/06 55Section 6 Controller Operation and Test

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6.2 Control Connections

Wiring harnesses connect the generator set control board to the system remote controls and the engine. Figure 6-2 shows the wiring harness connections to the control board. See the wiring diagrams in Section 8 for pinouts and connection details. Figure 6-3 defines the abbreviations used in the wiring diagrams.

Other models use a momentary start/stop generator set switch that returns to the center position when released. Be sure to set the remote switch to the OFF position before servicing the generator set. Hold the generator set master switch in the STOP position while disconnecting the starting battery.

6.2.2 Remote Start/Stop Connections

P6 P1

R37

M-337000C-B

1. Generator set to remote control system interface harness, GM14245

2. Generator set control circuit board

3. Engine interface harness, GM14244

Figure 6-2 Generator Set Control Connections

Abbreviation Definition

N Ground

OVC Overcrank

N/C Not connected

STT Start

LOP Low oil pressure

STP Stop

OVT Overtemperature

OVS Overspeed

DCP DC output sensing

DCN DC output sensing

AC1 AC speed sensing

AC2 AC speed sensing

M1 Throttle control

M2 Throttle control

M3 Throttle control

M4 Throttle control

P Battery

70 Run

71 Crank

Figure 6-3 Pin Abbreviations

For remote operation, connect a three-wire remote start/stop switch to P6 of the interface harness. To start, open a contact between pins 6 and 7 and close a contact between pins 5 and 6 of connector P6 (see the wiring diagrams). To stop, close the contact between pins 6 and 7 and open the contact between pins 5 and 6.

6.2.3 Status Indicators

Eight LEDs on the generator set control board indicate the system status conditions and fault shutdowns listed in Figure 6-4. Figure 6-1 shows the LED locations.

Remote

LED Indicates

1 Overspeed shutdown Yes

2 Overtemperature shutdown Yes

3 Engine running status indicator Ye s

4 Low oil pressure fault shutdown Ye s

5 Overcrank shutdown Yes

6 Fuel valve energized No

7 Cranking energized No

8 Common fault indicator No

Annunciation

Figure 6-4 Control Board LEDs

6.3 Fault Shutdowns

The generator set shuts down automatically under the fault conditions listed in Figure 6-5 and cannot be restarted until the controls are reset. Correct the fault condition and then 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.

Refer to the troubleshooting charts in Sections 4 to further diagnose the cause of a fault shutdown.

6.2.1 Generator Set Master Switch

Some models use a 3-position generator set master switch. Set the switch to the AUTO position for remote operation. Set both the generator set master switch and the remote switch to the STOP or OFF position and disconnect the engine starting battery before servicing the generator set.

TP-6482 8/0656 Section 6 Controller Operation and Test

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Fault Description Fault Condition/Possible Cause

High engine temperature

Low oil pressure Shuts down 5 seconds after the fault. The low oil pressure shutdown does not

Overcrank Shuts down after 70 seconds of cyclic cranking. The factory sets the circuit

Overspeed Shuts down immediately if the engine speed exceeds 3750 rpm. D Engine rpm exceeds 3750

Shuts down 5 seconds after the fault. When the engine cools, the fault clears and allows the generator set to be started without resetting the controller. The high engine temperature shutdown is inhibited (does not function) during the first 30 seconds after startup.

function during the first 30 seconds after startup.

Note: The low oil pressure shutdown does not protect against low oil level.

board for three starting attempts: crank 20 sec., rest 5 sec., crank 20 sec., rest 5 sec., crank 20 sec., overcrank fault.

Overcrank shutdown also occurs in the case of a locked rotor.

D Engine reaches shutdown

temperature

D Very low oil level D Air inlet or outlets blocked D Cooling system malfunction

D Engine oil pressure drops below

low oil pressure limit

D Very low oil level

D Starting problem D Locked rotor (2 seconds without

rotation or no AC speed sensor input)

D Loss of speed (AC) sensing

Figure 6-5 Fault Shutdowns

6.3.1 Control Resetting Procedure (Following Fault Shutdown)

Use the following procedure to restart the generator set after a fault shutdown.

1. Move either the generator set master switch or the remote switch to the STOP position.

2. Correct the cause of the fault shutdown. See the safety precautions at the beginning of this section before proceeding.

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.

Remove the generator set from the enclosure to gain access to the components in the following tests. See Section 5.1 for instructions to remove the generator set and run it using the service fixtures.

Note: If you run the generator set outside the enclosure,

place the cover over the top of the generator to prevent contact with rotating parts. The cover has an opening in the center to allow cooling air flow.

Check the continuity of the wiring harness leads before replacing the control board. Refer to the wiring diagrams in Section 8 for the lead codes and connecting terminals.

If these tests are inconclusive, test the individual shutdown circuit components as described in Section 6.5.

DANGER

Hazardous voltage.

6.4 Fault Shutdown Tests

Verify operation of the controller overspeed, overcrank, low coolant level, low oil pressure, and high engine

Will cause severe injury or death.

Only authorized personnel should open the enclosure.

temperature shutdowns by performing the following tests with the generator set running. Observe the LEDs on the controller circuit board during the tests. Refer to the service views in Section 1.4 for component locations.

TP-6482 8/06 57Section 6 Controller Operation and Test

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WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

Moving rotor.

6.4.3 Overcrank Shutdown

The generator set shuts down and LED5 lights after approximately 70 seconds of cyclic cranking (three attempts to start). The manufacturer sets the circuit board for three cranking attempts: crank 20 seconds, rest 5 seconds, crank 20 seconds, rest 5 seconds, crank 20 seconds, shutdown. Use the following procedure to test the overcrank shutdown operation.

Overcrank Shutdown Test Procedure

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.

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.

6.4.1 Low Oil Pressure (LOP) Shutdown

The low oil pressure (LOP) switch closes 5 seconds after the oil pressure drops below 5 psi, shutting down the generator set and lighting LED4. The low oil pressure shutdown does not function during the first 30 seconds after startup.

To test the operation of the LOP shutdown, connect a jumper wire from pin J4-13 of the controller-to-engine wiring harness to the generator set ground. Start the generator set. After approximately 35 seconds the generator set shuts down and the fault lamp lights. If the generator set does not shut down, replace the control board.

1. Turn off the fuel supply to prevent flooding and remove the coil wire from the ignition module.

2. Move the generator set master switch to the RUN position.

3. Verify that the generator set shuts down and the fault lamp lights after the third crank/rest cycle.

6.4.4 Overspeed Shutdown

The generator set shuts down and LED1 lights when the engine speed exceeds 3750 rpm.

Use the following procedure to test the operation of the overspeed shutdown.

Overspeed Shutdown Test Procedure

Note: Do not increase engine speed above 3950 rpm.

Increasing the engine speed above 3950 rpm can raise the output voltage high enough to damage generator and connected equipment.

1. Disconnect the load from the generator set.

2. Connect a tachometer to the engine spark plug lead to measure the engine speed during the test.

6.4.2 High Engine Temperature (HET) Shutdown

The high engine temperature (HET) switch closes 5 seconds after the generator set temperature reaches 305°F, shutting down the generator set and lighting LED2 on the control board. The high engine temperature shutdown does not function during the first 30 seconds after startup.

To test the HET shutdown, connect a jumper from the HET switch (lead ) to the generator set ground. Start the generator set. After approximately 35 seconds the generator set shuts down and the fault lamp lights. Five seconds after the jumper is removed, the fault lamp goes out and the generator set restarts. If the generator set does not shut down and restart as described, replace the control board.

Note: If a tachometer is not available, connect a

frequency meter across terminals C and E on the AC side of the voltage rectifier. Increase the engine speed as instructed in step 3. The generator set should shut down when the output frequency reaches 750 Hz. Do not exceed 790 Hz.

3. With the generator set running, carefully move the throttle linkage to increase the engine speed. Watch the tachometer and note the speed when the generator set shuts down.

4. Reset the controller by moving the master switch to the OFF position and then back to AUTO.

If the generator set does not shut down when the engine speed exceeds 3750 rpm, replace the control board.

TP-6482 8/0658 Section 6 Controller Operation and Test

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6.5 Control Board Tests

Use the troubleshooting procedures in Section 4 to diagnose generator set and engine problems. If the troubleshooting procedures indicate a problem with the controller circuit board, use the tests in this section to check the board.

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.

6.5.1 Fuel Control Circuit

Refer to the wiring diagrams in Section 8 when troubleshooting the generator set control circuit board. Circuit board components cannot be repaired or replaced; if the troubleshooting process reveals a faulty component on the circuit board, replace the board.

Note: Use an ohmmeter or continuity tester to check for

shorts or open leads in the wiring harnesses before replacing the controller circuit board or other system components.

Disconnect the generator system from the remote control system at plug P6 and use the generator set master switch to operate the generator set. If the generator set operates normally when P6 is disconnected, then the problem is with the remote control system. Refer to the manufacturer’s instructions for the remote control system to troubleshoot the problem. If the problem persists after P6 is disconnected, use the troubleshooting procedures in this manual to diagnose the problem.

DANGER

Move the generator set master switch to the START position and check for 12 VDC on pin P5-1 (lead 70) of the fuel valve connector. If the valve receives voltage but does not open, replace the valve.

If there is no voltage to the valve, check the battery voltage, battery connections, and ignition system (see Section 5.5). If the battery and ignition system function correctly but the fuel valve does not receive voltage, replace the controller circuit board.

6.5.2 Speed Sensing and Governor (Throttle Control) Circuits

The controller monitors the AC voltage produced by the stator to sense and control the engine speed. If the engine speed varies erratically, test the governor operation as described in Section 5.4. If the tests show that the erratic operation is not caused by a faulty governor, replace the controller circuit board.

6.5.3 Start Circuits

Move the generator set master switch to the START or RUN position. If the engine does not crank, check the following components.

Hazardous voltage. Will cause severe injury or death.

Only authorized personnel should open the enclosure.

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

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.

1. Check the battery voltage. Recharge or replace a weak or dead battery.

2. Check for 12 VDC to the starter motor. Also verify that the starter motor is grounded. See Section 8, Wiring Diagrams. If the starter motor is receiving voltage but not functioning, replace it. If there is no voltage to the starter motor, check the harness and connections and then proceed to step 3 to check the starter (crank) relay.

3. Check for 12 VDC to the crank relay. See Section 8, Wiring Diagrams. If the crank relay is receiving voltage but not functioning, replace it. If there is no voltage to the crank relay, check the harness and connections.

4. Check for 12 VDC from the control board at P2-1. If there is no voltage, replace the controller circuit board.

TP-6482 8/06 59Section 6 Controller Operation and Test

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6.5.4 Ignition Circuits

6.7 Control Board Replacement

Move the generator set master switch to the START position. If the engine cranks but does not start, check for voltage from lead 70 to ground at terminal B on the ignition module and at the positive terminal of the ignition coil. If no voltage is present during cranking, replace the controller circuit board. If the ignition system is receiving 12 VDC, check the spark plug and test the other ignition system components.

6.6 Voltage Programming Shunt

Control board GM22402 uses a programming shunt for voltage selection. See Figure 6-6 for the programming shunt location. Set programming shunts JP1A through JP1D to select the generator set kW and voltage as shown in Figure 6-6 and Figure 6-7.

3.5 5.0 7.5

D1 D2 R1

R2 R3 R4 R5 R6

U3 R7 R8

R100

LED1 GEN

FAIL

Q1 R10 R11

D11

R12

D12

R13

D13

D14

R14 R15

D15

R16

D16

R17

D17

MC1413BP

10 12

D6 D7 D8 D9

1 3

Figure 6-6 Programming Shunt Location

kW rating JP1A JP1B

Voltage Rating, VDC JP1C JP1D

Note: Jumpers JP1E and JP1F have no function.

Figure 6-7 Jumper Configurations

C13

Y1 R18 D10

C10

R19

C11

87C196KB16

C12

74HC14U574HC14

D18C9D19

D20 D21

TYPE FST

12.5A 250V

C14

C15

JP116U6

JP1A JP1B JP1C JP1D JP1E JP1F JP1G

JP1H

R29

R20 R21 R22

R30

R23

R31

R24

C16

R25 R26

C17

R27 R28

C18

L297/1

L293D

D22

C19

R32

C20

VR1

C21

R33 R34 R35 R36 R37 R38

R39 R40 R41

C23 R42 R43 R44 Z1

R45 R46 R47 R48

D23 D24

C24

R49 D25 R50

Q3Q4

C27 R51 R52

C28

LM2902N

C29

D26 D27 D28 D29 R53

SW1

C25 C26

U10

LM2903N

BARCODE

C30 C31

U11

MAX680

C32 C33 R56

R57 R58 R59 R60 R61

C34 D30 D31 D32 D33 C35

Z3 R62 R63 R64 R65

C37

C36

1 R54

R55

+ +

JP1A JP1B JP1C JP1D JP1E JP1F JP1G JP1H

Power Selection Jumpers

3.5 OUT OUT

5.0 OUT IN

7.5 IN OUT

Voltage Selection Jumpers

24 OUT OUT

36 OUT IN

48 IN OUT

96 IN IN

Jumpers JP1G and JP1H are for factory use only.

JP1

GM22402

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.

If the controller tests in Section 6 or the troubleshooting procedures in Section 4 indicate that the control board needs to be replaced, follow these guidelines:

D Keep the new board in its protective wrapping until

installation.

D Wear a grounding strap while handling the circuit

board to prevent damage to the circuit board components.

D Set the programming shunts for kW and voltage. See

Section 6.6.

D Check that all plug connections are secure.

D Calibrate the voltage after installing the board.

The new circuit board must be calibrated after installation. Use the following procedure to calibrate the board.

Installation Procedure

1. Place the generator set master switch in the OFF position.

2. Disconnect the power to the battery charger, if equipped.

3. Disconnect the generator set engine starting battery(ies), negative (--) lead first.

4. Open the enclosure to access the control board.

5. Disconnect all connectors to the control board, and remove the board from the enclosure.

6. Before installing replacement control board GM22402, install the jumper(s) (294634) as shown in Figure 6-7 to obtain the rated power (kW) and voltage for the generator set. Zero (0) to three jumpers are required, depending on the selected voltage and power ratings. See Figure 6-6 for the jumper locations.

Note: Verify that connector P2 is not connected to

the board during jumper installation or removal.

TP-6482 8/0660 Section 6 Controller Operation and Test

Page 61

7. Install the control board and connect all connectors removedinstep5.

8. Verify board mounting and connections and then close the enclosure.

9. Check that the generator set master switch is in the OFF position.

Calibration Procedure

Use the following procedure to calibrate the voltage.

1. Connect a voltmeter to the output terminals of the voltage rectifier.

2. Turn R37 on the circuit board fully clockwise.

10. Reconnect the generator set engine starting battery, negative (--) lead last.

11. Reconnect power to the battery charger, if equipped.

12. Test run the generator set to verify the rated output voltage.

3. Start the generator set with no load.

4. Adjust R37 to obtain the voltage output shown in Figure 6-8.

Generator Set Model Measured Output Voltage, VDC

36 Volt 39

48 Volt 52

Figure 6-8 Output Voltages, VDC

TP-6482 8/06 61Section 6 Controller Operation and Test

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Notes

TP-6482 8/0662 Section 6 Controller Operation and Test

Page 63

Section 7 Disassembly/Reassembly

Before disassembly, remove the generator set from any enclosure. Refer to Section 3.3 for instructions. Disconnect the battery (negative [--] lead first), fuel line, exhaust system, remote start switch, load leads, and other wiring harnesses. In addition to the precautions included in the text, observe all safety precautions listed at the beginning of this manual during the disassembly/reassembly procedure.

WARNING

Hazardous voltage. Can cause severe injury or death.

Only authorized personnel should open the enclosure.

(600 volts and under)

WARNING

7.1 Disassembly Procedure

1. Follow the instructions in Section 3.3 to open the cabinet, disconnect the generator set, and remove it from the cabinet. See Figure 7-1

2. Set the generator set on the service fixture, aligning the generator set’s mounting holes with the pins in the fixture.

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

NOTICE

Hardware damage. The engine and generator set may use both American Standard and metric hardware. Usethe correct size tools to prevent rounding of the bolt heads and nuts.

1. Load lead connector

2. Wiring harness connectors

3. Fuel connection

4. Exhaust pipe connection (not visible in this photo)

Figure 7-1 Generator Set Installed in the cabinet

TP6076

TP-6482 8/06 63Section 7 Disassembly/Reassembly

Page 64

3. Note the three stator lead connections to the voltage rectifier for reconnection later. Disconnect the stator leads from the voltage rectifier. See Figure 7-2.

2 3

NGLP

TP--6092

1. Scroll

2. Fan

3. Fan screw (3 ea.)

4. Stator

Figure 7-3 Alternator with Fan

4251 3

7 8

1. Output connector

2. Stator leads

3. Exhaust connection

M--337000B-H

Figure 7-2 Generator Set

4. Disassemble the fan and alternator. See Figure 7-3 and Figure 7-4.

a. Remove three fan screws and remove the fan.

b. Remove the four socket head cap screws

securing the stator to the engine adaptor.

c. Remove the stator, guiding the three stator

leads through the opening in the shroud.

1. Stator screws (4)

2. Fan screws (3)

3. Flywheel bolt

4. Convex washer

5. Spacer/rotor screws (3)

6. Alternator scroll

7. Fan

8. Spacer

9. Stator

10. Flywheel

11. Engine crankshaft

12. Rotor

Figure 7-4 Alternator Assembly

M-337000A-H

TP-6482 8/0664 Section 7 Disassembly/Reassembly

Page 65

d. Remove the three screws securing the spacer

and rotor to the flywheel. Remove the spacer and the rotor. See Figure 7-5.

1. Spacer

2. Rotor/spacer screws (3)

3. Rotor

4. Engine adaptor

5. Flywheel

Figure 7-5 Rotor and Spacer (shroud and stator

removed)

5. Remove the flywheel, if necessary.

a. Remove the thrubolt and convex washer at the

center of the flywheel taper. See Figure 7-4.

b. Pull the flywheel off the engine crankshaft.

TP-6092

c. Use three 63.5 mm (3/8-16 x 2.5 in.) hex head

screws to secure the spacer and rotor to the flywheel. See Figure 7-5. Do not tighten the screws.

d. Place the stator in position as shown in

Figure 7-6. Feed the stator leads through the opening in the alternator scroll.

1. Stator

2. Scroll

3. Stator leads

Figure 7-6 Generator Set Top View

e. Use four 44.5 mm (1/4-20 x 1.75 in. ) socket

head cap screws to secure the stator to the alternator adaptor. Do not tighten the screws.

M-337000A-H

7.2 Reassembly Procedure

1. Install the flywheel, if it was removed.

a. Clean the engine crankshaft and flywheel taper

with a dry cloth.

b. Slide the flywheel onto the engine crankshaft.

c. Install the M10-1.50 x 45 mm (1.772 in.)

thrubolt and convex washer. Install the washer with the convex side up, as shown in Figure 7-4.

d. Use a torque wrench to tighten the thrubolt to

67 Nm (49.4 ft. lb.).

2. Reassemble the alternator. See Figure 7-4.

a. Slide the rotor over the flywheel taper, aligning

the bolt holes in the rotor and the flywheel.

b. Place the spacer on the rotor, aligning the bolt

holes.

f. Use a 0.25 mm (0.010 in.) feeler gauge to

check the gap between the rotor and stator at several places. Adjust the stator position so that the gap is even all around. Use a torque wrench to tighten the rotor screws to 38 Nm (28.0 ft. lb.). Tighten the stator screws to 11 Nm (8.1 ft. lb.) and verify that the gap is

0.25 mm (0.010 in.) all around.

3. Install the fan.

a. Place the fan on the spacer, aligning the bolt

holes with the three unused holes in the spacer, rotor, and flywheel.

b. Use three 82.5 mm (3/8-16 x 3.25 in.) hex head

screws and washers to secure the fan. Use a torque wrench to tighten the screws to 25 Nm (18.4 ft. lb.).

4. Connect the stator leads to the voltage rectifier. Tighten the voltage rectifier terminal screws to 5Nm(44in.lb.).

TP-6482 8/06 65Section 7 Disassembly/Reassembly

Page 66

5. Follow the instructions in Section 3.3 to install the generator set in the cabinet.

6. Reconnect the generator set components.

a. Reconnect the exhaust pipes at the lower left

side of the generator set.

b. Reconnect the fuel line.

c. Reconnect the wiring harnesses.

d. Reconnect the engine starting battery, negative

(--) lead last.

TP--6092

1. Stator

2. Rotor

3. Spacer

4. Flywheel taper

5. Engine adapter

Figure 7-7 Alternator (shroud removed to show

components)

TP-6482 8/0666 Section 7 Disassembly/Reassembly

Page 67

Section 8 Diagrams and Drawings

Specification Numbers Drawing Description Drawing Number Figure

PA-195023, PA-195027 Wiring Diagram GM11880-C Figure 8-1

Schematic ADV-6536-C Figure 8-2

GM14140-GA1, GM14140-GA2, GM14140-GA3, GM14140-GA4, GM14140-GA5, GM14140-GA6, GM14140-GA7, GM14140-GA8, GM14140-GA9, GM14140-GA10, GM14140-GA11

Wiring Diagram GM14258-B Figure 8-3

TP-6482 8/06 67Section 8 Diagrams and Drawings

Page 68

Figure 8-1 Wiring Diagram, GM11880-C

TP-6482 8/0668 Section 8 Diagrams and Drawings

Page 69

Figure 8-2 Schematic Diagram, ADV-6536-C

TP-6482 8/06 69Section 8 Diagrams and Drawings

Page 70

Figure 8-3 Wiring Diagram, GM14258-B

TP-6482 8/0670 Section 8 Diagrams and Drawings

Page 71

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimensional

AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards

AO anticipatory only API American Petroleum Institute approx. approximate, approximately AR as required, as requested AS as supplied, as stated, as

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary A/V audiovisual avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery

BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block

blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CARB California Air Resources Board CB circuit breaker cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cert. certificate, certification, certified cfh cubic feet per hour

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

cfm cubic feet per minute CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide

cogen. cogeneration com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards

CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., ° degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung

DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection

EPS emergency power system ER emergency relay ES engineering special,

ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust

substrate (semiconductor)

Association

e. V. (also Deutsche Industrie Normenausschuss)

Association

Agency

engineered special

ext. external F Fahrenheit, female fglass. fiberglass FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lb. foot pounds (torque) ft./min. feet per minute ggram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter

GND, gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temperature,

hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air

HWT high water temperature Hz hertz (cycles per second) IC integrated circuit ID inside diameter, identification IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting in. inch in. H in. Hg inches of mercury in. lb. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe ISO International Organization for

J joule JIS Japanese Industry Standard k kilo (1000) K kelvin

ground

high engine temperature

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

TP-6482 8/06 Appendix 71

Page 72

kA kiloampere KB kilobyte (2 kg kilogram

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter

bytes)

kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound, pounds

lbm/ft

pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side L

sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (10

units), male

cubic meter

/min. cubic meters per minute

when used with SI

mA milliampere man. manual max. maximum MB megabyte (2

bytes) MCM one thousand circular mils MCCB molded-case circuit breaker meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm,

mΩ milliohm MOhm,

MΩ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second MTBF mean time between failure

MTBO mean time between overhauls mtg. mounting MW megawatt mW milliwatt μF microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical

Manufacturers Association

NFPA National Fire Protection

Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe

thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment

manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health

Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph., ∅ phase PHC Phillips head crimptite (screw) PHH Phillips hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent-magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only

memory psi pounds per square inch pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency)

power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference RH round head RHM round head machine (screw)

rly. relay rms root mean square rnd. round ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive

Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites,

International System of Units SI/EO side in/end out sil. silencer SN serial number SPDT single-pole, double-throw SPST single-pole, single-throw spec,

specs specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to

normal TDES time delay engine start TDNE time delay normal to

emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple

locations) UF underfrequency UHF ultrahigh frequency UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer

TP-6482 8/0672 Appendix

Page 73

Appendix B Common Hardware Application Guidelines

Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made.

Bolt/Screw Length: When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method.

Washers and Nuts: Use split lock washers as a bolt locking device where specified. Use SAE flat washers with whiz nuts, spiralock nuts, or standard nuts and preloading (torque) of the bolt in all other applications.

See Appendix C, General Torque Specifications, and other torque specifications in the service literature.

Preferred Nut/Bolt Clearance

Steps for common hardware application:

1. Determine entry hole type: round or slotted.

2. Determine exit hole type: fixed female thread (weld nut), round, or slotted.

For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter, or 1/2 inch in diameter or less. Hardware that is greater than 1/2 inch in diameter takes a standard nut and SAE washer. Hardware 1/2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut. See Figure 2.

3. Follow these SAE washer rules after determining exit hole type:

a. Always use a washer between hardware and a

slot.

b. Always use a washer under a nut (see 2 above

for exception).

c. Use a washer under a bolt when the female

thread is fixed (weld nut).

Unacceptable Nut/Bolt Clearance

1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut

3. Below top of nut

Figure 1 Acceptable Bolt Lengths

G-585

4. Refer to Figure 2, which depicts the preceding hardware configuration possibilities.

1. Cap screw

2. Entry hole types

3. Standard nut and SAE washer

4. Whiz nut or spiralock: up to 1/2 in. dia. hardware

5. Weld nuts: above 1/2 in. dia. hardware

6. Exit hole types

G-585

Figure 2 Acceptable Hardware Combinations

TP-6482 8/06 73Appendix

Page 74

Appendix C General Torque Specifications

American Standard Fasteners Torque Specifications

Size

8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) —

10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) —

10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) —

1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 (132)

1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144)

5/16-18 Nm (in. lb.) 13.6 (120) 21.7 (192) 29.8 (264)

5/16-24 Nm (in. lb.) 14.9 (132) 23.1 (204) 32.5 (288)

3/8-16 Nm (ft. lb.) 24.0 (18) 38.0 (28) 53.0 (39)

3/8-24 Nm (ft. lb.) 27.0 (20) 42.0 (31) 60.0 (44)

7/16-14 Nm (ft. lb.) 39.0 (29) 60.0 (44) 85.0 (63)

7/16-20 Nm (ft. lb.) 43.0 (32) 68.0 (50) 95.0 (70) SeeNote3

1/2-13 Nm (ft. lb.) 60.0 (44) 92.0 (68) 130.0 (96)

1/2-20 Nm (ft. lb.) 66.0 (49) 103.0 (76) 146.0 (108)

9/16-12 Nm (ft. lb.) 81.0 (60) 133.0 (98) 187.0 (138)

9/16-18 Nm (ft. lb.) 91.0 (67) 148.0 (109) 209.0 (154)

5/8-11 Nm (ft. lb.) 113.0 (83) 183.0 (135) 259.0 (191)

5/8-18 Nm (ft. lb.) 128.0 (94) 208.0 (153) 293.0 (216)

3/4-10 Nm (ft. lb.) 199.0 (147) 325.0 (240) 458.0 (338)

3/4-16 Nm (ft. lb.) 222.0 (164) 363.0 (268) 513.0 (378)

1-8 Nm (ft. lb.) 259.0 (191) 721.0 (532) 1109.0 (818)

1-12 Nm (ft. lb.) 283.0 (209) 789.0 (582) 1214.0 (895)

Measurement

Torque

Assembled into Cast Iron or Steel

Grade 2 Grade 5 Grade 8

Assembled into

luminum

Grade2or5

Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into Cast Iron or Steel

Size (mm)

M6 x 1.00 6.2 (4.6) 9.5 (7) 13.6 (10)

M8 x 1.25 15.0 (11) 23.0 (17) 33.0 (24)

M8 x 1.00 16.0 (11) 24.0 (18) 34.0 (25)

M10 x 1.50 30.0 (22) 45.0 (34) 65.0 (48)

M10 x 1.25 31.0 (23) 47.0 (35) 68.0 (50)

M12 x 1.75 53.0 (39) 80.0 (59) 115.0 (85)

M12 x 1.50 56.0 (41) 85.0 (63) 122.0 (90) SeeNote3

M14 x 2.00 83.0 (61) 126.0 (93) 180.0 (133)

M14 x 1.50 87.0 (64) 133.0 (98) 190.0 (140)

M16 x 2.00 127.0 (94) 194.0 (143) 278.0 (205)

M16 x 1.50 132.0 (97) 201.0 (148) 287.0 (212)

M18 x 2.50 179.0 (132) 273.0 (201) 390.0 (288)

M18 x 1.50 189.0 (140) 289.0 (213) 413.0 (305)

Notes:

1. The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or assembly drawings when they differ from the above torque values.

2. The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are used.

3. Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to prevent stripped threads.

4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength and a friction coefficient of 0.125.

Grade 5.8 Grade 8.8 Grade 10.9

Assembled into

luminum

Grade 5.8 or 8.8

TP-6482 8/0674 Appendix

Page 75

Appendix D Common Hardware Identification

Screw/Bolts/Studs

Head Styles

Hex Head or Machine Head

Hex Head or Machine Head with Washer

Flat Head (FHM)

Round Head (RHM)

Pan Head

Hex Socket Head Cap or Allent Head Cap

Hex Socket Head or Allent Head Shoulder Bolt

Sheet Metal Screw

Stud

Drive Styles

Hex

Hex and Slotted

Phillipsr

Nuts

Nut Styles

Hex Head

Lock or Elastic

Square

Cap or Acorn

Wing

Washers

Washer Styles

Plain

Split Lock or Spring

Spring or Wave

External Tooth Lock

Internal Tooth Lock

Internal-External Tooth Lock

Hardness Grades

American Standard

Grade 2

Grade 5

Grade 8

Grade 8/9 (Hex Socket Head)

Metric

Number stamped on hardware; 5.8 shown

5.8

Slotted

Hex Socket

Allent head screw is a trademark of Holo-Krome Co.

Phillipsr screw is a registered trademark of Phillips Screw Company.

Sample Dimensions

American Standard (Screws, Bolts, Studs, and Nuts)

1/4-20 x 1

Metric (Screws, Bolts, Studs, and Nuts)

M8-1.25 x 20

Length In Inches (Screws and Bolts)

Threads Per Inch

Major Thread Diameter In Fractional Inches Or Screw Number Size

Length In Millimeters (Screws and Bolts)

Distance Between Threads In Millimeters

Major Thread Diameter In Millimeters

Plain Washers

9/32

x5/8x 1/16

Lock Washers

5/8

Thickness

External Dimension

Internal Dimension

TP-6482 8/06 Appendix 75

Page 76

Appendix E Common Hardware List

The Common Hardware List lists part numbers and dimensions for common hardware items.

American Standard

Part No. Dimensions Hex Head Bolts (Grade 5)

X-465-17 1/4-20 x .38 X-465-6 1/4-20 x .50 X-465-2 1/4-20 x .62 X-465-16 1/4-20 x .75 X-465-18 1/4-20 x .88 X-465-7 1/4-20 x 1.00 X-465-8 1/4-20 x 1.25 X-465-9 1/4-20 x 1.50 X-465-10 1/4-20 x 1.75 X-465-11 1/4-20 x 2.00 X-465-12 1/4-20 x 2.25 X-465-14 1/4-20 x 2.75 X-465-21 1/4-20 x 5.00 X-465-25 1/4-28 x .38 X-465-20 1/4-28 x 1.00

X-125-33 5/16-18 x .50 X-125-23 5/16-18 x .62 X-125-3 5/16-18 x .75 X-125-31 5/16-18 x .88 X-125-5 5/16-18 x 1.00 X-125-24 5/16-18 x 1.25 X-125-34 5/16-18 x 1.50 X-125-25 5/16-18 x 1.75 X-125-26 5/16-18 x 2.00 230578 5/16-18 x 2.25 X-125-29 5/16-18 x 2.50 X-125-27 5/16-18 x 2.75 X-125-28 5/16-18 x 3.00 X-125-22 5/16-18 x 4.50 X-125-32 5/16-18 x 5.00 X-125-35 5/16-18 x 5.50 X-125-36 5/16-18 x 6.00 X-125-40 5/16-18 x 6.50

X-125-43 5/16-24 x 1.75 X-125-44 5/16-24 x 2.50 X-125-30 5/16-24 x .75 X-125-39 5/16-24 x 2.00 X-125-38 5/16-24 x 2.75

X-6238-2 3/8-16 x .62 X-6238-10 3/8-16 x .75 X-6238-3 3/8-16 x .88 X-6238-11 3/8-16 x 1.00 X-6238-4 3/8-16 x 1.25 X-6238-5 3/8-16 x 1.50 X-6238-1 3/8-16 x 1.75 X-6238-6 3/8-16 x 2.00 X-6238-17 3/8-16 x 2.25 X-6238-7 3/8-16 x 2.50 X-6238-8 3/8-16 x 2.75 X-6238-9 3/8-16 x 3.00 X-6238-19 3/8-16 x 3.25 X-6238-12 3/8-16 x 3.50 X-6238-20 3/8-16 x 3.75 X-6238-13 3/8-16 x 4.50 X-6238-18 3/8-16 x 5.50 X-6238-25 3/8-16 x 6.50

Part No. Dimensions Hex Head Bolts, cont.

X-6238-14 3/8-24 x .75 X-6238-16 3/8-24 x 1.25 X-6238-21 3/8-24 x 4.00 X-6238-22 3/8-24 x 4.50

X-6024-5 7/16-14 x .75 X-6024-2 7/16-14 x 1.00 X-6024-8 7/16-14 x 1.25 X-6024-3 7/16-14 x 1.50 X-6024-4 7/16-14 x 2.00 X-6024-11 7/16-14 x 2.75 X-6024-12 7/16-14 x 6.50

X-129-15 1/2-13 x .75 X-129-17 1/2-13 x 1.00 X-129-18 1/2-13 x 1.25 X-129-19 1/2-13 x 1.50 X-129-20 1/2-13 x 1.75 X-129-21 1/2-13 x 2.00 X-129-22 1/2-13 x 2.25 X-129-23 1/2-13 x 2.50 X-129-24 1/2-13 x 2.75 X-129-25 1/2-13 x 3.00 X-129-27 1/2-13 x 3.50 X-129-29 1/2-13 x 4.00 X-129-30 1/2-13 x 4.50 X-463-9 1/2-13 x 5.50 X-129-44 1/2-13 x 6.00

X-129-51 1/2-20 x .75 X-129-45 1/2-20 x 1.25 X-129-52 1/2-20 x 1.50

X-6021-3 5/8-11 x 1.00 X-6021-4 5/8-11 x 1.25 X-6021-2 5/8-11 x 1.50 X-6021-1 5/8-11 x 1.75 273049 5/8-11 x 2.00 X-6021-5 5/8-11 x 2.25 X-6021-6 5/8-11 x 2.50 X-6021-7 5/8-11 x 2.75 X-6021-12 5/8-11 x 3.75 X-6021-11 5/8-11 x 4.50 X-6021-10 5/8-11 x 6.00

X-6021-9 5/8-18 x 2.50

X-6239-1 3/4-10 x 1.00 X-6239-8 3/4-10 x 1.25 X-6239-2 3/4-10 x 1.50 X-6239-3 3/4-10 x 2.00 X-6239-4 3/4-10 x 2.50 X-6239-5 3/4-10 x 3.00 X-6239-6 3/4-10 x 3.50

X-792-1 1-8 x 2.25 X-792-5 1-8 x 3.00 X-792-8 1-8 x 5.00

Part No. Dimensions Type

Hex Nuts

X-6009-1 1-8 Standard

X-6210-3 6-32 Whiz X-6210-4 8-32 Whiz X-6210-5 10-24 Whiz X-6210-1 10-32 Whiz

X-6210-2 1/4-20 Spiralock X-6210-6 1/4-28 Spiralock X-6210-7 5/16-18 Spiralock X-6210-8 5/16-24 Spiralock X-6210-9 3/8-16 Spiralock X-6210-10 3/8-24 Spiralock X-6210-11 7/16-14 Spiralock X-6210-12 1/2-13 Spiralock X-6210-15 7/16-20 Spiralock X-6210-14 1/2-20 Spiralock

X-85-3 5/8-11 Standard X-88-12 3/4-10 Standard X-89-2 1/2-20 Standard

Washers

Bolt/

Part No. ID OD Thick. Screw

X-25-46 .125 .250 .022 #4 X-25-9 .156 .375 .049 #6 X-25-48 .188 .438 .049 #8 X-25-36 .219 .500 .049 #10 X-25-40 .281 .625 .065 1/4 X-25-85 .344 .687 .065 5/16 X-25-37 .406 .812 .065 3/8 X-25-34 .469 .922 .065 7/16 X-25-26 .531 1.062 .095 1/2 X-25-15 .656 1.312 .095 5/8 X-25-29 .812 1.469 .134 3/4 X-25-127 1.062 2.000 .134 1

TP-6482 8/0676 Appendix

Page 77

Metric

Hex head bolts are hardness grade 8.8 unless noted.

Part No. Dimensions Hex Head Bolts (Partial Thread)

M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M931-06055-60 M6-1.00 x 55 M931-06060-60 M6-1.00 x 60 M931-06060-SS M6-1.00 x 60 M931-06070-60 M6-1.00 x 70 M931-06070-SS M6-1.00 x 70 M931-06075-60 M6-1.00 x 75 M931-06090-60 M6-1.00 x 90 M931-06145-60 M6-1.00 x 145 M931-06150-60 M6-1.00 x 150

M931-08035-60 M8-1.25 x 35 M931-08040-60 M8-1.25 x 40 M931-08045-60 M8-1.25 x 45 M931-08050-60 M8-1.25 x 50 M931-08055-60 M8-1.25 x 55 M931-08055-82 M8-1.25 x 55* M931-08060-60 M8-1.25 x 60 M931-08070-60 M8-1.25 x 70 M931-08070-82 M8-1.25 x 70* M931-08075-60 M8-1.25 x 75 M931-08080-60 M8-1.25 x 80 M931-08090-60 M8-1.25 x 90 M931-08095-60 M8-1.25 x 95 M931-08100-60 M8-1.25 x 100 M931-08110-60 M8-1.25 x 110 M931-08120-60 M8-1.25 x 120 M931-08130-60 M8-1.25 x 130 M931-08140-60 M8-1.25 x 140 M931-08150-60 M8-1.25 x 150 M931-08200-60 M8-1.25 x 200

M931-10040-82 M10-1.25 x 40* M931-10040-60 M10-1.50 x 40 M931-10045-60 M10-1.50 x 45 M931-10050-60 M10-1.50 x 50 M931-10050-82 M10-1.25 x 50* M931-10055-60 M10-1.50 x 55 M931-10060-60 M10-1.50 x 60 M931-10065-60 M10-1.50 x 65 M931-10070-60 M10-1.50 x 70 M931-10080-60 M10-1.50 x 80 M931-10080-82 M10-1.25 x 80* M931-10090-60 M10-1.50 x 90 M931-10090-82 M10-1.50 x 90* M931-10100-60 M10-1.50 x 100 M931-10110-60 M10-1.50 x 110 M931-10120-60 M10-1.50 x 120 M931-10130-60 M10-1.50 x 130 M931-10140-60 M10-1.50 x 140 M931-10180-60 M10-1.50 x 180 M931-10235-60 M10-1.50 x 235 M931-10260-60 M10-1.50 x 260 M960-10330-60 M10-1.25 x 330

M931-12045-60 M12-1.75 x 45 M960-12050-60 M12-1.25 x 50 M960-12050-82 M12-1.25 x 50* M931-12050-60 M12-1.75 x 50 M931-12050-82 M12-1.75 x 50* M931-12055-60 M12-1.75 x 55 M931-12060-60 M12-1.75 x 60 M931-12060-82 M12-1.75 x 60* M931-12065-60 M12-1.75 x 65 M931-12075-60 M12-1.75 x 75 M931-12080-60 M12-1.75 x 80 M931-12090-60 M12-1.75 x 90 M931-12100-60 M12-1.75 x 100 M931-12110-60 M12-1.75 x 110

Part No. Dimensions Hex Head Bolts (Partial Thread),

continued

M960-16090-60 M16-1.50 x 90 M931-16090-60 M16-2.00 x 90 M931-16100-60 M16-2.00 x 100 M931-16100-82 M16-2.00 x 100* M931-16120-60 M16-2.00 x 120 M931-16150-60 M16-2.00 x 150

M931-20065-60 M20-2.50 x 65 M931-20090-60 M20-2.50 x 90 M931-20100-60 M20-2.50 x 100 M931-20120-60 M20-2.50 x 120 M931-20140-60 M20-2.50 x 140 M931-20160-60 M20-2.50 x 160

M931-22090-60 M22-2.50 x 90 M931-22120-60 M22-2.50 x 120 M931-22160-60 M22-2.50 x 160

M931-24090-60 M24-3.00 x 90 M931-24120-60 M24-3.00 x 120 M931-24160-60 M24-3.00 x 160 M931-24200-60 M24-3.00 x 200

Hex Head Bolts (Full Thread)

M933-04006-60 M4-0.70 x 6

M933-05030-60 M5-0.80 x 30 M933-05035-60 M5-0.80 x 35 M933-05050-60 M5-0.80 x 50

M933-06010-60 M6-1.00 x 10 M933-06012-60 M6-1.00 x 12 M933-06014-60 M6-1.00 x 14 M933-06016-60 M6-1.00 x 16 M933-06020-60 M6-1.00 x 20 M933-06025-60 M6-1.00 x 25 M933-06030-60 M6-1.00 x 30 M933-06040-60 M6-1.00 x 40 M933-06050-60 M6-1.00 x 50

M933-07025-60 M7-1.00 x 25

M933-08010-60 M8-1.25 x 10 M933-08012-60 M8-1.25 x 12 M933-08016-60 M8-1.25 x 16 M933-08020-60 M8-1.25 x 20 M933-08025-60 M8-1.25 x 25 M933-08030-60 M8-1.25 x 30 M933-08030-82 M8-1.25 x 30*

M933-10012-60 M10-1.50 x 12 M961-10020-60 M10-1.25 x 20 M933-10020-60 M10-1.50 x 20 M933-10025-60 M10-1.50 x 25 M961-10025-60 M10-1.25 x 25 M933-10025-82 M10-1.50 x 25* M961-10030-60 M10-1.25 x 30 M933-10030-60 M10-1.50 x 30 M933-10030-82 M10-1.50 x 30* M961-10035-60 M10-1.25 x 35 M933-10035-60 M10-1.50 x 35 M933-10035-82 M10-1.50 x 35* M961-10040-60 M10-1.25 x 40

Part No. Dimensions Hex Head Bolts (Full Thread),

continued

M933-12016-60 M12-1.75 x 16 M933-12020-60 M12-1.75 x 20 M961-12020-60F M12-1.50 x 20 M933-12025-60 M12-1.75 x 25 M933-12025-82 M12-1.75 x 25* M961-12030-60 M12-1.25 x 30 M933-12030-82 M12-1.75 x 30* M961-12030-82F M12-1.50 x 30* M933-12030-60 M12-1.75 x 30 M933-12035-60 M12-1.75 x 35 M961-12040-82 M12-1.25 x 40* M933-12040-60 M12-1.75 x 40 M933-12040-82 M12-1.75 x 40*

M961-14025-60 M14-1.50 x 25 M933-14025-60 M14-2.00 x 25 M961-14050-82 M14-1.50 x 50*

M961-16025-60 M16-1.50 x 25 M933-16025-60 M16-2.00 x 25 M961-16030-82 M16-1.50 x 30* M933-16030-82 M16-2.00 x 30* M933-16035-60 M16-2.00 x 35 M961-16040-60 M16-1.50 x 40 M933-16040-60 M16-2.00 x 40 M961-16045-82 M16-1.50 x 45* M933-16045-82 M16-2.00 x 45* M933-16050-60 M16-2.00 x 50 M933-16050-82 M16-2.00 x 50* M933-16060-60 M16-2.00 x 60 M933-16070-60 M16-2.00 x 70

M933-18035-60 M18-2.50 x 35 M933-18050-60 M18-2.50 x 50 M933-18060-60 M18-2.50 x 60

M933-20050-60 M20-2.50 x 50 M933-20055-60 M20-2.50 x 55

M933-24060-60 M24-3.00 x 60 M933-24065-60 M24-3.00 x 65 M933-24070-60 M24-3.00 x 70

Pan Head Machine Screws

M7985A-03010-20 M3-0.50 x 10 M7985A-03012-20 M3-0.50 x 12

M7985A-04010-20 M4-0.70 x 10 M7985A-04016-20 M4-0.70 x 16 M7985A-04020-20 M4-0.70 x 20 M7985A-04050-20 M4-0.70 x 50 M7985A-04100-20 M4-0.70 x 100

M7985A-05010-20 M5-0.80 x 10 M7985A-05012-20 M5-0.80 x 12 M7985A-05016-20 M5-0.80 x 16 M7985A-05020-20 M5-0.80 x 20 M7985A-05025-20 M5-0.80 x 25 M7985A-05030-20 M5-0.80 x 30 M7985A-05080-20 M5-0.80 x 80 M7985A-05100-20 M5-0.80 x 100

M7985A-06100-20 M6-1.00 x 100

Flat Head Machine Screws

M965A-04012-SS M4-0.70 x 12

M965A-05012-SS M5-0.80 x 12 M965A-05016-20 M5-0.80 x 16 M965A-06012-20 M6-1.00 x 12

* This metric hex bolt’s hardness is grade 10.9.

TP-6482 8/06 Appendix 77

Page 78

Metric, continued

Part No. Dimensions Type Hex Nuts

M934-03-50 M3-0.50 Standard

M934-04-50 M4-0.70 Standard M934-04-B M4-0.70 Brass

M934-05-50 M5-0.80 Standard

M934-06-60 M6-1.00 Standard M934-06-64 M6-1.00 Std. (green) M6923-06-80 M6-1.00 Spiralock M982-06-80 M6-1.00 Elastic Stop

M934-08-60 M8-1.25 Standard M6923-08-80 M8-1.25 Spiralock M982-08-80 M8-1.25 Elastic Stop

M934-10-60 M10-1.50 Standard M934-10-60F M10-1.25 Standard M6923-10-80 M10-1.50 Spiralock M6923-10-62 M10-1.50 Spiralock[ M982-10-80 M10-1.50 Elastic Stop

M934-12-60 M12-1.75 Standard M934-12-60F M12-1.25 Standard M6923-12-80 M12-1.75 Spiralock M982-12-80 M12-1.75 Elastic Stop

M982-14-60 M14-2.00 Elastic Stop

M6923-16-80 M16-2.00 Spiralock M982-16-80 M16-2.00 Elastic Stop

M934-18-80 M18-2.5 Standard M982-18-60 M18-2.50 Elastic Stop

M934-20-80 M20-2.50 Standard M982-20-80 M20-2.50 Elastic Stop

M934-22-60 M22-2.50 Standard

M934-24-80 M24-3.00 Standard M982-24-60 M24-3.00 Elastic Stop

M934-30-80 M30-3.50 Standard

Washers

Bolt/

Part No. ID OD Thick. Screw

M125A-03-80 3.2 7.0 0.5 M3 M125A-04-80 4.3 9.0 0.8 M4 M125A-05-80 5.3 10.0 1.0 M5 M125A-06-80 6.4 12.0 1.6 M6 M125A-08-80 8.4 16.0 1.6 M8 M125A-10-80 10.5 20.0 2.0 M10 M125A-12-80 13.0 24.0 2.5 M12 M125A-14-80 15.0 28.0 2.5 M14 M125A-16-80 17.0 30.0 3.0 M16 M125A-18-80 19.0 34.0 3.0 M18 M125A-20-80 21.0 37.0 3.0 M20 M125A-24-80 25.0 44.0 4.0 M24

[ This metric hex nut’s hardness is grade 8.

TP-6482 8/0678 Appendix

Page 79

Page 80

TP-6482 8/06

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455