Kohler 5EOZ, 8EOZ, 10EOZ, 4EFOZ, 6.5EFOZ User Manual

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Page 1

Service

Marine Generator Sets

Models:

5EOZ 8EOZ 9EOZ

10EOZ

4EFOZ

6.5EFOZ 8EFOZ 9EFOZ

TP-6053 7/04a

Page 2

Page 3

Table of Contents

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

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

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

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

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

1.2 Service Views 2.............................

1.3 Engine 5...................................

1.4 Generator 6.................................

Section 2 Scheduled Maintenance 7...........

2.1 General 7..................................

2.2 Lubrication System 7.........................

2.3 Battery 8...................................

2.4 Generator Storage 9.........................

Section 3 Intake and Exhaust System 11........

3.1 Air Intake Silencer/Filter 11....................

3.2 Exhaust System 11...........................

3.3 Mixing Elbow 11..............................

Section 4 Fuel System 13.....................

4.1 General 13..................................

4.2 Fuel Specifications 13.........................

4.3 Fuel Filter 13.................................

4.4 Bleed the Fuel System 14......................

4.5 Fuel Solenoid 15.............................

4.6 Fuel Pump 16................................

4.7 Governor 17.................................

Section 5 Cooling System 19..................

5.1 General 19..................................

5.2 Water-Cooled Exhaust Manifold 20..............

5.3 Closed Heat Exchanger 20.....................

5.4 Fill Check and Coolant 20.....................

5.5 Flush and Clean Cooling System 20.............

5.6 Pressure Cap 21.............................

5.7 Impeller Inspection and Replacement 21.........

5.8 Belt Tension 22...............................

5.9 Siphon Break 23..............................

5.10 Anticorrosion Zinc Anode 24...................

Section 6 Controller Troubleshooting 25........

6.1 General 25..................................

6.2 Controller Sequence of Operation 25............

6.2.1 Start 25.............................

6.2.2 Run 25..............................

6.2.3 Stop 26..............................

6.3 Engine Safety Shutdown Switches 26...........

6.3.1 Low Oil Pressure (LOP) Shutdown 26...

6.3.2 High Water Temperature and High Exhaust Temperature

Shutdown Switch 26..................

6.4 Controller Circuit Board 27.....................

6.5 Troubleshooting 28...........................

Section 7 Generator Troubleshooting 33........

7.1 General 33..................................

7.2 General Troubleshooting 33....................

7.3 Separate Excitation 34........................

7.4 PowerBoost IIIE Voltage Regulators 34..........

7.4.1 Voltage Regulator Test 35..............

7.4.2 Voltage Regulator Adjustment 35.......

7.5 Exciter Field 36...............................

7.6 Exciter Armature 37...........................

7.7 Rectifier Module 38...........................

7.8 Rotor 38.....................................

7.9 Stator 39....................................

Section 8 Component Troubleshooting 41......

8.1 General 41..................................

8.2 Remote Panels (Optional) 43...................

Section 9 Generator Disassembly/

Reassembly 45...............................

9.1 Disassembly 45..............................

9.2 Reassembly 47...............................

Section 10 Voltage Reconnection and

Wiring Diagrams 51...........................

10.1 Voltage Reconnection 51......................

10.1.1 100--120-Volt Configurations 51.........

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

Configurations 52.....................

10.1.3 200--240-Volt Configurations 52.........

10.2 Marine Manual (Ship-to-Shore)

Transfer Switch 53............................

10.3 Wiring Diagram, Schematic 54.................

10.4 Wiring Diagram, Point-to-Point 55...............

10.5 Remote Start Panel 56........................

10.6 Remote Start and 2-Meter Panel 56.............

10.7 Remote Start and 4-Meter Panel 57.............

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-6053 7/04 Table of Contents

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Notes

TP-6053 7/04Table of Contents

Page 5

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.

This manual has severaltypesofsafety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe

personal injury,death,orsubstantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe

personal injury,death,or substantial property damage.

CAUTION

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

NOTICE

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

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

Accidental Starting

WARNING

Accidental starting. Can cause severe injury or death.

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

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

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

Battery

WARNING

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

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

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid

can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a containerwith4L(1gal.)ofwaterand mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

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

can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

TP-6053 7/04 ISafety Precautions and Instructions

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Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash Fire

WARNING

Fire. Can cause severe injury or death.

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

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

set with the air cleaner/silencer removed.

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

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

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

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

Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

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

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

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

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

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

Copper tubing exhaust systems. Carbon monoxide can cause severe nausea, fainting, or death. Do not

use copper tubing in diesel exhaust systems. Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in exhaust/water leakage.

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

safety of the craft’s occupants, install a carbon monoxide detector. Consult the boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.

Operating the generator set. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide

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

TP-6053 7/04II Safety Precautions and Instructions

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Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

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

Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an

explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.

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

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

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

explosive. Use extreme care when handling and storing fuels. Store fuels inawell-ventilatedareaawayfrom spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Donot operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation.

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

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

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

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

Hazardous Noise

CAUTION

Hazardous noise. Can cause hearing loss.

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

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

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

Hazardous Voltage

WARNING

Hazardous voltage. Can cause severe injury or death.

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

CAUTION

Welding the generator set. Can cause severe electrical equipment damage.

Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution

is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Moving rotor.

TP-6053 7/04 IIISafety Precautions and Instructions

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

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

Welding the generator set. Can cause severe electrical equipment damage. Before welding the generator

set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine batterycharging alternator connections. (5) Attach the weld ground connection close to the weld location.

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

cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

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

is present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator.

(PowerBoostt, PowerBoostt III, and PowerBoostt V voltage regulator models only)

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

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

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

trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically.

(600 volts and under)

Hot Parts

WARNING

Hot coolant and steam. Can cause severe injury or death.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

WARNING

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

Do not work on the generator set until it cools.

Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool.

Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank.

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

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

TP-6053 7/04IV Safety Precautions and Instructions

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Moving Parts

WARNING

Hazardous voltage. Can cause severe injury or death.

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

WARNING

Rotating parts. Can cause severe injury or death.

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

WARNING

Airborne particles. Can cause severe injury or blindness.

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

Moving rotor.

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

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

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death.

Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

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

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

(Sound-shield-equipped models only)

Notice

NOTICE

This generator set has been rewired from its nameplate voltage to

NOTICE

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

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

NOTICE

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

TP-6053 7/04 VSafety Precautions and Instructions

246242

Page 10

Notes

TP-6053 7/04VI Safety Precautions and Instructions

Page 11

Introduction

This manual provides troubleshooting and repair instructions for 5--10EOZ/EFOZ model generator sets, controllers, and accessories.

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

x:in:001:001

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

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

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

D Consult the Yellow Pages under the heading

Generators—Electric

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

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

x:in:001:003

Service Assistance

China

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

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

Fax: (86) 10 6518 7955

D Visit the Kohler Power Systems website at

KohlerPowerSystems.com

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents included with the product

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

D Outside the US and Canada, call the nearest regional

office

Headquarters Europe, Middle East, Africa (EMEA)

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

Asia Pacific

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

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

India, Bangladesh, Sri Lanka

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

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

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

Latin America

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

TP-6053 7/04 iIntroduction

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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-6053 7/04ii Introduction

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Section 1 Specifications

1.1 General

This manual covers the operation, maintenance, troubleshooting, and repair of the alternating current marine generator sets.

Have an authorized service dealer/distributor perform required servicing to assure your unit continues to meet USCG requirements.

Please take a few moments to read this manual, then carefully follow all service recommendations. See Figure 1-1 through Figure 1-3 for identification and location of components.

The 5EOZ/4EFOZ models are powered by a Yanmar three-cylinder, water-cooled, four-cycle diesel engine. The three-cylinder engine with heat exchanger is model 3TNE68.

The 8EOZ/6.5EFOZ models are powered by a Yanmar three-cylinder, water-cooled, four-cycle diesel engine. The three-cylinder engine with heat exchanger is model 3TNE74.

The 9EOZ/8EFOZ models are powered by a Yanmar three-cylinder, water-cooled, four-cycle diesel engine. The three-cylinder engine with heat exchanger is model 3TNE78A.

The 10EOZ/9EFOZ models are powered by a Yanmar three-cylinder, water-cooled, four-cycle diesel engine. The three-cylinder engine with heat exchanger is model 3TNE82A.

Kohler Co. develops all Kohlerr marine 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.

TP-6053 7/04 1Section 1 Specifications

Page 14

1.2 Service Views

23 567 9

4 8 11

181920212223

1. Start/stop switch

2. Hourmeter

3. Controller

4. Nameplate

5. DC circuit breaker

6. AC circuit breaker

7. Air cleaner

8. Fuel solenoid

9. Fuel injectors

10. Fuel return connection

11. High water temperature switch

12. Oil fill

13. V-belts

14. Seawater pump (water inlet)

15. Coolant (fresh water) drain

16. Heat exchanger

17. Coolant drain (fresh water)

DK-250000

18. Anticorrosion zinc anode

19. Fuel filter

20. Oil filter

21. Oil drain valve and hose

22. Fuel feed pump

23. Oil check

24. Fuel inlet connection

25. Low oil pressure safety shutdown switch

26. Wet exhaust manifold

27. Thermostat

28. AC load lead connector

29. Remote start connector

30. High exhaust temperature safety shutdown switch

31. Mixing elbow

32. Water temperature sender

33. Engine starter

34. Battery charging alternator

Figure 1-1 Generator Set Service View (5EOZ/4EFOZ)

TP-6053 7/042 Section 1 Specifications

Page 15

24567 8 9

103

1617181920212223

25 28

1. Start/stop switch

2. Controller

3. Nameplate

4. Hourmeter

5. DC circuit breaker

6. AC circuit breaker

7. Air cleaner

8. Coolant recovery bottle

9. Pressure cap

10. Fuel return connection

11. High water temperature shutdown switch

12. Oil fill

13. Seawater pump (water inlet)

14. V-belts

15. Heat exchanger

16. Coolant drain (fresh water)

17. Anticorrosion zinc anode

18. Fuel filter

19. Oil filter

20. Oil drain valve and hose

21. Fuel feed pump

22. Oil check

23. Fuel inlet connection

24. Low oil pressure safety shutdown switch

25. Wet exhaust manifold

26. Thermostat

27. AC load lead connector

28. Remote start connector

29. High exhaust temperature safety shutdown switch

30. Mixing elbow

31. Engine starter

32. Water temperature sender

33. Battery charging alternator

A-358000A-A

Figure 1-2 Generator Set Service View (8EOZ/6.5EFOZ)

TP-6053 7/04 3Section 1 Specifications

Page 16

4567 9 1011

151617181920

1. Start/stop switch

2. Controller

3. Nameplate

4. Hourmeter

5. DC circuit breaker

6. AC circuit breaker

7. Air cleaner

8. Coolant overflow bottle

9. Low oil pressure safety shutdown switch

10. Pressure cap

11. Oil fill

12. High water temperature safety shutdown switch

13. V-belts

14. Seawater pump (water inlet)

15. Fuel filter

16. Oil drain valve and hose

17. Oil filter

A-358000A-A

303132

18. Fuel feed pump

19. Fuel inlet connection

20. Oil check

21. Coolant drain (fresh water)

22. Fuel return

23. Wet exhaust manifold

24. Thermostat

25. AC load lead connector

26. Remote start connector

27. High exhaust temperature safety shutdown switch

28. Mixing elbow

29. Anticorrosion zinc anode

30. Engine starter

31. Heat exchanger

32. Coolant drain (fresh water)

33. Water temperature sender

34. Battery charging alternator

Figure 1-3 Generator Set Service View (9/10EOZ and 8/9EFOZ)

TP-6053 7/044 Section 1 Specifications

Page 17

1.3 Engine

Generator Model 5EOZ/4EFOZ 8EOZ/6.5EFOZ 9EOZ/8EFOZ 10EOZ/9EFOZ

Engine manufacturer Yanmar Engine model 3TNE68 3TNE74 3TNE78A 3TNE82A Number of cylinders 3 Cylinder block material Cast iron Cylinder head material Cast iron Piston rings 2 compression/1 oil Crankshaft material Stamped forging Connecting rod material Forged carbon steel Governor Centrifugal, mechanical Bore x stroke, mm (in.) 68 x 72 (2.67 x 2.83) 74 x 78 (2.91 x 3.07) 78 x 84 (3.07 x 3.30) 82 x 84 (3.22 x 3.30) Displacement, L (CID) 0.784 (47.83) 1.006 (61.39) 1.204 (73.45 ) 1.330 (81.14) Compression ratio 23.0:1 18.0:1 Horsepower, 60/50 Hz 10.1/8.4 14/11.6 17.7/14.8 RPM, 60/50 Hz 1800/1500 Direction of rotation

(as viewed from generator end) Lubrication system Pressure, trochoid pump Lube oil capacity w/filter, L (qts.) 3 (3.2) 2.4 (2.3) 5.2 (5.5) 3.4 (3.6) Oil recommendation, API CD, CD/CC, or CC Engine firing order

(#1 cylinder nearest to flywheel) Fuel injection timing (BTDC) 14°±1° 16° ±1° 10° ±1° Fuel injection pressure,

kg/cm sq. (psi)

Combustion system

Battery voltage 12 volt, negative ground Battery recommendation, min. 500 CCA, 100 amp hr. Battery charging (alternator) 40 amps @ 12 volts 50 amps @ 12 volts Fuel recommendation Diesel, ISO 8217 DMA, BS 2869 Part 1 Class A1 or Part 2 Class A2 Fuel shutoff solenoid system Electric Fuel feed pump Electric, rotary vane Fuel pump priming Electric Max. recommended fuel pump

lift, m (ft.) Coolant capacity, L (qts.) 1.8 (1.9) 3.9 (4.12) 5.2 (5.5) Coolant recovery tank capacity,

L(oz.) Recommended coolant 50% ethylene glycol; 50% clean, softened water Thermostat 71°C (160°F) Pressure cap rating, kPa (psi) 96.5 (14.0)

Starter motor 0.8 kW Bendix automotive type

Indirect injection,

swirl precombustion chamber

120 (1706) 200 (2844)

Counterclockwise

1-3-2

Direct injection

1.2 (4)

0.24 (8.0)

1.8 kW Bendix,

gear-reduction automotive type

TP-6053 7/04 5Section 1 Specifications

Page 18

Engine (continued)

Generator Model 5EOZ/4EFOZ 8EOZ/6.5EFOZ 9EOZ/8EFOZ 10EOZ/9EFOZ

Intake/exhaust valve clearance (cold), mm (in.)

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

Flex plate to rotor bolt torque (3/8-16), Nm (ft. lbs.)

Flex plate to flywheel bolt torque (M8-1.25), Nm (ft. lbs.)

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

Inlet water line hose ID (seawater pump inlet), mm (in.)

Outlet water line hose ID (mixing elbow outlet), mm (in.)

Fuel inlet (fuel pump inlet) 1/4 NPT

Fuel return size type 1/4 NPT

45 (35) 36.6 (27) 45 (35) 38 (28)

25 (20) 38 (28) 25 (20) 19 (14)

45 (35) 34 (25) 45 (35) 34 (25)

0.15--0.25 (0.006--0.010)

10--15 (0.4--0.6)

16 (5/8)

51 (2)

1.4 Generator

Generator Model 5/8EOZ and 4/6.5EFOZ 9/10EOZ and 8/9EFOZ

Hot exciter field voltage/current readings at rated voltage*

No load (63 Hz) (volts/amps) 19/0.9 12/0.8

Full load (60 Hz) (volts/amps) 32/1.5 33/2.2

Resistor (F1 lead to exciter field) (ohms) 15 ±2 10 ±2

Cold exciter field resistance (ohms) 4.8

Cold exciter armature resistance (ohms) 1.2

Cold main field (rotor) resistance (ohms) 5.0 5.7

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

1--2, 3--4, 33--44 (volts) 81 11 5

33--55 (volts) 105 155

B1-B2 (volts) 10 15

Cold stator resistance

1--2, 3--4, 33--44 (ohms) 0.3 0.2

33--55 (ohms) 2.1 1.9

B1-B2 (ohms) 0.1

* Includes resistor in exciter field circuit.

TP-6053 7/046 Section 1 Specifications

Page 19

Section 2 Scheduled Maintenance

2.1 General

WARNING

Accidental starting. Can cause severe injury or death.

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

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

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

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

(Sound-shield-equipped models only)

NOTICE

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

Note: See the generator set operation manual for the

service schedule and other service not included in this manual.

2.2 Lubrication System

The following paragraphs describe the engine lubrication system.

Use oil that meets the American Petroleum Institute (API) classification of CD, CC/CD, or CC. Using unsuitable oil or neglecting an oil change may result in damage and a shorter engine life. Figure 2-1 shows the recommended Society of Automotive Engineers (SAE) viscosity designation for given operating temperature ranges.

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: Failure to observe these standards may cause

inadequate lubrication/oil pressure and coldstarting difficulties.

SAE Service Grade

°C°F--30 --20 --10 0 10 20 30 40

5W20

20W40

10W30

20W20

20W30

20W40

0204060 80 100°C°F

Operating Temperature

TP-5856-1

Figure 2-1 Engine Oil Selection

TP-6053 7/04 7Section 2 Scheduled Maintenance

Page 20

Electric Oil-Drain/Oil-Fill Procedure

1. Connect the pump to the end of the oil-drain hose.

2. Place the pump outlet hose into a container. Remove the oil-fill cap(s). One is located near the top of the engine on the valve cover and one is located near the governor.

3. Activate the pump until all of the oil is removed. Allow ample time for all of the oil to drain.

4. Turn the valve at the base of the oil-drain hose to the closed position.

5. Replace the engine oil filter.

6. Fill the engine crankcase to the specified level with oil. The figures in Section 1 show typical oil fill locations. See Figure 2-1 for oil selection and Figure 2-2 for oil capacities.

7. Start the generator set and check for oil leaks.

8. Stop the generator set. Check the oil level. Add oil, as necessary, to bring the level up to the Max mark on the dipstick.

Model L (Qts.)

5EOZ and 4EFOZ 3.0 (3.2)

8EOZ and 6.5EFOZ 2.3 (2.4)

9EOZ and 8EFOZ 5.2 (5.5)

10EOZ and 9EFOZ 5.2 (5.5)

Figure 2-2 Oil Capacities

2.3 Battery

Consult the battery manufacturer’s instructions regarding battery care and maintenance.

WARNING

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

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

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause

blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke

or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

TP-6053 7/048 Section 2 Scheduled Maintenance

Page 21

2.4 Generator Storage

7. Stop the generator set.

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

Storage Procedure

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

2. Stop the generator set.

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

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

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

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

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

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

Note: Use antifreeze with the lowest available

temperature rating.

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

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

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

TP-6053 7/04 9Section 2 Scheduled Maintenance

Page 22

Notes

TP-6053 7/0410 Section 2 Scheduled Maintenance

Page 23

Section 3 Intake and Exhaust System

3.1 Air Intake Silencer/Filter

A dry-type air cleaner silences and filters the intake air. The air intake silencer assembly connects to the intake manifold via a flexible hose.

At the interval specified in the service schedule, clean or replace the air intake silencer. Clean or replace the air cleaner more frequently in dirty, dusty conditions. Follow the procedure described below.

Air Cleaner Service/Replacement Procedure

1. Release the four spring clips to open the housing and remove the air silencer element.

2. Tap the element lightly against a flat surface to dislodge loose surface dirt. Do not clean the element in any liquid or use compressed air as these will damage the filter element.

3. Examine the element and its housing for damage and wear. Replace the element or its housing, if necessary.

4. Wipe the cover and base with a clean rag to remove any dirt. Make sure the sealing surfaces fit correctly and reattach the spring clips.

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

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

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

Replace the hoses as needed.

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps.

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

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks. Check for carbon

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

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

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

3.2 Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

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

the craft’s occupants, install a carbon monoxide detector. Consult the boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.

3.3 Mixing Elbow

Check the mixing elbow for carbon buildup and corrosion inside the pipe. Clean the residual carbon buildup with a wire brush. Inspect the exhaust manifold flange for cracking and corrosion. The mixing elbow combines high temperature exhaust and cooling seawater. The mixture, when exposed to engine vibration, makes conditions conducive to rapid deterioration and failure if not correctly maintained. If any damage is detected with the mixing elbow or other exhaust components, replace the damaged components to prevent engine exhaust (carbon monoxide) leakage.

TP-6053 7/04 11Section 3 Intake and Exhaust System

Page 24

Notes

TP-6053 7/0412 Section 3 Intake and Exhaust System

Page 25

Section 4 Fuel System

4.1 General

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

To fuel pump

Propulsion Engine

1. Fuel tank

2. Dual dip tubes

3. Fuel filter

4. Fuel feed pump

Figure 4-1 Fuel System Schematic Typical

Generator Set

4.3 Fuel Filter

The quality and condition of the fuel largely determine the filter’s useful life. Replace the fuel filter element according to the service schedule. Section 1.2 shows the location of the fuel filter. There are two types of fuel filtering systems, the spin-on fuel filter and the fuel filter element. Use the applicable procedure below to replace the fuel filter. See Figure 4-2 or Figure 4-3.

Spin-On Fuel Filter Replacement Procedure

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

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

3. Close the fuel supply valve.

4. Remove the fuel filter. See Figure 4-2.

5. Clean the contact surface of the fuel filter adapter.

6. Lightly lubricate the gasket surface of the new fuel filter with fresh fuel. Thread the filter onto the adapter until the gasket makes contact; hand-tighten the filter an additional one-half turn.

7. Open the fuel supply valve.

4.2 Fuel Specifications

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

Fuel Recommendation

United States

United Kingdom BS 2869-1983, Part 2 Class A2

Germany DIN 51 601-1978

ISO 8217 DMA, BS 2869 Part 1 Class A1 or Part 2 Class A2

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

9. Bleed the fuel system. See Section 4.4.

1. Fuel filter adapter

2. Fuel filter

3. Removal (counterclockwise)

4. Installation (clockwise)

TP-606111

Figure 4-2 Spin-On Fuel Oil Filter

TP-6053 7/04 13Section 4 Fuel System

Page 26

Fuel Filter Element Replacement Procedure

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

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

3. Close the fuel supply valve.

4.4 Bleed the Fuel System

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

1. The generator set operates until the fuel supply is emptied.

4. Remove the retaining ring, filter cup, o-ring, fuel filter element and spring.

5. Replace the fuel filter element and install as shown in Figure 4-3.

6. Open the fuel supply valve.

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

8. Bleed the fuel system. See Section 4.4.

2. The air leaks in the suction side of the fuel system.

3. Replacing the fuel filter.

4. Vapor lock.

Note: Connect the battery during the priming procedure

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

Fuel System Bleeding Procedure

1. Loosen the fuel filter screw at position 1. See Figure 4-4.

2. Toggle the start/stop switch until fuel, free of air bubbles, flows from the vent screw at position 1. Tighten the screw.

3. Loosen the fuel filter screw at position 2.

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

1. Fuel strainer assembly

2. Body

3. Fuel element

4. Spring

5. O-ring

6. Filter cup

7. Retaining ring

Figure 4-3 Fuel Oil Filter Element

5. Loosen the fuel injection pump screw at position 5.

6. Toggle the start/stop switch until fuel, free of air bubbles, flows from the vent screw at position 5. Tighten the screw.

TP-561633

TP-6053 7/0414 Section 4 Fuel System

Page 27

5/8EOZ and 4/6.5EFOZ Models

4.5 Fuel Solenoid

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

9/10EOZ and 8/9EFOZ Models

1. Vent screw, position 1

2. Vent screw, position 2

3. Fuel return

4. Fuel filter

5. Fuel injection pump

6. Vent screw, position 5

The generators in this manual use a 3-lead fuel solenoid. This solenoid has a white lead (P) which energizes the pull-in coil only during cranking. During operation, the red lead energizes the hold coil and the black lead is the common ground.

Current (amps) and resistance readings are shown in Figure 4-5. Resistance readings determine if the solenoid windings are open or shorted. These readings must be taken with fuel solenoid disconnected from engine wiring harness.

TP-5586-3

Figure 4-5 Fuel Solenoid Readings

Fuel Solenoid Reading

Pull-In

Hold

Black-White (P) Leads

Black-Red Leads

0.12--0.26 Ohms 11-13 Ohms

50 Amps

1.0 Amps

Figure 4-4 Fuel System Bleed Points, Typical

TP-6053 7/04 15Section 4 Fuel System

Page 28

In addition to the ohmmeter test, check for smooth, non-binding movement of the plunger. It is important that the linkage between the fuel solenoid and the fuel injection pump lever be properly adjusted to allow the solenoid plunger to fully compress. Improper adjustment may cause burnout of the pull-in coil. If the fuel solenoid setting is suspected to be incorrect, use the following procedure to correct and see Figure 4-6.

Fuel Solenoid Adjustment Procedure

1. Remove the fuel solenoid linkage.

2. With the fuel solenoid’s plunger fully compressed, align the linkage and check injection pump lever for travel. The fuel solenoid should fully compress and the injection pump lever should be 1.6 mm (0.05 in.) before the lever reaches the stop (internal full open) position.

Note: The fuel solenoid must compress (bottom)

fully or burnout of the fuel solenoid pull-in coil will occur.

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

4.6 Fuel Pump

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

Fuel Pump Test Procedure

1. Remove the two leads from the terminals at the bottom of the fuel pump. The pump terminals are labeled (--) and (+). See Figure 4-7.

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

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

Stop

1. Fuel solenoid

2. Locknuts

3. Ball joints

Run

Adjust 1/16 inch for max.

Stop Lever

Figure 4-6 Fuel Solenoid Linkage

1. Fuel inlet

2. Negative terminal

3. Positive terminal

4. Fuel outlet

I-940

Figure 4-7 Fuel Pump

TP-6053 7/0416 Section 4 Fuel System

Page 29

4.7 Governor

The centrifugal, mechanical governor keeps the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. No regular service is required on the governor. The factory adjusts the governor during run-in, and further adjustment should not be needed unless poor governor control develops after extended generator usage.

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

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

Check the engine speed using a frequency meter connected to the load leads. Loosen the locking nut on the speed adjusting screw. Turn the screw clockwise to increase the speed and frequency. Turn the screw counterclockwise to decrease the speed. Tighten the locknut at the new setting. See Figure 4-8 or Figure 4-9.

1. Locknut

2. Speed adjusting screw

ED-250000A-N

Figure 4-9 Governor, 8/9/10EOZ and 6.5/8/9EFOZ

1. Locknut

2. Speed adjusting screw

Figure 4-8 Governor, 5EOZ/4EFOZ

DK-250000B-D

TP-6053 7/04 17Section 4 Fuel System

Page 30

Notes

TP-6053 7/0418 Section 4 Fuel System

Page 31

5.1 General

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

WARNING

Hot coolant and steam. Can cause severe injury or death.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

Section 5 Cooling System

Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool. Release pressure

from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank.

NOTICE

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

1. Engine block

2. Exhaust manifold

3. Exhaust mixer elbow

4. Outlet flapper

5. Silencer

6. Thermostat

Seawater

Coolant/Antifreeze

60531099

7. Heat exchanger

8. Engine seawater pump

9. Seawater strainer

10. Seacock

11. Intake strainer

12. Engine-driven water pump

Figure 5-1 Cooling System Components

TP-6053 7/04 19Section 5 Cooling System

Page 32

5.2 Water-Cooled Exhaust Manifold

Each generator set is equipped with a water-cooled exhaust manifold. Engine coolant circulates through the manifold, reducing the amount of heat radiated from the exhaust into the surrounding area. The engine thermostat is located in the manifold. See Section 1 for the thermostat location. See Figure 5-2 and Figure 5-3 for exhaust manifold bolt tightening sequence and torques.

5EOZ/4EFOZ 8EOZ/6.5EFOZ

glycol and 50% clean, softened water to inhibit rust and corrosion and to prevent freezing. Add additional coolant mixture, as necessary to the coolant recovery tank. Periodically check the coolant level on closed systems by removing the pressure cap. Do not rely solely on the level in the coolant recovery tank. Add fresh coolant mixture until the level is just below the overflow tube opening.

Do not add coolant to a hot engine. Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until the engine has cooled.

Note: Coolant solution. A coolant solution of 50%

ethylene glycol provides freezing protection to

-- 3 7 _C(--34_F) and overheating protection to 129°C (265°F). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can cause engine or component damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant. Consult the engine manufacturer’s operation manual for engine coolant specifications.

9/10EOZ and 8/9EFOZ

5847316

Figure 5-2 Water-Cooled Exhaust Manifold Bolt

Tightening Sequence

Model Bolt Torque

5EOZ/4EFOZ 8Nm(6ft.lbs.)

8/9/10EOZ and 6.5/8/9EFOZ 19 Nm (14 ft. lbs.)

Figure 5-3 Exhaust Manifold Bolt Tightening Torques

5.3 Closed Heat Exchanger

In a closed cooling system, the seawater circulates through separate chambers within the heat exchanger to cool the engine water. The seawater then mixes with engine exhaust and ejects out the exhaust outlet. See Section 1.3 for the coolant capacities. Add an additional

0.24 L (8.0 oz.) of coolant to the coolant recovery tank.

5.4 Fill Check and Coolant

Keep the coolant recovery tank approximately 1/4 full. Before filling the cooling system, close all petcocks and tighten all hose clamps. Use a solution of 50% ethylene

5.5 Flush and Clean Cooling System

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

Pay special attention to the coolant level. Check the coolant level as described earlier.

Flush and Clean Procedure

1. Remove the pipe plug located in the heat exchanger.

2. Open the petcocks on the engine block and cooling system and let the system drain completely. Some models may have petcocks located behind the belt guard.

3. Remove the pressure cap to simplify draining.

4. Drain, clean, and flush the cooling system, including the coolant recovery tank, with clean water.

5. Close the petcocks.

6. Fill the cooling system with recommended coolant.

TP-6053 7/0420 Section 5 Cooling System

Page 33

5.6 Pressure Cap

9. Open the seacock.

Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant, enabling higher operating temperatures. If the cap leaks, replace it with a cap having the same temperature rating.

5.7 Impeller Inspection and Replacement

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

Inspection and Replacement Procedure

1. Close the seacock.

2. Remove the seawater pump coverplate. See Figure 5-4.

3. Remove the impeller.

4. Inspect the impeller for damage, including visible cracked, broken, worn or missing fins. The impeller vanes should be straight and flexible. See Figure 5-5.

10. Start the generator set and check for leaks.

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

1. Seawater pump

2. Coverplate

3. Gasket

4. Impeller

5. Bearing

TP-5936-28

6. Housing

7. Pulley

8. Drive shaft

9. Washer

10. Nut

Figure 5-4 Seawater Pump, Typical

5. Lubricate the impeller with soapy water before re-installation.

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

7. Inspect the coverplate and gasket for corrosion and/or damage. Replace damaged or worn components.

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

TP-5936-57

1. Flat spot

2. Crack

3. Broken vane

Figure 5-5 Worn Impeller

TP-6053 7/04 21Section 5 Cooling System

Page 34

5.8 Belt Tension

7. Tighten the adjusting arm pivot screw and alternator pivot screw.

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.

Check the belt tensions at the interval specified in the service schedule. If the tensions are not within specifications, adjust as necessary using the following procedure.

Belt Tensioning Procedure

1. Stop the generator set.

8. Recheck and adjust the belt tension as necessary.

9. Replace the belt guard.

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

Belt Type Deflection mm (in.) Force (kgf) N

New (7--9) 0.3--0.4 (10) 98

Used (10--15) 0.4--0.6 (10) 98

Figure 5-6 Belt Specifications

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

3. Remove the belt guard.

4. Check the belt tension at the midpoint of the longest span of the belt by pressing the belt with your finger and measuring the resulting deflection. See Figure 5-6 and Figure 5-7. If the belt is not within specifications, go to step 5. If the belt is within specifications, go to step 9.

5. Loosen the adjusting arm pivot screw, alternator pivot screw, and alternator adjusting screw.

6. While prying the alternator outward, tighten the alternator screw.

1. Adjusting arm pivot screw

2. Battery charging alternator pulley

3. Adjusting screw

4. Alternator pivot screw

5. Check alternator belt tension here

6. Crankshaft pulley

7. Check seawater pump belt tension here

8. Adjusting screw

9. Seawater pump pulley

10. Pivot screw

Figure 5-7 Belt Tension, Typical

TP-5586-3

TP-6053 7/0422 Section 5 Cooling System

Page 35

5.9 Siphon Break

3. Use a light detergent to clean the reed valve.

A siphon break prevents seawater entry into the engine when the engine exhaust manifold outlet is less than 23 cm (9 in.) above waterline. Check the siphon break at the interval listed in the service schedule. Use the following procedure and Figure 5-8 to ensure correct functioning of the siphon break.

Siphon Break Inspection Procedure

1. Stop the generator set.

2. Remove the retaining cap and the reed valve for inspection. See Figure 5-8.

4. Check that the reed valve opening is clear.

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

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

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

Note: Consult the installation manual for a complete

explanation of the dimensions and other installation considerations.

Waterline

1. Mounting holes

2. Retaining cap

3. Reed valve assembly

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

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

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

7. Siphon break

8. Exhaust mixer elbow

9. Heat exchanger (locations vary by model)

10. Coolant recovery tank (locations vary by model)

11. Seawater strainer

12. Seacock

13. Intake strainer

14. Engine-driven seawater pump

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

16. Water lock (optional)

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

18. Silencer (customer-supplied)

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

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

21. Seawater outlet

TP-5586-3

Figure 5-8 Siphon Break, Plastic “U” Type

TP-6053 7/04 23Section 5 Cooling System

Page 36

5.10 Anticorrosion Zinc Anode

The heat exchanger contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion of generator components by seawater.

Check and replace the zinc anode at intervals recommended by the operation manual’s service schedule.

5EOZ/4EFOZ

Anticorrosion Zinc Anode Replacement Procedure

1. With the generator set cooled, close the seacock, remove the zinc plug from the heat exchanger, and drain the coolant into a container.

2. Remove the corrosion on the zinc anode. Replace the anode when the percent of the zinc remaining is less than 50% of the length and diameter shown in Figure 5-10.

3. Clean the threaded opening of the heat exchanger and coat the threads of the zinc anode with pipe sealant.

4. Install the zinc anode into the heat exchanger.

5. Open the seacock.

6. Refill the cooling system.

7. Start the generator set and check for leaks at the zinc anode’s location. The pump is operating if cooling water flows from the exhaust outlet. If water is not discharging at the exhaust outlet stop the generator set. For seawater pump priming see the Prestart Checklist in the operation manual.

8EOZ/6.5EFOZ

9/10EOZ and 8/9EFOZ

1. Anticorrosion zinc anode (seawater drain)

2. Heat exchanger

3. Coolant drain

GA-250000C-G

TP-5586-3

1. Diameter: 9 mm (0.34 in.)

2. Length: 43 mm (1.7 in.)

Figure 5-10 Anticorrosion Zinc Anode (Plug)

Figure 5-9 Anticorrosion Zinc Anode

TP-6053 7/0424 Section 5 Cooling System

Page 37

Section 6 Controller Troubleshooting

6.1 General

The following section covers the controller troubleshooting procedure for generator sets equipped with the relay controller and related engine components. Refer to Figure 6-1 to identify the controller components.

shutdown modes. Use this as a starting point for controller fault identification. Use the LEDs on the controller circuit board to assist in the troubleshooting process. An illuminated LED indicates that the respective relay is receiving power; the LED does not indicate whether that relay is energized. Additional relay test procedures are covered later in this section. Refer to the wiring diagrams in Section 10, Voltage Reconnection and Wiring Diagrams, to assist in the troubleshooting procedure.

6.2.1 Start

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

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

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

1. Voltage regulator

2. DC circuit breaker

3. K25 relay

4. Hourmeter

A-229301-N

5. K20 relay

6. START/STOP switch

7. Controller circuit board

Figure 6-1 Controller Internal Components

6.2 Controller Sequence of Operation

The following text covers the controller’s sequence of operation during generator start, run, stop, and fault

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

6.2.2 Run

The B1 and B2 windings of the stator supply AC voltage to the bridged rectifier (BR1), the K1 relay energizes (LED1 lights). After a 5--10 second time delay, the K5 relay energizes (LED5 lights).

Note: Voltage to the K1 and K5 relays is rectified and

regulated at 12 volts DC by the bridge rectifier (BR1) and the voltage regulator (VR1).

Stator winding 33--34 provides a voltage sensing source to the voltage regulator (PBIIIE).

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

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

TP-6053 7/04 25Section 6 Controller Troubleshooting

Page 38

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

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

6.3 Engine Safety Shutdown Switches

6.3.1 Low Oil Pressure (LOP) Shutdown

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

Note: The low oil pressure (LOP) switch contacts open

when the engine develops oil pressure.

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

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

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

6.2.3 Stop

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

Note: During cranking the low oil pressure shutdown

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

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

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

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

6.3.2 High Water Temperature (HWT)

and High Exhaust Temperature (HET) Shutdown Switch

The K4 relay energizes (LED4 lights).

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

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

As the generator set shuts down, the K1 relay deenergizes (LED 1 goes out). The normally open K1 contacts open to deenergize the K2 relay (LED 2 goes out). The normally closed K2 contacts close to ground the circuit to the K4 relay until the generator set comes to a complete stop.

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

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

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

TP-6053 7/0426 Section 6 Controller Troubleshooting

Page 39

Component Ohmmeter Connections Procedure Results

K1 Relay Coil K1 coil terminals

(see relay schematic)

K2 Relay Coil K2 coil terminals

(see relay schematic)

K3 Relay Coil K3 coil terminals

(see relay schematic)

K4 Relay Coil K4 coil terminals

(see relay schematic)

K5 Relay Coil K5 coil terminals

(see relay schematic)

OhmmeteronRx10 scale

If functional, approximately 270 ohms. Low resistance (continuity), shorted coil. High resistance, open coil.

If functional, approximately 400 ohms. Low resistance (continuity), shorted coil. High resistance, open coil.

If functional, approximately 125 ohms. Low resistance (continuity), shorted coil. High resistance, open coil.

If functional, approximately 510 ohms. Low resistance (continuity), shorted coil. High resistance, open coil.

Figure 6-2 Relay Testing

6.4 Controller Circuit Board

Some controller circuit board components can be tested without removing the component from the circuit board. Perform these checks prior to installing a new circuit board and attempting startup. Use a high-quality multimeter and follow the manufacturer’s instructions. To obtain accurate readings when testing, remove all the circuit board connectors and conformal coating (transparent insulation) from component terminals. Use the chart in Figure 6-2 and the controller circuit board illustration in Figure 6-3.

The controller circuit board has light-emitting diodes (LEDs) which indicate relay coil power and aid in the circuit board and the generator fault detection. When the K1, K2, K3, K4, or K5 relays receive power the corresponding LED lights. The LED does not indicate whether the relay coil is energized. Determine if the relay coil is energized by analyzing the generator faults when performing a continuity test on the relay coil.

910

1. Engine crank control relay (K3)

2. P1 connector

3. P2 connector

4. Time delay relay (K5)

5. LED5

6. LED2

7. Engine run relay (K2)

8. AC crank disconnect relay (K1)

9. LED1

10. Fault shutdown relay (K4)

11. Relay schematic

12. LED4

13. LED3

Figure 6-3 Controller Circuit Board

H-239563

TP-6053 7/04 27Section 6 Controller Troubleshooting

Page 40

6.5 Troubleshooting

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

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

Press the start switch (local or remote).

Is the 10-amp controller circuit breaker okay?

YesNo

Does the engine crank?

Is the K2 relay LED lit?

Is the K2 relay functioning correctly?

Yes

YesNo

Is the K3 relay LED lit?

Is voltage present at the K20 relay coil?

Is the K3 relay functioning correctly?

Go to A (next page).

Yes

Reset the circuit breaker.

S Check the condition/

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

S Check the battery

condition and connections.

S Check the connections

at P1--14.

S Do all check okay?

Yes

Replace the circuit board (D9 open).

Replace the circuit board.

The K3 relay or K1relayisfaulty. Replace the circuit board.

Replace the K20 relay.

Is the K20 relay functioning correctly?

Replace the circuit board.

Is voltage present at the S relay coil?

YesNo

Check P4--22 Connection.

Replace the S relay.

Yes

Check the P1--4 connection.

Yes

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

Yes

Replace the starter motor.

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

TP-6053 7/0428 Section 6 Controller Troubleshooting

Page 41

Does the engine start?

Yes

Go to B (next page).

Is 12 volts DC

present at the fuel solenoid?

Yes

(check wiring)?

Isthe10-ampfuseokay?

Yes

Is the K25 relay functioning correctly?

Yes

Replace the K25 relay.

S Check the P1--8 connection. S Check the P4--14 connection. S Replace the circuit board

(the K2 relay is inoperative).

Replace the fuse.

Do the local and remote start/stop switches function correctly?

Replace the inoperative start/stop switch.

Is the K4 relay LED lit?Yes No

Engine fault: check the fuel

Yes

supply, fuel feed pump, fuel injection pump, etc.

Replace the circuit board (inoperative K4 relay).

Figure 6-5 Troubleshooting Relay Controller Circuit Board (2 of 4)

TP-6053 7/04 29Section 6 Controller Troubleshooting

Page 42

Does the engine continue to run after the start

Yes

switch is released?

Can the engine be stopped by using the stop switch?

Yes

Does the K1 relay LED light?

Yes

Go to C (next page).

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

Did the K4 relay LED light?

Yes

Did the K4 relay LED light?

Do the local and remote start/ stop switches function correctly?

Replace the circuit board (the K5 relay is inoperative).

Replace the circuit board (the K4 relay is inoperative).

Yes

Generator set checks out okay.

Yes

Is the fuel solenoid functioning correctly?

Yes

Replace the inoperative start/stop switch.

Is the K25 relay functioning correctly?

Replace the fuel solenoid.

Do the local and

Yes

remote start/stop switches function

correctly?

Yes

Replace the circuit board (inoperative K1 or K2 relay).

Replace the inoperative start/stop switch.

Does the low oil pressure (LOP) safety shutdown switch check out okay?

Replace the LOP safety shutdown switch.

Yes

Do the temperature

Yes

Does the engine have proper oil

safety shutdown switches check out okay?

pressure? Use a mechanical gauge to verify pressure.

Check the oil level. Repair/ replace oil pump.

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

Yes

Replace the circuit board (inoperative K4 relay).

Yes

Replace the inoperative temperature switch(es).

Replace the K25 relay.

Replace the circuit board (inoperative K4 relay).

TP-6053 7/0430 Section 6 Controller Troubleshooting

Page 43

Is there AC output when the start button

is HELD and the unit

Yes

is running?

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

Is the voltage regulator fuse okay?

Is there 12VDC at the exciter field?

Replace the controller circuit board.

Go to B at the beginning of the preceding page.

(OPTIONAL)

Yes

Test the stator, and the main field.

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

Yes

Replace the controller circuit board.

Yes

Replace the fuse.

Tes t the voltage regulator.

Test the stator, main field (rotor) and exciter/armature.

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

Is AC output voltage at spec.? (See Section 7.3, Separate Excitation).

Test the stator, main field (rotor), and exciter/armature.

Yes

Tes t the voltage regulator.

Figure 6-7 Troubleshooting Relay Controller Circuit Board (4 of 4)

TP-6053 7/04 31Section 6 Controller Troubleshooting

Page 44

Notes

TP-6053 7/0432 Section 6 Controller Troubleshooting

Page 45

Section 7 Generator Troubleshooting

7.1 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. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator.

(PowerBoostt, PowerBoostt III, and PowerBoostt V voltage regulator models only)

Moving rotor.

7.2 General Troubleshooting

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

General Troubleshooting Procedure

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

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

Generator has no

output

Separately

excite generator

Generator has

output

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.

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

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

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

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

Generator has

no output

Test the exciter circuit

and rectifier module

Test rotor

Test voltage

regulator and wiring

Test stator

Figure 7-1 General Troubleshooting

TP-598651

TP-6053 7/04 33Section 7 Generator Troubleshooting

Page 46

7.3 Separate Excitation

By separately exciting the generator to determine the presence of a faulty voltage regulator, it is possible to determine if a running fault exists in the rotor and/or stator. A generator component that appears 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.

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. 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.

Separate Excitation Procedure

1. Disconnect all the leads from the voltage regulator.

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

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

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

Example:

12 Volts (Battery Voltage)

3.5 Ohms Exciter Resistance

+—

F1 F2

1. Voltage regulator

2. 10-amp fuse

3. DC ammeter

4. Battery

5. Ground to generator frame

6. Exciter armature

7. Exciter field

8. 10- or 15-ohm resistor

9. P6 connector (disconnect P6 connector before separate excitation)

3.4-amp

Exciter Current

Figure 7-2 Separate Excitation Connections

Note: See Section 1, Specifications, for the stator

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

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

7.4 PowerBoost IIIE Voltage Regulators

The generator set is equipped with a PowerBoostt IIIE voltage regulator. See Figure 7-3.

The voltage regulator monitors the output voltage to the generator exciter field.

If the regulator’s 8-amp fuse blows, the generator set will shut down. Verify that the regulator fuse is functional before proceeding with the test.

+—

605372

TP-598653

Figure 7-3 PowerBoosttIIIE Voltage Regulator

TP-6053 7/0434 Section 7 Generator Troubleshooting

Page 47

7.4.1 Voltage Regulator Test

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

Use the following components to test the voltage regulator:

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

Regulator Test Procedure

1. Connect the components as shown in Figure 7-4.

12 3

66 443355--+

RYOW

1. 120 volts AC

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

TP-598654

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

3. Turn the variable transformer on. Slowly increase the variable transformer voltage to 100 volts. The test 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 voltage 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. An inoperative voltage regulator 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.

Figure 7-4 PowerBoosttIIIE Voltage Regulator Test

7.4.2 Voltage Regulator Adjustment

Kohler Co. 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. The following paragraphs describe the voltage regulator components.

Voltage Adjustment Pot adjusts the generator output within the range of 100--130 volts.

Stabilizer Pot fine-tunes regulator circuitry to reduce light flicker.

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

Note: The volts/Hz adjustment does not apply to the

following models: 4/6.5/8/9EFOZ and 5/8/9/10EOZ. On these models, turn the volts/Hz adjustment pot full counterclockwise to stop and seal. No further volts/Hz adjustments are required.

TP-6053 7/04 35Section 7 Generator Troubleshooting

Page 48

Voltage Regulator Adjustment Procedure

1. Stop the generator set.

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

3. Start the generator set.

4. Adjust the engine speed to 1800 rpm on 60 Hz units and 1500 rpm on 50 Hz units.

5. Rotate the voltage adjustment pot clockwise to increase the voltage or counterclockwise to decrease the voltage to achieve the desired output voltage.

8. Use the remote rheostat, if equipped, to make final voltage adjustments.

9. Stop the generator set.

7.5 Exciter Field

DC current from the battery magnetizes the exciter field. When the exciter armature rotates within the magnetized exciter field windings, an electrical current develops within the exciter armature. There will be low or no generator output if the exciter field is inoperative. Test the exciter field according to the following procedure.

Exciter Field Test Procedure

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

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

GY R

44 33 55

YOWBK

1. Voltage adjustment potentiometer

2. Stabilizer potentiometer

3. Volt/Hz potentiometer

4. Exciter connections (for reference only)

5. Lead color

6. DC output

7. Exciter

8. Rotor

9. Armature

10. 8-amp fuse

11. AC power input (aux.)

12. Main (2 and 1)

13. Control

14. Stator

15. Sensing

16. Main (3 and 4)

17. Remote rheostat (optional)

605375

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

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

3. Disconnect the P6 and P7 connectors.

4. Check the exciter field resistance by connecting an ohmmeter across exciter field FP and FN leads. See Section 1, Specifications, for the resistance reading of a cold exciter field. A low reading indicates an internal short and a high reading indicates an open winding. Repair or replace the exciter field if the ohmmeter readings indicate a inoperative exciter field. If the resistance test proves inconclusive, perform a megohmmeter test on the exciter field as described in the next step.

FP FN

1. Ohmmeter

2. Exciter field

3. Exciter armature

Figure 7-6 Exciter Field Resistance Check

558857

Figure 7-5 PowerBoosttIIIE Voltage Regulator

Adjustment

TP-6053 7/0436 Section 7 Generator Troubleshooting

Page 49

5. Check the exciter field for a grounded condition. Use a megohmmeter to apply 500 volts DC to the FP or FN lead and the exciter field frame. Follow the instructions of the megohmmeter manufacturer when performing this test. A reading of approximately 500 kOhms (1/2 megohm) and higher indicates the field winding is functional. A reading of less than approximately 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground. Repair or replace the exciter field.

AC AC AC

F+

F--

FP FN

558858

1. Ohmmeter

2. Frame connection

3. Exciter armature

4. Exciter field

Figure 7-7 Megohmmeter Connections on the

Exciter Field

7.6 Exciter Armature

The exciter armature supplies excitation current to the generator main field through the rectifier module. There will be low or no generator output if the exciter armature is inoperative. Test the exciter armature as described in the following steps. Disassemble the generator set prior to performing this test.

1. Main field (rotor)

2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Armature

6. Exciter field

Figure 7-8 Exciter Armature Ohmmeter Test

5. Check if the exciter armature winding is ground. Use a megohmmeter to apply 500 volts DC to either armature lead and the armature frame. Follow the instructions of the megohmmeter’s manufacturer when performing this test. See Figure 7-9. A reading of approximately 500 kOhms (1/2 megohm) and higher indicates that the exciter armature is functional. A reading of less than approximately 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground. Repair or replace the exciter armature.

AC AC AC

F+

F--

558878

Exciter Armature Test Procedure

1. Disassemble the alternator.

2. Disconnect the armature leads from the rectifier module AC terminals.

3. With an ohmmeter on the R x 1 scale, check the resistance across the exciter armature leads. See Figure 7-8. The armature resistance should be

0.6--0.8 ohms (continuity). No continuity indicates an open armature winding. Replace the armature.

4. Perform a megohmmeter test on the exciter armature as described in the next step. Consider the exciter armature good if the resistance reading (continuity) is low and there is no evidence of a shorted winding (heat discoloration).

TP-6053 7/04 37Section 7 Generator Troubleshooting

558879

1. Main field rotor

2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Shaft connection

6. Armature

7. Exciter field

Figure 7-9 Megohmmeter Connections on Exciter

Armature

Page 50

7.7 Rectifier Module

7.8 Rotor

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

Rectifier Module Test Procedure

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

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

The generator rotor (magnetized by DC current from the rectifier module) rotating within the stator windings induces AC voltage in the stator windings. Test the generator rotor (main field) as described in the following steps.

Rotor Test Procedure

1. Disassemble the generator.

2. Disconnect the generator main field windings from rectifier module terminals F+ and F--.

3. Check the main field resistance by connecting an ohmmeter across the main field F+ and F-- leads. See Figure 7-11. The resistance reading for a cold main field should be approximately 2.5--4.5 ohms. A low reading indicates an internal short and a high reading indicates an open winding. Replace the main field if the ohmmeter readings indicate that the main field is inoperative.

4. Perform a megohmmeter test on the main field as described in the next step.

(AC)

1. Diode terminal

(AC)

Figure 7-10 Testing Rectifier Module

+--

5588710

1. Main field (rotor)

2. Stator windings

3. Rectifier module

AC AC AC

F+

F--

4. Ohmmeter

5. Armature

6. Exciter field

Figure 7-11 Ohmmeter Connections on

Main Field

5588711

TP-6053 7/0438 Section 7 Generator Troubleshooting

Page 51

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

AC AC AC

F+

F--

Stator Test Procedure

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

2. Disconnect all the stator leads to isolate the windings. To check the stator continuity, set the ohmmeter on the R x 1 scale. Contact the red and black ohmmeter leads; adjust the ohmmeter to zero ohms. Check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 7-13. Perform the stator tests on all the stator windings. See Figure 7-14.

3. Contact the ohmmeter leads and readjust the ohmmeter to zero ohms. Check the cold resistance of the stator windings by connecting the meter leads to the stator leads 1 and 2, 3 and 4, B1 and B2, etc. See Section 1, Specifications, for the stator resistance values. Replace the stator if readings do not fall within the specified value.

5588712

1. Main field (rotor)

2. Stator windings

3. Rectifier module

4. Shaft connection

5. Megohmmeter

6. Armature

7. Exciter field

Figure 7-12 Megohmmeter Connections on Main

Field

7.9 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.

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 are rectified by BR1 to supply the control voltage. BR1 is located on the controller circuit board.

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

The stator produces electrical output (AC) as the magnetized main field rotates within the stator windings. Test the condition of the stator according to the following procedure. Refer to the schematic in Figure 7-13 when performing the following tests.

Note: The stator resistance will vary directly with

increased temperature.

33 3

F1 F2

F+

AC AC AC

F--

55 44

12B1 B2

1. Main field (rotor)

2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Armature

6. Exciter field

Figure 7-13 Stator Ohmmeter Connections

Between Leads Continuity

1 and 2

3 and 4 33 and 44 33 and 55

B1 and B2 1 and 3, 4, 33, 44, 55 1 and 55, B1, and B2

4 and B1 and B2

55 and B1 and B2

Any stator lead and ground

Figure 7-14 Stator Continuity

5588713

Yes Yes Yes Yes Yes

No No No No No

TP-6053 7/04 39Section 7 Generator Troubleshooting

Page 52

4. Perform a megohmmeter test on the stator as described in the next step. Consider the stator good if the resistance reading (continuity) is low and there is no evidence of shorted windings (heat discoloration).

Note: When taking an ohmmeter reading using

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

5. Check the stator for a short to ground 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 the stator windings have been tested. A reading of approximately 500 kOhms (1/2 megohm) and higher indicates the stator is good. A reading of less than approximately 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground. Repair or replace the stator.

F1 F2

55344

F+

AC AC AC

F--

B1 B2

5588715

1. Main field (rotor)

2. Stator windings

3. Rectifier module

4. Shaft connection

5. Megohmmeter

6. Armature

7. Exciter field

Figure 7-15 Megohmmeter Connections on Stator

TP-6053 7/0440 Section 7 Generator Troubleshooting

Page 53

Section 8 Component Troubleshooting

8.1 General

See Figure 8-1 through Figure 8-3 for component testing. With the generator set battery connected, check the generator wiring harness and the components listed in the following tables. Check each component using a multimeter to verify that the switches function and that voltage is present at each component.

WARNING

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

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

Hazardous voltage. Can cause severe injury or death.

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

Component

Hourmeter and wiring Connect the red test lead to

Stator auxiliary winding B1 and B2

Moving rotor.

Voltmeter Connections Procedure Results

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.

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

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

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

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

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.

TP-6053 7/04 41Section 8 Component Troubleshooting

Page 54

To further check the generator set components, disconnect the battery and remove the wiring harness plugs from the controller circuit board. Use an

Note: Before performing ohmmeter checks, disconnect

the generator set battery to prevent damage to the ohmmeter.

ohmmeter to check the continuity of the components and to isolate inoperative components. Refer to Figure 8-2 and Figure 8-3.

Component Ohmmeter Connections Procedure Results

Start/stop switch Connect the ohmmeter to the

K20 relay coil and wiring Connect the ohmmeter to the

Starter solenoid (S relay)

Controller 10-amp circuit breaker and wiring

P2-6 and P2-4 leads.

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

P1-4 and P1-9 leads.

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

Connect the ohmmeter to the battery positive (+) cable and the P1-14 lead. Note:TheJ4 and P4 leads must be connected to perform this test.

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 C relay coil and/or wiring. High resistance, open C relay and/or wiring. Replace the controller board.

If functional, approximately

0.5--0.6 ohms at 27°C(80°F).

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

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

TP-6053 7/0442 Section 8 Component Troubleshooting

Page 55

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

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

Low oil pressure (LOP) 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 P1-15 and engine block (ground). Note: Remove and isolate the LOP switch lead.

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

Place the ohmmeter on the Rx1scale.

Place the ohmmeter on the R x 1000 scale.

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

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

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

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

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

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

Figure 8-3 Engine/Generator Component Testing, Relay Controller

8.2 Remote Panels (Optional)

Kohler Co. offers three remote panels for connection to the generator set:

Troubleshooting Remote Start Panels

Generally, if the sender changes its resistance values as its respective pressure/temperature changes, it is working correctly. An inoperative sender will either be

D A panel with a start/stop switch

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

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

(engine oil pressure and water temperature)

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

voltmeter, engine oil pressure, water temperature, and hourmeter)

If difficulty with the remote operation occurs, test the switch, gauges, and gauge senders using the following

Figure 8-4 Water Temperature Sender Resistance

procedures. See Sections 10.5 through 10.7 for wiring diagrams.

345 kPa (50 psi)

690 kPa (100 psi)

2-Meter and 4-Meter Panels

Temperature Resistance

60_C (140_F)

90_C (194_F)

100_C (212_F)

2-Meter and 4-Meter Panels

Pressure Resistance

0 kPa (0 psi)

134.0 ±10 ohms

51.5 ±4 ohms

38.0 ±3 ohms

10 ohms

80 ohms

135 ohms

TP-6053 7/04 43Section 8 Component Troubleshooting

Figure 8-5 Oil Pressure Sender Resistance

Page 56

Refer to Figure 8-6 for troubleshooting information on the remote start panels.

Component Ohmmeter Connections Procedure Results

Remote start/stop switch

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

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

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

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

Water temperature gauge Connect the red test lead to

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

Oil pressure gauge Connect the red test lead to

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

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

Place the ohmmeter on the Rx1scale. Press the rocker switch to the START position.

Place the ohmmeter on the Rx1scale. Press the rocker switch to the STOP position.

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

Start the generator set for the test.

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

Continuity, the switch is functional.

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

If0.5--12-voltsDCispresent and the gauge does not function after the J3 is connected to controller, replace the gauge.

If0.5--12-voltsDCispresent and the gauge does not function after the J3 is connected to the controller, replace the gauge.

Figure 8-6 Remote Start Panels Troubleshooting

TP-6053 7/0444 Section 8 Component Troubleshooting

Page 57

Section 9 Generator Disassembly/Reassembly

9.1 Disassembly

Disconnect all 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, water line at the seawater pump, fuel line at the fuel pump filter inlet, and exhaust line at the mixing elbow. Observe all the safety precautions listed at the beginning of this manual during the disassembly/ reassembly procedures.

Note: Because this manual covers several models, the

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

Note: The voltage regulator is located in the controller

box. Remove the controller cover to service the voltage regulator. Adjustments are possible without removing the voltage regulator from the controller.

1. Remove the end panel from the alternator end of the generator set. See Figure 9-1.

2. Loosen the four screws and lift off the controller cover.

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

CD-250000-AJ

1. Controller cover

2. P4 (22-pin) connector

3. Ground strap

4. Generator end panel

Figure 9-1 Covers

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

4. Remove the bolt and disconnect the ground strap.

Note: It is possible to connect the output leads in

various positions for different volt configurations. Mark leads 1, 2, 3, and 4 for correct reconnection.

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

6. Remove the four controller mount locknuts. See Figure 9-2.

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

558863

1. Controller mount locknut

2. Neutral stud (L0)

Figure 9-2 Controller Removal

TP-6053 7/04 45Section 9 Generator Disassembly/Reassembly

Page 58

9. Disconnect the P7 (FP and FN) and P6 (F1 and F2) connectors. See Figure 9-3.

10. Remove the four bolts to remove the exciter field. SeeFigure9-3.

11. Remove the three bolts and spacers from the rectifier board.

12. Disconnect the main field rotor leads from the rectifier board positive/negative terminals. Remove the bolt and washer.

13. Remove the armature from the shaft, guiding rotor leads through the armature bores. See Figure 9-4.

14. Remove the tie wraps and disconnect the P5 (33, 44, 55, B1, and B2) wire connector.

1. P7 connector

2. P6 connector

3. F1 connector

4. Exciter field

Figure 9-3 Exciter Field Removal

15. Attach the hoist hook to the generator hoisting eye.

Note: The hoist capacity rating should be one-half

ton or greater.

16. Remove the two vibromount bolts. See Figure 9-5.

17. Raise the alternator end and place a wood block under the locator plate. Lower the alternator until the wood block supports the locator plate. See Figure 9-5.

18. Remove the four overbolts from the end bracket. See Figure 9-5.

558864

1. Armature

2. Armature retaining bolt

3. Rotor leads

4. Rectifier board

Figure 9-4 Armature Removal

558865

1. P5 connector

2. Backplate

3. Wood block

4. Vibromount bolts

5. Overbolts

Figure 9-5 Supporting the Generator

558866

TP-6053 7/0446 Section 9 Generator Disassembly/Reassembly

Page 59

19. Install a sling on the stator housing. See Figure 9-6.

20. Use a two-jaw puller to pull the end bracket/stator assembly from the bearing on the rotor shaft. See Figure 9-6.

21. Remove the stator assembly from the rotor. Remove or rotate the fan guard, if necessary, to clear the vibromounts.

22. Remove the four locknuts and remove the fan and fan spacer. See Figure 9-7.

23. Remove the six metric bolts to remove the drive disc/rotor assembly from the engine flywheel. See Figure 9-7.

24. Clamp the rotor in a soft-jaw vise. Remove the eight bolts and remove the drive disc assembly from the rotor. SeeFigure9-8.

9.2 Reassembly

1. Clamp the rotor in a soft-jaw vise. Install the drive disc on the rotor with disc studs facing the rotor. Tighten the eight bolts to 40 Nm (30 ft. lbs.). See Figure 9-8.

2. Install the rotor/drive disc assembly on the engine flywheel using six washers and bolts. Tighten the bolts to 27 Nm (20 ft. lbs.).

1. Sling

2. Fan guard

3. Two-jaw puller

4. End bracket

Figure 9-6 Stator Assembly Removal

558867

3. Install the fan to the drive disc using four spacers, washers, and locknuts.

Note: Install the fan with the flange side facing

away from the flywheel. Space the studs so that they allow the fan installation in one position only.

1. Fan

2. Bolt

3. Locknut

4. Rotor assembly

Figure 9-7 Disc/Rotor and Fan Assembly

1. Drive disc

2. Rotor

3. Bolt

558868

5588610

TP-6053 7/04 47Section 9 Generator Disassembly/Reassembly

Figure 9-8 Drive Disc

Page 60

4. Inspect the O-ring in the end bracket bearing bore and replace the O-ring if damaged. Use a sling to support the stator assembly while installing the stator over the rotor. Be careful not to damage the rotor. SeeFigure9-9.

5. Install the four overbolts (the two long bolts in the lower holes). Check that the alignment marks on the stator housing and locator plate match. See Figure 9-10. Tighten the overbolts to 40 Nm (30 ft. lbs.).

6. Use the hoist to raise the alternator end. Remove the wood block from under the locator plate. Lower the generator set and install a bolt, a large washer, two small washers, and a locknut in each vibromount. Tighten the mounting bolts to 28 Nm (20 ft. lbs.).

7. Apply antiseize compound to the keyed end of the rotor shaft. Bring the rotor leads through the bores in the armature while installing the armature on the shaft. Check the keyway of the shaft and key of the armature for damage. Install the armature retaining bolt and washer.

8. Use screws and lock washers to install the rotor leads to the rectifier board at the positive (+) and negative (--) terminals.

1. O-ring

Figure 9-9 Stator Installation

5588612

Note: Position the lock washers against the

rectifier board.

9. Install three spacers and bolts to mount the rectifier board to the armature.

10. Install the exciter field using four bolts and washers. The field leads are at the top. Connect the P6, P7, and F1 connectors. See Figure 9-11.

1. Alignment marks

Figure 9-10 Alignment Marks

5588613

1. P7 connector

2. P6 connector

3. F1 connector

4. Exciter field

Figure 9-11 Installing Exciter Field

5588614

TP-6053 7/0448 Section 9 Generator Disassembly/Reassembly

Page 61

11. Install tie wraps to secure the wires as necessary.

12. Route output leads 1, 2, 3, and 4 through the bottom of the controller box. Check that the grommet is intact and there are no sharp edges exposed that could damage the wiring. Install the box on the rubber mounts and install the four locknuts. Connect the leads to the circuit breaker and neutral stud (LO) as marked during disassembly.

Note: Check the generator set’s nameplate to

verify the original voltage configuration. See Section 10, Voltage Reconnection and Wiring Diagrams, for more information regarding voltage reconnection.

13. Connect the P4 (22-pin) connector. Connect the ground strap using a bolt, washer, and lock washer (install the lock washer against the ground strap).

14. Install the controller cover.

15. Install the end panel with the louvered openings down.

16. Reconnect all the external connections—the exhaust line to the mixing elbow, the fuel line to the fuel pump filter inlet, the water line to the seawater pump, the remote start panel to the controller P3 connector, the AC output leads in controller, and the battery cables to the battery (negative (--) lead last).

17. Open the seacock and the fuel valve.

TP-6053 7/04 49Section 9 Generator Disassembly/Reassembly

Page 62

Notes

TP-6053 7/0450 Section 9 Generator Disassembly/Reassembly

Page 63

Section 10 Voltage Reconnection and Wiring Diagrams

10.1 Voltage Reconnection

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

NOTICE

10.1.1 100--120-Volt Configurations

Load Side

LO (Neutral)

Ground

Factory 2-Pole or (2) 1-Pole Circuit Breakers

GRD

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

LO (Neutral)

Ground

Load Side

1-Pole Circuit Breaker

Line Side

GRD

Line Side

Jumper

Lead

4321

Stator Leads

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

100--120 Volt, 3 Wire

60 Hz 50 Hz

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

100--120 Volt, 2 Wire

4321

Stator Leads

60 Hz 50 Hz L0--L1 100--120 Volt 100--120 Volt L0--L2 100--120 Volt 100--120 Volt

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

TP-6053 7/04 51Section 10 Voltage Reconnection and Wiring Diagrams

Page 64

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

This configuration does not use a jumper lead. If the unit was originally wired for straight 100--120 volt, 3 wire, remove the jumper lead (see Figure 10-1 and Figure 10-2 for location). Select a circuit breaker manufactured with a 2-pole circuit breaker. Two 1-pole circuit breakers do not conform to NEC requirements when supplying a 200--240-volt load. This is true even if they are mechanically attached together. Since leads L1 and L2 are different phases, never connect them together.

LO (Neutral)

Ground

Load Side

Line Side

GRD

Factory 2-Pole Circuit Breaker

10.1.3 200--240-Volt Configurations

This configuration does not use a jumper lead. If the unit was originally wired for straight 100--200 volt, 3 wire, remove the jumper lead (see Figure 10-1 and Figure 10-2 for location).

LO (Neutral)

Ground

Load Side

Line Side

4321

200--220--240 Volt, 2 Wire

1-Pole Circuit Breaker

Tape to insulate from ground

Stator Leads

60 Hz 50 Hz

L0--L1 not used 200--240 Volt

GRD

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

4321

Stator Leads

60 Hz 50 Hz L0--L1 100--120 Volt 100--120 Volt L0--L2 100--120 Volt 100--120 Volt L1--L2 200--240 Volt 200--240 Volt

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

Figure 10-4 200--240 Volt, 2 Wire

TP-6053 7/0452 Section 10 Voltage Reconnection and Wiring Diagrams

Page 65

10.2 Marine Manual (Ship-to-Shore) Transfer Switch

Electro Switch

To Generator Set

2-Wire Generator Sets

2134

6578

To Load

To Shore Power

Kraus Naimler/American Solenoid

(Early Rectangular Design)

2-Wire Generator Sets

1265

348 7

To Shore Power

To Generator Set

3-Wire Generator Sets

2134

657 8

10 9 11 12

To Load

3-Wire Generator Sets

1265

348 7

91014 13

To Shore Power

To Generator Set

To Load

Kraus Naimler/American Solenoid

(Newer Round Design)

2-Wire Generator Sets

3241

768 5

To Load

To Shore Power

To Generator Set

To Load

3-Wire Generator Sets

3241

768 5

11 10 12 9

To Load

To Shore Power

TP-5399-5

TP-6053 7/04 53Section 10 Voltage Reconnection and Wiring Diagrams

Page 66

10.3 Wiring Diagram, Schematic

229294-N

TP-6053 7/0454 Section 10 Voltage Reconnection and Wiring Diagrams

Page 67

10.4 Wiring Diagram, Point-to-Point

TP-6053 7/04 55Section 10 Voltage Reconnection and Wiring Diagrams

229294-N

Page 68

10.5 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

P1-9

Black

10.6 Remote Start and 2-Meter Panel

+--

10-amp fuse

P1-1447P2-4

P2-3

P3-4

Violet

P2-7

P3-5 P3-6

J3-4 J3-5

Yellow/ Red

Local switch

Start

Relay circuit board

Grey/ Black

Stop

Start

Stop

P2-5 P2-6

P2-8 P2-9

J3-6

Remote switch

P3-1

P1-9

P4-2 P4-3

P3-2

J3-1

Black

W.T. sender

J3-2

Tan

O.P. sender

P3-3

J3-3

L. Blue

Gen. ON light

TP-5588-7

Gen. ON light

Water temp. gauge

Oil pressure gauge

TP-5588-7

TP-6053 7/0456 Section 10 Voltage Reconnection and Wiring Diagrams

Page 69

10.7 Remote Start and 4-Meter Panel

+--

10-amp fuse

P1-14

P2-3

P3-4

J3-4 J3-5

Violet

Yellow/ Red

Gen. ON light

Water temp. gauge

P2-4

P2-7

P3-5

Local switch

Start

Relay circuit board

Grey/ Black

Stop

Start

Stop

P2-8 P2-9

P3-6

P2-5 P2-6

P3-1

J3-6

Remote switch

P1-9

W.T. sender

P4-2 P4-3

P3-2

J3-1 J3-2 J3-3

Tan

Black

O.P. sender

P3-3

L. Blue

Oil pressure gauge

DC voltmeter

Hourmeter

TP-5588-7

TP-6053 7/04 57Section 10 Voltage Reconnection and Wiring Diagrams

Page 70

Notes

TP-6053 7/0458 Section 10 Voltage Reconnection and Wiring Diagrams

Page 71

Appendix A Abbreviations

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

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

AHWT anticipatory high water

AISI American Iron and Steel

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

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

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

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

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

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

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

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

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

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

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

EIA Electronic Industries

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

EPS emergency power system ER emergency relay ES engineering special,

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

substrate (semiconductor)

Association

e. V. (also Deutsche Industrie Normenausschuss)

Association

Agency

engineered special

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

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

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

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

IEEE Institute of Electrical and

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

J joule JIS Japanese Industry Standard

ground

high engine temperature

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

TP-6053 7/04 Appendix A-1

Page 72

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

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter

bytes)

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

lbm/ft

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

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

units), male

cubic meter

/min. cubic meters per minute

when used with SI

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

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

milliohm

MOhm, MΩ

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

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

Manufacturers Association

NFPA National Fire Protection

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

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

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

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

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

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

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

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

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

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

normal TDES time delay engine start TDNE time delay normal to

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

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

TP-6053 7/04A-2 Appendix

Page 73

Appendix B Common Hardware Application Guidelines

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

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

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

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

Preferred Nut/Bolt Clearance

Steps for common hardware application:

1. Determine entry hole type: round or slotted.

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

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

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

a. Always use a washer between hardware and a

slot.

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

for exception).

c. Use a washer under a bolt when the female

thread is fixed (weld nut).

Unacceptable Nut/Bolt Clearance

1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut

3. Below top of nut

Figure 1 Acceptable Bolt Lengths

G-585

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

1. Cap screw

2. Entry hole types

3. Standard nut and SAE washer

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

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

6. Exit hole types

G-585

TP-6053 7/04 Appendix A-3

Figure 2 Acceptable Hardware Combinations

Page 74

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-6053 7/04A-4 Appendix

Page 75

Appendix D Common Hardware Identification

Screw/Bolts/Studs

Head Styles

Hex Head or Machine Head

Hex Head or Machine Head with Washer

Flat Head (FHM)

Round Head (RHM)

Pan Head

Hex Socket Head Cap or Allent Head Cap

Hex Socket Head or Allent Head Shoulder Bolt

Sheet Metal Screw

Stud

Drive Styles

Hex

Hex and Slotted

Phillipsr

Nuts

Nut Styles

Hex Head

Lock or Elastic

Square

Cap or Acorn

Wing

Washers

Washer Styles

Plain

Split Lock or Spring

Spring or Wave

External Tooth Lock

Internal Tooth Lock

Internal-External Tooth Lock

Hardness Grades

American Standard

Grade 2

Grade 5

Grade 8

Grade 8/9 (Hex Socket Head)

Metric

Number stamped on hardware; 5.8 shown

5.8

Slotted

Hex Socket

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

Phillipsr screw is a registered trademark of Phillips Screw Company.

Sample Dimensions

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

1/4-20 x 1

Metric (Screws, Bolts, Studs, and Nuts)

M8-1.25 x 20

Length In Inches (Screws and Bolts)

Threads Per Inch

Major Thread Diameter In Fractional Inches Or Screw Number Size

Length In Millimeters (Screws and Bolts)

Distance Between Threads In Millimeters

Major Thread Diameter In Millimeters

Plain Washers

9/32

x5/8x 1/16

Lock Washers

5/8

Thickness

External Dimension

Internal Dimension

TP-6053 7/04 Appendix A-5

Page 76

Appendix E Common Hardware List

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

American Standard

Part No. Dimensions Hex Head Bolts (Grade 5)

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

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

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

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

Part No. Dimensions Hex Head Bolts, cont.

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

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

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

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

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

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

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

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

Part No. Dimensions Type

Hex Nuts

X-6009-1 1-8 Standard

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

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

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

Washers

Bolt/

Part No. ID OD Thick. Screw

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

TP-6053 7/04A-6 Appendix

Page 77

Metric

Hex head bolts are hardness grade 8.8 unless noted.

Part No. Dimensions Hex Head Bolts (Partial Thread)

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

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

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

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

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

continued

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

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

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

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

Hex Head Bolts (Full Thread)

M933-04006-60 M4-0.70 x 6

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

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

M933-07025-60 M7-1.00 x 25

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

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

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

continued

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

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

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

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

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

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

Pan Head Machine Screws

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

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

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

M7985A-06100-20 M6-1.00 x 100

Flat Head Machine Screws

M965A-04012-SS M4-0.70 x 12

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

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

TP-6053 7/04 Appendix A-7

Page 78

Metric, continued

Part No. Dimensions Type Hex Nuts

M934-03-50 M3-0.50 Standard

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

M934-05-50 M5-0.80 Standard

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

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

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

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

M982-14-60 M14-2.00 Elastic Stop

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

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

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

M934-22-60 M22-2.50 Standard

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

M934-30-80 M30-3.50 Standard

Washers

Bolt/

Part No. ID OD Thick. Screw

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

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

TP-6053 7/04A-8 Appendix

Page 79

Page 80

TP-6053 7/04a

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