Page 1
Service Manual
Commercial & Recreational Mobile
Generator Sets
Models:
15CCO
15CCFO
15CCOZ
15CCFOZ
20CCO
20CCFO
20CCOZ
20CCFOZ
TP-5606 6/02a
Page 2
Page 3
Table of Contents
SUBJECT PAGE SUBJECT PAGE
Safety Precautions and Instructions i.......
Routine Service Parts vi......................
Section 1. Specifications 1-1.................
Introduction 1-1...............................
General Specifications 1-1...................
Engine 1-2.................................
Generator 1-3..............................
Generator Models 15/20 kW 1-3..............
Section 2. Operation 2-1......................
Prestart Checklist 2-1..........................
Exercising the Generator 2-1.................
Controller (Single Phase) 2-2...................
Controller (Three Phase) 2-2...................
Preheat Feature 2-3...........................
Starting Procedure 2-3.........................
Stopping Procedure 2-3........................
Fault Shutdowns 2-4..........................
Low Oil Pressure Shutdown Switch 2-4........
High Water Temperature Shutdown Switch 2-4..
Circuit Protection 2-5..........................
Accessories 2-6..............................
Remote Panels (Optional) 2-7..................
Section 3. Scheduled Maintenance 3-1.........
General 3-1..................................
Lubrication System 3-3........................
Oil Selection 3-3............................
Oil Check 3-3..............................
Oil Change 3-4.............................
Oil Filter 3-5................................
Fuel System 3-6..............................
Specification 3-6............................
Fuel Filter 3-6..............................
Bleeding the Fuel System 3-7................
Fuel Solenoid 3-8...........................
Air Cleaner Service 3-9........................
Governor 3-10.................................
Cooling System 3-11...........................
Cooling System Description 3-11...............
Cooling System Servicing 3-14...................
Clean Radiator Fins/Inspect Hoses 3-14........
Change Coolant 3-14.........................
Check Coolant Level 3-14.....................
Battery Charging 3-15..........................
Belt Tension 3-15............................
Battery 3-16...................................
Cleaning 3-17...............................
Checking Electrolyte Level 3-17................
Checking Specific Gravity 3-18................
Engine Cylinder Head 3-19......................
Valve Clearance 3-19.........................
Head Bolt Torque 3-19........................
Wattage Requirements 3-20.....................
Generator Service 3-21.........................
General 3-21................................
Storage Procedure 3-21........................
Section 4. General Troubleshooting 4-1........
Section 5. Controller Troubleshooting 5-1......
Single-Phase Generator
Sequence of Operation 5-1.....................
Starting 5-1................................
Running 5-2................................
Stopping 5-3...............................
Automatic Safety Shutdowns 5-4..............
Three-Phase Generator
Sequence of Operation 5-5.....................
Starting 5-5................................
Running 5-6................................
Stopping 5-7...............................
Automatic Safety Shutdowns 5-8..............
Section 6. Generator/Controller
Troubleshooting 6-1.........................
Controller Circuit Board 6-1.....................
Section 7. Component Testing
and Adjustment 7-1..........................
Separate Excitation 7-1........................
PowerBoostä IIIE Voltage Regulator 7-4.........
PowerBoostä IIIE Voltage
Regulator Test Procedure 7-5................
PowerBoostä IIIE Voltage
Regulator Adjustment 7-6....................
PowerBoostä V Voltage Regulator 7-8...........
PowerBoostä V Voltage Regulator
Test Procedure 7-9..........................
PowerBoostä V Voltage Regulator
Adjustment 7-10.............................
Adjustment Procedure 7-11...................
Controller Circuit Board 7-12.....................
Engine/Generator Components 7-14..............
Rotor 7-18....................................
Single-Phase Rotor Tests 7-18.................
Three-Phase Rotor Tests 7-18.................
Stator 7-19....................................
Checking Single-Phase Stator
Continuity and Resistance 7-19................
Checking Three-Phase Stator
Continuity and Resistance 7-20................
Exciter Field 7-22..............................
Exciter Armature 7-23..........................
Fuel Solenoid 7-25.............................
Remote Start Panels (Optional) 7-26..............
TP-5606 6/02 Table of Contents
Page 4
SUBJECT PAGE SUBJECT PAGE
Sender Tests 7-26...........................
Panel Tests 7-26.............................
Section 8. Disassembly/Reassembly 8-1.......
Single-Phase Generator Disassembly 8-1........
Single-Phase Generator Brushes 8-5............
Single-Phase Generator Slip Ring 8-5...........
Single-Phase Generator Reassembly 8-6........
Three-Phase Generator Disassembly 8-7........
Reassembly 8-11..............................
Section 9. Wiring Diagrams 9-1...............
Twelve-Lead (Three-Phase) Generator Sets 9-5
Appendix A. Abbreviations A-1...............
Appendix B. Common Hardware Applications
Guidelines A-3...............................
Appendix C. General Torque Specifications A-4
Appendix D. Common Hardware Identification A-5
Appendix E. Common Hardware List A-6......
TP-5606 6/02Table of Contents
Page 5
Safety Precautions and Instructions
IMPORTANT SAFETY
INSTRUCTIONS. Electromechanical
equipment, including generator sets,
transfer switches, switchgear, 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 several types of safety
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.
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. If battery 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-5606 6/02 Safety Precautions and Instructions i
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.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
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 or
vehicle. Do not obstruct the exhaust
outlet when parking your vehicle. The
exhaust gases must discharge freely to
prevent carbon monoxide from
deflecting into the vehicle.
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.
Copper tubing exhaust systems.
Carbon monoxide can cause severe
nausea, fainting, or death. Do not
use copper tubing in diesel exhaust
systems. Sulfur in diesel exhaust
causes rapid deterioration of copper
tubing exhaust systems, resulting in
exhaust leakage.
ii Safety Precautions and Instructions TP-5606 6/02
Page 7
Installing the exhaust tail pipe.
Carbon monoxide can cause severe
nausea, fainting, or death. Install the
exhaust system tail pipe to prevent the
drawing of discharged exhaust gases
into the vehicle interior through
windows, doors, air conditioners, and
other openings. Do not use flexible tail
piping because it could crack and allow
lethal exhaust fumes to enter the
vehicle.
Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the
safety of the vehicle’s occupants, install
a carbon monoxide detector. Consult
the coach builder or dealer for
approved detector location and
installation. Inspect the detector before
each generator set use. In addition to
routine exhaust system inspection, test
the carbon monoxide detector per the
manufacturer’s instructions and keep
the detector operational at all times.
Fuel System
WARNING
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
inawell-ventilatedareaawayfrom
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Donot operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an
explosion. Use a container to catch fuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.
Hazardous Noise
Hazardous Voltage/
Electrical Shock
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
WARNING
Hazardous voltage.
Backfeed to the utility system can
cause severe injury, death, or
property damage.
Connect the generator set to the
building’s electrical system only
through an approved device and after
the building’s main switch is opened.
Moving rotor.
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
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.
CAUTION
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
TP-5606 6/02 Safety Precautions and Instructions iii
Page 8
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, transfer switch, 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.
Welding the generator set. Can
cause severe electrical equipment
damage. Before welding the generator
set perform the following steps:
(1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine batterycharging alternator connections.
(5) Attach the weld ground connection
close to the weld location.
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 the voltage regulator.
Hazardous voltage can cause
severe injury or death. High voltage
is present at the voltage regulator heat
sink. To prevent electrical shock do not
touch the voltage regulator heat sink
when testing the voltage regulator.
(PowerBoostt, PowerBoostt III, and
PowerBoostt V voltage regulator
models only)
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death.
Connect the generator set to the
building/campground electrical system
only through an approved device and
after the building/campground main
switch is opened. Backfeed
connections can cause severe injury or
death to utility personnel working on
power lines and/or personnel near the
work area. Some states and localities
prohibit unauthorized connection to the
utility electrical system. Install a
transfer switch to prevent
interconnection of the generator set
power and other sources of power.
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)
Servicing the generator set.
Hazardous voltage can cause
severe injury or death. Do not touch
electrical connections when flashing
the generator set. The alligator clips
carry line voltage when the pushbutton
is pressed to flash the generator set.
Hot Parts
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
Checking the coolant level. Hot
coolant can cause severe injury or
death. Allow the engine to cool.
Release pressure from the cooling
system before removing the pressure
cap. To release pressure, cover the
pressure cap with a thick cloth and then
slowly turn the cap counterclockwise to
the first stop. Remove the cap after
pressure has been completely
released and the engine has cooled.
Check the coolant level at the tank if the
generator set has a coolant recovery
tank.
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.
Combustible materials. Fire can
cause severe injury or death. A hot
exhaust system can ignite adjacent
combustible materials. Do not locate
electrical wiring, fuel lines, or
combustible materials above the
exhaust muffler. Exercise caution
when parking your vehicle to prevent
the exhaust system and hot exhaust
gases from starting grass fires.
iv Safety Precautions and Instructions TP-5606 6/02
Page 9
Combustible materials. Fire can
cause severe injury or death. A hot
generator set can ignite debris in the
compartment. Keep the compartment
and generator set clean and free of
debris and combustible materials to
minimize the possibility of fire. Do not
block the fuel/oil drain opening in the
generator set mounting tray. Cut a
corresponding hole in the subfloor, if
used, for the drain opening.
Moving Parts
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
WARNING
Rotating parts.
Can cause severe injury or death.
Moving rotor.
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.
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
This generator set has been
rewired from its nameplate voltage
to
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
Canadian installations only.For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
NOTICE
This generator set does not comply
with United States Coast Guard
(USCG) requirements and must not
be used for marine applications. For
marine installations use only generator
sets specified for marine use. USCG
Regulation 33CFR183 requires that a
generator set must be ignition
protected when used in a
gasoline-fueled environment.
Operate the generator set only when
all guards, screens, and covers are in
place.
WARNING
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
246242
NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
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.
TP-5606 6/02 Safety Precautions and Instructions v
Page 10
Routine Service Parts
Your Kohler generator
dealer/distributor has a complete
listing of parts for your generator
set. Contact him for service.
Part
Description
Air Cleaner Element 258646
Oil Filter 229841
Fuel Filter 225010
Alternator V-belt 225626
Black spray paint 221292
Kohler
Part No.
vi Safety Precautions and Instructions TP-5606 6/02
Page 11
Section 1. Specifications
Introduction
This manual provides troubleshooting and repair
instructions for the 15/20CCO, 15/20CCFO,
15/20CCOZ, and 15/20CCFOZ model generator sets,
controllers, and accessories.
Refer to the engine service manual for generator set
engine service information.
x:in:001:001
This manual may be used for models not listed on the
front cover.
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.
Obtain service from an authorized service distributor/
dealer to keep equipment in top condition.
General Specifications
15 kW (60 Hz) Model 20 kW (60 Hz) Model
Dimensions L x W x H in. (mm):
Remote Radiator (Single Phase) 39.57 x 20.89 x 25.61 39.57 x 20.89 x 27.25................... .....
(1005 x 531 x 650) (1005 x 531 x 692)
Remote Radiator (Single Phase) Airbag Mounted 39.57 x 22.00 x 25.61 39.57 x 22.00 x 27.25..... .....
(1005 x 559 x 650) (1005 x 559 x 692)
In-line Radiator (Single Phase) 45.02 x 20.99 x 28.00 45.02 x 20.99 x 28.00..................... .....
(1144 x 533 x 711) (1144 x 533 x 711)
In-line Radiator (Three Phase) 46.62 x 20.99 x 28.00 46.62 x 20.99 x 28.00..................... .....
(1184 x 533 x 711) (1184 x 533 x 711)
Weight—dry, lbs. (kg):
Remote Radiator (Single Phase) 684 (310) 695 (315)........................ ................
Remote Radiator (Single Phase) Airbag Mounted 684 (310) 695 (315).......... ................
In-line Radiator (Single Phase) 719 (326) 730 (331).......................... ................
In-line Radiator (Three Phase) 719 (326) 730 (331).......................... ................
Air Requirements CFM (M
Combustion. 70 (2) 70 (2)........................................... ...................
Cooling 1930 (55) 1930 (55).............................................. ................
Fuel Inlet Size in. (mm) 1/4-18 N.P.S.F 1/4-18 N.P.S.F.................................. ...........
Fuel Return Size in. (mm) 1/4-18 N.P.S.F 1/4-18 N.P.S.F................................ ...........
3
/min):
x:in:001:002:a
Fuel Consumption gph (Lph):
Load 25% 50% 75% 100%
15 kW 0.6 (2.3) 0.8 (3.0) 1.1 (4.2) 1.4 (5.3)
20 kW 0.9 (3.4) 1.2 (4.5) 1.5 (5.7) 1.9 (7.2)
DERATION: All units are rated 1.0 power factor. The kilowatts of the generator set will decrease 3.5% for each 1,000
feet (305 meters) above 500 feet (152 meters) above sea level and 1% for each 10_F (5.5_C) above 85_F (30_C).
TP-5606 6/02 Specifications 1-1
Page 12
Engine
Some general engine specifications are listed below. Refer to the appropriate service section and the engine service
manual for specific service details.
15 kW Model 20 kW Model
Manufacturer Yanmar.......................................................
Model 4TN84E-RK 4TN84TE-TK..................................... ..............................
Type Water-cooled, 4-cycle diesel engine..................................................
Number Cylinders 4.....................................................
Firing Order 1-3-4-2 1-3-4-2................................. ...................................
Compression Ratio 17.79:1 16.99:1........................... ...................................
Displacement cu. in. (cm
Rated Horsepower (60 Hz) 27.4 36.3..................... ......................................
RPM (60 Hz) 1800.........................................................
Bore in. (mm) 3.307 (84).....................................................
Stroke in. (mm) 3.386 (86)....................................................
Combustion System Direct Injection.............................................
Valve Clearance in. (mm)
Intake 0.0079 (0.2).......................................................
Exhaust 0.0079 (0.2)......................................................
Cylinder Block Material Cast Iron..............................................
Cylinder Head Tightening Torque ft. lbs. (Nm)
Step 1: 25.23--31.1 (3.5--4.3)..................................................
Step 2: 54.23--61.46 (7.5--8.5).................................................
Cylinder Head Material Cast Iron..............................................
Connecting Rod Forged Carbon Steel...............................................
Piston Rings 2 Compression/1 Oil..................................................
Main Bearings, Number and Type 4, Replaceable Sleeves...............................
Governor Mechanical.........................................................
Lubrication System Full Pressure...............................................
Oil Capacity (with filter) qts. (L) 6.1 (5.8).......................................
OilType(API) CCorCD......................................................
Oil Pressure psi (kPa) 42.66--56.88 (294--392).........................................
Fuel Recommendation Diesel--ASTM D975 No. 2-D (Cetane No. > 45).............................
Aspiration Natural Aspiration Turbocharged.............................. ............................
Fuel Injection Pump Yanmar YPES...............................................
Battery Voltage 12........................................................
Battery Ground Negative.....................................................
Battery Recommendation (min.) 625 Cold Cranking Amps 100 Amp Hr..........................
Starter Motor Bendix Automotive Type...............................................
Cooling System Capacity qts. (L)
Remote Radiator (Engine Water Jacket) 2.85 (2.7)...........................
In-lineRadiator 4qts.16oz.(4.26L)...........................................
Timing 16_ ± 1_ 12_ ± 1_..................................... ................................
Air Cleaner Dry Paper Element....................................................
3
) 116 (1910)..........................................
TP-5606 6/021-2 Specifications
Page 13
Generator
Models 15CCO/CCFO/CCOZ/CCFOZ
Model Voltage Amps/
Series Code Voltage Wire Pole kW PH
60 Hz Models:
15CCO 61 120/240 3 62.5 15.0 1
15CCO 101 100/200 3 75.0 15.0 1
15CCOZ 01 120/240 4 45.1 15.0 3
15CCOZ 51 139/240 4 45.1 15.0 3
15CCOZ 51 127/220 4 49.2 15.0 3
15CCOZ 71 227/480 4 22.6 15.0 3
15CCOZ 71 240/416 4 26.0 15.0 3
15CCOZ 81 120/208 4 52.0 15.0 3
50 Hz Models:
15CCFO 101 120/240 3 52.1 12.5 1
15CCFO 61 110/220 3 56.8 12.5 1
15CCFO 11 100/200 3 62.5 12.5 1
15CCFO 41 220 2 56.8 12.5 1
15CCFOZ 51 110/190 4 47.5 12.5 3
15CCFOZ 51 115/200 4 45.1 12.5 3
15CCFOZ 71 220/380 4 23.7 12.5 3
15CCFOZ 71 230/400 4 22.6 12.5 3
15CCFOZ 71 240/416 4 21.7 12.5 3
15CCFOZ 81 120/208 4 43.4 12.5 3
15CCFOZ 81 110/220 4 41.0 12.5 3
Note: 3 phase ratings at 0.8 power factor and
1 phase ratings at 1.0 power factor
Models 20CCO/CCFO/CCOZ/CCFOZ
Model Voltage Amps/
Series Code Voltage Wire Pole kW PH
60 Hz Models:
20CCO 61 120/240 3 83.3 20.0 1
20CCO 101 100/200 3 100.0 20.0 1
20CCOZ 01 120/240 4 60.1 20.0 3
20CCOZ 51 139/240 4 60.1 20.0 3
20CCOZ 51 127/220 4 65.6 20.0 3
20CCOZ 71 227/480 4 30.1 20.0 3
20CCOZ 71 240/416 4 34.7 20.0 3
20CCOZ 81 120/208 4 69.4 20.0 3
50 Hz Models:
20CCFO 101 120/240 3 69.4 16.5 1
20CCFO 61 110/220 3 75.8 16.5 1
20CCFO 11 100/200 3 83.3 16.5 1
20CCFO 41 220 2 75.8 16.5 1
20CCFOZ 51 110/190 4 62.7 16.5 3
20CCFOZ 51 115/200 4 59.6 16.5 3
20CCFOZ 71 220/380 4 31.4 16.5 3
20CCFOZ 71 230/400 4 29.8 16.5 3
20CCFOZ 71 240/416 4 28.7 16.5 3
20CCFOZ 81 120/208 4 57.3 16.5 3
20CCFOZ 81 110/220 4 54.2 16.5 3
Generator Models 15/20 kW
Single-Phase Models Three-Phase Models
RPM (60-Hz Models) 1800 1800..................... .....................................
RPM (50-Hz Models) 1500 1500..................... .....................................
Stator Resistance (ohms)** Leads:
1-2, 3-4, 33-44 0.07 N/A...................... ......................................
1-4, 2-5, 3-6, 7-10, 8-11, 9-12 N/A 0.04........... ......................................
55-33 1.3 N/A............................... .......................................
B1-B2 0.06 0.06.............................. .....................................
Rotor Resistance (ohms) 3.0 3.0.................. .......................................
Exciter Field Resistance N/A 5.8................... .......................................
Exciter Armature Resistance N/A 0.51............... ......................................
TP-5606 6/02 Specifications 1-3
Page 14
Generator Models 15/20 kW (continued)
Rotor field voltage/current readings
at rated voltage (hot)
No load (63 Hz) 19V/5.5 Amps 8V/1.1 Amps.............. ..............................
Full load (60 Hz) 38V/9.0 Amps 20V/2.5 Amps............. .............................
Rotor field voltage/current readings
at rated voltage (hot)
No load (63 Hz) 19V/5.5 Amps 8V/1.1 Amps.............. ..............................
Full load (60 Hz) 44V/10.2 Amps 30V/4.3 Amps............. ............................
20CCFO Single-Phase Models
Rotor field voltage/current readings
at rated voltage (hot)
No load (53 Hz) 23V/5.0 Amps..............
Full load (50 Hz) 60V/11 Amps.............
Stator output voltages with
separately excited rotor
using 12-volt battery (cold)
1-2, 3-4, 33-44 79V....................
33-55 110V...........................
B1-B2 10V...........................
15CCO Single-Phase Models 15CCOZ Three-Phase Models
(60/50 Hz) (60/50 Hz)
20CCO Single-Phase Models 20CCOZ Three-Phase Models
(60/50 Hz) (60/50 Hz)
(50 Hz)
Single-Phase Models
Three-Phase Models
Stator output voltages with
separately excited exciter field
using 12-volt battery (cold)
1-4, 2-5, 3-6, 7-10, 8-11, 9-12 160V.................................................
B1-B2 21V.....................................................................
V0-V7, V0-V8, V0-V9 160V........................................................
55-66 185V......................................................................
Single-Phase Models Three-Phase Models
Excitation Method Static Excited Rotating Exciter................... ............................
Overbolt Torque 25 ft. lbs. (300 in. lbs.).......................................
Voltage Regulator Type PowerBoostä IIIE PowerBoostä V.............. ..........................
Insulation (Rotor and Stator) Class 155, Epoxy Varnish, Vacuum Impregnated.................
Winding Material Copper.............................................
Bearing (Number and Type) 1, Replaceable Ball..............................
Circuit Protection:
Controller 10-Amp Fuse 10-Amp Circuit Breaker....................... .........................
Optional AC Output Manual-Reset Circuit Breaker.............................
Voltage Regulator 10-Amp Fuse 8-Amp Fuse................ ..............................
Fuel Solenoid 10-Amp Fuse.........................................
** Most ohmmeters will not give accurate readings when measuring less than 1 ohm. The stator can be considered
good if a low resistance reading (continuity) is obtained and there is no evidence of shorted windings
(discoloration). Do not confuse a low resistance reading with a reading indicating a shorted winding.
TP-5606 6/021-4 Specifications
Page 15
NOTES
TP-5606 6/02 Specifications 1-5
Page 16
Service View Components
Remote-Radiator Model (See Figure 1-1)
1. Optional AC Circuit Breaker
2. Voltage Regulator Fuse
3. Start-Stop/Preheat Switch
4. Fuel Solenoid Fuse
5. Controller Fuse
6. Hourmeter
7. Controller
8. Remote Connection (at rear of controller)
9. Air Cleaner
10. Lifting Eye
11. Intake Heater
12. Fuel Solenoid
13. Oil Fill
14. Lifting Eye
15. High Water Temperature Shutdown
18. Generator Nameplate
19. Mechanical Governor
20. Oil Filter
21. Fuel Filter
22. Ground Connection
23. Oil Drain
24. Fuel Pump
25. Fuel Inlet Connection Point
26. Fuel Return Connection Point
27. Oil Check
28. Heater Coil Relay
29. Low Oil Pressure Shutdown
30. Voltage Regulator
(inside junction/circuit breaker box)
31. Coolant Outlet
32. Exhaust Outlet
16. Coolant Inlet
17. Oil Fill
33. Battery-Charging Alternator (behind guard)
34. Starter
TP-5606 6/021-6 Specifications
Page 17
5
6
7
10
9
12
11
4
13
14
15
16
17
8
3
18
2
1
19
30
20
29
21
28
27
26
25
24
23
22
31
32
33
34
1-933
Figure 1-1. Service View of 20CCO-RV with Remote Radiator (Typical)
TP-5606 6/02 Specifications 1-7
Page 18
Service View Components
In-line-Radiator Model (See Figure 1-2)
1. Optional AC Circuit Breaker
2. Voltage Regulator Fuse
3. Start-Stop/Preheat Switch
4. Fuel Solenoid Fuse
5. Controller Fuse
6. Hourmeter
7. Controller
8. Remote Connection (at rear of controller)
9. Air Cleaner
10. Lifting Eye
11. Intake Heater
12. Fuel Solenoid
13. Oil Fill
14. Lifting Eye
15. High Water Temperature Shutdown
16. Pressure Cap/Initial Coolant Fill
17. Generator Nameplate
19. In-line Radiator
20. Mechanical Governor
21. Oil Filter
22. Coolant Drain
23. Ground Connection
24. Oil Drain
25. Fuel Inlet Connection Point
26. Fuel Pump
27. Fuel Return Connection Point
28. Oil Check
29. Fuel Filter
30. Heater Coil Relay
31. Low Oil Pressure Shutdown
32. Voltage Regulator
(inside junction/circuit breaker box)
33. Exhaust Outlet
34. Battery Charging Alternator (behind guard on
non-service side of unit)
18. Oil Fill
35. Starter (on non-service side of unit)
TP-5606 6/021-8 Specifications
Page 19
5
6
7
9
10
8
12
11
13
4
14
16
15
17
3
2
18
19
1
20
32
31
30
29
28
27
26
25
23
24
21
22
Figure 1-2. Service View of 20CCO-RV In-line Radiator (Typical)
33
34
35
1-933
TP-5606 6/02 Specifications 1-9
Page 20
TP-5606 6/021-10 Specifications
Page 21
Section 2. Operation
To ensure continued satisfactory operation, the
following items should be checked before each start-up.
Prestart Checklist
OIL LEVEL: Should be at or near full mark (not over).
AIR INLETS: Must be clear and unobstructed.
COMPARTMENT: Interior must be clean. Check the
condition of fuel system, exhaust piping, hoses, and
muffler. If fuel leaks, fumes, exhaust gases, or electrical
sparks are noted, contact a qualified service technician
before operating generator set.
AIR CLEANER: Must be clean and properly installed to
prevent unfiltered air from entering the engine.
ELECTRICAL: All connections (including battery) must
be tight.
FUEL LEVELS: Make sure the fuel tank(s) are full and
the fuel system primed for operation.
DRIVE BELT: Check radiator fan, water pump and
battery-charging belt to make sure it is properly
tensioned and in good condition.
COOLANT LEVEL: If the cooling system is equipped
with a coolant recovery tank, check coolant level (and
refill coolant as necessary) at tank. Maintain level
according to markings on the tank. Coolant level should
be just below the filler neck [approx. 3/4 to 1 1/2 in.
(19.38 mm)] when the engine is cold.
BATTERY: Check connections. Consult the battery
manufacturer’s instructions regarding battery care and
maintenance.
OPERATING AREA: Make sure there are no
obstructions that could block the flow of cooling air.
Make sure the area is clean. Rags, tools, or debris must
not be left on or near the generator set.
EXHAUST SYSTEM: Check for exhaust leaks and
blockages. Check the muffler and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components for cracks and
corrosion (exhaust manifold, exhaust line, exhaust
clamps, and muffler).
D Check for corroded or broken metal parts and replace
them as needed.
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 Check the exhaust gas color. If the exhaust is blue or
black, contact your local distributor/dealer.
D Visually inspect for exhaust leaks. Check for carbon
or soot residue on exhaust components. Carbon and
soot residue indicates an exhaust leak. Seal leaks as
needed.
D Ensure that the carbon monoxide detector is (1) in the
vehicle, (2) functional, and (3) energized whenever
the generator set operates.
Note: Never operate the generator set without a
functioning carbon monoxide detector.
Exercising the Generator
Note: Block heater damage. The block heater will fail
if the energized heater element is not immersed
in coolant. Fill the cooling system before turning
on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from
the system before energizing the block heater.
TP-5606 6/02 Operation 2-1
Run the generator set once a week for one hour (under
load). The operator should be in attendance during this
period. Be sure to make all “Prestart Checks” before
starting the exercise procedure. Start the generator set
according to the procedure given for the generator
controller.
Page 22
Controller (Single Phase)
Depending on application, the Kohler relay controller
may be located at the set or at a location remote from the
generator. Remote harnesses for the controller are
available in 7.5- and 15-foot (2.3- and 4.6-meter)
lengths. If the generator set has automatically stopped
due to high water temperature (230_F/110_C) or low oil
pressure (6.8 psi/46.9 kPa or less), the cause must be
corrected before the set can be restarted.
Refer to Figure 2-1 and the following descriptions to
identify controller components.
1. Generator Start and Stop/Preheat Switch
serves the dual function of generator operation and
generator preheat. When pressed to the “preheat”
position, the preheat switch aids in cold weather
starting. Refer to “Start/Stop” and “Preheating”
procedures following.
2. Fuel Solenoid Fuse. 10-amp fuse protects fuel
solenoid circuitry.
3. Controller Fuse. 10-amp fuse protects controller
circuitry against damage if a short develops in the
engine wiring system or the wiring to the remote
start/stop switch.
4. Remote Switch Connection (located at rear of
controller). Connect the remote start/stop switch to
operate the generator set at a location remote from
the set. Controller connections are made through
the plug connector at the rear of the unit.
5. Hourmeter. Records total generator set operating
hours for reference in maintenance schedule.
1 2 3 4 5
1-932
Figure 2-1. Single-Phase Controller
Controller (Three Phase)
For identification of three-phase controller, see
Figure 2-2.
1 2 3 4 5
1-932
Figure 2-2. Three-Phase Controller
1. Generator Start and Stop Preheat Switch serves
the dual function of generator operation and
generator preheat. When pressed to the “preheat”
position, the preheat switch aids in cold weather
starting. Refer to “Start/Stop” and “Preheating”
procedures following.
2. DC Circuit Breaker--the generator set will
shutdown automatically after fault. See “Circuit
Protection” following.
3. Hourmeter. Records total generator set operating
hours for reference in maintenance schedule.
4. AC Circuit Breaker (optional) will trip when a fault
is detected in the output circuit. Used to disconnect
generator set during maintenance of vehicle
wiring. To close circuit breaker(s), place in ON
position.
5. Fuel Solenoid Fuse (located inside the controller).
10-amp fuse protects fuel solenoid circuitry.
TP-5606 6/022-2 Operation
Page 23
Preheat Feature
Stopping Procedure
During cold weather starts (below 23_F[--5_C]), place
controller start switch in STOP/PREHEAT position for
15 to 20 seconds before attempting to start the
generator set. This provides energizing of the air heater
coil. Do not energize preheat feature for more than 30
seconds or damage may occur.
Starting Procedure
Move the START-STOP/PREHEAT switch to the
START position and hold in this position until the engine
is running, then release. Do not crank engine
continuously for more than 10 seconds at a time. If the
engine does not start, allow a 60-second cooldown
period between cranking attempts. If the unit fails to start
after three attempts, contact an authorized service
dealer/distributor for repair. Failure to follow these
guidelines may result in burnout of the starter motor.
NOTE
If the engine starts and then stops, allow the engine to
come to a complete stop before making a restart
attempt. If the flywheel ring gear is still rotating when the
starter pinion gear is engaged, the pinion gear will clash
which may damage the ring gear teeth.
NOTE
Whenever possible, allow a brief cooling period by
running the set at low or no load for a few minutes just
prior to shutdown. To stop, move the switch to the STOP
position and hold until the set comes to a complete halt.
If the generator set shuts down automatically, identify
and correct the problem before attempting to restart.
NOTE
Do not place Start-Stop/Preheat switch in Stop/Preheat
position for more than 30 seconds or damage to the
preheat feature may occur.
If ambient temperature is below 23_F(--5_C), see
“Preheat Feature”.
TP-5606 6/02 Operation 2-3
Page 24
Fault Shutdowns
High Water Temperature
Shutdown Switch
Low Oil Pressure
Shutdown Switch
The low oil pressure (LOP) shutdown feature protects
the engine against internal damage if the oil pressure
drops below 6.8 psi (46.9 kPa) due to an oil pump fault or
other engine malfunction. The LOP shutdown does not
protect the set from damage due to operating with the oil
level below the safe range—IT IS NOT A LOW OIL
LEVEL SHUTDOWN. The only protection against
running out of oil is to check the oil level regularly and
add oil as needed. Location of the LOP shutdown switch
is shown in Figure 2-3.
NOTE
This is not a low oil level shutdown. Proper oil level must
be maintained for low oil pressure shutdown switch to
function.
1
The generator set is also equipped with a high water
temperature (HWT) shutdown switch. See Figure 2-4.
The unit will automatically shut down when the engine
coolant temperature exceeds 230_F(110_C). Cause of
the shutdown must be corrected before the generator
can be restarted.
NOTE
This is not a low coolant level switch. Proper coolant
level must be maintained for high water temperature
shutdown switch to function.
1
1-933
1. Low Oil Pressure Switch
Figure 2-3. Low Oil Pressure Shutdown Switch
1-933
1. High Water Temperature Switch
Figure 2-4. High Water Temperature
Shutdown Switch
TP-5606 6/022-4 Operation
Page 25
Circuit Protection
Refer to Figure 2-5 and the following descriptions to
identify controller components.
1. 10-Amp Fuel Solenoid Fuse. A replaceable
10-amp fuse protects the fuel solenoid. (On
three-phase models the in-line fuse is mounted
inside the controller.) If this fuse is blown, the
generator will shut down. If the fuse is replaced
then blows again, have the generator set examined
by an authorized Kohler service dealer/distributor.
2. 10-Amp Controller-Input Fuse (Single Phase)
or Circuit Breaker (Three Phase). The controller
circuitry is protected by a replaceable 10-amp fuse
or circuit breaker. If the generator will not crank and
the battery and/or connections appear okay, the
controller fuse/breaker may be blown or tripped.
Contact an authorized Kohler service
dealer/distributor if fuse/breaker blows/trips
repeatedly.
3. 10-Amp PowerBoostä IIIE Voltage Regulator
Fuse (Single-Phase Models) or
8-Amp PowerBoostä V Voltage Regulator Fuse
(Three-Phase Models).
A replaceable fuse protects the voltage regulator
circuitry. If this fuse is blown, the generator set will
shut down. If this fuse is replaced then blows again,
have the generator set examined by an authorized
Kohler service dealer/distributor.
4. Optional AC Circuit Breaker(s) will trip when a
current overload is detected in the AC output
circuit. See Section 4--Troubleshooting to
determine cause of fault. After fault is corrected,
reset AC circuit breaker by placing in “ON” position.
1 2
34
Single Phase
1, 3
2 4
Three Phase
1-933
Figure 2-5. Circuit Protection
TP-5606 6/02 Operation 2-5
Page 26
Accessories
Several accessories are available to finalize the
installation or to add convenience to operation and
service. All the most current information can be obtained
by contacting your local Kohler dealer/distributor.
Available accessories at the time of print of this
publication are as follows.
Remote Connection/Extension
Harness
Provides additional wiring between all remote panels
and controller connector in 15 ft. (4.6 m) or 25 ft. (7.6 m)
increments. One required for each Remote Meter Panel
Kit.
Engine Sender Kit
Provides gauge senders for the Remote Start and
Two-Meter Panel kit, and the Remote Start and
Four-Meter Panel kit. The gauge sender kit is required to
make the oil pressure and water temperature gauges
functional.
12-Inch Remote Wiring Harness
This one-foot (0.3-m) wiring harness has a 6-pin
connector on one end which is keyed to controller box
connector. The other end has pigtails for connection to
customer-supplied start switch, generator “ON” light,
hourmeter, etc.
Exhaust Systems
This silencer is engineered and designed specifically for
your Kohler RV generator set to assure optimal
performance and sound attenuation. Stainless steel
flexible exhaust connectors help to absorb shock and
prevent damage to your genset’s exhaust system.
Exhaust connectors are both corrosion and heat
resistant.
TP-5606 6/022-6 Operation
Page 27
Remote Panels
(Optional)
Remote Start Panel
Allows starting/stopping from a location remote of the
generator set. Supplied with 15 ft. (4.6 m) connection
harness. Overall mounting dimensions are 4.06 in. (103
mm) by 2.12 in. (54 mm). Generator sets are equipped
with a 6-pin connector on controller for connection of the
kit. See Figure 2-6 and Figure 2-7.
+-
P
10 A.
Fuse
P
P1-14
K2
K1
P2-3
53(70) 3(47)
P3-2
(P3-4)
Violet
Yellow/
Red
P3-4
(P3-5)
Stop/Preheat
Local
Switch
3(47)
P2-4
Relay
Circuit
Board
P2-7
Stop/
Preheat
Start
Start
Grey/
Black
2(43)
P2-5 P2-6
P2-8
2(43)
P3-5
(P3-6)
Remote
Switch
N
P1-9
4(N)
P2-9
4(N)
P3-1
Black
Figure 2-6. Remote Start Panel
TT-872
Gen. ‘ON’
Light
NOTE
Wire and pin numbers for
single-phase systems may differ
from those for three-phase systems,
where they are different, the
single-phase numbers are shown
first followed by the three-phase
numbers in parentheses.
NOTE
Remote Start Panel harness is not
color coded. Lead 2(43) connects to
J3-6. Lead 3(47) connects to J3-5.
Lead 4(N) connects to J3-1. Lead
53(70) connects to J3-4. Color
coded leads used on remote
harnesses only.
NOTE
When the Start-Stop/ Preheat
Switch is in the Start position,
contacts 3 and 4 are closed.
TT-872
Figure 2-7. Remote Start Panel Kit
TP-5606 6/02 Operation 2-7
Page 28
Remote Start and
Two-Meter Panel Kit
Water Temperature Gauge--Measures engine coolant
temperature. Normal engine operating range is
180--205° F (82--96°C).
Allows starting/stopping from a location remote of the
generator set. The illuminated gauges include engine oil
pressure gauge and water temperature gauge.
Generator sets come equipped with a 6-pin connector
on controller for connection of the kit. Overall
dimensions are 6 in. (152 mm) by 6 in. (152 mm) with a
minimum mounting depth of 2.75 in. (70 mm). Requires
Remote Connection/Extension Harness and sender kit.
See Figure 2-8 and Figure 2-9 for remote start and
two-meter panel kit.
+-
P
10 A.
Fuse
P
P1-14
K2
K1
P2-3
53(70)
P3-2
(P3-4)
Violet
Yellow/
Red
Stop/Preheat
Local
Switch
3(47)
P2-4
Relay
Circuit
Board
P2-7
3(47)
P3-4
(P3-5)
Stop/
Preheat
Start
Start
Grey/
Black
2(43)
4(N)
P2-5 P2-6
P2-8 P2-9
4(N)
2(43)
P3-1
P3-5
(P3-6)
Remote
Switch
N
P1-9
Black
P4-13
(P4-2)
10(5)
Tan
W.T.
Sender
P3-3
(P3-2)
P4-10
(P4-3)
11( 7 C )
L.
Blue
O.P.
Sender
P3-6
(P3-3)
TT-874
Figure 2-8. Remote Start & Two-Meter Panel Kit
Start-Stop/Preheat Switch--Rocker-type switch with
“ON” light used to start and stop generator set.
During cold weather starts (below 50_F[10_C]):
Place controller start switch in STOP/PREHEAT
position for 15--20 seconds before attempting to start
generator set. This provides energizing of the glow
plugs.
Engine Oil Pressure Gauge--Measures engine oil
pressure. Normal engine operating range is 36--50 psi
(248--345 kPa).
NOTE
During the engine break-in period, it is normal for the
engine to produce higher oil pressure readings.
Gen. ‘ON’
Light
Water Temp.
Gauge
Oil Pressure
Gauge
NOTE
Wire and pin numbers for
single-phase systems may differ
from those for three-phase systems,
where they are different, the
single-phase numbers are shown
first followed by the three-phase
numbers in parentheses.
NOTE
When the Start-Stop/Preheat
Switch is in the Start position,
contacts 3 and 4 are closed.
Figure 2-9. Remote Start and
Two-Meter Panel Kit
TT-874
TP-5606 6/022-8 Operation
Page 29
Remote Start and
Four-Meter Panel Kit
Hourmeter--Records total generator set operating
hours for reference in maintenance scheduling.
Allows starting/stopping from a location remote of the
generator set. The illuminated gauges include a DC
voltmeter, engine oil pressure gauge, water
temperature gauge, and generator running time
hourmeter which records total generator set operating
hours. Generator sets come equipped with a 6-pin
connector on controller back panel for connection of the
kit. Overall dimensions are 9 in. (229 mm) by 6 in. (152
mm) with a minimum depth of 4 in. (102 mm). Requires
Remote Connection/Extension Harness and sender kit.
See Figure 2-10 and Figure 2-11 for remote start and
four-meter panel features.
+-
P
10 A.
Fuse
P
P1-14
K2
K1
P2-3
53(70)
P3-2
(P3-4)
Violet
Yellow/
Red
Stop/Preheat
Local
Switch
3(47)
P2-4
3(47) 2(43) 4(N)
Start
Relay
Circuit
Board
P2-7
Grey/
Black
P3-4
(P3-5)
Stop/
Preheat
Start
2(43)
P2-5 P2-6
P2-8
P2-9
P3-1
P3-5
(P3-6)
Remote
Switch
4(N)
N
P1-9
P4-13
(P4-2)
Black
W.T.
Sender
10(5)
P3-3
(P3-2)
Tan
O.P.
Sender
P4-10
(P4-3)
11( 7 C )
P3-6
(P3-3)
L.
Blue
TT-873
Figure 2-10. Remote Start and
Four-Meter Panel Features
Start-Stop/Preheat Switch--Rocker-type switch with
“ON” light used to start and stop the generator set.
During cold weather starts (below 50_F[10_C]):
Place controller start switch in STOP/PREHEAT
position for 15--20 seconds before attempting to start
generator set. This provides energizing of the glow
plugs.
DC Voltmeter--Measures voltage of starting
battery(ies). Normal battery operating range is 12--14
Vol ts.
Engine Oil Pressure Gauge--Measures engine oil
pressure. Normal engine operating range is 36--50 psi
(248--345 kPa).
NOTE
During the engine break-in period, it is normal for the
engine to produce higher oil pressure readings.
Water Temperature Gauge--Measures engine coolant
temperature. Normal engine operating range is
180--205° F (82--96° C).
Gen. ‘ON’
Light
Water Temp.
Gauge
Oil Pressure
Gauge
DC Voltmeter
Hourmeter
NOTE
Wire and pin numbers for
single-phase systems may differ
from those for three-phase systems,
where they are different, the
single-phase numbers are shown
first followed by the three-phase
numbers in parentheses.
NOTE
When the Start-Stop/Preheat
Switch is in the Start position,
contacts 3 and 4 are closed.
TT-873
Figure 2-11. Remote Start & Four-Meter Panel Kit
TP-5606 6/02 Operation 2-9
Page 30
TP-5606 6/022-10 Operation
Page 31
Section 3. Scheduled Maintenance
General
Schedule routine maintenance using the Maintenance
Schedule following and the hourmeter located on the
generator controller. If the generator will be subject to
extreme operating conditions, service the unit more
frequently. Instructions to perform most of the
scheduled services are provided in the following pages.
Items in the maintenance scheduled marked with an
asterisk (*) should be performed more often if the
generator set is operated in dirty, dusty conditions. Items
identified with asterisks (**) should be performed only by
an authorized Kohler service dealer/distributor. Tools
and instruments required for these additional steps are
usually not available to the generator set owner. For this
reason, the set should be returned periodically to an
authorized service dealer/distributor for complete
servicing and tune-up. The benefits of such service will
be improved performance and continuous satisfactory
operation during a long trouble-free service life.
NOTE
The items listed in the maintenance schedule must be
performed at the designated intervals for the life of the
generator. For example, an item to be serviced “every
100 hours or 3 months” must also be serviced after 200
hours or 6 months, 300 hours or 9 months, etc. The
generator will eventually accumulate enough hours to
warrant a complete overhaul. The exact time at which
extensive service will be necessary cannot be
predicted. However, rough operation, lack of power, and
excessive oil use indicate serious generator set
problems. As part of a preventive maintenance
program, service the engine (clean cylinder head,
inspect valves, check compression, etc.) and generator
(replace bearing, inspect wiring, remove debris, etc.) at
the earliest indication that a serious problem exists.
TP-5606 6/02 Scheduled Maintenance 3-1
Page 32
Every 300
Hours or
6 Months
Perform Service at Intervals Indicated (X)
Before
Each
Start-up
Every 50
Hours or
1 Month
Every 100
Hours or
3 Months
FUEL SYSTEM
Check the fuel level X........................
Fill fuel tank X...............................
Remove sediment from fuel tank X.............
Replace the fuel filter element X X.......................... ....................
(Break-in Period)
Remove sediment from the fuel/water
separator, if equipped X X................................ ................................
(Break-in Period) (Replace
Check the injection timing** X...............................................................
Check governor operation and adjust
as necessary** X.........................................................................
Check the injection spray condition** X.......................................................
LUBRICATION SYSTEM
Check the oil level in crankcase X..............
Replace the oil in crankcase* X X........................... .........
(Break-in Period)
Replace the lube oil filter element* X X....................... .........
(Break-in Period)
COOLING SYSTEM
Check coolant level X........................
Adjust the tension of water pump V-belt X X.................. .........
(Break-in Period)
Change coolant X..........................................................................
Clean radiator fins, inspect hoses X...................................
INTAKE/EXHAUST SYSTEM
Replace the air cleaner element* X...............................................
Clean the breather pipe* X...........................................
Inspect the complete exhaust system and components ** X......................................
ELECTRICAL SYSTEM
Verify proper operation of gauges (if equipped) X.
Check the electrolyte level in the battery X......
Check the electrical connections X........................
Check the battery specific gravity X...................................
Adjust battery charging alternator V-belt X X.................. .........
(Break-in Period)
CYLINDER HEAD
Check for leakage of water and oil X X............ ........
Retighten all major nuts and bolts X X....................... ................................
(Break-in Period)
Check mounting bolts and vibro mounts
for tightness X...............................................................
Retighten the cylinder head bolts** X.........................................................
Adjust intake and exhaust valve clearance** X.....................................
GENERATOR
Blow dust out of generator* X................................................................
Clean slip rings and inspect brushes (Single-phase units only)** X................................
* Service more frequently if operated in dusty areas.
** Should be performed by an authorized Kohler service dealer/distributor.
Every 500
Hours or
Yearly
element at
600 hours)
TP-5606 6/023-2 Scheduled Maintenance
Page 33
Lubrication System
Oil Selection
The selection of engine oil is very important to a diesel
engine. If an unsuitable oil is used or an oil change is
neglected, damage and a shorter engine life may result.
Oil must meet the American Petroleum Institute (API)
classification of CC or CD. Avoid mixing different brands
of oils and lubricants; oils of different manufacturers may
be incompatible and deteriorate when mixed.
Recommended SAE viscosity designations for given
temperature ranges in which the generator set will be
operated are listed in Figure 3-1.
NOTE
Failure to observe these standards may cause
inadequate oil pressure and cold-starting difficulties.
S.A.E. Service
Grade
5W
10W
5W
5W20
10W
Oil Check
Check crankcase oil level daily or before each start to
insure that the level is in the safe range. To check oil
level, remove oil dipstick and wipe dipstick clean (see
Figure 3-2). Reposition dipstick in crankcase and push it
all the way down into the tube. Remove dipstick and
check the level. Oil level should read between MIN and
MAX marks on dipstick. Do not operate set if oil level
exceeds the MAX mark or registers below the MIN mark
on dipstick.
1
2
10W30
20W
20
30
40
°C°F--30 --20 --10 0 10 20 30 40
0 20 40 60 80 100
Figure 3-1. Engine Oil Selection
20W
20W40
SAE 20
SAE 30
SAE 40
Operating Temperature
Recommended Value
Usable Limit
°C
°F
1-933
1. MAX Level 2. MIN Level
Figure 3-2. Oil Level Check
NOTE
Do not check oil level when the set is in operation. The
engine must be stopped and on a level surface when
checking oil. Most accurate oil reading is obtained by
shutting down the generator and waiting several
minutes before checking oil.
TP-5606 6/02 Scheduled Maintenance 3-3
Page 34
Oil Change
NOTE
On a new engine, change the oil after the first 50 hours of
operation and thereafter at 100-hour intervals or 3
months, whichever occurs first. Change oil more
frequently under dirty, dusty conditions. Change oil
while the engine is still warm.
1. Place a container below the oil drain hole and
remove oil drain plug. Allow sufficient time for the
old oil to drain completely. Replace oil drain plug.
Dispose of used engine oil in an environmentally
safe manner. Take used oil to a suitable collection
facility in the area. DO NOT POUR USED OIL ON
THE GROUND, DOWN SEWERS, OR INTO
STREAMS OR OTHER BODIES OF WATER.
2. Remove oil fill cap. One is located on the
rocker-arm cover and one is located near the fuel
injector pump. See Figure 3-4.
3. If the engine oil filter is to be replaced, see “Oil
Filter” following.
4. Fill crankcase with proper amount and type of oil,
see Figure 3-3 and “Oil Selection.”
Too high an oil level causes high oil consumption and
carbonizing of the engine. Low oil level will cause engine
damage.
1
NOTE
To avoid overfilling, check dipstick before adding
the last quart of oil. Add oil gradually and check oil
level several times.
5. Start the generator set and check for oil leaks.
6. Stop the generator set. Remove the dipstick and
wipe clean, reinsert as far as possible, and remove
to check oil level. Add oil, as necessary, to bring
leveluptoMAXmark.
OIL CAPACITY
(with Filter)
qts. (L)
15 kW 6.1 (5.8).........................
20 kW 6.1 (5.8).........................
1-933
1. Oil Fill
Figure 3-4. Oil Fill Locations
Figure 3-3.
TP-5606 6/023-4 Scheduled Maintenance
Page 35
Oil Filter
Replace the oil filter for the first time after 50 hours or 1
month of operation and then every 100 hours or 3
months. Change more frequently if operating in dirty,
dusty conditions. See Figure 3-5 and refer to the
following procedure.
1
1-933
1. Loosen oil filter by turning with a filter wrench in a
counterclockwise direction. Use rags to clean up
spilled oil. Remove and discard.
2. Clean contact surface on oil filter adapter.
3. Lightly lubricate the gasket surface of the new oil
filter with the fresh engine oil. Thread oil filter to
adapter until gasket makes contact, hand tighten
an additional one-half turn.
4. Fill crankcase with fresh oil and check for leaks as
detailed in steps 4 thru 6 of Oil Change procedure
on previous page.
1. Oil Filter
Figure 3-5. Oil Filter Location
TP-5606 6/02 Scheduled Maintenance 3-5
Page 36
Fuel System
Specification
Use a clean, good quality No. 2-D (DIN 51 601) diesel
fuel oil. The fuel must meet the requirements of the
American Society of Testing and Materials (ASTM)
diesel fuel classification D975 (Federal Specification
W-F-800a). Cleanliness of the fuel is especially
important on diesel engines which have easily clogged
precision fuel injectors and pumps. See chart below.
United States ASTM/D975 No. 2-D Diesel
United KingdomBS2869 Class A1 or Class A2
Other Considerations:
Sulfur Content Less than 0.5%...................
Sediment/Water Content Not to exceed 0.1%.......
Cetane Number 45 minimum.....................
Pour point At least 10_F (5.6_C)..................
Below the lowest outside
air temperature
NOTE
Fuel Filter
The fuel filter serves to remove water and dirt contained
in the fuel. The fuel filter element is paper and no attempt
should be made to clean it. Its useful life will be
determined largely by the quality and condition of the
fuel used. Under normal conditions, the fuel filter
element should be replaced for the first time after 50
hours or one month and then every 300 hours or six
months. See Figure 3-6 for location and use the
following procedure to service the fuel filter.
1. Loosen the fuel filter by turning in a
counterclockwise direction. Use rags to clean up
spilled fuel oil. Remove and discard filter.
2. Clean contact surface on the fuel filter adapter.
3. Lightly lubricate the gasket surface of the new fuel
filter with fresh fuel oil. Thread the fuel filter to the
adapter until the gasket makes contact, hand
tighten an additional one-half turn.
4. See “Bleeding” section following.
1
Never store diesel fuel in galvanized containers; diesel
fuel and the galvanized coating react chemically to
produce flaking which quickly clogs filters or causes
failure of the fuel pump or injectors. Do not run the
generator set out of fuel; air will be drawn into the fuel
lines and the entire system will have to be bled before
the unit can be restarted.
NOTE
Avoid storing fuel over long periods of time. Take special
precautions to keep all dirt, water, and other
contaminants out of the fuel. Storage tanks containing
diesel fuel contaminated with water may cause the
growth of “microbes.” The presence of microbes will
form a slime which will clog fuel filters and lines.
1-933
1. Fuel Filter
Figure 3-6. Fuel Filter Location
TP-5606 6/023-6 Scheduled Maintenance
Page 37
Bleeding the Fuel System
If the generator set engine runs out of fuel, air leaks
develop in the suction side of the fuel system, or the fuel
filter is replaced, it will be necessary to bleed the entire
system to prevent starting failures and/or erratic
operation. See Figure 3-7 and refer to the following
procedure.
1. Disconnect lead 5 (single phase) or 71A (three
phase) from the starter relay to disable cranking
during the bleeding procedure.
2. Fill the fuel tank.
3. Loosen the line connection at the fuel filter.
4. Crank the engine until fuel (free from bubbles)
flows from the loosened connection. Tighten the
fuel line connection.
5. Loosen the small vent screw (with Phillips head) on
the fuel filter.
6. Crank the engine until fuel (free from bubbles),
flows from this point. Tighten vent screw.
Draining the fuel system. Explosive fuel vapors can
cause severe injury or death. Spilled fuel can cause an
explosion. Use a container to catch fuel when draining the fuel
system. Wipe up spilled fuel after draining the system.
1
2
3
4
7. Loosen the line connection (bleed point) at the fuel
injection pump inlet.
8. Crank the engine to operate the fuel pump until fuel
(free from bubbles) flows from this loosened
connection. Tighten line connection.
9. Reconnect lead 5 or 71A to the starter relay.
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and
using fuels.
6
1. Line Connection (Bleed
Point)
2. Vent Screw
3. Line Connection (Bleed
Point)
5
4. Fuel Injection Pump
5. Electric Fuel Pump
6. Fuel Filter
Figure 3-7. Bleeding the Fuel System
1-933
TP-5606 6/02 Scheduled Maintenance 3-7
Page 38
Fuel Solenoid
The fuel solenoid (Figure 3-8) serves to stop fuel flow
through the fuel injection pump when the
start-stop/preheat switch is placed in the STOP position.
If the fuel solenoid is removed or the setting is believed
incorrect, readjust according to the following procedure.
Do not modify the solenoid linkage during reconnection.
1. Disconnect the ball joint from the fuel solenoid
plunger.
2. Pull the linkage toward the fuel solenoid until the
fuel control lever contacts its internal full-open
stop.
3. Push the linkage back toward the fuel control lever
1/16 in. (1.6 mm) and hold the linkage in this
position.
4. Push the plunger fully into the solenoid.
5. Adjust the linkage length so the ball joint can be
attached to the fully depressed plunger while the
fuel control lever is still 1/16 in. (1.6 mm) from the
full-open position.
1
1. Fuel Solenoid
2. Ball Joint
Figure 3-8. Fuel Solenoid Location
2
3. Linkage
3
1-933
6. Re-attach the ball joint to the solenoid plunger.
TP-5606 6/023-8 Scheduled Maintenance
Page 39
Air Cleaner Service
The paper element should be replaced at 300-hour or
6-month intervals; change more frequently if operating
under dirty, dusty conditions. Operating the set with a
dirty air cleaner element may cause engine damage and
increased fuel consumption. At the time of service,
clean the air cleaner breather pipe and remove all dust
and foreign matter from the air cleaner housing. See
Figure 3-9 and refer to the following procedure.
1
2
1. Loosen eyebolt and clamp enough to remove the
air cleaner cover.
2. Remove wing nut and slide air cleaner element
from the threaded rod.
3. Clean dry element by tapping edges on a hard
surface. Replace if damaged or very dirty.
NOTE
Do not attempt to clean dry-type element in any
liquid or with compressed air as this will damage
paper filter material.
4. Wipe dirt or dust accumulation from cover and
base. Check that all clamps are tight on inlet/outlet
connections.
5. Install air cleaner element on threaded rod. Tighten
wing nut making sure parts fit properly.
6. Position cover with arrow up; place clamp over
base and cover, and tighten eyebolt.
6
1. Eyebolt/Clamp
2. Base
3. Cover
5
4. Element
5. Threaded Rod
6. Wing Nut
Figure 3-9. Air Cleaner Components
34
1-932
TP-5606 6/02 Scheduled Maintenance 3-9
Page 40
Governor
The centrifugal, mechanical-type governor serves to
keep the engine speed constant by automatically
adjusting the amount of fuel supplied to the engine
according to changes in the load. No regular service is
required on the unit. The governor is adjusted during
run-in at the factory, and further adjustment should not
be needed unless greatly varying load conditions are
encountered or if poor governor control develops after
extended usage.
60-Hz generator sets are designed to operate at 60--63
Hz, 1800 rpm under full load and 1890 rpm under no
load.
50-Hz generator sets are designed to operate at
50--52.5 Hz, 1500 rpm under full load and 1575 rpm
under no load.
1
1-933
To check speed, use a hand-held tachometer or
frequency meter. See Figure 3-10. Loosen the locking
nut on the speed-adjusting screw. Turn the screw in a
counterclockwise direction to increase speed (and
frequency) or in a clockwise direction to decrease
speed. Tighten the locknut to secure at new setting.
1. Locking Nut
Figure 3-10. Governor
TP-5606 6/023-10 Scheduled Maintenance
Page 41
Cooling System
Cooling System Description
The generator set engine is water cooled. The closed
loop cooling system includes the engine water pump,
which circulates the cooling water, and the engine
thermostat which opens and closes the cooling water
flow to maintain a constant engine temperature.
Depending upon the installation requirements, the fan
may be pusher type that blows air away from the engine
or a suction type that draws air toward the engine.
Hot water from the engine is cooled in a radiator and
then returned to the water pump for recirculation in the
cooling passages of the engine. Depending upon the
generator set model, the radiator may be mounted
in-line (on the front of the engine) or at a remote location
by the coach manufacturer. Components of the cooling
system with an in-line radiator are shown in Figure 3-11
and Figure 3-12. For a cooling system with a remote
radiator, the radiator and its mounting provisions on the
engine are replaced by a belt guard. See Figure 3-13.
Hoses then connect the water pump and thermostat
ports to the remote radiator. Either system may include
an optional overflow tank connected to the overflow tube
from the radiator.
TP-5606 6/02 Scheduled Maintenance 3-11
Page 42
3
4
13
14
15
16
17
1
2
To
Water
Pump
To Engine
10
2
5
6
7
8
12
1. Upper Radiator Hose
2. Hose Clamp
3. Radiator Pressure Cap
4. Radiator Assembly
5. Lower Radiator Hose
6. Radiator Mounting Bracket
7. Vibro Mount
8. Radiator Bracket
9. Engine Mounting Bracket
11
10. Engine Mounting Bracket
11. Right Belt Guard
12. Top Belt Guard
13. Left Belt Guard
14. Fan Shroud
15. Fan
16. Gasket
17. Thermostat Housing
Figure 3-11. In-Line Radiator Cooling System Components
9
CM-250000
TP-5606 6/023-12 Scheduled Maintenance
Page 43
1
2
ADV-5834-B
1. Initial Coolant Fill 2. Coolant Drain
Figure 3-12. Initial Coolant Fill and Coolant Drain Locations (In-line-Radiator Model)
1
2
3
ADV-5834-B
1. Coolant Outlet (Thermostat Housing)
2. Belt Guard
3. Coolant Inlet (Water Pump)
Figure 3-13. Coolant Inlet and Outlet Connections (Remote-Radiator Model)
TP-5606 6/02 Scheduled Maintenance 3-13
Page 44
Cooling System Servicing
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
Checking the coolant level. Hot coolant can cause severe
injury or death. Allow the engine to cool. Release pressure
from the cooling system before removing the pressure cap. To
release pressure, cover the pressure cap with a thick cloth and
then slowly turn the cap counterclockwise to the first stop.
Remove the cap after pressure has been completely released
and the engine has cooled. Check the coolant level at the tank
if the generator set has a coolant recovery tank.
Clean Radiator Fins/Inspect Hoses
To prevent the inconvenience of having the generator
set shut down or become damaged due to overheating,
keep the cooling air inlets clean and unobstructed at all
times. Inspect the exterior of the radiator for
obstructions; remove all dirt and foreign material with a
soft brush or cloth (to avoid damaging radiator fins).
Check all hoses and connections for leaks and replace
any hoses that are cracked, frayed, or feel spongy.
When coolant level checks are made, check condition of
the radiator cap rubber seal; replace if cracked or
deteriorating. Remove dirt and other debris from the
radiator cap and filler neck.
for remote radiator cooling system capacity. Drain
petcocks are provided on the bottom tank of the radiator
and another in the engine block to drain the system.
When draining the coolant, remove the radiator cap and
open the block drain located near the flywheel housing;
this will allow the entire system to drain and prevent air
pockets from forming and restricting coolant passage in
the block. To refill the cooling system, close the drain
petcocks and fill the radiator to the proper level with the
recommended coolant mixture. Install the radiator cap
and operate the engine until the thermostat opens and
the radiator upper hose becomes hot. Stop the engine
and allow to cool. Add coolant to the radiator to just
below the overflow tube on the filler neck. Install the
radiator cap.
A coolant solution of 50% ethylene glycol and 50%
clean, softened water is required to inhibit corrosion,
prevent freezing to --34_F(--37_C), and to improve
cooling. The antifreeze should contain a rust inhibitor
and be changed every two years. Do not use alcohol or
methanol antifreeze or mix them with the coolant. Do not
add coolant to an engine that has overheated until the
engine has cooled. Adding coolant to an extremely hot
engine can cause a cracked block or cylinder head.
Check Coolant Level
Check coolant level frequently and add antifreeze
solution as needed to maintain level just below the
overflow tube and at the min. level in the coolant
recovery tank when cold (max. when hot).
NOTE
Change Coolant
Coolant capacity for the 15/20 kW in-line radiator model
is 4 qts. 16 oz. (4.26 L). Consult the coach manufacturer
Special attention should be given when checking for
proper coolant level. After a radiator has been drained,
some time is normally required before complete refill of
all air cavities take place.
TP-5606 6/023-14 Scheduled Maintenance
Page 45
Battery Charging
WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
Exposed moving parts can cause severe injury or death.
Keep hands, feet, hair, and clothing away from belts and
pulleys when unit is running. Replace guards, covers, and
screens before operating generator set.
The generator is equipped with a 40-amp, belt-driven
battery charging alternator. See Figure 3-14. It is
attached to the engine block by a bracket and serves to
keep the battery constantly charged. Be sure to observe
battery polarity when connecting the battery to the
generator set. The alternator requires no maintenance
other than maintaining belt tension. To adjust the
alternator belt tension, see “Belt Tension.”
Belt Tension
The tension of the alternator/fan belt should be adjusted
so that it can be depressed about 0.4--0.6 in. (10--15
mm) when finger pressure is applied. See Figure 3-15.
Use the following procedure to adjust the belt.
1
2
3
4
1
1. Battery-Charging Alternator
Figure 3-14. Battery-Charging Alternator
1-933
CN250000
1. Adjusting Screw
2. Battery-Charging
Alternator Pulley
3. Pivot Screw
4. Check Alternator Belt
Tension Here
Figure 3-15. Belt Tension
1. Disconnect battery, negative lead first.
2. Loosen pivot and adjusting screws.
3. While prying battery-charging alternator outward to
attain proper tension, tighten adjusting screw.
4. Tighten pivot screw.
5. Recheck and adjust as necessary.
6. Reconnect battery, negative lead last.
NOTE
Also, check fan belt for cracks or tears and replace
if necessary.
TP-5606 6/02 Scheduled Maintenance 3-15
Page 46
Battery
Use a 12-volt battery with a rating of at least 625 cold
cranking amps. When using a Maintenance-Free
battery, it is not necessary to check the specific gravity or
electrolyte level. Otherwise these procedures should be
done at the intervals specified in the Maintenance
Schedule. A negative ground system is used. Battery
connections are shown on the wiring diagrams. Make
sure that the battery is properly connected and the
terminals are tight.
NOTE
The generator set will not start if the battery connections
are made in reverse.
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
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. If
battery 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 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.
TP-5606 6/023-16 Scheduled Maintenance
Page 47
Cleaning
Keep battery clean by wiping it with a damp cloth. Keep
all electrical connections dry and tight. If corrosion is
present, disconnect cables from battery and remove
corrosion with a wire brush. Clean battery and cables
with a solution of baking soda and water. Be careful that
cleaning solution does not enter battery cells. When
cleaning is complete, flush battery and cables with clean
water and wipe with a dry cloth. After the battery cables
are reconnected, coat terminals with petroleum jelly or
other nonconductive grease.
Checking Electrolyte Level
Check the level of electrolyte before each start-up.
Remove filler caps and check to see that electrolyte
level is up to bottoms of filler holes. See Figure 3-16.
Refill as necessary with distilled water or clean tap
water. DO NOT add fresh electrolyte! Be sure filler caps
are tight.
1-046
Figure 3-16. Battery Electrolyte Level
TP-5606 6/02 Scheduled Maintenance 3-17
Page 48
Checking Specific Gravity
Use a battery hydrometer to check the specific gravity of
the electrolyte in each battery cell. While holding the
hydrometer vertical, read the number on the glass bulb
at the top of the electrolyte level. If the hydrometer used
does not have a correction table, use the one in
Figure 3-17. Determine specific gravity and electrolyte
temperature of battery cells. Locate temperature in
Figure 3-17 and adjust specific gravity by amount
shown. The battery is fully charged if the specific gravity
is 1.260 at an electrolyte temperature of 80°F (26.7°C).
The difference between specific gravities of each cell
should not exceed ±0.01. The battery should be
charged if the specific gravity is below 1.215 at an
electrolyte temperature of 80°F (26.7°C).
°C °F
71.1
65.6
60.0
54.4
48.9
43.3
37.8
32.2
26.7
21.1
15.6
10
4.4
-- 1 . 1
-- 6 . 7
-- 12.2
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
Correction
+ .032
+ .030
+ .028
EXAMPLE NO. 1 --
+ .026
Temperature below 80°F
(26.7°C)
+ .024
+ .022
Hydrometer Reading 1.250
+ .020
+ .018
Acid Temperature 20°F
+ .016
(--6.7°C)
+ .014
+ .012
Subtract 0.024 Sp. Gravity
Corrected Sp. Gravity is
+ .010
1.226
+ .008
+ .006
+ .004
EXAMPLE NO. 2 --
+ .002
Temperature above 80°F
0
(26.7°C)
-- .002
-- .004
Hydrometer Reading 1.235
-- . 006
-- .008
Acid Temperature 100°F
(37.8°C)
-- .010
-- .012
Add 0.008 Sp. Gravity
-- .014
Corrected Sp. Gravity is 1.243
-- .016
-- .018
-- .020
-- .022
-- .024
-- .026
-- .028
The Temperature correction amounts to about
0.004 (4 “points”) of specific gravity for each 10_F
(5.5_C) change in temperature.
Figure 3-17. Specific Gravity
Temperature Correction
TP-5606 6/023-18 Scheduled Maintenance
Page 49
Engine Cylinder Head
WARNING
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.
Valve Clearance
1
1. Clearance
2. Adjusting Screw
3. Locknut
Figure 3-18. Valve Clearance Adjustment
Head Bolt Torque
2
3
The engine uses poppet-type valve mechanisms which
are adjusted as follows:
1. Remove screws and carefully lift rocker-arm cover
off engine.
NOTE
Be careful not to damage gasket or mating
surfaces. Gasket must be replaced if damaged.
2. Turn engine over to obtain maximum clearance
between intake/exhaust valves and related rocker
arms. This occurs during the period between the
closing of the intake valve and the opening of the
exhaust valve.
3. Using a feeler gauge, check the clearance
between each rocker arm and its related valve. See
Figure 3-18. The clearance should be 0.0079 in.
(0.2 mm). If not, loosen the locknut, turn the
adjusting screw, and retighten the locknut. Then
recheck the clearance again.
4. After checking the clearance of all eight valves,
realign the gasket, install the rocker-arm cover,and
secure by installing and tightening the cover
screws.
The head bolts should be retightened as follows:
1. Remove screws and carefully lift rocker-arm cover
off engine.
NOTE
Be careful not to damage gasket or mating
surfaces. Gasket must be replaced if damaged.
2. Retighten each head bolt in the sequence shown in
Figure 3-19 to a torque of 54.2 to 65.1 ft. lbs. (73.5
to 83.3 Nm).
3. Realign the gasket, install the rocker-arm cover,
and secure by installing and tightening the cover
screws.
2
18
12
10
1
3
571315
1
16
14
6
8
4
2
11
9
17
4
1. Generator End
2. Exhaust Manifold Side
3. Fan End
4. Intake Manifold Side
Figure 3-19. Head Bolt Tightening Sequence
3
TP-5606 6/02 Scheduled Maintenance 3-19
Page 50
Wattage Requirements
If the rated capacity of the generator is exceeded, the
circuit breaker(s) located in the controller will trip to
protect the generator against damage. This could be
caused by a short in the AC circuit in the vehicle or
simply by having too many appliances (or tools) turned
on at the same time resulting in an overload condition. If
the circuit breaker(s) trip, the set may continue running
but there will be no AC output to the protected circuit.
Before resetting the circuit breaker(s), turn off some of
the appliances (or tools) and lights inside the vehicle to
bring the load down within the rated limits of the set. If
this is done and the circuit breaker(s) trips again after
being reset, a short circuit is indicated. In this event, turn
off the set and have a qualified electrician locate and
correct the cause of the short circuit.
The average wattage requirements of some common
RV/Mobile appliances/tools and motor loads are listed in
the following charts. Use these figures to calculate the
total load on this set to avoid the inconvenience of
having the circuit breaker trip due to overload. The
lighting load is easily determined by adding the wattage
rating of each bulb in the circuit. Check the nameplate
rating on motors and appliances in this vehicle for exact
wattage requirements.
Electrical Appliance Rating (Watts)
Motor
Starting
Construction Tools
Air Compressor (Small) 1500 725
Air Compressor 3/4 hp 4000+ 2000
Drill, 1/4 in. 500 250
Drill, 3/8 in. 600 350
Drill, 1/2 in. 800 600
Grinder 1/2 hp 1500 1200
Hammer, Demolition 2000 1800
Hammer, HD Rotary 1500 1200
Paint Sprayer (Airless) 400 240
Polisher, Orbit 500 360
Power Paint Roller 120 90
Power Plane 600 450
Router 900 700
Saw, Circular 6 1/2 in. 2200 1000
Saw, Circular 7 1/4 in. 2500 1200
Saw, Table 10 in. 4000 1500
Saw, Sabre (Worm Drive) 2500 1200
Sander, Belt 1500 600
Sander, Finishing 900 360
Screwdriver, Power 1000 530
Shear, 12 gauge 1800 720
Soldering Gun — 250
Vacuum Cleaner, Wet/Dry 1500 1260
Wrench, Impact 1/2 in. 2000 840
Watts
Running
Watts
Blanket 50--250................................
Blender 600...................................
Broiler 1350...................................
Fan, Air Circulating 25--100......................
Fan, Furnace 270..............................
Heater, Space 750--1500.........................
Heater, Water 1500.............................
Pan, Frying 1200...............................
Percolator, Coffee 650..........................
Radio 50--100..................................
Television 300--750.............................
Toaster 750--1200...............................
Figure 3-20. Appliance Average
Wattage Ratings
Figure 3-21. Construction Tool Average
Wattage Ratings
NOTE
Motor-driven equipment generally takes 2 to 3 times the
listed running amperage or wattage to start the motor.
Always check the tool or motor nameplate to be sure.
TP-5606 6/023-20 Scheduled Maintenance
Page 51
Generator Service
General
Under normal conditions, generator service will not be
required on a regular basis. If operating under dusty and
Storage Procedure
If the generator set is to be out of service for a
considerable length of time (2 months or more), the
following steps should be taken to preserve the set
before placing it in storage.
1. Drain the oil (while hot) from the crankcase then
refill with regular grade oil. See Section 3, “Oil
Selection” in this manual.
2. Drain the fuel from the fuel tank to prevent
accumulated moisture from mixing with the fuel.
dirty conditions, use dry compressed air to blow dust out
the generator at frequent intervals. Do this with the
generator set operating and direct the stream of air in
through the cooling slots at the end of the generator.
3. Check the engine coolant protection. See Section
3, “Cooling System” for additional information.
4. Disconnect battery (negative lead first) and place
in storage.
5. Seal all openings in the engine with non-absorbent
adhesive tape. Mask off all areas to be used for
electrical contact.
6. Clean exterior surface of the generator. Spread a
light film of oil over unpainted metallic surfaces
which could rust or corrode.
TP-5606 6/02 Scheduled Maintenance 3-21
Page 52
TP-5606 6/023-22 Scheduled Maintenance
Page 53
Section 4. General Troubleshooting
Use the following tables as a quick reference in
troubleshooting individual problems. Generator set
faults are listed by specific groups and include likely
causes and remedies. The source of more detailed
information needed to correct a problem is indicated.
These sources include various sections of this manual,
the Operation and Installation Manual (TP-5605), and
the Yanmar Engine Service Manual (TP-5365).
When troubles occur, don’t overlook simple causes. A
starting problem could be caused, for example, by
improper fuel or an empty fuel tank. Make sure all
electrical connections are secure. Remember the
battery negative must have a good ground.
Corrective action and testing in many cases requires
knowledge of electrical and electronic circuits. It is
recommended that service be done only by authorized
Service dealers/distributors. Improper repair by
unqualified personnel can lead to additional failures.
General Troubleshooting 4-1TP-5606 6/02
Page 54
Problem Possible Cause Corrective Action Reference
ENGINE
Will not Controller 10-amp Replace fuse. Section 7. Engine/
crank (dead) supply fuse blown If fuse Generator Components
failure continues, Section 8. Wiring Diagrams
replace fuse and
troubleshoot DC
circuit and wiring.
Battery disconnected Check connections Section 9. Wiring Diagrams
or improperly Section 3. Battery
connected
Dead battery Check electrolyte level Section 3. Battery
and specific gravity
(batteries with filler
caps only).
Perform load test
Corroded or loose Clean or replace Section 3. Battery
battery connections
Defective battery Replace alternator Section 3. Battery
charging alternator Charging
Loose battery Check/tighten or Section 3. Drive Belt
charging alternator replace belt
belt
Open wiring, terminal, Check continuity Section 7. Component
pin, foil, etc. Testing
Section 9. Wiring Diagrams
Defective starter Service or replace Engine Service Manual
Defective starter Check continuity of Section 7. Engine/
solenoid circuit. Bypass solenoid Generator Components
using jumper wire. If Section 9. Wiring Diagrams
starter cranks, replace Engine Service Manual
solenoid.
Defective start/stop Check continuity Section 7. Component
switch Testing
Section 9. Wiring Diagrams
Defective K2, K3, Check/replace Section 7. Controller
or K25 relay defective relay Circuit Board
Section 7. Engine/Generator
Components Testing
4-2 General Troubleshooting TP-5606 6/02
Page 55
Problem Possible Cause Corrective Action Reference
Will not No fuel in tank Replenish
start
(cranks Defective fuel Check continuity Section 7. Fuel Solenoid
okay) solenoid
Defective fuel Replace fuel pump Engine Service Manual
pump NOTE:
Fuel pump is polarity
sensitive and will fail
if the lead connections
are made in reverse.
Air cleaner clogged Clean or replace element Section 3. Air Cleaner
Service
Air in fuel system Bleed air Section 3. Fuel System
Water, dirt in fuel Drain, flush fuel
system system
Improper type of fuel Use proper type of fuel; Section 3. Fuel System
consult fuel supplier
Dirty or faulty injectors Check injectors Engine Service Manual
Improper valve Correct or replace Engine Service Manual
timing timing gear
Incorrect injection Adjust injection timing Engine Service Manual
timing
Defective injection Repair/replace Engine Service Manual
timing injection pump
Fuel cam shaft worn Replace fuel cam shaft Engine Service Manual
Fuel leak Tighten fittings Engine Service Manual
Improper compression Check compression Engine Service Manual
Improper type of Use proper lube oil Section 3. Lubrication
crankcase lube oil System
Improper valve clearance Check valve clearance Section 3. Valve adjustment/
Engine Service Manual
Clogged fuel filter Replace filter Section 3. Fuel Filter
Service/Engine Service Manual
Open wiring, terminal, Check continuity Section 9. Wiring Diagrams
or pin (P2 connector)
K4 relay Check relay coil Section 7. Controller
defective (K2 relay continuity Circuit Board
must be energized) Section 9. Wiring Diagrams
General Troubleshooting 4-3TP-5606 6/02
Page 56
Problem Possible Cause Corrective Action Reference
Will not start Weak or dead battery Recharge battery. Section 3. Battery
(cranks okay) Check electrolyte level
(continued) and specific gravity
(batteries with filler
caps only).
Perform load test,
or replace battery.
Defective air heater Check/replace air heater Engine Service Manual
Defective C1 relay Check/replace C1 relay Section 7. Engine/Generator
Components
Problem Possible Cause Corrective Action Reference
Engine Incorrect generator Check AC output Section 9. Wiring Diagrams
starts, but output voltage voltage. Section 7. Component
stops after Testing--Separate Excitation
start switch
is released
Open wiring (P1 or P2 Check continuity Section 9. Wiring Diagrams
connector)
K1 relay coil defective Check continuity Section 7. Controller
Circuit Board
Section 9. Wiring Diagrams
If LED1 is not lit, K1 Test stator Section 7. Stator
relay is not receiving Section 7. Engine/
power from stator Generator Components
B1/B2 winding
No/low oil pressure Check oil level; Section 3. Lubrication System
add oil if low Engine Service Manual
Check/repair oil pump
High water temperature Check engine cooling Engine Service Manual
system
Low oil pressure Disconnect lead from one switch and isolate
switch, high engine the lead from ground. If engine continues to run,
temperature switch replace that switch.
NOTE: Verify proper pressure or temperature
before replacing switch.
4-4 General Troubleshooting TP-5606 6/02
Page 57
Problem Possible Cause Corrective Action Reference
Hard starting Stale or bad fuel Replace
Air in fuel system Bleed air Section 3. Fuel System
Water, dirt in fuel Drain fuel system
system and/or replace fuel filters
Dirty or faulty injectors Check injectors Engine Service Manual
Improper type of fuel Use proper type of fuel; Section 3. Fuel System
consult fuel supplier
Air cleaner clogged Clean or replace Section 3. Service Air
element Cleaner
Worn piston rings, Check compression Engine Service Manual
valves, etc. and oil consumption
Improper cooling Inspect cooling system Section 3. Cooling System
(hot engine only)
Defective air heater Check/replace air heater Engine Service Manual
Defective C1 relay Check/replace C1 relay Section 7. Engine/Generator
Components
Problem Possible Cause Corrective Action Reference
Generator No fuel in tank Replenish
set shuts
down by Fuel line restriction Inspect fuel lines and
itself tank
Clogged fuel filter Replace filter Section 3. Fuel System
Defective fuel Check fuel pump Engine Service Manual
pump NOTE:
Fuel pump is polarity
sensitive and will fail
if the lead connections
are made in reverse.
Air in fuel system Bleed air Section 3. Fuel System
Engine overloaded Reduce electrical load Section 3. Wattage
Requirements
Engine overheated Check air intake, Section 3. Scheduled
(hot engine only) governor adjustment, Maintenance
oil level, etc. Engine Service Manual
Loss of generator Check AC voltage at Section 9. Wiring Diagrams
output voltage to K1 B1/B2 winding
relay (LED1 not lit) Check continuity of Section 7. Stator
B1/B2 stator leads
Air cleaner clogged Clean or replace Section 3. Servicing Air
element Cleaner
General Troubleshooting 4-5TP-5606 6/02
Page 58
Problem Possible Cause Corrective Action Reference
Generator No/low oil pressure Check oil level, oil Engine Service Manual
set shuts pressure, and oil pump,
down by
itself
(continued)
High water temperature Check engine cooling Engine Service Manual
shutdown system
Low oil pressure switch, Disconnect lead from one switch and isolate
high engine temperature the lead from ground. If engine continues to run, replace
switch that switch.
NOTE: Verify proper pressure, or temperature
before replacing switch.
Problem Possible Cause Corrective Action Reference
Will not Excessive load Reduce electrical load Section 3. Wattage
carry load connected to Requirements
or runs generator
rough
Improper cooling Inspect cooling system Section 3. Cooling System
(hot engine only)
Governor not properly Check speed using Section 3. Governor
adjusted or defective tachometer or
(Engine not operating frequency meter.
at rated rpm)
NOTE: For 60 Hz--1800 RPM
For 50 Hz--1500 RPM
Engine in need Contact Kohler Engine Service
of overhaul distributor Distributor
4-6 General Troubleshooting TP-5606 6/02
Page 59
Problem Possible Cause Corrective Action Reference
Will not Fuel line restriction Inspect fuel lines and
carry load tank.
or runs
rough Vent in fuel tank cap Clean cap in solvent, blow
(continued) obstructed dry
Dirty fuel filter Replace fuel filter Section 3. Fuel System
Improper type of fuel Use proper type of fuel; Section 3. Fuel System
consult fuel supplier
Water, dirt, or air in fuel Drain, fill, and Section 3. Fuel System
system bleed air in the system
Replace fuel filters
Defective fuel Check fuel pump Engine Service Manual
pump NOTE:
Fuel pump is polarity
sensitive and will fail
if the lead connections
are made in reverse
Fuel leak Tighten fittings Engine Service Manual
Valves not sealing Compression test Engine Service Manual
Air cleaner clogged Clean or replace Section 3. Air Cleaner
element Service
Incorrect fuel injection Check injection timing Engine Service Manual
timing
Dirty or faulty injectors Check injectors Engine Service Manual
Improper cylinder top Check clearance Engine Service Manual
clearance
Defective piston or Check compression Engine Service Manual
piston rings
Defective crankshaft Check components Engine Service Manual
bearing or piston pin
bearing
Improper valve Adjust proper valve Section 3. Valve Clearance
clearance clearance Engine Service Manual
General Troubleshooting 4-7TP-5606 6/02
Page 60
Problem Possible Cause Corrective Action Reference
Will not Defective injection Check injection pump Engine Service Manual
carry load pump
or runs
rough Improper lube oil Use proper viscosity Section 3. Lubrication
(continued) oil System
Problem Possible Cause Corrective Action Reference
Lacks power Governor not properly Check engine speed Section 3. Governor
adjusted or defective using frequency meter
(Engine not operating or tachometer.
at rated RPM)
NOTE: For 60 Hz--1800 RPM
For 50 Hz--1500 RPM
Air cleaner clogged Clean or replace Section 3. Air Cleaner
element Service
Improper cooling Inspect cooling system Section 3. Cooling System
Engine overloaded Reduce electrical load Section 3. Wattage
Requirements
Stale or bad fuel Replace
Fuel line restriction Check fuel lines and
tank
Dirty fuel filter Replace fuel filter Section 3. Fuel System
Incorrect injection timing Adjust injection timing Engine Service Manual
Uneven fuel injection Repair/replace injectors Engine Service Manual
and/or injection pump
Compression leak Replace head gasket. Engine Service Manual
Tighten cylinder head
bolt, air heater,
and nozzle holder
4-8 General Troubleshooting TP-5606 6/02
Page 61
Problem Possible Cause Corrective Action Reference
Overheats Low coolant Replenish cooling Section 3. Cooling System
system
Air cleaner clogged Clean or replace Section 3. Air Cleaner
element Service
Fan belt broken Tighten/replace Section 3. Drive Belt
or loose fan belt
Radiator clogged Clean radiator
or dirty (inside and outside)
Radiator cap Replace radiator cap
defective
Defective water pump Check water pump Engine Service Manual
Engine malfunction Troubleshoot engine Engine Service Manual
Defective K30 Check/replace Section 3. Engine/Generator
relay (remote K30 relay Component Testing
radiator system)
Problem Possible Cause Corrective Action Reference
Operates Air cleaner clogged Clean or replace Section 3. Air Cleaner
erratically element Service
Stale or bad fuel Replace
Governor not properly Check engine speed Section 3. Governor
adjusted or defective using frequency meter
(Engine not operating or tachometer.
at rated RPM)
NOTE: For 60 Hz--1800 RPM
For 50 Hz--1500 RPM
Fuel line restriction Inspect fuel lines and
tank.
General Troubleshooting 4-9TP-5606 6/02
Page 62
Problem Possible Cause Corrective Action Reference
Unit is noisy Exhaust system leak Check and replace as Operation and Installation
necessary Manual--Exhaust Systems
Broken or damaged Check and replace as Section 8. Disassembly/
vibromounts necessary Reassembly
Loose or vibrating Retighten screws
sheet metal/housing
Inadequate Check clearances Operation and Installation
compartment Manual--Compartment
clearances Size
Exhaust piping or air Inspect for loose parts Operation and Installation
inlets/outlets not Manual--Exhaust Systems
securely installed
No compartment Install fireproof Operation and Installation
sound insulation insulation Manual--Compartment
Size
Excessive vibration-- Check rotor, crankshaft, Section 8. Disassembly/
engine/generator bearing, etc. Reassembly
(Disassembly of engine Engine Service Manual
and/or generator may Kohler Service
be required) Distributor
4-10 General Troubleshooting TP-5606 6/02
Page 63
Problem Possible Cause Corrective Action Reference
ELECTRICAL
SYSTEM
Battery will Loose or corroded Clean and tighten Section 3. Battery
not charge or connections connections
goes dead
Sulfated or worn-out Check electrolyte level Section 3. Battery
battery and specific gravity
(batteries with filler
caps only)
Defective alternator Test and replace, Engine Service Manual
if necessary
Loose or defective Adjust belt tension Section 3. Belt Tension
alternator belt or replace belt
Defective alternator Test and replace, Engine Service Manual
voltage regulator if necessary
Loose or corroded Clean and tighten Section 3. Battery
engine ground strap
Problem Possible Cause Corrective Action Reference
Starter does Loose or corroded Clean and tighten loose Section 3. Battery
not work connections connections
properly
Low battery output Check electrolyte level Section 3. Battery
and specific gravity
(batteries with filler
caps only)
Defective starter Check starter solenoid Section 7. Component
solenoid Replace starter Testing
solenoid, as necessary Engine Service Manual
Defective start/stop Replace switch Section 7. Component
switch Testing
Defective wiring Check wiring Section 9. Wiring Diagrams
Defective starter Replace starter Engine Service Manual
Battery cables undersize Select proper size Section 1. Specifications
cable Chart--Installation
Operation and Installation
Manual--Electrical System
Loose or corroded Clean and tighten Section 3. Battery
engine ground strap
General Troubleshooting 4-11TP-5606 6/02
Page 64
Problem Possible Cause Corrective Action Reference
Starter Low battery output Check electrolyte level Section 3. Battery
cranks and specific gravity
slowly (batteries with filler
caps only)
Too heavy viscosity Use proper viscosity Section 3. Lubrication
lube oil oil System
Loose or corroded Clean and tighten Section 3. Battery
wiring loose connections
High starter current Repair/Replace starter Engine Service Manual
draw
Battery cable Select proper size Operation and Installation
undersize cable Manual--Electrical Systems
4-12 General Troubleshooting TP-5606 6/02
Page 65
Problem Possible Cause Corrective Action Reference
GENERATOR
No Optional AC output Check position of Section 2. Circuit
generator circuit breaker open circuit breaker Protection
output or defective Check AC voltage on Section 9. Wiring Diagrams
voltage generator side of circuit
breakers
Optional AC circuit Reduce load Section 3. Wattage
breaker tripping due to Reset and attempt Requirement
overload on unit startup
No battery voltage to Check flashing Section 7. Separate
field during current Excitation Test
cranking
Open flashing diode Check for open or Section 9. Wiring Diagrams
(D4 or D7; D5 or D8) shorted diode (a good Section 7. Circuit Board
diode has high
resistance one way
and low resistance the
other way, when tested
with ohmmeter)
K1 relay (Normally Check continuity Section 9. Wiring Diagrams
Closed) contacts open Section 7. Circuit Board
Defective rotor (open, Test and/or replace Section 7. Rotor
grounded, or shorted
windings)
Defective stator (open, Test and/or replace Section 7. Stator
grounded, or shorted
windings)
Defective exciter field Test and/or replace Section 7. Exciter Field
(3-phase models only) Section 8. Disassembly/
Assembly
Defective exciter Test and/or replace Section 7. Exciter Armature
armature Section 8. Disassembly/
(3-phase models only) Assembly
Defective diode Check for open Section 8. Disassembly/
board or shorted diode Assembly
(3-phase models only) (a good diode has
high resistance one
way and low resistance
the other way, when
tested with ohmmeter).
Brushes sticking Check alignment Section 8. Brushes
in holder
(1-phase models only)
General Troubleshooting 4-13TP-5606 6/02
Page 66
Problem Possible Cause Corrective Action Reference
GENERATOR
No Rotor slip rings dirty Check and/or service Section 8. Brushes
generator or corroded
output (1-phase models only)
voltage
(continued) Broken, weak, or Check condition Section 8. Brushes
missing brush spring
(1-phase models only)
Fuse blown in Replace fuse. If Section 7. Voltage
voltage regulator fuse blows again, Regulator
circuit (lead 55) check voltage regulator Section 9. Wiring Diagrams
and stator aux. windings
Defective voltage Excite (rotor) Section 7. Separate
regulator separately Excitation
Misadjusted voltage Section 7. Voltage
regulator Regulator Test/
Alignment
Problem Possible Cause Corrective Action Reference
Low Low engine rpm Check engine speed Section 3. Governor
generator using frequency meter Adjustments
output or tachometer.
voltage
NOTE: For 60 Hz--1800 RPM
For 50 Hz--1500 RPM
Set overloaded Make sure capacity is Section 3. Wattage
not being exceeded Requirements
Defective rotor Test and/or replace Section 7. Rotor
Defective stator Test and/or replace Section 7. Stator
Defective voltage Test and/or replace Section 7. Voltage
regulator Regulator
Improperly adjusted Readjust Section 7. Voltage
voltage regulator Regulator
4-14 General Troubleshooting TP-5606 6/02
Page 67
Problem Possible Cause Corrective Action Reference
High Defective voltage Test and/or replace Section 7. Voltage
generator regulator Regulator
output
voltage Voltage regulator Readjust Section 7. Voltage
misadjusted Regulator
Open or poor splice Check continuity Section 7. Stator
connection at and clean connections Section 9. Wiring
regulator sensing Diagrams
terminals on stator
or poor pin
connection at
voltage regulator
General Troubleshooting 4-15TP-5606 6/02
Page 68
4-16 General Troubleshooting TP-5606 6/02
Page 69
Section 5. Controller Troubleshooting
Data in this section describes the controller sequence of
operation during starting, running, and stopping of the
generator set. The controller for a single-phase
generator is different than the controller for a
three-phase generator. Therefore, separate sequence
of operation information is provided for single-phase
and three-phase generators. Use this data as a starting
point for controller fault identification.
Single-Phase Generator
Sequence of Operation
Starting
Preheating—A heater mounted on the intake manifold
is used to preheat intake air during starting in cold
weather. Preheating is initiated by rocking the Start/Stop
switch on the control panel to the STOP/PREHEAT
position for the time period specified in Section 2. This
action energizes the C1 relay. As a result, normally open
contacts of the C1 relay close to energize the air heater.
At the end of the specified time period, the Start/Stop
switch is released or rocked out of the STOP/PREHEAT
position. Either of these actions opens the ground path
to the C1 relay, de-energizing the C1 relay and the air
heater.
Engine Start-up—The engine is started by rocking the
start/stop switch on the control panel to the START
position. At this point, the 10-ampere fuse must be good.
If not, power to the starting circuits is interrupted and
none of the following actions described below occur.
Setting the Start/Stop switch to the START position
energizes the K2 relay (LED2 lights). As a result,
normally open contacts of K2 close to energize the K3
relay, the K25 relay, and the FP (Fuel Pump) motor.
Energizing the K3 relay (LED3 lights) causes a set of
normally open contacts to close and energize relay K20.
A set of normally open contacts of K20 then close to
energize the S solenoid (Starter Solenoid). As a result,
normally open contacts of the S relay close to energize
the M (starter) motor and the starter motor gear engages
the ring gear on the engine flywheel to begin cranking
the engine. At the same time, the power supplied to the
starter motor also energizes the pull-in coil of the FS
(Fuel Supply) Solenoid.
Energizing the K25 relay closes a set of normally open
contacts to energize the hold coil of the fuel solenoid to
complete the conditions necessary for engine start-up.
For units with remote radiators, energizing K2 also
energizes the K30 relay. Energizing the K30 relay closes
a set of normally open contacts to energize a 12 VDC
fan. This fan provides cooling for the remote radiator.
Releasing the Start/Stop switch allows the switch to
return to its neutral position. If the switch is released
before the engine starts (the K1 relay is still
de-energized), the K2 relay de-energizes. The normally
open contacts of the K2 relay then open to interrupt
power to the engine start-up circuits. As a result the K3
relay, the K25 relay, the K20 relay, the K30 relay, the
Fuel Pump, the Fuel Solenoid, and the Starter Solenoid
all de-energize to cease start-up of the engine.
12 VDC
K20
10 A.
K2
C1
S
K3
K4B
10 A.
15 A.
K25
K30
LED3
K3
TO REMAINING
B.C.
ALT
12VDC
LED2
K2
K20
K25
K30
FP
CIRCUITS
AIR HEATER
C1
M
FS
STOP/
PREHEAT
START
S
FAN
K1C
K1D
K1E
Figure 5-1. Single-Phase Generator Sequence of
Operation, Starting
TP-5606 6/02 Controller Troubleshooting 5-1
Page 70
Running
During engine start-up, flashing current is provided to
the generator field through a normally open contact of
the K2 relay, two diodes, and the normally closed K1A
and K1B contacts. The flashing current plus the rotation
of generator rotor induce electrical currents in the
generator stator windings. The resulting generator
output from the B1/B2 stator winding, rectified and
regulated to a 12 VDC level, energizes the K1 relay
(LED1 lights). After a 5- to 10-second delay, the same
signal energizes the K5 relay (LED5 lights). Both relays
remain energized during normal running.
Energizing the K1 relay opens the normally closed K1A
and K1B contacts that supply flashing current to the
generator exciter field. Field current for continued
operation is then supplied by the voltage regulator,
operating from an input supplied by generator stator
winding 55/66.
Energizing the K1 relay also opens the normally closed
K1C contacts between the Start/Stop switch and the K2
relay in the engine start-up circuit. However, at the same
time, the normally open K1D contacts close to keep the
K2 relay energized in order to maintain operating power
for the other relays and hourmeter of the controller.
K20
10 A.
K2
C1
S
K3
K4B
LED4
10 A.
15 A.
K4
K25
K30
LED3
K3
K5
REMOTE PANEL
BV
12 VDC
B.C.
ALT
12VDC
LED2
K2
K20
K25
K30
FP
FROM SAFETY
SHUTDOWN
SWITCHES
HR
AIR HEATER
C1
M
FS
STOP/
PREHEAT
START
S
FAN
K4A
K1C
K1D
K1E
K2
Energizing the K1 relay also opens the normally closed
K1E contacts to de-energize the K3 relay. As a result,
K20 and the S (Starter) solenoid de-energize to
disengage and de-energize the starter motor, even
when the Start/Stop switch is held in the Start position.
The other devices energized during engine starting, that
is the K25 relay, the K30 relay (and 12 VDC fan), the fuel
pump, and the fuel solenoid, remain energized to keep
the engine running and to supply excitation to the B.C.
Alt (battery-charging alternator).
Finally, energizing the K1 relay also closes the normally
open K1F contacts to activate the hourmeter, oil
pressure gauge, water temperature gauge, and battery
voltage gauge on an optional remote panel.
10 A.
MAIN FIELD
OP
WT
K1B
LED1 LED5
K1 K5
L2
LO
K1A
K1F
VO LTAG E
REGULATOR
LO
L1
HR
GEN
ON
Figure 5-2. Single-Phase Generator Sequence of
Operation, Running
TP-5606 6/025-2 Controller Troubleshooting
Page 71
Stopping
A normal stop is initiated by rocking the Start/Stop
Switch on the controller front panel to the Stop position
and then releasing the switch. Holding the switch in
the Stop position energizes the C1 relay, causing
further, unnecessary heating of the intake manifold.
In the Stop position, the Start/Stop switch provides a
ground through two blocking diodes to energize the K4
relay (LED4 lights). The normally open K4A contacts
then close, latching the K4 relay in an energized
condition.
At the same time, normally closed K4B contacts open to
de-energize the FP (fuel pump) motor, the K25 relay,
and the K30 relay. The normally open K30 relay contacts
open to de-energize the 12 VDC fan for the remote
radiator. The normally open K25 contacts open to
de-energize the FS (fuel) solenoid, turning off the flow of
fuel. With the fuel supply and fuel pump both turned off,
the engine turns off.
When the engine turns off, the generator output decays
and causes relays K1 and K5 to de-energize (LED1 and
LED5 go out). The normally open K1D contacts then
open, de-energizing the K2 relay (LED2 goes out).
When the K2 relay de-energizes, the normally open K2
contacts open to interrupt power to the remaining
controller relay circuits, including relay K4. As a result,
thelatch-upoftheK4relayisbrokentoreturnthe
controller circuits to a normal prestart condition.
K20
10 A.
K2
C1
S
K3
K4B
LED4
10 A.
15 A.
K4
LED3
12 VDC
K25
K30
K3
K5
AIR HEATER
B.C.
ALT
12VDC
FAN
LED2
K2
K20
K25
K30
FP
FROM SAFETY
SHUTDOWN
SWITCHES
HR
C1
M
FS
STOP/
PREHEAT
START
S
K1D
K1E
K4A
K2
K1C
REMOTE PANEL
BV
10 A.
MAIN FIELD
OP
WT
K1B
LED1 LED5
K1 K5
L2
LO
K1A
K1F
VO LTAG E
REGULATOR
LO
L1
HR
GEN
ON
Figure 5-3. Single-Phase Generator Sequence of
Operation, Stopping
TP-5606 6/02 Controller Troubleshooting 5-3
Page 72
Automatic Safety Shutdowns
The engine is equipped with two switches that monitor
critical operating conditions. These switches are:
D A High Engine Temperature Switch that closes
when engine coolant temperature rises toward an
unsafe level.
D A Low Oil Pressure Switch, which closes when the
oil pressure is insufficient, to indicate inadequate
lubrication of the engine.
During normal running, closing either of the above
switches results in an engine shutdown. During start-up,
this shutdown function is disabled by normally open
contacts of the K5 relay until 5 to 10 seconds after the
engine starts in order to allow the monitored conditions
to stabilize.
Once the normally open contacts of K5 close, the engine
safety switches are enabled. If either switch then closes,
the K4 relay is energized (LED4 lights). Energizing relay
K4 causes the normally open K4A contacts to close,
latching the K4 relay in an energized condition.
K20
10 A.
K2
C1
S
K3
K4B
LED4
10 A.
15 A.
K4
LED3
LOW OIL
PRESS.
K25
K30
K3
K5
12 VDC
B.C.
ALT
LED2
K2
K20
K25
K30
FP
HR
AIR HEATER
C1
M
FS
PREHEAT
S
12VDC
FAN
HIGH
ENGINE
TEMP.
STOP/
START
START
K1D
K1E
K4A
K2
K1C
At the same time the K4A contacts close, the normally
closed K4B contacts open to de-energize the FP (fuel
pump) motor and the K25 relay. The normally open K25
contacts then open to de-energize the FS (fuel supply)
solenoid, turning off the flow of fuel. With the fuel supply
and fuel pump both turned off, the engine shuts off.
When the engine shuts off, the generator output decays
and causes relays K1 and K5 to de-energize (LED1 and
LED5 go out). The normally open K1D contacts then
open, de-energizing the K2 relay (LED2 goes out) and
opening the normally open K2 contacts to interrupt
power to the remaining controller relay circuits,
including relay K4. As a result, the latch-up of the K4
relay is broken to return the controller circuits to a normal
prestart condition.
K1F
REMOTE PANEL
K1A
VO LTAG E
REGULATOR
LO
L1
10 A.
MAIN FIELD
LED1 LED5
K1 K5
K1B
L2
LO
Figure 5-4. Single-Phase Generator Sequence of
Operation, Emergency Shutdowns
TP-5606 6/025-4 Controller Troubleshooting
Page 73
Three-Phase Generator
Sequence of Operation
Starting
Preheating—Preheating of the air heater in the diesel
engine is initiated by rocking the start/stop switch on the
control panel to the STOP/PREHEAT position for the
time period specified in Section 2. This action energizes
the AH relay. As a result, normally open contacts of the
AH relay close to energize the air heater.
Releasing the Start/Stop switch allows the switch to
return to its neutral position. If the switch is released
before the engine starts (the K1 relay is still
de-energized), the K2 relay de-energizes. The normally
open contacts of the K2 relay then open to interrupt
power to the engine start-up circuits. As a result the K3
relay, the K25 relay, the K20 relay, the Fuel Pump, the
Fuel Solenoid, and the Starter Solenoid all de-energize
to cease start-up of the engine.
12 VDC
AH
AIR HEATER
At the end of the specified time period, the start/stop
switch is released or switched out of the
STOP/PREHEAT position. Either of these actions
opens the ground path to the AH relay, de-energizing the
AH relay and the air heater.
Engine Start-up—The engine is started after air heater
preheating by rocking the start/stop switch on the
control panel to the START position. At this point, the
10-ampere fuse must be good. If not, power to the
starting circuits is interrupted and none of the following
actions described in this section occur.
Setting the Start/Stop switch to the START position
energizes the K2 relay (LED2 lights). As a result,
normally open contacts of K2 close to energize the K3
relay, the K25 relay, and the FP (Fuel Pump) motor.
Energizing the K3 relay (LED3 lights) causes a set of
normally open contacts to close and energize relay K20.
A set of normally open contacts of K20 then close to
energize the S solenoid (Starter Solenoid). As a result,
normally open contacts of the S relay close to energize
the M (starter) motor and the starter motor gear engages
the ring gear on the engine flywheel to begin cranking
the engine. At the same time, the power supplied to the
starter motor also energizes the pull-in coil of the FS
(Fuel Solenoid).
K20
10 A.
K2
S
K3
K4
10 A.
K25
LED3
K3
AH
B.C.
ALT
LED2
K2
K20
K25
FP
TO REMAINING
CIRCUITS
M
FS
STOP/
PREHEAT
START
S
K1D
K1E
K1C
Energizing the K25 relay closes a set of normally open
contacts to energize the hold coil of the fuel solenoid to
complete the conditions necessary for engine start-up.
TP-5606 6/02 Controller Troubleshooting 5-5
Figure 5-5. Three-Phase Generator Sequence
of Operation, Starting
Page 74
Running
12 VDC
During engine start-up, flashing current is provided to
the generator exciter field through a normally open
contact of the K2 relay and normally closed contacts of
the K1 relay. The resulting generator output from the
B1/B2 stator winding, rectified and regulated to a 12
VDC level, energizes the K1 relay (LED1 lights). After a
5- to 10-second delay, the K5 relay is energized (LED5
lights). Both relays remain energized during normal
running.
Energizing the K1 relay opens the normally closed K1A
and K1B contacts that supply flashing current to the
generator exciter field. Field exciter current for
continued operation is then supplied by the voltage
regulator, operating from an input supplied by generator
stator winding 55/66.
Energizing the K1 relay opens the normally closed K1C
contacts between the Start/Stop switch and the K2 relay
in the engine start-up circuit. However, at the same time,
the normally open K1D contacts close to keep the K2
relay energized. Energizing K1 also closes the normally
open K1F contact to activate BV, OP, HR, WT, and Gen.
on light on the remote panel.
Energizing the K1 relay opens the normally closed K1E
contacts to de-energize the K3 relay. As a result, K20
and the S (Starter) solenoid de-energize to disengage
and de-energize the starter motor, even when the
Start/Stop switch is held in the Start position. The other
devices energized during engine starting, that is relay
K25, the fuel pump, and the fuel solenoid, remain
energized to keep the engine running and to supply
excitation to the B.C. Alt (battery-charging alternator).
K1A
K20
10 A.
K2
K4B
K1F
AH
S
K3
10 A.
LED4
K4
K25
LED2
LED3
K3
K5
REMOTE PANEL
BV
HR
GEN
ON
AIR HEATER
AH
FS
B.C.
ALT
K2
K20
K25
FP
FROM SAFETY
SHUTDOWN
SWITCHES
HR
OP
WT
OVERSPEED
PROTECTION
CIRCUIT BOARD
M
STOP/
PREHEAT
START
S
K1D
K1E
K4A
K2
SDR
SDR
K1C
K1B
VO LTAG E
REGULATOR
8A.
MAIN FIELD
LED1 LED5
K1 K5
Figure 5-6. Three-Phase Generator Sequence of
Operation, Running
TP-5606 6/025-6 Controller Troubleshooting
Page 75
Stopping
12 VDC
Normal Stop—A normal stop is initiated by rocking the
Start/Stop Switch on the controller front panel to the
Stop position and then releasing the switch. Holding
the switch in the Stop position energizes the AH
relay, causing further, unnecessary heating of the
air heater. In the Stop position, the Start/Stop switch
provides a ground through two blocking diodes to
energize the K4 relay (LED4 lights). The normally open
K4A contacts then close, latching the K4 relay in an
energized condition.
At the same time, normally closed K4B contacts open to
de-energize the FP (fuel pump) motor and the K25 relay.
The normally open K25 contacts then open to
de-energize the FS (fuel supply) solenoid, turning off the
flow of fuel. With the fuel supply and fuel pump both
turned off, the engine turns off.
With the engine turned off, the generator output decays
and causes relays K1 and K5 to de-energize (LED1 and
LED5 go out). The normally open K1D contacts then
open, de-energizing the K2 relay (LED2 goes out) and
opening the normally open K2 contacts to interrupt
power to the remaining controller relay circuits,
including relay K4. As a result, the latch-up of the K4
relay is broken to return the controller circuits to a normal
prestart condition.
K20
10 A.
K2
K4B
AH
S
K3
10 A.
LED4
K4
LED3
K25
K3
K5
AIR HEATER
B.C.
ALT
LED2
K2
K20
K25
FP
FROM SAFETY
SHUTDOWN
SWITCHES
HR
AH
M
FS
STOP/
PREHEAT
START
S
K1D
K1E
K4A
K2
SDR
K1C
REMOTE PANEL
BV
OP
WT
OVERSPEED
PROTECTION
CIRCUIT BOARD
MAIN FIELD
K1B
SDR
K1A
K1F
VO LTAG E
REGULATOR
HR
GEN
ON
8A.
LED1 LED5
K1 K5
Figure 5-7. Three-Phase Generator Sequence of
Operation, Stopping
TP-5606 6/02 Controller Troubleshooting 5-7
Page 76
Automatic Safety Shutdowns
12 VDC
Overspeed—The overspeed protection circuit board
monitors the output frequency of the generator set. If the
frequency is too high, the SDR relay on the circuit board
energizes. Normally open SDR contacts then close to
energize the K4 relay (LED4 lights). As a result, the
normally open K4A contacts close to latch the K4 relay
energized.
At the same time the K4A contacts close, normally
closed K4B contacts open to de-energize the FP (fuel
pump) motor and the K25 relay. The normally open K25
contacts then open to de-energize the FS (fuel supply)
solenoid, turning off the flow of fuel. With the fuel supply
and fuel pump both turned off, the engine turns off.
With the engine turned off, the generator output decays
and causes relays K1 and K5 to de-energize (LED1 and
LED5 go out). The normally open K1D contacts then
open, de-energizing the K2 relay (LED2 goes out) and
opening the normally open K2 contacts to interrupt
power to the remaining controller relay circuits,
including relay K4. As a result, the latch-up of the K4
relay is broken to return the controller circuits to a normal
prestart condition.
Engine Safety Switches—The engine is equipped with
two switches that monitor critical operating conditions.
These switches include:
D A High Engine Temperature Switch that closes
when the cooling water is not circulating properly
and the engine temperature rises toward an unsafe
level.
D A Low Oil Pressure Switch, which closes when the
oil pressure is insufficient, to indicate inadequate
lubrication of the engine.
K1A
AH
S
K20
10 A.
K3
K2
K4
LOW OIL
PRESSURE
LED4
K1F
VO LTAG E
REGULATOR
10 A.
K4
K25
LED2
LED3
K3
K5
REMOTE PANEL
BV
HR
GEN
ON
8A.
AIR HEATER
AH
M
FS
B.C.
ALT
S
K2
K20
K25
FP
HIGH
ENGINE
TEMP
HR
OP
WT
OVERSPEED
PROTECTION
CIRCUIT BOARD
STOP/
PREHEAT
START
K1D
K1E
K4A
K2
SDR
SDR
K1C
K1B
During normal running, closing any one of the above
switches results in an engine shutdown. During start-up,
this shutdown function is disabled by normally open
contacts of the K5 relay until 5 to 10 seconds after the
engine starts in order to allow the monitored conditions
to stabilize.
Once the normally open contacts of K5 close, the engine
safety switches are enabled. If any of the switches close,
the K4 relay is energized to produce a shutdown in the
same manner as described above for an overspeed
condition.
MAIN FIELD
LED1 LED5
K1 K5
Figure 5-8. Three-Phase Generator Sequence of
Operation, Emergency Shutdowns
TP-5606 6/025-8 Controller Troubleshooting
Page 77
Section 6. Generator/Controller
Troubleshooting
The section contains flow charts to troubleshoot the
generator set including the controller circuit board.
Before beginning the troubleshooting, read all safety
precautions at the beginning of this manual. Additional
safety precautions are included with the tests; DO NOT
NEGLECT THESE PRECAUTIONS.
Controller Circuit Board
The controller circuit board is equipped with LEDs (light
emitting diodes) to indicate the presence of relay coil
power and aid in circuit board and generator fault
detection. See Figure 6-1.
When K1, K2, K3, K4, or K5 relays are receiving power,
the corresponding LED will light. The LED does not
indicate whether the relay coil is good or bad. This
conclusion can only be reached through analysis of the
fault.
Use the flow chart (Figure 6-2) as an aid in
troubleshooting the generator set.
Where a check or test is referenced, go to the procedure
for detailed instructions.
LED5
K5
LED1
K1
Figure 6-1. Controller Circuit Board
K4
LED4
E-239563
K3
LED2
E-239563-
LED3
K2
Generator/Controller Troubleshooting 6-1TP-5606 6/02
Page 78
Start
(Engine
Stopped)
.
Rock and hold
Start/Stop
Switch to Start
Position. Does
Engine Crank?
No
Yes
.
Go to A
(Sheet 2)
Is LED2 lit
while Start/Stop
Switch is in
Start Position?
No
Check 10A fuse on
controller front panel.
Is fuse good?
No
Replace fuse. If
trouble persists,
check circuits
for shorts.
Is LED3 lit
while Start/Stop
Yes
Switch is in
Start Position?
Replace
circuit board.
Check/replace
Start/Stop Switch.
Check/service/
replace battery and
battery connections.
Check/service/
repair battery
charging alternator.
Check/replace glow
plug (C1) relay.
Check/repair wiring
to P1-14, P1-9,
P2-4, and P2-6.
No
Is 12 VDC
present across
Yes
coil of relay K20
(wire 71 to GND)
while LED3 is lit?
No
Is 12 VDC
present at P1-4
when LED3
is lit?
No
Replace
circuit board.
Is 12 VDC
present across S
Yes
solenoid coil while
LED3 is lit?
Check wiring
from starter
solenoid to K20
relay, if good
replace K20
relay.
YesYes
No
Check/repair
wiring between
P1-4 and K20.
Is 12 VDC
present across
Yes Yes
starter motor
while LED3 is lit?
No
Check wiring from
starter solenoid to
starter motor, if
good replace S
(starter) solenoid.
Replace
starter
motor.
Figure 6-2. Troubleshooting Flow Chart (Sheet 1 of 4)
6-2 Generator/Controller Troubleshooting TP-5606 6/02
Page 79
.
A
(From
Sheet 1)
Does engine
start?
No
Yes
.
Go to B
(Sheet 3)
Was intake air
preheated?
Yes
Is 12 VDC present
across fuel solenoid
(hold coil) with
Start/Stop Switch in
Start Position?
No
Does LED4 light
while Start/Stop
Switch is in Start
Position?
Rock Start/Stop
Switch to Stop
No
Position and hold
there for time given
in Section 2 to
activate air heater.
Yes
Yes
Test fuel
solenoid pull-in
and hold-in
resistances. Is
fuel solenoid
good?
No
Replace fuel
solenoid.
Replace circuit
board.
Rock and hold
Start/Stop Switch
in Start Position.
Does engine start?
No
Yes
Check for open
wire between
starter motor and
fuel solenoid. If
wire is good,
engine fault. (See
Engine Service
Manual)
Yes
.
Go to B
(Sheet 3)
No
Check 10A fuel
solenoid fuse in
controller wiring
harness. Is fuse
good?
No
Replace fuse.
Does trouble
repeat?
No
Trouble
corrected.
Fuse was
defective.
Yes
Yes
Is 12 VDC present
at K25 contact
(wire 70A to GND)
with Start/Stop
Switch in Start
Position?
Yes
Check/repair
wiring from P4-14
to P5-4.
Check fuel
solenoid pull-in
and hold-in
resistances. Is
fuel solenoid
good?
No
Replace fuel
solenoid.
No
Yes
Check wiring to
K25 coil.
Is 12 VDC present at
K25 coil with Start/
Stop Switch in Start
Position?
Check wiring to
fuel solenoid for
shorts.
Figure 6-2. Troubleshooting Flow Chart (Sheet 2 of 4)
No
Yes
Replace K25
relay.
Generator/Controller Troubleshooting 6-3TP-5606 6/02
Page 80
.
B
(From
Sheet 2)
Does engine
continue to run
after Start/Stop
Switch is
released?
No
Yes
.
Go to C
(Sheet 4)
Observe LED’s
while starting set
again. Does
LED1 light?
No
Yes
Does LED4
light?
No
Replace
controller
circuit board.
Yes
Does LED5
light less than 5
seconds after
LED1 lights?
No
Does LED4 light
before LED5?
No
Check possible
engine oil
pressure
problem.
Check possible
engine high
temperature
problem.
If there is no
engine problem,
replace
controller circuit
board.
Replace
Yes
controller circuit
board.
Is generator a
single-phase unit?
Yes Yes
No
Does generator
output exceed
63 Hz?
No
Replace
controller
circuit board.
Replace controller
circuit board.
Does AC Voltmeter
indicate any generator
output when Start/Stop
Switch is in Start
Position?
No
Perform separate
excitation test.
Does test pass?
No
Follow separate
excitation test
instructions to
isolate defective
exciter, rotor, or stator.
Yes
Yes
Replace
controller
circuit board.
Test B1/B2
stator winding
output. Is
output good?
No
Repair/replace
defective
stator.
Yes
Replace
controller
circuit board.
Figure 6-2. Troubleshooting Flow Chart (Sheet 3 of 4)
6-4 Generator/Controller Troubleshooting TP-5606 6/02
Page 81
C
(From
Sheet 3)
.
Rock Start/Stop
Switch to Stop
Position. Does
engine stop?
No
Yes
Complete
Generator
Set checks
out okay.
Observe LED4
while Start/Stop
Switch is in
Stop. Does
LED4 light?
No
Check Start/Stop
Switch operation
and wiring.
Is switch good?
Check for 12
VDC across hold
coil of fuel
Yes Ye s Ye s
solenoid. Is 12
VDC present?
No
Check for stock
fuel solenoid.
Replace controller
circuit board.
Yes
Is 12 VDC
present across coil
of relay K25
(wire 70 to GND)
while LED4 is lit?
No
Replace K25
relay.
Replace circuit
board.
No
Replace Start/Stop
Switch.
Figure 6-2. Troubleshooting Flow Chart (Sheet 4 of 4)
Generator/Controller Troubleshooting 6-5TP-5606 6/02
Page 82
6-6 Generator/Controller Troubleshooting TP-5606 6/02
Page 83
Section 7. Component Testing
and Adjustment
This section is a guide for checking generator, controller,
and some engine components for improper operation.
Follow the safety precautions at the beginning of this
manual during all test procedures. Additional safety
precautions are included with the tests; OBSERVE
THESE PRECAUTIONS!
Separate Excitation
To determine the cause of no AC output, separately
excite the generator. The generator field (rotor) may be
excited (magnetized) using an outside DC power source
or 12-volt automotive battery and the following
procedures. While separately exciting the generator to
determine the presence of a faulty voltage regulator, it is
possible to determine if a running fault exists in the rotor
and/or stator. A generator component appearing good
while static (stationary), may exhibit a running open or
short while dynamic (moving). This fault can be caused
by centrifugal forces acting on the windings while
rotating or insulation breakdown as temperatures
increase.
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, transfer switch, 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.
Moving rotor.
Component Testing and Adjustment 7-1TP-5606 6/02
Page 84
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
1
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. If
battery 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 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.
1. Disconnect wiring harness plug from connector on
voltage regulator. See Figure 7-1. Also disconnect
plug P7.
PowerBoostä III E
1-850
1
8
7
6
5
4
3
2
1
1-850
LED 3
1. Connector
Single-Phase Generator
LED 1
LED 2
PowerBoostä V
Three-Phase Generator
Figure 7-1. Voltage Regulator
2. Connect an ammeter and a DC power supply
12-volt automotive battery to the positive (+) and
negative (-) brushes or exciter leads. Include a
10-amp fuse to protect the circuit in case of a
shorted rotor. Refer to Figure 7-2. Note and record
the ammeter reading.
7-2 Component Testing and Adjustment TP-5606 6/02
Page 85
Voltage Regulator
PowerBoost IIIE
Black (+)
White (-)
Rotor
Slip
Rings
Single-Phase Generator
10-Amp
Fuse
DC
AM
-+
P5--12
P5--10
10 AMP
FUSE
D.C.
A.M.
+-
12 Volt
Battery
Brushes
TP-5414-6
To Controller
P4
P4
P6 P7
3. The approximate ammeter reading should be
battery voltage divided by specified rotor
(single-phase generator) or exciter field
(three-phase generator) resistance. For
resistances, see Specifications--Generator in
Section 1.
Example:
12 Volts (Battery Voltage)
4.7 Ohms (Rotor or Exciter
Field Resistance)
2.6 Amps
=
(Rotor Current)
4. Start engine and check that ammeter reading
remains stable. An increasing meter reading
indicates a shorted rotor or exciter field. A
decreasing meter reading to zero or an unstable
reading suggests a running open (see Rotor or
Exciter Field heading later in this section). If
ammeter is stable proceed to Step 5.
5. Check for AC output across stator leads (see
Stator heading later in this section) and compare to
readings in Specifications--Generator of Section 1.
If readings vary considerably from specified
values, a faulty stator is likely (see Stator heading
later in this section).
6. If rotor and stator test good in prior steps, the
voltage regulator is probably defective. (Refer to
appropriate Voltage Regulator heading later in this
section.)
NOTE
-- +
12 Volt
Battery
Three-Phase Generator
Figure 7-2. Separate Excitation Connections
Exciter
Field
Stator output voltages found in
Specifications--Generator of Section 1 are based
on a battery voltage of 12 volts. Should actual
battery voltage vary (11-14 volts), resulting values
will also vary.
NOTE
You’ll need to hold the fuel rack in to maintain
engine operation.
Component Testing and Adjustment 7-3TP-5606 6/02
Page 86
PowerBoostä IIIE
Voltage Regulator
The voltage regulator used on single-phase generator
models is the Powerboostä IIIE. The voltage regulator
monitors output voltage magnitude and frequency to
supply current to the generator exciter field. To test the
voltage regulator the following components will be
needed:
D Variable Transformer, 0--140 volts (0.5-amp
Minimum)
D 120-volt AC Plug
D 120-volt, 100-watt Lamp
D AC voltmeter
D #14 AWG Copper Wire (minimum)
WARNING
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.
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, transfer switch, 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.
Testing the voltage regulator. Hazardous voltage can
cause severe injury or death. High voltage is present at the
voltage regulator heat sink. To prevent electrical shock do not
touch the voltage regulator heat sink when testing the voltage
regulator.
(PowerBoostt, PowerBoostt III, and PowerBoostt V
voltage regulator models only)
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
7-4 Component Testing and Adjustment TP-5606 6/02
Page 87
PowerBoostä IIIE Voltage
Regulator Test Procedure
1. Disconnect P10 of wiring harness from connector
on voltage regulator. (See Figure 7-1.)
2. Connect components as shown in Figure 7-3.
3. Turn variable transformer setting to zero. Plug in
variable transformer.
4. Turn variable transformer on. Slowly increase
variable transformer voltage to 100 volts. The
lamp should go on between 30 to 40 volts up to
100 volts. If the lamp does not light, turn the
AC VOLTMETER
voltage adjustment pot clockwise. If the light still
does not go on, the voltage regulator is defective
and should be replaced. This would correspond to
a low- or no-voltage output condition.
5. Slowly increase voltage to 120 volts. The lamp
should go out and stay out as voltage is further
increased. If the lamp does not go out, turn the
voltage adjustment pot counterclockwise. If the
light still does not go out, the voltage regulator is
defective and should be replaced. This would
correspond to a high voltage output condition.
6. Turn variable transformer to zero and unplug AC
cord.
VOLTAGE
REGULATOR
POWERBOOST
IIIE
66 44 33 55 - +
STATOR/ROTOR
CONNECTIONS
(For reference only)
120
VOLTS
AC
VARIABLE
TRANSFORMER
Figure 7-3. PowerBoost IIIE Voltage Regulator Test
GY R Y O W BK
LEAD
COLOR
120 VOLT,
100 WATT
LAMP
TP-5348-7
Component Testing and Adjustment 7-5TP-5606 6/02
Page 88
PowerBoostä IIIE Voltage
Regulator Adjustment
been tampered with, readjust according to the following
procedure. Voltage regulator components are identified
in Figure 7-4 and described in the following paragraphs.
The voltage regulator is factory set for proper generator
operation under a variety of load conditions. Under
normal circumstances, no further adjustment is
necessary. However, if the regulator is replaced or has
VOLTAGE ADJUSTMENT POT
OPTIONAL
REMOTE
RHEOSTAT
(See NOTE A)
33
B1
3
MAIN
4
66
33
44
SENSING
NOTE
The voltage regulator is located in the junction box.
Adjustments are possible without removing the
regulator from the junction box. See Figure 7-5.
STABILIZER POT
VOLTAGE
VOLTS/HZ POT
REGULATOR
POWERBOOST
IIIE
STATOR/ROTOR
CONNECTIONS
66 33 55 -- +
44
(For reference
only)
GY R Y O W BK
LEAD COLOR
DC
OUTPUT
CONTROL
B2
STATOR
21
MAIN
Figure 7-4. PowerBoostä IIIE Voltage Regulator
55
10 AMP
FUSE
AC POWER
INPUT (AUX.)
+--
ROTOR
TP-5414-7
7-6 Component Testing and Adjustment TP-5606 6/02
Page 89
1
1-933
1. Voltage Regulator
Figure 7-5. PowerBoostä IIIE
Voltage Regulator Installed
NOTE A
A customer-provided rheostat may be connected
across regulator leads/terminals 33 and 66 to adjust
generator output voltage from a location remote from
the set. The rheostat (10k ohms, 1/2-watt minimum) will
provide a 5-volt adjustment range.
Voltage Adjustment Pot --Adjusts generator output
within range of approx. 100--130 Volts.
The 15/20CCO generator sets have the Volts/Hzfeature
disabled by turning the Volts/Hz pot out (fully
counterclockwise).
NOTE
For optimum results, full load should be applied when
adjusting stability pot.
1. With generator set off, turn remote rheostat (if
equipped) to midpoint. Turn Voltage and
Stability pots fully counterclockwise. Connect
voltmeter and frequency meter to AC circuit or an
electrical outlet.
2. Start generator set. Rotate voltage adjustment
pot clockwise to increase voltage
(counterclockwise to decrease voltage) until
desired output voltage is achieved.
3. Rotate stability pot clockwise until minimum light
flicker is obtained.
4. Readjust voltage adjustment pot (if necessary).
5. Readjust engine speed to normal (1800 rpm for 60
Hz or 1500 rpm for 50 Hz).
6. Readjust voltage adjustment pot (if necessary).
Stabilizer Pot --Fine-tunes regulator circuitry to reduce
light flicker.
Volts/Hz Pot --Adjustment determines engine speed
(Hz) at which generator output voltage will begin to drop.
7. Readjust stability pot (if necessary).
8. Use optional remote rheostat (if equipped) to
make final voltage adjustments. STOP
GENERATOR SET.
Component Testing and Adjustment 7-7TP-5606 6/02
Page 90
PowerBoostä V Voltage Regulator
The voltage regulator used on three-phase generator
models is PowerBoostä V.SeeFigure7-6.
LED 1
LED 3
LED 2
8
7
6
5
4
3
2
1
1-850
Figure 7-6. PowerBoostä V Voltage Regulator
The PowerBoostä V voltage regulator monitors output
voltage magnitude to control current to the generator
exciter field. The voltage regulator has an
underfrequency unloading feature which is referred to
as Volts-per-Hz (V/Hz). To determine if the voltage
regulator is functioning properly, reduce engine speed
(Hz) and watch for a corresponding drop in AC voltage.
AC voltage should remain constant until engine speed
drops below 57.5 Hz (on 60 Hz models) or 47.5 Hz ( on
50 Hz models). When frequency drops below 57.5/47.5
Hz, AC voltage should decline. To further check the
voltage regulator for proper function, perform the
following test to check regulator output. To test the
voltage regulator the following components will be
needed:
D Step-up Transformer, 1:2, 120 to 240 Volts (1.0
Amp minimum)
D Variable Transformer, 0--140 Volts (1.0 Amp
minimum)
D 120 Volt, 100 watt Lamp
D AC Voltmeter 250 Volt (minimum)
D 1 Amp Fuse
D 1 SPST Switch, 1 Amp (minimum)
D 120 Volt AC Plug
D #14 AWG Copper Wire (minimum)
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
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.
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, transfer switch, 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.
Testing the voltage regulator. Hazardous voltage can
cause severe injury or death. High voltage is present at the
voltage regulator heat sink. To prevent electrical shock do not
touch the voltage regulator heat sink when testing the voltage
regulator.
(PowerBoostt, PowerBoostt III, and PowerBoostt V
voltage regulator models only)
Moving rotor.
7-8 Component Testing and Adjustment TP-5606 6/02
Page 91
PowerBoostä V Voltage Regulator
Test Procedure
1. Disconnect P5 of wiring harness from connector
on voltage regulator. (See Figure 7-1.)
2. Connect components as shown in Figure 7-7.
3. Turn variable transformer setting to zero. Plug in
variable transformer. Plug in power source to
terminals 5 and 6.
volt system it would be 220 volts, etc. If the voltage
regulator functions as described, the voltage
regulator is okay.
If the lamp does not turn on, turn the voltage
regulator Vo l t s adjustment pot to the approximate
midpoint and repeat test. If the lamp fails to go on
after adjusting the Volts pot, replace the voltage
regulator. A voltage regulator testing bad as
described would cause a generator to have a
no/low voltage condition.
4. Turn variable transformer on. Turn SPST switch
on. Slowly increase variable transformer voltage.
The lamp should go on. Continue to increase
variable transformer voltage and when the preset
voltage is reached (observe voltmeter) the lamp
will turn off and continue to stay off as voltage is
further increased. The preset voltage is
determined by the setting of the Volts adjustment
pot on the voltage regulator. The preset voltage for
a 120/240 volt system is 240 volts, for a 110/220
POWERBOOSTä V VOLTAGE REGULATOR
LED 1
Volts
LED 2
LED 3
100-120
VOLTS AC
P5
If the lamp fails to turn off as voltage is increased,
turn the voltage regulator Vo l t s adjustment pot to
the approximate midpoint and repeat test. If the
lamp fails to go off after adjusting the Volts pot,
replace the voltage regulator. A voltage regulator
testing bad as described would cause a generator
to have a high voltage condition.
5. Turn variable transformer to zero and unplug AC
cord. Turn SPST switch off and unplug cord.
8
7
6
5
4
3
2
1
66
120 Volt,
100 Watt
Lamp
AC
Voltmeter
250 Volt
(min.)
55
100-120
VOLTS AC
1:2 Step-up
Transformer
Black
Variable
Transformer
White
1 Amp
Fuse
SPST
Switch
Figure 7-7. PowerBoostä V Voltage Regulator Test
Component Testing and Adjustment 7-9TP-5606 6/02
Page 92
PowerBoostä V Voltage Regulator
Adjustment
The PowerBoostä V voltage regulator monitors
generator output to control current flow to the generator
field. PowerBoostä V maintains generator output under
load until the generator engine speed drops to a preset
level (factory setting 57.5 Hz on 60 Hz models and 47.5
Hz on 50 Hz models). At this point (under factory
settings) the regulator allows generator voltage and
current to drop to a level sufficient to handle load. When
PowerBoostä V Voltage Regulator
the generator speed returns to normal (60 Hz or 50 Hz)
as load is accepted, generator output also returns to
normal. The voltage regulator is factory set for proper
generator operation under a variety of load conditions.
Under normal circumstances, no further adjustment is
necessary. However, if the regulator is replaced, has
been tampered with, or voltage/frequency reconnection
has been done, readjust according to the following
procedure. Voltage regulator components are identified
in Figure 7-8 and Figure 7-9 and described in the
following paragraphs.
STAB
LED 3
LED 1
LED 2
VOLTSV/HZ
FN
V1
V4
Exciter Field
Exciter Armature
FP
Voltage
Regulator Power
Supply Leads
66 55
AC
-+
Sensing Leads
(208-240 Volts nominal)
Stator Windings
710811B1
Main Field
B2
AC
Rectifier
Module
142536912
Figure 7-8. PowerBoostä V Voltage Regulator
7-10 Component Testing and Adjustment TP-5606 6/02
Page 93
Hazardous voltage 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 adjustments are
made. Remove wristwatch, rings, and jewelry that can
cause short circuits.
LED 1
LED 2
1 2 3
STAB
VOLTSV/HZ
LED 3
NOTE
The voltage regulator is located in the generator junction
box and is serviceable by removing four screws.
1. Stability Pot -- “Fine-tunes” regulator to reduce light
flicker.
2. Volts/Hz Pot--Adjustment determines engine speed
(Hz) at which generator output voltage will begin to drop.
3. Voltage Adjustment Pot--Adjusts generator output
within range of 190-- 270 Volts (line-to-line).
Figure 7-9. PowerBoostä V Adjustments
Hazardous voltage can cause severe injury or
death. The heat sink of the voltage regulator contains
high voltage. Do not touch voltage regulator heat sink
when testing or electrical shock will occur.
Adjustment Procedure
1. Turn Voltage, Volts/Hz, and Stability pots fully
counterclockwise. Connect voltmeter to AC circuit
or an electrical outlet.
2. Start generator set. Rotate Voltage Adjustment
pot clockwise (increase voltage) or
counterclockwise (decrease voltage) until desired
output voltage is achieved.
3. Rotate Stability pot clockwise until minimum light
flicker is obtained.
4. Readjust Voltage Adjustment pot (if necessary).
5. Mechanical Governor:
Adjust engine speed to desired cut-in frequency
(factory setting 57.5--58 Hz for 60 Hz models or
47.5--48 Hz for 50 Hz models) as measured on
frequency meter. See Section 3. Governor.
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
6. Rotate Volts/Hz Adjustment pot clockwise until
voltage level begins to drop (as measured on
voltmeter). When set to these specifications, the
generator will attempt to maintain normal output
until engine speed drops below the frequency set
in step 5 (as load is applied).
7. Mechanical Governor:
Readjust engine speed to normal (63 Hz/1890
rpm for 60 Hz or 52.5 Hz/1575 rpm for 50 Hz). See
Section 3. Governor.
8. Readjust Voltage Adjustment pot (if necessary).
9. Readjust Stability pot (if necessary).
10. STOP GENERATOR SET.
Component Testing and Adjustment 7-11TP-5606 6/02
Page 94
Controller Circuit Board
It is possible to check some controller circuit board
components (relays) without removing the component
from the board. These checks should be made prior to
installing a new board and attempting startup. Most of
the tests are referenced in Section 4. General
Troubleshooting. Use a high quality multimeter and
Ohmmeter
Component
K1 Relay Coil K1 coil terminals
K2 Relay Coil K2 coil terminals
K3 Relay Coil K3 coil terminals
K4 Relay Coil K4 coil terminals
K5 Relay Coil K5 coil terminals
Connections
(See relay
schematic)
(See relay
schematic)
(See relay
schematic)
(See relay
schematic)
(See relay
schematic)
Ohmmeter on
R x 10 scale
Ohmmeter on
R x 10 scale
Ohmmeter on
R x 10 scale
Ohmmeter on
R x 10 scale
Ohmmeter on
R x 10 scale
follow the manufacturer’s instructions. To obtain
accurate readings when testing, remove all circuit board
connectors and conformal coating (transparent
insulation) from component terminals. Use the chart,
Figure 7-10, and refer to the controller circuit board
layout and schematic in Figure 7-11.
Remarks Results
If good--approx. 160 ohms. Low
resistance (continuity)--shorted coil.
High resistance--open coil.
If good--approx. 160 ohms. Low
resistance (continuity)--shorted coil.
High resistance--open coil.
If good--approx. 400 ohms. Low
resistance (continuity)--shorted coil.
High resistance--open coil.
If good--approx. 125 ohms. Low
resistance (continuity)--shorted coil.
High resistance--open coil.
If good--approx 510 ohms. Low
resistance (continuity)--shorted coil.
High resistance--open coil.
Figure 7-10. E-239563 Circuit Board Tests
7-12 Component Testing and Adjustment TP-5606 6/02
Page 95
P1--14
P1--4
P1--1
P2--1
P1--8
P2--3
K3B
43
12 VDC
K4C
4
5
12 VDC
K1B
32
12 VDC
2
3
D9
1A
K2B
12 VDC
D11
1A
LED2
R9
1/4 W
K2A
1
8
12 VDC
C3
LED4
R7
1/4 W
K4A
61
5 VDC
LED3
R10
1/4 W
K3A
21
12 VDC
D10
1A
R8
1/4 W
K1D
12 VDC
E-239563-
P1--9
67
3
K4B
5 VDC
K2E
12 VDC
D2
1A
D1
1A
32
57
K5B
12 VDC
1
D4
5A
D6
1A
P1--15
P2--2
P1--13
P1--7
P1--10
P2--8
P2--5
P1--2
P2--6
P2--9
P1--5
P1--12
P1--3
P1--6
D7
5A
D5
5A
K1C
42
5 VDC
BR1
D8
1A
K1E
57
12 VDC
VR1
12 V
VOVI
GRD
C1
D3
1A
R2
1/4 W
R4
1/4 W
Q1
R3
1/4 W
Figure 7-11. Controller Circuit Board Testing
R1
1/4 W
LED5
R5C2
1/4 W
P2--4
P2--7
5
K5A
2
12 VDC
Q2
30 V
1
8
K1A
12 VDC
R6
1/4 W
LED1
Y-5179
Component Testing and Adjustment 7-13TP-5606 6/02
Page 96
Engine/Generator Components
With the generator set battery connected, the wiring
harness and some engine/generator components can
be checked with a voltmeter as described in
Figure 7-12. Place the controller or remote start/stop
Component
Hourmeter and
wiring
B1 and B2 stator
auxiliary winding
Fuel solenoid
(three-lead)
Voltmeter Connections Remarks Results
Red test clip to hourmeter
(+) terminal. Black test clip
to (--) terminal.
None (see Remarks) Disconnect hourmeter
Disconnect B1/B2 leads.
Connect AC voltmeter to
leads.
NOTE: Voltage can only be
measured momentarily
since unit will not continue
to run after start switch is
released.
Red test clip to #6 lead of
solenoid and black test clip
to engine block (ground).
Place controller switch to
Start position. STOP
generator set.
None (see Remarks) Push out leads #6 and “P”
Figure 7-12. Engine/Generator Component Testing with Voltmeter
switch in the prescribed position and check for 12 volts
DC at each component using a DC voltmeter. This will
verify that the switches function and 12 volt DC is
present at each component.
Voltmeter setting 12 volts. If wiring harness is
good--12 volts DC or
greater. To determine if
hourmeter is good, proceed
to next step.
If good--hourmeter will
leads and apply 12 volts
DC to hourmeter.
NOTE: Hourmeter is
polarity sensitive.
Voltmeter setting 20 volts
AC or greater. Start
generator set by holding
Start/Stop switch in Start
and allow to reach proper
speed. Take reading and
then stop generator.
Voltmeter setting 12 volts or
greater. If lead can not be
disconnected, cut leads
and crimp-on fully insulated
push-on terminals.
at the 4-pin connector.
Apply 12 volts DC to #6
lead and momentarily apply
12 volts DC to “P” lead.
NOTE: Apply voltage only
momentarily to “P” lead to
prevent fuel solenoid
damage. This coil draws 50
amps and is intended only
to energize the solenoid.
operate.
Reading of 12--15 volts
indicates B1/B2 winding is
good.
If wiring is good--12 volts
DC. To determine if fuel
solenoid is good, proceed
to next step.
If good--fuel solenoid will
energize and move plunger
when voltage is applied to
“P” lead and remain
held in after “P” lead is
disconnected as long
as #6 lead has voltage
appliedtoit.
7-14 Component Testing and Adjustment TP-5606 6/02
Page 97
WARNING
To further check generator set components, disconnect
the battery and remove wiring harness plugs from the
controller circuit board. Use an ohmmeter to check
continuity and to isolate defective components as
described in Figure 7-13. Also refer to the proper wiring
diagram in Section 9.
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
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.
NOTE
Before performing ohmmeter checks, disconnect
generator set battery to prevent damage to the
ohmmeter.
Component Testing and Adjustment 7-15TP-5606 6/02
Page 98
Ohmmeter
Component
Connections
Controller switch P2-6 and P2-4 Ohmmeter on R x 1 scale.
PlacerockerswitchinSTART
position.
Remarks Results
If good--zero ohms
(continuity). Any resistance
other than zero or very low
ohms--replace switch.
P2-6 and P2-5 Ohmmeter on R x 1 scale.
PlacerockerswitchinSTOP
position.
If good--zero ohms
(continuity). Any resistance
other than zero or very low
ohms--replace switch.
K20 relay coil P1-4 and P1-9 Ohmmeter on R x 1 scale If good--85 ohms. Low
resistance--shorted K20 relay
coil and/or wiring. High
resistance--open K20 relay
and/or wiring.
K25 relay coil P1-8 and P1-9 Ohmmeter on R x 1 scale If good--85 ohms. Low
resistance--shorted K25 relay
coil and/or wiring. High
resistance--open K25 relay
and/or wiring.
Starter solenoid
(‘S’ relay)
P4-4 and battery (--) cable.
NOTE: J4 and P4 must be
Ohmmeter on R x 1 scale. If good--approx. 0.20--0.35
ohms at 80_ F(27_ C).
disconnected to perform this
test.
Controller 10amp fuse and
wiring
Battery positive (+) cable and
P1-14
NOTE: J4 and P4 must be
connected to perform this
Ohmmeter on R x 1 scale. If good--zero or very low
ohms. No reading
(infinity)--open circuit or fuse
blown.
test.
Air heater relay
(C1onsingle
P4-8 and P4-1 Ohmmeter on R x 1 scale. If good--approx. 16--20 ohms
at 80_F(27_C).
phase and AH on
three phase)
Figure 7-13. Engine/Generator Set Component Testing with Ohmmeter (Sheet 1 of 2)
7-16 Component Testing and Adjustment TP-5606 6/02
Page 99
Ohmmeter
Component
P1 ground
P1-9 and ground Ohmmeter on R x 1 scale. If good--zero ohms
Connections
connection
Low oil pressure
(LOP) safety
shutdown switch
P1-15 and engine block
(ground)
NOTE: J4 and P4 must be
connected to perform this
test.
High water
temperature
(HWT) safety
shutdown switch
P1-15 and engine block
(ground)
NOTE: LOP switch lead
should be removed and
isolated.
NOTE: J4 and P4 must be
connected to perform this
test.
Rotor See separate paragraph with
same title.
Stator See separate paragraph with
same title.
Exciter Field See separate paragraph with
same title.
Exciter Armature See separate paragraph with
same title.
Fuel Solenoid See separate paragraph with
same title.
Remarks Results
(continuity). Any other
reading indicates a poor
ground connection.
Ohmmeter on R x 1 scale.
This test is not conclusive
until the temperature
shutdown switches are
checked.
If good--zero ohms
(continuity). Then, disconnect
LOP switch lead and isolate
terminal. Meter reading
reading should show an open
circuit.
Ohmmeter on R x 1 scale. If good--open circuit. Any
continuity suggests that
temperature switch(es) are
defective. Disconnect
individual leads to determine
which switch is defective.
See separate paragraph with
same title.
See separate paragraph with
same title.
See separate paragraph with
same title.
See separate paragraph with
same title.
See separate paragraph with
same title.
See separate paragraph with
same title.
See separate paragraph with
same title.
See separate paragraph with
same title.
See separate paragraph with
same title.
See separate paragraph with
same title.
Figure 7-13. Engine/Generator Set Component Testing with Ohmmeter (Sheet 2 of 2)
Component Testing and Adjustment 7-17TP-5606 6/02
Page 100
Rotor
The four-pole rotor creates the magnetic field needed to
sustain alternating current in the stator windings. Prior to
testing, inspect the rotor for visible damage to pole
shoes, insulation, exposed coil windings, and slip ring
surfaces. Check rotor bearing for noisy operation,
excessive wear, and heat discoloration. Replace or
repair these components if any of the above conditions
exist.
1-362
Single-Phase Rotor Tests
Slip rings acquire a glossy brown finish in normal
operation. Do not attempt to maintain a bright, newly
machined appearance. Ordinary cleaning with a dry,
lint-free cloth is usually sufficient. Very fine sandpaper
(#00) may be used to remove roughness. Use light
pressure on the sandpaper. Do not use emery or
carborundum paper or cloth. Clean out all carbon dust
from the generator. If the rings are black or pitted,
remove the rotor and remove some of the surface
material using a lathe.
Check the rotor for continuity and resistance. Measure
the rotor resistance (ohms) between the two slip rings
(Figure 7-14). See Specifications--Generator in Section
1 for typical readings.
NOTE
Since ohmmeters do vary in their accuracy, use values
in Section 1 as a reference for approximate readings.
Readings must be at room temperature or about 70° F
(21° C). Rotor resistance will vary directly with increase
in temperature.
To check for rotor shorted to ground, adjust ohmmeter to
zero ohms. Touch one ohmmeter lead to either slip ring
and other lead to rotor poles or shaft. Meter should
register no continuity.
Figure 7-14. Rotor Resistance Check
NOTE
When checking rotor resistance with rotor installed,
brushes must not be in contact with rotor slip rings. Use
brush retainer on brushes for accurate resistance
readings.
The rotor must be repaired or replaced if any faults are
detected in the previous tests.
Three-Phase Rotor Tests
Check the rotor for continuity and resistance. To perform
check, disconnect rotor leads from rectifier module
circuit board and then measure the rotor resistance
(ohms) between the two rotor leads (Figure 7-15). See
Specifications--Generator in Section 1 for typical
readings.
NOTE
Since ohmmeters do vary in their accuracy, use values
in Section 1 as a reference for approximate readings.
Readings must be at room temperature or about 70° F
(21° C). Rotor resistance will vary directly with increase
in temperature.
7-18 Component Testing and Adjustment TP-5606 6/02
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