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Industrial Generator Sets

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3. 5 Introduction EIER EGER RAUS Ea nena a ee pd nA E 11 List of Related Materials 11 Service Assistance RS 12 Section 1 Specifications svi ee ee dee ee sdb beeen dee es 13 Tele Introduction eret Een Shalt ae eee ei 13 1 2 20 400 kW 25 500 kVA Permanent Magnet Alternator Concept 13 1 3 Short Circuit Performance 13 1 4 Electrical Val es Sexe de tea ee ees 15 1 5 Torque Values 2 ecu eaten wane stag Laake 15 1 6 Alternator Adapter to Flywheel Housing Torque Values 16 1 7 Drive Discs to Flywheel Torque Values 16 Section 2 Troubleshooting 17 Section Component Testing and Adjustment 23 3 4 Alternator Troubleshooting 23 3 1 1 Troubleshooting Alternator No Output Voltage 24 3 1 2 Troubleshooting Alternator High Output Voltage 25 3 2 Alternator Testing 26 3 2 1 No Output On Any
4. 0 273000 Engine side of flywheel Flywheel Junction box side cover Stud Alternator assembly Spacer Section 4 Alternator Disassembly Reassembly 39 257657 1 LED circuit board cover 2 LED circuit board 3 Photo transistor circuit board 4 Insulating washer 5 Insulator 6 Magnetic actuator 7 End bracket 8 Exciter field assembly 9 Rotor assembly 10 SCR assembly 11 Alternator fan 12 Drive discs 13 Stator assembly 14 Alternator adapter 15 Alternator fan guard Figure 4 2 Alternator Components Typical 40 Section 4 Alternator Disassembly Reassembly 6353 3 12 WARNING AS 5 Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic tra
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6. 1 7 Drive Discs to Flywheel Torque Values Hardware Hardware Type Sequence 20 kW Ford LRG 425 3 8 16 grade 8 stud 53 39 Stud spacer hardened washer nut 20 40 John Deere 3 8 16 grade 8 stud 53 39 Stud spacer hardened washer grade 8 nut 25 60 kW GM 50 60 kW John Deere 3 8 16 grade 8 stud 53 39 60 125 kW GM 80 180 kW John Deere 3 8 16 grade 8 stud 53 39 Stud spacer hardened washer nut 135 150 kW DDC Series 50 60 Gas 1 2 18 grade 8 bolt 60 44 150 275 kW DDC Series 50 60 Gas 1 2 13 grade 8 bolt 130 96 Bolt hardened washer 180 kW Doosan M12 grade 10 9 bolt 122 90 200 kW DDC Series 40 3 8 16 grade 8 stud 53 39 Stud spacer hardened washer grade 8 nut 1 2 13 grade 8 bolt 130 96 M12 grade 10 9 bolt 122 90 200 300 kW John Deere 1 2 13 grade 8 bolt 130 96 1 2 13 grade 8 bolt 130 96 M12 grade 10 9 bolt 122 90 230 300 kW DDC Series 60 Diesel 1 2 13 grade 8 bolt 130 96 250 kW Doosan 3 8 16 grade 8 stud 53 39 Stud spacer hardened washer grade 8 nut 350 400 DDC Series 60 1 2 13 grade 8 bolt 130 96 350 400 kW Volvo 7 16 14 grade 8 bolt 85 63 200 kW Doosan Bolt hardened washer 200 300 kW Volvo Bolt hardened washer 16 Section 1 Specifications TP 6353 3 12 This section contains generator set troubleshooting diagnostic and repair information
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8. Yes Troubleshoot voltage regulator TP 6353 3 12 Section Component Testing and Adjustment 25 3 2 Alternator Testing This section covers alternator testing for the following conditions e No output on any phase e Overvoltage e Fluctuating voltage Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends ofthe leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safegu
9. and 5B at the LED board See Figure 3 5 Shine the flashlight on the photo transistor The DC voltage reading should drop showing the AVR is functioning If voltages are not observed refer to the AVR test Stop the generator set 6353 3 12 Figure 3 5 Checking LED Board 3 4 SCR Assembly and Photo Transistor Board The SCR assembly is located behind the exciter armature and controls current flow to the alternator field The command and sensing circuitry is located on the shaft mounted photo transistor board See Figure 3 6 The generator set will only function if both components are functional The following test determines which component is defective Since it is necessary to remove the end bracket from the set to correctly test these components do not begin this procedure unless there is reasonable certainty that these components are defective See Section 3 1 Alternator Troubleshooting Examine the photo transistor board for visible signs of damage open foil patterns and heat discoloration before removing the entire SCR assembly for testing Refer to Section 3 10 End Bracket Removal and Replacement if the end bracket only needs removal Refer to Section 4 Alternator Disassembly Reassembly for complete alternator disassembly To test the SCR assembly and photo transistor board the following components are needed e One 120 volt 110 watt light bulb with socket e Switch DPST double pole single
10. 1 Check the alternator output leads for proper connections Refer to the wiring diagrams manual 2 Check the stator windings for e Shorted windings for burnt or hot windings Replace the stator if these conditions exist See Figure 3 13 Note Disconnect V7 V8 V9 VO at AC from controller terminal blocks before doing test 2 1 AVR board in junction box 2 Controller terminal strip Figure 3 12 AVR and Connections 2 If there is continuity between V7 and V8 check for continuity in the voltage adjustment circuit leads 1 Windings 2 Leads 67 and 68 With the harness disconnected check resistance between pins 1 and 3 This resistance Figure 3 13 Stator should change as the voltage adjust rheostat is turned Repair or replace defective components as necessary defective voltage adjust rheostat usually results in a nonadjustable voltage 94 Section 3 Component Testing and Adjustment 6353 3 12 Open windings With ohmmeter check each pair of leads for low resistance readings continuity High resistance across A or low resistance continuity across B and ground indicates a faulty stator replace stator See Figure 3 14 014040 040 40 E A Continuity Resistance B No Continuity C No Continuity Figure 3 14 Stator Winding Test 3 7 Alternator Field Hazardous voltage can cause severe injury or death Carefully follow instruc
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12. Standard Standard Spiralock Spiralockt 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 M3 M4 5 6 8 10 12 14 16 M18 3 0 M20 40 Me4 o0 0ooooo00 This metric hex nut s hardness is grade 8 58 Appendix TP 6353 3 12 Appendix F Rotor Assembly Service Tool Y 5718 8L28 A ON 5MG 80 91 2 8 284 TH 80 91 2 GaxosHo 1 OLOHd ASSY HOLOH 80 9 2 STWAOUddY 4 d L STONY GUIHL 06 0 S31ONV SL F x 01 XX HSINIS 6 szo F XXX EVSSONVHTIOL SH33ITIIW NI SNOISN3WIG 031410345 ISIMHIHLO SSTINN 114 QVO OIH L3IN 48 6 H3d 8 5 1 3svadoad 1508 40 8883 38 LSNW WALI 007 sz g oo 9 5 LON 99927 0 suoisueuuiq 79315 HONI vo OF ONIHONITO 413S OIHLIN 15 2 2929 uva 79915 No8uvo
13. Use the chart on the following page to diagnose and correct common problems First check for simple causes such as a dead engine starting battery or an open circuit breaker The chart includes a list of common problems possible causes of the problem recommended corrective actions and references to detailed information or repair procedures 6353 3 12 Section 2 Troubleshooting Maintain a record of repairs and adjustments performed on the equipment If the procedures in this manual do not explain how to correct the problem contact an authorized distributor dealer Use the record to help describe the problem and repairs or adjustments made to the equipment Section 2 Troubleshooting 17 w s L eBeyo pue 40 4991109 S 1 yeu pue oz nuaw o1 sBunies uonejedo OGG eui 01 19 91 OGG e seu eu SIU jepeep 1oinquisip pezuouine ue enuen 38945 945 5 5 enuen 5 enuey enuen uonejeisu 4 N 395 ues
14. 60 44 92 68 130 96 1 2 20 Nm ft Ib 66 49 103 76 146 108 9 16 12 Nm ft Ib 81 60 133 98 187 138 9 16 18 Nm ft Ib 91 67 148 109 209 154 5 8 11 Nm ft Ib 113 83 183 135 259 191 5 8 18 Nm ft Ib 128 94 208 153 293 216 3 4 10 Nm ft Ib 199 147 325 240 458 338 3 4 16 Nm ft Ib 222 164 363 268 513 378 1 8 Nm ft Ib 259 191 721 532 1109 818 1 12 Nm ft Ib 283 209 789 582 1214 895 Metric Fasteners Torque Specifications Measured in Nm ft Ib Assembled into Cast Iron or Steel Assembled into Aluminum Size mm Grade 5 8 Grade 8 8 Grade 10 9 Grade 5 8 or 8 8 M6 x 1 00 62 46 9 5 7 13 6 10 M8 x 125 15 11 23 17 33 24 M8 x 1 00 16 11 24 18 34 25 M10 x 1 50 30 22 45 65 48 10 1 25 31 23 47 35 68 50 12 1 75 53 39 80 59 115 85 12 1 50 56 41 85 63 122 90 14 2 00 83 61 126 93 180 133 14 1 50 87 64 133 98 190 140 16 2 00 127 94 194 143 278 205 16 1 50 132 97 201 148 287 212 18 2 50 179 132 273 201 390 288 3 18 1 50 189 140 289 213 413 305 20 2 50 245 181 374 276 535 395 M20 x 1 50 264 195 402 297 576 425 22 2 50 332 245 507 374 725 535 M22 x 1 50 351 259 535 395 766 565 24 3 00 42
15. 792 5 1 8 3 00 6238 20 3 8 16 3 75 792 8 1 8 5 00 X 6238 13 3 8 16 x 4 50 X 6238 18 3 8 16 x 5 50 6238 25 3 8 16 x 6 50 56 Appendix TP 6353 3 12 Metric 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 60 931 06070 55 931 06075 60 931 06090 60 931 06145 60 931 06150 60 931 08035 60 931 08040 60 931 08045 60 931 08050 60 931 08055 60 931 08055 82 931 08060 60 931 08070 60 931 08070 82 931 08075 60 931 08080 60 931 08090 60 931 08095 60 931 08100 60 931 08110 60 931 08120 60 931 08130 60 931 08140 60 931 08150 60 931 08200 60 931 10040 82 931 10040 60 931 10045 60 931 10050 60 931 10050 82 931 10055 60 931 10060 60 931 10065 60 931 10070 60 931 10080 60 931 10080 82 931 10090 60 931 10090 82 931 10100 60 931 10110 60 931 10120 60 931 10130 60 931 10140 60 931 10180 60 931 10235 60 931 10260 60 960 10330 60 931 12045 60 960 12050 60 960 12050 82 931 12050 60 931 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 6353 3 12 Dimensions 5 0 80 x 55 M6 1 00 x 40 M6 1 00 x 55 M6 1 0
16. Service Industrial Generator Sets Models 20 400 kW Alternators Fast Response Permanent Magnet Alternator NATIONALLY REGISTERED KOHLER PER SYSTEMS ossi California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 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 Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Product Identification Information 2 Safety Precautions and Instructions
17. AHWT AISI ALOP alt ANSI AO APDC API approx AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux AWG AWM bat BBDC BC BCA BCI BDC BHP blk htr BMEP bps br BTDC Btu Btu min CARB CB CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour 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 Air Pollution Control District American Petroleum Institute approximate approximately Air Quality Management District 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 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
18. DC voltmeter 2 12 volt battery or DC power supply 3 Sensing surface Figure 3 19 Speed Sensor Test Section Component Testing and Adjustment 37 2 Touch sensing surface with a flat piece of iron or steel at least 4 1 cm 1 4 cu in in size 3 The voltmeter test reading should equal the source voltage 4 Remove the iron or steel piece from the sensing surface and observe the voltmeter reading 3 10 End Bracket Removal and Replacement Use this procedure to access the SCR and photo transistor board for testing and replacement purposes when it is deemed unnecessary to remove and disassemble the entire alternator assembly Note On some models it is necessary to loosen the generator set junction box to remove the end bracket Remove the six junction box mounting screws and pull the junction box away from the engine to remove end bracket 1 Remove the LED board and cover Disconnect the leads from the speed sensor 2 Remove the screws holding the magnetic actuator and photo transistor board 3 Reach in and remove the leads photo transistor board leads from the SCR assembly This will allow slack when removing the end bracket 4 Remove the four bolts holding the end bracket to the stator 38 Section 3 Component Testing and Adjustment 5 Use a puller tool to remove the end bracket See Figure 3 20 Note To avoid loosening the exciter field magnets do not attempt to remove the end bracket by pound
19. 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 control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge est E Stop etc exh ext F fglass FHM fl oz flex freq FS ft ft Ib ft min ftp 9 genset GFI GND gov gph gpm gr GRD gr wt estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol 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 x W xD height by width by depth HC HCHT HD HET hex Hg HH hr HS hsg HVAC HWT Hz IC ID IEC
20. Hex and Slotted Phillips Slotted au T e e Hex Socket Washers Washer Styles Plain Split Lock or Spring Spring or Wave External Tooth Lock Internal Tooth Lock Internal External Tooth Lock Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company 1 4 20x 1 Metric Screws Bolts Studs and Nats 25 x 20 Threads Per Inch Sample Dimensions American Standard Screws Bolts Studs and Nuts L Length In Inches Screws and Bolts Length In Millimeters Screws and Bolts Distance Between Threads In Millimeters Major Thread Diameter In Millimeters 6353 3 12 Major Thread Diameter In Fractional Inches Or Screw Number Size Metric Number stamped on hardware 5 8 shown Plain Washers 9 32 x 5 8 x 1 16 L Thickness External Dimension Internal Dimension Lock Washers 5 8 Internal Dimension Appendix 55 Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Dimensions Part No Dimensions Part No Dimensions Hex Head Bolts Grade 5 Hex Head Bolts cont Hex Nuts X 465 17 1 4 20 x 38 6238 14 3 8 24 75 inno E X 465 6 1 4 20 x 50 X 6238 16 3 8 24 x 1 25 1 8 Standard X 465 2 1 4 20 x 62 6238 21 3 8 24 x 4
21. If output voltage disappears the problem is in the including connections and or wiring 1 Examine photo transistor board for visible signs of damage open foil pattern or heat discoloration Replace photo transistor board if visibly damaged If overvoltage continues after replacement of photo transistor board proceed to Step 2 6353 3 12 SELECTOR SWITCH T2 T3 T1 AC AMPS SAFEGUARD BREAKER CONTROL RELAY CONTACTS BATTERY GENERATOR FIELD SCR ASSEMBLY 2 Remove green center lead from G terminal and red lead from F terminal of SCR assembly Tape each terminal end of leads to prevent contact with adjacent metal components With safeguard breaker open start generator set The lack of AC output indicates the SCR assembly is functioning properly If overvoltage continues replace the SCR assembly Note When replacing SCR assembly do not exceed torque value of 0 9 Nm 8 in Ib when tightening SCR mounting bolts Section 3 Component Testing and Adjustment 27 4 If overvoltage is measured with the safeguard breaker closed check for an open circuit in leads V7 and V8 to the AVR or controller fuse block If these circuits are open or shorted repair or replace Check the voltage rheostat circuit at leads 67 and 68 Repair or replace as necessary 5 circuits described in step 4 are okay check the AVR as described in Section 3 5 3 2 3 Fluctuating Voltage 1 Check t
22. connections with tools or jewelry while making adjustments repairs Remove all jewelry before servicing the equipment Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed utility electrical system can cause severe injury or death to utility personnel working on power lines 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 ofthe 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 A WARNING Airborne particles Can cause severe injury or blindness We
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24. 0 80 100 6 1 00 100 Flat Head Machine Screws 965 04012 55 M965A 05012 SS M965A 05016 20 965 06012 20 M4 0 70 x 12 5 0 80 x 12 5 0 80 x 16 M6 1 00 x 12 Appendix 57 Metric continued Part No Hex Nuts M934 03 50 M934 04 50 M934 04 B M934 05 50 934 06 60 934 06 64 M6923 06 80 M982 06 80 M934 08 60 M6923 08 80 982 08 80 934 10 60 M934 10 60F M6923 10 80 M6923 10 62 M982 10 80 M934 12 60 M934 12 60F M6923 12 80 M982 12 80 M982 14 60 M6923 16 80 M982 16 80 M934 18 80 M982 18 60 M934 20 80 M982 20 80 M934 22 60 M934 24 80 M982 24 60 M934 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 M4 0 70 5 0 80 6 1 00 6 1 00 6 1 00 6 1 00 8 1 25 8 1 25 8 1 25 10 1 50 10 1 25 10 1 50 10 1 50 10 1 50 12 1 75 12 1 25 12 1 75 12 1 75 14 2 00 16 2 00 16 2 00 18 2 5 18 2 50 20 2 50 20 2 50 22 2 50 M24 3 00 M24 3 00 30 3 50 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 Brass Standard Standard Std green Spiralock Elastic Stop Standard Spiralock Elastic Stop
25. 12 mm 1 4 1 2 in of the adapter lip See Figure 4 12 3 087 R8348 14 Figure 4 13 Supporting Alternator Assembly 10 Fasten the lifting eye and hoist hook to the rotor flange See Figure 4 14 Hoist the rotor to a 1 End bracket lifting eye vertical position taking care not to damage 2 Stator mounting bracket windings laminations or bearing 3 Adapter lifting eye Figure 4 12 Aligning Adapter and Stator 6 Position the adapter hoisting eye opposite of the stator mounting bracket and directly below the end bracket hoisting eye Align the adapter with the stator and start the bolts with washers Lower the stator onto the adapter and tighten the bolts Torque to specifications N Attach hoisting hooks to the adapter as shown in Figure 4 13 Suspend the alternator assembly Before lowering the alternator place boards along the edge of end bracket Maintain sufficient clearance underneath the center of the end bracket to prevent damage to the photo transistor board and magnetic actuator when installing the rotor 8 Rotor shaft bearing installation Use a hydraulic press bearing heater or heavy rubber mallet anda piece of round steel stock with an outside diameter less than the bearing inner race to install the new bearing using measurements taken during the disassembly procedure 1 Hoist hook Figure 4 14 Hoisting Rotor TP 6353
26. 26 3 2 2 Overvoltage 27 3 2 8 Fluctuating Voltage 28 3 3 CED Circuit Board ik Ra MER Lakes 28 3 4 Assembly and Photo Transistor Board 29 3 5 Automatic Voltage Regulator Operation and Adjustment 32 3 5 1 Volt Hz Potentiometer Adjustment 33 3 5 2 Automatic Voltage Regulator 5 34 3 6 berba tus iube de uiae Te MUS 34 3 7 Alternator Field illic Seki ed ve Se id 35 3 8 Exciter Armature ji seeders See bah ge Gea 36 3 9 Speed Sensor Test 37 3 10 End Bracket Removal and 38 Section 4 Alternator Disassembly Reassembly 39 4 1 Disassembly 5 e beet tette 42 42 Beassembly bilan Aaa Ye de tha bee gd mais Sack then a SS ee eae 44 Appendix A Abbreviations 51 Appendix Common Hardware Application Guidelines 53 Appendix C General Torque 54 Appendix D Common Hardware Identifica
27. AC leads if the test indicates the lead is shorted to ground Solder and insulate the splices Use new sleeving when tying the leads to the shaft or heat sink 9 Repair or replace the rotor assembly if the test shows the armature is shorted to ground 6353 3 12 3 9 Speed Sensor Test Follow the procedure outlined below to determine if the speed sensor overspeed fault is emitting a signal 1 With generator set master switch in OFF RESET position connect a DC voltmeter between the positive lead wire 24 at speed sensor and the ground wire 2 The voltmeter should read approximately 8 10 volts DC 2 With the generator set running connect a DC voltmeter negative probe to 0 terminal wire 16 white on speed sensor Place voltmeter positive probe on the positive terminal wire 24 red Voltmeter should indicate approximately 12 volts DC Note During the test the controller leads must remain connected to the speed sensor terminals Slide leads from speed sensor terminals only enough to expose connection for test leads Do not disconnect leads If the speed sensor is emitting a signal check continuity ofthe speed sensor leads wires 2 16 and 24 between controller P1 connector and lead terminals at speed sensor If the speed sensor is not emitting a signal test the speed sensor through the following procedure 1 Connect speed sensor voltmeter and DC voltage source as shown in Figure 3 19 1
28. BIAS POSITIONS 1 amp 3 VOLTAGE BIAS ONLY POSITIONS 2 amp 3 CURRENT BIAS ONLY e TB20 1 CEXURRENT BIAS 27 7 cse C ii i GM63560 A 4 20mA current bias lead input Voltage bias lead input Dip switch for bias input select 1 amp 4 No input bias 2 amp 4 No input bias 1 amp 0 5 VDC voltage bias only 2 amp 3 4 20mA current bias only Switch 2 Phase sensing On 3 Phase Off 1 Phase Grounding pad Voltage adjustment potentiometer 90 Hz V Hz adjustment potentiometer 60 Hz V Hz adjustment potentiometer Switch 1 Frequency select 60 Hz Off 50 Hz Stability potentiometer Figure 3 10 Voltage Regulator GM47955 GM63560 with Bias Adjust TP 6353 3 12 3 5 1 Volt Hz Potentiometer Adjustment This adjustment determines engine speed Hz at which alternator output voltage will begin to drop The bias adjust voltage regulator has DIP switch for specific applications see Figure 3 11 DIP Switch Position On Off SW1 Hz Selection 60 50 3 Phase 1 Phase SW2 Sensing Phase Selection SW3 Bias Input Selection No Input Bias 1 2 8 4 Voltage Bias 163 10 from 3 to 3 volt source Current Bias 2 amp
29. Hz for 60 Hz models or 47 5 48 0 Hz for 50 Hz models as measured on frequency meter See the governor manual for information on engine adjustment 11 Rotate the volts Hz adjustment potentiometer clockwise until voltage level begins to drop as measured on voltmeter When set to these specifications the generator set will attempt to maintain normal output until engine speed drops below the frequency set in the previous step as load is applied 12 Adjust the engine speed to obtain a full load engine speed of 1800 rpm 60 Hz or 1500 rpm 50 Hz Confirm and adjust the output voltage as needed 13 Use the coarse voltage adjustment bias adjust voltage regulator only and then use the controller voltage adjustment potentiometer or remote voltage adjustment potentiometer to make final adjustments to the generator set while running under normal load 14 Readjust stability potentiometer if necessary To determine whether the AVR is functioning properly reduce the engine speed Hz and watch for a corresponding drop in AC voltage At 60 Hz operation the voltage will remain constant until the engine speed drops below 58 Hz approximately If AC frequency drops below 58 Hz the AC voltage will decline At 50 Hz operation the AC voltage remains constant until the engine speed is reduced to 48 Hz approximately Ifthe AVR is not functioning properly refer to the following test to determine the cause of malfunction Section 3
30. IEEE IMS in in Ib int int ext ISO J JIS hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp 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 of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard Appendix 51 kg kg cm kgm kg m3 kHz kJ km kOhm kQ kPa kph kV kVA kVAR kW kWh kWm kWth L LAN LxWxH Ib Ibm ft3 LCB LCD Id shd LED Lph Lpm LOP LP LPG LS Lwa LWL LWT m M m3 m hr m min mA man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilo 1000 kelvin kiloampere kilobyte 219 bytes Kohler communication protocol kilogram kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilow
31. Installing Photo Transistor Board 20 300 kW models shown Figure 4 16 Mounting Photo Transistor Board and WARNING Magnetic Actuator 20 300 kW models shown Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place 46 Section 4 Alternator Disassembly Reassembly TP 6353 3 12 Before connecting to the SCR studs secure the leads with tie wraps Reconnect the photo transistor circuit board white lead to SCR AC stud red lead to stud green lead to G stud and black lead to the remaining AC stud Secure the leads with stop nuts See Figure 4 17 for SCR connections and respective wiring diagram as 13 350 400 kW only Remove the photo transistor circuit board screws Attach service tool Y 5718 or equivalent to rotor shaft and attach photo transistor circuit board to service tool The service tool positions the photo transistor circuit board so that it will pass through the end bracket hole when installing the rotor assembly needed Torque connections to specifications 14 Suspend the rotor over the alternator assembly Lower the rotor field into the stator Be extremely careful while lowering the rotor to avoid damaging the photo transistor circuit board exciter armature field magnets stator windings or rotor laminations See Figure 4 18 Carefully align rotor bearing into end bracket Check for an outer race mea
32. all exceed a torque value of 0 9 Nm 8 in Ib sources of light during this test If both components when tightening SCR mounting bolts are functional the test fixture light bulb will light when the external light source is applied to the photo transistor board Remove the light source the fixture light bulb should go out If the test fixture light bulb does not light or is lit prior to receiving external light source the component being tested is defective in this example the SCR Replace the SCR assembly 8 Note The 350 400 kw components are similar SCR assembly 20 150 kW Photo transistor board SCR assembly 180 300 kW Light source flashlight White wire 120 volt 100 watt lamp Red wire Fuse 1 amp Green wire Switch DPST S1 Black wire 120 volts AC Figure 3 7 SCR Assembly and Photo Transistor Board TP 6353 3 12 Section 3 Component Testing and Adjustment 31 3 5 Automatic Voltage Regulator Operation and Adjustment The following procedure applies to the analog voltage regulator If the unit has a controller with an integrated digital voltage regulator see the controller operation and or service manuals for operation and adjustment The AVR monitors output voltage magnitude and frequency to supply current to the stationary LED board See Figure 3 8 for the voltage regulator adjustments The volts Hz adjustment is factory set and normally requires no further adjustmen
33. 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 Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions Natural Gas Adequate ventilation is mandatory Because natural gas rises install natural gas detectors high in a room Inspect the detectors per the manufacturer s instructions 6353 3 12 Fuel tanks Explosive fuel vapors can cause severe injury or death Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion Store only diesel fuel in tanks Draining the fuel system Explosive fuel vapors can ca
34. charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends ofthe leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Testing the photo transistor circuit board Hazardous voltage can cause severe injury or death When the end cover is removed do not expose the photo transistor circuit board mounted on the generator set end bracket to any external light source as exposure to light causes high voltage Keep foreign sources of light away from the photo transistor circuit board during testing Place black electrical tape over the LED on the circuit
35. effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6353 3 12 cfm CG CID CL cm CMOS cogen com Coml Rec conn cont CPVC crit CRT CSA CT Cu cUL CUL cu in cw CWC cyl D A DAC dB dB A DC DCR deg dept DFMEA dia DI EO DIN DIP DPDT DPST DS DVR E emer ECM EDI EFR e g EG EGSA EIA emiss eng EPA EPS ES ESD cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories 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 Design Failure Mode and Effects Analysis diameter dual inlet end outlet
36. equipment damage Before welding on 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 Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies 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
37. instructions of the megohmmeter manufacturer when performing this test A reading of approximately 500 kOhms 1 2 megohm and higher indicates the field winding is good A reading of less than 500 kOhms approximately indicates deterioration of winding insulation and possible current flow to ground Repair or replacement of the rotor assembly is necessary Repair the and F leads if test should show leads shorted to ground Solder and insulate the splices Use new sleeving when tying leads to shaft or heat sink Replace the alternator rotor assembly if test shows a shorted or grounded winding Section 3 Component Testing and Adjustment 35 1 Megohmmeter connections across and F leads and rotor shaft Figure 3 16 High Voltage Test 3 8 Exciter Armature Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field and exciter armature become hot enough to cause severe burns High voltage test Hazardous voltage can cause severe injury or death Follow the instructions ofthe test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure 1 Disconnect the battery negative lead first 2 Remove the end bracket Refer to Section 3 10 End Bracket Removal and Replacement if only t
38. os 5 12217 L WALI 14 0901 se 81607 680 0001 H3JNVHO o SV X 0 9 8200 079 5 06 NMOG 0708 N 007 el 00 vH gt LE Y N Sz 0 0v 9 7 XZ 0706 X QV3WHLL 0 L 9N Appendix 59 6353 3 12 5 60 Appendix TP 6353 3 12 6353 3 12 5 61 62 5 6353 3 12 6353 3 12 2005 2008 2012 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowercom Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
39. throw 120 volt 10 amp minimum e Fuse 1 amp in holder e 120 volt AC plug with cord e One known functional SCR assembly and photo transistor board Section 3 Component Testing and Adjustment 29 This test simulates the normal operation of the components when the alternator is running In the test known functional component example photo transistor board is matched with a component of unknown quality example SCR assembly If the B 292902 GM36080 1 Photo transistor circuit board 20 300 kW 2 Photo transistor circuit board 350 400 kW 3 SCR assembly 20 150 kW 4 SCR assembly 180 300 kW components do not function normally during the test itis reasonable to assume that the component of unknown quality is defective Test either component in this manner B 258545 A E PENEN m PER Pe PP 11 AC G F AC F N 2 2 N 2 IN R12758 8 A 233999 B Note Part numbers are subject to change 5 SCR assembly 350 400 Figure 3 6 Phototransistor Circuit Board and SCR Assembly Types and Locations Hazardous voltage can cause severe injury or death Carefully follow instructions in the equipment manual when testing or servicing generator set in the presence of voltage Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is p
40. with one of the following prefix designations 4P 4Q 45 40 4UA or 4V Example Gen Model 4511 The letters W and X do not appear in alternator model designations relevant to the information in this manual The generator set is a rotating field alternator with a smaller rotating armature alternator turned by a common shaft The main rotating field alternator supplies current to load circuits while the rotating armature exciter alternator supplies DC to excite the main alternator s field The generator set is a 4 pole rotating field with brushless permanent magnet PM alternator excitation system The PM system provides short circuit excitation current up to 300 at 60Hz approximately 275 at 50 Hz for a minimum of 10 seconds to allow selective circuit breaker tripping Solid state voltage regulator is powered maintenance free and encapsulated for moisture protection The voltage regulator provides 1 2 no load to full load voltage regulation adjustable volts Hz underspeed protection 3 phase RMS sensing and over excitation protection as standard TP 6353 3 12 Section 1 Specifications 1 2 20 400 kW 25 500 kVA Permanent Magnet Alternator Concept The alternator excitation system uses a permanent magnet exciter with a silicon controlled rectifier SCR assembly which controls the amount of DC current fed to the alternator field This type of system uses a voltage regulator which signals the SCR assembly thro
41. 0 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 M8 1 25 x 35 8 1 25 x 40 8 1 25 x 45 M8 1 25 x 50 M8 1 25 x 55 8 1 25 55 8 1 25 60 8 1 25 70 8 1 25 705 8 1 25 75 8 1 25 80 8 1 25 90 8 1 25 95 8 1 25 100 8 1 25 110 8 1 25 120 8 1 25 130 8 1 25 140 8 1 25 150 8 1 25 200 10 1 25 405 10 1 50 40 10 1 50 45 10 1 50 50 10 1 25 505 10 1 50 55 10 1 50 60 10 1 50 65 10 1 50 70 M10 1 50 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 50 x 235 M10 1 50 x 260 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 16100 82 M931 16120 60 M931 16150 60 M931 20065 60 M931 20090 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 M931 24200 60 Dimensions M16 1 50 x 90 M16 2 00 x 90 M16 2 00 x 100 M16 2 00 x 100 M16 2 00 x 120 M16 2 00 x 150 M20 2 50 x 65 M20 2
42. 00 X 6210 3 6 32 Whiz 2 6 bp 75 6238 22 3 8 24 4 50 6210 4 8 32 Whiz 465 18 4 20 x 88 X 6210 5 10 24 Whiz VE 1 4 20 x 1 00 X 6024 5 7 16 14 x 75 X610 1035 465 8 14 20 x 125 X 6024 2 7 16 14 x 1 00 X 465 9 1 4 20 x 1 50 edad d ay x 22 6210 2 1 4 20 Spiralock X 465 10 1 4 20 x 1 75 4 Teda x 200 6210 6 1 4 28 Spiralock X 465 11 1 4 20 x 2 00 2 0 2 6210 7 5 16 18 Spiralock 465 12 1 4 20 x 2 25 x i X E X 6210 8 5 16 24 Spiralock X 465 14 1 4 20 x 2 75 6210 9 3 8 16 Spiralock X 465 21 1 4 20 x 5 00 X 129 15 1 2 13 x 75 X 6210 10 3 8 24 Spiralock X 465 25 1 4 28 x 38 X 129 17 1 2 13 x 1 00 X 6210 11 7 6 14 Spiralock X 465 20 1 4 28 x 1 00 X 129 18 1 2 13 x 1 25 X 6210 12 1 2 13 Spiralock X 129 19 1 2 13 x 1 50 X 6210 15 7 16 20 Spiralock 125 33 5 16 18 x 50 Mu 129 20 1 2 13 1 75 6210 14 1 2 20 Spiralock X 125 23 5 16 18 x 62 125 3 5 16 18 75 129 21 1 2 13 2 00 125 31 5 16 18 88 129 22 1 2 13 2 25 85 3 5 8 11 Standard 125 5 5 16 18 1 00 129 23 1 2 13 2 50 88 12 3 4 10 Standard X 129 24 1 2 13 x 2 75 X 89 2 1 2 20 Standard X 125 24 5 16 18 x 1 25 110 125 34 5 16 18 x 1 50 125 25 5 16 18 1 75 dede 2 13 x X 129 29 1 2 13 x 4 00 Washers X 125 26 5 16 18 x 2 00 3 129 30 1 2 13 4 50 230578 5 16 18 2 25 pe 15 13 x 5 50 Bolt X 125 29 5 16 18 x 2 50 pps ID Thi
43. 3 1096 from 4 10 mA source Figure 3 11 Bias Adjust Voltage Regulator with DIP Switches 1 Place the generator set master switch to OFF RESET position Decision Maker 1 and 3 2 Make the selection for single or three phase sensing at SW2 Bias adjust voltage regulator only 3 Make the frequency selection either 50 or 60 Hz at SW1 Bias adjust voltage regulator OR Place the T1 T2 T3 Jumper is the respective position T1 amp T2 60 Hz or T1 amp T3 50 Hz Non bias adjust voltage regulator 4 Turn stability potentiometer fully counterclockwise 5 Connect a 100 watt light bulb across terminals VO and V7 on controller terminal strip or across terminals on the frequency meter of the Decision Maker 3 controller 6 Startthe generator set With the generator running at no load observe light bulb flicker Excessive light bulb flicker indicates poor stability 7 Adjust stability potentiometer until minimum flicker is obtained 6353 3 12 8 Use the coarse voltage adjustment bias adjust voltage regulator only and then use controller voltage adjustment potentiometer or remote voltage adjustment potentiometer to make adjustments to the generator set while running under normal load if required 9 Set SWS for No Input Bias Refer to Figure 3 11 Bias adjust voltage regulator only 10 Adjust the engine speed to the desired cut in frequency factory setting is 57 5 58 0
44. 3 12 Section 4 Alternator Disassembly Reassembly 45 11 While the rotor is suspended install the photo Installing the photo transistor circuit board Hazardous transistor board insulator board and magnetic voltage can cause severe injury or death Ensure that the actuator Place the photo transistor board lead foil side of the photo transistor circuit board the end of the through the magnetic actuator as shown in shaft and the threaded holes are clean and free of metal i particles and chips Metal debris may short circuit the photo Figure 4 15 Push the lead through the hole the transistor circuit board and cause hazardous voltage in the rotor shaft and then through the exciter laminations generator set Do not reconnect the generator set to the load ending near the SCR assembly until the AC voltmeter shows the correct output 12 Attach the photo transistor circuit board and magnetic actuator to the end of rotor shaft with two mounting screws See Figure 4 16 Cut off excess lead wire leaving enough wire to reach the SCR assembly Strip 50 75 mm 2 3 in of gray insulator jacket from the lead Cut off all exposed uninsulated wire Strip about 0 6 mm 1 4 in of insulation on red and black leads and crimp on 8 electrical terminals part no 283 7 TIR 12758 29 1 Magnetic actuator 2 Photo transistor board Figure 4 15
45. 40 60 M933 12040 82 M961 14025 60 M933 14025 60 M961 14050 82 M961 16025 60 M933 16025 60 M961 16030 82 M933 16030 82 M933 16035 60 M961 16040 60 M933 16040 60 M961 16045 82 M933 16045 82 M933 16050 60 M933 16050 82 M933 16060 60 M933 16070 60 M933 18035 60 M933 18050 60 M933 18060 60 M933 20050 60 M933 20055 60 M933 24060 60 M933 24065 60 M933 24070 60 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 75 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 M14 1 50 x 25 M14 2 00 x 25 M14 1 50 x 50 M16 1 50 x 25 M16 2 00 x 25 M16 1 50 x 30 M16 2 00 x 30 M16 2 00 x 35 M16 1 50 x 40 M16 2 00 x 40 M16 1 50 x 45 M16 2 00 x 45 M16 2 00 x 50 M16 2 00 x 50 M16 2 00 x 60 M16 2 00 x 70 M18 2 50 x 35 M18 2 50 x 50 M18 2 50 x 60 M20 2 50 x 50 M20 2 50 x 55 M24 3 00 x 60 M24 3 00 x 65 M24 3 00 x 70 Pan Head Machine Screws M7985A 03010 20 M7985A 0301 2 20 M7985A 04010 20 M7985A 04016 20 M7985A 04020 20 M7985A 04050 20 M7985A 04100 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 x 12 5 0 80 16 5 0 80 20 5 0 80 25 5 0 80 30 5 0 80 80 5
46. 5 314 649 479 928 685 24 2 00 447 330 682 503 976 720 M27 x 8 00 937 692 1341 990 M27 x 2 00 985 727 1409 1040 M30 x 3 50 1278 943 1829 1350 M30 x 2 00 1349 996 1931 1425 Notes The torque values above are general guidelines Always use the torque values specified in the service manuals and or assembly drawings when they differ from the above torque values The torque values above are based on new plated threads Increase torque values by 15 if non plated threads are used Hardware threaded into aluminum must have either two diameters of thread engagement or a 30 or more reduction in the torque to prevent stripped threads Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 9096 of the yield strength 1 2 3 4 and a friction coefficient of 0 125 54 Appendix 6353 3 12 Appendix D Common Hardware Identification Screw Bolts Studs Nut Styles Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head with Washer Lock or Elastic Grade 5 Flat Head FHM y Square Grade 8 Round Head RHM gym Cap or Acorn Grade 8 9 Hex Socket Head Pan Head Wing 2 al Hex Socket Head Allen Head Cap Hex Socket Head or Allen Head Shoulder Bolt i uy Sheet Metal Screw Stud Drive Styles Hex
47. 50 x 90 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 00 120 M24 3 00 x 160 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M933 05030 60 M933 05035 60 M933 05050 60 M933 06010 60 M933 06012 60 M933 06014 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06030 60 M933 06040 60 M933 06050 60 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 M4 0 70 x 6 M5 0 80 x 30 M5 0 80 x 35 M5 0 80 x 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 30 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 Part No Dimensions Hex Head Bolts Full Thread continued M933 12016 60 M933 12020 60 M961 12020 60F M933 12025 60 M933 12025 82 M961 12030 60 M933 12030 82 M961 12030 82F M933 12030 60 M933 12035 60 M961 12040 82 M933 120
48. 71 red to stud 23 threads and install into flywheel as shown in Figure 4 21 Install studs completely into flywheel Apply Loctite No 242 blue to stud threads on nut side 1 Flywheel studs 24 Figure 4 21 Flywheel Studs 22 Place hoist hooks into the end bracket and adapter eye Raise the alternator assembly and align the studs with the drive discs by turning the flywheel Move the alternator as necessary to work the drive 25 discs over studs When the drive discs are about 25 mm 1 in over the studs install spacers if so equipped See Figure 4 22 1 Drive discs 2 Studs 3 Spacers Figure 4 22 Installing Spacers Loctite is a registered trademark of Loctite Corporation 6353 3 12 26 Move the alternator as necessary to align the alternator adapter and the flywheel housing Fasten and final tighten the adapter to the flywheel housing using bolts and hardened lock washers See Figure 4 23 Torque bolts to specifications 3 083 R8371 17 Figure 4 23 Aligning Adapter and Flywheel Housing Install the hardware attaching the drive discs to the flywheel Do not final tighten at this time Note Some models mount drive discs to flywheel using bolts Some applications use hardened washers Hoist the alternator and engine slightly to remove the wood block s from under the flywheel housing Align the alternator assembly and skid Lower the alternator and tighten the vibromount m
49. Component Testing and Adjustment 33 3 5 2 Automatic Voltage Regulator Test 3 Check for battery voltage at the voltage regulator harness plug pins 2 and 11 with the generator set With the safeguard breaker closed if equipped running If there is nota voltage reading check the safeguard circuit breaker If battery voltage is not present there should be a very low voltage at the main output leads 1 Disconnect the wiring harness connector from the voltage regulator and check for continuity between the voltage sensing leads V7 and V8 pins 4 and 10 See Figure 3 12 If this circuit is open repair 4 While the generator set is running check for or replace An open circuit will normally result in a approximately 1 2 volts DC output at terminals 3B high voltage or overvoltage condition Check the 4 and 5B on the LED board Disconnect the 15 amp fuse separate 3B 5B connector and check for 8 volts approximately at the connector If voltage is not measured at connector check for open or short circuit in wiring back to voltage regulator If a fault exists in the voltage regulator wiring repair or replace as necessary If the voltage regulator wiring tests good replace the voltage regulator Low voltage at the LED circuit board may cause a low output voltage fault 3 6 Stator Note Generator sets use a skewed slanted rotor with a straight stator When replacing either rotor or stator be sure replacement is same as original
50. UES 19 While the rotor assembly is suspended remove the photo transistor circuit board insulator and magnetic actuator Remove F3 G and AC leads from SCR assembly Cut off photo transistor circuit board terminals to remove the circuit board If the photo transistor circuit board is reused leave the leads as long as possible 20 Slowly lower the rotor to the horizontal position Setthe rotor on a wooden surface Take care notto damage the windings laminations or bearing See Figure 4 8 1 Rotor assembly P Figure 4 8 Lowering Rotor 21 Use a hydraulic press to remove the bearing if d needed Make note of the bearing location 207300 RW rotor assembly SNOWN dimensions from the rotor shaft end for reference during installation TP 6353 3 12 Section 4 Alternator Disassembly Reassembly 43 22 Place the alternator assembly on the alternator adapter end in order to remove the alternator adapter and end bracket from the stator Fasten chains to the alternator adapter and lower to a horizontal position Fasten hook to the end bracket eye and hoistto a vertical position See Figure 4 9 1 Exciter magnets Figure 4 10 End Bracket View 3 Position the end bracket on the stator assembly and use bolts to align the holes Use a rubber mallet to mount the end bracket flush with the stator assembly See Figure 4 11 Place the end bracket hous
51. Yes If no DC voltage is If DC voltage of Replace rotor Replace SCR assembly 24 Section 3 Component Testing and Adjustment present check wiring between voltage regulator and LED circuit board Does wiring check out okay No Yes Replace voltage regulator Repair replace wiring 6 12 volts is present replace LED circuit board LED or flyback diode is shorted and or grounded TP 6353 3 12 3 1 2 Troubleshooting Alternator High Output Voltage High output voltage Turn safeguard circuit breaker to Remove and red leads is detected OFF position Does output 1 from SCR assembly Does voltage remain high output voltage remain high No No Yes Turn safeguard circuit breaker to OFF position Measure sensing If no voltage is Replace voltage 190 277 volts at detected replace SCR assembly controller fuse block V7 and V8 photo transistor board If no voltage check for open wiring between high Is voltage Troubleshoot stator and safeguard regulator part of circuit breaker the 550 controller Sensing voltage is If sensing voltage is low or correct check No voltage on all phases No Is voltage balanced on all windings Test stator windings Troubleshoot voltage regulator
52. afely outside Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e 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 andremain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air TP 6353 3 12 Fuel System WARNING 4 W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment
53. ar protective goggles and clothing when using power tools hand tools or compressed air TP 6353 3 12 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 Heavy Equipment WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid 6353 3 12 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 A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field and exciter armature become hot enough to cause severe burns 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 Notice NOTICE Th
54. ard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Follow all safety precautions listed in the front of this manual and the additional precautions within the text Figure 3 1 lists various alternator output conditions and component tests Refer to Figure 3 2 AC Voltage Control for assistance in troubleshooting 321 No Output On Any Phase 1 Check the safeguard breaker if equipped If the safeguard breaker is open close breaker and with set running check AC voltmeter for proper output voltage 2 If proper output does not show then Check wire 1B from safeguard breaker and wire 7N ground to voltage regulator b Check for voltage to safeguard breaker if equipped 3 If all items in step 2 are okay proceed to the LED circuit board flashlight test as described Section 3 3 LED Circuit Board Test and automatic voltage regulator AVR test described Section 3 5 Automatic Voltage Regulator Operation and Adjustment 4 If the tests indicate the LED circuit board and AVR are functioning correctly visually inspect the photo transistor board for damage open foil pattern or heat discoloration 5 If the photo transistor board test appears good proceed to the exciter armature test as described later in this section 6 Ifthe exciter armature test indicates the armature is functioning correctly proceed to the alter
55. ath Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions Perform the following steps prior to disassembling the generator set 1 Disconnect negative lead first and remove starting batteries from work area to prevent fire hazard Disconnect AC powered accessories such as battery charger block heater and fuel transfer pump 2 Shut off fuel supply Drain fuel system as necessary by emptying fuel into proper containers Remove fuel containers from work area to prevent fire hazard Ventilate the work area to clear fumes 3 Disconnect fuel cooling and exhaust systems as necessary to tilt generator set Disconnect output leads or load circuit cables at generator set 4 Any cranes hoists or other lifting devices used in the disassembly or reassembly procedure must be rated for the weight of the generator set Check generator set nameplate or spec sheet for weight Section 4 Alternator Disassembly Reassembly 41 41 Disassembly 1 Disconnect all controller to engine and engine to alternator harnesses and wiring Disconnect alarm horn circuit board connector if equipped LED board and housing and speed sensor Remove the junction box and contr
56. att kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display load shed light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature meter milli 1 1000 mega 108 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm MQ millionm MOhm MQmegohm MOV MPa mpg mph MS ms m sec MTBF metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mean time between failure 52 Appendix MTBO mtg MTU MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA oz pF PF ph 2 PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH RHM rly mean time between overhauls mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not a
57. board before starting the generator set 1 Remove the junction box panels from the generator end of unit and remove the photo transistor board LED board cover See Figure 3 3 1 Photo transistor LED board cover Figure 3 3 Photo Transistor Board Cover 6353 3 12 2 With the generator set running at no load shine a flashlight on the exposed photo transistor board See Figure 3 4 Figure 3 4 LED Flashlight Test 3 Observe the AC output voltmeter High AC output voltage indicates the SCR assembly and photo transistor board are functioning properly The fault is likely in the wiring AVR or LED circuit board as the output voltage should drop to low level when the flashlight is removed If no output is observed check the SCR assembly and photo transistor board 4 If high output voltage exists with the flashlight off stop the generator set and place a small piece of black electrical tape over the phototransistor Restart the unit If the output voltage is reduced there is a source of external light contamination STOP the generator set Find the external light source and eliminate it or block it from reaching the phototransistor circuit board If the output voltage remains high there is a failure in the phototransistor circuit board or SCR assembly 5 With the generator set running approximately 1 2 volts DC should be observed at
58. ck Screw X 25 46 125 250 022 4 X 125 28 5 16 18 x 3 00 X 129 51 1 2 20 x 75 e9 125 22 5 16 18 4 50 129 45 1 2 20 1 25 25 9 156 375 049 6 125 32 5 16 18 5 00 129 52 1 2 20 1 50 25 48 188 438 049 8 125 35 5 16 18 5 50 25 36 219 500 09 10 125 36 5 16 18 6 00 6021 3 5 8 11 1 00 X 25 40 281 625 065 1 4 X 125 40 5 16 18 x 6 50 3 E e 25 85 344 687 065 5 16 ud xX 2 125 43 5 16 24 1 75 6021 1 5 8 11 1 75 2 pe p 25 16 169014 273049 5 8 11 x 2 00 25 26 531 1 062 095 1 2 ERBEN 6021 65 5 8 11 x 2 25 X 25 15 656 1312 095 58 125 39 5 16 24 2 00 6021 6 5 8 11 2 50 KIED BID 4459 454 34 X 125 38 5 16 24 x 2 75 X 6021 7 11 27 25 29 8 5 8 5 25 127 1 062 2000 134 1 X 6238 2 3 8 16 x 62 6021 12 5 8 11 3 75 X 6238 10 3 8 16 75 21 11 lt 2 8 11 4 50 6238 3 3 8 16 88 6021 10 5 841 x 6 00 6238 11 3 8 16 1 00 6021 9 5 8 18 2 50 6238 4 3 8 16 1 25 6238 5 3 8 16 x 1 50 X 6239 1 3 4 10 x 1 00 X 6238 1 3 8 16 x 1 75 X 6239 8 3 4 10 x 1 25 X 6238 6 3 8 16 x 2 00 X 6239 2 3 4 10 x 1 50 238 17 3 8 16 2 25 X 6239 3 3 4 10 x 2 00 X 6238 7 3 8 16 x 2 50 X 6239 4 3 4 10 x 2 50 X 6238 8 3 8 16 x 2 75 X 6239 5 3 4 10 x 3 00 X 6238 9 3 8 16 x 3 00 X 6239 6 3 4 10 x 3 50 X 6238 19 3 8 16 x 3 25 X 792 1 1 8 2 25 6238 12 3 8 16 x 3 50 mney 2
59. e alternator end until the alternator flywheel housing rests on the blocks See Figure 4 3 9 Remove bolts holding the adapter to the flywheel housing 10 Remove hardware holding the drive discs to the 77 flywheel 7 7820 11 Work drive discs over the studs if equipped to 1 Rotor assembly service tool separate the alternator from the engine See 2a Photo Figure 4 4 Figure 4 5 Rotor Assembly Service Tool Y 5718 42 Section 4 Alternator Disassembly Reassembly TP 6353 3 12 15 To remove the rotor assembly hook hoist to adapter and place the alternator assembly on the floor in a vertical position See Figure 4 6 Before lowering assembly place boards along edge of end bracket to prevent damage to the photo transistor circuit board 3 093 1 Drive disc removal R8348 22 2 End bracket support 1 Hoist hook locations Figure 4 6 Alternator Support Drive Disc and Fan Figure 4 7 Rotor Removal Removal 16 Remove the drive discs and fan from the alternator assembly See Figure 4 6 SS 17 Fasten the lifting eye and hoist hook to the rotor flange Hoist the rotor assembly carefully to avoid damaging the photo transistor circuit board exciter armature or exciter field magnets See Figure 4 7 GEGEN 18 350 400 kW only Remove the photo transistor circuit board service tool ROURGUBSURSURM
60. e 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 6353 3 12 Accidental Starting A WARNING Pa Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles clothing Battery acid may cause blindness and burn skin WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the batt
61. ernator then sustains up to 300 of its rated current Sustained high current will cause correspondingly rated load circuit fuses breakers to trip The safeguard breaker kit serves to collapse the generator set s main field in the event of a sustained heavy overload or short circuit Section 1 Specifications 13 Field Main alternator SCR assembly Exciter alternator Exciter field magnets Figure 1 1 Alternator Schematic 14 Section 1 Specifications 6 Exciter armature 7 Optical coupling 8 Starting battery 9 Safegaurd breaker optional TP 5353 1 10 AC voltage regulator 11 LED board 12 Photo transistor board 13 Stator 6353 3 12 1 4 Electrical Values Component Specification Alternator field resistance F F 20 60 kW 2 0 2 9 ohms Alternator field resistance F 80 150 kW 1 8 2 2 ohms Alternator field resistance F F 180 400 kW 1 0 1 5 ohms Exciter armature resistance 20 30 kW 24 pole 0 19 ohms Exciter armature resistance 40 60 kW 24 pole 0 13 ohms Exciter armature resistance 80 150 kW 16 pole 0 27 ohms Exciter armature resistance 180 300 kW 16 pole 0 26 ohms Exciter armature resistance 350 400 kW 8 pole 0 62 ohms End bracket to bearing outer race clearance 20 400 kW 6 35 mm 0 25 in Speed sensor air gap 20 400 kW 0 36 0 71 mm 0 014 0 028 in Speed sensor vo
62. ery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Safety Precautions and Instructions 5 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 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 pr
63. event 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 fromthe 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 Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together 6 Safety Precautions and Instructions Engine Backfire Flash Fire WARNING 7 e 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire cause
64. he end bracket needs removal Refer to Section 4 Alternator Disassembly Reassembly for complete alternator disassembly 3 Disconnect AC leads from SCR assembly 36 Section Component Testing and Adjustment 4 With an ohmmeter check for continuity across the AC leads See Figure 3 17 1 Ohmmeter connections across AC leads Figure 3 17 Exciter Armature Continuity Check 5 Repair the AC leads if damaged or open Solder and insulate the splices Use new sleeving when tying leads to the shaft or heat sink 6 Visually check the exciter armature for shorted winding s and with an ohmmeter check for low resistance readings See Section 1 4 Specifications Electrical Values See Figure 3 17 Low resistance readings indicate a faulty exciter armature requiring replacement of the rotor assembly TP 6353 3 12 7 Using a megohmmeter apply 500 volts DC to the rotor shaft and either AC lead See Figure 3 18 Follow the instructions of the megohmmeter manufacturer when performing this test A reading of approximately 500 kOhms 1 2 megohm and higher indicates the field winding is good A reading of less than 500 kOhms approximately indicates deterioration of winding insulation and possible current flow to ground Repair or replace the rotor 1 Megohmmeter connections across either AC lead and rotor shaft Figure 3 18 High Voltage Test 8 Repair the
65. he alternator output leads for proper connections Refer to the respective wiring diagrams manual 2 Check for loose connections to the AVR LED board photo transistor board or SCR assembly 3 Checkthe stator for shorted or open windings refer to stator testing later in this section 4 Verify the AVR adjustment See Section 3 5 Automatic Voltage Regulator Operation and Adjustment 5 Check the SCR and photo transistor circuit board by performing the flashlight test See Section 3 3 LED Circuit Board Test 3 3 LED Circuit Board Test The following procedure provides information on testing the LED circuit board Certain steps require that the generator set be running When the generator set is not running disable the generator set See the safety precautions listed below Disconnect all load from the generator set during this test WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery 28 Section 3 Component Testing and Adjustment Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery
66. he information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See Appendix F General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance Lu i E EA EA EA Unacceptable Nut Bolt Clearance 1 3 1 1 2 of bolt diameter 2 Min 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths 6353 3 12 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
67. hoot the generator set when no voltage or high voltage is detected The remaining parts of this section give additional and more detailed information about the individual checks tests mentioned in the flowchart Use the flowchart to initially isolate the possible problem 6353 3 12 Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard ci
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69. ing bolts 20 400 kW See chart following Drive discs to flywheel bolts 6353 3 12 20 400 kW See chart following Section 1 Specifications 15 1 6 Alternator Adapter to Flywheel Housing Torque Values Hardware Alternator Hardware Type Sequence 20 kW Ford LRG 425 3 8 16 grade 8 bolt 53 39 Bolt washer 3 20 40 kW John Deere 3 8 16 grade 8 bolt 53 39 25 60 kW GM 3 8 16 grade 8 bolt 53 39 3 8 16 grade 8 bolt 50 60 kW John Deere M10 grade 10 9 bolt 53 39 60 150 kW GM 3 8 16 grade 8 bolt 53 39 3 8 16 grade 8 bolt 53 39 60 180 kw John Deere 7 16 14 grade 8 bolt 60 44 M10 grade 10 9 bolt 65 48 135 150 kW DDC Series 50 60 Gas 7 16 14 grade 8 bolt 60 44 150 275 kW DDC Series 50 60 Gas 7 16 14 grade 8 bolt 85 63 180 kW Doosan M10 grade 10 9 bolt 65 48 200 kW DDC Series 40 3 8 16 grade 8 bolt 53 39 Bolt hardened washer M10 grade 10 9 bolt 65 48 7 16 14 grade 8 bolt 85 63 3 8 16 grade 8 bolt 53 39 200 300 kW John Deere 7 16 14 grade 8 bolt 85 63 M10 grade 10 9 bolt 65 48 7 16 14 grade 8 bolt 85 63 M10 grade 10 9 bolt 65 48 230 300 kW DDC Series 60 Diesel 7 16 14 grade 8 bolt 85 63 85 63 steel cast iron 60 44 aluminum 350 400 kW Volvo 1 2 13 grade 8 bolt 130 96 200 250 kW Doosan 200 300 kW Volvo 350 400 kW DDC Series 60 7 16 14 grade 8 bolt
70. ing eye opposite the stator mounting bracket during reassembly 1 Hoist hook 3 End bracket 2 Hoist hook 4 Adapter Figure 4 9 Removing Alternator Adapter 23 Remove the alternator adapter mounting bolts Fasten the hoist hooks to the end bracket and raise the assembly slightly Tap the alternator adapter loose by using a rubber mallet 24 Lower the stator assembly Remove end bracket mounting bolts Separate the end bracket from the stator by tapping loose with a rubber mallet 25 Remove the exciter magnets from the end bracket See Figure 4 10 4 2 Reassembly 1 Attach the exciter field to the end bracket with four mounting screws See Figure 4 10 Torque to specifications 1 Stator mounting bracket 2 Placethe stator assembly in a vertical position with 2 End bracketlifting eye the end bracket side up Figure 4 11 Mounting End Bracket on Stator Note The end bracket side of the stator assembly has four mounting bosses 44 Section 4 Alternator Disassembly Reassembly TP 6353 3 12 4 Attach the end bracket to the stator using the 9 Place the alternator assembly on the end bracket original hardware Torque to specifications end when installing the rotor Fasten the hoisting hook to the end bracket eye and lower the 5 Attach hoist hooks to the end bracket and suspend alternator assembly to a horizontal position the stator Place the alternator adapter on the floor and lower the stator to within 6
71. ing with a hammer Figure 3 20 Removing End Bracket 6 Pullthe end bracket and exciter field assembly over the exciter armature Be extremely careful to avoid damaging the exciter field magnets or photo transistor board 7 Reverse order of disassembly to reinstall end bracket exciter field assembly TP 6353 3 12 Section 4 Alternator Disassembly Reassembly Before beginning the alternator disassembly procedure carefully read all safety precautions at the beginning of this manual Please observe these precautions and those included in the text during the disassembly reassembly procedure The following procedures cover many models and some steps may not apply to a particular engine Use Figure 4 1 and Figure 4 2 to help understand 1 Voltage regulator terminal strip 2 Voltage regulator Skid 3 Voltage regulator wiring harness 4 Junction box 5 Alternator rodent guard Drive discs Figure 4 1 Alternator Components Typical 6353 3 12 Junction box rear cover component descriptions and general configuration of the alternator Use disassembly procedure as a step by step means to help disassemble the alternator The disassembly procedure provides important information to minimize disassembly time and indicates where special configurations exist that may require taking notes The reassembly procedure includes important alignment steps and provides critical torque specs
72. is 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 Canadian installations only standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 Safety Precautions and Instructions 9 5 10 Safety Precautions and Instructions 6353 3 12 This manual provides troubleshooting and repair instructions for the generator set models listed on the front cover using permanent magnet alternators Wiring diagram manuals are available separately Refer to the generator set controller operation manual for operating instructions Refer to the engine operation manual for generator set engine scheduled maintenance information Refer to the engine service manual for generator set engine repair and overhaul information Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injur
73. ithin 60 clockwise CW or counterclockwise CCW of the bottom position as viewed when the stator is installed on the skid Torque the drive disc s mounting bolts to specifications Remove the two alignment pins or bolts 48 Section 4 Alternator Disassembly Reassembly 18 Attach the hoist to adapter eye and place the alternator assembly in a horizontal position Take care not to damage the rotor or stator Place the hoisting eyes of alternator to the top 19 350 400 kW only Remove the photo transistor circuit board service tool Attach the photo transistor circuit board insulator and magnetic actuator to the rotor shaft using two screws Position the insulator notch opposite the magnetic actuator cutout See Figure 4 20 2 7 Q OQ GM37670B GM39068 A GM41772 1 Photo transistor circuit board 2 Insulator notch opposite of the magnetic actuator cutout 3 Magnetic actuator cutout 4 Rotor shaft Figure 4 20 Photo Transistor Circuit Board Mounting 850 400 models shown 20 UA alternator only Remove the vent sight hole screw from the end bracket located 180 from the grease fitting Use a grease gun and fill with Chevron SRI2 or equivalent lithium based grease until grease is visible at the vent sight hole Wipe excess grease from the end bracket Replace the vent sight hole screw and torque to specifications TP 6353 3 12 21 If studs are used apply Loctite No 2
74. ltage 1 5 Torque Values 20 400 kW Use the torque values shown below during alternator assembly For assembly torque values not shown use the guidelines in Appendix C General Torque Specifications Component Specification Ground lug assembly nuts 2 black amp 16 white 3 6 volts DC 2 black amp 24 red 8 10 volts DC Torque Value 20 400 kW 45 Nm 34 ft Ib SCR assembly terminal nuts 20 150kW 0 9 Nm 8 in Ib SCR assembly mounting bolts 180 400 kW 0 9 Nm 8 in Ib Fan to rotor flange bolts 20 300 kW 29 Nm 260 Ib Fan to rotor flange bolts 350 400 kW 35 Nm 28 ft Ib End bracket to stator bolts 20 300 kW 47 Nm 35 ft Ib End bracket to stator bolts 350 400 kW 95 Nm 70 ft Ib Exciter field assembly to end bracket 350 400 kW 45 Nm 34 ft Ib Terminal block to stator bolts 350 400 kW 9 5 Nm 7 0 ft Ib Drive disks to rotor shaft bolts 20 300 kW 68 Nm 50 ft Ib Drive disks to rotor shaft bolts 350 400 kW 115 Nm 85 ft Ib End bracket grease fitting 180 400 kw 9 5 Nm 7 ft Ib End bracket grease vent screw 180 400 kW 9 5 Nm 7 ft Ib Photo transistor circuit board insulator and magnetic actuator to rotor shaft screws 20 400 kW 4 7 Nm 42 in Ib Alternator adapter to stator bolts 350 400 kW 95 Nm 70 ft Ib Alternator adapter to flywheel hous
75. nator field test as described later in this section 7 If the alternator field test indicates the field is functioning correctly replace SCR assembly or the photo transistor board as described lin Section 3 4 SCR Assembly and Photo Transistor Board Components and Circuits to Test Under Certain Alternator Output Conditions Photo Transistor Board Automatic Voltage SCR Regulator Assembly Alternator Output Condition No Output Safeguard Voltage Adjustment Potentiometer Alternator Stator Exciter Alternator Breaker Armature Field Overvoltage Fluctuating Voltage No output voltage if voltage adjustment potentiometer circuit is open or shorted to ground Overvoltage will occur if an outside light source is present when the LED board is removed If the unit has a 550 controller the voltage regulator is part of the controller see the controller operation or service manual for operation setup and or troubleshooting Figure 3 1 Troubleshooting Guide 26 Section 3 Component Testing and Adjustment TP 6353 3 12 VOLTAGE ADJUSTMENT RHEOSTAT 12 LEAD STATOR PHOTO TRANSISTOR MAGNETS LED BOARD BOARD Figure 3 2 AC Voltage Control Typical 3 2 2 Overvoltage Note If overvoltage occurs disconnect harness plug at If overvoltage continues the problem lies in the photo transistor circuit and or SCR assembly proceed through the following checks
76. nsfer switch remote start stop switch or engine start command from a remote computer WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools 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 A WARNING 4 Ww Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels 6353 3 12 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 ina 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 notreplaceflexiblefuellines 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 de
77. ntact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution High voltage test Hazardous voltage can cause severe injury or death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure Testing the photo transistor circuit board Hazardous voltage can cause severe injury or death When the end cover is removed do not expose the photo transistor circuit board mounted on the generator set end bracket to any external light source as exposure to light causes high voltage Keep foreign sources of light away from the photo transistor circuit board during testing Place black electrical tape over the LED on the circuit board before starting the generator set 8 Safety Precautions and Instructions Installing the photo transistor circuit board Hazardous voltage can cause severe injury or death Ensure that the foil side of the photo transistor circuit board the end of the shaft and the threaded holes are clean and free of metal particles and chips Metal debris may short circuit the phototransistor circuitboard and cause hazardous voltage in the generator set Do not reconnect the generator set to the load until the AC voltmeter shows the correct output Welding on the generator set Can cause severe electrical
78. ocuments 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 Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 12 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 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 91 803315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 TP 6353 3 12 1 1 Introduction The specification sheets for each generator set provide specific alternator and engine information Refer to the respective specification sheet for data not supplied in this manual Consult the generator set operation manual installation manual engine operation manual and engine service manual for additional specifications A permanent magnet alternator is identified
79. oller as a unit 2 Remove the fan guard 3 Remove the LED circuit board cover 4 Remove the alternator rodent guard on the end bracket if equipped 5 Remove the speed sensor from the end bracket 6 Remove bolts from the alternator vibromounts 1 Drive discs 7 Suspend the alternator at both ends with hooks in Figure 4 4 Separating Alternator and Engine lifting eyes Use a hoist to raise the alternator end 12 Use astud remover and remove the studs from the off the vibromounts See Figure 4 3 flywheel if damaged 13 Set alternator assembly on the floor in a horizontal position Remove the support slings or chains 14 350 400 kW only Remove the photo transistor circuit board screws Remove the magnetic actuator and insulator Attach service tool Y 5718 or equivalent to rotor shaft and attach the photo transistor circuit board to the service tool See Figure 4 5 ts si The service tool positions the photo transistor circuit board so that it will pass through the end bracket hole when removing the rotor assembly Note Fabricate service tool Y 5718 using Appendix F information 1 Hook 2 Alternator adapter 3 Wood block s Figure 4 3 Hoisting Alternator 8 Support the engine by placing wood blocks under the flywheel housing Lower th
80. ossible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electricalleads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution 1 Connect components as illustrated in Figure 3 7 If testing the photo transistor board SCR assembly must be known functional f testing the SCR assembly the photo transistor board must be known functional 30 Section Component Testing and Adjustment Note When testing the SCR assembly used on 20 150 kW models connections must make good electrical contact with the SCR foil pattern Secure all SCR connections with terminal nuts to ensure good electrical contact with foil pattern during testing The SCR threaded terminals are insulated from the SCR foil pattern and are not in contact except when bridged by the terminal nut electrical lead terminal etc Do not exceed 0 9 Nm 8 in Ib when tightening the SCR terminal nuts 2 With the cord switch in the OFF position plug in the electrical cord 3 Turn the cord switch to the ON position 6353 3 12 4 Apply light source directly to the photo transistor Note When replacing SCR assembly do not board Shield the photo transistor board from
81. ot mean square round read only memory rotate rotating revolutions per minute right side remote terminal unit room temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor total indicator reading tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer TP 6353 3 12 Appendix Common Hardware Application Guidelines Use t
82. ounting bolts Remove the chains or slings used for suspending the alternator Final tighten the drive discs to the flywheel Torque hardware to specifications Section 4 Alternator Disassembly Reassembly 49 27 Install the speed sensor to the end bracket Adjust 28 Replace the alternator rodent guard on the end the air gap See Figure 4 24 bracket if equipped 29 Replace the LED circuit board cover to the end bracket 30 Install the fan guard 31 Reinstall the junction box and controller 32 Reconnect all controller to engine and engine to alternator harnesses and wiring Refer to the wiring diagrams as required 33 Replace the junction box panels 34 Reconnect the fuel cooling and exhaust systems 0 36 0 71 mm disconnected during disassembly Reconnect the 0 014 0 028 in output leads or load circuit cables at the alternator Open the fuel supply valve 35 Reconnect the starting batteries negative lead last Connect any AC powered accessories such as the battery charger block heater fuel transfer pump etc Speed sensor Wire 16 white clear Wire 24 red Wire 2 black Air Gap 0 36 0 71 mm 0 014 0 028 in Magnetic actuator Figure 4 24 Speed Sensor Air Gap 50 Section 4 Alternator Disassembly Reassembly 6353 3 12 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC adj ADV Ah
83. pplicable 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 programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay rms rnd ROM rot rpm RS RTU RTV SAE scfm SCR S sec SI SI EO sil SNMP SPDT SPST spec specs sq Sq cm sq in 55 std stl tach ro
84. rcuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Section 3 Component Testing and Adjustment 23 3 1 1 Troubleshooting Alternator No Output Voltage No output voltage is detected Is safeguard circuit breaker in ON position Yes m Do flashlight test on photo transistor board See Section 3 3 LED Circuit Board Test Place safeguard circuit breaker to ON position If high voltage is detected check for battery voltage at voltage regulator Is battery voltage present If no voltage is detected remove G and red leads from SCR assembly Tape to insulate lead ends Keep the Check wiring to voltage regulator black lead from the generator field rotor connected to the F terminal on the SCR assembly Jumper G terminal and one AC terminal on SCR Check DC voltage at Yes LED circuit board If high voltage is detected replace photo transistor If no voltage is detected test rotor Do exciter armature and main field If no voltage is present unplug connector at LED circuit board and check voltage windings check out okay board If DC voltage of 6 12 volts is present replace LED circuit board LED is open No
85. 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 air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Combustible materials A 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 recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation fire X prevention procedures Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped s
86. surement of 6 35 mm 1 4 in from bracket to bearing Make sure the photo transistor board and magnetic actuator have clearance below the end bracket 6 Brown 2 Black 7 Blue 3 Red 8 Orange 9 0 1 Green 4 From photo board Exciter armature leads 5 White 10 Rotor field leads Figure 4 17 SCR Connections Figure 4 18 Installing Rotor TP 6353 3 12 Section 4 Alternator Disassembly Reassembly 47 15 Place the fan over the rotor flange and torque bolts to specifications 16 Align the individual drive disks with the hex holes together and with the hole burr sides facing the same direction Temporarily place two alignment pins not supplied or bolts in the outer holes at opposite ends and 90 from the hex hole before installing the drive disk to the rotor shaft The pins help maintain concentric alignment of the individual drive disks during installation See Figure 4 19 Note User supplied pins should be no smaller than 0 025 mm 0 001 in of disc hole Install alignment pins or bolts here Rolled corner Burr side 120 total position drive disk hex hole at stator bottom position or within 60 or CCW from stator bottom position Hex hole Figure 4 19 Aligning and Mounting Drive Disks 17 Attach the drive disc s to the end of the rotor shaft with the hole burr side toward the alternator fan and with the hex hole at the stator bottom position or w
87. t If replacement of the controller circuit board or operation of the generator under extreme loads results in voltage instability adjust the potentiometers according to the following procedure See Figure 3 9 and Figure 3 10 C 255670 GM47955 A 354653 GM63560 60 Hz Voltage Adjustment 50 Hz Voltage Adjustment Stability Adjustment Voltage Adjustment Coarse T1 T2 T3 Jumper DIP Switches Figure 3 8 Voltage Regulator Adjustments Volt Hz Potentiometer 50 60 Hz This adjustment determines engine speed Hz at which generator output voltage will begin to drop Stability Potentiometer Fine tunes voltage regulator to reduce light flicker Voltage Adjustment Potentiometer This adjustment provides a 30 coarse voltage adjustment Bias adjust voltage regulator only 32 Section 3 Component Testing and Adjustment R 049992 0 ASSY 808 T m SC ano 2 Nn RC 8s n 89 1 ET N ET eu Q LOT NO C 255670 B A 354653 C 2 60 Hz voltage adjustment 3 50 Hz voltage adjustment 4 Stability adjustment 1 T1 T2 T3 Jumper T1 amp 2 60 Hz 11473 50 Hz Figure 3 9 Voltage Regulator 255670 354653 SW3 BIAS INPUT SELECT POSITIONS 1 amp 4 NO INPUT BIAS POSITIONS 2 amp 4 INPUT
88. tion 55 Appendix E Common Hardware List 56 Appendix F Rotor Assembly Service Tool Y 5718 59 TP 6353 3 12 Table of Contents 3 5 6353 3 12 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that 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 property damage CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or servic
89. tions in the equipment manual when testing or servicing generator set in the presence of voltage Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field and exciter armature become hot enough to cause severe burns High voltage test Hazardous voltage can cause severe injury or death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure 1 Disconnect the battery negative lead first Remove the end bracket Refer to Section 3 10 End Bracket Removal and Replacement if only the end bracket needs removal Refer to Section 4 Alternator Disassembly Reassembly for complete alternator disassembly Disconnect the and F leads from the SCR assembly 2 With an ohmmeter check for continuity across the F and F leads See Figure 3 15 Resistance readings are shown in Section 1 4 Specifications Electrical Values 3 Check for a grounded alternator field No continuity should exist between the field leads and the rotor assembly TP 6353 3 12 1 Ohmmeter connections across F and F leads Figure 3 15 Field Continuity Check 4 Using a megohmmeter apply 500 volts DC to the or F lead and the rotor shaft See Figure 3 16 Follow the
90. ugh an optical coupling The voltage regulator monitors engine speed and alternator output voltage to turn a stationary light emitting diode LED on or off according to engine speed and output voltage The LED is mounted on the end bracket opposite a photo transistor board which rotates on the shaft The photo transistor picks up the signal from the LED and tells the SCR assembly to turn on or off depending upon the need as dictated by the voltage regulator See Figure 1 1 The voltage recovery period of this type of alternator is several times faster than the conventionally wound field brushless alternator because it does not have to contend with the inductance of the exciter field It also has better recovery characteristics than the static excited machine because it is not dependent upon the generator set output voltage for excitation power Possibly the greatest advantage of this type machine is its inherent ability to support short circuit current and allow system coordination for tripping downstream branch circuit breakers The generator set systems deliver exciter current to the main field within 0 05 seconds of a change in load demand 1 3 Short Circuit Performance When a short circuit occurs in the load circuit s being served output voltage drops and amperage momentarily rises to 600 1000 of the generator set s rated current until the short is removed The SCR assembly sends full exciter power to the main field The alt
91. use 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 Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble LP liquid withdrawal fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi 621 kPa Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble 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 le
92. vels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Moving Parts A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby normal sources of supply Safety Precautions and Instructions 7 CAUTION C j Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never co
93. whiz nut or spiralock nut See Figure 2 3 Follow these SAE washer rules after determining exit hole type a Alwaysuse a washer between hardware and a 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 Figure 2 which depicts the preceding hardware configuration possibilities EN LV 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 53 Appendix General Torque Specifications American Standard Fasteners Torque Specifications Torque Assembled into Cast Iron or Steel Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5 8 32 Nm in Ib 18 16 23 20 10 24 Nm in Ib 29 26 3 6 32 10 32 Nm in Ib 29 26 3 6 32 1 4 20 Nm in Ib 68 60 10 8 _ 96 149 132 1 4 28 Nm Ib 81 72 12 2 108 163 144 5 16 18 Nm in Ib 13 6 120 217 192 29 8 264 5 16 24 Nm in Ib 149 132 231 204 32 5 288 3 8 16 Nm ft Ib 24 18 38 28 53 39 3 8 24 Nm ft Ib 27 20 42 81 60 44 7 16 14 Nm ft Ib 39 29 60 44 85 63 7 16 20 Nm ft Ib 43 32 68 50 95 70 See Note 3 1 2 13 Nm ft Ib
94. y W o ulejs s Burueis 19 19 eu Jo eoejdeu peddinba JI Jo W o eui uoneorqnd 10 uonoes suonoy 2 9 4 4014 esiou euuouqe JO 8AISS92X3 uonduunsuoo Jen eunsseJd Jewod sxyoe Ajueppns sdojs 1ndino 40 ON pejs seop yng 40219 yuelo you suiojdui AS 6353 3 12 TP 20 Section 2 Troubleshooting Joyeujeye pue 195 104 4981109 SI uoisJ8A epoo pue oey 02 nuan o1 10 OGG 01 19191 OGG seu eun JI SIU woad Jepeep 1oingquisip pezuouine ue e eH enuey 12945 oeds s s enuen 1 enuey enuen 19S J01eeuec uec euiBu3 yms 5 v sjy jo
95. y Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference TP 6353 3 12 Introduction The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service at the prescribed intervals Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service List of Related Materials Separate literature contains voltage regulator setup information not provided in this manual when the generator set has a controller with an integrated digital voltage regulator Figure 1 lists the available literature part numbers Literature Part No Manual Description Decision Maker 550 Controller Operation Manual TP 6200 Decision Maker 3000 Controller Operation Manual TP 6694 Decision Maker 6000 Controller Operation Manual TP 6750 Figure 1 Related Literature Introduction 11 Service Assistance For professional advice on generator set 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 KohlerPower com e Lookatthe labels and stickers on your Kohler product or review the appropriate literature or d

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