Kohler 5ECD, 4EFCD, 7.3ECD, 5ECD-Low CO, 4EFCD-Low CO Service Manual

Service

Marine Generator Sets

Models:

5ECD/4EFCD

7.3ECD/6EFCD

5ECD/4EFCD--Low CO

7.3ECD/6EFCD--Low CO

Controller:

Advanced Digital Control

TP-6391 9/08a

TP-6391 9/082

Table of Contents

Safety Precautions and Instructions 5........................................................

Introduction 9...............................................................................

Service Assistance 10........................................................................

Section 1 Specifications 11...................................................................

1.1 Introduction 11..........................................................

1.2 Generator Set Ratings 11.................................................

1.3 Controller Specifications 11...............................................

1.4 Alternator Specifications 11...............................................

1.5 Alternator Specifications, Continued 12.....................................

1.6 Torque Specifications 12..................................................

1.7 Engine Specifications 13..................................................

1.8 Service View 14.........................................................

Section 2 Scheduled Maintenance 15..........................................................

2.1 General 15..............................................................

2.2 Service Schedule 16.....................................................

Section 3 Troubleshooting 17.................................................................

3.1 Introduction 17..........................................................

3.2 Initial Checks 17.........................................................

3.3 Troubleshooting Chart 17.................................................

Section 4 Controller 23.......................................................................

4.1 Introduction 23..........................................................

4.2 Controller Display and Keypad 24..........................................

4.3 Master Switch 24........................................................

4.4 Sequence of Operation 25................................................

4.4.1 Starting the Generator Set 25......................................

4.4.2 Running Sequence 25............................................

4.4.3 Stopping the Generator Set 25.....................................

4.5 Faults 25...............................................................

4.5.1 Shutdowns 25...................................................

4.5.2 Warnings 25.....................................................

4.5.3 SECM Fault Codes and Diagnostics 29.............................

4.6 Relay Interface Board (RIB) 35............................................

4.7 CO Sensor Module 35....................................................

4.8 K5 Main Power Relay 35..................................................

4.9 Silicon Controlled Rectifier (SCR) Module 36................................

4.10 Controller Replacement 37................................................

4.11 Controller Configuration and Adjustment 38.................................

4.11.1 Voltage Adjustments 38...........................................

4.11.2 Controller Configuration 41........................................

Section 5 Component Testing and Adjustment 45..............................................

5.1 Theory of Operation 45...................................................

5.2 Separate Excitation 45....................................................

5.3 Stator 47................................................................

5.4 Main Field (Rotor) 48.....................................................

5.4.1 Rotor Continuity and Resistance Tests 48...........................

5.5 Slip Rings 50............................................................

5.6 Brushes

5.7 Voltage 51..............................................................

5.7.1 Voltage Regulation 51............................................

5.7.2 Voltage Adjustment 51............................................

50..............................................................

TP-6391 9/08 Table of Contents 3

Table of Contents, continued

5.8 Voltage Reconnection 52.................................................

5.9 Governor System 52.....................................................

5.10 Fault Shutdown Tests 52..................................................

5.10.1 Controller Fault Shutdown Functions 52.............................

5.10.2 Fault Shutdown Switches 53.......................................

5.11 Electronic Throttle Assembly 57............................................

5.12 Fuses 57...............................................................

5.13 Continuity Checks 58.....................................................

Section 6 Generator Disassembly/Reassembly 59..............................................

6.1 Disassembly 59..........................................................

6.2 Collector Ring and Bearing Replacement 62.................................

6.3 Reassembly 63..........................................................

Section 7 Wiring Diagrams 65................................................................

Appendix A Abbreviations 79..................................................................

Appendix B Common Hardware Application Guidelines 81........................................

Appendix C General Torque Specifications 82...................................................

Appendix D Common Hardware Identification 83.................................................

Appendix E Common Hardware List 84.........................................................

TP-6391 9/084 Table of Contents

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
including generator sets, transfer
switches, switchgear,andaccessories,
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,orsubstantial
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
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to preventstarting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command froma
remote computer.

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 backfire flame
arrester. A sudden backfire can
cause severe injury or death. Do not

operate the generator set with the
backfire flame arrester removed.

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

set with the air cleaner removed.

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

or sparks near the generator set. Keep
the compartment andthe generator set
clean and free of debris to minimizethe
risk of fire. Catch fuels in an approved
container. 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.

TP-6391 9/08 5Safety Precautions and Instructions

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

monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause deathif
inhaled for even a short time. 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. Never
operate the generator set without a
functioning carbon monoxide detector.
Inspect the detector before each
generator set use.

Operating the generator set. Carbon
monoxide can cause severe nausea,
fainting, or death. 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 thelee side (the
side sheltered from the wind). Always
be aware of others, making sure your
exhaust is directed away from other
boats and buildings.

Fuel System

WARNING

Explosive fuel vapors.
Can cause severe injury or death.

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

WARNING

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.

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

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

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 containertocatchfuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.

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.

Hazardous Noise

CAUTION

Hazardous noise.
Can cause hearing loss.

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

Hazardous Voltage/
Moving Parts

WARNING

Hazardous voltage.
Can cause severe injury or death.

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

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.

Moving parts.

TP-6391 9/086 Safety Precautions and Instructions

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

is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. 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
turning off 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.

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 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 followtheinstructionsofthe
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.

Notice

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.

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
turned off. Backfeed connections can
cause severe injury or death to utility
personnel working on power lines
and/or personnel near the work area.
Some states and localities prohibit
unauthorized connection to the utility
electrical system. Install a
ship-to-shore transfer switch to prevent
interconnection of the generator set
power and shore power.

TP-6391 9/08 7Safety Precautions and Instructions

Notes

TP-6391 9/088 Safety Precautions and Instructions

Introduction

This manual provides troubleshooting and repair
instructions for the generator set models listed on the
front cover.

For engine service procedures not covered in this
manual, refer to the Engine Service Manual listedbelow.

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

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

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

List of Related Materials

Separate manuals contain operation, installation, and
parts information not provided in this manual. Separate
engine Operation and Service manuals are also
available. The following table lists the available manual
part numbers.

Routine Service Parts

The following table contains part numbers for
recommended spare parts. Contact your Kohler
generator distributor/dealer for a complete list of service
parts for your generator set or for models or spec
numbers not listed.

Part Description Part Number

Backfire flame arrestor GM24212

Fuse, (F1) 10 amp,

Auxiliary Winding

Fuse, (F2) 10 amp,

Controller

Fuse, (F3) 10 amp,

Customer Connection

Fuse, (F4) 15 amp,

Coils/Injectors

Fuse, (F5) 15 amp,

ECM, O

Fuse, (F6) 15 amp,

Voltage Regulator and Battery Charging
Alternator

Fuse, (F7) 20 amp,

Starter Motor and Crank Solenoid

Oil Filter 359771

Seawater Pump Impeller Kit 359978

Spark Plug GM46180

Spray Paint (White) 221335

Zinc Anode 260085

Sensor, and Fuel Pumps

2

Figure 2 Maintenance and Service Parts

358337

223316

223316

283645

283645

283645

GM39266

Literature Type Part Number

Installation Manual TP-5982
Operation Manual (Generator) TP-6390
Operation Manual (Engine) TP-6001
Parts Catalog* TP-5987
Service Manual (Generator) TP-6391
Service Manual (Engine) TP-6002
Service Manual Supplement (Engine) TP-6008

* One manual combines Generator and Engine information.

Figure 1 Generator Set Literature

TP-6391 9/08 9Introduction

Service Assistance

For professional advice on generator set 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

KohlerPower.com

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents
included with the product

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

D Outside the US and Canada, call the nearest regional

office

Headquarters Europe, Middle East, Africa
(EMEA)

Kohler Power Systems
3 rue de Brennus
93200 Saint Denis
France
Phone: [phone]
Fax: [phone]

Asia Pacific

Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]

China

North China Regional Office, Beijing
Phone: [phone]

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

Fax: [phone]

East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

Latin America

Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

TP-6391 9/0810 Service Assistance

Section 1 Specifications

C

4EFCD2F

2

160

6EFCD2F

2

150

1.1 Introduction

The spec sheets for each generator set provide specific
generator and engine information. Refer to the
generator set spec sheet for data not supplied in this

1.3 Controller Specifications

The generator set is equipped with the Advanced Digital
Control. For a specific description of the controller, see

Section 2, Operation, in the operation manual.
manual. Consult the generator set installation manual,
engine operation manual, and engine service manual
for additional specifications.

1.2 Generator Set Ratings

See the generator set ratings in Figure 1-1. Consult
generator set nameplate for specific generator set

Environmental Specification ADC 2100

Operating temperature

Humidity 0--95% condensing

Power requirements:

Voltage 12 VDC

urrent

-- 2 0 _ to 70_C

(--4_ to 158_F)

250 mA@12VDC

ratings.

25_C(77_F)

Model Series Alternator Vo lt age Ph Hz

5ECD 2F2

4EFCD 2F2

7.3ECD 2F2

6EFCD 2F2

RATINGS: Marine continuous ratings per ISO 3046, ISO 8528-1, and Kohler ISO rating guideline 2.14. Obtain technical information bulletin
(TIB-101) on ratings guidelines for complete ratings definitions.

120

120/240

110 36.36 4/4

110/220

220

120

120/240

110 54.55 6/6

110/220

220

1 60

1 60

1 60

1 50

Amps

41.67 5/5

20.83 5/5

18.18 4/4

18.18 4/4

60.83 7.3/7.3

30.42 7.3/7.3

27.27 6/6

27.27 6/6

25_C(77_F)

kW/kVA

Figure 1-1 Generator Set Ratings

1.4 Alternator Specifications

Alternator Specification 5ECD/4EFCD 7.3ECD/6EFCD

Alternator model 2F2 2F2

Stator leads, qty. 4 4

Phase 1 1

Rotor resistance, ohms, cold 3.4 3.4

Stator resistance, ohms,* cold

Main winding: 1-2, 3-4 0.16 0.16

Aux. winding: 55-66 1.70 1.70

Stator output voltage with separately excited rotor using 12-volt battery, minimum

Main winding: 1-2, 3-4, volts 145 145

Aux. winding: 55-66, volts 190 190

Rotor field voltage/current readings at rated output voltage, hot

No load, volts/amps 13/3.82 13/3.82

Full load, volts/amps 47/13.82 47/13.82

* Most ohmmeters do not give accurate readings when measuring less than 1 ohm. The stator can be considered good if a low resistance

reading (continuity) is obtained and there is no evidence of shorted windings (discoloration). Do not confuse a low resistance reading with
a reading indicating a shorted winding.

TP-6391 9/08 11Section 1 Specifications

1.5 Alternator Specifications,

Continued

5/7.3ECD

Alternator Specification

Frequency Hz 60/50 Hz

Excitation method Brush type

Voltage regulator type Digital

Coupling type Flexible disc

Winding material Class H

Bearing, quantity and type 1 sealed

Circuit protection

Auxiliary winding (F1) 10 amp fuse

Controller (F2) 10 amp fuse

Customer connection (F3) 10 amp fuse

Coils/injectors (F4) 15 amp fuse

ECM, O2sensor, and
fuel pumps (F5)

Voltage regulator and battery
charging alternator (F6)

Starter motor and crank
solenoid (F7)

Brush length, new 1.9 cm (0.75 in.)

4/6EFCD

15 amp fuse

15 amp fuse

20 amp fuse

1.6 Torque Specifications

Follow the general torque specification found in Appendix C

of this manual unless noted below or provided in the Engine

Service Manual.

5/7.3ECD

Torque Specifications

Rotor bolt 23 Nm (204 in. lbs.)

Generator overbolts 13 Nm (120 in. lbs.)

Lifting eye bolt 19 Nm (14 ft. lbs.)

Generator adapter to engine bolts 15 Nm (132 in. lbs.)

Engine oil drain boss (inside
generator adapter)

Generator adapter to exhaust
manifold

Spark plugs

Intake manifold to engine

Timing wheel to flywheel 9.5Nm(7ft.lbs.)

Catalyst assembly 9.5Nm(7ft.lbs.)

Seawater pump mounting plate 7 Nm (60 in. lbs.)

Seawater pump 15 Nm (132 in. lbs.)

Vibromounts 24 Nm (16.8 ft. lbs.)

Air intake adapter 0.8 Nm (7.0 in. lbs.)

End drive fitting to pump 11 Nm (96 in. lbs.)

Heat exchanger to exhaust
manifold

Exhaust manifold to cylinder head 7Nm(5ft.lbs.)

4/6EFCD

47 Nm (35 ft. lbs.)

13.6 Nm (120 in. lbs.)

12--17 Nm

(9--12 ft. lbs.)

Tighten the mounting

bolts to 4 Nm
(35 in. lbs.). Then
tighten the bolts in

sequence 3 Nm (26

in. lbs.) at a time until

the torque on each

bolt is 7.8 Nm (69 in.

lbs.)

13.5 Nm (120 in. lbs.)

TP-6391 9/0812 Section 1 Specifications

1.7 Engine Specifications

Engine Specification 5/7.3ECD 4/6EFCD

Manufacturer Kawasaki

Model FD501D

Cycle 4

Number of cylinders 2

Compression ratio 9.3:1

Displacement, L (cu. in.) 0.4 (21.9)

Max. power at rated rpm, HP 16 13.8

Rpm 3600 3000

Bore x stroke, mm (in.)

Cylinder head material Aluminum

Cylinder block material Aluminum

Piston rings 2 compression/1 oil

Piston material Aluminum

Crankshaft material Aluminum

Crankshaft bearings, type Inserts

Governor, type Electronic

Lubrication system Full pressure

Oil capacity (w/filter), L (qt.) 1.36 (1.44)

Oil pressure, kPa (psi) 276 (40)

Oil recommendation (API)

Fuel system, type

Battery charging 15 amps

Battery voltage 12 VDC

Battery ground Negative

Battery recommendation,
minimum

Spark plug gap, mm (in.)

Ignition system Inductive

Starter motor

Cooling system Water-cooled

Valve material

67 x 62

(2.64 x 2.44)

SC, SD, SE, SF, SG,

SH, or SJ

Throttle body

fuel injected

260 CCA

0.6--0.7

(0.024--0.028)

Bendix automotive

type

Steel alloy

(JIS SUH3)

TP-6391 9/08 13Section 1 Specifications

1.8 Service View

31

2

1 3

12

4

5

6

10 11

9

87

13

14

15

16

18

17

19

20

21

30

SERVICE VIEW

29 28

1. Spark plug (also one located on the nonservice side)

2. Oil fill

3. Overflow tube

4. Pressure cap (coolant fill location after draining coolant)

5. Seawater pressure switch (appears as auxiliary fault on ADC)

6. Lifting eye

7. Heat exchanger

8. Anticorrosion zinc anode

9. AC circuit breaker

10. AC load lead connector (nonservice side)

11. Nameplate (top)

12. Remote start connector (nonservice side)

13. Fuses (F1, F2, F3, F4, F5, F6, and F7)

14. Runtime hour display

15. ADC 2100

16. High exhaust temperature switch (located on the catalyst on
the nonservice side). Available on units with serial numbers
2199434 and later. (Appears as LOC fault on ADC.)

22

23

26

27

17. CO sensor module (available on units with serial number
2085259 and later)

18. Generator set master switch

19. Catalyst assembly, water outlet/exhaust outlet (nonservice
side)

20. Seawater drain (remove plate for service)

21. Seawater pump (water inlet)

22. Cooling air inlet

23. Fuel filter/fuel inlet

24. Fuel pump

25. Fuel pump/cooler

26. Oil check

27. Coolant drain (remove hose clamp to drain coolant)

28. Oil drain valve

29. Lube oil filter

30. Coolant overflow bottle (daily coolant check/fill location)

31. Air intake silencer/backfire flame arrestor

Note: Consult installation drawings in Spec Sheet or Installation

Manual for fuel- and battery-connection points.

25

24

ADV7025A-A

Figure 1-2 Service Views

TP-6391 9/0814 Section 1 Specifications

Section 2 Scheduled Maintenance

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 connected equipment, disable the generator
set as follows: (1) Move the generator setmasterswitch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

WARNING

Engine Service. Perform generator set engine service
at the intervals specified by the engine service literature.
Contact an authorized Kohlerr service distributor/
dealer to obtain engine service literature.

Generator Set Service. See the Safety Precautions
and Instructions at the beginning of this manual before
attempting to service, repair, or operate the generator
set. Have an authorized Kohlerr service distributor/
dealer perform all generator service.

Routine Maintenance. Refer to the following generator
set service schedule, the engine service schedule, and
the runtime hours displayed on the ADC 2100 to
determine when to schedule routine maintenance.
Service the generator set more frequently if it is subject
to extreme weather, long operating hours, or dusty or
dirty conditions.

Service Schedule. Perform maintenance on each item
in the service schedule at the designated interval for the
life of the generator set.

Tools. Tools and instruments used to perform some
maintenance items are not generally available to the
generator set owner. Therefore, have service
performed by an authorized distributor/dealer.

Hazardous voltage.
Can cause severe injury or death.

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

Moving parts.

Alternator Service. Under normal operating conditions
the generator set alternator does not require scheduled
service. Refer to the service schedule for items that
require maintenance.

2.1 General

Perform the items listed in the service schedule at the
designated intervals for the life of the generator set. For
example, an item serviced every 100 hours or 3 months
must also be serviced after 200 hours or 6 months,
300 hours or 9 months, etc.

Note: See the generator set operation manual and the

engine service manualfor service procedures not
included in this manual.

TP-6391 9/08 15Section 2 Scheduled Maintenance

2.2 Service Schedule

After

50 Hrs or

1 Month

Perform Service at Intervals Indicated (X)

Before

Starting

FUEL SYSTEM

Check the fuel level and fill as necessary X
Check fuel lines and replace as necessary *[ X
Replace the fuel filter *[ X

LUBRICATION SYSTEM

Check crankcase oil level and add as necessary X

Replace the oil in crankcase *

Replace the lube oil filter element *

X (20 hrs
break-in)

X (20 hrs
break-in)

COOLING SYSTEM

Check coolant level and fill as necessary * X

Check seawater outlet and clean as necessary [

X (during

operation)
Check function of siphon break, if equipped X
Replace seawater pump impeller *[ X (check) X
Check heat exchanger anticorrosion zinc condition * X
Replace heat exchanger anticorrosion zinc * X
Flush cooling system *[ X (400 hrs)

IGNITION SYSTEM

Clean and regap spark plugs * X
Replace spark plugs * X

INTAKE/EXHAUST SYSTEM

Inspect exhaust system components *[

Check the exhaust gas condition

X

X (during

operation)
Service backfire flame arrestor * X
Check and/or replace the catalyst assembly *[
Clean the water passage slots/holes in the exhaust

manifold/catalyst *[
Replace the CO sensor module, if equipped *[
Check the crankcase breather pipe for obstructions *[ X
Inspect the complete exhaust system [ X

ELECTRICAL SYSTEM

Keep battery charged and in good condition ⊕ X
Check and tighten electrical connections * X
Clean battery cables [ X (200 hrs)

ENGINE AND MOUNTING

Check for water, fuel, coolant, and oil leakage *[] X
Retighten all nuts and bolts * X
Check tightness of mounting bolts/vibromounts * X (200 hrs)
Check and adjust valve clearance *[ X
Clean combustion chamber *[ X

REMOTE CONTROL SYSTEM

Check remote control operation X (break-in) X

GENERATOR

Test run generator set X (weekly)
Blow dust out of generator *[ X
Clean slip rings and inspect brushes *[ X (1000 hrs)

* Requires removal of sound shield, if installed.

[ Consult your local distributor/dealer for service.

] Read WARNING found at the beginning of manual regarding

moving parts.

⊕ Consult battery manufacturer’s instructions.

Every

100 Hrs or

3Months

X

X (200 hrs)

Every

300 Hrs or

6Months

X

(200 hrs)

Every

500 Hrs or

Yearly

X

X (2 years)

TP-6391 9/0816 Section 2 Scheduled Maintenance

Section 3 Troubleshooting

3.1 Introduction

Corrective action and testing in many cases requires
knowledge of electrical systems and electronic circuits.
Have an authorized distributor/dealer or trained service
technician perform testing and service.

Refer to the Engine Service Manual, TP-6002 and
TP-6008, for engine service information.

The first step in troubleshooting the generator set
controls is to verify that the controller is correctly
configured for the generator set. The Generator Set
Installation Manual explains how to check and change
the controller configuration.

If the troubleshooting procedures in this section identify
a bad part, refer to the parts catalog for replacement part
numbers. See the List of Related Materials in the
Introduction for the parts catalog number.

3.2 Initial Checks

When troubleshooting, always check for simple
problems first. Check for the following common
problems before replacing parts:

D Loose connections or damaged wiring.

D Dead battery.

D Fault shutdown. Check for a fault code on the

ADC 2100 display. Section 4.5 describes the
warning and shutdown fault codes.

D Blown fuses. See Figure 3-1 for fuse identification.

Always check and replace the fuses before replacing
other components. See Figure 2 for fuse part
numbers.

Label Amp Fuse

F1 10 Auxiliary winding

F2 10 Controller

F3 10 Customer connection

F4 15 Coils/injectors

F5 15 ECM, O2sensor, fuel pumps, and temp.

sender

F6 15 Voltage regulator and battery charging

alternator

F7 20 Starter motor and crank solenoid

Figure 3-1 Fuse Identification

D Incorrect controller settings. Always check the

controller configuration settings before replacing the
controller. Section 4.11 explains how to check and
change the controller settings.

3.3 Troubleshooting Chart

Use the following table(s) as a reference in
troubleshooting individual problems. Generator set
faults are listed in groups and include likely causes and
remedies. The simplest and most likely causes of the
problem are listed first; follow the recommendations in
the order shown. The reference column provides
additional sources of information in this and related
manuals regarding the problem and solution.

TP-6391 9/08 17Section 3 Troubleshooting

Note: In the following table(s), O/M refers to the

Operation Manual, I/M refers to the Installation
Manual, and S/M refers to the Service Manual.

Troubleshooting Chart

k

,

y

Problem Possible Cause Corrective Action Reference

Generator
set does
notcran

Weak or dead battery Recharge or replace battery. Generator O/M

Battery connections Check for reversed or poor battery connections. —

Open circuit in engine/controller
connections

Blown fuse F2, controller Replace fuse; if fuse blows again, check circuit and

Blown fuse F2, relay interface
board (RIB)

Crank relay on relay interface
board (RIB)

Generator set master switch

Poor ground (--) connection Clean and retighten. —
Starter

Controller Check controller connections and operation. Check for

BlownF3fuse Verify line circuit. Section 7

BlownF6fuse Check voltage regulator wiring. Section 7

BlownF7fuse Check wiring for open grounds or loose connections.

Check for loose connections.
Check the wire harness continuity.

components.

Replace fuse. Section 5.12

If fuse blows again, disconnect the board leads one at a
time to identify the cause of the blown fuse:

Lead 70A
Leads FP and FN at the rotor
Repair or replace the component causing the blown

fuse.

If fuse continues to blow and the previous step did not
identify the cause, check the continuity of leads FP and
FN and the leads from the P14 connector. Replace any
bad leads. Use a pin pusher, part #241918 (large) or
241919 (small) to remove leads from the connector, if
necessary. If replacing the leads does not solve the
problem, replace the RIB.

Check connections to the RIB. Check for 12VDC to the
RIB on lead 71N.

Check for a good ground connection (lead N). Section 7

Check crank relay K2 operation (LED3). Replace the
RIB if relay does not operate.

Check connections to the master switch on the
ADC 2100.

Test function of switch. Section 5.13

Check starter connections. Section 7

Rebuild or replace starter. Engine S/M

power to the controller. Move generator set master
switch to OFF/RESET and then to RUN.

Also, check for pushed out pins.

Section 7

Section 5.12
Section 7

Section 7

Section 7
Section 4.6

Section 4.6
Section 7

Section 4.6

Section 4.3
Section 5.13

Section 4
Section 7

Section 7

TP-6391 9/0818 Section 3 Troubleshooting

Troubleshooting Chart, continued

Problem Possible Cause Corrective Action Reference

Cranks but
does not
start

Starts hard

Starts but
shuts
down

Stops
suddenly

No fuel Check the fuel supply. —

Spark plugs or spark plug
connections

Loose connection or open circuit Check for loose or open connections at the fuel solenoid

Backfire flame arrestor clogged Clean or replace. O/M

Incorrect controller configuration Check for correct controller configuration parameters:

Ignition system spark control or
ignition coil

No engine rotation sensed (check
for an overcrank fault shutdown)

BlownF2fuse Replace fuse. Section 5.12

BlownF4fuse Check GNDs on coil. Section 7

BlownF5fuse Check ECM ground connection pin 14. Section 7

Low battery voltage Check battery voltage. O/M

Backfire flame arrestor clogged Clean or replace. O/M

Spark plug(s) Replace or regap spark plug(s). O/M

Spark plug wire(s) Check spark plug wires and connections. Replace

Ignition components (spark
control or ignition module)

Worn piston rings, valves Check compression. Engine S/M

BlownF5fuse Check ECM ground connection pin 14. Section 7

BlownF6fuse Check voltage regulator wiring. Section 7

Fault shutdown Check for a fault shutdown code on the controller’s LED

Fault shutdown Check for a fault shutdown code on the controller’s LED

No fuel Check the fuel supply. —

Fuel line restriction Inspect fuel lines. —

Backfire flame clogged Replace element. O/M

Blown controller fuse (F2) Replace fuse. Section 5.12

Blown auxiliary winding fuse (F1) Replace fuse. If fuse blows again, test generator

Blown relay interface board (RIB)
fuse (F2)

Spark plug(s) Replace and regap plug(s). Engine S/M

Engine overheated (hot engine
only)

Low oil pressure (LOP) switch Attempt startup. If unit shuts down, remove lead from

Engine overloaded Reduce electrical load. I/M

Loss of generator output voltage
to controller

Ignition module Test and/or replace. Engine S/M

K3 (flash) relay Check for Flash LED illumination. Check RIB fuse.

Check spark plug wires and connections. Replace or
clean and regap spark plugs.

and at the engine control module. Check
controller/engine wiring continuity.

unit configuration (UC) and engine configuration (EC).
Test and/or replace components. Engine S/M

Check for locked rotor. Section 5.4

spark plug wires.
Test/replace ignition components. Engine S/M

display. Correct the fault and then move the generator
set master switch to OFF/RESET to reset the controller.

display. Correct the fault and then move the generator
set master switch to OFF/RESET to reset the controller.

components.
Replace fuse. Section 5.12

Check air intake, fuel, oil level, air inlet/outlet. O/M and I/M

LOP switch and reset controller. A successful restart
attempt indicates a faulty LOP shutdown switch.

Note: Check engine oil pressure before performing test
and/or replacing LOP shutdown switch.

Check connections at P15 plug.
Check continuity of AC sensing leads 11 and 44.

Replace relay board.

O/M

Section 7

Section 4.11

Section 7

Engine S/M

Section 4.5
Section 5.10

Section 4.5
Section 5.10

Section 5.12

Engine S/M

Section 7

Section 4.6

TP-6391 9/08 19Section 3 Troubleshooting

Troubleshooting Chart, continued

d

denl

p

p

dropi

n

Problem ReferenceCorrective ActionPossible Cause

Stops
su
(continued)

Operates
erratically

Lacks
power

Overheats

Low output
or
excessive

voltage

BlownF3fuse Verify line circuit. Section 7

y

BlownF5fuse Check ECM ground connection pin 14. Section 7

Backfire flame arrestor clogged Clean or replace. O/M

Spark plug(s) Replace and regap plugs. O/M

Spark plug wire(s) Replace spark plug wires. Engine S/M

Fuel line restriction Check fuel lines.

Ignition system Test and/or replace components. Engine S/M

Inadequate cooling (hot engine
only)

Carbon buildup in engine Clean cylinder head. Engine S/M

Engine valves not seating
correctly

Air intake restriction, inadequate
cooling

Generator overloaded Reduce load. —

Spark plug(s) Replace and regap plug(s). O/M

Spark plug wire(s) Replace spark plug wires. Engine S/M

Engine not running at rated rpm Check controller settings for unit configuration (UC) and

Engine power loss Refer to the Engine Service Manual for troubleshooting

Ignition system Test and/or replace. Engine S/M

BlownF5fuse Check ECM ground connection pin 14. Section 7

Inadequate cooling Inspect cooling system for air intake obstructions. —

Backfire flame arrestor clogged Clean or replace. O/M

Generator overloaded Reduce load. —

Incorrect controller configuration Check and adjust the controller configuration

Incorrect controller voltage
settings

Alternator or control system Perform separate excitation procedure to isolate

SCR module Check wiring and connections to the SCR module.

Controller Check controller settings. Check controller fuse, wiring

Rotor (open, grounded, or
shorted windings)

Stator (open, grounded, or
shorted windings)

Brush connection Check for loose brush connections.

Low engine speed causing
voltage roll-off

—

Inspect air inlet and outlet. —

Check cylinder pressures with leakdown test. Inspect
valves and valve seats.

Inspect air intakes and exhaust for obstructions.
Check air cleaner.

engine type (EC).

and repair instructions.

parameters.

Check and adjust the controller voltage settings. Section 4.11.2

problem to the alternator or the control system.

Check auxiliary winding fuse F1 (lead 55).
Replace SCR module and test voltage.

and connections.
Before replacing controller, replace SCR module and

test voltage.

Test and/or replace. Section 5.4

Test and/or replace. Section 5.3

Check the resistance through the brushes. Resistance
through the brushes should be low, 0.1--0.2 ohms
without meter lead resistance.

Check system voltage/frequency (Uu) and engine type
(Ec) parameters.

Troubleshoot the engine.

Engine S/M

—

Section 4.11.2

Engine S/M

Section 4.11.2

Section 5.2

Section 5.12
Section 4.9

Section 4.11.2

Section 4.10

Section 5.6

Section 4.11.2

Engine S/M

TP-6391 9/0820 Section 3 Troubleshooting

Troubleshooting Chart, continued

p

Problem ReferenceCorrective ActionPossible Cause

Light
flicker

High
output
voltage

No output
voltage

Voltage stability (gain) setting Check and adjust the voltage stability (gain) setting

Incorrect controller configuration Check and adjust the controller configuration

Incorrect controller voltage
settings

Loose voltage sensing
connections

SCR module Check wiring and connections to the SCR module.

Controller Check fuses, wiring and connections. Before replacing

AC output circuit breaker open Check for AC voltage on the generator side of circuit

Alternator or control system Perform separate excitation procedure to isolate the

Aux. winding F1 fuse blown Replace blown fuse. If fuse blows again, check stator. Section 5.3

SCR module Check auxiliary winding fuse F1 (lead 55).

Controller Check controller settings. Check wiring and

Open wiring, terminal, or pin in
buildup circuit or SCR module
circuit

Brushes

Rotor connections Check for open circuit in rotor connection circuit (leads

Rotor slip rings dirty or corroded Check slip ring condition. Section 5.4

Rotor (open, grounded, or
shorted windings)

Stator (open, grounded, or
shorted windings)

Flash relay (K3) on relay
interface board (RIB)

BlownF2fuse Replace fuse If fuse blows again, check circuit and

BlownF5fuse Check ECM ground connection pin 14. Section 7

using the ADC 2100.

parameters.

Check and adjust the controller voltage settings. Section 5.7

Check connections: stator leads 11 and 44 and P15
controller connection.

Check auxiliary winding fuse F1 (lead 55).
Replace SCR module and recheck voltage.

controller, replace SCR module and test voltage.

breaker. If there is AC voltage on the generator side of
the breaker, then a problem in the load circuits is
causing the line circuit breaker to trip. Check for and
correct short circuits or overloading on the load side
before resetting the circuit breaker.

problem to the alternator or the control system. Then
troubleshoot the alternator or control system
components as follows.

Replace SCR module and test voltage.

connections. Before replacing controller, replace SCR
module and check voltage.

Check continuity. Section 5.13

Inspect brushes and replace if worn. Section 5.6

Check for brushes sticking in brush holder or broken
brush spring.

FN and FP to SCR and RIB).

Check voltage and continuity. Section 5.4

Check voltage and continuity. Section 5.3

Check flash LED on RIB.
Check fuse F2 and troubleshoot RIB.

components.

Section 5.7

Section 4.11.2

Section 7

Section 4.9
Section 5.12
Section 4.9

Section 4.10

—

Section 5.2

Section 5.12
Section 4.9

Section 4.11.2
Section 4.10

Section 7

Section 5.6

Section 7

Section 4.6

Section 5.12
Section 7

TP-6391 9/08 21Section 3 Troubleshooting

Troubleshooting Chart, continued

y

Problem ReferenceCorrective ActionPossible Cause

Noisy
operation

Exhaust system leaks Check and replace as necessary. O/M

Engine not running smoothly See “Generator set operates erratically,” this table. —

Broken or damaged
vibromount(s)

Loose or vibrating sheet
metal/housing

Exhaust piping or air inlets/outlets
not securely installed

Excessive engine/generator
vibration

Check and replace as necessary. —

Retighten screws, replace rivets.

Inspect for loose parts and secure if necessary. —

Check, rotor, crankshaft, bearing, etc. (disassembly of
engine and/or alternator may be required).

—

Engine S/M

TP-6391 9/0822 Section 3 Troubleshooting

Section 4 Controller

4.1 Introduction

This section describes the operation and replacement of
the ADC 2100 controller. Controller configuration and
adjustment are explained in Section 4.11. See Section 3
for troubleshooting procedures.

See Figure 4-1 for the locations of the ADC 2100
controller and related components.

Top View

A relay interface board (RIB) is used with the ADC
controller. Section 4.6 describes the relay interface
board.

A silicon controlled rectifier (SCR) module works with
the controller to regulate the output voltage. See
Section 4.9.

1

2

3

4

5

Service-Side View

1. LO stud

2. Ground stud

3. Relay interface board (RIB)

4. SCR module

5. K5 main power relay

6. Line circuit breaker panel (load connection)

Figure 4-1 Advanced Digital Control (ADC 2100)

10

7

8

9

GM39685D-J

6

7. Fuse location. See Section 5.12

8. ADC 2100 controller

9. CO sensor module (available on units with serial number
2085259 and later)

10. Generator set master switch

TP-6391 9/08 23Section 4 Controller

4.2 Controller Display and Keypad

The controller has an LED display and a three-button
keypad. See Figure 4-2. The LED display shows
runtime hours, fault codes, application program version
number, or controller parameters during configuration
and adjustment. See Figure 4-3. The keypad is used to
enter the controller’s configuration and adjustment
menus, and to change the controller settings.

A password key sequence is required to enter the
configuration and adjustment menus. Section 4.11
contains the instructions to enter the configuration and
adjustment menus and change the settings using the
controller keypad.

Controller Display

Item Description

Crank indication Displays CC_1, CC_2, or CC_3 to indicate

Runtime hours Displays total generator set runtime hours

Fault codes Flashes a 2- or 3-letter fault code to indicate

System
parameters

Application
program version
number

the first, second or third attempt to start the
engine. The last digit flashes during the
crank cycle rest periods.

when no other code is displayed.

various fault conditions. See Section 4.5.

Displays 2-letter codes or 4-digit
alphanumeric codes during system
configuration or adjustment. See
Section 4.11.2.

Displays the version number of the
controller’s application program before
entering the configuration or adjustment
mode. See Section 4.11.2.

4.3 Master Switch

The generator set master switch is a three-position
(RUN\OFF/RESET\AUTO) rocker switch. The leads
connecting to the master switch are labeled RUN, VBAT,
and AUTO. Check that the three pink connectors are
connected to the terminals on the back of the switch as
shown in Figure 4-4. Be careful not to reverse the RUN
and AUTO leads.

1

3

2

Figure 4-3 ADC controller LED Display

1

4

1. LED display

2. Select button (use for setup and adjustment only)

3. Upanddownarrow buttons (use for setup and adjustmentonly)

4. Generator set master switch

Figure 4-2 ADC Controller

GM28707A-C

4 23

RUN

VBAT

AUTO

1. Engine wiring harness connector plug (P1)

2. J15 connector

3. J16 connector

4. Generator set master switch

Figure 4-4 Controller Connections

tp6196

TP-6391 9/0824 Section 4 Controller

4.4 Sequence of Operation

4.4.3 Stopping the Generator Set

The following sections describe the controller sequence
of operation during generator start, run, stop, and fault
shutdown modes. Use this as a starting point for
controller and relay board fault identification. Refer to
the wiring diagrams in Section 7 to assist in the
troubleshooting procedure.

4.4.1 Starting the Generator Set

Local Starting

When the master switch is moved to the RUN position,
there is a delay of about 2 seconds before the controller
attempts to start the engine. The run relay energizes
and the run LED (1) turns on. The crank and flash relays
energize and the corresponding LEDs (2 and 3) turn on

0.5 seconds later. The controller display indicates the
crank cycle 1 code, CC 1.

The controller attempts to start the generator set three
times (three crank cycles, 7 seconds crank and 15
seconds off). If the generator set does not start in three
attempts, the system shuts down on an overcrank fault.

When the engine comes up to speed, the low oil
pressure switch contacts open.

Note: The controller circuit board prevents fault

shutdowns during startup until the crank
disconnect relay energizes.

The following procedures describe the actions required
to stop the generator set.

Local Stopping

1. Run the generator set at no load for at least
2 minutes to ensure adequate engine cooldown.

2. Move the generator set master switch to the
OFF/RESET position. The run relay deenergizes
and the run LED (1) turns off. The generator set
stops.

Auto (Automatic) Stopping.

1. Run the generator set at no load for at least
2 minutes to ensure adequate engine cooldown.

2. With the generator set master switch in the AUTO
position, the generator set stops when the remote
start/stop switch contacts close momentarily.

Note: If the ADC 2100 is configured for a CAN gauge,

consult Figure 4-20 for power-down times.

Note: If the ADC 2100 is not configured for a CAN

gauge, the controller will power down after
48 hours (if the master switch is in the AUTO
position). If the generator has been started, the
controller will power down 48 hours after the
generator stops.

The cyclic cranking cycle is programmed into the
controller’s application code and is not adjustable in the
field.

The factory sets the cranking cycle for three cycles of
7 seconds on time and 15 seconds off time. If the
cranking cycle seems shorter than the factory setting,
check the engine starting battery.

Auto (Automatic) Starting.

When the master switch is set to the AUTO position, the
generator set starts when the remote start switch
contacts close momentarily.

The start sequence proceeds as described in
Section 4.4.1 above.

4.4.2 Running Sequence

When the engine speed reaches 750 rpm, the crank
relay deenergizes and the crank LED (3) turns off.
When the output voltage on leads 11 and 44 reaches
about 30 VAC, the flash relay deenergizes and the flash
LED (2) turns off.

4.5 Faults

4.5.1 Shutdowns

Under the fault conditions listed in Figure 4-5, the
controller displays a fault code and the generator set
shuts down.

Always identify and correct the cause of a fault
shutdown before restarting the generator set. Refer to
Section 3, Troubleshooting, for instructions to identify
and correct the cause of the fault.

Move the generator set master switch to the
OFF/RESET position to reset the controller after a fault
shutdown. Then move the switch to the AUTO or RUN
position.

4.5.2 Warnings

The fault conditions listed in Figure 4-6 will cause the
controller to display a fault code but will not shut down
the generator set.

TP-6391 9/08 25Section 4 Controller

Code Fault Description Check

AF Auxiliary fault Input from a customer-supplied switch that closes when

CO-1* Carbon

monoxide
shutdown

CO-2* Carbon

monoxide
shutdown

CO-3* Carbon

monoxide
sensor
shutdown

HE High engine

temperature

LCL Low coolant

level

LOC Loss of coolant Shutdown occurs 5 seconds after a loss of coolant

LOP Low oil

pressure

the fault is active. The generator set shuts down 0.3
seconds after the fault is detected and will not start when
the fault is active (input is grounded). This protection
becomes active 3 seconds after crank disconnect.

Sensor fault shutdown occurs because of the presence
of CO.

Shutdown occurs because of the presence of CO or
deteriorating emission-control components (such as the
catalyst).

Shutdown occurs if communication is lost between the
CO sensor and the ADC.

Shutdown occurs if the engine coolant temperature
exceeds the maximum temperature for more than
5 seconds. This protective becomes active after the
engine reaches the crank disconnect speed.

Not used. — —

condition is detected. This protection becomes active
10 seconds after the engine has reached its stated crank
disconnect speed and remains active as long as the
generator run command is active.

Units with serial number 2199434 and later: In the
event of a shutdown because of the high exhaust
temperature switch, the ADC will display fault code LOC.

Shutdown occurs if a low oil pressure condition exists for
more than 5 seconds. This protective becomes active
30 seconds after the engine has reached crank
disconnect speed (30 second inhibit).

Note: The low oil pressure shutdown does not protect
against low oil level. Check the oil level at the engine.

Check the condition and operation of the
customer-supplied equipment
connected to the auxiliary fault input
P21-6.

Immediate service required. Contact
an authorized distributor/dealer for
service.

Ensure windows are open for proper
ventilation.

Operate the blower to expel dangerous
fumes.

Move the vessel away from other
vessels (as another vessel may be the
source for the presence of the CO).

Check the generator exhaust system
(see the O/M).

Immediate service required. Contact
an authorized distributor/dealer for
service.

Ensure windows are open for proper
ventilation.

Operate the blower to expel dangerous
fumes.

Move the vessel away from other
vessels (as another vessel may be the
source for the presence of the CO).

Check the generator exhaust system
(see the O/M).

Check the connections to the CO
sensor.

If connections are okay, replace the CO
sensor.

Contact an authorized distributor/dealer
for service.

Check for blocked air inlets and exhaust
outlets.

Check for a clogged seawater intake or
sea strainer.

Check for a damaged seawater pump
impeller.

Check the high exhaust temperature
switch, if equipped.

Check for leaks in the lubrication
system.

Check the oil level and add oil if the
level is low.

Check low oil pressure switch
connections and operation.

Check the oil pump and lubrication
system.

Refer to
Section

—

—

—

—

1.8

O/M
I/M

O/M

O/M

5.10

Engine
S/M

TP-6391 9/0826 Section 4 Controller

OC

0%yqyp5

yg0

OF Overfrequency Shutdown occurs when the governed frequency exceeds

OS Overspeed Shutdown occurs if the engine speed exceeds 115% of

OU Overvoltage Shutdown occurs if the voltage exceeds 120% of the

UF Underfrequency Shutdown occurs when the governed frequency falls

UU Undervoltage Shutdown occurs if the voltage falls below 80% of the

SCF0 Software

Note: O/M = Generator set Operation Manual; I/M = Generator Set Installation Manual

Overcrank Shutdown occurs after 3 unsuccessful starting attempts.

Communication
Fault 0

The crank cycle is set for three starting attempts of
7 seconds cranking and 15 seconds rest.

The generator set shuts down on an overcrank fault if no
engine rotation is sensed. Shuts down after 3 seconds of
cranking or 1 second after the fault is detected.

110% of the system’s frequency setpoint for more than 5
seconds. This protective becomes active 10 seconds
after engine start (10 second inhibit).

the normal running speed for more than 0.3 seconds.

system nominal voltage for more than 2 seconds.

blow 90% of the nominal system frequency for more than
5 seconds or below 59 Hz for more than 60 seconds.
This protective becomes active 10 seconds after engine
start. (10 second inhibit).

nominal system voltage for more than 10 seconds.

Indicates a software or communication problem within
the ADC 2100.

Check the fuel supply.

Check spark plug and battery.

See Troubleshooting Chart, generator
set cranks but does not start.

Check for a locked rotor. 5.4

Check system frequency setting
(parameter UU) on controller.

Check engine governing system,
controlled by the engine ECM.

Check engine governing system,
controlled by the engine ECM.

Check AC voltage.

Check wiring and connections.

Reduce the load and restart the
generator set.

Reduce the load and restart the
generator set.

Check wiring and connections. 7

Check controller configuration, system
voltage and frequency (parameter UU).

Check AC voltage and adjust, if
necessary.

Replace the SCR module and test
voltage again.

Separately excite unit. 5.2

Check stator continuity. 5.3

Replace the controller. 4.10

I/M

O/M

3.3

4.11

Engine
S/M

Engine
S/M

5.7

7

4.11

5.7

4.9

—

—

* Available on units with serial number 2085259 and later.

Figure 4-5 Fault Shutdown Codes

TP-6391 9/08 27Section 4 Controller

Code Fault Description Check

CO-4* Carbon monoxide

warning

CO-5* Carbon monoxide

warning

CO-6* Carbon monoxide

sensor warning

HB High battery

voltage warning

LB Low battery

voltage warning

Fault code is displayed if the presence of CO is
detected because of the time-weighted average
presence of CO. Activates the CO cabin alarms.

Fault code is displayed if the presence of CO is
detected. Warning occurs if the sensor detects
acceptable but increasing CO levels.

Fault code is displayed if the CO sensor is inoperative. Replace the CO sensor.

Fault code is displayed if the engine starting battery
voltage rises above 16 VDC for a 12 VDC system or
above 30 VDC for a 24 VDC system for more than
2 seconds when the engine is not running. This fault
condition does not inhibit engine starting.

The fault condition clears when the battery voltage
returns to a voltage within the limits for more than
2 seconds.

Fault code is displayed if the engine starting battery
voltage falls below 9.5 VDC for a 12 VDC system or
below 16 VDC for a 24 VDC system for more than
2 seconds when the engine is not running. This fault
condition does not inhibit engine starting.

The fault condition clears when the battery voltage
returns to a voltage within the limits for more than
2 seconds.

Ensure windows are open for proper ventilation.

Operate the blower to expel dangerous fumes.

Move the vessel away from other vessels (as another
vessel may be the source for the presence of the CO).

Check the generator exhaust system (see the
Operation Manual).

Contact an authorized distributor/dealer for service if
problem continues.

Ensure windows are open for ventilation.

Operate the blower to expel dangerous fumes.

Move the vessel away from other vessels (as another
vessel may be the source for the presence of the CO).

Check the generator exhaust system (see the
Operation Manual).

Generator service for emissions required.

Contact an authorized distributor/dealer for service if
problem continues.

Contact an authorized distributor/dealer for service if
problem continues.

Check the battery rating and condition.

Check the battery rating and condition.

Charge or replace the battery.

* Available on units with serial number 2085259 and later.

Figure 4-6 Fault Warning Codes

TP-6391 9/0828 Section 4 Controller

4.5.3 SECM Fault Codes and Diagnostics

Fault
Code
Displayed

EC9 Throttle Position Sensor

EC10* Throttle Position Sensor

EC11* Throttle Position Sensor

EC12 Throttle Position Sensor

EC39 Electronic Throttle Control

EC40* Electronic Spark Trigger

EC41* Electronic Spark Trigger

EC42* Electronic Spark Trigger

* Indicates a stored fault code.

Description Check

No Faults (Fault Code 0)

(TPS1) Input High

(TPS1) Range High

(TPS1) Range Low

(TPS1) Input Low

(ETC) Sticking

(EST) 1 Low

(EST) 1 High

(EST) 2 Low

Fault appears if the sensor signal wire is shorted, the sensor has failed, or the SECM has
failed. Check the throttle connector and sensor wiring for a shorted circuit:

ETC Pin 6 to SECM Pin 17 (SIGNAL)
ETC Pin 2 to SECM Pin 1 (GND)

Fault appears if the sensor potentiometer has malfunctioned. Check for dirt or oxidation on the
sensor traces. Check the throttle connector and pins for corrosion. To check, disconnect the
throttle connector and measure the resistance of 1.25 kOhms ¦ 30% from:

TPS Pin 2 (GND) to Pin 6 (TPS1 SIGNAL)
TPS Pin 3 (PWR) to Pin 6 (TPS1 SIGNAL)

NOTE: Do not service this sensor. Repair by replacing the throttle body assembly.

Fault appears if the sensor potentiometer has malfunctioned. Check for dirt or oxidation on the
sensor traces. Check the throttle connector and pins for corrosion. To check, disconnect the
throttle connector and measure the resistance of 1.25 kOhms ¦ 30% from:

TPS Pin 2 (GND) to Pin 6 (TPS1 SIGNAL)
TPS Pin 3 (PWR) to Pin 6 (TPS1 SIGNAL)

NOTE: Do not service this sensor. Repair by replacing the throttle body assembly.

Fault appears if the sensor signal wire is disconnected or the circuit is opened to the SECM.
(EC12 and EC11 are expected faults when the ETC connector is unplugged). Check the
throttle connector connection and sensor for an open circuit:

ETC Pin 6 to SECM Pin 17 (SIGNAL)
ETC Pin 2 to SECM Pin 1 (GND)

Fault appears if either of the electronic throttle control driver signals are opened or
disconnected. This happens if the throttle plate sticks inside the throttle body. Check for debris
or obstructions inside the throttle body; a loose throttle plate, or the throttle-plate shaft for
bearing wear. Check the ETC driver wiring for an open circuit:

ETC+ Pin 1 to SECM Pin 22

ETC-- Pin 4 to SECM Pin 24
Check the ETC internal motor drive by disconnecting the throttle connector and measuring the
motor drive resistance at the throttle:

TPS Pin 1 (+DRIVER) to Pin 4 (--Driver) approx. 3.0 Ohms ¦ 30%.
NOTE: Do not service the throttle components. Repair or replace the throttle body assembly.

The Electronic Spark Trigger is a current driver signal. This fault appears if the signal from the
SECM is shorted to ground or the coil driver signal is low or undercurrent. Check the coil driver
wiring and connector for shorts:

SECM Pin 7 (EST 1) to COIL Pin A

Verify GND on COIL Pin B

Verify GND on COIL Pin C

Verify GND on COIL Pin D

Verify +12VDC on COIL Pin E
To check the internal circuit, disconnect the coil connector and measure the resistance from pin
to pin. See Figure 5-20.

The Electronic Spark Trigger is a current driver signal. This fault appears if the signal from the
SECM is open or lost or the coil driver signal is high or overcurrent.
Check the coil driver wiring for an open circuit or disconnected connector:

SECM Pin 7 (EST 1) to COIL Pin A

Verify GND on COIl Pin B

Verify GND on COIL Pin C

Verify GND on COIL Pin D

Verify +12VDC on COIL Pin E
To check the internal circuit, disconnect the coil connector and measure the resistance from pin
to pin. See Figure 5-20.

The Electronic Spark Trigger is a current driver signal and this fault appears if the signal from
the SECM is shorted to ground or the coil driver signal is low or undercurrent. Check the coil
driver wiring and connector for shorts:

SECM Pin 7 (EST1) to COIL Pin A

Verify GND on COIL Pin B

Verify GND on COIL Pin C

Verify GND on COIL Pin D

Verify +12VDC on COIL Pin E
To check the internal circuit, disconnect the coil connector and measure the resistance from pin
to pin. See Figure 5-20.

TP-6391 9/08 29Section 4 Controller

SECM Fault Codes and Diagnostics (Continued)

Fault
Code
Displayed

EC43* Electronic Spark Trigger

EC46 Injector Input is Low Fault appears when the power to the injector is low.

LOP Low Oil Pressure Fault appears when the oil pressure switch is opened or disconnected, normally indicating a

EC48 Electronic Throttle Control

EC49 Manifold Air Pressure

EC50 Manifold Air Pressure

EC51 Electronic Throttle Control

HB* Battery Voltage Sensor

LB* Battery Voltage Sensor

EC54 Transducer Voltage (XDRP)

Description Check

(EST) 2 High

(ETC) Spring Test Failed

(MAP) Sensor Input High

(MAP) Sensor Input Low

(ETC) Driver Fault

Input High

Input Low

Sensor Input High

The Electronic Spark Trigger is a current driver signal and this fault appears if the signal from
the SECM is open or lost or the coil driver signal is high or overcurrent.
Check the coil driver wiring for an open circuit or disconnected connector:

SECM Pin 7 (EST 1) to COIL Pin A

Verify GND on COIl Pin B

Verify GND on COIL Pin C

Verify GND on COIL Pin D

Verify +12VDC on COIL Pin E
To check the internal circuit, disconnect the coil connector and measure the resistance from pin
to pin. See Figure 5-20.

low oil condition. See Figure 4-5.

Upon initial engine startup, the SECM performs a safety test of the throttle return spring. If this
spring has become weak, the throttle will fail this test and set the fault. Perform a throttle spring
test by cycling the ignition and rechecking for the fault.
NOTE: Do not service the throttle components. Repair or replace the throttle body assembly.

The manifold air pressure sensor fault appears if the TMAP pressure signal wire is shorted to
power, shorted to the IAT signal, the TMAP has failed, or the SECM has failed. Check the
TMAP connector and MAP signal wiring for a shorted circuit:

TMAP Pin 4 to SECM Pin 5 (SIGNAL)

TMAP Pin 1 to SECM Pin 1 (GND)

TMAP Pin 3 to SECM Pin 18 (XDCR +5VDC)
Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor:

TMAP Pin 1 (GND) to Pin 4 (PRESSURE SIGNAL KPA) of 2.4 kOhms -- 8.2 kOhms

TMAP Pin 3 (PWR) to Pin 4 (PRESSURE SIGNAL KPA) of 3.4 kOhms -- 8.2 kOhms

The manifold air pressure sensor fault appears if the TMAP pressure signal wire is
disconnected or the circuit is opened to the SECM. (EC50 and EC56 are expected faults when
the TMAP connector is unplugged). Check the TMAP connector and MAP signal wiring for an
open circuit:

TMAP Pin 4 to SECM Pin 5 (SIGNAL)

TMAP Pin 1 to SECM Pin 1 (GND)

TMAP Pin 3 to SECM Pin 18 (XDCR +5VDC)
Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor:

TMAP Pin 1 (GND) to Pin 4 (PRESSURE SIGNAL KPA) of 2.4 kOhms -- 8.2 kOhms

TMAP PIn 3 (PWR) to Pin 4 (PRESSURE SIGNAL KPA) of 3.4 kOhms -- 8.2 kOhms

Fault appears if an overcurrent condition occurs on either the ETC+ or ETC-- driver signals.
Check the ETC driver wiring for a shorted circuit:

ETC+ Pin 1 to SECM Pin 22

ETC-- Pin 4 to SECM Pin 24
Check the ETC internal motor drive by disconnecting the throttle connector and measuring the
motor drive resistance at the throttle:

TPS Pin 1 (+DRIVER) to Pin 4 (--DRIVER) approx. 3.0 Ohms ¦ 30 %.

Fault appears if the power to the SECM increases above 15.9 VDC. See Figure 4-6.
Check the battery and charging system voltage:

Check the battery voltage during starting and with the engine running.

Check the voltage regulator, alternator, and charging system.

Check the battery and wiring for overheating and damage.

Measure the battery power at the SECM with a multimeter:

Fault appears if the power to the SECM drops below 9.5 VDC. See Figure 4-6.
Check the battery voltage:

Perform a maintenance check on the electrical connections to the battery and ground.

Check the battery voltage during starting and with the engine running to verify charging

system and alternator function.

Measure the battery power at the SECM with a multimeter:

Fault appears if the sensor power from the SECM increases above 5.9 VDC.
Measure the transducer power at the TMAP connector with a multimeter:

TMAP Pin 3 +5VDC to TMAP Pin 1 XDCR GND
Verify transducer power at the SECM with a multimeter:

SECM Pin 18 +5VDC to SECM Pin 1 XDCR GND
Verify transducer power at ETC with a multimeter:

ETC Pin 3 XDCR PWR to ETC Pin 2 XDCR GND

SECM Pin 13 (BATT+) to SECM Pin 14 (BATT--)

SECM Pin 13 (BATT+) to SECM Pin 14 (BATT--)

* Indicates a stored fault code.

TP-6391 9/0830 Section 4 Controller

SECM Fault Codes and Diagnostics (Continued)

Fault
Code
Displayed

EC55 Transducer Voltage (XDRP)

EC56* Intake Air Temperature (IAT)

EC57* Intake Air Temperature (IAT)

EC58* Engine Coolant

EC59* Engine Coolant

EC60* Oxygen Sensor Input High Fault appears if the O2 sensor SECM driver signal is shorted to power. Check if the O2 sensor

EC61 Oxygen Sensor Input Low Fault appears if the oxygen sensor input is low. Check the O2 sensor connector and wiring for

EC62 Seawater Pump Pressure Fault appears when seawater cooling is lost. Check the seawater strainer for clogged material.

OS Engine Overspeed Fault Fault appears when the engine RPM increases beyond the max. RPM setpoint. Typically this

HE Engine Coolant

EC69* O2 Sensor Switching Fault Fault appears when the O2 sensor can no longer switch or be driven above and below 500mv

EC72* CAN Receive Message

* Indicates a stored fault code.

Description Check

Sensor Input Low

Input Sensor High

Input Sensor Low

Temperature (ECT) Sensor
Input High

Temperature (ECT) Sensor
Input Low

Temperature (ECT) Sensor
Range High

Fault

Fault appears if the sensor power from the SECM drops below 4.8 VDC. (EC11, EC12, and
EC50 are expected faults when the transducer power is lost).
Measure the transducer power at the TMAP connector with a multimeter:

TMAP Pin 3 +5VDC to TMAP Pin 1 XDCR GND
Verify transducer power at the SECM with a multimeter:

SECM Pin 18 +5VDC to SECM Pin 1 XDCR GND
Verify transducer power at the ETC with a multimeter:

ETC Pin 3 XDCR PWR to ETC Pin 2 XDCR GND

Fault appears if the TMAP temperature signal wire is disconnected or the circuit is open to the
SECM. Check the TMAP connector and IAT signal wiring for an open circuit:

TMAP Pin 2 to SECM Pin 4 (SIGNAL)

TMAP Pin 1 to SECM Pin 1 (GND)

TMAP Pin 3 to SECM Pin 18 (XDCR +5VDC)
To check the IAT sensor of the TMAP, disconnect the TMAP connector and measure the IAT
resistance. See Figure 5-15.

Fault appears if the TMAP temperature signal wire has become shorted to ground, shorted to
the MAP signal, the TMAP has failed or the SECM has failed. Check the TMAP connector and
IAT signal wiring for a shorted circuit:

TMAP Pin 2 to SECM Pin 4 (SIGNAL)

TMAP Pin 1 to SECM Pin 1 (GND)

TMAP Pin 3 to SECM Pin 18 (XDCR +5VDC)
To check the IAT sensor of the TMAP, disconnect the TMAP connector and measure the IAT
resistance. See Figure 5-15.

Fault appears if the coolant sensor wire is disconnected or the circuit is opened to the SECM.
Check if the sensor connector is disconnected or for an open circuit:

SECM (SIGNAL) Pin 16 to ECT Pin A

SECM (GND) Pin 1 to ECT Pin B

Fault appears if the coolant sensor wire is shorted to ground or the sensor has failed. Check
the sensor connector and wiring for a short to GND:

SECM (SIGNAL) Pin 16 to ECT Pin A

SECM (GND) Pin 1 to ECT Pin B

is shorted to +5VDC or battery:

O2 (SIGNAL) Pin B to SECM Pin 3
Verify operation of O2 sensor heater circuit by measuring circuit resistance of 2.1 ohms
¦ 0.4 ohms:

O2 Pin C (HEATER GND) to Pin D (HEATER PWR)

a short to ground:

ECM (SIGNAL) Pin 3 to O2 Sensor Pin B

ECM (GND) Pin 1 to O2 Sensor Pin A

Check the seawater pump impeller. Check if wire 215 is shorted to ground. See Figure 4-5.

occurs with one or more throttle faults. Check for ETC sticking or other ETC faults. See
Figure 4-5.

Fault appears when the sensor has measured an excessive coolant temperature typically due
to engine overheating. Check the coolant system for seawater blockages, proper coolant level,
and any leaks in the coolant system. See Figure 4-5. Check for possible ECT short to GND.
Check the ECT signal wiring:

SECM (SIGNAL) Pin 16 to ECT Pin A

SECM (GND) Pin 1 to ECT Pin B

by the SECM. O2 Sensor is not switching across the reference AFR voltage. Check for an
open coil by disconnected the connector and measuring the resistance (approx. 26 ohms¦
2 ohms):

Pin A (SIGNAL) to Pin B (PWR)

See Figure 4-7 and Figure 4-8.

TP-6391 9/08 31Section 4 Controller

Note: Generator sets built after serial number 2175814 have a different engine harness design. For serial numbers

after 2175814, the communication wires are green and yellow. Pin locations remain the same. Resistors are
removable.

Note: For complete wiring diagram details, see Section 7.

Verify Battery Voltage to ECM

Verify battery voltage between P10-13 (positive) referenced to P10-14 (negative).

If no battery voltage, change the negative reference on the meter to the engine block ground. If there’s now a battery voltage
reading, the ground wire to the ECM is open. Trace the negative wire to its ground source and determine the cause of the
open circuit. If there’s still no battery voltage, the problem is the positive supply (F5 wire).

The F5 wire supplies the battery voltage to the ECM and is switched thru the K5 relay contacts. Access the K5 relay on the
non-service side of the generator set (behind the ADC 2100 control).
NOTE: Older harness designs have a small black relay that is mounted to the generator end bell with spade connectors at
the bottom. Newer harness designs (after serial number 2175814) have the relay attached directly to the harness (P30
connector) at the same location.

Verify power at 12P wire at the K5 relay. Reference negative to P10-14.

If there’s power at 12P, verify power on PF4 (the other side of the normally open (NO) relay contact).

If there’s power at PF4, verify power to PF5 off of the F5 fuse.

If there’s power at PF5 at the F5 fuse, the problem’s between the F5 fuse and the ECM connection.

If there’s no power at 12P, verify power at F3 fuse, wires F3 and PF2.

If there’s power at this point, trace the wire between F3 and 12P on the K5 relay.

If there’s no power at F3 fuse, verify that F3 is not open. If F3 is open, replace it.

If there’s no power to F3, verify connections at the Crank Solenoid (CS) PF3 and battery positive connection.

Figure 4-7 Troubleshooting EC72 Fault Code (Verifying Battery Voltage to the ECM)

TP-6391 9/0832 Section 4 Controller

Note: Generator sets built after serial number 2175814 have a different engine harness design. For serial numbers

after 2175814, the communication wires are green and yellow. Pin locations remain the same. Resistors are
removable.

Note: For complete wiring diagram details, see Section 7.

Verify Control Area Network (CAN) Resistance

Disconnect the ADC 2100 control plug (P1), ECM (P10), remote12-pin customer interface (P4), and SmartCraftt
communications plug (P19).

Measure the resistance at the P1 (ADC) connector pins 11 and 10 (YEL and GRN labeled wires). The meter should indicate
60 ohms.

If the meter reads 0 ohms, there’s an open circuit between the pins to the R1 resistor.

If the meter reads 120 ohms, the two resistors in the harness are no longer in parallel. Check the connections between the
resistors.

Verify a resistance of 60 ohms at the P4 (customer interconnect) connector, pins 1 and 2 (YEL and GRN). The meter should
read 60 ohms.

If the meter reads 0 ohms, there are open wires from the P4 connector to the Insul 14 and Insul 12.

If the meter reads 120 ohms, the two resistors in the harness are no longer in parallel. Check the connections between the
resistors.

TP-6391 9/08 33Section 4 Controller

Verify resistance of 60 ohms at P19 (SmartCraftt) wire 219 and 206, pins C and D.

If the meter reads 0 ohms, there’s an open circuit to the R2 resistor.

If the meter reads 120 ohms, the two resistors in the harness are no longer in parallel. Check the connections between the
resistors.

Verify resistance of 60 ohms at the P10 (ECM) connector, wires BLK and RED, pins 6 and 19.

If the meter reads 0 ohms, there’s an open circuit between these pins, wires and/or the harness resistors.

If the meter reads 120 ohms, the two resistors in the harness are no longer in parallel. Check the connections between the
resistors.

Figure 4-8 Troubleshooting EC72 Fault Code (Verifying Control Area Network (CAN) Resistance)

TP-6391 9/0834 Section 4 Controller

4.6 Relay Interface Board (RIB)

4.7 CO Sensor Module

The relay interface board (RIB) contains the K2 crank,
K3 flash, and K5 run relays. Three LEDs indicate relay
operation. See Figure 4-9.

Refer to the schematic diagram in Section 7 for the relay
board connections.

The RIB is protected by a 10 amp fuse (F2). If the fuse
blows repeatedly, disconnect the board leads one at a
time to identify the cause of the blown fuse:

D Lead 70A

D Leads FP and FN at the rotor

If the fuse continues to blow and disconnecting
components did not identify the cause, remove the
leads from the P14 connector using a pin pusher, part
#241918 (large) or 241919 (small). If replacing the
leads does not solve the problem, replace the RIB.

The individual relays are not replaceable. If one or more
relays are faulty, replace the entire RIB.

To replace the RIB:

1. Disconnect P14 and the brush leads FP and FN.

2. Pull the board straight off the mounting stand-offs.

The CO sensor module is located behind the ADC 2100.
Replace the CO sensor module every two years. See
Figure 4-10.

Note: The CO sensor module is equipped on generator

sets with serial number 2085259 and later.

GM463262-

Figure 4-10 CO Sensor Module

4.8 K5 Main Power Relay

The K5 relay powers the ECM, injector, coils, governor
assembly/throttle body, TMAP sensor, and O2 sensor.
See Figure 4-11.

3. Snap the new board onto the stand-offs and
reconnect P14 and the brush leads.

1

COMMON
FAULT

K1

2

K2

CRANK

3

3

D3D1 D2

VBAT

K3

1. K1 common fault relay (optional)

2. K2 crank relay (standard)

3. K3 flash relay (standard)

4. K4 auxiliary run relay (optional)

5. K5 run relay (standard)

6. P14, engine harness connection (standard)

7. P13, connection to optional relay harness (optional)

9

FLASH

7

3

1

46

P13

P14

T1

FN

D4

D5

FP

T2

K5

RUN

1

7

K4

LED2

FLASH

LED3

CRANK

AUX
RUN

R1

LED1

RUN

R

R

D7

D6

R2

R3

R

GM29671-A

6

Figure 4-9 Relay Board

4

5

SCHEMATIC

(sINGLE POLE DOUBLE THROW)

GM28787-K

Rated Voltage 12 VDC
Operating Current 133 mA
Coil Resistance 90 ± 10 ohms
Pull-In Voltage < 8 V
Release Voltage 1.2 V
Max. Operating Voltage 15.6 V

Figure 4-11 K5 Relay Specs

TP-6391 9/08 35Section 4 Controller

4.9 Silicon Controlled Rectifier
(SCR) Module

The silicon controlled rectifier (SCR) module works with
the ADC 2100 to regulate the output voltage. The
ADC 2100 monitors generator output voltage and
adjusts the excitation current to the rotor through the
SCR module. The SCR module location is shown in
Figure 4-1.

The SCR module is powered through stator leads 55
and 66 connected to SCR terminals AC1 and AC2.
Leads G connected to terminals G1 and G2 provide the
controller signal. Leads FP and FN connected to the
positive (+) and negative (--) SCR terminals provide
excitation current to the rotor. See Figure 4-12 and the
wiring diagrams in Section 7.

The SCR module is protected by a 10-amp fuse (F1) in
lead 55 in the wiring harness. Check the fuse and
replace it, if blown.

In the case of output voltage problems, check the
controller configuration and settings. Then test the SCR
module using the following procedure.

3. Connect the ohmmeter from AC1 to (+) on the SCR
module. You should read high resistance in both
directions.

4. Connect the ohmmeter from AC1 to (--) on the SCR
module. You should read high resistance in one
direction and low resistance in the other.

5. Repeat steps 3 and 4 for AC2.

6. Connect the ohmmeter from G1 to (+) on the SCR
module. You should read low resistance in both
directions.

7. Repeat step 6 for G2. You should read low
resistance in both directions.

8. See Figure 4-13. Connect the negative (--) lead
from the DC power source to the positive (+)
terminal on the SCR module.

Note: The SCR module may be damaged if the

power supply is connected incorrectly. Be
sure to connect the negative lead from the
battery to the positive terminal on the SCR
module.

SCR Module Test Procedure

Required equipment:

D Ohmmeter

D 12-volt test lamp (or voltmeter)

D 12-volt DC power source

D 100--500 ohm resistor

D Jumper

1. Set the ohmmeter to the R x 1 scale.

2. Connect the ohmmeter from (+) to (--) on the SCR
module. You should read high resistance in one
direction and low resistance in the other (reverse
the leads).

AC1 --

G1

G2AC2

+

(--)

1

4

G1

(+)

G2

1. 12VDC power source

2. 12 VDC test lamp

3. SCR module

4. Jumper

5. 100--500 ohm resister

Figure 4-13 SCR Test

(+)

AC1

AC2

2

5

3

(--)

tp6198

Figure 4-12 Silicon Controlled Rectifier (SCR)

Module

GM28483

9. Connect the positive (+) lead from the DC power
source, with the lamp in series, to terminal AC1 on
the SCR module. The lamp should not glow.

TP-6391 9/0836 Section 4 Controller

10. Connect the jumper, with the resistor in series, from
the positive leadof the DC power source to terminal
G1 on the SCR module. The lamp should glow.

11. Repeat steps 9 and 10, with the positive (+) lead
and lamp connected to terminal AC2 on the SCR
module, and connecting the jumper with resister to
terminal G2.

7. Attach plugs P1, P15, and P16 to the new
controller.

8. Place the new controller into position and install the
four mounting screws.

9. Verify that the generator set master switch is in the
OFF position.

12. If any of the above checks indicates a bad SCR
module, replace the module.

4.10 Controller Replacement

If the troubleshooting procedures in Section 3 identify a
bad controller, use the procedure in this section for
controller replacement. Always check the controller
configuration, fuse, wiring, and connections before
replacing the controller. For output voltage problems,
replace the SCR module and check the operation again
before replacing the controller.

After replacing the controller, verify that the new
controller’s configuration settings match the generator
set system voltage and frequency, unit configuration,
engine type, engine data input types, battery voltage,
and communications settings. Refer to Section 4.11 for
instructions to check the controller configuration and to
change the settings, if necessary.

After the controller configuration has been checked and
set to match the generator set, use a voltmeter to check
the generator set output voltage. If the output voltage
needs adjustment, use the Voltage Adjustment
Procedure in Section 5.7.2 and the controller voltage
adjustment instructions in Section 4.11.

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

11. Reconnect power to the battery charger, if
equipped.

12. Follow the instructions in Section 4.11 to change
the new controller’s configuration settings to match
the generator set system voltage and frequency,
unit configuration, engine type, engine data input
types, battery voltage, and communications
settings.

13. Use a voltmeter to check the output voltage. Follow
the instructions in Section 5.7.2, Voltage
Adjustment, to adjust the output voltage and
stability.

14. Place the generator set master switch in the AUTO
position if an ATS or remote start/stop switch is
used.

1

ADC 2100 Controller Replacement Procedure

1. Place the generator set master switch in the OFF
position.

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

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

4. Remove four mounting screws from the front of the
controller.

5. Carefully pull the controller forward, angling it so
that the P1 connector on the right side clears the
opening in the mounting plate.

6. Disconnect plugs P1, P15, and P16 from the ADC
controller. See Figure 4-14.

TP-6391 9/08 37Section 4 Controller

1. Engine wiring harness connector plug (P1)

2. J15 connector

3. J16 connector

Figure 4-14 Controller Connections

23

tp6196

4.11 Controller Configuration and
Adjustment

This section contains instructions for using the
controller’s password-protected menus to check and
adjust the generator output and controller configuration.
The controller configuration and generator set output
are factory-set and should not require field adjustment
under normal circumstances. Check and adjust the
configuration and/or output in the following cases:

D Check and adjust the controller configuration and

generator output after generator set reconnection to a
different voltage.

D Check the controller configuration when

troubleshooting generator set problems.

D Check and adjust the generator set output after

installation if the voltage requires adjustment for a
particular application.

4.11.1 Voltage Adjustments

WARNING

controller to adjust the output voltage while the
generator set is running. The flowcharts in Figure 4-16
and Figure 4-17 outline the adjustment procedures.

Note: Be sure to save your settings before exiting the

configuration mode.

Voltage changes are lost if they are not saved before the
generator set shuts down. The generator set continues
to run with the new settings until it shuts down but then
reverts to the previous settings at the next startup if the
changes have not been saved.

Pressing the Select button when SAVE is displayed
returns to the first parameter, voltage adjust (1P).

Note: Refer to the flowcharts in Figure 4-16 and

Figure 4-17 during the voltage adjustment
procedure.

Voltage Adjustment Procedure

1. With the generator set off, connect a digital
multimeter to the output leads or an electrical outlet
on the load side of the generator set. Set the meter
to measure AC voltage.

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.

Moving parts.

The controller’s adjustment mode allows adjustment of
the output voltage, if necessary. Have adjustments
performed by an authorized distributor/dealer or service
technician.

Note: A digital voltmeter is required for these

adjustments.

Use a voltmeterto check the output voltage. If theoutput
voltage is not within specifications, use the ADC

2. Start the generator set by moving the generator set
master switch to the RUN position.

3. Use the ADC controller to adjust the voltage
(parameter 1P) until the output voltage reaches the
desired value. See Figure 4-15 for the
approximate change in voltage per step in
parameter 1P.

Measured

Voltage, VAC

85--132 5 0.5

180--251 7 0.7

Voltage Change per Step, VAC

Coarse Adjust Fine Adjust

Figure 4-15 Voltage Adjustment (approximate)

4. Adjust the voltage stability (gain, parameter 2P) to
minimize light flicker.

5. Readjust the voltage, if necessary.

6. Save the settings.

7. Stop the generator set.

TP-6391 9/0838 Section 4 Controller

Output Voltage Adjustment Mode:

Move the generator set master switch to the RUN position. The generator set
engine starts and the controller display shows the engine runtime hours.

Display :*

x x x x

Hold:

The controller is now in the voltage coarse adjustment mode.

Press:

Wait about 5 seconds until the display changes from runtime hours
to the program version number.

Press the down arrow key and then the up arrow key 3 times to enter the
adjustment mode. (This is the controller “password.”)

or

or

To raise or lower the voltage in large increments
(approximately 5--7 volts per step).

To enter fine voltage adjustment mode.

To raise or lower the voltage in smaller increments
(approximately 0.5--0.7 volts per step).

x

1 P

1 P

1 P

x x

.

x x

x x

xx

To enter coarse voltage stability (gain) adjustment mode.

or

2 P

To raise or lower the voltage stability (gain) in large
increments.

To enter fine voltage stability (gain) adjustment mode.

x x

2 P

or

To raise or lower the voltage stability (gain) in smaller
increments.

To enter volts/Hz adjustment mode.

3 P 0

or

Continued on Figure 4-17.

* Shaded boxes show which character in the controller display changes for each adjustment. “x” in the

examples above denotes any number from 0 to 9. The actual values may vary from model-to-model.

To raise or lower the volts/Hz: 00=low; 09= high

xx

x

TP6196

Figure 4-16 Output Voltage Adjustments

TP-6391 9/08 39Section 4 Controller

Continued from Figure 4-16:

Display:*

To enter SAVE mode.

Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to

the last saved settings when the master switch is moved to the OFF/RESET position.

There are 3 options when the display says SAVE:
Press:

To return to the first parameter, coarse voltage adjustment, to check
or change settings before saving. See Figure 4-16.

or

To save changes.

or

To discard changes without saving.

“Yes”or “no” flashes when the up or down arrow is pressed and then the
controller exits the configuration mode. The display returns to the
runtime hours.

S A V E

S A V E

1 P

x x

Y E S

n o

x x x x

Now move the master switch to OFF/RESET.

* “x” in the examples above denotes any number from 0 to 9. The actual values may vary from

model-to-model.

Figure 4-17 Output Voltage Adjustments, Continued

TP-6391 9/0840 Section 4 Controller

4.11.2 Controller Configuration

The controller configuration for each generator model is
set at the factory and should not normally require
changes. The controller’s configuration mode allows
adjustment of the system parameters listed in this
section. Use the instructions in this section to check the
configuration after installation and change them to
match the settings shown in Figure 4-18, if necessary.

The controller will automatically exit the configuration
mode without saving any changes after about 1 minute
if no buttons are pressed. Start the configuration
procedure over again from the beginning if the controller
exits the configuration mode before the settings have
been saved.

Follow the instructions in Figure 4-21 to enter the
configuration mode while the engine is not running and
then step through the following parameters. Use the up
(∧) and down (∨) arrow buttons to select the appropriate
setting for the application.

Engine configuration (Ec). The engine configuration
must match the generator set engine type. The engine
configuration setting for the 5/7.3ECD and 4/6EFCD is
Ec04.

Advanced configuration mode (Adnc). The data
input types, battery voltage, and communications
setting can be changed in the advanced configuration
mode. Press the up arrow button when Adnc is
displayed to enter the advanced configuration mode.

Engine data input types (Ed). This setting defines the
type of senders used on the generator set engine. Use
Ed00 for the 5/7.3ECD and 4/6EFCD.

The remote digital gauge requires the optional analog oil
pressure sender. Install the optional sender and change
the Ed parameter to Ed02.

Battery voltage (Bt). This setting toggles between 12
and 24 VDC for the engine starting battery voltage. The
5/7.3ECD and 4/6EFCD uses a 12-volt battery, Bt12.

Voltage/frequency setting (Uu). Select the system
voltage and frequency from the table in Figure 4-18. For
system voltages not listed in the table, select the setting
closest to the system voltage and then adjust the output
voltage to the desired level using the instructions in
Section 4.11.1.

Note: This parameter sets the nominal system voltage

and frequency. To adjust the output (measured)
voltage, see Section 4.11.

Unit configuration (Uc). This parameter sets the
generator set type: marine, standby, or mobile. The
setting for the 5/7.3ECD and 4/6EFCD is Uc00, marine.

Communications setting (Cn). This setting allows the
user to set the controller for communication with
optional meters. The 5/7.3ECD and 4/6EFCD is
factory-set for CAN communications, Cn02.

Note: Be sure to save your settings before exiting the

configuration mode. The controller reverts to the
last saved settings when the master switch is
moved to the OFF/RESET position.

TP-6391 9/08 41Section 4 Controller

Vol ts ,

MarineG

l

i

F

4EFCD50

5ECD6

0

ECD

6EFCD50

7.3ECD6

0

5/7.3EC

D

g

g

g

g

aso

Model

ne

4EFCD 50

5ECD 60

ECD
EFCD

6EFCD 50

7.3ECD 60

* Use voltage/frequency parameters Uu07--Uu23 only with ADC application program version 1.20 or higher.

[ See Figure 4-19 for Ed settings with optional sender kits.
] See Figure 4-20 for Cn settings with optional digital gauges (gauges are available on selected models only).

Note: Replacement controllers from Kohler Aftermarket Parts are shipped with factory settings for the 8.5/12RES.
Note: Setting the Ec parameter automatically selects the Ed parameter for the standard data inputs for that engine.

If you change Ec, check the Ed setting.

req.
Hz

Voltage, Phases

230 V, 1 Ph, 2 W 2

115/230 V, 1 Ph, 3 W 6

115V,1Ph,2W 5

120/240 V, 1 Ph, 3 W 1

120 V, 1 Ph, 3 W 0

120 V, 1 Ph, 2 W 0

230 V, 1 Ph, 2 W 2

115/230 V, 1 Ph, 3 W 6

115V,1Ph,2W 5

120/240 V, 1 Ph, 3 W 1

120 V, 1 Ph, 3 W 0

120 V, 1 Ph, 2 W 0

Market

Hz

Uu* Uc Ec

Engine

Typ e

0 4 0 1 12

Data

Inputs

Ed[

CO

CO Bt

Figure 4-18 Configuration Parameters

Model Sender Kit Ed

5/7.3ECD
4/6EFCD

* OP and WT sender kits

None 0

GM45891-KA1 * No Change

Battery
Voltage

CANbus

Comm.

Cn]

2or8]

Figure 4-19 Ed Settings with Optional Sender Kits

Power Down

Time (when

Gauge Kit Gauge Description

None — Cn00 48 hours No CAN communication (not for use with these models)

GM32337-KP1 Remote Digital Gauge for

Marine

GM46035-KP1 Three-Inch Digital Gauge

GM50822-KP1 Two-Inch Digital Gauge

* For ADCs with removable power mode jumpers, refer to TT-1439 for power down information.

[ Smartcraftt settings for ADC code version 2.00 or higher only, for models 5/7.3ECD and 4/6EFCD.
] Smartcraftt settings for ADC code version 2.20 or higher only.

w Before ADC code version 3.20, the power-down time was 48 hours.

SmartCraftt is a trademark of Mercury Marine, a division of Brunswick Corporation.

Cn

Setting

Cn01 Never/None 3-inch J1939 gauge with no sleep mode

Cn02 48 hours

Cn03 48 hours

Cn04 48 hours

Cn05 48 hours

Cn07 48 hours

Cn08

Cn09

master switch in

AUTO position)

1 hour w Smartcraftt 2-inch gauge for generator set #1 with ECM ]

1 hour w Smartcraftt 2-inch gauge for generator set #1 without ECM ]

Description

CAN communication (not for use with these models)

Smartcraftt 3-inch gauge for generator set #1 with ECM [

Smartcraftt 3-inch gauge for generator set #2 with ECM [

Smartcraftt 3-inch gauge for generator set #3 with ECM [

Smartcraftt 3-inch gauge for generator set #4 with ECM [

Smartcraftt 3-inch gauge for generator set #1 without ECM [
(not for use with these models)

(not for use with these models)

Figure 4-20 Communication Parameter Cn Settings (optional gauges are available on selected models only)

TP-6391 9/0842 Section 4 Controller

Controller Configuration Mode:

Hold the Select button:

Move the generator set master switch to the RUN
position. (The generator set engine will not start.)

Wait about 5 seconds until the display shows the
program version number. (The number may be
different than the one shown here.)

Press the down arrow key and then the up arrow
key 3 times to enter the configuration mode.
(This is the controller “password.”)

Now release the Select button.

Press:

or

To set the voltage/frequency setting to Uu01. See
Figure 4-18.

To step to the next parameter, unit configuration
Uc.

Display:

. 0

1 0 4

U u 0 x

U u 0 x

or

or

Now either save your settings or enter the Advanced Configuration Mode to
set the engine data inputs, battery voltage, and communications.

Press:

or

or To proceed to the save mode without

To set the unit configuration setting to Uc00, if
necessary.

To step to the next parameter, engine type Ec.

To set the engine type to Ec04, if necessary.

To step to the next parameter, advanced
configuration mode or save mode selection.

To enter advanced configuration mode.

Go to Figure 4-22.

entering the advanced configuration mode.

Go to Figure 4-23.

U c 0 0

E c 0 4

A d n c

E d 0 0

S A V E

Note: Shaded boxes show which number in the controller display changes when the up or down arrow

keyispressed.x

Figure 4-21 Configuration Mode (system voltage/frequency, unit configuration, and engine type parameters)

TP-6391 9/08 43Section 4 Controller

Pressing the up arrow key at the Adnc display (See Figure 4-21) puts you
into the Advanced Configuration Mode.

Press:

or

or

or

Note: Be sure to save your settings before exiting the configuration mode. The controller reverts

to the last saved settings when the master switch is moved to the OFF/RESET position.

Figure 4-22 Advanced Configuration Mode (engine data input types, battery voltage, and engine

communications)

To set the engine data input type to Ed00.
See Figure 4-18.

To enter battery voltage selection mode.

To toggle between 12 and 24 VDC. Set this
parameter to 12 VDC.

To enter communications selection mode.

To set the communications parameter to
Cn00 or Cn01. See Figure 4-18.

To enter SAVE mode. Go to Figure 4-23.

E d 0 0

B t 1 2

C n 0 0

S A V E

There are 3 options when the display says SAVE:
Press:

To return to the first parameter, system voltage/frequency
Uu, to check or change settings before saving. See
Figure 4-21.

or

To save changes.

or

To discard changes without saving.

“Yes”or “no” flashes when the up or down arrow is pressed and then
the controller exits the configuration mode. The display returns to
the runtime hours.

Now move the master switch to OFF/RESET.

* “x” in the runtime hours display above denotes any number from 0 to 9.

Figure 4-23 Save Mode (after configuring generator set parameters)

S A V E

U u 0 1

Y E S

n o

x x xx

TP-6391 9/0844 Section 4 Controller

Section 5 Component Testing and Adjustment

5.1 Theory of Operation

Model 5/7.3ECD and 4/6EFCD generator sets utilize a
rotating-field alternator to produce AC voltage. Upon
activation of the generator master switch, DC current
from the battery magnetizes the rotor (field). When the
magnetized rotor rotates within the stator windings, an
electrical voltage develops within the stator. As engine
speed and generator output increase, the SCR module
feeds rectified stator output current to the rotor through
the brushes/slip rings to increase the strength of the
rotor field. As the rotor field increases in strength,
generator output also increases. The ADC 2100
controller monitors the generator output voltage through
leads 11 and 44 and adjusts the DC current from the
SCR module to the rotor to meet load requirements.
SeeFigure5-1.

5.2 Separate Excitation

To determine the cause of no or low AC output, refer to
the troubleshooting flow chart in Figure 5-2. Before
beginning the test procedures, read all safety
precautions at the beginning of this manual. Many of the
test procedures include additional safety precautions.

1

55

ADC 2100

66

55
66

G

F+

FP

11

44

8

AC1

SCR

AC2

G1
G2
(+)

(--)

FN

345521

44

7

6

1. Fuse

2. Power lead (55)

3. Excitation to rotor

4. Brushes

5. Slip rings

6. Main field (rotor)

7. Stator windings

8. Sensing leads (11--44)

Figure 5-1 Generator Schematic

2

3

FP

11

FN

66

4

5

TP6198

Check the condition of the alternator fuse before
performing the separate excitation procedure. See
Figure 5-1. The fuse is located on the fuse panel. See
Figure 4-1 for the fuse panel location. If the fuse is not
blown, use the following procedure to separately excite
the generator using an external voltage source (a
12-volt automotive battery).

Separately exciting the generator can identify faulty
voltage regulation by the ADC controller or reveal a
running fault in the rotor and/or stator. An external
power source duplicates the role of the voltage regulator
and excites the generator field (rotor). A generator
component that appears to be in good condition while
stationary may exhibit a running open or short circuit
while moving. Centrifugal forces acting on the windings
during rotation cause a broken circuit to open, or
increasing temperatures cause the insulation to break
down, resulting in a running fault.

No Generator Output

Separate Excitation

Output within

Specifications

Check Wiring, Fuses,

Erratic or No Output

SCR Module and

Controller

Check Rotor

Check Stator

Figure 5-2 Generator Troubleshooting

TP563273

TP-6391 9/08 45Section 5 Component Testing and Adjustment

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

whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Nevercontact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.

Main Field (Rotor), to test the rotor. If the ammeter
reading is stable, proceed to step 4.

4. Check for AC output across the stator leads; see
Section 5.3, Stator. Compare the readings to the
AC output values shown in Section 1,
Specifications. If the readings vary considerably, a
faulty stator is likely. Refer to Section 5.3, Stator,
for further information.

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.

Separate Excitation Procedure

Perform the following procedure to use an external
voltage source to excite the main field (rotor).

1. Disconnect the black FN and FP leads from the
alternator at the SCR module (+) and (--) terminals.

2. Connect a DC ammeter, 10-amp fuse, and a
12-volt automotive battery to the positive (FP) and
negative (FN) brush leads as shown in Figure 5-3.
Note and record the ammeter reading.

Note: The approximate ammeter reading should

be the battery voltage divided by the
specified rotor resistance. See Section 1,
Specifications, for specified rotor resistance
values.

Example:

12 volts (battery voltage)

3.4 ohms (rotor resistance)

3.5 amps

=

(rotor current)

3. Start the engine and check that the ammeter
reading remains stable. An increasing meter
reading indicates a shorted rotor. A meter reading
decreasing to zero or an unstable reading
suggests a running open. Refer to Section 5.4,

5. If this test shows that the rotor and stator are in
good condition, check the wiring and fuses. Check
the SCR module. See Section 4.9, Silicon
Controlled Rectifier (SCR) Module. Check the
controller settings and connections. See
Section 4, Controller.

FP

7

+

8

23 4

+

-

TP563274

1

FN

-

9

1. SCR module

2. FN lead disconnected from SCR

3. FP lead disconnected from SCR

4. 10-amp fuse

5. DC ammeter

6. 12V battery

7. Brushes

8. Slip rings

9. Main field (rotor)

Figure 5-3 Separate Excitation Connections

5

6

TP-6391 9/0846 Section 5 Component Testing and Adjustment

5.3 Stator

The stator contains a series of coils of wire laid in a
laminated steel frame. The stator leads supply AC
voltage to the load and voltage regulator. Before testing
the stator, inspect it for heat discoloration and visible
damage to housing lead wires, exposed coil windings,
and exposed areas of frame laminations. Be sure the
stator is securely fastened to the stator housing.

Note: Disconnect all stator leads before performing all

stator tests.

Note: For single-phase models, leads 1--4 are the

generator output leads. Leads 11, 44, 55,
and 66 are the controller and SCR module
sensing and supply leads. Refer to the
schematic in Figure 5-5 when performing
the following steps.

Note: When taking an ohmmeter reading using

lead 55, make the connection before the
in-line fuse.

6. Contact the ohmmeter leads and readjust the
ohmmeter to read zero ohms.

WARNING

Hazardous voltage.
Can cause severe injury or death.

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

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

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

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.

Stator Continuity and Resistance Tests

1. Place the generator set master switch in the OFF
position.

Moving parts.

7. Check the cold resistance of the stator windings by
connecting the meter leads to the stator leads. See
Section 1.4, Alternator Specifications, for stator
winding resistances.

Note: Most ohmmeters do not provide accurate

readings below 1 ohm. Low resistance
readings (continuity) and no evidence of
shorted windings (heat discoloration)
indicate a stator in good condition. See
Figure 5-6.

8. If the resistance test proves inconclusive, use a
megohmmeter to test the stator as described in the
next step.

Note: Because ohmmeter accuracy varies,

resistance readings are approximate
readings. Take readings of the rotor and
stator at room temperature.

Note: Make sure that all stator leads are

disconnected before running the
megohmmeter test.

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

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

4. Disconnect all stator leads before performing all
stator tests.

5. To check for stator continuity, set the ohmmeter on
R x 1 scale. First set the ohmmeter zero by holding
the red and black meter leads together and setting
the ohmmeter reading to zero. Then check the
stator continuity by connecting the meter leads to
the stator leads as shown in Figure 5-4.

TP-6391 9/08 47Section 5 Component Testing and Adjustment

R14807-14

Figure 5-4 Testing Stator Windings

9. Use a megohmmeter to determine whether the

N

o

stator is shorted to ground.

a. Apply 500 volts DC to any stator lead and the

stator frame. Perform the megohmmeter test
following the instructions of the megohmmeter
manufacturer.

b. Repeat the test on the other stator leads until

each coil is tested.

Note: A reading of approximately 500 kOhms

(1/2 megohm) and higher indicates a
good stator.

c. Repair or replace the stator if any reading is

less than approximately500 kOhms. A reading
of less than 500 kOhms indicates deterioration
of the winding insulation and possible current
flow to ground.

5.4 Main Field (Rotor)

The two-pole rotor creates the magnetic field needed to
produce alternating current in the stator windings.
Before testing, inspect the rotor for visible damage to
pole shoes, insulation, exposed coil windings, and slip
ring surfaces. Rotate the bearing to check for wear,heat
discoloration, or noise.

5.4.1 Rotor Continuity and Resistance
Tests

WARNING

Hazardous voltage.
Can cause severe injury or death.

Moving parts.

44

4

3

66

55

2

1

11

6198

Figure 5-5 Single-Phase Alternator Stator Leads

Leads Continuity

1 and 2

1 and 11

2 and 11

3 and 4

3 and 44

4 and 44

55 and 66

1 and 3, 4, 44, 55, or 66

2 and 3, 4, 44, 55, or 66

3 and 1, 2, 11, 55, or 66

4 and 1, 2, 11, 55, or 66

Any stator lead and ground on stator
housing or frame laminations

Yes

Figure 5-6 Continuity Test Results on a Good Stator

(Single-Phase)

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

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

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

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

whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Nevercontact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.

Rotor Test Procedure

1. Place the generator set master switch in the OFF
position.

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

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

4. Remove the brush cover from the alternator end
bracket.

TP-6391 9/0848 Section 5 Component Testing and Adjustment

5. Check the rotor for continuity and resistance.
Raise the brushes from the slip rings while
performing ohmmeter tests. Measure the rotor
resistance (ohms) between the two slip rings; see
Figure 5-7. See Section 1.4, Alternator
Specifications, for rotor resistance readings. If the
resistance readings are low, perform a
megohmmeter test on rotor as described in the
next step.

Note: Because ohmmeter accuracy varies,

resistance readings are approximate. Take
readings at room temperature.

R13929-7

Figure 5-7 Rotor Resistance Check

2-221

6. Perform a megohmmeter test to determine
whether the rotor is shorted to ground.

a. Raise and secure the brushes away from the

slip rings by inserting a retaining wire in the
brush holder hole.

b. Using a megohmmeter, apply 500 volts DC to

one rotor slip ring and the rotor poles or shaft.
Follow the instructions of the megohmmeter
manufacturer when performing this test.

Note: A reading of approximately 500 kOhms

(1/2 megohm) or higher indicates a
good rotor.

c. Repair or replace the rotor if the reading is less

than approximately 500 kOhms. A reading of
less than 500 kOhms indicates deterioration of
the winding insulation and possible current flow
to ground.

d. Following the test, remove the retainer wire

from the brush holder and check the brush
positions on the slip rings. See Section 5.6,
Brushes.

e. Reinstall the brush cover on the end bracket.

TP-6391 9/08 49Section 5 Component Testing and Adjustment

5.5 Slip Rings

Slip rings acquire a glossy brown finish in normal
operation. Do not attempt to maintain a bright,
newly-machined appearance on the slip rings. Cleaning
with a dry, lint-free cloth is usually sufficient. Use very
fine sandpaper (#00) and apply light pressure to remove
roughness. Do not use emery or carborundum paper or
cloth. Clean all carbon dust from the generator after
sanding the slip rings. If the rings are black or pitted,
remove the rotor and use a lathe to remove some of the
slip ring surface material.

5.6 Brushes

The brushes transfer current from the SCR module to
the slip rings. The brushes should last the life of the
generator. Abrasive dust on the slip rings, however,
shortens the life of the brushes. Excessive arcing at the
brushes could damage the SCR module and the
controller. Weak springs, damaged slip rings, sticking
brushes, a loose brush holder, or poor brush contact
causes arcing.

The brushes must be free to move within the holder and
be held in contact with the slip rings by the springs.
When correctly positioned, spring pressure on the brush
surface causes the brush to wear evenly. The entire
brush must ride on the ring or arcing occurs and causes
burned rings or voltage regulator failure. Figure 5-8
shows the correct positioning of the brushes. Add or
remove shims as necessary to center the brushes on
the slip rings. Replace the brushes if they show uneven
wear or are worn to one half their original length.

Check the resistance through the brushes. Resistance
through the brushes should be low, 0.1--0.2 ohms
without meter lead resistance.

7

6

New 1.9 cm (0.75 in.)

3

1. Brush holder

2. Slip ring

3. Brush

4. Retainer wire

5. Shim

6. Spring

Alternator End View

Front View

4

5

8

3

2

7. Brush holder

8. Correctly positioned
brush

9. Incorrectly positioned
brush

1

2

GM39685A-J

Side View

9

2

TP5867

Figure 5-8 Brush Assembly

TP-6391 9/0850 Section 5 Component Testing and Adjustment

5.7 Voltage

5.7.1 Voltage Regulation

Voltage regulation is performed by the Advanced Digital
Control (ADC) and the SCR module. The ADC monitors
generator output voltage and adjusts the excitation
current to the rotor through the SCR module.

5.7.2 Voltage Adjustment

WARNING

Hazardous voltage.
Can cause severe injury or death.

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

Moving parts.

The factory sets the voltage for correct generator
operation under avariety of load conditions. Usually, the
voltage needs no further adjustment. Adjust the voltage
when necessary according to the following procedure.

The adjustment procedure requires a meter that can
measure voltage and frequency.

Use the ADC controller to adjust the voltage, gain, and
volts/Hz. Refer to Section 4.11.2 for instructions to
adjust each parameter and save the changes using the
controller keypad.

Note: The ADC controller will time out and exit the

adjustment mode after approximately 1 minute if
no buttons are pressed. Any unsaved changes
are discarded if the controller times out before the
settings are saved. Refer to Section 4.11.2 for
instructions to save your settings.

Voltage Adjustment. Adjusts generator output
between 100 and 130 volts.

Gain (Stability) Adjustment. Fine tunes regulator
circuitry to reduce light flicker.

Volts/Hz Adjustment. Determines frequency (Hz) at
which generator output voltage begins to drop.

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

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

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

whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Nevercontact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.

Voltage Adjustment Procedure

1. Connect a digital voltmeter from one side of the
circuit breaker to the LO terminal on the end
bracket casting. See Figure 5-9. Set the meter to
measure voltage.

Note: For 120- or 240-volt systems the voltage

measured from one side of the breaker to
LO should be approximately 120 VAC. For
240-volt systems, the voltage measured
from one side of the circuit breaker to the
other should be approximately 240 VAC.

The controller maintains generator output at the
specified voltage under load until the generator engine
speed drops to a preset level (factory setting 57.5 Hz on
60 Hz models and 47.5 Hz on 50 Hz models). Then the
controller allows the generator voltage and current to
drop. The voltage/current drop enables the engine to
pick up the load. When the generator speed returns to
normal (60 Hz or 50 Hz) as load is accepted, the
generator output also returns to normal.

TP-6391 9/08 51Section 5 Component Testing and Adjustment

2. Start the generator set.

3. Follow the controller instructions in Section 4.11.2
to enter the adjustment mode and increase voltage
or decrease voltage (parameter 1P) until the output
reaches the desired voltage.

4. Follow the controller instructions to step to the
voltage gain adjustment menu. Adjust the voltage
gain (parameter 2P) until the light flicker minimizes.
Save the settings.

5. Check and readjust the voltage if necessary.

6. Save the settings.

Note: The controller will revert to the previous

settings at the next startup if the changes
are not saved.

7. Stop the generator set.

5.10 Fault Shutdown Tests

Verify the operation of the generator set overspeed,
overcrank, and low oil pressure shutdowns by
performing the following tests. If these tests are
inconclusive, test individual shutdown circuit
components (wiring harness, switch, etc.) as described
elsewhere in this section.

WARNING

Top View

1

2

3

4

1. Load connection terminal LO

2. Ground connection terminal GRD

3. Controller location

4. Line circuit breaker

GM39685D-J

Figure 5-9 Circuit Breaker, LO, and GRD Terminal

Locations

5.8 Voltage Reconnection

Voltage Reconnection is covered in the generator set
Installation Manual. See the List of Related Materials for
the document number.

Hazardous voltage.
Can cause severe injury or death.

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

Servicing the generator set whenit 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.

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.

Moving parts.

5.10.1 Controller Fault Shutdown
Functions

Check the operation of the fault functions programmed
in the ADC 2100 by performing the following tests. If the
ADC 2100 does not operate as described, check the
controller configuration settings; see Section 4.11. Also
check the controller wiring and connections.

5.9 Governor System

The frequency of the alternator output is determined by
the speed of the engine. A two-pole alternator must be
driven at 3600 RPM to provide 60 Hertz and 3000 RPM
to provide 50 Hertz. The engine speed is maintained by
the Engine Control Module (ECM). See the engine
documentation for ECM information.

TP-6391 9/0852 Section 5 Component Testing and Adjustment

Overcrank Shutdown

Disconnect the starter motor lead at the starter solenoid.
Move the controller master switch to the RUN position.
Observe that the generator set simulates cranking for
7 seconds and then rests for 15 seconds. Check that the
generator set shuts down after the third crank/rest cycle.

High Engine Temperature Shutdown

Remove the connector from the coolant temperature
sensor (CTS). Attempt to start the generator set by
moving the master switch to the RUN position. The unit
should not start and the ADC control should display fault
code EC58. Move the master switch to the OFF position.

Connect a jumper wire across terminals A and B of the
connector, shorting the wires. Attempt to start the
generator set by moving the master switch to the RUN
position. The unit should start and run but the ADC
control should display warning code EC59. Move the
master switch to the OFF position.

If available, insert a resistor (100--120 Ohm) into the
CTS connector. Attempt to start the generator set by
moving the master switch to the RUN position. Shortly
after ignition, the unit should shut down and the ADC
control should display fault code HE. Move the master
switch to the OFF position.

Replace the CTS connector onto the coolant
temperature sensor.

5.10.2 Fault Shutdown Switches

Check the low oil pressure and high engine temperature
shutdown switches on the engine by performing the
following tests. If the sensor does not function as
described, replace it.

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.

Temperature Sensor (CTS)

The coolant temperature sensor (CTS) is used to
monitor engine temperature for the high engine
temperature fault shutdown (HE). See Figure 5-11 for
the coolant temperature sensor location. Set the
generator set master switch to the OFF position and
allow the generator set to cool. Disconnect the CTS and
use an ohmmeter to measure the resistance across the
sensor. The sensor resistance varies with temperature
and should be within the values shown in Figure 5-10. If
the resistance is very low (indicating a short circuit) or
very high (indicating an open circuit) replace the CTS.

Temperature, _C

(_F)

100 (212) 177 0.75

90 (194) 241 0.97

80 (176) 332 1.25

70 (158) 467 1.59

60 (140) 667 2.00

50 (122) 973 2.47

40 (104) 1459 2.97

30 (86) 2238 3.46

20 (68) 3520 3.89

10 (50) 5670 4.25

--40 (--40) 100700 4.95

Figure 5-10 Coolant Temperature Sensor Resistance

Readings

Sensor Resistance,

Ohms

1

Signal

Voltage

WARNING

Hazardous voltage.
Can cause severe injury or death.

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

Servicing the generator set whenit 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-6391 9/08 53Section 5 Component Testing and Adjustment

Moving parts.

1. Coolant temperature sensor (CTS)

GM39685D-J

Figure 5-11 Coolant Temperature Sensor (CTS)

Seawater Pressure Switch

See Figure 5-12. Remove the seawater pressure
switch and install a pressure gauge to verify that the
seawater pressure is within the range specified before
testing or replacing the seawater pressure switch. To
test the seawater pressure switch, reinstall the switch
and start the generator set. If the unit shuts down,
disconnect lead 87 from the seawater pressure switch
and reset the controller. Restart the generator set and
verify that it does not shut down. A successful restart
indicates a bad seawater pressure switch. Replace the
switch.

The calibration pressure of the seawater pressure
switch is 0.5 psi ¦ 0.3.

1

GM39685C-J

1. Seawater pressure switch

Figure 5-12 Seawater Pressure Switch Location

TMAP Sensor

The TMAP sensor monitors intake manifold
temperature and pressure. This allows the ECM full
control to monitor actual airflow compared to desired
airflow. The TMAP sensor incorporates both intake
manifold temperature and pressure measurements in
one, single unit. See Figure 5-13 for the TMAP sensor
location.

To test the TMAP sensor, set the generator set master
switch to the OFF position and allow the generator set to
cool. Disconnect the TMAP sensor and use an
ohmmeter to measure the resistance across the sensor.
The sensor resistance varies with temperature and
should be within the values shown in Figure 5-15. If the
resistance is very low (indicating a short circuit) or very
high (indicating an open circuit) replace the TMAP
sensor.

2

1

3

1. TMAP Sensor

2. Manifold elbow

3. Intake manifold assembly

GM39685D-J

Figure 5-13 TMAP Sensor Location

Thermal Characteristics

T emperature,

_C(_F)

130 (266) ¦ 1 85.45 45 (113) ¦ 1 1008.6

125 (257) ¦ 1 96.68 40 (104) ¦ 1 1199.6

120 (248) ¦ 1 109.65 35 (95) ¦ 1 1431.8

115 (239) ¦ 1 124.66 30 (86) ¦ 1 1715.4

110 (230) ¦ 1 142.08 25 (77) ¦ 1 2062.9

105 (221) ¦ 1 162.35 20 (68) ¦ 1 2510.6

100 (212) ¦ 1 186.00 15 (59) ¦ 1 3074.9

95 (203) ¦ 1 213.68 10 (50) ¦ 1 3791.1

90 (194) ¦ 1 246.15 5 (41) ¦ 1 4706.9

85 (185) ¦ 1 284.06 0 (32) ¦ 1 5886.7

80 (176) ¦ 1 329.48 --5 (23) ¦ 1 7419.0

75 (167) ¦ 1 382.89 --10 (14) ¦ 1 9426.0

70 (158) ¦ 1 466.33 --15 (5) ¦ 1 12078

65 (149) ¦ 1 521.91 --20 (--4) ¦ 1 15614

60 (140) ¦ 1 612.27 --25 (--13) ¦ 1 20376

55 (131) ¦ 1 720.65 --30 (--22) ¦ 1 26855

50 (122) ¦ 1 851.10 --35 (--31) ¦ 1 35763

Resistance,

Sensor

Ohms

Nominal

T emperature,

_C(_F)

Sensor

Resistance,

Ohms

Figure 5-14 TMAP Sensor Resistance Readings

TMAP Sensor Pin Resistance Check

TMAP Pin 1 (GND) to Pin 4
(PRESSURE SIGNAL KPA)

TMAP Pin 3 (PWR) to Pin 4
(PRESSURE SIGNAL KPA)

TMAP Pin 1 (GND) to Pin 2
(TEMPERATURE SIGNAL)

2.4 -- 8.2 kOhms

3.4 -- 8.2 kOhms

See Figure 5-14

Figure 5-15 TMAP Sensor Resistance

Max. Ratings of TMAP Sensor

Supply voltage 16 volts

Pressure 500 kPa

TP-6391 9/0854 Section 5 Component Testing and Adjustment

Crankshaft Position Sensor

The crankshaft position sensor monitors speed control,
timing (firing of spark plugs), and fuel injection. See
Figure 5-16 for the crankshaft position sensor location.
The crankshaft position sensor is an electromagnetic
device which contains a permanent magnet surrounded
by a winding. The sensor is used with the timing wheel.
The timing wheel has 30 gear teeth with 5 teeth removed
at precise locations allowing the ECM a very accurate
speed reference signal. The timing wheel rotation near
the sensor’s tip changes the magnetic flux, creating an
analog voltage signal in the sensor coil.

The spark is sent to the appropriate cylinder via the rotor
arm and spark plug wires. The ECM uses the signal
from the crankshaft position sensor to determine the
engine position and RPM. This information, together
with the TPS and TMAP sensor information is used to
calculate the correct ignition timing settings.

1

1. Crankshaft position sensor

GM39685B-J

Figure 5-16 Crankshaft Position Sensor Location

Model Crankshaft Position Sensor Gap

All 0.030 --0.060 in.

Figure 5-17 Crankshaft Position Sensor Gap

To test the crankshaft position sensor, set the generator
set master switch to the OFF position and allow the
generator set to cool. Disconnect the crankshaft
position sensor and use an ohmmeter to measure the
resistance across the sensor pins. See Figure 5-18.

Ignition Coil

This system uses a single coil incorporating the ignition
driver circuitry inside the coil. See Figure 5-19. The
ECM signals the coil to begin its cycle. Then the coil
waits for the trigger signal from the ECM.

To test the ignition coil, set the generator set master
switch to the OFF position and allow the generator set to
cool. Disconnect the ignition coil and use an ohmmeter
to measure the resistance across the coil pins. See
Figure 5-20 for the coil resistance.

Crankshaft Position Sensor Pin Resistance (approx.)

Pin 1 (+) to Pin 2 (--) 320 Ohms

Figure 5-18 Crankshaft Position Sensor Resistance

Check

Figure 5-19 Ignition Coil

TP-6391 9/08 55Section 5 Component Testing and Adjustment

Ignition Coil Pin Resistance Check (approx.)

Pin A (SIGNAL) to Pin B 10 kOhms

Pin A (SIGNAL) to Pin D 34 kOhms

Pin A (SIGNAL) to Pin E (PWR) 15 kOhms

Pin B to Pin D 44 kOhms

Pin B to Pin E (PWR) 26 kOhms

Pin D to Pin E (PWR) 17 kOhms

Figure 5-20 Ignition Coil Resistance Check

Heated Oxygen (O2) Sensor

The heated oxygen sensor is used to monitor O2in the
exhaust. See Figure 5-22 for the heated oxygen sensor
location.

Note: The heated oxygen sensor is calibrated to work

with this system. Do not use alternate sensors.

The oxygen sensor operates like an electrolyte with its
platinum layers serving as electrodes. After the internal
element reaches approx. 600_ F, it becomes electrically
conductive and attracts negatively charged ions of
oxygen. These ions collect on the inner and outer
platinum surfaces.

A heated element is added to the sensor housing in
order for the sensor to conduct and create an electrical
signal below 600_ F. Two wires provide 12VDC and a
ground signal for the heater element. A fourth wire
provides an independent ground for the sensor. The
targeted air/fuel ratio signal is approx. 500mV and
changes slightly based on speed and load conditions.
When the sensor sends a voltage signal less than
500mV, the ECM interprets the air/fuel mixture as lean
so the ECM decreases the duty cycle. If the ECM
receives a voltage signal above 500mV, the air/fuel
mixture would be interpreted as too rich and the ECM
would increase the duty cycle.

Set the generator set master switch to the OFF position
and allow the generator set to cool. Disconnect the
heated oxygen sensor and use an ohmmeter to
measure the resistance across the sensor pins. See
Figure 5-21.

O2Sensor Pin Resistance Check

Pin C (HEATER GND) to
Pin D (HEATER PWR)

Figure 5-21 O2Sensor Resistance

2.1 ¦ 0.4 Ohms

Detail A

2

See Detail A

1

Top View

1. Heated oxygen sensor

2. Exhaust manifold

GM39685B-J

Figure 5-22 Heated Oxygen Sensor Location

High Exhaust Temperature (HET) Switch

Note: The high exhaust temperature switch is installed

on units with serial numbers 2199434 and later.

In the event of a shutdown because of the high exhaust
temperature switch, the ADC 2100 controller will display
fault code LOC. See Figure 5-23 for the high exhaust
temperature switch location.

High exhaust temperature of 215_±5_F (102_±2.8_C)
will cause the unit to shut down.

Top View

1

1. High exhaust temperature switch

Figure 5-23 High Exhaust Temperature (HET) Switch

Location

TP-6391 9/0856 Section 5 Component Testing and Adjustment

5.11 Electronic Throttle Assembly

5.12 Fuses

The electronic throttle body assembly (ETC) contains
the throttle valve, throttle valve actuator, and throttle
position sensor (TPS1). The ECM calculates the correct
throttle valve opening, makes any adjustments, and
then generates an electrical signal to the throttle-valve
actuator. The ECM calculates the correct throttle
position based on RPM and MAP and compares this to
the actual throttle position based on TPS1. The ECM
continuously checks and monitors all sensors and
calculated data. If no redundant signal is available orthe
calculated data cannot solve the malfunction, the ECM
shuts the engine down, storing the fault information in
the ECM.

See Figure 5-26 for fuse ratings and part numbers.

Always identify and correct the cause of a blown fuse
before restarting the generator set. Refer to Section 3,
Troubleshooting, for conditions that may indicate a
blown fuse. Replace blown fuses with identical
replacement parts.

Part

Label Fuse Amps

F1 Auxiliary Winding 10 358337

F2 Controller 10 223316

F3 Customer Connection 10 223316

F4 Coils/Injectors 15 283645

F5 ECM, O2Sensor, and Fuel

Pumps

F6 Voltage Regulator and Battery

Charging Alternator

F7 Starter Motor and Crank

Solenoid

Number

15 283645

15 283645

20 GM39266

Figure 5-26 Fuses

F1 F2 F3

Figure 5-24 Electronic Throttle Body Assembly

Set the generator set master switch to the OFF position
and allow the generator set to cool. Disconnect the TPS
sensor and use an ohmmeter to measure the resistance
across the sensor pins. See Figure 5-25.

TPS (Electronic Throttle) Sensor

Pin Resistance Check (approx.)

Pin 2 (GND) to Pin 6 (TPS1 SIGNAL)

Pin 3 (PWR) to Pin 6 (TPS1 SIGNAL)

Pin 1 (+DRIVER) to Pin 4 (--DRIVER)

1.25 kOhms

¦ 30%

1.25 kOhms

¦ 30%

3.0 Ohms

¦ 30%

Figure 5-25 TPS (Electronic Throttle) Sensor

Resistance

F6

F4

F7

F5

ADV7025A-A

Figure 5-27 Fuse Location

TP-6391 9/08 57Section 5 Component Testing and Adjustment

5.13 Continuity Checks

WARNING

Figure 5-28 illustrates the generator set master switch
continuity with the switch in the RUN and AUTO
positions.

Zero ohms (continuity) across

RUN and COM terminals

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.

Moving parts.

Note: Disconnect the generator set battery before

performing continuity checks to prevent damage
to the ohmmeter.

To further check generator set components, disconnect
the battery and remove wiring harness plugs from the
controller circuit board. Refer to the wiring diagrams in
Section 7, and use an ohmmeter to check for continuity
and good ground connections. A zero reading on the
ohmmeter indicates continuity. No ohmmeter reading
indicates very high resistance or an open circuit.

321

Master Switch
in RUN Position

RUN

Zero ohms (continuity) across

COM and AUTO terminals

321

Master Switch in
AUTO Position

RUN

AUTO

AUTO

tp6196

Figure 5-28 Generator Set Master Switch Continuity

Checks (back view of switch)

TP-6391 9/0858 Section 5 Component Testing and Adjustment

Section 6 Generator Disassembly/Reassembly

6.1 Disassembly

Disconnect all of the external connections—battery
cables at the battery (negative (--) lead first), AC-output
leads, remote interface connector. Close the seacock.
Remove the water line at the seawater pump, fuel line at
the fuel pump filter inlet, and exhaust line at the catalyst
assembly. Remove the sound shield enclosure, if
equipped. Observe all of the safety precautions listed at
the beginning of this manual during the
disassembly/reassembly procedures.

Note: Because this manual covers several models, the

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

1

tp6196

1. Controller mounting screws (4 ea.)

Note: Mark leads that are disconnected. Refer to the

wiring diagrams in Section 7 during reassembly.

1. Place the generator set master switch in the OFF
position.

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

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

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.

4. Disconnect wiring harness plugs P1, P15, and P16
from the ADC 2100.

5. Loosen and remove the four controller mounting
screws at the front of the controller. See
Figure 6-1. Remove the controller.

Figure 6-1 ADC 2100 Mounting Screws

6. Disconnect the generator output leads from the
circuit breaker and disconnect QCON1 from the F1
fuse.

7. Disconnect the LO and GRD lead connections.
See Figure 6-2.

8. Disconnect the FP and FN leads.

9. Remove the SCR module and relay board as
necessary. See Figure 6-2.

Top View

1. LO stud

2. Ground stud

3. Relay interface board (RIB)

4. SCR module

5. K5 main power relay

GM39685D-J

Figure 6-2 Advanced Digital Control (ADC 2100)

1

2
3
4

5

TP-6391 9/08 59Section 6 Generator Disassembly/Reassembly

10. Remove the junction box from the support bracket.

11. Disconnect the ground strap.

12. Remove the fuel inlet hose

13. Close the seacock and remove the water inlet hose
from the seawater pump.

14. Remove the fuel pump and line from the generator.

15. Remove the alternator cover plate. See
Figure 6-3.

16. Push the brushes into the holder. Secure the
brushes into position by sliding a retainer into the
brush keeping holder. See Section 5.6.

1

598691

1. Block of wood

Figure 6-4 Raising the Generator

17. Remove the brush holder and carefully pull the
leads out of the stator housing. See Figure 6-6.

18. Remove the generator end vibromount hardware.
SeeFigure6-3.

1

3

1. Alternator cover plate

2. Vibromount hardware

3. Seawater pump

2

Figure 6-3 Alternator End Cover

21. Remove the overbolts. See Figure 6-6. Use a
rubber mallet to separate the end bracket from the
stator housing.

22. Carefully remove the stator assembly from the
generator adapter plate.

23. Remove the rotor bolt and end drive fitting.

24. Reinstall the rotor bolt (without end fitting), finger
tighten, and back off two turns.

25. Strike the bolt with a hammer until the rotor is freed
from the engine’s tapered drive shaft. Do not
damage the through bolt threads or bolt head. See
Figure 6-5.

1

2

19. Attach a hoist hook to the generator lifting eye.

Note: The hoist capacity rating should be one-half

ton or greater.

20. Tilt the generator set up and brace it with a block of
wood. See Figure 6-4.

1. Rotor bolt

598692

2. Hammer

Figure 6-5 Removing the Rotor

TP-6391 9/0860 Section 6 Generator Disassembly/Reassembly

2

3, 4, 5

6

9

8

1

10 11

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

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

88

99

GM39685A-K

Figure 6-6 Alternator Assembly Components

TP-6391 9/08 61Section 6 Generator Disassembly/Reassembly

6.2 Collector Ring and Bearing
Replacement

.38 maximum
(as soldered)

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 6-8.

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

Note: The new collector rings must be turned down to a

finish of 32 micro inches using a 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 6-8.

8. Test to ensure continuity at the collector rings.

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)

90°

2

View A-A

1. Collector ring leads

2. Keyways

Figure 6-8 Rotor Assembly

A

A

1

598695

Figure 6-7 Collector Ring Dimensions

TP-6391 9/0862 Section 6 Generator Disassembly/Reassembly

6.3 Reassembly

Note: See Section 1.6 and Appendix C for torque

specifications.

11. Reinstall the support bracket to mount the junction
box. See Figure 4-1.

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

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. See Figure 6-6.

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 5.6.

8. Install the coverplate and torque the coverplate
bolts to 6.8 Nm (60 in. lbs.).

9. Use the hoist to raise the alternator end. Remove
the wood block from under the locator plate. Lower
the generator set and install a bolt, a large washer,
two small washers, and a locknut on each
vibromount. Tighten the mounting bolts.

10. Install the SCR module and relay board.

13. Reconnect the leads to the circuit breaker, QCON1
to the F1 fuse, FP and FN leads, neutral stud (LO),
and ground stud (GRD) as marked during
disassembly. Refer to the wiring diagrams in
Section 7.

Note: Check the generator set nameplate to verify

the original voltage configuration.

14. Reinstall the ADC 2100.

15. Reconnect the P1, P15, and P16 connectors.
Connect the ground strap using bolt, washer, and
lock washer (install the lock washer against the
ground strap).

16. Reconnect all of the external connections—the
exhaust line to the catalyst assembly, the fuel line
to the fuel pump filter inlet, the water line to the
seawater pump, the remote interface connector,
the AC output leads, and the battery cables to the
battery (negative (--) lead last).

17. Verify that the generator set master switch is in the
OFF position.

18. Reconnect the engine starting battery, negative (--)
lead last.

19. Reconnect power to the battery charger, if
equipped.

TP-6391 9/08 63Section 6 Generator Disassembly/Reassembly

Notes

TP-6391 9/0864 Section 6 Generator Disassembly/Reassembly

Section 7 Wiring Diagrams

A

GM39836revision

F

ADV-7029revisionF

A

GM39836revision

H

ADV-7029revisionG

A

GM50546

ADV-728

5

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 connected equipment, disable the generator
set as follows: (1) Move the generator setmasterswitch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

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. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Nevercontact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.

Moving parts.

Model

Before Serial Number 2085259:

5ECD GM39685-GA1

4EFCD GM39685-GA3

7.3ECD GM39685-GA2

6EFCD GM39685-GA4

Model Specification Number Point-to-Point Wiring Diagram Schematic Wiring Diagram

With Serial Number 2085259 to 2199434:

5ECD GM39685-GA1

4EFCD GM39685-GA3

7.3ECD GM39685-GA2

6EFCD GM39685-GA4

Model Specification Number Point-to-Point Wiring Diagram Schematic Wiring Diagram

5ECD GM39685-GA5

4EFCD GM39685-GA7

7.3ECD GM39685-GA6

6EFCD GM39685-GA8

Specification Number Point-to-Point Wiring Diagram Schematic Wiring Diagram

GM39836 revision F

(Figure 7-1 and Figure 7-2)

GM39836 revision H

(Figure 7-5 and Figure 7-6)

GM50546

(Figure 7-9 and Figure 7-10)

DV-7029 revision F

(Figure 7-3 and Figure 7-4)

DV-7029 revision G

(Figure 7-7 and Figure 7-8)

DV-7285

(Figure 7-11 and Figure 7-12)

TP-6391 9/08 65Section 7 Wiring Diagrams

Figure 7-1 Point-to-Point Wiring Diagram (Sheet 1 of 2). For Units With Serial Numbers before 2085259.

GM39836A--F

TP-6391 9/0866 Section 7 Wiring Diagrams

Figure 7-2 Point-to-Point Wiring Diagram (Sheet 2 of 2). For Units With Serial Numbers before 2085259.

TP-6391 9/08 67Section 7 Wiring Diagrams

GM39836B--F

Figure 7-3 Schematic Wiring Diagram (Sheet 1 of 2). For Units With Serial Numbers before 2085259.

ADV7029A--F

TP-6391 9/0868 Section 7 Wiring Diagrams

Figure 7-4 Schematic Wiring Diagram (Sheet 2 of 2). For Units With Serial Numbers before 2085259.

TP-6391 9/08 69Section 7 Wiring Diagrams

ADV7029B--F

Figure 7-5 Point-to-Point Wiring Diagram (Sheet 1 of 2). For Units With Serial Number 2085259 to 2199434.

GM39836A--H

TP-6391 9/0870 Section 7 Wiring Diagrams

Figure 7-6 Point-to-Point Wiring Diagram (Sheet 2 of 2). For Units With Serial Number 2085259 to 2199434.

TP-6391 9/08 71Section 7 Wiring Diagrams

GM39836B--H

Figure 7-7 Schematic Wiring Diagram (Sheet 1 of 2). For Units With Serial Number 2085259 to 2199434.

ADV7029A--G

TP-6391 9/0872 Section 7 Wiring Diagrams

Figure 7-8 Schematic Wiring Diagram (Sheet 2 of 2). For Units With Serial Number 2085259 to 2199434.

TP-6391 9/08 73Section 7 Wiring Diagrams

ADV7029B--G

Figure 7-9 Point-to-Point Wiring Diagram (Sheet 1 of 2).

GM50546A--B

TP-6391 9/0874 Section 7 Wiring Diagrams

Figure 7-10 Point-to-Point Wiring Diagram (Sheet 2 of 2).

TP-6391 9/08 75Section 7 Wiring Diagrams

GM50546B--B

Figure 7-11 Schematic Wiring Diagram (Sheet 1 of 2).

ADV7285A--B

TP-6391 9/0876 Section 7 Wiring Diagrams

Figure 7-12 Schematic Wiring Diagram (Sheet 2 of 2).

TP-6391 9/08 77Section 7 Wiring Diagrams

ADV7285B--B

Notes

TP-6391 9/0878 Section 7 Wiring Diagrams

Appendix A Abbreviations

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

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

AHWT anticipatory high water

AISI American Iron and Steel

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

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

ASE American Society of Engineers
ASME American Society of

assy. assembly
ASTM American Society for Testing

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

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

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

drawing

temperature

Institute

Institute
(formerly American Standards
Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

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

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

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

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

EIA Electronic Industries

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

EPS emergency power system
ER emergency relay
ES engineering special,

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

substrate (semiconductor)

Association

e. V.
(also Deutsche Industrie
Normenausschuss)

Association

Association

Agency

engineered special

exh. exhaust
ext. external
F Fahrenheit, female
fglass. fiberglass
FHM flat head machine (screw)
fl. oz. fluid ounce
flex. flexible
freq. frequency
FS full scale
ft. foot, feet
ft. 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

ground

high engine temperature

conditioning

Commission

Electronics Engineers

O inches of water

2

Standardization

TP-6391 9/08 Appendix 79

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

2

kg/cm

kgm kilogram-meter
kg/m

kilograms per square
centimeter

3

kilograms per cubic meter

10

bytes)

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

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, quarts
qty. quantity
R replacement (emergency)

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

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

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

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

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

normal
TDES time delay engine start
TDNE time delay normal to

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

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

TP-6391 9/0880 Appendix

Appendix B Common Hardware Application Guidelines

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

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

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

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

Preferred Nut/Bolt Clearance

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 Figure 2.

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

a. Always use a washer between hardware and a

slot.

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

for exception).

c. Use a washer under a bolt when the female

thread is fixed (weld nut).

Unacceptable Nut/Bolt Clearance

3

1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut

3. Below top of nut

Figure 1 Acceptable Bolt Lengths

G-585

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

1

6

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

2

3

5

4

G-585

TP-6391 9/08 81Appendix

Figure 2 Acceptable Hardware Combinations

Appendix C General Torque Specifications

T

A

lumi

A

lumi

American Standard Fasteners Torque Specifications

orque

Size

8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) —

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

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

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

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

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

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

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

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

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

7/16-20 Nm (ft. lb.) 43.0 (32) 68.0 (50) 95.0 (70) SeeNote3

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

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

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

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

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

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

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

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

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

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

Measurement

Assembled into Cast Iron or Steel

Grade 2 Grade 5 Grade 8

Assembled into

num

Grade2or5

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

Assembled into Cast Iron or Steel

Size (mm)

M6 x 1.00 6.2 (4.6) 9.5 (7) 13.6 (10)

M8 x 1.25 15.0 (11) 23.0 (17) 33.0 (24)

M8 x 1.00 16.0 (11) 24.0 (18) 34.0 (25)

M10 x 1.50 30.0 (22) 45.0 (34) 65.0 (48)

M10 x 1.25 31.0 (23) 47.0 (35) 68.0 (50)

M12 x 1.75 53.0 (39) 80.0 (59) 115.0 (85)

M12 x 1.50 56.0 (41) 85.0 (63) 122.0 (90) SeeNote3

M14 x 2.00 83.0 (61) 126.0 (93) 180.0 (133)

M14 x 1.50 87.0 (64) 133.0 (98) 190.0 (140)

M16 x 2.00 127.0 (94) 194.0 (143) 278.0 (205)

M16 x 1.50 132.0 (97) 201.0 (148) 287.0 (212)

M18 x 2.50 179.0 (132) 273.0 (201) 390.0 (288)

M18 x 1.50 189.0 (140) 289.0 (213) 413.0 (305)

Notes:

1. Do not use these values when the torque values are specified on the assembly drawing.

2. These values are based on new plates threads. Increase values by 15% if non-plated threads are used.

3. Hardware threaded into aluminum must have two diameters of thread engagement or may require 30% or more reduction in the torque.

4. Torques are calculated as equivalent stress loading to American hardware and approximately a preload of 90% of yield strength and
friction coefficient of 0.125.

Grade 5.8 Grade 8.8 Grade 10.9

Assembled into

num

Grade 5.8 or 8.8

TP-6391 9/0882 Appendix

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-6391 9/08 Appendix 83

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-6391 9/0884 Appendix

Metric

Hex head bolts are hardness grade 8.8 unless noted.

Part No. Dimensions
Hex Head Bolts (Partial Thread)

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

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

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

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

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

continued

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

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

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

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

Hex Head Bolts (Full Thread)

M933-04006-60 M4-0.70 x 6

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

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

M933-07025-60 M7-1.00 x 25

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

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

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

continued

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

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

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

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

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

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

Pan Head Machine Screws

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

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

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

M7985A-06100-20 M6-1.00 x 100

Flat Head Machine Screws

M965A-04012-SS M4-0.70 x 12

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

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

TP-6391 9/08 Appendix 85

Metric, continued

Part No. Dimensions Type
Hex Nuts

M934-03-50 M3-0.50 Standard

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

M934-05-50 M5-0.80 Standard

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

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

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

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

M982-14-60 M14-2.00 Elastic Stop

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

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

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

M934-22-60 M22-2.50 Standard

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

M934-30-80 M30-3.50 Standard

Washers

Bolt/

Part No. ID OD Thick. Screw

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

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

TP-6391 9/0886 Appendix

TP-6391 9/08 87

TP-6391 9/08a

E 2006 and 2008 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044
Phone [phone], Fax [phone]
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US and Canada, phone [phone]
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Kohler Power Systems
Asia Pacific Headquarters
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Singapore 619159
Phone [phone], Fax [phone]