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1 - Whale Watching Guatemala

1. 1 2 Collector ring leads Keyways Figure 9 6 Rotor Assembly Section 9 Generator Disassembly Reassembly 39 Notes 40 Section 9 Generator Disassembly Reassembly TP 5986 4 03 Section 10 Wiring Diagrams and Voltage Reconnection WARNING Pa or Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator setasfollows 1 Placethe generator setstart stop switch in the STOP position 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch TP 5986 4 03 WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution
2. UH HOLIMS 1NY 1000 LOH H3TIOHINOO GND land 36n4 Wi HOLIMS ANIONI S13 3NIN3 983 1 1000 S19 BONVS 1 INY1000 910 Y3LV3H HOHO cue ab HOLVINOAH 3OV L0A 3 wr 7109 11 8 098 ON amp UBIBWITOA AHS LIV AS ER En INFA tin ON gE SOVLIOA OLLYNOLNY HAV ta ON GIONSTOs 13531 E N EDENI ita ws iow oz ABO Sup eJ 999 1915 ici 1 05 02 8 ge 24 e ed 4 SNOLLO3NNOO S13 Ss us sao 612 SNOLLO3NNOO td 98 023 NER 12 4 N ES A 489 S 4 aad ied 8 6 Gea 2v Can 886 sss y ev 659 02 d d i 3NION3 wed oz 4 o zin 48 93 5 ans cj ION P SNOILOSNNOO ZIT YNOILdO NOWH wis vis di vis vis SNOILOANNOO 6 19 44 e u za sr 09 1 dd A ci
3. 9 stop the engine switch is released The generator set is No L Did the K4 relay LED light functioning properly Does the K1 relay LED light Is the LOP switch Yes functional Does the relay LED LOP switch Yes light after 5 10 seconds of running time Does the engine have proper oil i Is the K3 LED out pressure Use a mechanical gauge to verify pressure Replace the circuit No board the 5 relay is inoperative Replace the circuit board the K6 relay is inoperative Y Go to D next page Check the oil level Repair replace the oil pump Y Is the temperature Replace the inoperative HET safety shutdown temperature switch switch functional Yes Y Is the low coolant switch functional Replace the switch Yes Replace the Y nissim Is the coolant level low K4 relay Fill the cooling Yes system and check for leaks Figure 6 5 Troubleshooting Relay Controller Circuit Board 3 of 4 TP 5986 4 03 Section 6 Controller Troubleshooting 23 Is there AC output when the start button I is he
4. 0 P KINO 3NIBVW 1 01 14 01 4 INO rte Na 7 oS el SNR Y 7 2 igi 7 lt gt 2 11 59 s19 Tos 6 64 02 04 z NODD HO HIHO SNOLLO3NNOO 6d 6 01 1 019 d 92 m ze anso R7 MN SS3NuVH ANIONS OL 3NION3 1 YOLVYANSD SNOLLO3NNOO HOLVEUN3O 33S ann n zz vr do8 21 7 avi 01 44 zi 4 ss us 49 27 n 020 aH 2 8 ano 8 19 04 8 029 re NTS Aeh sl ANA UISS 090 HO nS Ni ss us ss us 401918 1418 HOLMS 1 15 4018 SSS AINO 1 58 INO ANIEW AVT3H HSLMVLS us HOLON H3IHVIS WS 73 103NNOO vis oma HOLOSNNOO 10 840 vis 141 Nld SOND 553 4 10 90 SNOLLOSNNOO OLF SNOILOANNOO Old HOLIMS 3 dO1 GIONSTOS HALEVIS 02 HO193NNOO Wr DNFINSNI amp inSNI NOLLINSI NOI
5. Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system TP 5986 4 03 Section 4 Fuel System 4 1 General In most instal
6. 18 Section 6 Controller Troubleshooting 19 6 1 Sequence of Operation 19 6 1 1 Start x iios P Aere pen EE 19 6 1 2 FAUT 19 OAS STOP Lol Ebert d 20 TP 5986 4 03 Table of Contents 6 2 Engine Safety Shutdown Switches 20 6 2 1 Low Oil Pressure LOP Shutdown 20 6 2 2 1055 of Coolant Switch LCS Shutdown 20 6 2 3 High Engine Temperature Switch HET Shutdown 20 6 2 4 Controller Circuit Board 20 6 25 Troubleshooting 21 Section 7 Generator Troubleshooting 25 7 1 General iones ewe es 25 7 1 1 Troubleshooting 25 7 1 2 Separate Excitation 26 7 2 PowerBoost Voltage Regulators 27 7 2 1 Voltage Regulator 27 7 2 2 Voltage Regulator Adjustment 28 LS ROW tebe ERE RENE a bts 29 G4 Sato ssl la kc ERG 29 7 5 Br she8 ssi Eee 31 Section 8 Component Troubleshooting 33 8 1 Engine Generator Components 33 8 2 Remote Panels Optional 35 Section 9 Generator Disassembly Reassembly 37 91 Disassembly 37 9 2 Collector Ring and Bearing Replacement 39 9 3 39 Section 10 Wiring Diagrams and Voltage Reconnec
7. 6 hardness is grade 8 A 8 Appendix TP 5986 4 03 5986 4 03b 2000 2003 by Kohler Co All rights reserved KOHLER POVVER SYSTEMS KOHLER Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
8. General Troubleshooting 1 Check the condition of the voltage regulator s 10 amp fuse 2 If the fuse is functional separately excite the generator See Section 7 1 2 The separate excitation test duplicates the role of the voltage regulator by providing excitation current to the rotor Generator has no output Check for flashing voltage at the brushes Troubleshoot controller Separately excite Generator has output generator Test voltage regulator and wiring Generator has no output Test rotor Test stator TP 598651 Figure 7 1 General Troubleshooting Section 7 Generator Troubleshooting 25 1 12 Separate Excitation separately exciting the generator to determine the presence of a faulty voltage regulator it is possible to determine if a running fault exists in the rotor and or stator A generator component that appears functional while static stationary may exhibit a running open or short circuit while dynamic moving Centrifugal forces acting on the windings during rotation or insulation breakdown as temperatures increase can cause short circuits Note It is not necessary to separately excite the generator if there is AC output with flashing voltage Separate Excitation Procedure 1 Disconnect all of the leads from the voltage regulator 2 Disconnect the P10 F1 F2 connector 3 Connect a separate excitation
9. Goolifig rs heeds DERART 1 1 5 gt Generator eese RES eR ads 2 1 6 Torque usse VES bade g 2 1 7 Service Views 3 Section 2 Scheduled Maintenance 5 2 4 General ils ep ERREUR 5 2 2 Lubrication 5 Section 3 Intake and Exhaust System 7 3 4 Backfire Flame Arrestor 7 3 2 Exhaust ithe dels tad 7 Section 4 Fuel System 9 44 General 9 4 2 Float Bowl Vent 9 43 Fuel Pump and Filter 9 4 4 Fuel Pump Troubleshooting 10 4 5 Carburetor Troubleshooting 10 4 5 1 Hard Starting 10 45 2 Stalling 10 4 5 3 Flooding verme ree 11 45 4 cece eee eee 11 4 5 5 Leaking Carburetor 11 4 6 Governor 60 Hz to 50 Hz Conversion 11 Section 5 Cooling System 13 5 1 ee ad ko 13 5 2 Closed 14 5 3 Check and Fill Coolant 14 5 4 Flush and Clean Cooling System 14 5 5 Impeller 15 5 6 Siphon 16 5 7 Anticorrosion Zinc Anode 17 5 8 Generator Storage
10. 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 watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 5986 4 03 Appendix Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance I s ra rat Unacceptable Nut Bolt Clearance Test 5 1 1 2 of bolt diameter
11. Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permitflames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Safety Precautions and Instructions Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the
12. terminals together Engine Backfire Flash Fire WARNING Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Servicing the backfire flame arrester A sudden backfire can cause severe injury or death Do not operate the generator set with the backfire flame arrester removed Combustible materials A sudden flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the fuel system Keep the compartment and the generator set clean and free of debris to minimize the risk of fire Wipe up spilled fuels and engine oil I Safety Precautions and Instructions 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 as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation fi
13. threads All torque values are 0 10 The charts list values for new plated zinc phosphate or American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel assembled into Torque Aluminum Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5 Z Z 2 Z zZ oum z 3533353833 a lt 2222 333333333333333 Z 3 108 138 154 191 216 338 378 Zz 3 3 ou ww xx 3 3 3 3 232 3 aX XT Assembled into Aluminum Size mm Grade 5 8 Grade 8 8 Grade 10 9 Grade 5 8 or 8 8 Assembled into Cast Iron or Steel A 4 Appendix TP 5986 4 03 Appendix D Common Hardware Identification Screw Bolts Studs Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head FHM Square Grade 8 Grade 8 9 Hex Socket Head Metric Round Head RHM Cap or Acorn Pan Head Wing Number stamped on Hex Socket Head Cap or Washers hardware 5 8 shown Allen Head Cap Washer Styles Hex Socket Head or Allen w Head Shoulder Bolt Plain Sheet Metal Screw Split Lock or Spring Stud c Spring or Wave Drive Styles External Tooth Lock Hex Internal Tooth Lock Internal External Tooth Lock 0 Hex and Slotted A Phillips Slotted
14. 2 Minimum 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths TP 5986 4 03 Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nut and SAE washer Hardware 1 2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut See the diagram below 3 Follow these SAE washer rules after determining exit hole type a Always use a washer between hardware and slot b Always use a washer under a nut see 2 above for exception Use a washer under a bolt when the female thread is fixed weld nut 4 Refer to the diagram below which depicts the preceding hardware configuration possibilities lc 9 Ong 6 4 Cap screw Entry hole types Standard nut and SAE washer Whiz nut or spiralock up to 1 2 in dia hardware Weld nuts above 1 2 in dia hardware Exit hole types Figure 2 Acceptable Hardware Combinations Appendix A 3 Appendix General Torque Specifications Use the following torque specifications when service oiled threads Increase values by 15 for nonplated literature instructions give no specific torque values
15. 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 Hex Nuts X 6009 1 X 6210 3 X 6210 4 X 6210 5 X 6210 1 X 6210 2 X 6210 6 X 6210 7 X 6210 8 X 6210 9 X 6210 10 X 6210 11 X 6210 12 6210 15 6210 14 85 3 88 12 89 2 Washers Part No X 25 46 X 25 9 X 25 48 X 25 36 X 25 40 X 25 85 X 25 37 X 25 34 X 25 26 X 25 15 X 25 29 X 25 127 1 062 Dimensions Type 1 8 Standard 6 32 Whiz 8 32 Whiz 10 24 Whiz 10 32 Whiz 1 4 20 Spiralock 1 4 28 Spiralock 5 16 18 Spiralock 5 16 24 Spiralock 3 8 16 Spiralock 3 8 24 Spiralock 7 16 14 Spiralock 1 2 13 Spiralock 7 16 20 Spiralock 1 2 20 Spiralock 5 8 11 Standard 3 4 10 Standard 1 2 20 Standard Bolt ID OD Thick Screw 125 250 022 4 156 375 049 6 188 438 049 8 219 500 049 10 281 625 065 1 4 344 687 065 5 16 406 812 065 3 8 469 922 065 7 16 531 1 062 095 1 2 656 1 312 095 5 8 812 1 469 134 3 4 2 000 134 1 5986 4 03 Metr
16. 25 x 70 M8 1 25 x 70 M8 1 25 x 75 M8 1 25 x 80 M8 1 25 x 90 M8 1 25 x 95 M8 1 25 x 100 M8 1 25 x 110 M8 1 25 x 120 M8 1 25 x 130 M8 1 25 x 140 M8 1 25 x 150 M10 1 25 x 40 M10 1 50 x 40 M10 1 50 x 45 M10 1 50 x 50 M10 1 25 x 50 M10 1 50 x 55 M10 1 50 x 60 M10 1 50 x 65 M10 1 50 x 70 M10 1 50 x 80 M10 1 25 x 80 M10 1 50 x 90 M10 1 50 x 90 M10 1 50 x 100 M10 1 50 x 110 M10 1 50 x 120 M10 1 50 x 130 M10 1 50 x 140 M10 1 50 x 180 M10 1 25 x 330 M12 1 75 x 45 M12 1 25 x 50 M12 1 25 x 50 M12 1 75 x 50 M12 1 75 x 50 M12 1 75 x 55 M12 1 75 x 60 M12 1 75 x 60 M12 1 75 x 65 M12 1 75 x 75 M12 1 75 x 80 M12 1 75 x 90 M12 1 75 x 100 M12 1 75 x 110 Part No Hex Head Bolts Partial Thread continued M960 16090 60 M931 16090 60 M931 16100 60 M931 16120 60 M931 16150 60 M931 20065 60 M931 20100 60 M931 20120 60 M931 20140 60 M931 20160 60 M931 22090 60 M931 22120 60 M931 22160 60 M931 24090 60 M931 24120 60 M931 24160 60 Dimensions M16 1 50 x 90 M16 2 00 x 90 M16 2 00 x 100 M16 2 00 x 120 M16 2 00 x 150 M20 2 50 x 65 M20 2 50 x 100 M20 2 50 x 120 M20 2 50 x 140 M20 2 50 x 160 M22 2 50 x 90 M22 2 50 x 120 M22 2 50 x 160 M24 3 00 x 90 M24 3 00 x 120 M24 3 00 x 160 Hex Head Bolts Full Thread M933 04006 60 M933 05030 60 M933 05035 60 M933 05050 60 M933 06010 60 M933 06012 60 M933 0601 4 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06040 60 M933 06050 60
17. 5 PowerBoost Voltage Regulator Volts Hz Pot feature allows the voltage to drop if the load imposed on the generator causes the engine speed to fall below a predetermined RPM or frequency This reduction of voltage results in a decrease of starting kW load allowing the governor to recover the engine speed 28 Section 7 Generator Troubleshooting Voltage Regulator Adjustment Procedure 1 2 Volts AC Stop the generator set Turn the remote rheostat if equipped to the midpoint Turn the voltage and stabilizer pots fully counterclockwise Connectthe voltmeter to the AC circuit or an electrical outlet Start the generator set Adjust the generator frequency using a frequency meter Set the no load speed at 52 5 Hz for 50 Hz operation or 63 Hz for 60 Hz operation Rotate the voltage adjustment pot clockwise to increase the voltage or counterclockwise to decrease the voltage to achieve the desired output voltage Connect a 120 volt light bulb to the AC plug on the generator set Rotate the stability pot clockwise until the light bulb flickers minimally Readjust the voltage adjustment pot to achieve the desired output voltage Disconnect the 120 volt light bulb Turn the volts Hz pot completely clockwise to decrease the Hz rolloff point See Figure 7 6 00 40 42 44 46 48 50 52 54 56 58 60 62 64 Frequency Hz 6
18. ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cow CEC cfh cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic
19. Figure 9 3 Use a rubber mallet to separate the end bracket from the stator housing 19 Carefully remove the stator assembly from the generator adaptor plate 20 Remove the rotor bolt and end drive fitting 21 Reinstall the rotor bolt without end fitting finger 598692 1 Rotor bolt 2 Hammer Figure 9 4 Removing the Rotor 38 Section 9 Generator Disassembly Reassembly 22 tighten and back off two turns Strike the bolt with hammer until the rotor is freed from the engine tapered drive shaft Do not damage through bolt threads or bolt head See Figure 9 4 TP 5986 4 03 9 2 Collector Ring and Bearing Replacement Unsolder the collector ring leads from the collector ring terminals Remove the collector rings with a three jaw puller Remove the bearing with a three jaw puller Press the new bearing onto the rotor shaft Align the collector ring keyway with the keyway the rotor shaft See Figure 9 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 Solder the leads onto the collector ring terminals The connection is not to exceed 9 65 mm 0 38 in beyond the collector rings See Figure 9 6 Test to ensure continuity at the collector rings 9 3 Reassembly 1 Apply antiseize compound to the tapered
20. Introduction China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 Fax X in 008 001a TP 5986 4 03 Routine Service Parts The following table contains a list of recommended spare parts Contact your Kohler generator distributor dealer for a complete list of service parts for your generator set Part Number 262389 Part Description Battery Charging Fuse 25 amp Input Fuse 10 amp 223316 Oil Filter 359771 Seawater Pump Impeller Kit 359978 Spark Plug For Engine Model AS 04 359796 Spark Plug For Engine Model BS 04 359979 Spray Paint White 221335 Touch Up Paint White GM19490 Voltage Regulator Fuse 10 amp 223316 Zinc Anode 267928 TP 5986 4 03 Service Parts Publications List of Related Literature The following table identifies literature available for the generator sets covered in this manual Only qualified persons should install or service the gener
21. M933 07025 60 M933 08010 60 M933 08012 60 M933 08016 60 M933 08020 60 M933 08025 60 M933 08030 60 M933 08030 82 M933 10012 60 M961 10020 60 M933 10020 60 M933 10025 60 M961 10025 60 M933 10025 82 M961 10030 60 M933 10030 60 M933 10030 82 M961 10035 60 M933 10035 60 M933 10035 82 M961 10040 60 M933 12016 60 M933 12020 60 M961 12020 60F M933 12025 60 933 12025 82 961 12030 60 M961 12030 82F 933 12030 60 933 12035 60 961 12040 82 M933 12040 60 M933 12040 82 M4 0 70 x 6 5 0 80 x 30 5 0 80 35 5 0 80 50 M6 1 00 x 10 M6 1 00 x 12 M6 1 00 x 14 M6 1 00 x 16 M6 1 00 x 20 M6 1 00 x 25 M6 1 00 x 40 M6 1 00 x 50 M7 1 00 x 25 M8 1 25 x 10 M8 1 25 x 12 M8 1 25 x 16 M8 1 25 x 20 M8 1 25 x 25 M8 1 25 x 30 M8 1 25 x 30 M10 1 50 x 12 M10 1 25 x 20 M10 1 50 x 20 M10 1 50 x 25 M10 1 25 x 25 M10 1 50 x 25 M10 1 25 x 30 M10 1 50 x 30 M10 1 50 x 30 M10 1 25 x 35 M10 1 50 x 35 M10 1 50 x 35 M10 1 25 x 40 M12 1 75 x 16 M12 1 75 x 20 M12 1 50 x 20 M12 1 75 x 25 M12 1 75 x 25 M12 1 25 x 30 M12 1 50 x 30 M12 1 75 x 30 M12 1 75 x 35 M12 1 25 x 40 M12 1 75 x 40 M12 1 75 x 40 Part No Dimensions Hex Head Bolts Full Thread continued 961 14025 60 933 14025 60 961 14050 82 961 16025 60 933 16025 60 961 16030 82 933 16030 82 933 16035 60 961 16040 60 933 16040 60 961 16045 82 933 16045 82 933 16050 60 933 16050 82 933 160
22. circuit as shown in Figure 7 2 Connect an ammeter and a 10 amp fuse in series with F1 Note and record the ammeter reading 4 The approximate ammeter reading should equal battery voltage divided by the specified rotor resistance cold See Section 1 Specifications for the correct values Example 12 Volts Battery Voltage 3 5 amp 3 4 Ohms Rotor Resistance Ammeter reading 5 Start the engine and check that the ammeter remains stable An increasing meter reading indicates a shorted rotor A decreasing meter reading to zero or unstable reading suggests a running open in the rotor If the ammeter is stable continue with step 6 6 With a jumper wire ground the negative lead from the rotor to the engine block An increased current reading or a fluctuating reading indicates a grounded rotor winding Replace the rotor if the ammeter reading fluctuates If the ammeter is stable continue with step 7 26 Section 7 Generator Troubleshooting 7 Remove the jumper wire and reverse the positive and negative leads on the rotor Repeat step 5 If the ammeter is stable ground the negative lead at its new location on the rotor to the engine block Replace the rotor if the ammeter reading fluctuates 8 Check for AC output across the stator leads and compare the measured output to the values in Section 1 Specifications If the output varies considerably from those listed a faulty stator rotor rectifie
23. e Hex Socket Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company Sample Dimensions American Standard Screws Bolts Studs and Nuts Plain Washers 1 4 20 1 Jl L Length In Inches Screws and Bolts ane 128 Thickness Threads Per Inch External Dimension Major Thread Diameter In Fractional Inches Or Screw Number Size Internal Dimension Metric Screws Bolts Studs and Nuts M8 1 25 x 20 Lock Washers Length In Millimeters Screws and Bolts 5 8 Distance Between Threads In Millimeters Internal Dimension Major Thread Diameter In Millimeters TP 5986 4 03 Appendix A 5 Appendix 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 12
24. hose clamp to secure the coolant hose 6 Fill the cooling system with the recommended coolant 7 Bleed the air from the cooling system 8 Replace the pressure cap TP 5986 4 03 5 5 Impeller This model uses a direct driven seawater pump located on the generator end Check and change the seawater pump impeller at the interval specified in the service schedule Follow the instructions included with the impeller kit If the instructions are not included with the kit use the following procedure Impeller Inspection Replacement Procedure 1 2 Seawater pump Coverplate Gasket Close the seacock Remove the seawater pump coverplate See Figure 5 2 Remove the impeller Inspect the impeller for damaged cracked broken missing or flattened vanes The impeller vanes should be straight and flexible See Figure 5 3 Replace the impeller if it is damaged 10 Q QR 7 Pulley Drive shaft Washer Impeller Nut Bearing Housing Mechanical seal if equipped Figure 5 2 Seawater Pump Typical TP 5986 4 03 1 Flat spot 2 Crack 3 Broken vane Figure 5 3 Worn Impeller 10 11 Note Impeller pieces can cause blockage and overheating Locate and remove all missing impeller pieces from the cooling system Lubricate the impeller with soapy water before installation While installing the impeller always rotate the drive shaft and th
25. of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 210 bytes Appendix A 1 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kQ 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 LxWxH length by width by height Ib pound pounds Ibm ft pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display Id 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 Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 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 mi
26. overbolts 120 Full load 60 Hz volts amps 47 13 82 Cold main field rotor resistance ohms 3 4 Stator output voltages with separately excited generator using 12 volt battery 60 Hz only 1 2 3 4 33 44 VAC 145 55 66 VAC 190 B1 B2 VAC 14 Cold stator resistance 1 2 3 4 33 44 ohms 0 16 55 66 ohms 1 70 B1 B2 ohms 2 Section 1 Specifications 0 05 Mounting plate to end bracket bolts 6 8 60 Lift eye bolts 19 0 168 Generator adapter to engine bolts 14 9 132 Engine oil drain boss inside generator adapter 47 5 420 Generator adapter to exhaust manifold 13 6 120 High exhaust temp switch 13 6 120 Spark plugs 12 17 106 150 Bolts that hold the coverplate over the impeller 3 4 30 5986 4 03 1 7 Service Views ADV 6395 A GY 250000 A ENGINE END VIEW Electric choke on carburetor Carburetor choke linkage Spark plug also one on nonservice side Oil fill Overflow tube Pressure cap coolant fill location after draining coolant High water temp switch Controller Start Stop switch Nameplate top AC load lead conn
27. replaced Use this chart for the main circuit board and the entire generator set Ifthe component testing only Always check the continuity of prescribed remedy does not correct the problem the the wires between components Press the start switch Does the engine crank Goto A local or remote T next page Check the battery condition and connections Does the K2 relay LED light while cranking Is the relay LED lit No Is voltage present at the K20 relay coil P1 4 connector Is 10 amp controller fuse functional The 2 relay is faulty Replace the circuit board No 2 1 faulty Replace the circuit board Is there continuity between N and 47 while pressing the start stop switch Y Yes Replace or repair Replace the fuse Y the wiring harness y Is there 12 volts at P1 14 Is voltage present Replace the circuit at the starter relay board Replace or repair the wiring harness No Is voltage present at the starter Replace the K20 relay No Yes Replace Replace the starter repair the relay starter motor Figure 6 3 Troubleshooting Relay Controller Cir
28. the P1 9 and ground P1 ground connection Place the ohmmeter on the R x 1 scale If functional zero ohms continuity Any other reading indicates a poor ground connection Connect the ohmmeter to the P13 1 and engine block ground Low oil pressure LOP safety shutdown switch Place the ohmmeter on the 1000 scale This test is not conclusive until the If functional zero ohms continuity Then disconnect LOP switch lead and isolate temperature shutdown switches are checked terminal Meter reading should show an open circuit Place the ohmmeter on the R x 1000 scale Connect the ohmmeter to the P1 15 and engine block ground Note Remove and isolate the LOP switch lead High exhaust temperature HET low coolant LCS safety shutdown switches If functional open circuit Any continuity suggests an inoperative temperature switch es Disconnect individual leads to inoperative switch Figure 8 3 Engine Generator Component Testing Relay Controller Troubleshooting Remote Start Panels 8 2 Remote Panels Optional Generally ifthe sender changes its resistance values as its respective pressure temperature changes it is working correctly An inoperative sender will either be open or shorted Refer to Figure 8 4 and Figure 8 5 for resistance values 2 Meter and 4 Meter Panels Temperature 60 C 140 F 134 0 10 ohms 90 194 F 51 5 100 C 212 F 38 0 Koh
29. 0Hz Models 50Hz Models Counterclockwise to increase Hz rolloff Clockwise to decrease Hz rolloff Figure 7 6 Volts Hz Rolloff Chart TP 5986 4 03 11 Set engine speed to 47 5 Hz for 50 Hz generator sets and 57 5 Hz for 60 Hz generator sets for the desired cut in frequency 12 Slowly turn the volts Hz pot counterclockwise until the frequency matches that of the engine frequency 47 5 or 57 5 Hz or until the voltage just begins to drop 13 Reset the engine speed to the normal frequency 50 Hz or 60 Hz 14 Recheck the AC voltage output and stability as described in steps 5 7 15 Stop the generator set 7 3 Rotor The two pole rotor creates the magnetic field needed to sustain alternating current in the stator windings Before testing inspect the rotor for visible damage to pole shoes insulation exposed coil windings and collector ring surfaces Check the rotor bearing for noisy operation excessive wear radial or axial movement and or heat discoloration Replace or repair as necessary Collector rings acquire a glossy brown finish in normal operation Do not attempt to maintain a bright newly machined appearance Wipe the collector rings with a dry lint free cloth Use a commutator stone to remove the groves on the collector rings Do not use emery or carborundum paper or cloth Remove all carbon dust from the generator Remove the black or pitted surface of the collector rings using a lathe Check the rot
30. 5 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 A 6 Appendix 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 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
31. 60 60 933 16070 60 933 18035 60 933 18050 60 933 18060 60 933 20050 60 933 20055 60 933 24060 60 933 24065 60 933 24070 60 14 1 50 25 14 2 00 25 14 1 50 50 16 1 50 25 16 2 00 25 M16 1 50 305 16 2 00 30 16 2 00 35 16 1 50 40 16 2 00 40 16 1 50 45 16 2 00 45 16 2 00 50 16 2 00 505 16 2 00 60 16 2 00 70 18 2 50 35 18 2 50 50 18 2 50 60 20 2 50 50 20 2 50 55 24 3 00 60 24 3 00 65 24 3 00 70 Pan Head Machine Screws M7985A 0301 0 20 M7985A 0301 2 20 M7985A 04010 20 M7985A 04016 20 M7985A 04020 20 M7985A 04050 20 M7985A 041 00 20 M7985A 05010 20 M7985A 0501 2 20 M7985A 05016 20 M7985A 05020 20 M7985A 05025 20 M7985A 05030 20 M7985A 05080 20 M7985A 05100 20 M7985A 06100 20 M3 0 50 x 10 M3 0 50 x 12 M4 0 70 x 10 M4 0 70 x 16 M4 0 70 x 20 M4 0 70 x 50 M4 0 70 x 100 5 0 80 x 10 5 0 80 12 5 0 80 16 5 0 80 20 5 0 80 25 5 0 80 30 5 0 80 80 5 0 80 100 6 1 00 100 Flat Head Machine Screws M965A 04012 SS 965 05012 55 M965A 05016 20 M965A 0601 2 20 M4 0 70 x 12 5 0 80 12 5 0 80 16 6 1 00 12 Appendix 7 Metric continued Part No Hex Nuts M934 03 50 M934 04 50 M934 05 50 M982 05 60 M934 06 60 M934 06 64 M6923 06 80 M982 06 80 M934 08 60 M6923 08 80 M982 08
32. 7 Service Views for location Close the seacock and remove the hose at the seacock Place the hose in a container having approximately 3 7 7 5 L 1 2 gal of marine antifreeze Kohler Co recommends using an environmentally friendly potable antifreeze such as Peak RV marine propylene glycol water mix or equivalent With a container at the exhaust outlet run the generator set until coolant discharges at the exhaust outlet or until depleting the coolant 18 Section 5 Cooling System 10 11 12 13 14 15 16 17 Connect the hose to the seacock mixture Do not allow the coolant mixture to flow into waterways Stop the generator set Leave the seacock closed Check the coolant level of the heat exchanger and add coolant if necessary Note Use antifreeze with the lowest available temperature rating Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces which may be subject to rust or corrosion Remove the spark plugs Pour one tablespoon of engine oil into each spark plug hole Toggle the generator set start stop switch to crank the engine two or three revolutions to lubricate the cylinders Reinstall the spark plugs and torque them to specifications Disconnect and remove the battery Place the battery in a dry location for the storage period Recharge the battery once a month to maintain a full charge Cover
33. 80 934 10 60 M934 10 60F M6923 10 80 M6923 10 62 982 10 80 934 12 60 M934 12 60F M6923 12 80 M982 12 80 M982 14 60 M6923 16 80 982 16 80 934 18 80 982 18 60 934 20 80 982 20 80 934 22 60 934 24 80 982 24 60 934 30 80 Washers Part No M125A 03 80 M125A 04 80 M125A 05 80 M125A 06 80 M125A 08 80 M125A 10 80 M125A 12 80 M125A 14 80 M125A 16 80 M125A 18 80 M125A 20 80 M125A 24 80 Dimensions M3 0 50 M4 0 70 5 0 80 5 0 80 M6 1 00 M6 1 00 M6 1 00 M6 1 00 M8 1 25 M8 1 25 M8 1 25 M10 1 50 M10 1 25 M10 1 50 M10 1 50 M10 1 50 M12 1 75 M12 1 25 M12 1 75 M12 1 75 M14 2 00 M16 2 00 M16 2 00 M18 2 5 M18 2 50 M20 2 50 M20 2 50 M22 2 50 M24 3 00 M24 3 00 M30 3 50 ID 3 2 4 3 5 3 6 4 8 4 10 5 13 0 15 0 17 0 19 0 21 0 25 0 OD 7 0 9 0 10 0 12 0 16 0 20 0 24 0 28 0 30 0 34 0 37 0 44 0 Type Standard Standard Standard Elastic Stop Standard Std green Spiralock Elastic Stop Standard Spiralock Elastic Stop Standard Standard Spiralock Spiralock Elastic Stop Standard Standard Spiralock Elastic Stop Elastic Stop Spiralock Elastic Stop Standard Elastic Stop Standard Elastic Stop Standard Standard Elastic Stop Standard Bolt Thick Screw 4 5 6 8 M10 M12 M14 M16 M18 3 0 M20 40 M24 NNN OO 0 0 This metric hex
34. C SD SE SF SG SH or Su Using unsuitable oil or neglecting an oil change may result in engine damage that is not covered by the engine warranty Figure 2 1 shows the recommended Society of Automotive Engineers SAE viscosity designation for given operating temperature ranges Do not mix different oil brands Incompatibility could cause a breakdown of lubricating ingredients and reduce engine protection F 4 14 32 C 20 10 0 30 86 Using multigrade causes greater consumption Figure 2 1 Recommended SAE Viscosity Grades Section 2 Scheduled Maintenance 5 Notes 6 Section 2 Scheduled Maintenance TP 5986 4 03 Section 3 Intake and Exhaust System 3 1 Backfire Flame Arrestor At the interval specified in the service schedule inspect clean or replace the backfire flame arrestor Check the wire mesh screen for accumulated oil or dirt that could clog the element and cause poor performance See Figure 3 1 TP603531 1 Wire mesh screen Figure 3 1 Intake 3 2 Exhaust WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Consult the boat builder or dealer for approved detector location and installation Inspect the dete
35. EATER CTG COOLANT TEMPERATURE GAUGE CTS COOLANT TEMPERATURE SENDER D f DIODE ETS ENGINE TEMPERATURE SWITCH F FUSE FP FUEL PUMP HIGH COOLANT TEMPERATURE SWITCH HR HOURMETER IGN IGNITION K1 CRANK DISCONNECT RELAY K2 ENGINE START RUN RELAY K3 ENGINE CRANK RELAY K4 FAULT SHUTDOWN RELAY K5 FAULT SHUTDOWN TIME DELAY RELAY K6 CRANK INTERLOCK RELAY 20 STARTER SOLENOID RELAY LED LIGHT EMITTING DIODE LOP LOW OIL PRESSURE SWITCH OPG OIL PRESSURE GAUGE OPS OIL PRESSURE SENDER P PLUG Q TRANSISTOR QCON QUICK CONNECT R RESISTOR SR STARTER RELAY MARINE ONLY SS STARTER SOLENOID MOBILE ONLY SSS STOP START SWITCH STAT STATOR 359343 J TP 5986 4 03 359343 J Paw sav INO AINO 1 SN oz 4 CC Ge Che SNOILOANNOO 17 73A Gaums ud 619 z NO NOLLISOd O L 391430 Qv31 vd 2 HQODINIOd b bd WE aoa 61 ae 908 8 4 zi vd dvi dtt del 4585 33S SNOLLO3NNOO HOL1VH3N39 HOS iH Pa INO INO ZINSNI i ANO SIBON s
36. Replace the anode when the percent of the zinc remaining is less than 5096 of the length and diameter shown in Figure 5 5 3 Clean the threaded opening of the heat exchanger and coat the threads of the zinc anode with pipe sealant suitable for marine applications TP 5986 4 03 4 Install the zinc anode into the heat exchanger 5 Open the seacock 6 Refill the cooling system 7 Start the generator set and check for leaks at the zinc anode location The pump is operating if cooling water flows from the exhaust outlet If water is not discharging at the exhaust outlet stop the generator set For seawater pump priming see the Prestart Checklist in the operation manual 1 Diameter 9 mm 0 34 in 2 Length 48 mm 1 7 in Figure 5 5 Anticorrosion Zinc Anode Plug Section 5 Cooling System 17 5 8 Generator Storage Perform the generator storage procedure while the craft is afloat Follow the procedure below when storing your generator set for 3 months or more Generator Storage Procedure 1 Change the oil and oil filter Add fuel stabilizer to the fuel tank of gasoline powered generator sets Follow the fuel stabilizer manufacturer s recommendation Start and run the generator set until it reaches operating temperature about 30 minutes Stop the generator set See the operation manual Drain the seawater from the heat exchanger by removing the seawater zinc anode See Section 1
37. Service Marine Generator Sets Models 5E 4EF 7 3E 6EF NATIONALLY REGISTERED KOHLER POWER SYSTEMS TP 5986 4 03b Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number x in 007 001a Safety Precautions and Instructions Introduction i Service Assistance ii Service Information ii Product Information ii Service Parts Publications iii Routine Service iii List of Related Literature iii Section 1 Specifications 1 T General ias E RERLERZEG 1 1 2 ENJINS 1 12379 Fiel P bI EC 1 VA
38. an cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do notoperate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation TP 5986 4 03 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 containerto catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Installing the fuel system Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Do not modify the tank orthe propulsion engine fuel system Equip the craft with a tank that a
39. ar hearing protection when near an operating generator set Hazardous Voltage Electrical Shock WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place CAUTION Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Safety Precautions and Instructions Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during test
40. at or a fuel inlet needle held off its seat either by improper seating or dirt particles A punctured or leaking float admitting fuel becomes gas logged causing a heavy float high fuel level and flooding If flooding occurs disassemble the carburetor observe the operation and condition of components and repair or replace components as necessary 4 5 4 Hunting A low fuel level because of an improperly adjusted float a clogged main jet restricted main jet passages or an improperly sized main jet for the application can cause hunting Clean adjust or replace inoperative components An incorrect throttle linkage adjustment a binding throttle linkage a sticking throttle shaft or a loose throttle shaft in the throttle body or bore can cause inconsistent idle speed 4 5 5 Leaking Carburetor Loose fuel connections a cracked carburetor body a sticking fuel inlet needle or an inoperative float can cause aleaking carburetor Adjust repair or replace the affected components 4 6 Governor 60 Hz to 50 Hz Conversion Governors are adjusted at the factory and further adjustments should not be necessary TP 5986 4 03 Note Never tamper with the governor settings to increase the generator output Overspeeding can cause equipment parts to exceed design limitations resulting in component failure Governor 60 Hz to 50 Hz Conversion Procedure 1 Change the spring to the 50 Hz position See Figure 4 3 2 Adjust the
41. ator Disassembly Reassembly Disassembly Disconnect the external connections battery cables at the battery negative lead first AC output leads in the controller remote start panel at the controller P3 connector water line at the seawater pump fuel line at the fuel pump filter inlet and exhaust line at the mixing elbow Observe all of the safety precautions listed during the disassembly reassembly procedures Disassembly Procedure 1 2 10 11 12 13 Place the start stop switch in the STOP position Disconnect the generator set engine starting battery the negative lead first Remove the controller cover Disconnect the P4 22 pin connector from J4 Disconnect the controller ground strap generator side Note It is possible to connect the output leads in various positions for different voltage configurations Mark the leads for correct reconnection Disconnect the generator output leads 1 2 3 and 4 from the circuit breaker and the neutral stud LO Disconnect the P11 FP and FN and P10 F1 and F2 connectors Remove the fuel inlet hose Close the seacock and remove the water inlet hose from the water pump Remove the sound shield enclosure if equipped If the generator set is not equipped with a sound shield enclosure lift the controller from the rubber mounts while guiding the leads through the bottom opening of the controller box Remove the fuel p
42. ator set Part Number TP 5982 TP 5985 TP 6001 TP 5987 TP 5986 TP 6002 TP 6008 Literature Type Installation Manual Operation Manual Generator Operation Manual Engine Parts Catalog Service Manual Generator Service Manual Engine Service Manual Supplement Engine One manual combines Generator and Engine information Introduction iii Notes iv Introduction TP 5986 4 03 1 1 General The 7 3E 6EF and 5E 4EF units are powered two cylinder water cooled four cycle gasoline engine with heat exchanger Kohler Co develops all Kohler marine generator set ratings using accepted reference conditions of 25 C 77 F and pressure of 99 kPa 29 2 Hg dry barometer ISO 3046 and ISO 8528 1 include reference conditions and output calculations Obtain technical information bulletin TIB 101 on ratings guidelines for complete ratings definitions 1 2 Engine Generator Model 7 3E 6EF 5E 4EF Engine manufacturer Kawasaki Engine model FD501D Number of cylinders 2 Cylinder block material Aluminum Cylinder head material Aluminum Piston rings 2 compression 1 oil Governor Gear driven centrifugal Bore x stroke mm in 67 2 64 x 62 2 44 Displacement L CID 0 4 26 7 Compression ratio 9 3 1 Horsepower 60 50 Hz 16 13 8 RPM 60 50 Hz 3600 3000 Lubrication system Pre
43. centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute TP 5986 4 03 CG CID CL cm CMOS cogen Com conn cont CPVC crit CRT CSA CT Cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electroma
44. ction 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 atthe prescribed intervals Maintenance work must be performed by appropriately skiled and suitably trained maintenance personnel familiar with generator set operation and service Introduction i Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPowerSystems com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Africa Europe Middle East London Regional Office Langley Slough England Phone 44 1753 580 771 Fax 44 1753 580 036 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 ii
45. ctor before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times TP 5986 4 03 Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper for cracks leaks and corrosion e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps as needed e Check that the exhaust outlet is unobstructed e Check the exhaust gas color If the exhaust is blue or black contact your local distributor dealer e Visually inspect for exhaust leaks Check for carbon or soot residue on exhaust components Carbon and sootresidue indicates an exhaustleak Seal leaks as needed e Ensure that the carbon monoxide detector s is 1 in the craft 2 functional and 3 energized whenever the generator set operates Note Never operate the generator set without a functioning carbon monoxide detector Section 3 Intake and Exhaust System 7 Notes 8 Section 3 Intake and Exhaust System TP 5986 4 03 WARNING LI 4
46. cuit Board 1 of 4 TP 5986 4 03 Section 6 Controller Troubleshooting 21 Does the engine start Y Is the K4 relay LED lit uU Is there continuity between No 1s there12 volts DC Yes ls the fuel P4 5 and N present at the fuel pump working pump P9 2 Is there continuity No Y between P1 9 and P9 1 Yes Troubleshoot the engine refer to the engine service manual Y Is there continuity y Go to C between P9 2 and P1 8 Replace the No next page fuel pump Y Yes Is there continuity between Y P2 8 and N Is there continuity between P1 8 and P1 14 i m Disconnect the P2 connector Is there continuity between Is there continuity across the P2 5 and N P1 P4 and P9 connectors Check the wiring for Yes open circuits Replace the remote start stop switch Check the connectors for open circuits Y Replace the start stop switch Figure 6 4 Troubleshooting Relay Controller Circuit Board 2 of 4 22 Section 6 Controller Troubleshooting TP 5986 4 03 Does the engine continue Does using the stop switch to run after the start Yes
47. d 18 oL SNOILOANNOO tir 5 calli 348 SNOILO3NNOO 14 Ed YSTIOULNOD 43 Section 10 Wiring Diagrams and Voltage Reconnection 10 2 Point to Point Wiring Diagram TP 5986 4 03 10 3 Reconnection Diagram 100 120 V 60 amp 50 Hz 100 120V 60Hz 100 120V 50Hz JUMPER LEAD L1 GRD LO NEUTRAL F LO NEUTRAL Hr 2 GROUND GROUND L1 L2 FACTORY ONE POLE TWO POLE CIRCUIT OR 2 BREAKER ONE POLE CIRCUIT BREAKERS JUMPER LEAD 3 1 4 2 1 x5 STATOR LEADS 100 120 VOLT STATOR LEADS 100 120 VOLT 3 WIRE 2 WIRE ADV 5857 10 4 Reconnection Diagram 100 120 200 240 V 60 amp 50 Hz 100 120 200 240V 60Hz 100 120 200 240V 50Hz MAA LO NEUTRAL gt GROUND L1 L2 FACTORY TWO POLE CIRCUIT BREAKER 3 2 4 1 STATOR LEADS 100 120 200 240 VOLT 3 WIRE ADV 5857 44 Section 10 Wiring Diagrams and Voltage Reconnection 10 5 Reconnection Diagram 220 240 V 50 Hz 220 240V 50Hz GRD LO NEUTRAL GROUND ONE POLE CIRCUIT BREAKER 3 2 4 1 STATOR LEADS 200 240 VOLT 2 WIRE 10 6 Remote Start Panel 55 Ju d P Stop 10 amp Local Fuse switch x Start Relay circuit board P2 3 2 7 70 47 pu
48. e Grey P3 4 p35 Black J3 4 J3 5 Se J3 6 Violet Stop O Yellow Red switch 2 Gen ON light TP 5986 4 03 10 7 Remote Start and Two Meter Panel Start 43 Relay circuit board 7 47 A P3 5 70 A P3 4 J3 4 Violet Grey Black J3 5 Yellow Red 43 VR gt Remote 5 switch N P3 6 Gen ON light Water temp gauge Oil pressure gauge TP 5986 4 03 J3 1 Black W T sender 2 P43 A P3 2 J3 2 Tan s 43 3 L 5 7C Blue TP 5588 7 Panel circuit board P2 7 7 A P3 5 J3 4 Violet Yellow Red J3 5 43 N Grey Black 6 P3 1 CMWON StPiO Ja gt Remote Black W T sender 5 A P3 2 J3 2 Tan 10 8 Remote Start and Four Meter sender Start switch Gen ON light Water temp gauge Oil pressure DC voltmeter Hourmeter Section 10 Wiring Diagrams and Voltage Reconnection 45 Notes 46 Section 10 Wiring Diagrams and Voltage Reconnection TP 5986 4 03 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC
49. e impeller together in the same direction as the engine rotation Inspect the coverplate and gasket for corrosion and or damage necessary Replace components as Lubricate the gasket with petroleum jelly and install the gasket and coverplate to the seawater pump housing Open the seacock Start the generator set and check for leaks Stop the generator set and repair leaks or replace components as necessary Section 5 Cooling System 15 5 6 Siphon Break A siphon break prevents seawater entry into the engine when the engine exhaust manifold outlet is less than 23 cm 9 in above waterline Check the siphon break at the interval listed in the service schedule Use the following procedure and Figure 5 4 to ensure correct functioning of the siphon break Siphon Break Inspection Procedure 1 Stop the generator set 2 Remove the retaining cap and the reed valve for inspection See Figure 5 4 3 Use a light detergent to clean the reed valve Check that the reed valve opening is clear Replace the siphon break if it is cracked or if the reed valve material has hardened or deteriorated Install the reed valve downward into the mounting base Install the retaining cap and finger tighten only Do not overtighten Restart the generator set and inspect the reed assembly for leaks Replace the reed valve if leakage occurs Note Consult the installation manual for a complete explanation
50. ection 7 Generator Troubleshooting Note The stator resistance varies directly with increased temperature If the stator readings vary considerably during the previous checks repair or replace the stator 7 Check the stator for a grounded condition using a megohmmeter Apply 500 volts DC to any stator lead from each winding and the stator frame Follow the instructions of the megohmmeter manufacturer when performing this test Repeat the test on the other leads until all the stator windings have been tested reading of approximately 3 5 megohms and higher indicates the stator is functional A reading of less than approximately 3 5 megohms indicates deterioration of the winding insulation and possible current flow to ground Replace the stator Between Leads Continuity 1 and 2 3 and 4 55 and 66 B1 and B2 1 and 3 4 33 44 55 1 and 55 B1 and B2 4 and B1 and B2 55 and B1 and B2 Any stator lead and ground Figure 7 8 Stator Continuity TP 5986 4 03 7 5 Brushes The brushes provide a current path from the voltage regulator to the collector rings Because the brushes carry low current inspect them every 1000 1500 hours Abrasive dust on the collector rings could however shorten the life of the brushes Excessive arcing at the brushes could damage the voltage regulator Weak springs damaged collector rings sticking brushes a loose holder or poor brush contact can cause arcing at the brushes The brus
51. ector nonservice side Input fuse Battery charging fuse AC circuit breaker Voltage regulator Remote start connector nonservice side Voltage regulator fuse Figure 1 1 Service Views TP 5986 4 03 Hourmeter Heat exchanger Anticorrosion zinc anode Seawater drain remove zinc anode Seawater pump water inlet Cooling air inlet High exhaust temp switch on mixing elbow nonservice side Fuel filter fuel inlet Fuel feed pump Oil check Coolant drain remove hose clamp to drain coolant Oil drain valve Lube oil filter Low oil pressure switch Antidieseling solenoid on carburetor Air intake silencer backfire flame arrestor Coolant overflow bottle daily coolant check fill location Section 1 Specifications Notes 4 Section 1 Specifications TP 5986 4 03 2 1 General WARNING AS Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator setas follows 1 Place the generator set start stop switch in the STOP position 2 Disconnect the
52. fuel pump to the positive terminal of a 12 volt battery 5 Connect the negative N terminal of the fuel pump to the negative terminal of the battery The pump should operate and fuel should discharge from the pump outlet Ifthe pump does not operate replace the pump Figure 4 2 Fuel System Exploded View 10 Section 4 Fuel System 4 5 Carburetor Troubleshooting This section is for fuel related problems only Use for basic carburetor troubleshooting Note When troubleshooting the fuel system it is important to have an adequate fuel supply A lean or rich fuel condition can reduce power output and cause poor acceleration Symptoms of a Lean Condition e Hard starting e Stalling e Rough idle e Surging above idle Symptoms of a Rich Condition Hard starting Stalling Rough idle Percolation Flooding Leaking carburetor 4 5 1 Hard Starting A flooded engine improperly adjusted or inoperative choke dirty carburetor lean condition or improper idle fuel mixture can cause hard starting 4 5 2 Stalling Improper idle air fuel mixture or a dirty carburetor can cause stalling Clogged idle air bleeds idle air passages or an idle discharge port can cause stalling because of a lean condition Clean or adjust the carburetor TP 5986 4 03 4 5 3 Flooding Flooding occurs from a float level set too high improperly adjusted fuel pressure improperly installed fuel pump a sticking choke plate or flo
53. generator frequency using a frequency meter Set the no load speed at 52 5 Hz for 50 Hz operation or 63 Hz for 60 Hz operation 3 Replace the governor speed adjusting bolt The 50 Hz bolt is X 6284 7 and is 65 mm long The 60 Hz bolt is M933 5050 60 and is 50 mm long 4 Adjust the voltage regulator volt Hz rolloff point Refer to Section 7 2 2 1 60 Hz governor spring position 2 50 Hz governor spring position 3 Governor arm 4 Governor speed adjusting bolt X 6284 7 for 50 Hz M933 5050 60 for 60 Hz Figure 4 3 Governor 60 Hz to 50 Hz Conversion Section 4 Fuel System 11 Notes 12 Section 4 Fuel System TP 5986 4 03 Section 5 Cooling System 5 1 General The heat exchanger cooling system consists of a heat engine circulating pump a water cooled exhaust exchanger with a coolant recovery tank a thermostat a manifold and an exhaust mixer See Figure 5 1 for rubber impeller seawater pump a centrifugal type cooling system components Seawater Coolant Antifreeze Engine block Heat exchanger Exhaust manifold Engine seawater pump Exhaust mixer elbow Seawater strainer Outlet flapper Seacock Silencer Intake strainer Thermostat Engine driven water pump Figure 5 1 Cooling System Components TP 5986 4 03 Section 5 Cooling System 13 5 2 Closed Heat Exchanger In a closed cooling system the seawater circulates through separate chambers within the heat exchanger to cool
54. gnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft ft Ibs ft min g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext IP ISO J JIS k K kA KB hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches
55. hes must be free to move within the holder and be held in contact by the springs When properly positioned spring pressure on the brush surface will cause the brush to wear evenly Brushes must ride 100 on the collector rings or arcing will occur and cause burned rings or failure of the voltage regulator Figure 7 9 shows the correct positioning of the brushes Add or remove spacers as necessary to center brushes on collector rings Replace brushes if they show excessive or uneven wear TP 598657 1 Correct position 2 Brush holder 3 Incorrect position 4 Generator collector rings Figure 7 9 Brush Positioning TP 5986 4 03 Use a retainer wire such as a paper clip to contain the brushes during disassembly and reassembly Push the brushes into the brush holder until the retainer wire can be inserted into the brush keeping hole See Figure 7 10 Replace brushes when they are worn to half of their original size TP 598658 1 Brush holder 2 Retainer paper clip 3 Mounting screw 4 Alignment shim s 5 Brush 6 Spring Figure 7 10 Brush Holder Section 7 Generator Troubleshooting 31 Notes 32 Section 7 Generator Troubleshooting TP 5986 4 03 8 1 Section 8 Component Troubleshooting Engine Generator Components See Figure 8 1 through Figure 8 3 for engine generator component testing With the generator set battery connected check
56. ic Hex head bolts are hardness grade 8 8 unless noted Part No Hex Head Bolts Partial Thread M931 05055 60 M931 06040 60 M931 06055 60 M931 06060 60 M931 06060 SS M931 06070 60 M931 06070 SS M931 06075 60 M931 06090 60 M931 06145 60 M931 06150 60 M931 08035 60 M931 08040 60 M931 08040 82 M931 08045 60 M931 08050 60 M931 08055 60 M931 08055 82 M931 08060 60 M931 08070 60 M931 08070 82 M931 08075 60 M931 08080 60 M931 08090 60 M931 08095 60 M931 08100 60 M931 08110 60 M931 08120 60 M931 08130 60 M931 08140 60 M931 08150 60 M931 10040 82 M931 10040 60 M931 10045 60 M931 10050 60 M931 10050 82 M931 10055 60 M931 10060 60 M931 10065 60 M931 10070 60 M931 10080 60 M931 10080 82 M931 10090 60 M931 10090 82 M931 10100 60 M931 10110 60 M931 10120 60 M931 10130 60 M931 10140 60 M931 10180 60 M960 10330 60 M931 12045 60 M960 12050 60 M960 12050 82 M931 12050 60 M931 12050 82 931 12055 60 931 12060 60 931 12060 82 931 12065 60 931 12075 60 931 12080 60 931 12090 60 931 12100 60 931 12110 60 This metric hex bolt s hardness is grade 10 9 TP 5986 4 03 Dimensions 5 0 80 x 55 M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M6 1 00 x 145 M6 1 00 x 150 8 1 25 x 35 8 1 25 40 8 1 25 405 M8 1 25 x 45 M8 1 25 x 50 M8 1 25 x 55 M8 1 25 x 55 M8 1 25 x 60 M8 1
57. ine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware Servicing the generator set when itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Sound shield removal Exposed moving parts can cause severe injury or death The generator set must be operating in order to perform some scheduled maintenance procedures Be especially careful if the sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the b
58. ine voltage adjustment connect a remote rheostat to voltage regulator terminal 66 TP 598654 120 volts AC Variable transformer AC voltmeter Voltage regulator PowerBoost Stator rotor connections for reference only Lead color 120 volt 100 watt lamp Figure 7 4 PowerBoost IIIE Voltage Regulator Test Section 7 Generator Troubleshooting 27 7 2 2 Voltage Regulator Adjustment The factory sets the voltage regulator and under normal circumstances the regulator requires further adjustment However if the voltage regulator has been replaced or tampered with or if voltage frequency reconnection has been done readjust the voltage regulator according to the following procedure See Figure 7 5 The following paragraphs describe the voltage regulator components Voltage Adjustment Pot adjusts the generator output within the range of 100 130 volts Stabilizer Pot fine tunes regulator circuitry to minimize AC voltage fluctuation 2 11 1 10 TP 598655 Optional remote rheostat Voltage adjustment pot PowerBoost voltage regulator Stabilizer pot Volts Hz pot Stator rotor connections for reference only DC output Rotor 10 amp fuse AC power input aux Main 2 and 1 Control Stator Sensing Main 3 and 4 Figure 7
59. ing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Welding the generator set Can cause severe electrical equipment damage Before welding the generator set perform the following steps 1 Remove the battery cables negative lead first 2 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connectors 4 Disconnect the engine battery charging alternator connections 5 Attach the weld ground connection close to the weld location Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment IV Safety Precautions and Instructions Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is present at the voltage regulator heat sink To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator PowerBoost PowerBoost and PowerBoost V voltage regulator models only Electrical backfeed to the utility Hazardous backfeed voltage can cause severe inju
60. is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water oron wetground because these conditions increase the risk of electrocution Section 10 Wiring Diagrams and Voltage Reconnection 41 10 1 Schematic Wiring Diagram 12 VOLT 13 2 BATTERY CHARGING 55 P4 11 Y P4 12 14 28 S104 2 4 Y P1 14 MOBILE ONLY N oN 1 MARINE ONLY P2 2 8 gt 2 2 K6 D9 gt 1 21 12 9 5A 2 8 2 1 2 4 t 2 7 lt START 55 REMOTE START P3 5 Bes 2222 SCREEN 42 Section 10 Wiring Diagrams and Voltage Reconnection 3 Up STAT MAIN FIELD LEGEND ADS ANTI DIESEL SOLENOID AVR AUTOMATIC VOLTAGE REGULATOR BATTERY CHARGING COIL BCR BATTERY CHARGING REGULATOR BR BRIDGE RECTIFIER BV BATTERY VOLTMETER C CAPACITOR CHTR CHOKE H
61. lations both the generator set and the vehicle s engine operate from common fuel tank with a dual dip tube arrangement The generator set s dip tube may be shorter than the vehicle engine s dip tube With this arrangement fuel may not be available to the generator set when the fuel supply is low See Figure 4 1 for fuel system schematic Vehicles engine Generator set fuel pump 1 Fuel tank 2 Dual dip tubes 3 Fuel filter Figure 4 1 Fuel System Schematic Typical 4 2 Float Bowl Vent System The float bowl vent system prevents fuel from overflowing into the bilge In the event of an overflowing float bowl due to a sticking float valve the float bowl vent tube redirects the unused fuel back into the intake per USCG regulations Check for fuel leakage at the backfire flame arrestor for troubleshooting an overflowing float bowl 4 3 Fuel Pump and Filter Electric fuel pumps draw gasoline from the fuel tank through a filter and supply clean gasoline at the proper pressure and quantity to the generator set engine carburetor Section 4 Fuel System 9 4 4 Fuel Pump Troubleshooting The fuel pump transfers fuel from a source to the carburetor Fuel Pump Test Procedure 1 Connect the inlet side of the pump to a fuel source 2 Disconnect the outlet hose from the fuel filter and place the end in a container to catch the fuel 3 Disconnect the P9 connector gt Connect the positive 70 terminal the
62. ld and the unit is running No Is there approximately 12VDC at the exciter field No Separately excite the generator set to determine if other components are inoperative See Section 7 1 2 Separate Excitation Is there AC output voltage No Is there 12 volts AC output at the B1 B2 stator winding 16 the stator and rotor functional Is the voltage regulator fuse functional Y Replace inoperative components Is the voltage regulator functional Replace the fuse Y Is the stator functional No Replace the stator Replace the voltage regulator Figure 6 6 Troubleshooting Relay Controller Circuit Board 4 of 4 24 Section 6 Controller Troubleshooting Replace the Yes circuit board Replace the circuit board TP 5986 4 03 Section 7 Generator Troubleshooting 7 1 General Before beginning the following troubleshooting procedures read all the safety precautions at the beginning of this manual The following tests include additional safety precautions OBSERVE THESE PRECAUTIONS A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in
63. ler Co offers three remote panels for connection to the generator set e A panel with a start stop switch e A panel with a start stop switch and two gauges engine oil pressure and water temperature e A panel with a start stop switch and four gauges voltmeter engine oil pressure water temperature and hourmeter 4 ohms 3 ohms If difficulty with the remote operation occurs test the switch gauges and gauge senders using the following procedures See Sections 10 6 10 7 or 10 8 to identify the location for the appropriate panel Figure 8 4 Water Temperature Sender Resistance 2 Meter and 4 Meter Panels Pressure 0 Opsi 10 ohms 50 psi 80 ohms 135 ohms 345 kPa 690 kPa 100 psi Figure 8 5 Oil Pressure Sender Resistance TP 5986 4 03 Section 8 Component Troubleshooting 35 Refer to Figure 8 6 for troubleshooting information on the remote start panels Component Remote start stop switch Ohmmeter Connections Remote switch yellow red wire terminal and black wire terminal Procedure Place the ohmmeter on the Rx 1 scale Press the rocker switch to the START position Results Continuity the switch is functional Remote switch grey black wire terminal and black wire terminal Place the ohmmeter on the Rx 1 scale Press the rocker switch to the STOP position Continuity the switch is functional Generator set ON light gauge lights DC voltmeter and hou
64. lliohm MOhm MQ 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 A 2 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns oc OD OEM OF opt 0 OV oz ph PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw
65. llows one of the pickup arrangements described in the installation section The tank and installation must conform to USCG Regulations Pipe sealant Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Use pipe sealanton all threaded fittings to prevent fuel leakage Use pipe sealant that resists gasoline grease lubrication oil common bilge solvents salt deposits and water Ignition protected equipment Explosive fuel vapors can cause severe injury or death Gasoline vapors can cause an explosion USCG Regulation 33CFR183 requires that all electrical devices ship to shore transfer switch remote start panel etc must be ignition protected when used in gasoline gaseous fueled environment The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous fueled environmentsuch as an engine room or near fuel tanks Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss We
66. ly open K1 contacts close to maintain voltage to the K2 relay allowing the function of the fuel pump FP choke heater CHTR antidiesel solenoid ADS ignition IGN hourmeter HR and the remote panel gauges The normally closed K1 contacts open ending the flashing by preventing battery voltage to the main field and TP 5986 4 03 The relay energizes The normally open contacts close latching itself on The normally closed K6 contacts open preventing inadvertent starter engagement by disabling the the relay The relay is deenergized LED3 Off The contacts open deenergizing the K20 relay The K20 contacts open deenergizing the starter relay and starter motor STOP START Controller circuit board PBIIIE voltage regulator K20 relay Fuses Start stop switch Hourmeter Figure 6 1 Controller Section 6 Controller Troubleshooting 19 At the same time the 1 relay is energized the time delay for the K5 relay starts After 5 10 seconds the K5 relay is energized LED 5 lights The normally open K5 contacts close to permit the function of the engine safety shutdown switches 6 1 3 Stop Close the start stop switch between N and 43 local or remote The K4 relay energizes LED4 lights The normally closed K4 contacts open disabling the fuel pump FP choke heater CHTR antidiesel solenoid ADS and ignition IGN The normally open K4 contacts cl
67. nd or wiring Connect the ohmmeter to the P4 22 lead and the battery positive 4 cable Note The J4 and P4 leads must be disconnected to perform this test Starter solenoid S relay Place the ohmmeter on the R x 1 scale If functional approximately 0 5 0 6 ohms at 27 C 80 F Connect the ohmmeter to the battery positive cable and the P1 14 lead Note The J4 and P4 leads must be connected to perform this test Controller 10 amp circuit breaker and wiring Place the ohmmeter on the R x 1000 scale Figure 8 2 Engine Generator Component Testing Relay Controller 34 Section 8 Component Troubleshooting If functional zero or very low ohms No reading infinity open circuit or circuit breaker tripped TP 5986 4 03 Ohmmeter Connections Component Procedure Results Disconnect the P10 and P11 connectors and connect the ohmmeter to P10 1 and P10 2 leads Main field rotor Place the ohmmeter on the Rx 1 scale If functional see Section 1 Specifications Low resistance rotor windings shorted High resistance rotor windings open Connect the ohmmeter to the P11 1 and P11 2 leads Note Disconnect P11 and J11 to perform this test B1 B2 stator windings Place the ohmmeter on the R x 1 scale If functional see Section 1 Specifications Low resistance B1 B2 windings shorted High resistance B1 B2 windings open Connect the ohmmeter to
68. of the dimensions and other installation considerations Waterline Mounting holes Retaining cap Reed valve assembly Silencer vertical lift 1 2 4 ft max Exhaust mixer elbow distance above waterline If less than 23 cm 9 in a siphon break is required Siphon break distance above waterline 30 5 cm 1 ft min Siphon break Exhaust mixer elbow Heat exchanger locations vary by model Coolant recovery tank Figure 5 4 Siphon Break Plastic U Type 16 Section 5 Cooling System gt Seawater strainer Seacock Intake strainer Engine driven seawater pump Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Water lock optional Silencer distance from exhaust mixer elbow 3 m 10 ft max Silencer customer supplied Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Exhaust outlet distance above waterline 10 cm 4 in min Seawater outlet TP 5986 4 03 5 7 Anticorrosion Zinc Anode The heat exchanger contains an anticorrosion zinc anode plug to prevent electrolytic corrosion by seawater Check and replace the zinc anode at intervals recommended by the operation manuals service schedule Anticorrosion Zinc Anode Replacement Procedure 1 With the generator set cooled close the seacock remove the zinc plug from the heat exchanger and drain the coolant into a container 2 Remove the corrosion on the zinc anode
69. olt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown questionable NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Safety Precautions and Instructions V Notes VI Safety Precautions and Instructions TP 5986 4 03 This manual provides troubleshooting repair instructions for 5E 4EF and 7 3E 6EF model generator sets controllers and accessories Refer to the engine service manuals TP 6002 and 6008 for generator set engine service information This manual may be used for models not listed on the front cover Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever TP 5986 4 03 Introdu
70. or for continuity and resistance Lift the brushes and measure the rotor resistance between the two collector rings See Section 1 5 Note When checking rotor resistance with the rotor installed brushes must not be in contact with rotor collector rings Use a brush retainer on brushes for accurate resistance readings TP 5986 4 03 Note Use the values in Section 1 as a reference for rotor resistance readings Take readings at room temperature or about 21 C 70 F Rotor resistance will vary directly with increase in temperature To check whether the rotor is shorted to ground touch one ohmmeter lead to either collector ring and the other lead to the rotor poles or shaft The meter should register no continuity Repair or replace the rotor if the previous tests detect any faults 7 4 Stator The stator consists of a series of coils of wire laid in a laminated steel frame The stator leads supply voltage to the AC load and exciter regulator See Figure 7 7 for coil lead description Stator Leads Description Output coil Output coil Control wires from 3 and 4 Voltage regulator power source Controller power source Figure 7 7 Stator Coil Lead Description Before testing the stator inspect it for heat discoloration and visible damage to the exposed coil windings and varnished areas of the frame laminations Be sure the stator is securely fastened in the stator housing The stator produces electrical output AC a
71. ose latching the circuit to the K4 relay until the generator set comes to a complete stop 6 2 Engine Safety Shutdown Switches 6 2 1 Low Oil Pressure LOP Shutdown When low oil pressure occurs the LOP shutdown switch contacts close energizing the K4 relay LED4 lights E LI 09 i Figure 6 2 10516 Controller Circuit Board 20 Section 6 Controller Troubleshooting The generator shuts down described Section 6 1 3 Note During cranking the low oil pressure shutdown switch deactivates until the K5 relay energizes This delay allows the engine to reach normal operating oil pressure 6 2 2 Loss of Coolant Switch LCS Shutdown When the coolant level is low the LCS contacts close energizing the K4 relay LED4 lights The generator shuts down as described in Section 6 1 3 6 2 3 High Engine Temperature Switch HET Shutdown When the engine temperature exceeds 110 C 230 F the HET contacts close energizing the K4 relay LED4 lights The generator shuts down as described in Section 6 1 3 6 2 4 Controller Circuit Board The controller circuit board has light emitting diodes LEDs that indicate the presence of relay coil power When any of the relays K1 K5 receive power the corresponding LED lights NO3 13901 PCB ASSY 610516 TP 5986 4 03 6 2 5 Troubleshooting Use the following flowchart as an aid in troubleshooting circuit board may have to be
72. place Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is present at the voltage regulator heat sink To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator PowerBoost PowerBoost and PowerBoost V voltage regulator models only Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water oron wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment TP 5986 4 03 7 1 4 Troubleshooting To determine the cause of no or low AC output refer to the following steps and the troubleshooting flowchart Figure 7 1 Verify the operation of the alternator components before replacing the controller board or voltage regulator
73. power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set TP 5986 4 03 Section 2 Scheduled Maintenance Sound shield removal Exposed moving parts can cause severe injury or death The generator set must be operating in order to perform some scheduled maintenance procedures Be especially careful if the sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Note See the generator set operation manual for the service schedule and other service not included in this manual 2 2 Lubrication System Use oil that meets the American Petroleum Institute API classification of S
74. programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw 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 5 sec second Sl 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 4 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
75. r module or armature is likely If there is no generator output during normal operation but output is available when the generator set is separately excited the voltage regulator may be inoperative Note See Section 1 Specifications for the stator output voltages with separately excited generator These specifications are based ona battery voltage of 12 volts Should the battery voltage vary the resulting stator output values will also vary TP 598652 7 Brushes 8 Collector rings 9 Main field rotor 10 Jumper lead 11 Engine ground Voltage regulator Terminal P 10 2 Terminal P10 1 10 amp fuse DC ammeter 12 volt battery DC Figure 7 2 Separate Excitation Connections TP 5986 4 03 7 2 Voltage Regulators The generator set is equipped with a PowerBoost IIIE voltage regulator See Figure 7 3 1 1 2 1 Voltage adjustment potentiometer 2 Stability adjustment potentiometer 3 Volts Hz adjustment potentiometer 598653 Figure 7 3 PowerBoost Voltage Regulator The voltage regulator monitors the output voltage of the generator set The 10 amp regulator fuse protects the alternator stator windings power supply 55 33 from excessive current draw because of an inoperative voltage regulator or a downstream short Ifthe regulator
76. re prevention procedures Exhaust System WARNING Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e 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 ifthe 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 Consultthe boat builder or dealer for approved detector location installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times Operating
77. rmeter Connect the red test lead to P3 4 and black test lead to P3 1 If 12 volts DC is present and the component does not function after the J3 is connected to the controller replace the component Place the controller rocker switch to the START position Stop the generator set when the test is complete Voltmeter setting 12 volts or greater Generator set does not need to be running just cranking for this test Note If the hourmeter is not illuminated test by connecting it to a 12 volt battery Note The hourmeter is polarity sensitive Water temperature gauge Connect the red test lead to P3 4 socket side and black test lead to P3 2 socket side Start the generator set for the test If 0 5 12 volts DC is present and the gauge does not function after the J3 is connected to controller replace the gauge Voltmeter setting 12 volts or greater Oil pressure gauge Connect the red test lead to P3 4 socket side and black test lead to P3 3 socket side Start the generator set for the test If 0 5 12 volts DC is present and the gauge does not function after the J3 is connected to the controller replace the gauge Voltmeter setting 12 volts or greater Note Check continuity of gauge wiring and extension harness before replacing components Figure 8 6 Remote Start Panels Troubleshooting 36 Section 8 Component Troubleshooting TP 5986 4 03 9 1 Section 9 Gener
78. ry or death Connect the generator set to the building marina electrical system only through an approved device and after the building marina main switch is opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a ship to shore transfer switch to prevent interconnection of the generator set power and shore power Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure WARNING 8 ae ade l Hot engine and exhaust system Can ca
79. s 10 amp fuse blows the generator set will shut down Verify that the regulator fuse is functional before proceeding with the test 7 2 1 Voltage Regulator Test Perform the following test to check the regulator output Use the following components to test the voltage regulator e Variable transformer 0 140 volts 0 5 amp minimum e Plug 120 volts AC e Lamp 120 volts 100 watts e AC voltmeter e Insulated copper wire 14 AWG minimum TP 5986 4 03 Regulator Test Procedure 1 Connect the components as shown in Figure 7 4 2 Turn the variable transformer setting to zero Plug in the variable transformer 3 Turn the variable transformer on Slowly increase the variable transformer voltage to 100 volts The test lamp should light If the lamp does not light turn the voltage adjustment potentiometer pot clockwise f the lamp still does not light the voltage regulator is inoperative Replace the voltage regulator An inoperative voltage regulator causes a generator no low output condition 4 Slowly increase the voltage to 120 volts The lamp should go out and stay out as the voltage increases If the lamp remains lit turn the voltage adjustment pot counterclockwise If the lamp still remains lit replace the voltage regulator A voltage regulator which tests bad causes a generator high voltage output condition 5 Turn the variable transformer to zero and unplug the AC cord Note For applications requiring f
80. s the magnetized main field rotates within the stator windings Test the condition of the stator according to the following procedure Leads 1 2 3 and 4 are the generator output leads Leads 33 44 and 55 are the voltage regulator supply and sensing leads The output of leads B1 and B2 is the control voltage for the controller Section 7 Generator Troubleshooting 29 Stator Test Procedure 1 Place the generator start stop switch in the STOP position Disconnect the generator set engine starting battery negative lead first Check the generator output lead connections See Section 10 Wiring Diagrams and Voltage Reconnection Disconnect all of the stator leads to isolate the windings To check the stator continuity set the ohmmeter on the 1 scale Check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 7 8 Perform the stator tests on all the stator windings Note When taking an ohmmeter reading using lead 55 make the connection prior to the in line fuse Check the cold resistance of the stator windings by connecting the meter leads to the stator leads 1 4 2 5 3 6 etc See Section 1 Specifications for the stator resistance values Perform a megohmmeter test on the stator as described in step 7 Note Consider the stator functional if the resistance reading continuity is low and there is no evidence of shorted windings heat discoloration 30 S
81. shaft of the engine 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 Ibs Carefully slide the stator assembly over the rotor Replace the end bracket o ring Install the end bracket and torque the overbolts to 13 6 Nm 120 in Ibs Feed the brush leads inside the stator housing up through the opening Secure the brush holder using the original screws Remove the brush retainer and check the brush alignment See Section 7 5 Install the coverplate and torque the coverplate bolts to 6 8 Nm 60 in Ibs TP 5986 4 03 10 11 12 13 14 15 Install the sound shield enclosure Install the fuel line and fuel pump Reconnect the water inlet hose to the water pump Guide the leads from the stator through the bottom opening of the controller Secure the controller Reconnect the leads from the stator to the controller using the reverse procedure of that listed in Section 9 1 Refer to Section 10 Wiring Diagrams Connect the generator set starting battery the positive lead first Test the generator operation Min diameter mm in 57 15 2 250 Max finish 32 micro inches M ax eccentricity mm in 0 08 0 003 Max out of round mm in 0 01 0 0002 Figure 9 5 Collector Ring Dimensions 38 maximum as soldered
82. ssure mechanical Lube oil capacity L U S qts w filter 1 36 1 44 Low oil pressure shutdown kPa psi 96 5 14 Oil recommendation API SC SD SE SF SG SH or SJ Battery voltage 12 volt standard Battery recommendation minimum 260 CCA Battery charging 15 amps Starter motor TP 5986 4 03 Bendix automotive type Section 1 1 3 Fuel Fuel recommendation Specifications Unleaded 87 octane Fuel pump Electric Fuel pump operating kPa psi 13 8 24 1 2 0 3 5 Fuel filter inlet hose mm in ID 1 4 Cooling Recommended coolant 6 35 0 25 50 ethylene glycol 50 clean softened water Coolant capacity L U S qts approx 2 84 3 0 Thermostat C F 91 195 Pressure cap rating kPa psi 97 14 High temperature shutdown C F 111 232 High exhaust temperature shutdown C F 102 215 Inlet water line hose ID seawater pump inlet mm in 19 0 75 Outlet water line hose ID mixing elbow outlet mm in 51 2 00 Max water pump inlet pressure kPa psi 34 5 5 0 Section 1 Specifications 1 1 5 Generator Component Specification Rotor field voltage current readings at rated voltage hot 1 6 Torque Component Rotor bolt Torque Nm in Ibs 204 No load 63 Hz volts amps 13 3 82 Generator
83. the wiring harness and the engine generator components Component Hourmeter and wiring Voltmeter Connections Connect the red test lead to the hourmeter positive terminal Connect the black test lead to the hourmeter negative terminal listed in the following tables Check each component using a multimeter to verify that the switches function and that voltage is present at each component Procedure Set the voltmeter to 12 volts DC or greater Start the generator set Results A 12 volt DC reading indicates the wiring harness is functional None see Procedure Disconnect the hourmeter leads and apply 12 volts DC to the hourmeter The hourmeter is polarity sensitive If functional hourmeter operates Stator auxiliary winding B1 and B2 Figure 8 1 TP 5986 4 03 Connect the AC voltmeter leads to the B1 and B2 windings at connector P11 Stop the generator set Set the voltmeter setting 20 volts AC or greater Crank the generator set and allow the set to reach rated its speed Engine Generator Component Testing Relay Controller A reading of 12 15 volts AC indicates a functional B1 B2 winding Section 8 Component Troubleshooting 33 WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe inj
84. the coolant level on closed systems by removing the pressure cap Do not rely solely on the level in the coolant recovery tank Add fresh coolant until the level is just below the overflow tube opening 14 Section 5 Cooling System Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled Note Coolant solution coolant solution of 5096 ethylene glycol provides freezing protection to 37 34 F and overheating protection to 129 C 265 F A coolant solution with less than 5096 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Consult the engine manufacturer s operation manual for engine coolant specifications 5 4 Flush and Clean Cooling System For optimum protection drain flush and refill the cooling system at the interval listed in the operation manual s service schedule Pay special attention to the coolant level Check the coolant level as described earlier Flush and Clean Procedure 1 Remove the hose clamp at the coolant hose See Section 1 for location 2 Remove the pressure cap to simplify draining 3 Drain clean and flush the coolant recovery tank 4 Flush the system with clean water 5 Replace the
85. the engine water The seawater then mixes with the engine exhaust and ejects out of the exhaust outlet The cooling capacity for the 5 7 3E and 4 6EF is 2 84 L 3 0 qts The capacity of the recovery tank is an additional 0 24 L 8 0 oz WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure fromthe cooling system before removing the pressure cap To release pressure coverthe pressure cap with athick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released andthe engine has cooled Checkthe coolant level atthe tank if the generator set has a coolant recovery tank NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces 5 3 Check and Fill Coolant Keep the coolant recovery tank approximately 1 4 full Before filling the cooling system close all petcocks and tighten all hose clamps Use a solution of 50 ethylene glycol and 50 clean softened water to inhibit rust and corrosion and to prevent freezing Add additional coolant mixture as necessary to the coolant recovery tank Periodically check
86. the entire unit with a breathable dust cover TP 5986 4 03 Section 6 Controller Troubleshooting 6 1 Sequence of Operation This section describes the controller sequence of operation during the generator start run stop and fault shutdown modes and describes the relay testing procedures Use this section as a starting point for controller fault identification Use the LEDs on the controller circuit board to assist in the troubleshooting process illuminated LED indicates that the respective relay is receiving power the LED does not indicate whether that relay is energized or working properly 6 1 1 Start Close the start stop switch between N and 47 local or remote The K2 relay energizes and LED2 is illuminated The normally open K2 contacts close to energize the K3 relay LED3 lights fuel pump FP choke heater CHTR antidiesel solenoid ADS ignition IGN and hourmeter HR Flashing of the main field occurs when the K2 contacts close The normally open K3 contacts close to energize the K20 relay The normally open K20 contacts close energizing the starter relay and the starter motor Note The normally closed LOP contacts open when the engine builds oil pressure This may take a few seconds after engine cranking is initiated 6 1 2 The bridged rectifier BR1 receives AC voltage 12 15 volts through the B1 and B2 windings of the stator The K1 relay energizes LED 1 lights The normal
87. the generator set Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Use the following precautions when installing and operating the generator set Do not installthe exhaustoutlet where exhaust can be drawn in through portholes vents or air conditioners If the generator set exhaust discharge outlet is near the waterline water could enter the exhaust discharge outlet and close or restrict the flow of exhaust Never operate the generator set without a functioning carbon monoxide detector Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats and buildings Avoid overloading the craft TP 5986 4 03 Fuel System WARNING Explosion Gasoline vapors 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 A WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors c
88. tion 41 10 1 Schematic Wiring Diagram 42 10 2 Point to Point Wiring Diagram 43 10 3 Reconnection Diagram 100 120 V Rep RP EAR ES 44 10 4 Reconnection Diagram 100 120 200 240 V 60 45 50 H2 edu sve dae aed 44 10 5 Reconnection Diagram 220 240 V 50 Hz 44 10 6 Remote Start Panel 44 10 7 Remote Start and Two Meter Panel 45 10 8 Remote Start and Four Meter Panel 45 Appendix A Abbreviations A 1 Appendix B Common Hardware Application ict tee te os DES A 3 Appendix C General Torque 5 4 Appendix Common Hardware Identification A 5 Appendix Common Hardware List A 6 Table of Contents Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated 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 A DANGER Danger indicates the presence of a hazard that
89. tive lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may resultin hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area
90. ump and line from the generator Remove the alternator coverplate See Figure 9 1 TP 5986 4 03 T 1 Alternator end cover 2 Water pump 3 Vibromount nuts Figure 9 1 14 15 16 17 Alternator end cover Push the brushes into the holder Secure the brushes into position by sliding a retainer into the brush keeping holes Refer to Section 7 5 Remove the brush holder and carefully pull the leads out of the stator housing See Figure 9 3 Remove the generator side vibromount nuts See Figure 9 1 Tilt the generator set up and brace it with a block of wood Figure 9 2 1 Block of wood Figure 9 2 Raising the Generator Section 9 Generator Disassembly Reassembly 37 201 191 1 1 Generator adapter plate bolt quantity 4 12 Bracket brush holder 2 Generator adapter 13 Fan guard bolts quantity 2 3 Spring 14 Fan guard 4 Brush holder 15 End bracket 5 Brush quantity 2 16 Pipe plug 6 Brush holder shim 17 End drive fitting 7 Rotor bolt 18 End bracket bearing 8 Hardened washer 19 O ring 9 Generator overbolt quantity 4 20 Stator assembly 10 Retainer wire 21 Rotor assembly 11 Brush assembly mounting screws quantity 2 Figure 9 3 Alternator Assembly Components 18 Remove the end bracket overbolts See
91. ury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Component Ohmmeter Connections Connect the ohmmeter to the P2 6 and P2 4 leads Start stop switch Connect the ohmmeter to the P2 6 and P2 5 leads To further check the generator set components disconnect the battery and remove the wiring harness plugs from the controller circuit board Use an ohmmeter to check the continuity of the components and to isolate inoperative components Refer to Figure 8 2 and Figure 8 3 Note Before performing ohmmeter checks disconnect the generator set battery to prevent damage to the ohmmeter Procedure Place the ohmmeter on the R x 1000 scale Place the rocker switch in the START position Place the ohmmeter on the R x 1000 scale Place the rocker switch in the STOP position Results If the switch is functional zero ohms continuity Any resistance other than zero or very low ohms replace the switch If the switch is functional zero ohms continuity Any resistance other than zero or very low ohms replace the switch Connect the ohmmeter to the P1 4 and P1 9 leads K20 relay coil and wiring Place the ohmmeter on the Rx 1 scale If functional 85 ohms Low resistance shorted C relay coil and or wiring High resistance open C relay a
92. use severe injury or death Do not work on the generator set until it cools Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank ifthe generator set has a coolant recovery tank Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation TP 5986 4 03 Moving Parts WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place A WARNING 2 Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air TP 5986 4 03 Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator set eng
93. will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial properly 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 TP 5986 4 03 Accidental Starting A WARNING Pars Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Place the generator set start stop switch in the STOP position 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the nega

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