Page 1
Service
Marine Generator Sets
Models:
5E/4EF
7.3E/6EF
TP-5986 4/03b
Page 2
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Number
x:in:007:001a
Page 3
Table of Contents
Safety Precautions and Instructions I.........
Introduction i...............................
Service Assistance ii.........................
Service Information ii..............................
Product Information ii..............................
Service Parts/Publications iii..................
Routine Service Parts iii............................
List of Related Literature iii.........................
Section 1 Specifications 1....................
1.1 General 1..................................
1.2 Engine 1...................................
1.3 Fuel 1......................................
1.4 Cooling 1...................................
1.5 Generator 2.................................
1.6 Torque 2...................................
1.7 Service Views 3.............................
Section 2 Scheduled Maintenance 5...........
2.1 General 5..................................
2.2 Lubrication System 5.........................
Section 3 Intake and Exhaust System 7........
3.1 Backfire Flame Arrestor 7.....................
3.2 Exhaust 7..................................
Section 4 Fuel System 9.....................
4.1 General 9..................................
4.2 Float Bowl Vent System 9.....................
4.3 Fuel Pump and Filter 9.......................
4.4 Fuel Pump Troubleshooting 10.................
4.5 Carburetor Troubleshooting 10.................
4.5.1 Hard Starting 10......................
4.5.2 Stalling 10...........................
4.5.3 Flooding 11..........................
4.5.4 Hunting 11...........................
4.5.5 Leaking Carburetor 11.................
4.6 Governor 60 Hz to 50 Hz Conversion 11.........
Section 5 Cooling System 13..................
5.1 General 13..................................
5.2 Closed Heat Exchanger 14.....................
5.3 Check and Fill Coolant 14.....................
5.4 Flush and Clean Cooling System 14.............
5.5 Impeller 15..................................
5.6 Siphon Break 16..............................
5.7 Anticorrosion Zinc Anode 17...................
5.8 Generator Storage 18.........................
Section 6 Controller Troubleshooting 19........
6.1 Sequence of Operation 19.....................
6.1.1 Start 19.............................
6.1.2 Run 19..............................
6.1.3 Stop 20..............................
6.2 Engine Safety Shutdown Switches 20...........
6.2.1 Low Oil Pressure (LOP) Shutdown 20...
6.2.2 Loss of Coolant Switch (LCS)
Shutdown 20.........................
6.2.3 High Engine Temperature Switch
(HET) Shutdown 20...................
6.2.4 Controller Circuit Board 20.............
6.2.5 Troubleshooting 21...................
Section 7 Generator Troubleshooting 25........
7.1 General 25..................................
7.1.1 Troubleshooting 25...................
7.1.2 Separate Excitation 26................
7.2 PowerBoost IIIE Voltage Regulators 27..........
7.2.1 Voltage Regulator Test 27..............
7.2.2 Voltage Regulator Adjustment 28.......
7.3 Rotor 29.....................................
7.4 Stator 29....................................
7.5 Brushes 31..................................
Section 8 Component Troubleshooting 33......
8.1 Engine/Generator Components 33..............
8.2 Remote Panels (Optional) 35...................
Section 9 Generator Disassembly/
Reassembly 37...............................
9.1 Disassembly 37..............................
9.2 Collector Ring and Bearing Replacement 39......
9.3 Reassembly 39...............................
Section 10 Wiring Diagrams and Voltage
Reconnection 41..............................
10.1 Schematic Wiring Diagram 42..................
10.2 Point-to-Point Wiring Diagram 43...............
10.3 Reconnection Diagram 100--120 V,
60 & 50 Hz 44................................
10.4 Reconnection Diagram 100--120/200--240 V,
60 & 50 Hz 44................................
10.5 Reconnection Diagram 220--240 V, 50 Hz 44.....
10.6 Remote Start Panel 44........................
10.7 Remote Start and Two-Meter Panel 45..........
10.8 Remote Start and Four-Meter Panel 45..........
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-5986 4/03 Table of Contents
Page 4
Page 5
Safety Precautions and Instructions
IMPORTANT SAFETY
INSTRUCTIONS. Electromechanical
equipment, including generator sets,
transfer switches, switchgear, and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury,death,orsubstantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury,death, or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
equipment connected to the set,
disable the generator set as follows:
(1) Place the generator set start/stop
switch in the STOP position.
(2) Disconnect the power to the battery
charger, if equipped. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
Battery electrolyte is a diluted
sulfuric acid. Batteryacid 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 permitflames 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
metalsurface 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-5986 4/03 Safety Precautions and Instructions I
Page 6
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 fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the backfire flame arrester.
A sudden backfire can cause severe
injury or death. Do not operate the
generator set with the backfire flame
arrester 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.
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
generatorset 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 operatingthe generator set. Do not
installthe 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.
II Safety Precautions and Instructions TP-5986 4/03
Page 7
Fuel System
WARNING
Explosive fuel vapors can cause
severe injury or death. Ta k e
additional precautions when using the
following fuels:
Gasoline—Store gasoline only in
approved red containers clearly
marked GASOLINE.
Hazardous Noise
CAUTION
Explosion.
Gasoline vapors can cause
explosion and severe injury or
death.
Before starting the generator set,
operate the blower 4 minutes and
check the engine compartment for
gasoline vapors.
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
in a well-ventilated area away from
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
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 drainingthe 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 modifythe 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.
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.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous
V oltage/Electrical
Shock
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
CAUTION
Welding the generator set.
Can cause severe electrical
equipment damage.
Moving rotor.
TP-5986 4/03 Safety Precautions and Instructions III
Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
Page 8
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Open the main circuit
breakers of all power sources before
servicing the equipment. Configure the
installation to electrically ground the
generator set, transfer switch, and
related equipment and electrical
circuits to comply with applicable codes
and standards. Never contact
electrical leads or appliances when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.
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 transferswitch 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.
IV Safety Precautions and Instructions TP-5986 4/03
Page 9
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 thruboltwhen 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-5986 4/03 Safety Precautions and Instructions V
246242
Page 10
Notes
VI Safety Precautions and Instructions TP-5986 4/03
Page 11
Introduction
This manual provides troubleshooting and repair
instructions for 5E/4EF and 7.3E/6EF model generator
sets, controllers, and accessories.
Refer to the engine service manuals (TP-6002 and
TP-6008) for generator set engine service information.
This manual may be used for models not listed on the
front cover.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriatelyskilled and suitably-trained maintenance personnel,
familiar with generator set operation and service.
Introduction iTP-5986 4/03
Page 12
Service Assistance
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
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
Africa, Europe, Middle East
London Regional Office
Langley, Slough, England
Phone: (44) 1753-580-771
Fax: (44) 1753-580-036
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax: (65) 264-6455
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131
X:in:008:001a
TP-5986 4/03ii Introduction
Page 13
Service Parts/Publications
Routine Service Parts
The following table contains a list of recommended
spare parts. Contact your Kohler generator
distributor/dealer for a complete list of service parts for
your generator set.
Part Description Part Number
Battery Charging Fuse (25 amp) 262389
Input Fuse (10 amp) 223316
Oil Filter 359771
Seawater Pump Impeller Kit 359978
Spark Plug
For Engine Model AS 04
Spark Plug
For Engine Model BS 04
Spray Paint (White) 221335
Touch-Up Paint (White) GM19490
Voltage Regulator Fuse (10 amp) 223316
Zinc Anode 267928
359796
359979
List of Related Literature
The following table identifies literature available for the
generator sets covered in this manual. Only qualified
persons should install or service the generator set.
Literature Type Part Number
Installation Manual TP-5982
Operation Manual (Generator) TP-5985
Operation Manual (Engine) TP-6001
Parts Catalog* TP-5987
Service Manual (Generator) TP-5986
Service Manual (Engine) TP-6002
Service Manual Supplement (Engine) TP-6008
* One manual combines Generator and Engine information.
TP-5986 4/03 Introduction iii
Page 14
Notes
TP-5986 4/03iv Introduction
Page 15
Section 1 Specifications
(
19(
0
)
(mixi
l
bow
1(2.00)
1.1 General
The 7.3E/6EF and 5E/4EF units are powered by a
two-cylinder, water-cooled, four-cycle gasoline engine
with heat exchanger.
Kohler Co. develops all Kohler marine generator set
ratings using accepted reference conditions of 25_C
(77_F) and pressure of 99 kPa (29.2 in. Hg) dry
barometer. ISO 3046 and ISO 8528-1 include reference
conditions and output calculations. Obtain technical
information bulletin (TIB-101) on ratings guidelines for
complete ratings definitions.
1.2 Engine
Generator Model 7.3E/6EF 5E/4EF
Engine manufacturer Kawasaki
Engine model FD501D
Number of cylinders 2
Cylinder block material Aluminum
Cylinder head material Aluminum
Piston rings 2 compression/1 oil
Governor Gear driven centrifugal
Bore x stroke, mm (in.) 67 (2.64) x 62 (2.44)
Displacement, L (CID) 0.4 (26.7)
Compression ratio 9.3:1
Horsepower, 60/50 Hz 16 13.8
RPM, 60/50 Hz 3600 3000
Lubrication system Pressure; mechanical
Lube oil capacity,
L (U.S. qts) (w/filter)
Low oil pressure
shutdown, kPa (psi)
Oil recommendation (API)
Battery voltage 12 volt (standard)
Battery recommendation,
minimum
Battery charging 15 amps
Starter motor Bendix automotive type
1.36 (1.44)
96.5 (14)
SC, SD, SE, SF,
SG, SH, or SJ
260 CCA
1.3 Fuel
Fuel recommendation Unleaded 87 octane
Fuel pump Electric
Fuel pump operating,
kPa (psi)
Fuel filter inlet hose,
mm (in.) ID
13.8--24.1 (2.0--3.5)
6.35 (0.25)
1.4 Cooling
Recommended coolant
Coolant capacity
L (U.S. qts.) (approx.)
Thermostat, _C(_F)
Pressure cap rating,
kPa (psi)
High temperature
shutdown, _C(_F)
High exhaust temperature
shutdown, _C(_F)
Inlet water line hose ID,
seawater pumpinlet),
mm (in.)
Outlet water line hose ID,
ng e
mm (in.)
Max. water pump inlet
pressure, kPa (psi)
outlet),
50% ethylene glycol; 50%
clean, softened water
2.84 (3.0)
91 (195)
97 (14)
111 (232)
102 (215)
.75
5
34.5 (5.0)
TP-5986 4/03 1Section 1 Specifications
Page 16
1.5 Generator
1.6 Torque
Component Specification Value
Rotor field voltage/current readings at rated voltage (hot)
No load (63 Hz) (volts/amps) 13/3.82
Full load (60 Hz) (volts/amps) 47/13.82
Cold main field (rotor) resistance (ohms) 3.4
Stator output voltages with separately excited generator,
using 12-volt battery (60 Hz only)
1--2, 3--4, 33--44 (VAC) 145
55--66 (VAC) 190
B1-B2 (VAC) 14
Cold stator resistance
1--2, 3--4, 33--44 (ohms) 0.16
55--66 (ohms) 1.70
B1-B2 (ohms) 0.05
Component Torque Nm (in. lbs.)
Rotor bolt 23.1 (204)
Generator overbolts 13.6 (120)
Mounting plate to end bracket
bolts
Lift eye bolts 19.0 (168)
Generator adapter to engine
bolts
Engine oil drain boss (inside
generator adapter)
Generator adapter to exhaust
manifold
High exhaust temp. switch 13.6 (120)
Spark plugs 12--17 (106--150)
Bolts that hold the coverplate
over the impeller
6.8 (60)
14.9 (132)
47.5 (420)
13.6 (120)
3.4 (30)
TP-5986 4/032 Section 1 Specifications
Page 17
1.7 Service Views
33
32
31
1
3 5 13
2
30 29 2627
6
7
28
84
9
SERVICE VIEW
1110
25
12
14
15
16
17
18
19
20
21
22
23
24
1. Electric choke (on carburetor)
2. Carburetor/choke linkage
3. Spark plug (also one on nonservice side)
4. Oil fill
5. Overflow tube
6. Pressure cap (coolant fill location after draining coolant)
7. High water temp. switch
8. Controller
9. Start/Stop switch
10. Nameplate (top)
11. AC load lead connector (nonservice side)
12. Input fuse
13. Battery charging fuse
14. AC circuit breaker
15. Voltage regulator
16. Remote start connector (nonservice side)
17. Voltage regulator fuse
ENGINE-END VIEW
18. Hourmeter
19. Heat exchanger
20. Anticorrosion zinc anode
21. Seawater drain (remove zinc anode)
22. Seawater pump (water inlet)
23. Cooling air inlet
24. High exhaust temp. switch on mixing elbow (nonservice side)
25. Fuel filter (fuel inlet)
26. Fuel feed pump
27. Oil check
28. Coolant drain (remove hose clamp to drain coolant)
29. Oil drain valve
30. Lube oil filter
31. Low oil pressure switch
32. Antidieseling solenoid (on carburetor)
33. Air intake silencer/backfire flame arrestor
34. Coolant overflow bottle (daily coolant check/fill location)
34
ADV-6395-A
GY-250000-A
Figure 1-1 Service Views
TP-5986 4/03 3Section 1 Specifications
Page 18
Notes
TP-5986 4/034 Section 1 Specifications
Page 19
Section 2 Scheduled Maintenance
2.1 General
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.
WARNING
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
Use oil that meets the American Petroleum Institute
(API) classification of SC, SD, SE, SF, SG, SH, or SJ.
Using unsuitable oil or neglecting an oil change may
result in engine damage that is not covered by the
engine warranty. Figure 2-1 shows the recommended
Society of Automotive Engineers (SAE) viscosity
designation for given operating temperature ranges.
Do not mix different oil brands. Incompatibility could
cause a breakdown of lubricating ingredients and
reduce engine protection.
SAE40
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.
TP-5986 4/03 5Section 2 Scheduled Maintenance
SAE5W-20*
°C-20
* Using multigrade oil causes greater oil consumption.
Figure 2-1 Recommended SAE Viscosity Grades
SAE10W-30/SAE 10W-40*
14°F-4
-10
0102030 40
SAE30
50 68 86 10432
Page 20
Notes
TP-5986 4/036 Section 2 Scheduled Maintenance
Page 21
Section 3 Intake and Exhaust System
3.1 Backfire Flame Arrestor
At the interval specified in the service schedule, inspect,
clean or replace the backfire flame arrestor. Check the
wire mesh screen for accumulated oil or dirt that could
clog the element and cause poor performance. See
Figure 3-1.
1
TP603531
1. Wire mesh screen
Figure 3-1 Air Intake
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components (exhaust
manifold, 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 as needed.
D Check that the exhaust outlet is unobstructed.
D Check the exhaust gas color. If the exhaust is blue or
black, contact your local distributor/dealer.
D Visually inspect for exhaust leaks. Check for carbon
or soot residue on exhaust components. Carbon and
soot residue indicates an exhaust leak. Seal leaks as
needed.
3.2 Exhaust
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.
D Ensure that the carbon monoxide detector(s) is (1) in
the craft, (2) functional, and (3) energized whenever
the generator set operates.
Note: Never operate the generator set without a
functioning carbon monoxide detector.
TP-5986 4/03 7Section 3 Intake and Exhaust System
Page 22
Notes
TP-5986 4/038 Section 3 Intake and Exhaust System
Page 23
Section 4 Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
The fuel system. Explosive fuel vapors can cause severe
injury or death. Vaporized fuels are highly explosive. Use
extreme care when handling and storing fuels. Store fuels in a
well-ventilated area away from spark-producing equipment
and out of the reach of children. Never add fuel to the tank
while the engine is running because spilled fuel may ignite on
contact with hot parts or from sparks. Do not smoke or permit
flames or sparks to occur near sources of spilled fuel or fuel
vapors. Keep the fuel lines and connections tight and in good
condition. Do not replace flexible fuel lines with rigid lines. Use
flexible sections to avoid fuel line breakage caused by
vibration. Do not operate the generator set in the presence of
fuel leaks, fuel accumulation, or sparks. Repair fuel systems
before resuming generator set operation.
Explosive fuel vapors can cause severe injury or death.
Take additional precautions when using the following fuels:
4.1 General
In most installations, both the generator set and the
vehicle’s engine operate from a common fuel tank with a
dual dip tube arrangement. The generator set’s dip tube
may be shorter than the vehicle engine’s dip tube. With
this arrangement, fuel may not be available to the
generator set when the fuel supply is low. See
Figure 4-1 for fuel system schematic.
Vehicles
engine
1
1. Fuel tank
2. Dual dip tubes
3. Fuel filter
2
Figure 4-1 Fuel System Schematic Typical
3
Generator
set fuel
pump
598641
Gasoline—Store gasoline only in approved red containers
clearly marked GASOLINE.
Draining the fuel system. Explosive fuel vapors can
cause severe injury or death. Spilled fuel can cause an
explosion. Use a container to catch fuel when draining the fuel
system. Wipe up spilled fuel after draining the system.
4.2 Float Bowl Vent System
The float bowl vent system prevents fuel from
overflowing into the bilge. In the event of an overflowing
float bowl due to a sticking float valve, the float bowl vent
tube redirects the unused fuel back into the intake per
USCG regulations. Check for fuel leakage at the
backfire flame arrestor for troubleshooting an
overflowing float bowl.
4.3 Fuel Pump and Filter
Electric fuel pumps draw gasoline from the fuel tank,
through a filter, and supply clean gasoline at the proper
pressure and quantity to the generator set engine
carburetor.
TP-5986 4/03 9Section 4 Fuel System
Page 24
4.4 Fuel Pump Troubleshooting
4.5 Carburetor Troubleshooting
The fuel pump transfers fuel from a source to the
carburetor.
Fuel Pump Test Procedure
1. Connect the inlet side of the pump to a fuel source.
2. Disconnect the outlet hose from the fuel filter and
place the end in a container to catch the fuel.
3. Disconnect the P9 connector.
4. Connect the positive (70) terminal of the fuel pump
to the positive (+) terminal of a 12-volt battery.
5. Connect the negative (N) terminal of the fuel pump
to the negative (--) terminal of the battery. The
pump should operate and fuel should discharge
from the pump outlet. If the pump does not operate,
replace the pump.
This section is for fuel-related problems only. Use for
basic carburetor troubleshooting.
Note: When troubleshooting the fuel system, it is
important to have an adequate fuel supply.
A lean or rich fuel condition can reduce power output
and cause poor acceleration.
Symptoms of a Lean Condition:
D Hard starting
D Stalling
D Rough idle
D Surging above idle
Symptoms of a Rich Condition:
D Hard starting
D Stalling
D Rough idle
D Percolation
D Flooding
D Leaking carburetor
Figure 4-2 Fuel System Exploded View
4.5.1 Hard Starting
A flooded engine, improperly adjusted or inoperative
choke, dirty carburetor (lean condition), or improper idle
fuel mixture can cause hard starting.
4.5.2 Stalling
Improper idle air/fuel mixture or a dirty carburetor can
cause stalling. Clogged idle air bleeds, idle air
passages, or an idle discharge port can cause stalling
because of a lean condition. Clean or adjust the
carburetor.
598642
TP-5986 4/0310 Section 4 Fuel System
Page 25
4.5.3 Flooding
Flooding occurs from a float level set too high,
improperly adjusted fuel pressure, improperly installed
fuel pump, a sticking choke plate or float, or a fuel inlet
needle held off its seat either by improper seating or dirt
particles. A punctured or leaking float admitting fuel
becomes gas-logged causing a heavy float, high fuel
level, and flooding.
Note: Never tamper with the governor settings to
increase the generator output. Overspeeding
can cause equipment parts to exceed design
limitations, resulting in component failure.
Governor 60 Hz to 50 Hz Conversion Procedure
1. Change the spring to the 50 Hz position. See
Figure 4-3.
If flooding occurs, disassemble the carburetor, observe
the operation and condition of components, and repair
or replace components as necessary.
4.5.4 Hunting
A low fuel level because of an improperly adjusted float,
a clogged main jet, restricted main jet passages, or an
improperly sized main jet for the application can cause
hunting. Clean, adjust, or replace inoperative
components.
An incorrect throttle linkage adjustment, a binding
throttle linkage, a sticking throttle shaft, or a loose
throttle shaft in the throttle body or bore can cause
inconsistent idle speed.
4.5.5 Leaking Carburetor
Loose fuel connections, a cracked carburetor body, a
sticking fuel inlet needle, or an inoperative float can
cause a leaking carburetor. Adjust, repair, or replace the
affected components.
2. Adjust the generator frequency using a frequency
meter. Set the no load speed at 52.5 Hz for 50 Hz
operation or 63 Hz for 60 Hz operation.
3. Replace the governor speed adjusting bolt. The
50 Hz bolt is X-6284-7 and is 65 mm long. The
60 Hz bolt is M933-5050-60 and is 50 mm long.
4. Adjust the voltage regulator volt/Hz rolloff point.
Refer to Section 7.2.2.
2
1
3
4
598643
4.6 Governor 60 Hz to 50 Hz
Conversion
Governors are adjusted at the factory and further
adjustments should not be necessary.
1. 60 Hz governor spring position
2. 50 Hz governor spring position
3. Governor arm
4. Governor speed adjusting bolt (X-6284-7 for 50 Hz,
M933-5050-60 for 60 Hz)
Figure 4-3 Governor 60 Hz to 50 Hz Conversion
TP-5986 4/03 11Section 4 Fuel System
Page 26
Notes
TP-5986 4/0312 Section 4 Fuel System
Page 27
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
Section 5 Cooling System
engine circulating pump, a water-cooled exhaust
manifold, and an exhaust mixer. See Figure 5-1 for
cooling system components.
12
1
2
3
4
5
6
7
8
9
Seawater
Coolant/Antifreeze
1. Engine block
2. Exhaust manifold
3. Exhaust mixer elbow
4. Outlet flapper
5. Silencer
6. Thermostat
10
11
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-5986 4/03 13Section 5 Cooling System
Page 28
5.2 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
the engine exhaust and ejects out of the exhaust outlet.
The cooling capacity for the 5/7.3E and 4/6EF is 2.84 L
(3.0 qts.). The capacity of the recovery tank is an
additional 0.24 L (8.0 oz.).
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
Checking the coolant level. Hot coolant can cause severe
injury or death. Allow the engine to cool. Release pressure
from the cooling system before removing the pressure cap. To
release pressure, cover the pressure cap with a thick cloth and
then slowly turn the cap counterclockwise to the first stop.
Remove the cap after pressure has been completely released
and the engine has cooled. Check the coolant level at the tank
if the generator set has a coolant recovery tank.
NOTICE
Saltwater damage. Saltwater quickly deteriorates metals.
Wipe up saltwater on and around the generator set and
remove salt deposits from metal surfaces.
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.
5.4 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 hose clamp at the coolant hose. See
Section 1 for location.
2. Remove the pressure cap to simplify draining.
3. Drain, clean, and flush the coolant recovery tank.
5.3 Check and Fill 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
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 until the level is just below the overflow
tube opening.
4. Flush the system with clean water.
5. Replace the hose clamp to secure the coolant
hose.
6. Fill the cooling system with the recommended
coolant.
7. Bleed the air from the cooling system.
8. Replace the pressure cap.
TP-5986 4/0314 Section 5 Cooling System
Page 29
5.5 Impeller
1
This model uses a direct-driven seawater pump located
on the generator end. 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.
Impeller Inspection/Replacement Procedure
1. Close the seacock.
2. Remove the seawater pump coverplate. See
Figure 5-2.
3. Remove the impeller.
4. Inspect the impeller for damaged, cracked, broken,
missing or flattened vanes. The impeller vanes
should be straight and flexible. See Figure 5-3.
Replace the impeller if it is damaged.
1
11
2
3
598653
1. Flat spot
2. Crack
3. Broken vane
Figure 5-3 Worn Impeller
Note: Impeller pieces can cause blockage and
overheating. Locate and remove all missing
impeller pieces from the cooling system.
5. Lubricate the impeller with soapy water before
installation.
6. While installing the impeller, always rotate the drive
shaft and the impeller together in the same
direction as the engine rotation.
10
5
9
1. Seawater pump
2. Coverplate
3. Gasket
4. Impeller
5. Bearing
6. Housing
8
6
7
7. Pulley
8. Drive shaft
9. Washer
10. Nut
11. Mechanical seal,
if equipped
Figure 5-2 Seawater Pump, Typical
7. Inspect the coverplate and gasket for corrosion
and/or damage. Replace components as
2
3
4
necessary.
8. Lubricate the gasket with petroleum jelly and install
the gasket and coverplate to the seawater pump
598652
housing.
9. Open the seacock.
10. Start the generator set and check for leaks.
11. Stop the generator set and repair leaks or replace
components as necessary.
TP-5986 4/03 15Section 5 Cooling System
Page 30
5.6 Siphon Break
4. Check that the reed valve opening is clear.
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 5-4 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 5-4.
3. Use a light detergent to clean the reed valve.
2
3
1
21
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.
8. Restart the generator set and inspect the reed
assembly for leaks. Replace the reed valve if
leakage occurs.
Note: Consult the installation manual for a
complete explanation of the dimensions and
other installation considerations.
7
6
8
9
10
19
Waterline
20
18
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
Figure 5-4 Siphon Break, Plastic “U” Type
5
4
15
16
17
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
14
13
11
12
TP-5586-3
TP-5986 4/0316 Section 5 Cooling System
Page 31
5.7 Anticorrosion Zinc Anode
4. Install the zinc anode into the heat exchanger.
The heat exchanger contains an anticorrosion zinc
anode (plug) to prevent electrolytic corrosion by
seawater.
Check and replace the zinc anode at intervals
recommended by the operation manual’s service
schedule.
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 5-5.
3. Clean the threaded opening of the heat exchanger
and coat the threads of the zinc anode with pipe
sealant suitable for marine applications.
5. Open the seacock.
6. Refill the cooling system.
7. Start the generator set and check for leaks at the
zinc anode 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.
1
2
TP-5586-3
1. Diameter: 9 mm (0.34 in.)
2. Length: 43 mm (1.7 in.)
Figure 5-5 Anticorrosion Zinc Anode (Plug)
TP-5986 4/03 17Section 5 Cooling System
Page 32
5.8 Generator Storage
Perform the generator storage procedure while the craft
is afloat. Follow the procedure below when storing your
generator set for 3 months or more.
Generator Storage Procedure
1. Add fuel stabilizer to the fuel tank of
gasoline-powered generator sets. Follow the fuel
stabilizer manufacturer’s recommendation.
2. Start and run the generator set until it reaches
operating temperature; about 30 minutes.
3. Stop the generator set.
4. Change the oil and oil filter. See the operation
manual.
5. Drain the seawater from the heat exchanger by
removing the seawater zinc anode. See
Section 1.7, Service Views, for location.
6. 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. Kohler Co. recommends using an
environmentally friendly potable antifreeze such as
PeakR RV/marine propylene glycol/water mix or
equivalent.
7. 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. Stop the generator set.
9. Connect the hose to the seacock. Leave the
seacock closed.
10. Check the coolant level of the heat exchanger and
add coolant if necessary.
Note: Use antifreeze with the lowest available
temperature rating.
11. 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.
12. Remove the spark plugs.
13. Pour one tablespoon of engine oil into each spark
plug hole.
14. Toggle the generator set start/stop switch to crank
the engine two or three revolutions to lubricate the
cylinders.
15. Reinstall the spark plugs and torque them to
specifications.
16. 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.
17. Cover the entire unit with a breathable dust cover.
TP-5986 4/0318 Section 5 Cooling System
Page 33
Section 6 Controller Troubleshooting
6.1 Sequence of Operation
This section describes the controller sequence of
operation during the generator start, run, stop, and fault
shutdown modes and describes the relay testing
procedures. Use this section as a starting point for
controller fault identification. Use the LEDs on the
controller circuit board to assist in the troubleshooting
process. An illuminated LED indicates that the
respective relay is receiving power; the LED does not
indicate whether that relay is energized or working
properly.
6.1.1 Start
Close the start/stop switch between N and 47 (local or
remote).
The K2 relay energizes and LED2 is illuminated. The
normally-open K2 contacts close to energize the K3
relay (LED3 lights), fuel pump (FP), choke heater
(CHTR), antidiesel solenoid (ADS), ignition (IGN), and
hourmeter (HR).
The K6 relay energizes. The normally-open K6 contacts
close, latching itself on. The normally-closed K6
contacts open, preventing inadvertent starter
engagement by disabling the the K3 relay.
The K3 relay is deenergized (LED3 Off). The K3
contacts open, deenergizing the K20 relay. The K20
contacts open, deenergizing the starter relay and starter
motor.
2
1
Flashing of the main field occurs when the K2 contacts
close.
The normally-open K3 contacts close to energize the
K20 relay. The normally-open K20 contacts close,
energizing the starter relay and the starter motor.
Note: The normally-closed LOP contacts open when
the engine builds oil pressure. This may take a
few seconds after engine cranking is initiated.
6.1.2 Run
The bridged rectifier (BR1) receives AC voltage
(12--15 volts) through the B1 and B2 windings of the
stator.
The K1 relay energizes (LED1 lights).
The normally-open K1 contacts close to maintain
voltage to the K2 relay, allowing the function of the fuel
pump (FP), choke heater (CHTR), antidiesel solenoid
(ADS), ignition (IGN), hourmeter (HR), and the remote
panel gauges.
The normally-closed K1 contacts open, ending the
flashing by preventing battery voltage to the main field
(+) and (--).
3
6
5
4
598161
1. Controller circuit board
2. PBIIIE voltage regulator
3. K20 relay
4. Fuses
5. Start/stop switch
6. Hourmeter
Figure 6-1 Controller
TP-5986 4/03 19Section 6 Controller Troubleshooting
Page 34
At the same time the K1 relay is energized, the time
delay for the K5 relay starts. After 5--10 seconds, the K5
relay is energized (LED 5 lights).
The normally-open K5 contacts close to permit the
function of the engine safety shutdown switches.
6.1.3 Stop
Close the start/stop switch between N and 43 (local or
remote).
The K4 relay energizes (LED4 lights).
The normally-closed K4 contacts open, disabling the
fuel pump (FP), choke heater (CHTR), antidiesel
solenoid (ADS), and ignition (IGN).
The normally-open K4 contacts close, latching the
circuit to the K4 relay until the generator set comes to a
complete stop.
6.2 Engine Safety Shutdown
Switches
The generator shuts down, as described in
Section 6.1.3.
Note: During cranking, the low oil pressure shutdown
switch deactivates until the K5 relay energizes.
This delay allows the engine to reach normal
operating oil pressure.
6.2.2 Loss of Coolant Switch (LCS)
Shutdown
When the coolant level is low, the LCS contacts close,
energizing the K4 relay (LED4 lights). The generator
shuts down, as described in Section 6.1.3.
6.2.3 High Engine Temperature Switch
(HET) Shutdown
When the engine temperature exceeds 110_C (230_F),
the HET contacts close, energizing the K4 relay (LED4
lights). The generator shuts down, as described in
Section 6.1.3.
6.2.4 Controller Circuit Board
6.2.1 Low Oil Pressure (LOP) Shutdown
When low oil pressure occurs, the LOP shutdown switch
contacts close energizing the K4 relay (LED4 lights).
11
The controller circuit board has light emitting diodes
(LEDs) that indicate the presence of relay coil power.
When any of the relays K1--K5 receive power, the
corresponding LED lights.
Figure 6-2 GM10516 Controller Circuit Board
GM10516
TP-5986 4/0320 Section 6 Controller Troubleshooting
Page 35
6.2.5 Troubleshooting
Use the following flowchart as an aid in troubleshooting
the main circuit board and the entire generator set. If the
prescribed remedy does not correct the problem, the
circuit board may have to be replaced. Use this chart for
component testing only. Always check the continuity of
the wires between components.
Press the start switch
(local or remote).
Does the K2 relay LED
light while cranking?
No
Is 10-amp controller
fuse functional?
YesNo
Does the engine crank?
Check the battery
condition and
connections.
Is there continuity between
N and 47 while pressing
the start/stop switch?
Yes
No
TheK2relayis
faulty. Replace
the circuit board.
No
Yes
Is the K3 relay LED lit?
Is voltage present at the K20 relay coil
(P1-4 connector)?
No
TheK2relayis
faulty. Replace
the circuit board.
No
Go to A
(next page).
Yes
Yes
Replace or repair
the wiring harness.
Replace the fuse.
Replace the circuit
board.
Yes
Yes
Is there 12 volts
at P1--14?
No
Replace or repair
the wiring harness.
Replace the
K20 relay.
Figure 6-3 Troubleshooting Relay Controller Circuit Board (1 of 4)
Is voltage present
at the starter relay?
No
Replace the starter
relay.
Yes
Is voltage present at
the starter?
No
Yes
Replace or
repair the
starter motor.
TP-5986 4/03 21Section 6 Controller Troubleshooting
Page 36
A
Does the engine start?
Yes
Go to B
(next page).
No
No
Is there continuity
between P1-9 and P9-1?
No
No
No
Is there continuity
between P9-2 and P1-8?
Is there continuity
between P1-8 and P1-14?
Is the K4 relay LED lit?
No
Is there12 volts DC
present at the fuel
pump (P9-2)?
Yes
Yes
Yes
Is there continuity across the
P1, P4, and P9 connectors?
Yes
Replace the
fuel pump.
Yes
Is the fuel
pump working?
No
Yes
Troubleshoot the engine.
refer to the engine service
manual.
Is there continuity between
P4-5 and N?
Go to C
No
(next page).
Is there continuity between
P2-8 and N?
Yes
Disconnect the P2 connector.
Is there continuity between
P2-5 and N?
Yes
Check the wiring for
Yes
open circuits.
Check the connectors
for open circuits.
Figure 6-4 Troubleshooting Relay Controller Circuit Board (2 of 4)
No
Replace the remote
start/stop switch.
Yes
Replace the
start/stop switch.
TP-5986 4/0322 Section 6 Controller Troubleshooting
Page 37
B
to run after the start
Yes
switch is released?
Does the engine continue
Does using the stop switch
stop the engine?
Yes
No
The generator set is
No
C
Did the K4 relay LED light?
functioning properly?
No
Does the K5 relay LED
light after 5--10 seconds
of running time?
No
Replace the circuit
board (the K5 relay
is inoperative).
Go to D
(next page).
Does the K1
relay LED light?
Yes
Is the K3 LED out?
No
Replace the circuit board
(the K6 relay is inoperative).
Check the oil level.
Repair/replace the oil pump.
Yes
Yes
Yes
No
Replace
LOP switch.
Is the LOP switch
functional?
Yes
Does the engine have proper oil
pressure? Use a mechanical
gauge to verify pressure.
No
Yes
Replace the inoperative
temperature switch.
Replace the switch.
No
No
Replace the
circuit board
(inoperative
No
K4 relay).
Fill the cooling
system and check
for leaks.
Figure 6-5 Troubleshooting Relay Controller Circuit Board (3 of 4)
Is the temperature
(HET) safety shutdown
switch functional?
Yes
Is the low coolant
switch functional?
Yes
Is the coolant level low?
Yes
TP-5986 4/03 23Section 6 Controller Troubleshooting
Page 38
Is there AC output
when the start button
D
is held and the unit is
running?
No
Is there approximately
12VDC at the exciter field?
Yes
No
Separately excite the
generator set to
determine if other
components are
inoperative. (See
Section 7.1.2,
Separate Excitation).
Is there AC output
voltage?
No
Is the stator and rotor
functional?
No
Is there 12 volts AC output at
the B1/B2 stator winding?
Yes
Yes
Is the voltage regulator
fuse functional?
No
Is the stator
functional?
No
Replace
the stator.
Yes
Yes
Replace the
circuit board.
Replace the
circuit board.
Replace inoperative
components.
No
Replace the fuse.
Figure 6-6 Troubleshooting Relay Controller Circuit Board (4 of 4)
No
Is the voltage
regulator
functional?
Yes
Replace the voltage
regulator.
TP-5986 4/0324 Section 6 Controller Troubleshooting
Page 39
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.
7.1.1 Troubleshooting
To determine the cause of no- or low-AC output , refer to
the following steps and the troubleshooting flowchart
(Figure 7-1). Verify the operation of the alternator
components before replacing the controller board or
voltage regulator.
General Troubleshooting
1. Check the condition of the voltage regulator’s
10-amp fuse.
2. If the fuse is functional, separately excite the
generator. See Section 7.1.2. The separate
excitation test duplicates the role of the voltage
regulator by providing excitation current to the
rotor.
Generator has no
output
Check for flashing
voltage at the brushes
Troubleshoot controller
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator
set, transfer switch, and related equipment and electrical
circuits to comply with applicable codes and standards. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk of
electrocution.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
Separately
excite
generator
Generator has no
output
Test r o tor
Generator has output
regulator and
Figure 7-1 General Troubleshooting
Test voltage
wiring
Test stator
TP-598651
TP-5986 4/03 25Section 7 Generator Troubleshooting
Page 40
7.1.2 Separate Excitation
By separately exciting the generator to determine the
presence of a faulty voltage regulator, it is possible to
determine if a running fault exists in the rotor and/or
stator. A generator component that appears functional
while static (stationary) may exhibit a running open or
short circuit while dynamic (moving). Centrifugal forces
acting on the windings during rotation or insulation
breakdown as temperatures increase can cause short
circuits.
Note: It is not necessary to separately excite the
generator if there is AC output with flashing
voltage.
Separate Excitation Procedure
1. Disconnect all of the leads from the voltage
regulator.
2. Disconnect the P10 (F1, F2) connector.
3. Connect a separate excitation circuit as shown in
Figure 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 rotor
resistance (cold). See Section 1, Specifications,
for the correct values.
7. Remove the jumper wire and reverse the
positive (+) and negative (--) leads on the rotor.
Repeat step 5. If the ammeter is stable, ground the
negative (--) lead at its new location on the rotor to
the engine block. Replace the rotor if the ammeter
reading fluctuates.
8. Check for AC output across the stator leads and
compare the measured output to the values in
Section 1, Specifications. If the output varies
considerably from those listed, a faulty stator, rotor,
rectifier module, or armature is likely.
If there is no generator output during normal operation
but output is available when the generator set is
separately excited, the voltage regulator may be
inoperative.
Note: See Section 1, Specifications, for the stator
output voltages (with separately excited
generator). These specifications are based on a
battery voltage of 12 volts. Should the battery
voltage vary, the resulting stator output values will
also vary.
1
5
A
11
4
2 3
Example:
12 Volts (Battery Voltage)
3.4 Ohms Rotor Resistance
3.5-amp
=
Ammeter reading
5. Start the engine and check that the ammeter
remains stable. An increasing meter reading
indicates a shorted rotor. A decreasing meter
reading to zero, or unstable reading, suggests a
running open in the rotor. If the ammeter is stable,
continue with step 6.
6. With a jumper wire, ground the negative (--) lead
from the rotor to the engine block. An increased
current reading or a fluctuating reading indicates a
grounded rotor winding. Replace the rotor if the
ammeter reading fluctuates. If the ammeter is
stable, continue with step 7.
10
1. Voltage regulator
2. (--) Terminal—(P10-2)
3. (+) Terminal—(P10-1)
4. 10-amp fuse
5. DC ammeter
6. 12-volt battery (DC)
+—
7
8
9
+—
7. Brushes
8. Collector rings
9. Main field (rotor)
10. Jumper lead
11. Engine ground
Figure 7-2 Separate Excitation Connections
6
TP-598652
TP-5986 4/0326 Section 7 Generator Troubleshooting
Page 41
7.2 PowerBoosttIIIE Voltage
Regulators
Regulator Test Procedure
1. Connect the components as shown in Figure 7-4.
The generator set is equipped with a PowerBoostt IIIE
voltage regulator. See Figure 7-3.
1
1. Voltage adjustment potentiometer
2. Stability adjustment potentiometer
3. Volts/Hz adjustment potentiometer
3
2
TP-598653
Figure 7-3 PowerBoostt IIIE Voltage Regulator
The voltage regulator monitors the output voltage of the
generator set.
The 10-amp regulator fuse protects the alternator stator
windings (power supply) 55-33 from excessive current
draw because of an inoperative voltage regulator or a
downstream short. If the regulator’s 10-amp fuse blows,
the generator set will shut down. Verify that the regulator
fuse is functional before proceeding with the test.
7.2.1 Voltage Regulator Test
Perform the following test to check the regulator output.
Use the following components to test the voltage
regulator:
2. Turn the variable transformer setting to zero. Plug
in the variable transformer.
3. Turn the variable transformer on. Slowly increase
the variable transformer 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. A voltage
regulator which tests bad 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.
4
2
1
3
66 443355--+
RYOW
GY
5
BK
6
7
D Variable transformer, 0--140 volts, 0.5-amp minimum
D Plug, 120 volts AC
D Lamp, 120 volts, 100 watts
D AC voltmeter
D Insulated copper wire, #14 AWG, minimum
TP-5986 4/03 27Section 7 Generator Troubleshooting
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
Figure 7-4 PowerBoosttIIIE Voltage Regulator Test
Page 42
7.2.2 Voltage Regulator Adjustment
Voltage Regulator Adjustment Procedure
The factory sets the voltage regulator and under normal
circumstances the regulator requires no further
adjustment. However, if the voltage regulator has been
replaced or tampered with, or if voltage/frequency
reconnection has been done, readjust the voltage
regulator according to the following procedure. See
Figure 7-5. 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 minimize
AC voltage fluctuation.
1
3
15
33
2
66
GY R
3
44 33 55
YOWBK
66
33
4
44
14
B1
12
B2
1. Optional remote rheostat
2. Voltage adjustment pot
3. PowerBoost™ IIIE voltage regulator
4. Stabilizer pot
5. Volts/Hz pot
6. Stator/rotor connections (for reference only)
7. DC output
8. Rotor
9. 10-amp fuse
10. AC power input (aux.)
11. Main (2 and 1)
12. Control
13. Stator
14. Sensing
15. Main (3 and 4)
13
2
11
55
9
1
10
4
5
6
+
--
7
8
+
--
TP-598655
Figure 7-5 PowerBoostt IIIE Voltage Regulator
Volts/Hz Pot feature allows the voltage to drop if the
load imposed on the generator causes the engine speed
to fall below a predetermined RPM or frequency. This
reduction of voltage results in a decrease of starting kW
(load) allowing the governor to recover the engine
speed.
1. Stop the generator set.
2. Turn the remote rheostat, if equipped, to the
midpoint. Turn the voltage and stabilizer pots fully
counterclockwise. Connect the voltmeter to the AC
circuit or an electrical outlet.
3. Start the generator set.
4. Adjust the generator frequency using a frequency
meter. Set the no load speed at 52.5 Hz for 50 Hz
operation or 63 Hz for 60 Hz operation.
5. Rotate the voltage adjustment pot clockwise to
increase the voltage or counterclockwise to
decrease the voltage to achieve the desired output
voltage.
6. Connect a 120-volt light bulb to the AC plug on the
generator set.
7. Rotate the stability pot clockwise until the light bulb
flickers minimally.
8. Readjust the voltage adjustment pot to achieve the
desired output voltage.
9. Disconnect the 120-volt light bulb.
10. Turn the volts/Hz pot completely clockwise to
decrease the Hz rolloff point. See Figure 7-6.
125
120
115
110
Volts (AC)
105
100
40 42 44 46 48 50 52 54 56 58 60 62 64
Frequency (Hz)
60Hz Models
50Hz Models
Counterclockwise to increase Hz rolloff
Clockwise to decrease Hz rolloff
Figure 7-6 Volts/Hz Rolloff Chart
TP-5986 4/0328 Section 7 Generator Troubleshooting
Page 43
11. Set engine speed to 47.5 Hz for 50 Hz generator
sets and 57.5 Hz for 60 Hz generator sets for the
desired cut-in frequency.
12. Slowly turn the volts/Hz pot counterclockwise until
the frequency matches that of the engine
frequency (47.5 or 57.5 Hz) or until the voltage just
begins to drop.
13. Reset the engine speed to the normal frequency
(50Hzor60Hz).
Note: Use the values in Section 1 as a reference for
rotor resistance readings. Take readings at room
temperature or about 21°C(70°F). Rotor
resistance will vary directly with increase in
temperature.
To check whether the rotor is shorted to ground, touch
one ohmmeter lead to either collector ring and the other
lead to the rotor poles or shaft. The meter should
register no continuity.
14. Recheck the AC voltage output and stability as
described in steps 5--7.
15. Stop the generator set.
7.3 Rotor
The two-pole rotor creates the magnetic field needed to
sustain alternating current in the stator windings. Before
testing, inspect the rotor for visible damage to pole
shoes, insulation, exposed coil windings, and collector
ring surfaces. Check the rotor bearing for noisy
operation, excessive wear, radial or axial movement,
and/or heat discoloration. Replace or repair as
necessary.
Collector rings acquire a glossy brown finish in normal
operation. Do not attempt to maintain a bright, newly
machined appearance. Wipe the collector rings with a
dry, lint-free cloth. Use a commutator stone to remove
the groves on the collector rings. Do not use emery or
carborundum paper or cloth. Remove all carbon dust
from the generator. Remove the black or pitted surface
of the collector rings using a lathe.
Check the rotor for continuity and resistance. Lift the
brushes and measure the rotor resistance between the
two collector rings. See Section 1.5.
Note: When checking rotor resistance with the rotor
installed, brushes must not be in contact with
rotor collector rings. Use a brush retainer on
brushes for accurate resistance readings.
Repair or replace the rotor if the previous tests detect
any faults.
7.4 Stator
The stator consists of a series of coils of wire laid in a
laminated steel frame. The stator leads supply voltage
to the AC load and exciter regulator. See Figure 7-7 for
coil lead description.
Stator Leads Description
1--2 Output coil
3--4 Output coil
33--44 Control wires from 3 and 4
55--33 Voltage regulator power source
B1--B2 Controller power source
Figure 7-7 Stator Coil Lead Description
Before testing the stator, inspect it for heat discoloration
and visible damage to the exposed coil windings and
varnished areas of the frame laminations. Be sure the
stator is securely fastened in the stator housing.
The stator produces electrical output (AC) as the
magnetized main field rotates within the stator windings.
Test the condition of the stator according to the following
procedure.
Leads 1, 2, 3, and 4 are the generator output leads.
Leads 33, 44, and 55 are the voltage regulator supply
and sensing leads. The output of leads B1 and B2 is the
control voltage for the controller.
TP-5986 4/03 29Section 7 Generator Troubleshooting
Page 44
Stator Test Procedure
1. Place the generator start/stop switch in the STOP
position.
2. Disconnect the generator set engine starting
battery, negative (--) lead first.
3. Check the generator output lead connections. See
Section 10, Wiring Diagrams and Voltage
Reconnection.
4. Disconnect all of the stator leads to isolate the
windings. To check the stator continuity, set the
ohmmeter on the R x 1 scale. Check the stator
continuity by connecting the meter leads to the
stator leads as shown in Figure 7-8. Perform the
stator tests on all the stator windings.
Note: When taking an ohmmeter reading using
lead 55, make the connection prior to the
in-line fuse.
5. Check the cold resistance of the stator windings by
connecting the meter leads to the stator leads 1-4,
2-5, 3-6, etc. See Section 1, Specifications, for the
stator resistance values.
6. Perform a megohmmeter test on the stator as
described in step 7.
Note: Consider the stator functional if the
resistance reading (continuity) is low and
there is no evidence of shorted windings
(heat discoloration).
Note: The stator resistance varies directly with
increased temperature.
If the stator readings vary considerably during the
previous checks, repair or replace the stator.
7. Check the stator for a grounded condition using a
megohmmeter. Apply 500 volts DC to any stator
lead from each winding and the stator frame.
Follow the instructions of the megohmmeter
manufacturer when performing this test. Repeat
the test on the other leads until all the stator
windings have been tested. A reading of
approximately 3--5 megohms and higher indicates
the stator is functional. A reading of less than
approximately 3--5 megohms indicates
deterioration of the winding insulation and possible
current flow to ground. Replace the stator.
Between Leads Continuity
1 and 2
3 and 4
55 and 66
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
Yes
Yes
Yes
Yes
No
No
No
No
No
Figure 7-8 Stator Continuity
TP-5986 4/0330 Section 7 Generator Troubleshooting
Page 45
7.5 Brushes
The brushes provide a current path from the voltage
regulator to the collector rings. Because the brushes
carry a low current, inspect them every
1000--1500 hours. Abrasive dust on the collector rings
could, however, shorten the life of the brushes.
Excessive arcing at the brushes could damage the
voltage regulator. Weak springs, damaged collector
rings, sticking brushes, a loose holder, or poor brush
contact can cause arcing at the brushes.
The brushes must be free to move within the holder and
be held in contact by the springs. When properly
positioned, spring pressure on the brush surface will
cause the brush to wear evenly. Brushes must ride
100% on the collector rings or arcing will occur and
cause burned rings or failure of the voltage regulator.
Figure 7-9 shows the correct positioning of the brushes.
Add or remove spacers as necessary to center brushes
on collector rings. Replace brushes if they show
excessive or uneven wear.
Use a retainer wire (such as a paper clip) to contain the
brushes during disassembly and reassembly. Push the
brushes into the brush holder until the retainer wire can
be inserted into the brush keeping hole. See
Figure 7-10. Replace brushes when they are worn to
half of their original size.
1
6
2
3
4
5
1
1. Correct position
2. Brush holder
3. Incorrect position
4. Generator collector rings
Figure 7-9 Brush Positioning
2
3
1. Brush holder
2. Retainer (paper clip)
3. Mounting screw
4. Alignment shim(s)
5. Brush
6. Spring
TP-598658
Figure 7-10 Brush Holder
4
TP-598657
TP-5986 4/03 31Section 7 Generator Troubleshooting
Page 46
Notes
TP-5986 4/0332 Section 7 Generator Troubleshooting
Page 47
Section 8 Component Troubleshooting
8.1 Engine/Generator Components
See Figure 8-1 through Figure 8-3 for engine/generator
component testing.
With the generator set battery connected, check the
wiring harness and the engine/generator components
Component Voltmeter Connections Procedure Results
Hourmeter and wiring Connect the red test lead to
Stator auxiliary winding B1
and B2
the hourmeter positive (+)
terminal. Connect the black
test lead to the hourmeter
negative (--) terminal.
None (see Procedure) Disconnect the hourmeter
Connect the AC voltmeter
leads to the B1 and B2
windings at connector P11.
Stop the generator set.
listed in the following tables. Check each component
using a multimeter to verify that the switches function
and that voltage is present at each component.
Set the voltmeter to 12 volts
DC or greater. Start the
generator set.
leads and apply 12 volts DC
to the hourmeter. The
hourmeter is polarity
sensitive.
Set the voltmeter setting 20
volts AC or greater. Crank
the generator set and allow
the set to reach rated its
speed.
A 12 volt DC reading
indicates the wiring harness
is functional.
If functional, hourmeter
operates.
A reading of 12--15 volts AC
indicates a functional B1/B2
winding.
Figure 8-1 Engine/Generator Component Testing, Relay Controller
TP-5986 4/03 33Section 8 Component Troubleshooting
Page 48
WARNING
To further check the generator set components,
disconnect the battery and remove the wiring harness
plugs from the controller circuit board. Use an
ohmmeter to check the continuity of the components
and to isolate inoperative components. Refer to
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
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
Moving rotor.
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.
Figure 8-2 and Figure 8-3.
Note: Before performing ohmmeter checks, disconnect
the generator set battery to prevent damage to
the ohmmeter.
Place the ohmmeter on the
R x 1000 scale. Place the
rocker switch in the START
position.
Place the ohmmeter on the
R x 1000 scale. Place the
rocker switch in the STOP
position.
Place the ohmmeter on the
Rx1scale.
Place the ohmmeter on the
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 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.
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-5986 4/0334 Section 8 Component Troubleshooting
Page 49
Component Ohmmeter Connections Procedure Results
Main field (rotor) Disconnect the P10 and P11
B1/B2 stator windings Connect the ohmmeter to the
P1 ground connection Connect the ohmmeter to the
Low oil pressure (LOP)
safety shutdown switch
High exhaust
temperature (HET), low
coolant (LCS) safety
shutdown switches
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
P13-1 and engine block
(ground).
Connect the ohmmeter to the
P1-15 and engine block
(ground). Note: Remove and
isolate the LOP switch lead.
Place the ohmmeter on the
Rx1scale.
Place the ohmmeter on the
Rx1scale.
Place the ohmmeter on the
Rx1scale.
Place the ohmmeter on the
R x 1000 scale. This test is
not conclusive until the
temperature shutdown
switches are checked.
Place the ohmmeter on the
R x 1000 scale.
If functional, see Section 1,
Specifications. Low
resistance, rotor windings
shorted. High resistance,
rotor windings open.
If functional, see Section 1,
Specifications. 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, zero ohms
(continuity). Then, disconnect
LOP switch lead and isolate
terminal. Meter reading
should show an open circuit.
If functional, open circuit. Any
continuity suggests an
inoperative temperature
switch(es). Disconnect
individual leads to inoperative
switch.
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
Figure 8-4 Water Temperature Sender Resistance
switch, gauges, and gauge senders using the following
procedures. See Sections 10.6, 10.7, or 10.8 to identify
the location for the appropriate panel.
Figure 8-5 Oil Pressure Sender Resistance
2-Meter and 4-Meter Panels Temperature
60_C (140_F) 134.0 ±10 ohms
90_C (194_F) 51.5 ± 4 ohms
100_C (212_F) 38.0 ± 3 ohms
2-Meter and 4-Meter Panels Pressure
0 kPa (0 psi) 10 ohms
345 kPa (50 psi) 80 ohms
690 kPa (100 psi) 135 ohms
TP-5986 4/03 35Section 8 Component Troubleshooting
Page 50
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
.
Generator set ON light,
gauge lights, DC voltmeter,
and hourmeter
terminal
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
R x 1 scale. Press the rocker
switch to the START position.
Place the ohmmeter on the
R x 1 scale. Press the rocker
switch to the STOP position.
If 12 volts DC is present and
the component does not
function after the J3 is
connected to the controller
P3, replace the component.
Place the controller rocker
switch to the START position.
Stop the generator set when
the test is complete.
Start the generator set for the
test. If 0.5--12-volts DC is
present and the gauge does
not function after the J3 is
connected to controller,
replace the gauge.
Start the generator set for the
test. If 0.5--12-volts DC is
present and the gauge does
not function after the J3 is
connected to the controller,
replace the gauge.
Continuity, the switch is
functional.
Continuity, the switch is
functional.
Voltmeter setting 12 volts or
greater. Generator set does
not need to be running, just
cranking for this test.
Note: If the hourmeter is not
illuminated, test by
connecting it to a 12-volt
battery.
Note: The hourmeter is
polarity sensitive.
Voltmeter setting 12 volts or
greater.
Voltmeter setting 12 volts or
greater.
Figure 8-6 Remote Start Panels Troubleshooting
TP-5986 4/0336 Section 8 Component Troubleshooting
Page 51
Section 9 Generator Disassembly/Reassembly
9.1 Disassembly
Disconnect the external connections—battery cables at
the battery (negative (--) lead first), AC-output leads in
the controller, remote start panel at the controller P3
connector, water line at the seawater pump, fuel line at
the fuel pump filter inlet, and exhaust line at the mixing
elbow. Observe all of the safety precautions listed
during the disassembly/reassembly procedures.
Disassembly Procedure
1. Place the start/stop switch in the STOP position.
2. Disconnect the generator set engine starting
battery, the negative (--) lead first.
3. Remove the controller cover.
4. Disconnect the P4 (22-pin) connector from J4.
5. Disconnect the controller ground strap (generator
side).
Note: It is possible to connect the output leads in
various positions for different voltage
configurations. Mark the leads for correct
reconnection.
6. Disconnect the generator output leads 1, 2, 3, and
4 from the circuit breaker and the neutral stud (L0).
1
2
3
598691
1. Alternator end cover
2. Water pump
3. Vibromount nuts
Figure 9-1 Alternator end cover
14. Push the brushes into the holder. Secure the
brushes into position by sliding a retainer into the
brush keeping holes. Refer to Section 7.5.
15. Remove the brush holder and carefully pull the
leads out of the stator housing. See Figure 9-3.
16. Remove the generator side vibromount nuts. See
Figure 9-1.
17. Tilt the generator set up and brace it with a block of
wood. Figure 9-2.
7. Disconnect the P11 (FP and FN) and P10 (F1 and
F2) connectors.
8. Remove the fuel inlet hose.
9. Close the seacock and remove the water inlet hose
from the water pump.
10. Remove the sound shield enclosure, if equipped.
11. If the generator set is not equipped with a sound
shield enclosure, lift the controller from the rubber
mounts while guiding the leads through the bottom
opening of the controller box.
12. Remove the fuel pump and line from the generator.
13. Remove the alternator coverplate. See Figure 9-1.
1
598691
1. Block of wood
Figure 9-2 Raising the Generator
TP-5986 4/03 37Section 9 Generator Disassembly/Reassembly
Page 52
3, 4, 5 6
10 11
2
9
8
1
9
8
1. Generator adapter plate bolt, quantity 4
2. Generator adapter
3. Spring
4. Brush holder
5. Brush, quantity 2
6. Brush holder shim
7. Rotor bolt
8. Hardened washer
9. Generator overbolt, quantity 4
10. Retainer wire
11. Brush assembly mounting screws, quantity 2
7
12
1314
88
1718192021
12. Bracket, brush holder
13. Fan guard bolts, quantity 2
14. Fan guard
15. End bracket
16. Pipe plug
17. End drive fitting
18. End bracket bearing
19. O-ring
20. Stator assembly
21. Rotor assembly
1516
99
201-191-1
Figure 9-3 Alternator Assembly Components
1. Rotor bolt
2. Hammer
Figure 9-4 Removing the Rotor
18. Remove the end bracket overbolts. See
Figure 9-3. Use a rubber mallet to separate the
1
end bracket from the stator housing.
19. Carefully remove the stator assembly from the
generator adaptor plate.
20. Remove the rotor bolt and end drive fitting.
2
21. Reinstall the rotor bolt (without end fitting), finger
tighten, and back off two turns.
598692
22. Strike the bolt with a hammer until the rotor is freed
from the engine tapered drive shaft. Do not
damage through bolt threads or bolt head. See
Figure 9-4.
TP-5986 4/0338 Section 9 Generator Disassembly/Reassembly
Page 53
9.2 Collector Ring and Bearing
Replacement
9. Install the sound shield enclosure.
10. Install the fuel line and fuel pump.
1. Unsolder the collector ring leads from the collector
ring terminals.
2. Remove the collector rings with a three-jaw puller.
3. Remove the bearing with a three-jaw puller.
4. Press the new bearing onto the rotor shaft.
5. Align the collector ring keyway with the keyway on
the rotor shaft. See Figure 9-6.
6. Press the new collector rings onto the rotor shaft.
Note: The new collector rings must be turned
downtoafinishof32microinchesusinga
lathe and commutator stones. Turn down
the collector rings on the rotor shaft.
7. Solder the leads onto the collector ring terminals.
The connection is not to exceed 9.65 mm (0.38 in.)
beyond the collector rings. See Figure 9-6.
8. Test to ensure continuity at the collector rings.
11. Reconnect the water inlet hose to the water pump.
12. Guide the leads from the stator through the bottom
opening of the controller. Secure the controller.
13. Reconnect the leads from the stator to the
controller using the reverse procedure of that listed
in Section 9.1. Refer to Section 10, Wiring
Diagrams.
14. Connect the generator set starting battery, the
positive (+) lead first.
15. Test the generator operation.
Min. diameter mm (in.) 57.15 (2.250)
Max. finish 32 micro inches
Max. eccentricity mm (in.) 0.08 (0.003)
Max. out-of-round mm (in.) 0.01 (0.0002)
Figure 9-5 Collector Ring Dimensions
.38 maximum
(as soldered)
9.3 Reassembly
1. Apply antiseize compound to the tapered shaft of
the engine.
2. Align the rotor onto the engine shaft and secure
with the end drive fitting and rotor bolt. Torque the
rotor to 23.1 Nm (204 in. lbs.).
3. Carefully slide the stator assembly over the rotor.
4. Replace the end bracket o-ring.
5. Install the end bracket and torque the overbolts to
13.6 Nm (120 in. lbs).
6. Feed the brush leads inside the stator housing up
through the opening. Secure the brush holder
using the original screws.
7. Remove the brush retainer and check the brush
alignment. See Section 7.5.
8. Install the coverplate and torque the coverplate
bolts to 6.8 Nm (60 in. lbs.).
90°
2
View A-A
1. Collector ring leads
2. Keyways
Figure 9-6 Rotor Assembly
A
A
1
598695
TP-5986 4/03 39Section 9 Generator Disassembly/Reassembly
Page 54
Notes
TP-5986 4/0340 Section 9 Generator Disassembly/Reassembly
Page 55
Section 10 Wiring Diagrams and Voltage Reconnection
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.
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator
set, transfer switch, and related equipment and electrical
circuits to comply with applicable codes and standards. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk of
electrocution.
Moving rotor.
TP-5986 4/03 41Section 10 Wiring Diagrams and Voltage Reconnection
Page 56
10.1 Schematic Wiring Diagram
359343-J
TP-5986 4/0342 Section 10 Wiring Diagrams and Voltage Reconnection
Page 57
10.2 Point-to-Point Wiring Diagram
TP-5986 4/03 43Section 10 Wiring Diagrams and Voltage Reconnection
359343-J
Page 58
10.3 Reconnection Diagram
100--120 V, 60 & 50 Hz
10.5 Reconnection Diagram
220--240 V, 50 Hz
10.4 Reconnection Diagram
100--120/200--240 V, 60 & 50 Hz
ADV-5857
ADV-5857
10.6 Remote Start Panel
+--
P
10-amp
Fuse
P
P1-14
P2-3 P2-7 P2-8 P2-9
70
P3-4
J3-4 J3-5 J3-1J3-6
Violet
47
P2-4
K2
K1
47
P3-5 P3-6 P3-1
Yellow/
Red
Local
switch
Start
Relay
circuit
board
Grey/
Black
Stop
Start
Stop
43
P2-5 P2-6
43
Remote
switch
ADV-5857
N
P1-9
N
N
Black
Gen. ON light
TP-5588-7
TP-5986 4/0344 Section 10 Wiring Diagrams and Voltage Reconnection
Page 59
10.7 Remote Start and Two-Meter
Panel
10.8 Remote Start and Four-Meter
Panel
+--
P
10-amp
fuse
P
P1-14
K2
K1
P2-3
70
P3-4
J3-4 J3-5
Violet
Yellow/
Red
47
P2-4
P2-7
47
P3-5 P3-6
Local
switch
Start
Relay
circuit
board
Grey/
Black
Stop
Start
Stop
43
P2-5 P2-6
P2-8 P2-9
43
P3-1
J3-6
Remote
switch
N
P1-9
N
N
J3-1
Black
W.T.
sender
P4-2 P4-3
7C
5
P3-2
P3-3
J3-2
Tan
L. Blue
O.P.
sender
J3-3
+--
P
10-amp
fuse
P
P1-14
K2
K1
P2-3
70
P3-4
J3-4 J3-5
Violet
Yellow/
Red
Gen. ON light
47
P2-4
P2-7
47
P3-5
Local
switch
Start
Relay
circuit
board
Grey/
Black
Stop
Start
Stop
P2-8 P2-9
P3-6
Remote
switch
43
P2-5 P2-6
43
P3-1
J3-6
N
P1-9
N
N
W.T.
sender
P4-2 P4-3
7C
5
P3-2
J3-1 J3-2 J3-3
Black
P3-3
Tan
O.P.
sender
L. Blue
Gen. ON light
Water temp.
gauge
Oil pressure
gauge
TP-5588-7
Water temp.
gauge
Oil pressure
gauge
DC voltmeter
Hourmeter
TP-5588-7
TP-5986 4/03 45Section 10 Wiring Diagrams and Voltage Reconnection
Page 60
Notes
TP-5986 4/0346 Section 10 Wiring Diagrams and Voltage Reconnection
Page 61
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
cfh cubic feet per hour
cfm cubic feet per minute
drawing
temperature
Institute
Institute
(formerly American Standards
Association, ASA)
suggested
Mechanical Engineers
Materials
charging
(engine)
CG center of gravity
CID cubic inch displacement
CL centerline
cm centimeter
CMOS complementary metal oxide
cogen. cogeneration
Com communications (port)
conn. connection
cont. continued
CPVC chlorinated polyvinyl chloride
crit. critical
CRT cathode ray tube
CSA Canadian Standards
CT current transformer
Cu copper
cu. in. cubic inch
cw. clockwise
CWC city water-cooled
cyl. cylinder
D/A digital to analog
DAC digital to analog converter
dB decibel
dBA decibel (A weighted)
DC direct current
DCR direct current resistance
deg., ° degree
dept. department
dia. diameter
DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung
DIP dual inline package
DPDT double-pole, double-throw
DPST double-pole, single-throw
DS disconnect switch
DVR digital voltage regulator
E, emer. emergency (power source)
EDI electronic data interchange
EFR emergency frequency relay
e.g. for example (exempli gratia)
EG electronic governor
EGSA Electrical Generating Systems
EIA Electronic Industries
EI/EO end inlet/end outlet
EMI electromagnetic interference
emiss. emission
eng. engine
EPA Environmental Protection
EPS emergency power system
ER emergency relay
ES engineering special,
ESD electrostatic discharge
est. estimated
E-Stop emergency stop
etc. et cetera (and so forth)
exh. exhaust
ext. external
F Fahrenheit, female
substrate (semiconductor)
Association
e. V.
(also Deutsche Industrie
Normenausschuss)
Association
Association
Agency
engineered special
fglass. fiberglass
FHM flat head machine (screw)
fl. oz. fluid ounce
flex. flexible
freq. frequency
FS full scale
ft. foot, feet
ft. lbs. foot pounds (torque)
ft./min. feet per minute
ggram
ga. gauge (meters, wire size)
gal. gallon
gen. generator
genset generator set
GFI ground fault interrupter
GND,
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. lbs. inch pounds
Inc. incorporated
ind. industrial
int. internal
int./ext. internal/external
I/O input/output
IP iron pipe
ISO International Organization for
J joule
JIS Japanese Industry Standard
k kilo (1000)
K kelvin
kA kiloampere
KB kilobyte (2
ground
conditioning
Commission
Electronics Engineers
O inches of water
2
Standardization
10
bytes)
TP-5986 4/03 Appendix A-1
Page 62
kg kilogram
2
kg/cm
kgm kilogram-meter
kg/m
kilograms per square
centimeter
3
kilograms per cubic meter
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
3
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
wa
sound power level, A weighted
LWL low water level
LWT low water temperature
m meter, milli (1/1000)
M mega (10
3
m
3
m
units), male
cubic meter
/min. cubic meters per minute
6
when used with SI
mA milliampere
man. manual
max. maximum
MB megabyte (2
20
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
qty. quantity
R replacement (emergency)
power source
rad. radiator, radius
RAM random access memory
RDO relay driver output
ref. reference
rem. remote
RFI radio frequency interference
RH round head
RHM round head machine (screw)
rly. relay
rms root mean square
rnd. round
ROM read only memory
rot. rotate, rotating
rpm revolutions per minute
RS right side
RTV room temperature vulcanization
SAE Society of Automotive
Engineers
scfm standard cubic feet per minute
SCR silicon controlled rectifier
s, sec. second
SI Systeme international d’unites,
International System of Units
SI/EO side in/end out
sil. silencer
SN serial number
SPDT single--pole, double--throw
SPST single--pole, single--throw
spec, specs
specification(s)
sq. square
sq. cm square centimeter
sq. in. square inch
SS stainless steel
std. standard
stl. steel
tach. tachometer
TD time delay
TDC top dead center
TDEC time delay engine cooldown
TDEN time delay emergency to
normal
TDES time delay engine start
TDNE time delay normal to
emergency
TDOE time delay off to emergency
TDON time delay off to normal
temp. temperature
term. terminal
TIF telephone influence factor
TIR total indicator reading
tol. tolerance
turbo. turbocharger
typ. typical (same in multiple
locations)
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-5986 4/03A-2 Appendix
Page 63
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 General Torque Specifications and other torque
specifications in the service literature.
Preferred Nut/Bolt Clearance
1
2
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 the diagram below.
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. Minimum 1 full thread beyond top of nut
3. Below top of nut
Figure 1 Acceptable Bolt Lengths
4. Refer to the diagram below, which depicts the
preceding hardware configuration possibilities.
3
G-585
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
1
6
2
3
5
4
G-585
TP-5986 4/03 A-3Appendix
Figure 2 Acceptable Hardware Combinations
Page 64
Appendix C General Torque Specifications
A
Assembledinto
A
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
Assembled into Cast Iron or Steel
Torque
Size
8-32 in.lbs.(Nm) 16 (1.8) 20 (2.3) — 16 (1.8)
10-24 in.lbs.(Nm) 26 (2.9) 32 (3.6) — 26 (2.9)
10-32 in.lbs.(Nm) 26 (2.9) 32 (3.6) — 26 (2.9)
1/4-20 in.lbs.(Nm) 60 (6.8) 96 (10.8) 132 (14.9) 60 (6.8)
1/4-28 in.lbs.(Nm) 72 (8.1) 108 (12.2) 144 (16.3) 72 (8.1)
5/16-18 in.lbs.(Nm) 120 (13.6) 192 (21.7) 264 (29.8) 120 (13.6)
5/16-24 in.lbs.(Nm) 132 (14.9) 204 (23.1) 288 (32.5) 132 (14.9)
3/8-16 ft. lbs. (Nm) 18 (24) 28 (38) 39 (53) 18 (24)
3/8-24 ft. lbs. (Nm) 20 (27) 31 (42) 44 (60) 20 (27)
7/16-14 ft. lbs. (Nm) 29 (39) 44 (60) 63 (85) —
7/16-20 ft. lbs. (Nm) 32 (43) 50 (68) 70 (95) —
1/2-13 ft. lbs. (Nm) 44 (60) 68 (92) 96 (130) —
1/2-20 ft. lbs. (Nm) 49 (66) 76 (103) 108 (146) —
9/16-12 ft. lbs. (Nm) 60 (81) 98 (133) 138 (187) —
9/16-18 ft. lbs. (Nm) 67 (91) 109 (148) 154 (209) —
5/8-11 ft. lbs. (Nm) 83 (113) 135 (183) 191 (259) —
5/8-18 ft. lbs. (Nm) 94 (128) 153 (208) 216 (293) —
3/4-10 ft. lbs. (Nm) 147 (199) 240 (325) 338 (458) —
3/4-16 ft. lbs. (Nm) 164 (222) 268 (363) 378 (513) —
1-8 ft. lbs. (Nm) 191 (259) 532 (721) 818 (1109) —
1-12 ft. lbs. (Nm) 209 (283) 582 (789) 895 (1214) —
Measurement
Grade 2 Grade 5 Grade 8
oiled threads. Increase values by 15% for nonplated
threads. All torque values are +0%/--10%.
ssembled into
Aluminum
Grade2or5
Metric Fasteners Torque Specifications, Measured in ft. lbs. (Nm)
Assembled into Cast Iron or Steel
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9
M6 x 1.00 4 (5.6) 7 (9.9) 10 (14) 4 (5.6)
M8 x 1.25 10 (13.6) 18 (25) 26 (35) 10 (13.6)
M8 x 1.00 16 (21) 18 (25) 26 (35) 16 (21)
M10 x 1.50 20 (27) 35 (49) 50 (68) 20 (27)
M10 x 1.25 29 (39) 35 (49) 50 (68) 29 (39)
M12 x 1.75 35 (47) 61 (83) 86 (117) —
M12 x 1.50 48 (65) 65 (88) 92 (125) —
M14 x 2.00 55 (74) 97 (132) 136 (185) —
M14 x 1.50 74 (100) 103 (140) 142 (192) —
M16 x 2.00 85 (115) 148 (200) 210 (285) —
M16 x 1.50 104 (141) 155 (210) 218 (295) —
M18 x 2.50 114 (155) 203 (275) 288 (390) —
M18 x 1.50 145 (196) 225 (305) 315 (425) —
Assembled into
luminum
Grade 5.8 or 8.8
TP-5986 4/03A-4 Appendix
Page 65
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
Internal Dimension
TP-5986 4/03 A-5Appendix
Page 66
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-5986 4/03A-6 Appendix
Page 67
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
M931-08040-82 M8-1.25 x 40*
M931-08045-60 M8-1.25 x 45
M931-08050-60 M8-1.25 x 50
M931-08055-60 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
M931-10040-82 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
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
M931-16120-60 M16-2.00 x 120
M931-16150-60 M16-2.00 x 150
M931-20065-60 M20-2.50 x 65
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
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
M933-06040-60 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
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
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*
Part No. Dimensions
Hex Head Bolts (Full Thread),
continued
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-5986 4/03 A-7Appendix
Page 68
Metric, continued
Part No. Dimensions Type
Hex Nuts
M934-03-50 M3-0.50 Standard
M934-04-50 M4-0.70 Standard
M934-05-50 M5-0.80 Standard
M982-05-60 M5-0.80 Elastic Stop
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-5986 4/03A-8 Appendix
Page 69
Page 70
Page 71
Page 72
TP-5986 4/03b
E2000, 2003 by Kohler Co. All rights reserved.
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPowerSystems.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65)264-6422, Fax (65)264-6455
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