Kohler 5ERKM, 4EFRKM Service Manual

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Page 1

Service

Commercial and Recreational

Mobile Generator Sets

Models:

5ERKM

4EFRKM

TP-6079 3/00

Page 2

Table of Contents

Safety Precautions and Instructions 1.........

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

Service Assistance ii.........................

Service Information ii..............................

Product Information ii..............................

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

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

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

1.3 Fuel 1......................................

1.4 Generator 1.................................

1.5 Torque 1...................................

1.6 Service Views 2.............................

Section 2 Scheduled Maintenance 3...........

2.1 General 3..................................

2.2 Lubrication System 3.........................

2.3 Air Intake System 4..........................

2.4 Exhaust System 4...........................

Section 3 Fuel System 5.....................

3.1 General 5..................................

3.2 Fuel Pump 5................................

3.3 Carburetor Troubleshooting 6.................

3.3.1 Hard Starting 6......................

3.3.2 Stalling 6...........................

3.3.3 Flooding 7..........................

3.3.4 Hunting 7...........................

3.3.5 Leaking Carburetor 7.................

3.4 Governor 7.................................

3.5 60 and 50 Hz Conversions 7..................

Section 4 Controller Troubleshooting 9........

4.1 Sequence of Operation 9.....................

4.1.1 Start 9.............................

4.1.2 Run 9..............................

4.1.3 Stop 10..............................

4.1.4 Low Oil Level (LOL) Safety Switch 10...

4.2 Controller Circuit Board 10.....................

4.3 Troubleshooting 11...........................

Section 5 Generator Troubleshooting 15........

5.1 General 15..................................

5.1.1 General Troubleshooting 15............

5.1.2 Separate Excitation 16................

5.2 PowerBoostt IIIE Voltage Regulators 17........

5.2.1 Voltage Regulator Test 17..............

5.2.2 Voltage Regulator Adjustment 18.......

5.3 Rotor 19.....................................

5.4 Stator 20....................................

5.5 Brushes 21..................................

Section 6 Component Troubleshooting 23......

6.1 Engine/Generator Components 23..............

6.2 Remote Panel (optional) 25....................

Section 7 Generator Disassembly/Reassembly 27

7.1 Disassembly 27..............................

7.2 Collector Ring and Bearing Replacement 30......

7.3 Reassembly 30...............................

Section 8 Reconnection and Wiring Diagrams 31

8.1 Reconnection Diagram 100--120 V,

60 & 50 Hz 32................................

8.2 Reconnection Diagram 100--120/200--240 V,

60 & 50 Hz 32................................

8.3 Reconnection Diagram 220--240 V, 50 Hz 32.....

8.4 Remote Start Panel 32........................

8.5 Wiring Diagram 5ERKM/4EFRKM 33............

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-6079 3/00 Table 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 hasseveral types ofsafety 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.

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

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.

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 gases. Explosion can cause severe injury or death. Battery gases

can cause an explosion. Do not smoke or permit flamesor 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 wristwatch, rings, and other 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-6079 3/00 Safety Precautions and Instructions I

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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 wristwatch, rings, and other jewelry before servicingthe equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (-- ) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash Fire

WARNING

Fire. Can cause severe injury or death.

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

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

set with the air cleaner removed.

Servicing the fuel system. A flash fire can cause severe injury or death.

Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor.

Combustible materials. A fire can cause severe injury or death.

Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.

Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide

is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathingexhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building or vehicle. Do not obstruct the exhaust outlet when parking your vehicle. The exhaust gases must discharge freely to prevent carbon monoxide from deflecting into the vehicle.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon

monoxide is a poisonous gas present in exhaust gases. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attentionifthe condition of affected persons does not improve within minutes of breathing fresh air.

Installing the exhaust tail pipe. Carbon monoxide can cause severe nausea, fainting, or death. Install the

exhaust system tail pipe to prevent the drawing of discharged exhaust gases into the vehicle interior through windows, doors, air conditioners, and other openings. Do not use flexible tail piping because it could crack and allow lethal exhaust fumes to enter the vehicle.

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

safetyof the vehicle’s occupants, install a carbon monoxide detector. Consult the coach builder or dealer for approved detector location and installation. Inspectthe 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.

II Safety Precautions and Instructions TP-6079 3/00

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Fuel System

Hazardous Noise

WARNING

Explosive fuel vapors. Can cause severe injury or death.

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

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 in a well-ventilated area away from 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. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation.

Explosive fuel vapors can cause severe injury or death. Ta k e

additional precautions when using the following fuels:

Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE.

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.

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 V oltage/Electrical Shock

WARNING

Hazardous voltage. Can cause severe injury or death.

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

Moving rotor.

Hazardous voltage. Backfeed to the utility system can cause severe injury, death, or property damage.

Connect the generator set to the building’s electrical system only throughan approved device and after the building’s main switch is opened.

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.

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 wristwatch, rings, and 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)

TP-6079 3/00 Safety Precautions and Instructions III

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

Connect the generator set to the building/campground electrical system only through an approved device and after the building/campground main switch is opened. Backfeed connections can cause serious injury or death to utility personnel working on power lines and/or personnel near the work area. Some states and localities prohibit unauthorized connection to the utility electrical system. Install a transfer switch to prevent interconnection of the generator set power and other sources of power.

Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have

trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove rings, wristwatch, and 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

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.

The engine and exhaust system components become extremely hot during operation.

Combustible materials. Fire can cause severe injury or death. A hot

exhaust system can ignite adjacent combustible materials. Do not locate electrical wiring, fuel lines, or combustible materials above the exhaust muffler. Exercise caution when parking your vehicle to prevent the exhaust system and hot exhaust gases from starting grass fires.

Combustible materials. Fire can cause severe injury or death. A hot

generator set can ignite debris in the compartment. Keep the compartment and generator set clean and free of debris and combustible materials to minimize the possibility of fire. Do not block the fuel/oil drain opening in the generator set mounting tray. Cut a corresponding hole in the subfloor, if used, for the drain opening.

Moving Parts

WARNING

Hazardous voltage. Can cause severe injury or death.

Moving rotor.

WARNING

Rotating parts. Can cause severe injury or death.

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

Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause

the hardware or pulley to release from the generator set engine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.

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.

WARNING

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

Do not work on the generator set until it cools.

IV Safety Precautions and Instructions TP-6079 3/00

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

Page 7

Notice

NOTICE

This generator set has been rewired from its nameplatevoltage to

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.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are

available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE

Canadian installations only.For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.

NOTICE

This generator set does not comply with United States Coast Guard (USCG) requirements and must not be used for marine applications. For

marine installations use only generator sets specified for marine use. USCG Regulation 33CFR183 requires that a generator set must be ignition protected when used in a gasoline-fueled environment.

TP-6079 3/00 Safety Precautions and Instructions V

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Notes

VI Safety Precautions and Instructions TP-6079 3/00

Page 9

Introduction

This manual provides troubleshooting and repair instructions for 5ERKM and 4EFRKM model generator sets, controllers, and accessories.

Refer to the engine service manual for generator set engine service information.

This manual may be used for models not listed on the front cover.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

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

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

Before installing a mobile generator set, obtain the most current installation manual from your local distributor/dealer. Only qualified persons should install the generator set.

x:in:001:002:a

Introduction iTP-6079 3/00

Page 10

Service Assistance

Service Information

Please contact a local authorized distributor/dealer for sales, service, or other information about Kohler Generator Division products.

To locate a local authorized distributor/dealer inside the U.S.A. and Canada

D Look on the product or in the information included with

the product

D Consult the Yellow Pages under the heading

Generators— Electric

D Visit the Kohler Generator Division web site at

www.kohlergenerators.com

D Call 1-800-544-2444

To locate a local authorized distributor/dealer outside the U.S.A. and Canada

D Look on the product or in the information included

with the product

D Consult the telephone directory under the heading

Generators—Electric

D Visit the Kohler Generator Division web site at

www.kohlergenerators.com

D Contact the nearest regional office

Africa, Europe, Middle East

London Regional Office Langley, Slough, England Phone: (44) 1753-580-771 Fax: (44) 1753-580-036

Australia

Australia Regional Office Queensland, Australia Phone: (617) 3893-0061 Fax: (617) 3893-0072

China

China Regional Office Shanghai, People’s Republic of China Phone: (86) 21-6482 1252 Fax: (86) 21-6482 1255

India, Bangladesh, Sri Lanka

India Regional Office Bangalore, India Phone: (91) 80-2284270

(91) 80-2284279

Fax: (91) 80-2284286

Japan

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

Latin America

Latin America Regional Office Lakeland, Florida, U.S.A. Phone: (941) 619-7568 Fax: (941) 701-7131

South East Asia

Singapore Regional Office Singapore, Republic of Singapore Phone: (65) 264-6422 Fax: (65) 264-6455

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.

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

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Number

Serial Number

TP-6079 3/00ii Introduction

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Section 1 Specifications

1.1 General

The 5ERKM and 4EFRKM units are powered by a one-cylinder, air-cooled, four-cycle gasoline engine.

Kohler Co. develops all Kohler mobile generator set ratings using accepted reference conditions of 25_C (77_F) and pressure of 98.9 kPa (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.

1.2 Engine

Engine Specifications

Engine manufacturer Kohler

Engine model CS12

Number of cylinders 1

Cylinder block material Aluminum

Cylinder head material Aluminum

Piston rings

Governor Mechanical

Bore x stroke, mm (in.) 85 x 63 (3.35 x 2.48)

Displacement, L (CID) 0.357 (21.79)

Compression ratio 8.1:1

Horsepower, 60/50 Hz 11.5/8

RPM, 60/50 Hz 3600/3000

Lubrication system Splash

Lube oil capacity L (U.S. qts) 2.0 (2.1)

Oil recommendation, API SC or SH

Battery voltage, standard, DC 12

Battery CCA recommendation, min.

Battery charging 10 amps

Starter motor Bendix automotive type

2 compression

1 oil control

250

1.4 Generator

Component Specifications

Hot exciter field voltage/current readings at rated voltage

No load (63 Hz) (volts/amps) 10.1/4.4

Full load (60 Hz) (volts/amps) 50.5/8.5

Cold main field (rotor) resistance (ohms) 3.7

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

1--2, 3--4, 33--44 (VAC) 145

55--66 (VAC) 190

B1--B2 (VAC) 14

Cold stator resistance

1--2, 3--4, 33--44 (ohms) 0.32

55--66 (ohms) 1.70

B1--B2 (ohms) 0.05

1.5 Torque

Component Torque Nm (in. lb.)

Rotor bolt 23.1 (204)

Generator overbolts 13.6 (120)

Mounting plate to end bracket bolts

Lift eyebolts 19.0 (168)

Generator adapter to engine bolts

Engine oil drain boss (inside generator adapter)

Generator adapter to exhaust manifold

Spark plug 12--17 (106--150)

6.8 (60)

14.9 (132)

47.5 (420)

13.6 (120)

1.3 Fuel

Fuel System Specifications

Fuel recommendation Unleaded 87 octane

Fuel pump Electric

Fuel pump, max. lift, m (ft.) 0.9 (3)

Fuel pump operating, kPa (psi) 13.8--24.1 (2.0--3.5)

Fuel pump inlet hose ID, mm (in.) 6.35 (0.25)

TP-6079 3/00 1Section 1 Specifications

Page 12

1.6 Service Views

SERVICE VIEW

1. Controller

2. Hourmeter

3. Start/Stop switch

4. Nameplate (top)

5. Input fuse

6. Battery charging fuse

7. Voltage regulator fuse

8. AC circuit breaker

9. Remote start connector (nonservice side)

10. Lifting eye

11. Muffler

1718

1516 14

ENGINE-END VIEW

FV-277000

12. Spark plug

13. Air intake silencer

14. Carburetor

15. Oil drain valve

16. Oil check

17. Fuel feed pump

18. Fuel inlet

19. Extended shaft (generator specification available)

20. Engine battery charging voltage regulator

21. End bracket cover plate

22. PowerBoostäIIIE voltage regulator

Figure 1-1 5ERKM/4EFRKM Service Views

TP-6079 3/002 Section 1 Specifications

Page 13

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

2.2 Lubrication System

Use oil that meets the American Petroleum Institute (API) classification of SC or SH. Using unsuitable oil or neglecting an oil change may result in engine damage that is not covered by the engine warranty. Figure 2-1 shows the recommended Society of Automotive Engineers (SAE) viscosity designation for given operating temperature ranges.

Do not mix different oil brands. Incompatibility could cause a breakdown of lubricating ingredients and reduce engine protection.

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.

Note: See the generator set operation manual for the

service schedule and other service not included in this manual.

Figure 2-1 Recommended SAE Viscosity Grades

TP-6079 3/00 3Section 2 Scheduled Maintenance

Page 14

2.3 Air Intake System

At the interval specified in the service schedule, inspect, clean, or replace the air filter element.

2.4 Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

Inspect the exhaust system components (exhaust manifold, exhaust line, exhaust clamps, and muffler) for cracks and corrosion.

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps and

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

D Check that the exhaust outlet is unobstructed.

D Check the exhaust gas color. If the exhaust is blue or

black, contact your local distributor/dealer.

D Visually inspect for exhaust leaks. Check for carbon

or soot residue on exhaust components. Carbon and soot residue indicates an exhaust leak. Seal leaks as needed.

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

D Ensure that the carbon monoxide detector is (1) in the

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

m:op:001:003

TP-6079 3/004 Section 2 Scheduled Maintenance

Page 15

Section 3 Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

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

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 in a well-ventilated area away from 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. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation.

3.2 Fuel Pump

Electric fuel pumps draw fuel from the fuel tank through a filter and supply clean fuel at the proper pressure and quantity to the generator set engine carburetor.

Fuel Pump Test Procedure:

1. Connect the inlet side of the pump to a fuel source.

2. Disconnect the outlet hose from the fuel filter and place the end in a container to catch the fuel.

3. Disconnect the P9 connector.

4. Connect the positive terminal (70) of the fuel pump to the positive terminal (+) of a 12-volt battery.

5. Connect the negative terminal (N) of the fuel pump to the negative terminal (--) of the battery. The pump should operate and fuel should discharge from the pump outlet. If the pump does not operate, replace the pump.

Explosive fuel vapors can cause severe injury or death.

Take additional precautions when using the following 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.

3.1 General

In most installations, both the generator set and the vehicle’s engine operate from a common fuel tank with a dual dip tube. The generator set’s dip tube may be shorter than the vehicle engine’s dip tube. With this arrangement, fuel may not be available to the generator set when the fuel supply is low. See Figure 3-1 for a fuel system schematic.

Vehicle’s engine

1. Dual dip tubes

2. Fuel filter

3. Fuel tank

Generator set fuel pump

Figure 3-1 Fuel System Schematic, Typical

598641

TP-6079 3/00 5Section 3 Fuel System

Page 16

3.3 Carburetor Troubleshooting

This section is for fuel-related problems and basic carburetor troubleshooting. See Figure 3-2 for carburetor component identification.

Note: When troubleshooting the fuel system, it is

important to have an adequate fuel supply.

A lean or rich fuel condition can reduce power output and cause poor acceleration.

Symptoms of a lean condition:

D Hard starting D Stalling D Hunting

Symptoms of a rich condition:

D Hard starting D Stalling D Percolation D Flooding D Leaking carburetor

If a rich condition occurs, remove the air cleaner element and observe the choke plate to ensure that it is fully open. The choke will not fully open until the engine is warm. If the choke does not fully open, test the bi-metallic strip and the choke pull-off. See Figure 3-2. Replace components as necessary.

Bi-metallic Strip Test Procedure:

1. Start and run the generator set until it reaches normal operating temperature. (5--10 minutes).

2. If the choke plate lever can be rotated counterclockwise adjust or replace the bi-metallic strip.

1. Choke pull-off

2. Bi-metallic strip

3. Choke linkage

4. Choke plate lever

Figure 3-2 Fuel System Exploded View

598642

Choke Pull-off Vacuum Solenoid Test Procedure:

1. Remove the vacuum hose that is connected to the back of the choke pull-off vacuum solenoid.

2. Push and hold the choke linkage into the choke pull-off vacuum solenoid.

3. Seal the vacuum port on the back of the solenoid and release the choke linkage. If the choke linkage moves back to the original location while the vacuum port is sealed, replace the choke pull-off vacuum solenoid.

3.3.1 Hard Starting

A flooded engine, an improperly adjusted or inoperative choke, or a dirty carburetor (lean condition) can cause hard starting.

3.3.2 Stalling

A dirty carburetor can cause stalling. Clogged idle air bleeds, idle air passages, or an idle discharge port can cause stalling because of a lean condition. To remedy this condition, clean or adjust the carburetor.

TP-6079 3/006 Section 3 Fuel System

Page 17

3.3.3 Flooding

3.5 60 and 50 Hz Conversions

Flooding occurs from a float level set too high, an inoperative bi-metallic strip, an inoperative choke pull-off, a sticking choke plate or float, or a fuel inlet needle held off its seat either by improper seating or dirt particles. A punctured or leaking float admitting fuel becomes gas-logged causing a heavy float, high fuel level, and flooding.

3.3.4 Hunting

A low fuel level because of an improperly adjusted float, a clogged main jet, restricted main jet passages, or an improperly sized main jet for the application can cause hunting. To remedy this condition, clean, adjust, or replace inoperative components.

An incorrect throttle linkage adjustment, a binding throttle linkage, a sticking throttle shaft, or a loose throttle shaft in the throttle body or bore can cause inconsistent idle speed.

3.3.5 Leaking Carburetor

Loose fuel connections, a cracked carburetor body, a sticking fuel inlet needle, or an inoperative float can cause a leaking carburetor. Adjust, repair, or replace the affected components.

3.4 Governor

The factory adjusts the governor and further adjustments should not be necessary.

To convert the generator set to 50 or 60 Hz follow the procedure below.

Governor 50 or 60 Hz Conversion Procedure:

1. Adjust the generator frequency by adjusting the generator speed adjusting screw. Using a frequency meter set the no load speed at 52.5 Hz for 50 Hz operation or 63 Hz for 60 Hz operation.

2. Adjust the voltage regulator volt/Hz roll-off point. Refer to Section 5.2.2.

1. Generator speed adjusting screw

Figure 3-3 Governor 60 Hz to 50 Hz Conversion

598643

Note: Never tamper with the governor settings to

increase the generator output. Overspeeding can cause equipment parts to exceed design limitations, resulting in component failure.

TP-6079 3/00 7Section 3 Fuel System

Page 18

Notes

TP-6079 3/008 Section 3 Fuel System

Page 19

Section 4 Controller Troubleshooting

4.1 Sequence of Operation

This section describes the controller sequence of operation during the generator start, run, stop, and fault shutdown modes and describes the relay testing procedures. Use this section as a starting point for controller fault identification. 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 or working properly. Unfold and use the wiring diagram in Section 8.5 to follow the sequence of operation in this section.

4.1.1 Start

Press the start/stop switch to the START position to close the start/stop switch between N and 47 (local or remote).

The K2 relay energizes and LED2 illuminates. The normally open K2 contacts close energizing the K3 relay (LED3 lights), fuel pump (FP), choke heater (CHTR), antidiesel solenoid (ADS), ignition (IGN), hourmeter (HR), and the main field (FP and FN).

Flashing of the main field occurs when the K2 contacts close.

The normally open K3 contacts close energizing the K20 relay. The normally open K20 contacts close, energizing the starter relay (SR). The SR normally open contacts close energizing the starter motor (SM).

4.1.2 Run

The bridged rectifier (BR1) receives AC voltage (12--15 volts) through the B1 and B2 windings of the stator.

1. PBIIIE voltage regulator

2. K20 relay

3. K25 relay

4. Controller circuit board

5. Fuses

6. Start/stop switch

7. Hourmeter

The K1 relay energizes (LED1 lights).

The normally open K1 contacts close maintaining voltage to the K2 relay, allowing the function of the fuel pump (FP), choke heater (CHTR), antidiesel solenoid (ADS), ignition (IGN), and hourmeter (HR).

The normally closed K1 contacts open, ending the flashing by preventing battery voltage to the main field (+) and (--).

The K6 relay energizes. The normally open K6 contacts close, latching the K6 relay on. The normally closed K6

contacts open, preventing inadvertent starter engagement by disabling the the K3 relay.

The K3 relay deenergizes (LED3 off). The K3 contacts open, deenergizing the K20 relay. The K20 contacts open, deenergizing the starter relay and starter motor.

At the same time the K1 relay energizes, the time delay

GM11919

for the K5 relay starts. After 5--10 seconds, the K5 relay energizes (LED 5 lights).

The normally open K5 contacts close permitting the function of the engine safety shutdown switch.

Figure 4-1 Controller

TP-6079 3/00 9Section 4 Controller Troubleshooting

Page 20

4.1.3 Stop

4.1.4 Low Oil Level (LOL) Safety Switch

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

The K4 relay energizes (LED4 lights).

The normally closed K4 contacts open, disabling the fuel pump (FP), choke heater (CHTR), antidiesel solenoid (ADS), and ignition (IGN).

The normally open K4 contacts close, latching the circuit to the K4 relay until the generator set comes to a complete stop.

When the oil level is low, the LOL shutdown switch contacts close energizing the K4 relay (LED4 lights). The generator set shuts down, as described in Section 4.1.3.

4.2 Controller Circuit Board

The controller circuit board has light emitting diodes (LEDs) that indicate the presence of relay coil power. When any of the relays K1--K5 receives power, the corresponding LED lights.

Figure 4-2 GM10516 Controller Circuit Board

GM10516

TP-6079 3/0010 Section 4 Controller Troubleshooting

Page 21

4.3 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. Use this chart for component testing only. Always check the continuity of

the wires between components. Always disconnect external components (remote start/stop switches, the engine gauge panel, dry relay contact kits, etc.) before performing troubleshooting procedures.

Press the start switch

(local or remote).

Check the battery

Does the K2 relay LED

light while cranking?

Is the 10-amp controller

fuse functional?

YesNo

Does the engine crank?

condition and

connections.

Yes

the circuit board.

Is there continuity between

N and 47 while pressing

the start/stop switch?

TheK2relayis faulty. Replace

Yes

Is the K3 relay LED lit?

Is voltage present at the K20 relay coil

(P1-4 connector)?

TheK2relayis faulty. Replace

the circuit board.

Go to A

(next page).

Yes

Replace or repair

the wiring harness.

Is voltage present

at the starter relay?

Replace the

K20 relay.

Replace the starter

Is voltage present at

the starter?

relay.

Yes

Replace or

repair the

starter motor.

Replace the fuse.

Replace the

circuit board.

Yes

Is there 12 volts

at P1--14?

Yes

Is the start/stop

switch functional?

Replace the

start/stop switch.

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

TP-6079 3/00 11Section 4 Controller Troubleshooting

Page 22

Does the engine start?

Yes

Go to B

(next page).

Is there continuity

between P1-9 and P9-1?

between P9-2 and P1-8?

between P1-8 and P1-14?

Is there continuity across the

P1, P4, and P9 connectors?

Is the K4 relay LED lit?

Is 12-volts DC present

at the fuel pump

(P9-2)?

Yes

Is there continuity

Yes

Is there continuity

Yes

Is the fuel

pump working?

Troubleshoot the engine.

refer to the engine service

Replace the

fuel pump.

Is there continuity between

P4-5 and N?

Yes

manual.

Is there continuity

between P2-8 and N?

Yes

Disconnect the P2 connector.

Is there continuity between

P2-5 and N?

Yes

Go to C

(next page).

Check the wiring for

Yes

open circuits.

Check the connectors

for open circuits.

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

Replace the remote

start/stop switch.

Yes

Replace the

start/stop switch.

TP-6079 3/0012 Section 4 Controller Troubleshooting

Page 23

Does the engine continue

to run after the start

Yes

Does using the stop switch

stop the engine?

Yes

switch is released?

The generator set is

Did the K4 relay LED light?

functioning properly.

Does the K5 relay LED

light after 5--10 seconds

of running time?

Replace the circuit

board (the K5 relay

is inoperative).

Go to D

(next page).

Does the K1

relay LED light?

Yes

Is the K3 LED lit?

Yes

Replace the circuit board

(the K6 relay is inoperative).

Does the engine have proper

Replace the

start/stop

oil level?

switch.

Yes

Is the start/stop

switch functional?

Yes

Is the LOL switch

functional?

Yes

Replace the circuit board

(inoperative K4 relay).

Replace the switch.

Fill the engine crankcase

with the specified amount of

oil. See Section 1.2.

Yes

Go to C

(above).

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

TP-6079 3/00 13Section 4 Controller Troubleshooting

Page 24

Is there AC output

when the start button is held and the unit is

Yes

running?

Is there approximately

12 VDC at the brushes?

Separately excite the

generator set to determine if

other components are

inoperative. (See Section

5.1.2, Separate Excitation.)

Is there AC output

voltage?

Is the stator and rotor

functional?

Is there 12 volts AC output at

the B1/B2 stator winding?

Yes

Is the voltage regulator

fuse functional?

Is the stator

functional?

Replace

the stator.

Yes

Replace the

circuit board.

Replace the

circuit board.

Replace inoperative

components.

Replace the fuse.

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

Is the voltage

regulator

functional?

Yes

Replace the voltage regulator.

TP-6079 3/0014 Section 4 Controller Troubleshooting

Page 25

Section 5 Generator Troubleshooting

5.1 General

Before beginning the following 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.

Testing the voltage regulator. Hazardous voltage can cause severe injury or death. High voltage is present at the

voltage regulator heat sink. Toprevent 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)

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.

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 wristwatch, rings, and jewelry before servicing the equipment.

Moving rotor.

5.1.1 General Troubleshooting

To determine the cause of no- or low-AC output , refer to the following steps and the troubleshooting flow chart (Figure 5-1). Verify the operation of the alternator components before replacing the controller board or voltage regulator.

General Troubleshooting:

1. Check the condition of the voltage regulator’s 10-amp fuse.

2. If the fuse is functional, separately excite the generator. (See Section 5.1.2.) The separate excitation test duplicates the role of the voltage regulator by providing excitation current to the rotor.

Generator has no

or low output

Check for flashing

voltage at the brushes

Separately

excite generator

Generator has

no output

Test rotor

Figure 5-1 General Troubleshooting

Troubleshoot

controller

Generator has

output

Test voltage

regulator and

wiring

Test stator

TP-598651

TP-6079 3/00 15Section 5 Generator Troubleshooting

Page 26

5.1.2 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 functional while static (stationary) may exhibit a running open or short circuit while dynamic (moving). Centrifugal forces acting on the windings during rotation or insulation breakdown as temperatures increase can cause short circuits.

Note: It is not necessary to separately excite the

generator if there is AC output with flashing voltage.

Separate Excitation Procedure:

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

2. Disconnect the P10 (F1, F2) connector.

3. Connect a separate excitation circuit as shown in Figure 5-2. Connect an ammeter and a 10-amp fuse in series with F1. Note and record the ammeter reading.

7. Remove the jumper wire and reverse the positive (+) and negative (--) leads on the rotor. Repeat step 5. If the ammeter is stable, ground the negative (--) lead at its new location on the rotor to the engine block. Replace the rotor if the ammeter reading fluctuates.

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

If there is no generator output during normal operation, but output is available when the generator set is separately excited, the voltage regulator may be inoperative.

Note: See Section 1, Specifications, for the stator

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

321

4. Divide the battery voltage by the exciter resistance (cold) to determine the exciter current. Disconnect the resistor leads and determine the exciter current value using an ohmmeter. See Section 1.3, Specifications, for the normal values.

Exciter Current =

Example :

12 VDC

3.7 Ohms

tteryVoltage

Exciter Resistance

= 3.2 Amps

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

6. With a jumper wire, ground the negative (--) lead from the rotor to the engine block. An increased current reading or a fluctuating reading indicates a grounded rotor winding. Replace the rotor if the ammeter reading fluctuates. If the ammeter is stable, continue with step 7.

4 5

9 8

1. Voltage regulator

2. (+) Terminal—(P10-1)

3. (--) Terminal—(P10-2)

4. 10-amp fuse

5. DC ammeter

6. 12-volt battery (DC)

+—

7. Brushes

8. Collector rings

9. Main field (rotor)

10. Jumper lead

11. Engine ground

+—

Figure 5-2 Separate Excitation Connections

TP-598652

TP-6079 3/0016 Section 5 Generator Troubleshooting

Page 27

5.2 PowerBoostääää IIIE Voltage Regulators

Regulator Test Procedure:

1. Connect the components as shown in Figure 5-4.

The generator set is equipped with a PowerBoostt IIIE voltage regulator. See Figure 5-3.

The voltage regulator monitors the output voltage of the generator set.

The 10-amp regulator fuse protects the alternator stator windings (power supply) 55--33 from excessive current draw because of an inoperative voltage regulator or a downstream short. If the regulator’s 10-amp fuse blows, the generator set will shut down. Verify that the regulator fuse is functional before proceeding with the test.

132

1. Voltage potentiometer

2. Stability potentiometer

3. Volts/Hz potentiometer

TP-598653

Figure 5-3 PowerBoostt IIIE Voltage Regulator

5.2.1 Voltage Regulator Test

Perform the following test to check the regulator output. Use the following components to test the voltage regulator:

2. Turn the variable transformer setting to zero. Plug in the variable transformer.

3. Turn the variable transformer on. Slowly increase the variable transformer to 100 volts. Thetest lamp should light. If the lamp does not light, turn the voltage adjustment potentiometer (pot) clockwise. If the lamp still does not light, the voltage regulator is inoperative. Replace the voltage regulator. An inoperative voltage regulator causes a generator no/low-output condition.

4. Slowly increase the variable transformer to 120 volts. The lamp should go out and stay out as the voltage increases. If the lamp remains lit, turn the voltage adjustment pot counterclockwise. If the lamp still remains lit, replace the voltage regulator. A voltage regulator that is inoperative causes a generator high voltage output condition.

5. Turn the variable transformer to zero and unplug the AC cord.

Note: For applications requiring fine voltage

adjustment, connect a remote rheostat to voltage regulator terminal 66.

12 3

66 443355--+

RYOW

D Variable transformer, 0--140 volts, 0.5-amp minimum D Plug, 120 volts AC D Lamp, 120 volts, 100 watts D AC voltmeter D Insulated copper wire, #14 AWG, minimum

TP-6079 3/00 17Section 5 Generator Troubleshooting

1. 120 volts AC

TP-598654

2. Variable transformer

3. AC voltmeter

4. Voltage regulator PowerBoosttIIIE

5. Stator/rotor connections (for reference only)

6. Lead color

7. 120-volt, 100-watt lamp

Figure 5-4 PowerBoosttIIIE Voltage

Regulator Test

Page 28

5.2.2 Voltage Regulator Adjustment

Voltage Regulator Adjustment Procedure:

The factory sets the voltage regulator and, under normal circumstances, the regulator 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. See Figure 5-5. The following paragraphs describe the voltage regulator components.

145

1. Optional remote rheostat

2. Voltage adjustment pot

3. PowerBoostä IIIE voltage regulator

4. Stabilizer pot

5. Volts/Hz pot

6. Stator/rotor connections (for reference only)

7. DC output

8. Rotor

9. 10-amp fuse

10. AC power input (aux.)

11. Main (2 and 1)

12. Control

13. Stator

14. Sensing

15. Main (3 and 4)

44 33 55

GY R

YOWBK

1011

TP-598655

Figure 5-5 PowerBoostt IIIE Voltage Regulator

Voltage Adjustment Pot adjusts the generator output

within the range of 100--130 volts.

Stabilizer Pot fine tunes regulator circuitry to minimize AC voltage fluctuation.

1. Stop the generator set.

2. Turn the remote rheostat, if equipped, to the midpoint. Turn the voltage and stabilizer pots fully counterclockwise. Connect the voltmeter to the AC circuit or an electrical outlet.

3. Start the generator set.

4. Adjust the generator frequency using a frequency meter. Set the no load speed at 52.5 Hz for 50 Hz operation or 63 Hz for 60 Hz operation. Rotate the voltage adjustment pot clockwise to increase the voltage or counterclockwise to decrease the voltage to achieve the desired output voltage.

5. Connect a 120-volt light bulb to the AC plug on the generator set.

6. Rotate the stability pot clockwise until the light bulb flickers minimally.

7. Readjust the voltage to achieve the desired output voltage.

8. Disconnect the 120-volt light bulb.

9. Turn the volts/Hz pot completely clockwise to decrease the Hz roll-off point. See Figure 5-6.

125

120

115

110

Volts (AC)

105

100

40 42 44 46 48 50 52 54 56 58 60 62 64

Frequency (Hz)

60 Hz Models

50 Hz Models

Counterclockwise to increase Hz roll-off

Volts/Hz Pot allows the voltage to drop if the load imposed on the generator causes the engine speed to fall below a predetermined frequency (roll-off point). This reduction of voltage results in a decrease of starting kW (load) allowing the governor to recover the engine speed.

Clockwise to decrease Hz roll-off

Figure 5-6 Volts/Hz Roll-Off Chart

TP-6079 3/0018 Section 5 Generator Troubleshooting

Page 29

10. Set the engine speed to 47.5 Hz for 50 Hz generator sets and 57.5 Hz for 60 Hz generator sets for the desired cut-in frequency.

11. Slowly turn the volts/Hz pot counterclockwise until the frequency matches that of the engine frequency (47.5 or 57.5 Hz) or until the voltage just begins to drop.

12. Reset the engine speed to the normal frequency (50Hzor60Hz).

13. Recheck the AC voltage output and stability as described in steps 4--7.

14. Stop the generator set.

5.3 Rotor

The two-pole rotor creates the magnetic field needed to sustain alternating current in the stator windings. Before testing, inspect the rotor for visible damage to pole shoes, insulation, exposed coil windings, and collector ring surfaces. Check the rotor bearing for noisy operation, excessive wear, radial or axial movement, and/or heat discoloration. Replace the rotor as necessary.

Collector rings acquire a glossy brown finish in normal operation. Do not attempt to maintain a bright, newly

machined appearance. Wipe the collector rings with a dry, lint-free cloth. Use a commutator stone to remove the groves on the collector rings. Do not use emery or carborundum paper or cloth. Remove all carbon dust from the generator. Remove the black or pitted surface of the collector rings using a lathe.

Check the rotor for continuity and resistance. Lift the brushes and measure the rotor resistance between the two collector rings. See Section 5.5.

Note: When checking rotor resistance with the rotor

installed, brushes must not be in contact with rotor collector rings. Use a brush retainer on brushes for accurate resistance readings.

Note: Use the values in Section 1 as a reference for

rotor resistance readings. Take readings at room temperature or about 21°C(70°F). Rotor resistance will vary directly with increase in temperature.

To check whether the rotor is shorted to ground, touch one ohmmeter lead to either collector ring and the other lead to the rotor poles or shaft. The meter should register no continuity.

Repair or replace the rotor if the previous tests detect any faults.

TP-6079 3/00 19Section 5 Generator Troubleshooting

Page 30

5.4 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. See Figure 5-7 for coil lead description.

Stator Leads Description

1--2 Output coil

3--4 Output coil

33--44 Control wires from 3 and 4

55--33 Voltage regulator power source

B1--B2 Controller power source

Figure 5-7 Stator Coil Lead Description

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

Note: When taking an ohmmeter reading using

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

5. Check the cold resistance of the stator windings by connecting the meter leads to the stator leads 1-4, 2-5, 3-6, etc. See Section 1, Specifications, for the stator resistance values.

6. Perform a megohmmeter test on the stator as described in step 7.

Note: Consider the stator functional if the

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

Note: The stator resistance varies directly with

increased temperature.

If the stator readings vary considerably during the previous checks, repair or replace the stator.

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 33, 44, and 55 are the voltage regulator supply and sensing leads. The output of leads B1 and B2 is the control voltage for the controller.

Stator Test Procedure:

1. Place the generator 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 8, Reconnection and Wiring Diagrams.

4. Disconnect all of 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 5-8. Perform the stator tests on all of the stator windings.

7. Check the stator for a grounded condition using a megohmmeter. Apply 500 volts DC to any stator lead from each winding and the stator frame. Follow the instructions of the megohmmeter manufacturer when performing this test. Repeat the test on the other leads until all of the stator windings have been tested. A reading of approximately 1.5 megohms and higher indicates the stator is functional. A reading of less than approximately 1.5 megohms indicates deterioration of the winding insulation and possible current flow to ground; if so, replace the stator.

Between Leads Continuity

1 and 2 Yes

3 and 4 Yes

55 and 66 Yes

B1 and B2 Yes

1 and 3, 4, 33, 44, 55 No

1 and 55, B1 and B2 No

4 and B1 and B2 No

55 and B1 and B2 No

Any stator lead and ground No

Figure 5-8 Stator Continuity

TP-6079 3/0020 Section 5 Generator Troubleshooting

Page 31

5.5 Brushes

The brushes provide a current path from the voltage regulator to the collector rings. Because the brushes carry a low current, inspect them every 3000 hours. Abrasive dust on the collector rings could shorten the life of the brushes. Excessive arcing at the brushes could damage the voltage regulator. Weak springs, damaged collector rings, sticking brushes, a loose holder, or poor brush contact can cause arcing at the brushes. See Figure 5-10 for brush component identification.

The brushes must be free to move within the holder and be held in contact by the springs. When properly positioned, spring pressure on the brush surface will cause the brush to wear evenly. The brushes must ride 100% on the collector rings or arcing will occur and cause burned rings or failure of the voltage regulator. Figure 5-9 shows the correct positioning of the brushes. Add or remove alignment shims as necessary to center the brushes on the collector rings.

Replace brushes if they show excessive or uneven wear.

Use a retainer wire (such as a paper clip) to contain the brushes during disassembly and reassembly. Push the brushes into the brush holder until the retainer wire can be inserted into the brush keeping hole.

Replace brushes when they are worn to half of their original size.

1. Correct position

2. Brush holder

3. Incorrect position

4. Generator collector rings

Figure 5-9 Brush Positioning

1. Brush holder

2. Retainer (paper clip)

3. Mounting screw

4. Alignment shim(s)

5. Brush

6. Spring

TP-598658

Figure 5-10 Brush Holder

TP-598657

TP-6079 3/00 21Section 5 Generator Troubleshooting

Page 32

Notes

TP-6079 3/0022 Section 5 Generator Troubleshooting

Page 33

Section 6 Component Troubleshooting

6.1 Engine/Generator Components

See Figure 6-1 through Figure 6-3 for engine/generator component testing. With the generator set battery connected, check the wiring harness and the engine/generator components listed in the following

Component Voltmeter Connections Procedure Results

Hourmeter and wiring. Connect the red test lead to

Stator auxiliary winding B1 and B2.

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.

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. Set the voltmeter to 20 volts AC or greater. Crank the generator set and allow the set to reach its rated 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 6-1 Engine/Generator Component Testing, Relay Controller

TP-6079 3/00 23Section 6 Component Troubleshooting

Page 34

WARNING

To further check the generator set components, disconnect the battery and remove the wiring harness plugs from the controller circuit board. Use an ohmmeter to check the continuity of the components and to isolate inoperative components. Refer to

Hazardous voltage. Can cause severe injury or death.

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

Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury

and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove wristwatch, rings, and jewelry before servicing the equipment.

Component Ohmmeter Connections Procedure Results

Start/stop switch. Connect the ohmmeter to the

K20 relay coil and wiring.

Controller 10-amp fuse and wiring.

Moving rotor.

P2-6 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 battery positive (+) cable and the P1-14 lead. Note: Connect the J4 and P4 leads to perform this test.

Figure 6-2 and Figure 6-3.

Note: Before performing ohmmeter checks, disconnect

the generator set battery to prevent damage to the ohmmeter.

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 the Rx1scale.

Place the ohmmeter on the R x 1000 scale.

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 K20 relay coil and/or wiring. High resistance, open K20 relay and/or wiring.

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

Figure 6-2 Engine/Generator Component Testing, Relay Controller

TP-6079 3/0024 Section 6 Component Troubleshooting

Page 35

Component Ohmmeter Connections Procedure Results

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

Low oil level (LOL) safety shutdown switch.

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

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

P1-9 and ground.

Connect the ohmmeter to the P4-6 and engine block (ground).

Place the ohmmeter on the Rx1scale.

Place the ohmmeter on the R x 1000 scale. The oil level in the engine must be drained for this test. Replace the engine oil after this test.

Low resistance indicates shorted rotor windings. High resistance indicates an open in the rotor windings. See Section 1, Specifications.

Low resistance indicates shorted B1/B2 windings. High resistance indicates an open in the B1/B2 windings. See Section 1, Specifications.

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

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

Figure 6-3 Engine/Generator Component Testing, Relay Controller

6.2 Remote Panel (optional)

Kohler Co. offers a remote panel with a start/stop switch and a hourmeter for connection to the generator set.

Component Ohmmeter Connections Procedure Results

Start/stop switch. Remote switch: yellow/red

wire terminal and black wire terminal.

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

If difficulty with the remote operation occurs, test the switch. See Figure 6-4 and Section 8.4 for troubleshooting the remote start/stop switch.

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

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

Continuity indicates a functional switch. No reading indicates an inoperative switch. Replace the switch

Figure 6-4 Remote Start Panel Troubleshooting

TP-6079 3/00 25Section 6 Component Troubleshooting

A-226965

Page 36

Notes

TP-6079 3/0026 Section 6 Component Troubleshooting

Page 37

Section 7 Generator Disassembly/Reassembly

7.1 Disassembly

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

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

WARNING

Explosive fuel vapors. Can cause severe injury or death.

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

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use

TP-6079 3/00 27Section 7 Generator Disassembly/Reassembly

Page 38

Disassembly Procedure:

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

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

14. Tilt the generator set up and brace it with a block of wood. See Figure 7-3.

15. Remove the end bracket overbolts. Use a rubber mallet to separate the end bracket from the stator housing. See Figure 7-3.

3. Remove the controller cover.

4. Disconnect the P4 (22-pin) connector from J4.

5. Disconnect the controller ground strap (engine side).

Note: It is possible to connect the output leads in

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

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

7. Disconnect the P11 (FP and FN) and P10 (F1 and F2) connectors.

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

9. Remove the fuel pump and fuel inlet line from the generator. See Figure 7-1.

10. Remove the coverplate.

11. Push the brushes into the holder. Secure the brushes into position by sliding a retainer into the brush keeping holes. Refer to Section 5.5.

12. Remove the brush holder and carefully slide the leads out of the stator housing. See Figure 7-2.

16. Carefully remove the stator assembly from the generator adaptor plate.

17. Loosen the rotor bolt, finger tighten, and back off two turns.

18. Strike the bolt with a hammer until the rotor is freed from the engine tapered drive shaft. Do not damage the bolt threads or the bolt head. See Figure 7-4.

FV-277000

1. Controller

2. Fuel pump

Figure 7-1 Fuel Pump and Controller Removal

13. Remove the generator side vibromount nuts.

TP-6079 3/0028 Section 7 Generator Disassembly/Reassembly

Page 39

67 89

1. Generator adapter plate bolt, quantity 4

2. Generator adapter

3. Brush holder assembly

4. Brush holder shim

5. Rotor bolt

6. Hardened washer

7. Generator overbolt, quantity 4

8. Retainer wire

9. Brush assembly mounting screws, quantity 2

10. Bracket, brush holder

12 11

1516171819

11. Fan guard

12. Fan guard bolts, quantity 2

13. End bracket

14. Pipe plug

15. End drive fitting (for marine application only)

16. End bracket bearing

17. O-ring

18. Stator assembly

19. Rotor assembly

1314

201-191-1

Figure 7-2 Alternator Components

1. End bracket

2. Rubber mallet

3. Block of wood

Figure 7-3 Raising the Generator

FV-277000

1. Mallet

2. Rotor bolt

Figure 7-4 Rotor Removal

FV-277000

TP-6079 3/00 29Section 7 Generator Disassembly/Reassembly

Page 40

7.2 Collector Ring and Bearing Replacement

1. Unsolder the collector ring leads from the collector ring terminals.

2. Remove the collector rings with a 3-jaw puller.

Minimum diameter, mm (in.) 57.15 (2.250)

Maximum finish, microinches 32.00

Maximum eccentricity, mm (in.) 0.08 (0.003)

Maximum out-of-round, mm (in.) 0.01 (0.0002)

Figure 7-6 Collector Ring Dimensions

3. Remove the bearing with a 3-jaw puller.

4. Press the new bearing onto the rotor shaft.

5. Align the collector ring keyway with the keyway on the rotor shaft. See Figure 7-5.

6. Press the new collector rings onto the rotor shaft.

Note: The new collector rings must be turned

downtoafinishof32microinchesusinga lathe and commutator stones. Turn down the collector rings on the rotor shaft. See Figure 7-6.

7. Solder the leads onto the collector ring terminals. The connection is not to exceed 9.65 mm (0.38 in.) beyond the collector rings. See Figure 7-5.

8. Test to ensure continuity at the collector rings.

.38 maximum (as soldered)

7.3 Reassembly

1. Apply antiseize compound to the tapered shaft of the engine.

2. Align the rotor onto the engine shaft and secure the rotor with the rotor bolt. Torque the rotor bolt to

23.1 Nm (204 in. lb.).

3. Carefully slide the stator assembly over the rotor.

4. Install the end bracket and torque the overbolts to

13.6 Nm (120 in. lb.). See Figure 7-2.

5. Feed the brush leads inside the stator housing up through the opening. Secure the brush holder using the original screws.

6. Remove the brush retainer wire and check the brush alignment. See Section 5.5.

7. Install the coverplate and torque it to 6.8 Nm (60 in. lb.).

8. Install the fuel line and fuel pump.

9. Guide the leads from the stator through the bottom opening of the controller. Secure the controller.

90°

VIEW A-A

1. Collector ring leads

2. Keyways

Figure 7-5 Rotor Assembly

10. Reconnect the leads from the stator to the

controller using the reverse procedure of that listed in Section 7.1. Refer to Section 8, Reconnection and Wiring Diagrams.

11. Connect the generator set starting battery, the positive (+) lead first.

12. Test the generator operation.

598695

TP-6079 3/0030 Section 7 Generator Disassembly/Reassembly

Page 41

Section 8 Reconnection and Wiring Diagrams

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

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

Moving rotor.

TP-6079 3/00 31Section 8 Reconnection and Wiring Diagrams

Page 42

8.1 Reconnection Diagram 100--120 V, 60 & 50 Hz

8.3 Reconnection Diagram 220--240 V, 50 Hz

8.2 Reconnection Diagram 100--120/200--240 V, 60 & 50 Hz

ADV-5857

8.4 Remote Start Panel

+--

10--amp fuse

P1-14

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

P3-4

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

Violet

P2-4

P3-5 P3-6 P3-1

Yellow/ Red

Local switch

Start

Relay circuit board

Grey/ Black

Stop

Start

Stop

P2-5 P2-6

Remote switch

ADV-5857

P1-9

Black

Hourmeter

TP-5588-7

TP-6079 3/0032 Section 8 Reconnection and Wiring Diagrams

Page 43

TP-6079 3/00 33Section 8 Reconnection and Wiring Diagrams

8.5 Wiring Diagram 5ERKM/4EFRKM

GM11960-

Page 44

TP-6079 3/0034 Section 8 Reconnection and Wiring Diagrams

Notes

Page 45

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 audio/visual 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 cfh cubic feet per hour cfm cubic feet per minute

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

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

cogen. cogeneration COM communications (port) conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards

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

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

EIA Electronic Industries

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

EPS emergency power system ER emergency relay ES engineering special,

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

substrate (semiconductor)

Association

e. V. (also Deutsche Industrie Normenausschuss)

Association

Agency

engineered special

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. lbs. 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. ground gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross 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. lbs. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe ISO International Organization for

J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (2 kg kilogram

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

bytes)

TP-6079 3/00 Appendix A-1

Page 46

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kW 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

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

/min. cubic meters per minute

units), male

cubic meter

when used with SI

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

bytes) MCM one thousand circular mils 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, mW

MOhm, MW

milliohm

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 mF 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 O/C overcrank OD outside diameter OEM original equipment

manufacturer O/F overfrequency opt. option, optional O/S oversize, overspeed OSHA Occupational Safety and Health

Administration O/V overvoltage oz. ounce p., pp. page, pages PA packed accessory 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 qty. quantity R replacement (emergency)

power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote 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) U/F underfrequency UHF ultrahigh frequency UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal U/S undersize, underspeed UV ultraviolet U/V 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-6079 3/00A-2 Appendix

Page 47

Appendix B Common Hardware Application Guidelines

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

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

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

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

Preferred Nut/Bolt Clearance

Steps for common hardware application:

1. Determine entry hole type: round or slotted.

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

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

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

a. Always use a washer between hardware and a

slot.

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

for exception).

c. Use a washer under a bolt when the female

thread is fixed (weld nut).

Unacceptable Nut/Bolt Clearance

1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut

3. Below top of nut

Figure 1 Acceptable Bolt Lengths

G-585

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

1. Cap screw

2. Entry hole types

3. Standard nut and SAE washer

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

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

6. Exit hole types

G-585

TP-6079 3/00 Appendix A-3

Figure 2 Acceptable Hardware Combinations

Page 48

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-6079 3/00A-4 Appendix

Page 49

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-6079 3/00 Appendix A-5

Page 50

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 Spiralock

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

Washers

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

Bolt/

TP-6079 3/00A-6 Appendix

Page 51

Metric

Hex head bolts are hardness grade 8.8 unless noted.

Part No. Dimensions

Hex Head Bolts (partial thread)

M931-06040-60 M6-1.00 x 40 M931-06055-60 M6-1.00 x 55 M931-06060-60 M6-1.00 x 60 M931-06070-60 M6-1.00 x 70 M931-06075-60 M6-1.00 x 75 M931-06090-60 M6-1.00 x 90

M931-08035-60 M8-1.25 x 35 M931-08040-60 M8-1.25 x 40 M931-08040-82 M8-1.25 x 40* M931-08045-60 M8-1.25 x 45 M931-08050-60 M8-1.25 x 50 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

M931-10040-60 M10-1.50 x 40 M931-10045-60 M10-1.50 x 45 M931-10050-60 M10-1.50 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 M931-10090-60 M10-1.50 x 90 M931-10100-60 M10-1.50 x 100

M931-12045-60 M12-1.75 x 45 M931-12050-60 M12-1.75 x 50 M931-12055-60 M12-1.75 x 55 M931-12060-60 M12-1.75 x 60 M931-12065-60 M12-1.75 x 65 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

M931-16090-60 M16-2.00 x 90

M931-20065-60 M20-2.50 x 65 M931-20120-60 M20-2.50 x 120 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

Part No. Dimensions

Hex Head Bolts (full thread)

M933-04006-60 M4-0.70 x 6

M933-05050-60 M5-0.80 x 50

M933-06010-60 M6-1.00 x 10 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 M933-06040-60 M6-1.00 x 40 M933-06050-60 M6-1.00 x 50

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

M933-10012-60 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 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

M933-12016-60 M12-1.75 x 16 M933-12020-60 M12-1.75 x 20 M933-12025-60 M12-1.75 x 25 M933-12025-82 M12-1.75 x 25* M933-12030-60 M12-1.75 x 30 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

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

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

Pan Head Machine Screws

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

M7985A-04020-20 M4-0.70 x 20

M7985A-05010-20 M5-0.80 x 10 M7985A-05012-20 M5-0.80 x 12

Flat Head Machine Screws

M965A-05016-20 M5-0.80 x 16

Part No. Dimensions Type

Hex Nuts

M934-03-50 M3-0.50 Standard

M934-04-50 M4-0.70 Standard

M934-05-50 M5-0.80 Standard M982-05-80 M5-0.80 Elastic Stop

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

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

M6923-10-80 M10-1.50 Spiralock M982-10-80 M10-1.50 Elastic Stop

M6923-12-80 M12-1.75 Spiralock M982-12-80 M12-1.75 Elastic Stop

M982-14-80 M14-2.00 Elastic Stop

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

M982-18-80 M18-2.50 Elastic Stop

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

M934-22-80 M22-2.50 Standard M982-22-80 M22-2.50 Elastic Stop

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

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 bolt’s hardness is grade 10.9.

TP-6079 3/00 Appendix A-7

Page 52

Page 53

Page 54

TP-6079 3/00

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Web site www.kohlergenerators.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444

Kohlerr Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455

Kohler 5ERKM, 4EFRKM Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual