Kohler 32EOZ, 27EFOZ Service Manual

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Page 1

Service

Marine Generator Sets

Models:

32EOZ

27EFOZ

TP-5936 7/04d

Page 2

Page 3

Table of Contents

Safety Precautions and Instructions I.........

Introduction i...............................

Service Assistance i.........................

Section 1 Specifications 1....................

1.1 General 1..................................

1.2 Engine 1...................................

1.3 Generator 2.................................

1.4 Service View 3..............................

Section 2 Scheduled Maintenance 5...........

2.1 General 5..................................

2.2 Lubrication System 6.........................

2.2.1 Oil Specifications 6..................

2.2.2 Oil Change 6........................

2.3 Generator Storage 6.........................

Section 3 Intake and Exhaust System 7........

3.1 Air Intake Silencer/Cleaner 7..................

3.2 Exhaust System 7...........................

3.3 Mixing Elbow 7..............................

Section 4 Fuel System 9.....................

4.1 General 9..................................

4.2 Fuel Specifications 9.........................

4.3 Fuel Filter 9.................................

4.4 Bleed the Fuel System 10......................

4.5 Fuel Solenoid 11.............................

4.6 Fuel Pump 12................................

4.7 Governor 12.................................

Section 5 Cooling System 13..................

5.1 General 13..................................

5.2 Water-Cooled Exhaust Manifold 14..............

5.3 Closed Heat Exchanger 14.....................

5.4 Check and Fill the Cooling System 14...........

5.5 Flush and Fill the Cooling System 14............

5.6 Siphon Break 15..............................

5.7 Impeller Inspection and Replacement 16.........

5.8 Anticorrosion Zinc Anode 17...................

Section 6 Controller Troubleshooting 19........

6.1 Controller 19.................................

6.2 Controller Sequence of Operation 19............

6.2.1 Start 19.............................

6.2.2 Run 20..............................

6.2.3 Stop 20..............................

6.3 Engine Safety Shutdown Switches 20...........

6.3.1 Low Oil Pressure (LOP) Shutdown 20...

6.3.2 High Water Temperature (HWT) and High Exhaust Temperature (HET) Shutdown

Switch 21............................

6.3.3 Controller Circuit Board 21.............

6.3.4 Troubleshooting 22...................

Section 7 Generator Troubleshooting 27........

7.1 General 27..................................

7.2 General Troubleshooting 27....................

7.3 Separate Excitation 28........................

7.4 PowerBoost V Voltage Regulators 28............

7.5 Voltage Regulator Adjustment 30...............

7.6 Exciter Field 31...............................

7.7 Exciter Armature 32...........................

7.8 Rectifier Module 33...........................

7.9 Rotor 33.....................................

7.10 Stator 34....................................

Section 8 Component Troubleshooting 37......

8.1 General 37..................................

8.2 Remote Panels (Optional) 39...................

Section 9 Generator Disassembly/

Reassembly 41...............................

9.1 Disassembly 41..............................

9.2 Reassembly 44...............................

Section 10 Voltage Reconnection and Wiring

Diagrams 45..................................

10.1 4-Lead Reconnection 45.......................

10.1.1 100--120-Volt Configurations 45.........

10.1.2 100--120-/200--240-Volt

Configurations 46.....................

10.1.3 200--240-Volt Configurations 46.........

10.2 12-Lead Reconnection 46.....................

10.3 Two and Three Wire Manual (Ship-to-Shore)

Transfer Switch 47............................

10.4 Four Wire Manual (Ship-to-Shore)

Transfer Switch 48............................

10.5 Generator Reconnection 48....................

10.6 Single-Phase Wiring Diagram—Schematic 50....

10.7 Single-Phase Wiring Diagram—Point-to-Point 51.

10.8 Three-Phase Wiring Diagram—Schematic 52.....

10.9 Three-Phase Wiring Diagram—Point-to-Point 53..

10.10 Remote Start Panel 54........................

10.11 Remote Start and Two-Meter Panel 54..........

10.12 Remote Start and Four-Meter Panel 55..........

Appendix A Abbreviations A-1................

Appendix B Common Hardware Application

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-5936 7/04 Table of Contents

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Notes

TP-5936 7/04Table of Contents

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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 severaltypesofsafety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe

personal injury,death,orsubstantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe

personal injury,death,or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals.

Accidental Starting

WARNING

Accidental starting. Can cause severe injury or death.

Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

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

working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Place the generator set start/stop switch in the STOP position. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

Battery

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

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.

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-5936 7/04 ISafety Precautions and Instructions

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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/silencer removed.

Combustible materials. A sudden flash fire can cause severe injury or death. Do not smoke or permit flames

or sparks near the fuel system. Keep the compartment and the generator set clean and free of debris to minimize the risk of fire. Wipe up spilled fuels and engine oil.

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.

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/water leakage.

Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the

safety of the craft’s occupants, install a carbon monoxide detector. Consult the boat 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.

Operating the generator set. 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. Use the following precautions when installing and operating the generator set. Do not install the exhaust outlet where exhaust can be drawn in through portholes, vents, or air conditioners. If the generator set exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow of exhaust. Never operate the generator set without a functioning carbon monoxide detector. Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate. If operating the generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always be aware of others, making sure your exhaust is directed away from other boats and buildings. Avoid overloading the craft.

TP-5936 7/04II Safety Precautions and Instructions

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Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

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

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.

Installing the fuel system. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an

explosion. Do not modify the tank or the propulsion engine fuel system. Equip the craft with a tank that allows one of the two pickup arrangements described in the installation section. The tank and installation must conform to USCG Regulations.

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.

Pipe sealant. Explosive fuel vapors can cause severe injury or death.

Fuel leakage can cause an explosion. Use pipe sealant on all threaded fittings to prevent fuel leakage. Use pipe sealant that resists gasoline, grease, lubrication oil, common bilge solvents, salt deposits, and water.

Ignition-protected equipment. Explosive fuel vapors can cause severe injury or death. Gasoline

vapors can cause an explosion. USCG Regulation 33CFR183 requires that all electrical devices (ship-to-shore transfer switch, remote start panel, etc.) must be ignition protected when used in a gasoline and gaseous-fueled environment. The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous-fueled environment such as an engine room or near fuel tanks. Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash.

Hazardous Noise

CAUTION

Hazardous noise. Can cause hearing loss.

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

Engine noise. Hazardous noise can cause hearing loss. Generator sets

not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage

WARNING

Hazardous voltage. Can cause severe injury or death.

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

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).

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.

TP-5936 7/04 IIISafety Precautions and Instructions

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Disconnecting the electrical load. Hazardous voltage can cause severe injury or death. Disconnect

the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads. High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load.

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)

Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death.

Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina 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 ship-to-shore transfer switch to prevent interconnection of the generator set power and shore 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)

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.

TP-5936 7/04IV Safety Precautions and Instructions

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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.

Operate the generator set only when all guards, screens, and covers are in place.

Moving rotor.

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.

Sound shield removal. Exposed moving parts can cause severe injury or death. The generator set

must be operating in order to perform some scheduled maintenance procedures. Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

(Sound-shield-equipped models only)

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

Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic). Do not substitute clear glass-type fuses for ceramic fuses. Refer to the wiring diagram when the ampere rating is unknown or questionable.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

WARNING

Airborne particles. Can cause severe injury or blindness.

Wear protective goggles and clothing when using power tools, hand tools, or compressed air.

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.

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-5936 7/04 VSafety Precautions and Instructions

Page 10

Notes

TP-5936 7/04VI Safety Precautions and Instructions

Page 11

Introduction

This manual provides troubleshooting and repair instructions for 32EOZ and 27EFOZ 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.

For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Maintenance work must be performed by appropriately skilled and suitably-trained maintenance personnel familiar with generator set operation and service.

x:in:001:003

Service Assistance

China

North China Regional Office, Beijing Phone: (86) 10 6518 7950

(86) 10 6518 7951 (86) 10 6518 7952

Fax: (86) 10 6518 7955

D Visit the Kohler Power Systems website at

KohlerPowerSystems.com

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents included with the product

D Call toll free in the US and Canada 1-800-544-2444

D Outside the US and Canada, call the nearest regional

office

Headquarters Europe, Middle East, Africa (EMEA)

Kohler Power Systems ZI Senia 122 12, rue des Hauts Flouviers 94517 Thiais Cedex France Phone: (33) 1 41 735500 Fax: (33) 1 41 735501

Asia Pacific

Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264-6422 Fax: (65) 6264-6455

East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office Bangalore, India Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727

Latin America

Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131

TP-5936 7/04 iIntroduction

Page 12

Product Information

Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.

Engine Identi

Record the product identification information from the engine nameplate.

Manufacturer

Model Number

Serial Number

Generator Set Identification Numbers

Record the product identification numbers from the generator set nameplate(s).

Model Number

Specification Number

Serial Number

Accessory Number Accessory Description

ication

TP-5936 7/04ii Introduction

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1.1 General

19(

)

6(3.0

)

The 32EOZ/27EFOZ units are powered by a Yanmar 4TNE98 four-cylinder, water-cooled, four-cycle diesel engine with heat exchanger.

Ratings: Kohler Co. develops all Kohler marine generator set ratings using accepted reference

1.2 Engine

Section 1 Specifications

conditions of 25_C(77_F) and pressure of 29.2 in. Hg dry barometer. ISO 3046 and ISO 8528-1 include reference conditions and output calculations. Obtain technical information bulletin (TIB-101) on ratings guidelines for complete ratings definitions.

Generator Model 32EOZ 27EFOZ

Engine Manufacturer Yanmar

Engine Model 4TNE98

Number of Cylinders 4

Cylinder Block Material Cast iron

Cylinder Head Material Cast iron

Piston Rings 2 compression/1 oil

Crankshaft Material Stamped forging

Connecting Rod Material Forged carbon steel

Governor Centrifugal, mechanical

Bore x Stroke, mm (in.) 98 x 110 (3.86 x 4.33)

Displacement, L (CID) 3.319 (202.5)

Compression Ratio 18.0:1

Horsepower, 60/50 Hz 55 46

RPM, 60/50 Hz (Full Load) 1800 1500

Direction of Rotation (as viewed from generator end)

Lubrication System Pressure, trochoid pump

Lube Oil Capacity, (w/filter) L(qts)

Oil Recommendation (API) CC or CD

Engine Firing Order (#1 cylinder nearest to flywheel)

Fuel Injection Timing (BTDC)

Fuel Injection Pressure, kPa (psi)

Combustion System Direct injection

Battery Voltage

Battery Charging (alternator)

Battery Recommendation, min.

Counterclockwise

4.7(5.0)

1-3-4-2

10--12_

1517--1586 (220--230)

12 volt (standard)

24 volt (optional)

50 amps

800 CCA, 100 amp hr

Generator Model 32EOZ 27EFOZ

ISO 8217 DMA, BS 2869

Fuel Recommendation

Fuel Shutoff Solenoid System

Fuel Feed Pump Electric, rotary vane

Fuel Pump Priming Electric

Max. Recommended Fuel Pump Lift, m (ft.)

Coolant Capacity, L (U.S. qts.) (approx.)

Coolant Recovery Tank, L(oz.)

Recommended Coolant

Thermostat 71°C (160°F)

Pressure Cap Rating, kPa (psi)

Starter Motor 2.3 kW

Intake/Exhaust Valve Clearance, mm (in.) (lash) (cold)

Belt Tension (force), @ 10 kg (22 lbs.), mm (in.)

Cylinder Head Torque

Final, Nm (ft. lbs.) (2-step intervals)

Initial, Nm (ft. lbs.) 49--58.8 (36--43)

Overbolt Torque (M10-1.5), Nm (ft. lbs.)

Inlet Water Line Hose ID, seawater pump inlet, mm (in.)

Outlet Water Line Hose ID, mixing elbowoutlet, mm (in.)

Fuel Inlet, (Fuel Pump Inlet)

Fuel Return Size, Type 1/4 NPT

Part 1, class 1

or Part 2, class 2

Electric

1.2 (4)

7.6 (8.0)

0.24 (8.0)

50% ethylene glycol; 50%

clean, softened water

97 (14)

0.15--0.25 (0.006--0.010 )

10--15 (0.4--0.6)

102.9--112.7 (76--83 )

38 (28)

.75

1/4 NPT

TP-5936 7/04 1Section 1 Specifications

Page 14

1.3 Generator

32EOZ/27EFOZ—4 Lead, 1 Phase Generator

Component Specification Value

Hot exciter field voltage/current readings at rated voltage*

No load (63 Hz) (volts/amps)

Full load (60 Hz) (volts/amps)

Cold exciter field resistance (ohms)

Cold exciter armature resistance (ohms)

Cold main field (rotor) resistance (ohms)

Stator output voltages with separately excited generator using 12-volt battery (60 Hz only)*

1--2, 3--4, 33--44 (volts) 84

55--66 (volts) 148

B1-B2 (volts) 10

Cold stator resistance

1--2, 3--4, 33--44 (ohms) 0.04

55--66 (ohms) 1.7

B1-B2 (ohms) 0.19

* Exciter field circuit includes resistor.

18.0/0.7

45.4/1.7

22.7ᐔ2.3

0.6ᐔ0.05

2.24

32EOZ/27EFOZ—12 Lead, 3 Phase Generator

Component Specification Value

Hot exciter field voltage/current readings at rated voltage*

No load (63 Hz) (volts/amps)

Full load (60 Hz) (volts/amps)

Cold exciter field resistance (ohms)

Cold exciter armature resistance (ohms)

Cold main field (rotor) resistance (ohms)

Stator output voltages with separately excited generator using 12-volt battery (60 Hz only)*

1--4, 2--5, 3--6, 7--10, 8--11, 9--12, 7--8 (volts)

55-66 (volts) 150

B1-B2 (volts) 6

Cold stator resistance

1--4, 2--5, 3--6, 7--10, 8--11, 9--12, 7--8 (ohms)

55--66 (ohms) 2.1

B1-B2 (ohms) 0.15

* Exciter field circuit includes resistor.

21.1/0.8

70.0/2.5

22.7ᐔ2.3

0.6ᐔ0.05

2.24

0.09

TP-5936 7/042 Section 1 Specifications

Page 15

1.4 Service View

1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17

2325

21222426

16 1227

1. Controller

2. Start/Stop switch

3. Hourmeter

4. DC circuit breaker

5. AC load lead connector (rear)

6. Nameplate (top)

7. Remote start connector (rear)

8. AC circuit breaker

9. Air intake silencer

10. Lifting eye

11. Fuel filter

12. Oil fill

13. Fuel return (or located behind valve cover and filter)

14. Governor

15. Fuel injection pump

16. Pressure cap

17. Overflow tube

GB-250000

18. High water temperature switch

19. Seawater pump (water inlet)

20. Coolant overflow bottle

21. Oil filter

22. Oil drain valve

23. Oil drain hose

24. Oil dipstick

25. Fuel inlet

26. Low oil pressure switch

27. Thermostat housing and thermostat

28. High temperature shutdown switch

29. Mixing elbow (water/exhaust outlet)

30. Engine starter motor

31. Heat exchanger

32. Water temperature sender (optional)

33. Battery charging alternator

Figure 1-1 Generator Set Service View

TP-5936 7/04 3Section 1 Specifications

Page 16

Notes

TP-5936 7/044 Section 1 Specifications

Page 17

Section 2 Scheduled Maintenance

2.1 General

WARNING

Accidental starting. Can cause severe injury or death.

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

generator set or 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.

Sound shield removal. Exposed moving parts can cause severe injury or death. The generator set must be operating

in order to perform some scheduled maintenance procedures. Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

(Sound-shield-equipped models only)

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

Note: See the generator set operation manual for the

service schedule and other service not included in this manual.

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

WARNING

Rotating parts. Can cause severe injury or death.

Operate the generator set only when all guards, screens, and covers are in place.

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.

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-5936 7/04 5Section 2 Scheduled Maintenance

Page 18

2.2 Lubrication System

The following paragraphs describe the engine lubrication system.

2.2.1 Oil Specifications

Use oil that meets the American Petroleum Institute (API) classification of CC or CD. Using unsuitable oil or neglecting an oil change may result in engine damage and a shorter engine life.

2.2.2 Oil Change

4. Drain the seawater from the heat exchanger by removing the coolant drain plug.

5. Close the seacock and remove the hose at the seacock. Place the hose in a container having approximately 3.7--7.5 L (1--2 gal.) of marine antifreeze. Use an environmentally safe marine antifreeze with corrosion inhibitors.

6. With a container at the exhaust outlet, run the generator set until coolant discharges at the exhaust outlet or until depleting the coolant mixture. Do not allow the coolant mixture to flow into waterways.

Change the engine oil according to the service schedule. Change the oil more frequently under dirty, dusty conditions. Change the oil while the engine is still warm. See Section 1.2 for oil capacities. See Section 1.4 , Service View, for the oil fill, oil check, and oil filter locations.

2.3 Generator Storage

Perform the generator storage procedure while the craft is afloat. Follow the procedure below when storing your generator set for 3 months or more.

Storage Procedure

1. Start and run the generator set until it reaches operating temperature, about 30 minutes.

2. Stop the generator set.

3. Change the oil and oil filter. See the generator set operation manual.

7. Stop the generator set.

8. Connect the hose to the seacock. Leave the seacock closed.

9. Check the coolant level in the heat exchanger and add coolant if necessary.

Note: Use antifreeze with the lowest available

temperature rating.

10. Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces which may be subject to rust or corrosion.

11. Disconnect and remove the battery. Place the battery in a dry location for the storage period. Recharge the battery once a month to maintain a full charge.

12. Cover the entire unit with a breathable dust cover.

TP-5936 7/046 Section 2 Scheduled Maintenance

Page 19

Section 3 Intake and Exhaust System

3.1 Air Intake Silencer/Cleaner

At the interval specified in the service schedule, clean or replace the air intake silencer. Clean more frequently in

dirty, dusty conditions.

3.2 Exhaust System

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of

the craft’s occupants, install a carbon monoxide detector. Consult the boat 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.

Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections.

D Check the hoses for softness, cracks, leaks, or dents.

Replace the hoses as needed.

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps.

Tighten or replace the hose clamps as needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). 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

craft, (2) functional. and (3) energized whenever the generator set operates.

3.3 Mixing Elbow

The mixing elbow combines high-temperature exhaust and cool seawater. When exposed to engine vibration this mixture can cause rapid deterioration and failure in an incorrectly maintained exhaust system.

1. Check inside the mixing elbow for carbon accumulation and corrosion.

2. Remove carbon accumulation.

3. Inspect the exhaust manifold mounting surface for cracks and corrosion.

Inspect the exhaust system components (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and outlet flapper) for cracks, leaks, and

4. Replace a damaged mixing elbow or other components to prevent engine exhaust (carbon monoxide) leakage.

corrosion.

TP-5936 7/04 7Section 3 Intake and Exhaust System

Page 20

Notes

TP-5936 7/048 Section 3 Intake Exhaust System

Page 21

Section 4 Fuel System

4.1 General

In most installations, both the generator set and the propulsion engine operate from a common fuel tank with a dual dip tube arrangement. The generator set dip tube is shorter than the propulsion engine’s dip tube. With this arrangement fuel may not be available to the generator set when the fuel supply is low. See Figure 4-1 for a fuel system schematic.

To fuel pump

Propulsion Engine

Generator Set

4.2 Fuel Specifications

Use a clean, good quality diesel fuel oil with a cetane number of 45 or greater. Clean fuel prevents diesel fuel injectors and pumps from clogging.

Fuel Recommendation

United States ISO 8217 DMA, BS 2869 Part 1 Class A1

or Part 2 Class A2

United Kingdom BS 2869-1983, Part 2 Class A2

Germany DIN 51 601-1978

4.3 Fuel Filter

The quality and condition of the fuel largely determine the filter’s useful life. Replace the fuel filter according to the service schedule.

1. Fuel tank

2. Dual dip tubes

3. Fuel filter

4. Fuel feed pump

Figure 4-1 Fuel System Schematic, Typical

TP-5936 7/04 9Section 4 Fuel System

Page 22

4.4 Bleed the Fuel System

Bleed the air from the fuel system to prevent starting failures and/or erratic operation. One or more of the following causes air to collect in the fuel system.

D The generator set operates until the fuel supply is

emptied.

D Air is drawn into the suction side of the fuel system.

D Replacing the fuel filter.

Note: Connect the battery during the priming procedure

to allow engine cranking. Do not allow the engine/generator to start. To prevent starting, toggle the start/stop switch by momentarily placing the start/stop switch in the START position for a few seconds and then placing the switch in the STOP position. Close the seacock during bleeding.

Procedure to Bleed the Fuel System

5. Loosen vent screw C at the fuel filter. See Figure 4-2.

6. Toggle the start/stop switch until fuel, free of air bubbles, flows from vent screw C. Tighten vent screw C.

1234 5

1. Loosen vent screw A at the fuel filter. See Figure 4-2.

2. Toggle the start/stop switch until fuel, free of air bubbles, flows from vent screw A. Tighten vent screw A.

3. Loosen vent screw B at the fuel filter. See Figure 4-2.

4. Toggle the start/stop switch until fuel, free of air bubbles, flows from vent screw B. Tighten vent screw B.

GB-250000A-K

1. Vent screw A

2. Vent screw B

3. Fuel filter

4. Vent screw C

5. Fuel injection pump

Figure 4-2 Fuel System, Typical

TP-5936 7/0410 Section 4 Fuel System

Page 23

4.5 Fuel Solenoid

The fuel solenoid pulls the injector pump lever to the fuel on position when energized. The fuel solenoid is spring loaded to return the injector pump lever to the fuel off position when deenergized.

The generator set uses a three-lead fuel solenoid. This solenoid has a white lead (P) which energizes the pull-in coil only during cranking. During operation, the red lead energizes the hold coil and the black lead is the common ground.

Figure 4-3 shows the current (amps) and resistance readings. Disconnect the fuel solenoid from the engine wiring harness and take the resistance readings to determine if the solenoid windings are open or shorted.

In addition to the ohmmeter test, check for smooth, non-binding movement of the plunger. Be sure to adjust the linkage between the fuel solenoid and the fuel injection pump lever to allow the solenoid plunger to fully compress. Incorrect adjustment may cause burnout of the pull-in coil. If the fuel solenoid is removed, see Figure 4-4 and use the following procedure.

Fuel Solenoid Test Procedure

1. Remove the linkage to allow the fuel solenoid plunger to be manually compressed.

Reading

Fuel Solenoid

Pull-In 50 amps 22 amps

Hold 1.0 amps 0.37 amps

Black-white (P) leads 0.12--0.26 ohms

Black-red leads 11--13 ohms

12V System 24V System

Figure 4-3 Fuel Solenoid Readings

GB-250000A-K

1. Fuel solenoid

Figure 4-4 Fuel Solenoid

2. With the fuel solenoid fully compressed, align the linkage and check the injection pump lever for travel. The fuel solenoid should fully compress and the injection pump lever should be at 1.6 mm (0.06 in.) before the lever contacts (internal full open) stop.

Note: The fuel solenoid must compress (bottom)

fully or the fuel solenoid pull-in coil will burn out.

3. If alignment is not correct, check the linkage and mounting brackets. Loosen the locknuts and adjust the ball joint length in or out to attain the correct alignment. Tighten the locknuts.

TP-5936 7/04 11Section 4 Fuel System

Page 24

4.6 Fuel Pump

The fuel pump transfers fuel from a source to the fuel injection pump.

Fuel Pump Test Procedure

1. Remove the two leads from the terminals at the bottom of the fuel pump. The pump terminals are labeled (--) and (+). See Figure 4-5.

2. Connect the inlet side of the pump to a fuel source. Disconnect the outlet hose from the fuel filter and place the hose end in a container to catch the fuel.

60 Hz generator sets are designed to operate at 57--63 Hz, 1800 rpm under full load and 1890 rpm under no load.

50 Hz generator sets are designed to operate at 47--53 Hz, 1500 rpm under full load and 1590 rpm under no load.

Check the engine speed using a frequency meter connected to the load leads. Loosen the locking nut on the speed adjusting screw. Turn the screw clockwise to increase the speed and frequency. Turn the screw counterclockwise to decrease the speed. Tighten the locknut at the new setting. See Figure 4-6.

3. Connect the positive (+) terminal of the 12-volt battery to the positive terminal of the fuel pump. Connect the negative terminal of the fuel pump to the negative (--) terminal of the battery. You should hear the pump operate and see the fuel discharge from the pump outlet. Replace the pump if it does not operate.

1. Fuel inlet

2. Negative terminal

3. Positive terminal

4. Fuel outlet

I-940

Governor Adjustment Procedure

1. Loosen the locknut on the speed adjusting screw.

2. Turn the speed adjusting screw clockwise to increase the speed and frequency or counterclockwise to decrease the speed.

3. Tighten the locknut at the new setting. See Figure 4-6.

4. Adjust the voltage regulator. See Section 7.5, Voltage Regulator Adjustment.

Figure 4-5 Fuel Pump

4.7 Governor

The centrifugal, mechanical governor keeps 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 governor. The factory adjusts the governor during run-in, and further adjustment should not be needed unless poor governor control develops after extended generator usage.

GB-250000A-K

1. Governor

2. Locknut

3. Speed adjusting screw

Figure 4-6 Governor

TP-5936 7/0412 Section 4 Fuel System

Page 25

Section 5 Cooling System

5.1 General

The heat exchanger cooling system consists of a heat exchanger with a coolant recovery tank, a thermostat, a rubber impeller seawater pump, a centrifugal-type engine circulating pump, a water-cooled exhaust manifold, and an exhaust mixer. See Figure 5-1 for cooling system components.

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.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

Note: Do not add coolant to a hot engine. Adding

coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until the engine has cooled.

1. Engine block

2. Exhaust manifold

3. Exhaust mixer elbow

4. Outlet flapper

5. Silencer

6. Thermostat

Seawater Coolant/Antifreeze

60531099

7. Heat exchanger

8. Engine seawater pump

9. Seawater strainer

10. Seacock

11. Intake strainer

12. Engine-driven water pump

Figure 5-1 Cooling System Components

TP-5936 7/04 13Section 5 Cooling System

Page 26

5.2 Water-Cooled Exhaust Manifold

5.4 Check and Fill the Cooling System

Each marine generator set has a water-cooled exhaust manifold. The coolant solution circulates through the manifold, reducing the amount of heat radiated from the exhaust into the surrounding area.

The engine thermostat is located in the water-cooled exhaust manifold. See Section 1 for the thermostat location. See Figure 5-2 and Figure 5-3 for exhaust manifold bolt tightening sequence and torques.

Model Bolt Torque

32EOZ/27EFOZ 19 Nm (14 ft. lbs. )

Figure 5-2 Water-Cooled Exhaust Manifold Bolt

Tightening Torques

Before filling the cooling system, close all the petcocks and tighten all of the hose clamps. Usea solution of 50% ethylene glycol and 50% fresh, softened water to inhibit rust/corrosion and prevent freezing. Add additional coolant, as necessary, to the coolant recovery tank. Maintain the level in the coolant recovery tank at approximately 1/4 full. Periodically check the coolant level on closed systems by removing the pressure cap. Do not rely solely on the level in the coolant recovery tank. Add fresh coolant until the level is just below the overflow tube opening.

5.5 Flush and Fill the Cooling System

For optimum protection drain, flush and refill the cooling system at the interval listed in the service schedule.

1. Open the petcocks located at the heat exchanger, engine block, and cooling system and let the system drain completely. The petcocks on some models are located behind the belt guard. Remove the pressure cap to simplify draining.

344848-E

Figure 5-3 Water-Cooled Exhaust Manifold Bolt

Tightening Sequence

5.3 Closed Heat Exchanger

In a closed cooling system, the seawater circulates through separate chambers within the heat exchanger to cool the engine coolant. The seawater then mixes with engine exhaust and ejects out the exhaust outlet. See Section 1.2 for the coolant capacities; include coolant recovery tank capacity of 0.24 L (8.0 oz.). See Section 1.2 for the thermostat and pressure cap ratings.

Note: Use antifreeze capable of withstanding the

lowest possible temperatures.

2. Drain, clean, and flush the coolant recovery tank.

3. Flush the cooling system with clean water.

4. Fill the cooling system with recommended coolant.

Note: Pay special attention to the coolant level. After

the coolant drains, allow time for complete refill of the engine water jacket. Check coolant level as prescribed in the prestart checklist in the operation manual.

TP-5936 7/0414 Section 5 Cooling System

Page 27

5.6 Siphon Break

A siphon break prevents seawater entry into the engine when the engine exhaust manifold outlet is less than 23 cm (9 in.) above the waterline of a fully-loaded craft. Check the siphon break at the interval listed in the service schedule. Use the following procedure and Figure 5-4 to inspect the siphon break.

Siphon Break Inspection Procedure

1. Place the generator set controller start/stop switch in the STOP position.

2. Remove the retaining cap to inspect the reed valve assembly.

3. Use a light detergent to clean the reed valve to remove the residue and oxidation.

4. Check that the reed valve opening is clear.

5. Replace the siphon break if it is cracked or if the reed valve material has hardened or deteriorated.

6. Install the reed valve into the mounting base with the valve downward.

7. Install the retaining cap and finger-tighten only. Do not overtighten.

Waterline

1. Mounting holes

2. Retaining cap

3. Reed valve assembly

4. Silencer vertical lift 1.2 m (4 ft.) max.

5. Exhaust mixer elbow distance above waterline. If less than 23 cm (9 in.), siphon break is required.

6. Siphon break distance above waterline 30.5 cm (1 ft.) min.

7. Siphon break

8. Exhaust mixer elbow

9. Heat exchanger (locations vary by model)

10. Coolant recovery tank

NOTE: Consult the installation manual for complete explanation of dimensions and other installation considerations.

11. Coolant recovery tank

12. Seawater strainer

13. Seacock

14. Intake strainer

15. Engine-driven seawater pump

16. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

17. Water lock (optional)

18. Silencer distance from exhaust mixer elbow 3 m (10 ft.) max.

19. Silencer (customer-supplied)

20. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

21. Exhaust outlet distance above waterline 10 cm (4 in.) min.

TP-5586-3

Figure 5-4 Siphon Break, Plastic U Type

TP-5936 7/04 15Section 5 Cooling System

Page 28

5.7 Impeller Inspection and Replacement

The belt-driven seawater pump is located on the service side of the generator set. Check and change the seawater pump impeller at the interval specified in the service schedule. Follow instructions in the impeller kit. If the instructions are not included with the kit use the following procedure.

Impeller Inspection and Replacement Procedure:

1. Close the seacock.

2. Remove the seawater pump coverplate. See Figure 5-5.

3. Remove the impeller.

1. Seawater pump

2. Coverplate

3. Gasket

4. Impeller

5. Bearing

6. Housing

7. Pulley

8. Drive shaft

9. Washer

10. Nut

TP-5936-28

4. Inspect the impeller for damage, including visible cracks, missing pieces, or flat spots. Impeller vanes should be straight and flexible. See Figure 5-6.

5. Lubricate the impeller with soapy water before installation.

6. While installing the impeller, always rotate the drive shaft and the impeller together in the same direction as the engine rotates.

7. Inspect the coverplate and gasket for corrosion and/or damage. Replace components as necessary.

8. Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing.

9. Open the seacock.

10. Start the generator set and check for leaks.

11. Stop the generator set and repair leaks or replace components as necessary.

Figure 5-5 Seawater Pump, Typical

1. Flat spot

2. Crack

3. Broken vane

Figure 5-6 Worn Impeller

TP-5936-57

TP-5936 7/0416 Section 5 Cooling System

Page 29

5.8 Anticorrosion Zinc Anode

The heat exchanger contains an anticorrosion zinc anode (plug) to prevent electrolyte corrosion by the seawater.

Check and replace the anticorrosion zinc anode at the intervals recommended in the service schedule. See Figure 5-7.

Inspection and Replacement Procedure

1. Place the generator set controller start/stop switch in the STOP position.

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

3. With the generator set cooled, close the seacock, open the engine petcock, and drain the coolant into a suitable container.

4. Remove the anticorrosion zinc anode from the heat exchanger. See Figure 5-7.

5. Remove the loose corrosion on the anticorrosion zinc anode. Replace the anode according to Figure 5-8 and Figure 5-9.

6. Apply pipe sealant suitable for marine applications to the threads of the anticorrosion zinc anode (plug) and install the anode in the heat exchanger.

1. Anticorrosion zinc anode (seawater drain)

2. Heat exchanger

3. Coolant drain

GB-250000A-K

Figure 5-7 Anticorrosion Zinc Anode Location

Anticorrosion Zinc Anode Replacement

Replace When

Models

32EOZ/27EFOZ 9 (0.34) x 19 (0.75)

New Anode

Dimensions mm (in.)

Percent of Zinc

Remaining is:

<50% of

length/diameter

Figure 5-8 Anticorrosion Zinc Anode Measurements

7. Close the engine petcock and open the seacock.

8. Refill the cooling system.

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

10. Start the generator set and check for leaks at the anticorrosion zinc anode location. The pump is running if cooling water flows from the exhaust outlet. If water is not being discharged at the exhaust outlet, see the Prestart Checklist, Seawater Pump Priming, in the operation manual.

1. Diameter: 9 mm (0.34 in.)

2. Length: 19 mm (0.75 in.)

Figure 5-9 Anticorrosion Zinc Anode

TP-5936 7/04 17Section 5 Cooling System

TP-5586-3

Page 30

Notes

TP-5936 7/0418 Section 5 Cooling System

Page 31

Section 6 Controller Troubleshooting

6.1 Controller

This section covers the controller troubleshooting procedure for generator sets equipped with a relay controller and related engine components. Refer to Section 1.4 to identify the controller external components. Refer to Figure 6-1 to identify the controller internal components.

6.2 Controller Sequence of Operation

The following describes the controller sequence of operation during generator start, run, stop, and fault shutdown modes. Use the LEDs on the controller circuit board to assist in the troubleshooting process. An illuminated LED indicates that the respective relay is receiving power; the LED does not indicate whether that relay is energized. Refer to the wiring diagrams in Section 10, Voltage Reconnection and Wiring Diagrams.

6.2.1 Start

Close the start/stop switch between N and 47 (local or remote starting).

The K2 relay energizes. The normally open K2 contacts close to energize the K3 relay (LED3 lights), the K25 (fuel solenoid) relay, the controller hourmeter, and the generator armature exciter field.

The K25 normally open contacts close to energize the fuel solenoid.

1. Controller circuit board

2. K25 relay (fuel solenoid)

3. Hourmeter

4. DC circuit breaker

5. Start/stop switch

6. Voltage regulator circuit board

7. K20 relay (starter solenoid relay)

8. AC circuit breaker location

Figure 6-1 Controller Internal Components

The K3 relay normally open contacts close to energize the K20 (starter) relay. The K20 relay normally open contacts close to energize the S relay (starter solenoid). The S relay normally open contacts close to energize the starter motor.

The normally closed low oil pressure (LOP) contacts open.

A-359001-C

TP-5936 7/04 19Section 6 Controller Troubleshooting

Page 32

6.2.2 Run

6.2.3 Stop

The K1 relay energizes (LED1 lights) when the B1 and B2 windings receive AC output from the stator main field. After a 5--10 second time delay, the K5 relay energizes (LED5 lights).

Note: The bridge rectifier (BR1) and the voltage

regulator (VR1) provides 12 volts DC voltage to the K1 and K5 relays.

Stator winding V1--V4 provides voltage sensing source to the voltage regulator (PBV).

The normally open K1 (A) contacts close to maintain voltage to the K2 relay (LED2 remains lit).

The normally open K2 contacts remain closed to maintain voltage to the fuel solenoid and the controller hourmeter.

The normally open K1 (B) contacts close to energize the (optional) oil pressure, coolant temperature, battery voltmeter, hourmeter gauges, and generator ON light.

The normally open K5 contacts close to permit the high water temperature (HWT), high exhaust temperature (HET), and low oil pressure (LOP) switches to function.

Close the start/stop switch between N and 43 (local or remote).

The K4 relay is energized (LED4 lights).

The normally closed K4 contacts open to deenergize the K25 relay. The K25 normally open contacts open to deenergize the fuel solenoid.

The normally open K4 contacts close to maintain ground to the K4 relay.

As the generator set is shutting down, the K1 relay is deenergized (LED1 goes out). The normally open K1 (A) contacts open to deenergize the K2 relay (LED2 goes out).

6.3 Engine Safety Shutdown Switches

6.3.1 Low Oil Pressure (LOP) Shutdown

When low oil pressure occurs, the LOP shutdown switch contacts close and energize the K4 relay (LED4 lights).

Note: The LOP switch contacts open when the engine

develops oil pressure.

One set of normally closed K1 (C) contacts open to disconnect the circuit to (+) connection of the exciter fields (field flashing).

A set of normally closed K1 (E) contacts open to disconnect the circuit to (--) connection of the exciter field (field flashing). The normally closed K1 (D) contacts open to deenergize the K3 relay (LED3 goes out) and prevent accidental reenergizing of the starter motor. The K3 contacts open to deenergize the K20 relay. The K20 contacts open to deenergize the S relay. The S contacts open to deenergize the starter motor.

When the generator set is running, the start switch contacts N and 47 are opened by releasing the start/stop rocker switch.

Note: During cranking, the LOP shutdown switch is

deactivated until the K5 relay is energized. This delay allows the engine to reach normal operating oil pressure. The normally closed LOP contacts open when the generator set develops adequate oil pressure.

The normally closed K4 contacts open to deenergize the K25 relay. The normally open K25 contacts open to deenergize the fuel solenoid.

The normally open K4 contacts close to maintain ground to the K4 relay.

As the generator set shuts down, the K1 relay is deenergized (LED1 goes out). The normally open K1 (A) contacts open to deenergize the K2 relay (LED2 goes out). The normally closed K2 contacts close to ground circuit to the K4 relay until the generator set comes to a complete stop.

TP-5936 7/0420 Section 6 Controller Troubleshooting

Page 33

6.3.2 High Water Temperature (HWT) and High Exhaust Temperature (HET) Shutdown Switch

When a high temperature is encountered at one (or both) of these sources, the shutdown switch contacts close and energize the K4 relay (LED4 lights).

The normally closed K4 contacts open to deenergize the K25 relay. The K25 normally open contacts open to deenergize the fuel solenoid.

The normally open K4 contacts close to maintain ground to the K4 relay.

As the generator set shuts down, the K1 relay deenergizes (LED1 goes out). The normally open K1 (A) contacts open to deenergize the K2 relay (LED2 goes out). The normally closed K2 contacts close to ground circuit to the K4 relay until the generator set comes to a complete stop.

6.3.3 Controller Circuit Board

Some controller circuit board components can be tested without removing the component from the circuit board. Perform these checks prior to installing a new circuit board and attempting startup. Refer to Figure 6-3, troubleshooting flow chart.

The controller circuit board has light-emitting diodes (LEDs) which indicate relay coil power and aid in the circuit board and the generator fault detection. When any of relays K1--K5 receive power, the corresponding LED lights. See Figure 6-2. The LED does not indicate whether the relay coil is energized. Determine if the relay coil is energized by analyzing the generator faults by performing a continuity test on the relay coil.

Relay Schematic

1. Engine crank control relay (K3)

2. P1 connector

3. P2 connector

4. Time delay relay (K5)

5. LED5

6. LED2

7. Engine run relay (K2)

8. AC crank disconnect relay (K1)

9. LED1

10. Fault shutdown relay (K4)

11. LED4

12. LED3

Figure 6-2 Controller Circuit Board

678910

H-239563-

TP-5936 7/04 21Section 6 Controller Troubleshooting

Page 34

6.3.4 Troubleshooting

Use the following flow chart as an aid in troubleshooting the main circuit board and the entire generator set. If the

prescribed remedy does not correct the problem, the circuit board may have to be replaced.

Press the start switch (Local or remote)

--Check condition/ connections of the start/stop switch (N, 43, and 47).

--Check the battery

condition and connections.

--Check the connections

at P1--14.

Does the engine crank?

Is K2 relay LED lit?

Is K2 relay functioning?

Yes

Is K3 relay LED lit?

Is voltage present at K20 relay coil?

Is K3 relay functioning?

Go to A (next page)

Yes

Is 10-amp controller circuit breaker okay?

YesNo

Reset the circuit breaker

Replace the circuit board (D9 open)

Replace the circuit board

Replace the K20 relay

K3relayorK1 relay faulty. Replace the circuit board

Is the K20 relay functioning correctly?

Figure 6-3 Troubleshooting Relay Controller Circuit Board (1 of 4)

Replace the circuit board

Is voltage present at the S relay coil?

YesNo

Check P4--22 connection

Replace the S relay

Check the P1--4 connection

Yes

Is voltage present at the S relay contact (starter motor side)?

Yes

Replace the starter motor

TP-5936 7/0422 Section 6 Controller Troubleshooting

Page 35

Does the engine start?

Yes

Go to B (next page)

Is there continuity between P1-9 and P9-1?

Is there continuity between P9-2 and P1-8?

Is there continuity between P1-8 and P1-14?

Is the K4 relay LED lit?

Is 12 volts DC present at the (P9-2)?

Yes

Is there continuity across the P1, P4, and P9 connectors?

Yes

Is the fuel pump working?

Is there continuity between P2-8 and N?

Yes

Disconnect the P2 connector. Is there continuity between P2-5 and N?

Replace the remote start/stop switch

Is there continuity between P4-5 and N?

- Diagnose engine safety shutdown switches (LOP, LCS, HET).

- Engine fault (check the

fuel supply, carburetion, ignition, compression)

Yes

See engine service manual.

Yes

Check wiring for opens

Yes

Replace fuel pump

Figure 6-4 Troubleshooting the Run Relay Controller Circuit (2 of 4)

Replace the start/stop switch

TP-5936 7/04 23Section 6 Controller Troubleshooting

Page 36

to run after the start

Yes

switch is released?

Does the engine continue

Can the engine be stopped by using the stop switch?

Yes

Go to C (next page)

Did the K4 relay LED light?

Does the K1 relay LED light?

Yes

Does the K5 relay LED light after 5--10 seconds of running time?

Yes

Did the K4 relay LED light?

Do the local and remote start/ stop switches function?

Replace the circuit board (K5 relay inoperative)

Yes

Replace the circuit board (K4 relay inoperative)

Generator set checks out okay

Yes

Is the fuel solenoid functioning?

Yes

Replace the inoperative start/stop switch

Is the K25 relay functioning?

Replace the fuel solenoid

Do the local and remote start/stop

Yes

Replace the circuit board (inoperative K1 or K2 relay)

switches function?

Replace the inoperative start/stop switch

Does the low oil pressure (LOP) safety shutdown switch function?

Yes

Use a mechanical gauge to

Yes

Replace the LOP safety shutdown switch

Do the temperature safety shutdown switches function?

verify oil pressure. Does the engine have proper oil pressure?

Check the oil level. Repair/replace the oil pump

Figure 6-5 Troubleshooting Relay Controller Circuit Board (3 of 4)

Yes

Replace the circuit board (inoperative K4 relay)

Yes

Replace the inoperative temperature switch(es)

Replace the K25 relay

Replace the circuit board (inoperative K4 relay)

TP-5936 7/0424 Section 6 Controller Troubleshooting

Page 37

Is there AC output when the start button

is HELD and the unit

Yes

is running?

Is AC output at the correct voltage, e.g. 120 volts AC?

Is the voltage regulator fuse okay?

Is there 12VDC at the exciter field?

Replace the controller circuit board

Go to B at the beginning of the preceding page

(OPTIONAL)

Yes

Tes t th e stator and main field

Replace the controller circuit board

Yes

Is there 12VAC output at the B1/B2 stator winding?

Yes

Replace the fuse

Yes

Test the voltage regulator Refer to Section 7

Separately excite the generator set to determine if other components are inoperative.

Is AC output voltage at spec (See Section 7, Separate Excitation)?

Test the stator, main field (rotor), and exciter/armature. Refer to Section 7

Yes

Test the voltage regulator. Refer to Section 7

Figure 6-6 Troubleshooting Relay Controller Circuit Board (4 of 4)

TP-5936 7/04 25Section 6 Controller Troubleshooting

Page 38

Notes

TP-5936 7/0426 Section 6 Controller Troubleshooting

Page 39

Section 7 Generator Troubleshooting

7.1 General

Before beginning the troubleshooting procedures, read all the safety precautions at the beginning of this manual. The following tests include additional safety precautions; OBSERVE THESE PRECAUTIONS!

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.

7.2 General Troubleshooting

To determine the cause of no- or low-AC output , refer to the following steps and the troubleshooting flow chart (Figure 7-1).

1. Check the condition of the voltage regulator 8-amp fuse.

2. If the fuse is good, separately excite the generator. (See Section 7.3) The separate excitation test duplicates the role of the voltage regulator in providing the excitation current to the rotor.

Generator has no

output

Separately

excite

generator

Generator has no

output

Generator has

output

Test voltage

regulator &

wiring

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.

Exciter circuit & rectifier module

Test rotor

Figure 7-1 General Troubleshooting

Test stator

TP-593651

TP-5936 7/04 27Section 7 Generator Troubleshooting

Page 40

7.3 Separate Excitation

By 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 that appears good while static (stationary) may exhibit a running open or short circuit while dynamic (moving). Short circuits can be caused by centrifugal forces acting on the windings during rotation or insulation breakdown as temperatures increase.

1. Disconnect all of the leads from the voltage regulator.

2. Disconnect the P6 (F1, F2) connector.

3. Connect separate excitation circuit as shown in Figure 7-2. Connect an ammeter and a 10 amp fuse in series with F1. Note and record the ammeter reading.

4. The approximate ammeter reading should be battery voltage divided by the specified exciter resistances (cold). Disconnect the resistor leads and determine the exciter current value using an ohmmeter. See Section 1, Specifications, for the normal values.

Example:

Note: See Section 1, Specifications, for the stator

output voltages (with separately excited generator). These specifications are based on a battery voltage of 12. Should the battery voltage vary (11--14 volts), the resulting stator output values will also vary.

+—

F1 F2

1. Voltage regulator

2. 10-amp fuse

3. DC ammeter

4. Battery

5. Ground to generator frame

6. Exciter armature

7. Exciter field

8. P6 connector

+—

TP-593653

Figure 7-2 Separate Excitation Connections

12 Volts (Battery Voltage)

22.7 Ohms Exciter

Resistance

0.5-amps

Exciter Current

5. Start the engine and check that the ammeter remains stable. An increasing meter reading indicates a shorted exciter field or inoperative F1 resistor. A decreasing meter reading to zero, or unstable reading, suggests a running open in the exciter or F1 resistor. If the ammeter is stable, continue with step 6.

6. Check for AC output across the stator leads and compare it to the values in Section 1, Specifications. If the output varies considerably from those listed, a faulty stator, rotor, rectifier module, or armature is likely.

If the AC output is not within specifications, the voltage regulator is probably inoperative. If there is no generator output during normal operation, but output is available when the generator set is separately excited, the voltage regulator is probably inoperative.

7.4 PowerBoost V Voltage Regulators

The generator set is equipped with a PowerBoostt V voltage regulator. See Figure 7-3. The PowerBoostt V voltage regulator monitors output voltage magnitude to control the current to the generator exciter field. The voltage regulator has an underfrequency unloading feature that is referred to as volts-per-Hz (V/Hz). To determine if the voltage regulator is functioning, reduce the engine speed (Hz) and watch for a corresponding drop in the AC voltage. The AC voltage should remain constant until the engine speed drops below 57.5 Hz on 60 Hz models or 47.5 Hz on 50 Hz models.

When the frequency drops below either 57.5 or 47.5 Hz, the AC voltage should decline. Perform the following test to check the regulator output.

TP-5936 7/0428 Section 7 Generator Troubleshooting

Page 41

The following components will be needed to test the voltage regulator:

D Step-up transformer, 1:2, 120 volts to 240 volts

(1.0 amp min.)

D Variable transformer, 0--140 volts (1.0 amp min.)

D Lamp, 250-volt, 100-watt

D AC voltmeter, 250 volt minimum

3. Plug the power cord into the outlet.

4. Turn the power supply on. The AC voltmeter should indicate a power supply voltage of 200--240 volts. The lamp should be off. If lamp is lit, replace the voltage regulator.

5. Slowly turn the volts adjustment pot clockwise. The lamp should light. Replace the voltage regulator if the lamp does not light.

D Fuse, 1-amp

D Switch, 1 single-pole single-throw (SPST) 1 amp

(minimum)

D Plug, 120-volt AC (200--240 volt AC plug optional)

D Copper wire, #14 AWG (minimum)

WARNING

Hazardous voltage. Can cause severe injury or death.

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

High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment

manufacturer when performing high-voltage tests on the rotor or stator. An improper test procedure can damage equipment or lead to generator set failure.

Voltage Regulator Test Procedure

1. Connect the components as shown in Figure 7-3. If a 200--240 volt power source is available, the step-up transformer is not required.

2. Turn the volts potentiometer (pot) fully counterclockwise.

Moving rotor.

STAB

Input

Green

V/HZ VOLTS

Sensing

Yellow

Output

Red

TP-593655

1. LED1 (input)

2. PowerBoostt V voltage regulator

3. LED2 (output)

4. 250-volt, 100-watt lamp

5. AC voltmeter 250 volt (minimum)

6. 1:2 step-up transformer

7. Single-pole single-throw switch

8. 1-amp fuse

9. LED3 (sensing)

10. Volts potentiometer

11. Black wire

12. 100--120 VAC

13. White wire

14. 200--240 VAC (optional)

Figure 7-3 PowerBoostt V Voltage Regulator Test

TP-5936 7/04 29Section 7 Generator Troubleshooting

Page 42

7.5 Voltage Regulator Adjustment

The voltage regulator is factory set and, under normal circumstances, requires no further adjustment. However, if the voltage regulator has been replaced, or tampered with, or if voltage/frequency reconnection has been done, readjust the voltage regulator according to the following procedure. The voltage regulator components are identified and described in the following paragraphs.

Output

Stab

V/HZ

Input

Green

Sensing

Yellow

Volt s

Red

66 55 4

Note: The voltage regulator is located inside the

generator set controller.

Voltage Adjustment Pot. Pot adjusts the generator output.

Stability Pot. Pot fine tunes the regulator circuitry to reduce light flicker.

Volts/Hz Pot. Pot adjustment determines the engine speed (Hz) at which the generator output begins to drop.

Voltage Regulator Adjustment Procedure

1. Place the generator set controller start/stop switch in the STOP position.

2. Turn the Volts/Hz and the stability pots fully counterclockwise. Connect the voltmeter to the AC circuit or an electrical outlet.

3. Start the generator set and rotate the voltage adjustment pot clockwise (increase voltage) or counterclockwise (decrease voltage) until the desired output voltage is achieved.

F+

AC AC AC

F--

B1 B2

1. Sensing leads

2. Main field (rotor)

3. Stator windings

4. Rectifier

5. Armature

6. Exciter field

7. Voltage regulator power supply leads

Figure 7-4 PowerBoostt V Voltage Regulator

Connection

STAB

V/HZ VOLTS

1. LED1 (green input)

2. LED2 (red output)

3. Voltage potentiometer

Input

Green

Sensing

Yellow

Output

Red

4. LED3 (yellow sensing)

5. Volts/Hz potentiometer

6. Stability potentiometer

TP-593656

TP-593657

4. Rotate the stability pot clockwise until light flickers minimally.

5. Readjust the voltage adjustment pot until the desired output voltage is achieved.

6. Adjust the engine speed to the specified cut-in frequency as measured on the frequency meter. The factory setting is 57.5--58 Hz for 60 Hz models and 47.5--48 Hz for 50 Hz models.

7. Rotate the volts/Hz pot clockwise until the voltage level as measured on the voltmeter begins to drop. When the regulator is set to these specifications, the generator will attempt to maintain normal output until the engine speed drops below the frequency set in step 6 as load is applied.

8. Readjust the engine speed to 1800 rpm for 60 Hz models and 1500 rpm for 50 Hz models.

9. Readjust the voltage adjustment pot until the desired output is achieved.

10. Readjust the stability pot until light flickers minimally.

11. Place the generator set controller start/stop switch in the STOP position.

Figure 7-5 PowerBoostt V Voltage Regulator

TP-5936 7/0430 Section 7 Generator Troubleshooting

Page 43

7.6 Exciter Field

Direct current from the battery magnetizes the exciter field. When the exciter armature rotates within the magnetized exciter field windings, an electrical current develops within the exciter armature. Test the exciter field according to the following procedure.

Exciter Field Test Procedure

F1 F2

1. Place the start/stop switch in the STOP position.

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

3. Disconnect the P6 connector (F1/F2 leads).

4. Check the exciter field resistance by connecting an ohmmeter across exciter field F1 and F2 leads. See Section 1, Specifications, for the resistance reading for a cold exciter field. A low reading indicates an internal short and a high reading indicates an open winding. Repair or replace the exciter field if the ohmmeter readings indicate a inoperative exciter field (Refer to Section 9 for removal). If the resistance test is inconclusive, perform a megohmmeter test on the exciter field as described in the next step.

5. Check the exciter field for a short to ground condition. Use a megohmmeter to apply 500 volts DCtotheF1orF2leadandtheexciterfieldframe. Follow the megohmmeter manufacturer’s instructions for using the megohmmeter. A reading of approximately 500 kOhms (1/2 megohm) and higher indicates the field winding is good. A reading of less than approximately 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground. Replace the exciter field.

1. Voltage regulator

2. Ohmmeter

3. Exciter field

4. Exciter armature

Figure 7-6 Exciter Field Resistance Test

F1 F2

1. Voltage regulator

2. Ohmmeter

3. Frame connection

4. Exciter armature

5. Exciter field

Figure 7-7 Megohmmeter Connections on the

Exciter Field

TP-593658

TP-593659

TP-5936 7/04 31Section 7 Generator Troubleshooting

Page 44

7.7 Exciter Armature

AC AC AC

F+

F--

TP-5936510

1. Main field (rotor)

2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Armature

6. Exciter field

Figure 7-8 Exciter Armature Ohmmeter Test

1. Main field rotor

2. Stator windings

3. Rectifier module

4. Megohmmeter

F+

AC AC AC

F--

5. Shaft connection

6. Armature

7. Exciter field

TP-5936511

Figure 7-9 Megohmmeter Connections on Exciter

Armature

The exciter armature supplies excitation current to the generator main field through the rectifier module. Test the exciter armature as described in the following steps.

Exciter Armature Test Procedure

1. Disassemble the alternator. Refer to Section 9.

2. With the alternator disassembled, disconnect the armature leads from the rectifier module AC terminals. Refer to Section 9.

3. With an ohmmeter on the R x 1 scale, check the resistance across the exciter armature leads. See Figure 7-8. See Section 1, Specifications, for the armature resistance. No continuity indicates an open armature winding. If the resistance test is inconclusive, perform a megohmmeter test on the exciter armature as described in the next step.

Note: Consider the exciter armature good if the

resistance reading (continuity) is low and there is no evidence of a shorted winding (heat discoloration).

4. Check the exciter armature winding for a short to ground condition. Use a megohmmeter to apply 500 volts DC to either armature lead and the armature frame. Follow the megohmmeter manufacturer’s instructions for using the megohmmeter. See Figure 7-9. A reading of approximately 500 kOhms (1/2 megohm) and higher indicates the exciter armature is good. A reading of less than approximately 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground. Replace the exciter armature.

TP-5936 7/0432 Section 7 Generator Troubleshooting

Page 45

7.8 Rectifier Module

The rectifier module converts the AC from the exciter armature to DC, which magnetizes the generator main field. Test the rectifier module as described in the following steps.

Rectifier Module Test Procedure

1. Disconnect the exciter armature and the main field leads from the rectifier module.

2. Use an ohmmeter on the R x 100 scale to check the resistance between the rectifier diodes as shown in Figure 7-10. The ohmmeter should show a low resistance in one direction and, upon reversing the ohmmeter leads, a high resistance in the other direction. Replace the rectifier module if any of the diodes test differently than described.

7.9 Rotor

The generator rotor (magnetized by DC from the rectifier module) rotating within the stator windings induces AC in the stator windings. Test the generator rotor (main field) as described in the following steps. Disassemble the generator prior to performing this test. See Section 9.

Generator Rotor Test Procedure

AC AC

1. Diode terminal

2. Diode terminal

3. Ohmmeter

Figure 7-10 Rectifier Module Test

F+

AC AC AC

F--

TP-5936512

1. With the generator disassembled, disconnect the generator rotor (main field) windings the rectifier module terminals F+ and F--.

2. Check the main field resistance by connecting an ohmmeter across the main field F+ and F-- leads. See Figure 7-11. See Section 1 for the resistance reading. A low reading indicates an internal short and a high reading indicates an open winding. Repair or replace the main field if the ohmmeter readings indicate the main field is inoperative. If the resistance test is inconclusive, perform a megohmmeter test on the main field as described in the next step.

3. Check the main field for a short to ground condition by using a megohmmeter. Apply 500 volts DC to either field lead and the main field frame. Follow the megohmmeter manufacturer’s instructions for using the megohmmeter. See Figure 7-12. A reading of 500 kOhms (1/2 megohm) and higher indicates the main field is good. A reading of less than 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground. Replace the main field.

1. Main field (rotor)

2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Armature

6. Exciter field

Figure 7-11 Ohmmeter Connections on Rotor

1. Main field (rotor)

2. Stator windings

3. Frame connection

4. Shaft connection

AC AC AC

F+

F--

5. Rectifier module

6. Megohmmeter

7. Armature

8. Exciter field

Figure 7-12 Megohmmeter Connections on

Main Field

TP-593613

TP-5936514

TP-5936 7/04 33Section 7 Generator Troubleshooting

Page 46

7.10 Stator

The stator consists of a series of coils of wire laid in a laminated steel frame. The stator leads supply voltage to the AC load and exciter regulator.

Before testing the stator, inspect it for heat discoloration and visible damage to the housing lead wires and exposed and varnished areas of the frame laminations. Be sure the stator is securely fastened in the stator housing.

The stator produces electrical output (AC) as the magnetized main field rotates within the stator windings. Test the condition of the stator according to the following procedure.

Leads 1, 2, 3, and 4 are the generator output leads. Leads 55 and 66 are the voltage regulator supply and sensing leads. The output of leads B1 and B2 is rectified by BR1 to supply the control voltage. BR1 is located on the controller circuit board. Refer to the schematic in Figure 7-13 when performing the following tests.

Stator Test Procedure

1. Place the start/stop switch in the STOP position.

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

3. Check the generator output lead connections. See Section 10, Voltage Reconnection and Wiring Diagrams.

33 3

F1 F2

F+

AC AC AC

F--

55 44

12B1 B2

1. Main field (rotor)

2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Armature

6. Exciter field

Figure 7-13 Stator Ohmmeter Connections

Between leads Continuity

1 and 2 3 and 4 55 and 66 B1 and B2

Yes Yes Yes

Yes 1 and 3, 4, 33, 44 1 and 55, B1, and B2 4 and B1 and B2 55 and B1 and B2 Any stator lead and ground

Figure 7-14 Stator Continuity, 1 Phase

TP-553615

No No No No No

4. Disconnect all the stator leads to isolate the windings. To check the stator continuity, set the ohmmeter on the R x 1 scale. Check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 7-13 through Figure 7-15. Perform the stator tests on all the stator windings.

Between leads Continuity

1 and 4 2 and 5 3 and 6 7 and 10 8 and 11 9 and 12 55 and 66 B1 and B2 1 and 2, 5, 3, 6, 7, 10, 8, 11, 9, 12 1 and 55, 66, B1, and B2 Any stator lead and ground

Figure 7-15 Stator Continuity, 3 Phase

Yes Yes Yes Yes Yes Yes Yes Yes

No No No

TP-5936 7/0434 Section 7 Generator Troubleshooting

Page 47

5. Contact the ohmmeter leads and readjust the ohmmeter to zero ohms. Check the cold resistance of the stator windings by connecting the meter leads to the stator leads 1-2, 3-4, etc. See Section 1, Specifications, for the stator resistance values. If the stator resistance test is inconclusive, perform a megohmmeter test on the stator as described in the next step.

Note: Consider the stator good if the resistance

reading (continuity) is low and there is no evidence of shorted windings (heat discoloration).

F1 F2

F+

AC AC AC

F--

B1 B2

Note: When taking an ohmmeter reading using

lead 55, make the connection prior to the in-line fuse.

Note: The stator resistance varies directly with

increased temperature.

6. If any of the stator readings vary during the previous checks, replace the stator.

7. Check the stator for a short to ground condition using a megohmmeter. See Figure 7-16 and Figure 7-17. Apply 500 volts DC to any stator lead from each winding and the stator frame. Follow the megohmmeter manufacturer’s instructions for using the megohmmeter. Repeat the test on the other leads until all the stator windings have been tested. A reading of 500 kOhms (1/2 megohm) and higher indicates the stator is good. A reading of less than 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground. Repair or replace the stator.

1. Voltage regulator power supply leads

2. Sensing leads (208--240 volts nominal)

3. Stator windings

4. Main field (rotor)

5. Rectifier module

6. Frame connection

7. Megohmmeter

8. Armature

9. Exciter field

TP-5936517

Figure 7-16 Megohmmeter Connections on Stator,

1 Phase

F1 F2

TP-5936 7/04 35Section 7 Generator Troubleshooting

TP-5936518

1. Voltage regulator power supply leads

2. Sensing leads (208--240 volts nominal)

3. Stator windings

4. Main field (rotor)

5. Frame connection

6. Megohmmeter

7. Rectifier module

8. Armature

9. Exciter field

Figure 7-17 Megohmmeter Connections on Stator,

3 Phase

Page 48

Notes

TP-5936 7/0436 Section 7 Generator Troubleshooting

Page 49

Section 8 Component Troubleshooting

8.1 General

WARNING

Hazardous voltage. Can cause severe injury or death.

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

Component Voltmeter Connections Procedure Results

Hourmeter and wiring Connect the red test lead to

Stator auxiliary winding B1 and B2

Moving rotor.

the hourmeter positive (+) terminal. Connect the black test lead to the hourmeter negative (--) terminal.

None (see Procedure) Disconnect the hourmeter

Connect the AC voltmeter leads to the B1 and B2 windings at connector P11.

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.

See Figure 8-1 through Figure 8-2 for component testing.

With the generator set battery connected, check the generator wiring harness and the components listed in the following tables. Check each component using a multimeter to verify that the switches function and that voltage is present at each component.

Set the voltmeter to 12 volts DC or greater. Start the generator set.

leads and apply 12 volts DC to the hourmeter. The hourmeter is polarity sensitive.

Stop the generator set. Connect a voltmeter to the B1 and B2 windings. Crank the generator set and allow the set to reach rated its speed.

A 12 volt DC reading indicates the wiring harness is functional.

If functional, hourmeter operates.

A reading of 12--15 volts AC indicates a functional B1/B2 winding.

Figure 8-1 Engine/Generator Component Testing, Relay Controller

TP-5936 7/04 37Section 8 Component Troubleshooting

Page 50

Note: Before performing ohmmeter checks, disconnect

the generator set battery to prevent damage to the ohmmeter.

To further check the generator set components,

plugs from the controller circuit board. Use an ohmmeter to check the continuity of the components and to isolate inoperative components. Refer to Figure 8-2.

disconnect the battery and remove the wiring harness

Component Ohmmeter Connections Procedure Results

Start/stop switch Connect the ohmmeter to the P2-6

K20 relay coil and wiring

Starter solenoid (S relay)

Controller 10-amp circuit breaker and wiring

Main field (rotor) Disconnect the P10 and P11

B1/B2 stator windings Connect the ohmmeter to the

P1 ground connection Connect the ohmmeter to the P1-9

High exhaust temperature (HET), low coolant (LCS) safety shutdown switches

Low oil pressure (LOP) safety shutdown switch

and P2-4 leads.

Connect the ohmmeter to the P2-6 and P2-5 leads.

Connect the ohmmeter to the P1-4 and P1-9 leads.

Connect the ohmmeter to the P4-22 lead and the battery positive (+) cable. Note: The J4 and P4 leads must be disconnected to perform this test.

Connect the ohmmeter to the battery positive (+) cable and the P1-14 lead. Note: The J4 and P4 leads must be connected to perform this test.

connectors and connect the ohmmeter to the P10-1 and P10-2 leads.

P11-1 and P11-2 leads. Note: Disconnect P11 and J11 to perform this test.

and ground.

Connect the ohmmeter to the P1-15 and engine block (ground). Note: Remove and isolate the LOP switch lead.

Connect the ohmmeter to the P13-1 and engine block (ground).

Place the ohmmeter on the R x 1000 scale. Place the rocker switch in the START position.

Place the ohmmeter on the R x 1000 scale. Place the rocker switch in the STOP position.

Place the ohmmeter on theRx1scale.

Place the ohmmeter on the R x 1000 scale.

Place the ohmmeter on theRx1scale.

Place the ohmmeter on the R x 1000 scale.

Place the ohmmeter on the R x 1000 scale. This test is not conclusive until the temperature shutdown switches are checked.

If the switch is functional, zero ohms continuity. Any resistance other than zero or very low ohms, replace the switch.

If functional, 85 ohms. Low resistance, shorted C relay coil and/or wiring. High resistance, open C relay and/or wiring. Replace the controller board.

If functional, approximately

0.5--0.6 ohms at 27°C(80°F).

If functional, zero or very low ohms. No reading (infinity), open circuit or circuit breaker tripped.

If the resistance readings match those specified in Section 1, Specifications, the rotor is functional. Low resistance, rotor windings shorted. High resistance, rotor windings open.

If the resistance readings match those specified in Section 1, Specifications, the B1/B2 windings are functional. Low resistance, B1/B2 windings shorted. High resistance, B1/B2 windings open.

If functional, zero ohms (continuity). Any other reading indicates a poor ground connection.

If functional, open circuit. Any continuity suggests an inoperative temperature switch(es). Replace the switch(es).

If functional, zero ohms (continuity). Then, disconnect the LOP switch lead and isolate the terminal. Meter reading should show an open circuit.

Figure 8-2 Engine/Generator Component Testing, Relay Controller

TP-5936 7/0438 Section 8 Component Troubleshooting

Page 51

8.2 Remote Panels (Optional)

open or shorted. Refer to Figure 8-3 and Figure 8-4 for resistance values. Refer to Figure 8-5 for

Kohler Co. offers three remote panels for connection to

troubleshooting information on the remote start panels.

the generator set:

D A panel with a start/stop switch

D A panel with a start/stop switch and two gauges

(engine oil pressure and water temperature)

D A panel with a start/stop switch and four gauges (DC

voltmeter, engine oil pressure, water temperature,

Figure 8-3 Water Temperature Sender Resistance

2-Meter and 4-Meter Panels

Temperature Resistance

60_C (140_F)

90_C (194_F)

100_C (212_F)

134 ± 10 ohms

51.5 ± 4 ohms

38 ± 3 ohms

and hourmeter)

If difficulty with the remote operation occurs, test the switch, gauges, and gauge senders using the following procedures. See Section 10, Voltage Reconnection and Wiring Diagrams.

345 kPa (50 psi)

690 kPa (100 psi)

2-Meter and 4-Meter Panels

Pressure Resistance

0 kPa (0 psi)

Generally, if the sender changes its resistance values as its respective pressure/temperature changes, it is

Figure 8-4 Oil Pressure Sender Resistance

working correctly. An inoperative sender will either be

Component Ohmmeter Connections Procedure Results

Remote start/stop switch

Generator set ON light, gauge lights, DC voltmeter, and hourmeter

Water temperature gauge

Oil pressure gauge

Note: Check continuity of gauge wiring and extension harness before replacing components.

Remote switch: yellow/red wire terminal and black wire terminal.

Remote switch: grey/black wire terminal and black wire terminal.

Connect the red test lead to P3-4 and black test lead to P3-1.

Connect the red test lead to P3-4 (socket side) and black test lead to P3-2 (socket side).

Connect the red test lead to P3-4 (socket side) and black test lead to P3-3 (socket side).

Place the ohmmeter on the R x 1 scale. Press the rocker switch to the START position.

Place the ohmmeter on the R x 1 scale. Press the rocker switch to the STOP position.

Place the controller rocker switch to the START position. Stop the generator set when the test is complete. Generator set does not need to be running, just cranking for this test. Note: If the hourmeter is not illuminated, test it by connecting it to a 12-volt battery. Note:The hourmeter is polarity sensitive.

Start the generator set for the test. If 0.5--12-volts DC is present and

Continuity, the switch is functional. Open, replace switch.

Continuity, the switch is functional.

If 12-volts DC is present and the component does not function after the J3 is connected to the controller P3, replace the component(s).

the gauge does not function after the J3 is connected to controller, replace the gauge.

the gauge does not function after the J3 is connected to the controller, replace the gauge.

10 ohms

80 ohms

135 ohms

Figure 8-5 Remote Start Panels Troubleshooting

TP-5936 7/04 39Section 8 Component Troubleshooting

Page 52

Notes

TP-5936 7/0440 Section 8 Component Troubleshooting

Page 53

Section 9 Generator Disassembly/Reassembly

9.1 Disassembly

In some installations, it is not possible to remove the generator set from the craft.

Disconnect the external connections—battery cables (negative lead first), AC-output leads in the controller, remote start panel at the controller P3 connector, water line at the seawater pump, fuel line at the fuel pump filter inlet, and exhaust line at the mixing elbow. Observe all of the safety precautions listed during the disassembly/ reassembly procedures.

Note: Because this manual covers several models, the

procedure for disassembly may vary because of product updates and the assembly variations.

Disassembly Procedure

1. Place the start/stop switch in the STOP position.

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

3. Loosen the 4 screws and lift off the controller cover.

4. Disconnect the P4 (22-pin) connector from J4. See Figure 9-1.

5. Remove the bolt and disconnect the ground strap. SeeFigure9-1.

Note: It is possible to connect the output leads in

various positions for different voltage configurations. Mark the leads for correct reconnection.

9 15

1. P4 (22-Pin) connector

2. Ground strap

Figure 9-1 22-Pin Connector

1. Controller mount locknut

2. Socket with extension

3. Neutral stud (L0)

Figure 9-2 Controller Removal

GB-250000B-G

558863

6. Disconnect the generator output leads 1, 2, 3, and 4 from the circuit breaker and the neutral stud (L0).

7. Remove the 4 controller mount locknuts. See Figure 9-2.

8. Lift the controller from the rubber mounts while guiding the leads through the bottom hole of the controller box.

9. Remove the tie wraps from the wire harness as necessary. Disconnect the F1 connectors from the resistor leads.

10. Disconnect the P7 (FP and FN) and P6 (F1 and F2) connectors.

TP-5936 7/04 41Section 9 Generator Disassembly/Reassembly

Page 54

1. 3/8 in. nut (4) and plain washer (4)

2. End bracket cover

3. Vibromount hardware

Figure 9-3 Alternator, End View

5936

1. Bolt (3/8 x 16 x 1.25)

558864

2. Plate 4” x 1/4” min.

3. Washers (4)

4. Alternator

5. Rotor

Figure 9-5 Securing the Rotor

11. Remove the vibromount mounting hardware. See Figure 9-3.

Note: Use a hoist with a capacity rating of one-half

ton or greater.

12. Remove the 4 nuts and washers securing the alternator end bracket cover to the alternator end. See Figure 9-3.

13. Raise the alternator end of the generator set and place a wood block under the oil pan/flywheel area. Lower the alternator. See Figure 9-4.

1. Alternator end bracket

2. Alternator end bracket mounting bolts

3. Alternator fan guard

4. Wood support block

Figure 9-4 Raising the Alternator

558865

14. Secure the rotor to the alternator with a bolt, plate, and 4 washers. The end of the rotor shaft is threaded for this purpose. See Figure 9-5.

15. Remove the 2 screws and clips securing the alternator fan guard to the alternator. See Figure 9-4.

TP-5936 7/0442 Section 9 Generator Disassembly/Reassembly

Page 55

16. Support the alternator assembly and remove the 8 bolts, washers, and spacers securing the rotor assembly to the engine flywheel. See Figure 9-6.

17. Remove the 12 bolts and washers securing the alternator side alternator adapter to the engine side alternator adapter and carefully remove the alternator assembly. See Figure 9-6.

18. Remove the 8 bolts and washers securing the armature drive discs to the rotor drive hub. See Figure 9-6.

19. Place the alternator assembly on the floor and remove the bolt, plate, and 4 washers.

20. Rotate the alternator assembly in a vertical position with the rotor hub facing upward. See Figure 9-7.

21. Connect the hoist securely to the rotor hub with an eyebolt or lifting plate.

22. Carefully lift the rotor out of the stator housing.

23. Remove the 4 alternator end bracket bolts. See Figure 9-8.

24. Carefully remove the end bracket with the exciter field and wires from the stator housing. See Figure 9-8.

558865

Figure 9-7 Alternator Position

1. Bolt (3/8-16 x 2.5 in.) and washer

2. Alternator side alternator adapter

3. Rotor

4. Rotor hub

5. Nut (10-32)

6. Alternator fan

7. Armature drive disc (alternator fan)

8. Armature drive disc (engine flywheel)

9. Engine side alternator adapter

10. Flywheel

11. Flywheel stud (8)

12. Bolt (M10-1.5) and washer

13. Bolt (3/8-16 x 1.25 in.) and washer (3/8 in.)

14. Spacers (16) 2 on each stud

15. Washer (8)

16. Nut (8) @39 ft. lbs.

Figure 9-6 Alternator Disassembly

558866

1. Alternator end bracket and exciter field

2. Stator

3. Stator mounting bolts (3/8-16 x 1.75 in.) and washers (6)

4. Alternator adapter mounting bolts (3/8-16 x 2.5 in.) and washers (12)

5. End bracket bolts

Figure 9-8 Alternator Disassembly

558865

TP-5936 7/04 43Section 9 Generator Disassembly/Reassembly

Page 56

9.2 Reassembly

1. Reinstall the alternator end bracket with the exciter field. Feed the exciter leads into the hole in the top of the stator housing. Torque the mounting bolts to

38.0 Nm (28 ft. lbs.). See Figure 9-9.

2. Gently insert the rotor into the stator housing. Be careful to avoid damaging the rotor assembly or the stator during installation. See Figure 9-10.

3. Secure the rotor to the alternator with a bolt, plate, and 4 washers. The end of the rotor shaft is threaded for this purpose. See Figure 9-5.

4. Using alignment pins, align the loose armature drive disk to the alternator fan and attach to the rotor drive hub with 8 bolts (3/8-16 x 1.25 in.) and washers. Torque the bolts to 61.0 Nm (45 ft. lbs.). SeeFigure9-6.

558865

Figure 9-10 Alternator Position

1. Alternator end bracket and exciter field

2. Stator

3. Stator mounting bolts (3/8-16 x 1.75 in.) and washers (6)

4. Alternator adapter mounting bolts (3/8-16 x 2.5 in.) and washers (12)

Figure 9-9 Exciter Reinstallation

558865

5. Secure the alternator assembly to the engine flywheel studs with washers, nuts, and spacers. Torque the mounting nuts to 52.9 Nm (39 ft. lbs).

6. Secure the alternator side adapter to the engine side alternator adapter with 12 bolts (3/8-16 x 2.5 in.) and washers. Torque the mounting bolts to 52.9 Nm (39 ft. lbs.).

7. Reinstall the alternator fan guard using two spring clips and screws.

8. Raise the alternator end of the generator set and remove the wood block under the oil pan/flywheel area. Lower the alternator.

9. Reinstall the vibromount mounting hardware (bolt, large washer, two small washers, and locknut in each vibromount). Tighten the mounting bolts to 28 Nm (20 ft. lbs.).

TP-5936 7/0444 Section 9 Generator Disassembly/Reassembly

Page 57

Section 10 Voltage Reconnection and Wiring Diagrams

10.1 4-Lead Reconnection

The following information illustrates the reconnection of 4-lead generator sets. In all cases, follow the National Electrical Code (NEC).

NOTICE

10.1.1 100--120-Volt Configurations

If the installation requires a factory two-pole circuit breaker, do not connect the load-side terminals of the circuit breaker together. See Figure 10-1. If the installation requires a 100--120-volt, 2-wire system, use a single-pole circuit breaker. See Figure 10-2. When connecting stator phase leads together, size the output lead (L1) accordingly to handle the amperage. Use a jumper lead on the line side of the circuit breaker to balance the load of the generator set.

L0 (Neutral)

Ground

Load Side

Line Side

4321

Stator Leads

60 Hz 50 Hz

L0--L1 100--120 Volt 100--120 Volt L0--L2 100--120 Volt 100--120 Volt

GRD.

Single-Pole Circuit Breaker

Figure 10-2 100--120-Volt, 2-Wire Configuration

L0 (Neutral)

Ground

Load Side

Line Side

4321

60 Hz 50 Hz

L0--L1 100--120 Volt 100--120 Volt L0--L2 100--120 Volt 100--120 Volt

GRD.

L1 L2

Two-Pole Circuit Breaker

Jumper lead

Figure 10-1 100--120-Volt, 3-Wire Configuration

TP-5936 7/04 45Section 10 Voltage Reconnection and Wiring Diagrams

Page 58

L0 (Neutral)

Ground

Load Side

Line Side

4321

Stator Leads

60 Hz 50 Hz

L0--L1 100--120 Volt 100--120 Volt L0--L2 100--120 Volt 100--120 Volt L1--L2 200--240 Volt 200--240 Volt

GRD.

Factory Two-Pole Circuit Breaker

Figure 10-3 100--120/200--240-Volt, 3-Wire

Configuration

L0 (Neutral)

Ground

Load Side

Line Side

4321

Stator Leads

60 Hz

L0--L1 200-240 Volt 200--220--240 Volt

Single-Pole Circuit Breaker

Tape to insulate from ground

GRD.

50 Hz

Figure 10-4 200--220--240-Volt 2-Wire Configuration

10.1.2 100--120-/200--240-Volt Configurations

The 100--120/200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 100--120 volt, 3 wire, remove the jumper lead (see

Figure 10-1 for location). Select a two-pole circuit breaker. Application of two single-pole circuit breakers does not conform to NEC requirements for supplying a 200--240-volt load, even if the breakers are mechanically attached together. Leads L1 and L2 are for different phases; never connect them together.

10.1.3 200--240-Volt Configurations

The 200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 100--120 volt, 3 wire, remove the jumper lead (see Figure 10-1 for location).

10.2 12-Lead Reconnection

The following reconnection procedure details voltage reconnections only. If the generator set requires frequency changes, adjust the governor and voltage regulator as described earlier in Section 7.5.

The following information illustrates the reconnection of 12-lead generator sets. In all cases, follow the National Electrical Code (NEC) guidelines.

Reconnect the stator leads of the generator set to change output phase or voltage. Refer to the following procedure and connection schematics. Follow all safety precautions at the front of this manual during reconnection procedure.

NOTICE

Reconnection Procedure

1. Move the generator set start/stop switch to STOP position.

2. Disconnect the engine starting battery, the negative (--) lead first. Disconnect the power to the battery charger, if equipped.

3. Use Figure 10-3 or Figure 10-4 to determine the generator set voltage configuration. Note the original voltage and reconnect as needed.

TP-5936 7/0446 Section 10 Voltage Reconnection and Wiring Diagrams

Page 59

10.3 Two and Three Wire Manual (Ship-to-Shore) Transfer Switch

Electro Switch

To Generator Set

2-Wire Generator Sets

2134

6578

To Load

To Shore Power

Kraus Naimler/American Solenoid

(Early Rectangular Design)

2-Wire Generator Sets

1265

348 7

To Shore Power

To Generator Set

3-Wire Generator Sets

2134

657 8

10 9 11 12

To Load

3-Wire Generator Sets

1265

348 7

91014 13

To Shore Power

To Generator Set

To Load

Kraus Naimler/American Solenoid

(Newer Round Design)

2-Wire Generator Sets

3241

768 5

To Load

To Shore Power

To Generator Set

To Load

3-Wire Generator Sets

3241

768 5

11 10 12 9

To Load

To Shore Power

TP-5399-5

TP-5936 7/04 47Section 10 Voltage Reconnection and Wiring Diagrams

Page 60

10.4 Four Wire Manual (Ship-to-Shore) Transfer Switch

Kraus Naimer/American Solenoid

4-Wire, 3-phase Generator Sets

To Generator Set To Shore Power

10.5 Generator Reconnection

Generator Connections

Single-Phase

Some sets not rated for single phase, see manuals

Not

Used

110/220 Volt 50 Hz 120/240 Volt 60 Hz

Remove V9 from terminal strip and tape

Single-Phase

(Marine Only)

Tape to insulate

from ground

Not

Used

To Load

3-Phase Delta

110/220 Volt 50 Hz 120/240 Volt 60 Hz

I-940

3-Phase WYE

190-208 Volt 50 Hz 208-240 Volt 60 Hz

3-Phase WYE

220 Volt 50 Hz 240 Volt 50 Hz

Remove V9 from terminal strip and tape

Notes:

CTs not used on all generator sets. Current transformers dot or “HI” toward generator.

380-416 Volt 50 Hz 416-480 Volt 60 Hz

EM-250000-

TP-5936 7/0448 Section 10 Voltage Reconnection and Wiring Diagrams

Page 61

Notes

TP-5936 7/04 49Section 10 Voltage Reconnection and Wiring Diagrams

Page 62

10.6 Single-Phase Wiring Diagram—Schematic

229937-G

TP-5936 7/0450 Section 10 Voltage Reconnection and Wiring Diagrams

Page 63

10.7 Single-Phase Wiring Diagram—Point-to-Point

TP-5936 7/04 51Section 10 Voltage Reconnection and Wiring Diagrams

229937-G

Page 64

10.8 Three-Phase Wiring Diagram—Schematic

229938-D

TP-5936 7/0452 Section 10 Voltage Reconnection and Wiring Diagrams

Page 65

10.9 Three-Phase Wiring Diagram—Point-to-Point

TP-5936 7/04 53Section 10 Voltage Reconnection and Wiring Diagrams

229938-D

Page 66

10.10Remote Start Panel

+--

P1-14

10-amp fuse

P2-4

Local switch

Start

Stop

P2-5 P2-6

P1-9

10.11 Remote Start and Two-Meter Panel

+--

10-amp fuse

P1-1447P2-4

Local switch

Start

Stop

P2-5 P2-6

P1-9

W.T. sender

O.P. sender

P2-3 P2-7 P2-8 P2-9

P3-4

J3-4 J3-5 J3-1J3-6

Violet

Yellow/ Red

Gen. ON light

Relay circuit board

Grey/

P3-5 P3-6 P3-1

Black

Stop

Start

Remote switch

Black

TP-5588-7

P2-3

P3-4

J3-4 J3-5

Violet

Yellow/ Red

Gen. ON light

Water temp. gauge

Oil pressure gauge

Relay circuit board

P2-7

P3-5 P3-6

Stop

Start

P2-8 P2-9

43 Grey/ Black

Remote switch

J3-6

P3-1

Black

P4-2 P4-3

P3-2

J3-1

J3-2

Tan

P3-3

J3-3

L. Blue

TP-5588-7

TP-5936 7/0454 Section 10 Voltage Reconnection and Wiring Diagrams

Page 67

10.12Remote Start and Four-Meter Panel

+--

10-amp fuse

P1-14

P2-3

P3-4

J3-4 J3-5

Violet

Yellow/ Red

Gen. ON light

Water temp. gauge

P2-4

P2-7

P3-5

Local switch

Start

Relay circuit board

Grey/ Black

Stop

Start

Stop

P2-8 P2-9

P3-6

P2-5 P2-6

P3-1

J3-6

Remote switch

P1-9

W.T. sender

P4-2 P4-3

P3-2

J3-1 J3-2 J3-3

Tan

Black

O.P. sender

P3-3

L. Blue

Oil pressure gauge

DC voltmeter

Hourmeter

TP-5588-7

TP-5936 7/04 55Section 10 Voltage Reconnection and Wiring Diagrams

Page 68

Notes

TP-5936 7/0456 Section 10 Voltage Reconnection and Wiring Diagrams

Page 69

Appendix A Abbreviations

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

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

AHWT anticipatory high water

AISI American Iron and Steel

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

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

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

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

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

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

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

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

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

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

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

EIA Electronic Industries

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

EPS emergency power system ER emergency relay ES engineering special,

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

substrate (semiconductor)

Association

e. V. (also Deutsche Industrie Normenausschuss)

Association

Agency

engineered special

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

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

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

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

IEEE Institute of Electrical and

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

J joule JIS Japanese Industry Standard

ground

high engine temperature

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

TP-5936 7/04 Appendix A-1

Page 70

k kilo (1000) K kelvin kA kiloampere KB kilobyte (2 kg kilogram

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter

bytes)

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

lbm/ft

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

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

units), male

cubic meter

/min. cubic meters per minute

when used with SI

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

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

milliohm

MOhm, MΩ

megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second

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

Manufacturers Association

NFPA National Fire Protection

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

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

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

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

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

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

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

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

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

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

normal TDES time delay engine start TDNE time delay normal to

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

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

TP-5936 7/04A-2 Appendix

Page 71

Appendix B Common Hardware Application Guidelines

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

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

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

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

Preferred Nut/Bolt Clearance

Steps for common hardware application:

1. Determine entry hole type: round or slotted.

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

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

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

a. Always use a washer between hardware and a

slot.

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

for exception).

c. Use a washer under a bolt when the female

thread is fixed (weld nut).

Unacceptable Nut/Bolt Clearance

1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut

3. Below top of nut

Figure 1 Acceptable Bolt Lengths

G-585

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

1. Cap screw

2. Entry hole types

3. Standard nut and SAE washer

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

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

6. Exit hole types

G-585

TP-5936 7/04 Appendix A-3

Figure 2 Acceptable Hardware Combinations

Page 72

Appendix C General Torque Specifications

lumi

Use the following torque specifications when service literature instructions give no specific torque values. The charts list values for new plated, zinc phosphate, or

American Standard Fasteners Torque Specifications

orque

Size

8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) — 1.8 (16)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Measurement

Assembled into Cast Iron or Steel

Grade 2 Grade 5 Grade 8

oiled threads. Increase values by 15% for nonplated threads. All torque values are +0%/--10%.

Assembled into

num

Grade2or5

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

Size (mm)

M6 x 1.00 5.6 (4) 9.9 (7) 14.0 (10) 5.6 (4)

M8 x 1.25 13.6 (10) 25.0 (18) 35.0 (26) 13.6 (10)

M8 x 1.00 21.0 (16) 25.0 (18) 35.0 (26) 21.0 (16)

M10 x 1.50 27.0 (20) 49.0 (35) 68.0 (50) 27.0 (20)

M10 x 1.25 39.0 (29) 49.0 (35) 68.0 (50) 39.0 (29)

M12 x 1.75 47.0 (35) 83.0 (61) 117.0 (86) —

M12 x 1.50 65.0 (48) 88.0 (65) 125.0 (92) —

M14 x 2.00 74.0 (55) 132.0 (97) 185.0 (136) —

M14 x 1.50 100.0 (74) 140.0 (103) 192.0 (142) —

M16 x 2.00 115.0 (85) 200.0 (148) 285.0 (210) —

M16 x 1.50 141.0 (104) 210.0 (155) 295.0 (218) —

M18 x 2.50 155.0 (114) 275.0 (203) 390.0 (288) —

M18 x 1.50 196.0 (145) 305.0 (225) 425.0 (315) —

Assembled into Cast Iron or Steel

Grade 5.8 Grade 8.8 Grade 10.9

Assembled into

luminum

Grade 5.8 or 8.8

TP-5936 7/04A-4 Appendix

Page 73

Appendix D Common Hardware Identification

Screw/Bolts/Studs

Head Styles

Hex Head or Machine Head

Hex Head or Machine Head with Washer

Flat Head (FHM)

Round Head (RHM)

Pan Head

Hex Socket Head Cap or Allent Head Cap

Hex Socket Head or Allent Head Shoulder Bolt

Sheet Metal Screw

Stud

Drive Styles

Hex

Hex and Slotted

Phillipsr

Nuts

Nut Styles

Hex Head

Lock or Elastic

Square

Cap or Acorn

Wing

Washers

Washer Styles

Plain

Split Lock or Spring

Spring or Wave

External Tooth Lock

Internal Tooth Lock

Internal-External Tooth Lock

Hardness Grades

American Standard

Grade 2

Grade 5

Grade 8

Grade 8/9 (Hex Socket Head)

Metric

Number stamped on hardware; 5.8 shown

5.8

Slotted

Hex Socket

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

Phillipsr screw is a registered trademark of Phillips Screw Company.

Sample Dimensions

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

1/4-20 x 1

Metric (Screws, Bolts, Studs, and Nuts)

M8-1.25 x 20

Length In Inches (Screws and Bolts)

Threads Per Inch

Major Thread Diameter In Fractional Inches Or Screw Number Size

Length In Millimeters (Screws and Bolts)

Distance Between Threads In Millimeters

Major Thread Diameter In Millimeters

Plain Washers

9/32

x5/8x 1/16

Lock Washers

5/8

Thickness

External Dimension

Internal Dimension

TP-5936 7/04 Appendix A-5

Page 74

Appendix E Common Hardware List

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

American Standard

Part No. Dimensions Hex Head Bolts (Grade 5)

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

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

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

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

Part No. Dimensions Hex Head Bolts, cont.

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

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

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

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

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

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

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

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

Part No. Dimensions Type

Hex Nuts

X-6009-1 1-8 Standard

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

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

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

Washers

Bolt/

Part No. ID OD Thick. Screw

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

TP-5936 7/04A-6 Appendix

Page 75

Metric

Hex head bolts are hardness grade 8.8 unless noted.

Part No. Dimensions Hex Head Bolts (Partial Thread)

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

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

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

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

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

continued

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

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

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

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

Hex Head Bolts (Full Thread)

M933-04006-60 M4-0.70 x 6

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

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

M933-07025-60 M7-1.00 x 25

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

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

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

continued

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

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

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

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

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

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

Pan Head Machine Screws

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

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

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

M7985A-06100-20 M6-1.00 x 100

Flat Head Machine Screws

M965A-04012-SS M4-0.70 x 12

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

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

TP-5936 7/04 Appendix A-7

Page 76

Metric, continued

Part No. Dimensions Type Hex Nuts

M934-03-50 M3-0.50 Standard

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

M934-05-50 M5-0.80 Standard

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

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

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

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

M982-14-60 M14-2.00 Elastic Stop

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

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

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

M934-22-60 M22-2.50 Standard

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

M934-30-80 M30-3.50 Standard

Washers

Bolt/

Part No. ID OD Thick. Screw

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

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

TP-5936 7/04A-8 Appendix

Page 77

Page 78

Page 79

Page 80

TP-5936 7/04d

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

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

Kohler 32EOZ, 27EFOZ Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual