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Application – Appendix K – Water Treatment OM Plan – Part 2

Contents

1. 5 L2 50 HZ 110 220V 8 0 SOME SETS RATED FOR CT3 NOT USED AE SINGLE PHASE SEE MANUALS 72 79 CT3 NOT USED j SR os TAPE TO INSULATE FROM GROUND ES OPTIONAL i DROOP COMP CT gei V 10 7 A A 1 v LO 7 70g 1 5 I 1 9 1 cn cnc s L1 LO 6 AA 3 O 122AAAA 9 v9 vo THK 5 V8 L 8 VT Ps X METER SCALE METER SCALE 1 METER SCALE OPTIONAL 08009 9 01 LAMP JUMPER 6 7 0 LAMP JUMPER 10 LAMP JUMPER 2 LEAD ALTERNATOR 4 WIRE LOW WYE 2 LEAD ALTERNATOR 4 WIRE HI WYE 6 LEAD ALTERNATOR 4 WIRE WYE 60 HZ 120 208 50 HZ 110 190V 60 HZ 220 380V 50 HZ 220 380V 60 HZ 347 600V 60 Hz 127 220 50 HZ 115 200V 60 HZ 240 416V 50 HZ 230 400V 60 Hz 139 240V 50 HZ 120 208V 60 HZ 277 480 50 HZ 240 416V TO PT1 H2 110 v7 vs 1 1 v9 0 70 OPTIONAL DROOP s L1 be a 12 2 x 254 1 24 x2 Ca Q 3 4 1 2 PT2 L3 VO _ 11 E 46 2 H1 xf 9 7 WN _8 LO 5 42 2 1 Nio i 22 E uc PT3 2 YR 02 GTS H m Nd 2 3 8 Myo OPTIONAL DROOP e 3E 7 COMP CT L3 6 v9 5 11 4 me TO PTi H1 10 50 27 Ke 28 1 1 N OPTIONAL DROOP 2 ES Ia cmo m lC X ec gu CT2 2 2 8
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3. Group Title 5 9 XS o o e 5 Q 9 Q v 9 9 3 5 5 5 O D gt d Ecce E 2 5 5 E SE 5 3 DS NS A U 2 9 O Sis qu a9 E que pas Group No 9a 9b 10 11 11b 12a 13a 13b 14 15 18 21a Variation Number Engine Model 3029DF 60 Hz 9902 9903 4004 3008 3008 28020 1501 1418 3710 1 4499 1901 30290 50 Hz 9902 9903 4004 3008 3008 28020 1501 1418 3710 1 4499 1901 3029TF 60 Hz 9902 9903 4006 3008 3008 2802T 1501 1418 3710 1 4499 1901 3029TF 50Hz 9902 9903 4006 3008 3008 2802T 1501 1418 3710 1 4499 1901 3029TF270 5105 5105 5939 3008 3008 2802T 1501 1453 3710 3500 4499 1901 TP 6141 12 03 Specification Number Index Group Title Be Gd e o S O X a 4 5 x 2 ppp p kd Ss BS 5 5 8 48 5 8 ere eis lt iT X RS 5 S lt lt lt Group No 21b 21c 22 22b 25 26 39a 39b 42 50 51a 51b 51c Variation Number Engine Model 3029DF 60 Hz 1299 5906 9915 9916 9928 1 1 9932 9910 3 3123 621
4. Part 344559 243845 246115 258845 258848 282824 292800 295145 295262 344557 344558 1064 284 10 51 11 51 15 51 53 224998 224685 336674 287945 290262 336677 336678 336679 50 6 70 3 336690 287945 290262 336677 336679 336691 50 6 70 3 360372 287945 336678 336679 25 36 50 6 70 3 360373 287945 336679 336691 25 36 50 6 70 3 354197 352291 352171 847 22 7 712 14 6116 2 02 Kit Parts List Description Qty Part No Description Qty Part No RS 485 Communication 354198 Cable multiconductor ribbon 1 352291 Flexible Exhaust PA 364307 assembly l O RS485 1 352173 Gasket exhaust 1 364326 Controller communications kits 1 TT 847 Adapter flex exhaust 1 364332 Washer lock 172 ID x 333 in OD 10 X057 Bushing reducing 2 x 3 in NPT 1 X 202 21 Spacer 25 OD 937 in 4 X 712 14 Flexible Exhaust PA 364308 Nut hex machine screw 8 32 4 X 72 4 Adapter flex exhaust 1 364333 Gasket exhaust 1 364383 Bushing reducing 2 x 3 in NPT 1 X 202 21 2 Flexible Exhaust 3 364417 Connection Kit Terminal Gasket exhaust 1 364383 Adapter flexible exhaust 1 364421 I 520 Flexible Exhaust Connector 4 in PA 364418 Strip Terminal 1 328913 Gasket exhaust 1 364155 Strip marker 1 328914 Adapter flexible exhaust
5. 13 1 25 Switches and Controls 14 1 2 6 Terminal Strips vss ee 14 1 2 72 DIPSSWIICDeS xbox xr bee Seeded ed 15 13 Expanded Decision Maker 1 16 Section 2 Operation u edi EEUU EE ena bie EE DE 17 21 Checklist e ok RIDERE IRR a ee de a RM RE 17 2 2 Generator Set Exercising 17 23 16 Light Controller Features 17 2 3 1 Normal Operation 17 2 3 2 Prime Power Mode Operation 18 2 3 3 Emergency Stopping 18 2 3 4 Fault Shutdowns 19 2 8 55 Controller Resetting After a Fault Shutdown 19 2 4 Expanded Decision Maker 1 20 2 4 1 Generator Set Starting 20 2 4 2 Generator Set Stopping 20 2 4 3 Fault Shutdowns 20 2 4 4 Controller Resetting After a Fault Shutdown 20 Section 3 Scheduled
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7. Part 334761 222908 222909 290020 324313 354518 364484 364494 934 04 50 6086 6 6128 3 6304 58 334762 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 61 334763 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 62 334764 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 65 334765 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 66 TP 6116 2 02 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker cir
8. 28 3 7 2 Cooling System Component 28 3 7 8 Cooling System Drainage Procedure 28 3 7 4 Cooling System Flush and Clean Procedure 29 3 7 5 Cooling System Refilling Procedure 29 3 8 Radiator Fan Bolt Retorque 29 3 9 Radiator Fan Bearing 30 3210 Battery u oso om pee Mex e ie s 31 31041 Cleaning 5 AME Mis 33 3 10 2 Electrolyte Level Inspection 33 3 10 3 Specific Gravity 33 3 10 4 Charging a e ere a aaa OAs 34 3 11 Detroit Diesel Engine Control Systems 34 Feature Sa ale toiture 34 3 11 2 DDEC Engine Diagnostics 34 3 12 Engine Control Systems 35 3 13 Storage Procedure 1 22522224 uda er e pui Aper PIS 35 3 13 1 Lubricating System 35 3 13 2 Cooling System 35 3 13 3 Fuel System Pa ee ee 36 3
9. SPECIFICATION OPTIONS Flex Connector braided stainless steel water connections available 176 177 Example SP3512FC APPLICATIONS Shopping Malls Office and Tenant Spaces Commercial Buildings restaurants etc Modular Buildings Modular Offices Public Hand Washing Designed to comply with 5 GPM handwashing Service Stations code target outlet temperature 105 110 Schools Concessions Stands Stadiums ADVANCED TECHNOLOGY HIGHEST EFFICIENCY DESIGNED FOR DURABILITY QUALITY FEATURES On Demand Hot Water no delay Prevents Legionella Bacteria Growth Cut Energy Waste flow switch activates heater only on Reduces Liming Calcification and Sedimentation demand no standby heat loss 9996 efficient Complies with Handicap Requirements Continuous Hot Water no storage capacity to run out Ni Chrome Element a unique patented flow path ensures Reduces Installation Cost no T amp P relief optimum heat transfer and extended element life valve needed check local codes Compact Size dimensions 10 75 x 5 25 x 2 875 Easy Installation only one cold water line need be weight 3 Ibs brought to lavatory integral compression fittings on top no sweat connections Mounts on wall at point of use Integral Flow Restrictor Built in to ensure proper temperature rise Complies with U S Federal regulations
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12. P Eh A P A Description Bus Bar 115 150 kW Bracket upper support Bracket support Insulator panel Bracket support Channel insulating Bracket support RS Bus Insulator lug Tag ground Washer lock 262 ID x 743 in OD Washer plain 266 ID x 1 in OD Washer plain 193 ID x 5 in OD Washer spring 39 ID x 81 in OD Bus Bar Support main bus Bracket lower support Channel insulating Insulator lug Tag ground Bus 170 kW Deutz Nut hex Washer plain 406 ID x 1 in OD Washer plain 193 ID x 5 in OD Washer spring 39 ID x 81 in OD Screw hex washer head drill Nut hex 3 8 16 zinc Bus Bar Bracket support LS Bracket support RS Bus Tag ground Bracket bus bar Insulator lug Washer plain 203 ID x 75 in OD Washer plain 193 ID x 5 in OD Rivet pop 187 in Bus Bar Tab identification Tab identification Tab identification Tab identification Insulator panel Bracket support LS Bracket support RS Bus Tag ground Bracket support Insulator lug Washer plain 281 ID x 625 in OD Washer plain 266 ID x 1 in OD Washer plain 344 ID x 875 in OD Washer plain 193 ID x 5 in OD Washer spring 39 ID x 81 in OD Rivet pop 187 in Rivet pop 187 in Nut hex 5 16 18 Bus Lug Kits Bus Lug Bracket lug restrainer Lug terminal aluminum Qty Part No GM10157 KA1 222963 222965 23326
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15. ANO 0 0 lt 6 F 18 01000 100528 5 1 0 NOSIGU 31405 ONINNIdS SI HOIOH mg ue v Mii 28100 00064 LIV 359380 DS NOMA3HO 30 Wld Xlddv NMOHS SV 35001 55 2 581 14 tE WN Sr OL SINN 40 135 300801 B 08 0 LN dx3 81 09 01 2769 355 OL HOldd NMOHS Sv ALAYO NI 28100 00066 LIV weil EE JO NI mo o z WO 702 8776 TWVISNI 9NISv3H2 3Hd OL YOled Ova HLM Q3dIM ONUS 30740 ONS ONINNIdS SI 80108 JIIHM NV31O NMOTIS 38 ASW 53993505 40108 353 1 c 08 01 vVSZLN 1569 on 5 MB9SLvnt ATHNGSSY MOIOM Y NMOHS MAS LYNE ATENASSY HOLVLS 5971 4 0 1 WN ee OL 1 c 18 02080 0000 11 350440 81 11 AIONO vergena Z MBIA 08908 1 696LENO 09 05001 8N SS 0I1 V 6 9n 08 01 c69N 828 8 uid 219 4355 IAY oo 14 395 14 0 2 INO SaaS 200 801915 OL S i SNIHOWLLY OL LAJSNI 3HvMQHvH HildvQv 4 568252 37207 assy om MIIA dX3 09 0 001 6N S5
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17. 21 3 1 Alternator Service uses esee E kt eese cbe rrr ere ees 21 3 2 e Engine Service I edm is 21 3 3 Service Sched le ide etae hr e nee colegas 22 3 4 Alternator Bearing 24 3 4 1 20 300 kW Models 24 3 4 2 350 2000 kW Models with Single Bearing Alternator 24 3 4 8 1250 2000 kW Model with Two Bearing Alternator 24 3 5 Diesel Fuel Systems u eR esee delV 24 3 5 1 Bleeding Air from Fuel System 24 3 5 2 Subbase Inner Fuel Tank Alarm 25 3 6 Gas Gasoline Fuel Systems 25 3 6 1 Gaseous Fuel System Concept 25 3 6 2 LP Liquid Withdrawal Fuel System 26 3 6 3 Gas Natural Gas Conversion for Straight Gas Fuel System 26 3 6 4 Fuel System Changeover 27 3 65 Carburetor Adjustment 27 3 6 6 Fuel System Maintenance 27 TP 6161 1 08 Table of Contents 3 Table of Contents continued 37 el upin dead dee e e aP 28 3 7 1 Coolant Level
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19. uonisod eonieA y eq juo pun siu Z e qissod se esn ulod eui o se eq pinous eu LINN ONILNNOW LL Anfu Jo ujeep ul uejs s siu eunjre 4 uonei do Qo GZ 156 16 JO 5 S HM pue poeJ109 e Buisn juepuedepul UMO S BABY Lem J9jeeu siu nsa JIM 6 9luol o 29 o snoues NO 1331 3dld JSN LON Od GATIVLSNI 51 LINN 3H L 31IHM S3dld 430105 LON OG os Bulog edid Jo sBum euonippe jou og Buidid 1eddoo ou 0 1 10 aiqeyns sinu pue uoiss iduuo2 perddns si yun eu 1 SIY perjddns y eq juo pinoys pue juejsuoo e sejeJodJoout 194224 eu aen Jo ulod eui o ejqissod se 1690 se eq pun sBulAes pue eoueuuojied oL ButuseA ejqeuns senyejeduie 11 pue aye o si uSAo pue MG Geng 3 19NIS 8 Aus Jepun eq Ajjeoyioads si Jejeeu ajBuls IVH3IN39 191
20. Ny Part 334796 222908 222909 290020 324314 336020 354518 364484 364497 364510 912 08025 60 6086 6 6128 3 6306 111 334797 222908 222909 290020 324314 336020 354518 364484 364497 364510 912 08025 60 6086 6 6128 3 6306 112 334798 222908 222909 290020 324314 336020 354518 364484 364497 364510 912 08025 60 6086 6 6128 3 6306 117 334799 222908 222909 290020 324314 336020 354518 364484 364497 364510 912 08025 60 6086 6 6128 3 6306 118 334800 222908 222909 290020 324313 336020 354518 364484 6086 6 6128 3 6306 96 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 1 5 in Breaker circuit 90 100 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A Line Circuit B
21. 47 Kit Parts List Description Qty Part No Day Tank Electronic Control Module GM22735 KA1 Power module 1 224825 Wiring harness extension 1 224881 Wiring harness 1 phase 1 224884 Switch float 1 pole 1 255600 Pump motor assembly 1 A 290024 Sensor float 1 GM16909 Connector 90 deg 1 2 in ID hose 2 X 391 13 Hose 1 X 422 30 Clamp hose 5 1 in 2 X 426 10 Day Tank Electronic Control Module GM22736 KA1 Power module 1 224825 Wiring harness extension 1 224881 Wiring harness 1 phase 1 224884 Switch float 1 pole 1 255600 Pump motor assembly 1 A 290024 Sensor float 1 GM16910 Connector 90 deg 1 2 in ID hose 2 X 391 13 Hose 1 X 422 30 Clamp hose 5 1 in 2 X 426 10 Converter Kits Decision Maker 340 Decision Maker 340 Converter PA 352249 Base converter 1 320306 Cover silkscreen 1 352520 PCB assembly RS232 RS485 converter 1 B 352175 Converter assembly 1 B 352250 Controller communications kits 1 TT 847 Washer lock 172 ID x 333 in OD 4 X 22 7 Nut hex machine screw 8 32 4 X 70 12 Spacer 25 OD 5 in 4 X 712 9 Screw slotted hex washer head mach 4 X 794 3 Controller Retrofit PA 354267 Lamp 28 V 4 8W 2 283420 DEC340 literature 1 350162 Controller assembly DEC340 1 A 347946 Cover Radiator Cap Kits Radiator Cap Cover 258998 Plug 1 253268 Hinge panel 1 258994 Bracket 2 258996 Cover 1 258997 Lock pad 1 289873 CSA For Reconnectible Generators Kits CSA 273741 Decal caution 1 2
22. 5 16 18 Nm in Ib 5 16 24 Nm in Ib 3 8 16 Nm ft Ib 3 8 24 Nm ft 7 16 14 Nm ft Assembled into Aluminum Grade 2 or 5 7 16 20 Nm See Note 3 1 2 18 Nm 1 2 20 Nm 9 16 12 Nm 9 16 18 Nm 5 8 11 Nm 5 8 18 Nm 3 4 10 Nm 3 4 16 Nm 1 8 Nm 1 12 Nm Metric Fasteners Torque Specifications Measured in Nm ft Ib Assembled into Cast Iron or Steel Size mm Grade 5 8 Grade 8 8 Grade 10 9 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 90 of the yield strength and a friction coefficient of 0 125 1 2 3 4 56 Appendix Assembled into Aluminum Grade 5 8 or 8 8 See Note 3 TP 6349 6 07 Appendix D Common Hardware Identification Screw Bolts Studs Hex Head or Machine Head
23. grade 8 5 2 Washer 10 18 2 500 13 3 Screw 3 8 in x 2 1 4 in 4 Screw 3 8 in x 2 3 8 in grade 8 5 Screw 3 8 in x 2 1 2 in grade 8 6 Screw cap 3 8 in x 1 7 8 in 7 336451 Cover kit 8 223620 Gasket 9 GMS32732 Fitting 10 GM21456 O ring 11 336454 Plug fitting 12 223410 Washer 13 Washer 21 64 in x 3 4 in x 0 035 in 14 224095 Spring 15 224058 Valve 16 223422 Seal 17 223451 Plug drain 18 GM21460 Washer Common hardware procure locally AR As Required gt lt lt lt lt x pai 28 6141 12 03 Group 21 Oil d CD42109 CEHA 4 a Var Item Part No Description 1901 1 GM21457 Gasket 1 2 GM21458 Pan oil 1 3 GM21459 Strap 24 4 Washer lock 3 8 in 26 5 Screw 3 8 1 SAE grade 8 24 6 GM21460 Ring copper 1 7 223616 Plug drain 1 8 Plug 1 2 in 14 NPT 1 9 Plug 3 4 in 14 NPT 1 10 Screw cap 120 mm 2 11 GM21461 Intake oil pump 1 12 224035 O ring 1 Common hardware procure locally TP 6141 12 03 29 Group 21b Oil Tube See Group 18 d GE 4 L e CD 25133 Part No Description 1299 1 223559 Gasket 1 2 GM21462 Cover 1 3 Washer 10 x 18 x 2 500 mm 2 4 Screw cap 3 8 in x 7 8 in 1 5 Screw cap 3 8 in x 2 1
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26. PHASE ROTATION C L1 L2 155 4 Remove the controller cover reposition the 6 Reconnect the starting battery negative lead meter scale lamp jumper see Figure 5 5 to match last Place the generator set master switch in the the position for desired voltage shown in RUN position to start the generator set Check the Figure 5 1 Figure 5 2 Figure 5 3 and voltmeter to verify that the voltage changed to the Figure 5 4 Replace the controller cover desired value 20 300 kW Models Adjust the voltage with the 52 2 1 voltage adjustment control on the generator set controller front panel switchgear See Figure 5 6 LOW V7F O MUNG O BAE rauer O Bren ORA ONPE ORRE ORI gt ADV 5849A 1 1 Output voltage adjustment control Figure 5 6 Voltage Adjustment b 350 2000 kW Models Adjust the voltage with the voltage adjustment control on the voltage regulator switchgear Use the applicable 1 Lamp Jumper technical manual for voltage regulator adjustment Figure 5 5 Meter Scale Lamp Jumper 7 Stop the generato
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29. 67 Housing Kits Weather 67 Load Bank 75 Mod bus Converter Kits 76 Modem Kits Computer 76 Module Kit Load Sharing 76 Mounting Kits Silencer 76 Oil Drain Extension Kits 78 Overspeed Shutdown Kits 78 Plug Pipe erret 78 Potentiometer Kit Remote Voltage 78 Potentiometer Kit Speed Adjusting 78 Prealarm Sender Kits 21 79 Rack and Cable Kits Battery 79 Relay Kit Common Failure 79 Relay Kit Run 80 Remote Annunciator Panel Kit 16 Light 80 Silencer Kits Exhaust 81 Software Monitor 82 Sound Shield Enclosure 82 Starting Kits Cold 88 Switch Kits Prime 88 Switch Kits Subbase Fuel Tank Float 88 Tachometer Kit reno 88 Tail Pipe and Rain Cap Kits 88 Transformer Kits Current 89 Ve
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31. Remove all leads from the three AC terminals on the rotating rectifier Figure 4 3 Make reconnection later assembly hub See notes as needed for Remove the leads from the terminals on the rotating rectifier assembly hub Make notes as needed for reconnection later Remove the diode assembly plates The varistor is accessible after the screws are removed Lift off the rotating rectifier assembly hub and magnetic actuator Section 4 Alternator Disassembly Reassembly 10 11 12 13 1 AC terminals 2 Diode terminal F red 3 Diode terminal F blue Remove bolts from the alternator vibromounts Suspend the alternator at both ends with hooks in lifting eyes Use a hoist to raise alternator end off vibromounts See Figure 4 4 Support the engine by placing wood blocks under the flywheel housing Lower the alternator end until the flywheel housing rests on the blocks See Figure 4 4 Remove the bolts holding the adapter to the flywheel housing Remove the hardware attaching the drive discs to the flywheel GM32507 TP 6349 4 4 Varistor 5 Mounting screws 6 Magnetic actuator Figure 4 3 Rotating Rectifier Assembly Hub and Components 1 Hook 2 Alternator adapter 3 Wood block s Figure 4 4 Hoisting Generator TP 6349 6 07 14 Work drive disc
32. ch OD ch 6141 12 03 Group 5 Fuel Injection System CD40816 CDP45524 12 TP 6141 12 03 Group 5 Fuel Injection System Qty Var Item Part No Description 1603 1641 16 16 164H 1 GM21495 Pump fuel injection 1 1 GM21496 Pump fuel injection 1 1 GM21497 Pump fuel injection 1 1 GM21498 Pump fuel injection 1 1 GM32727 Pump fuel injection 1 2 GM21499 Key shaft 1 1 1 1 1 3 224172 O ring 1 1 1 1 3 GM17487 O ring 1 4 223471 Washer lock 1 1 4 GM21501 Washer 1 1 4 GM17456 Washer 1 5 224161 Nut 1 1 1 5 GM21500 Nut 1 1 6 Nut 4 4 3 3 3 7 GM21503 Fuel line no 1 1 1 1 1 1 8 GM21504 Fuel line no 2 1 1 1 1 1 9 GM21505 Fuel line no 3 1 1 1 1 1 10 223572 Clamp 1 1 1 11 224071 Clamp 1 1 1 12 Screw cap M6 x 12 1 1 1 1 1 13 Not used 14 GM21502 Pinion 1 1 14 224238 Gear 1 1 1 15 223460 Fitting 1 1 15 223820 Fitting 1 1 1 16 GM21506 Fuel line 1 1 16 See table below Fuel line includes items 17 18 1 1 1 16 See table below Fuel line includes items 17 18 1 1 1 17 360141 Nut 2 2 2 18 223476 Packing 2 2 2 19 223504 Tube includes items 17 18 2 2 2 2 2 20 223710 Plug 1 21 223476 Packing 1 22 GM21455 Line fuel includes nut and sealing washer 1 1 1 1 22 GM21453 Nut not shown 2 2 2 2 22 GM17494 Washer sealing not shown 2 2 2 2 22 GM32728 Line fuel 1 23 222764 Fitting 1 1 23 360037 Fitting includes item 24 1 1 1 24 222760 O ring 1 1 24 360178 O rin
33. ee uv 8 Group 21b Fill Tube 30 Group 4a 9 Group 21c Oil 31 Group 4b Valve 10 Group 22a 32 Group 4c Rocker Arm Cover 11 Group 22b Connecting Rod 32 Group 5a Fuel Injection System 12 Group 25 Oil Pump 33 Group 5b Fuel Injection Nozzle 14 Group 26 Front Plate 34 Group 7 Cylinder Block 16 Group 39a Cylinder Head Gasket Set 35 Group 8a 18 Group 39b Overhaul Gasket Set 35 Group 8b Crankshaft Pulley 19 Group 42 Short Block 36 Group Cylinder Head and Valves 20 Group 50 Turbocharger amp Oil Lines 37 Group 9b Valves 20 Group 51a Alternator 38 Group 10 Oil Filter A Dipstick 21 Group 51b Alternator Brackets 39 Group 11a Starter 22 Group 51 Alternator Components 40 Introduction This manual contains a list of service replacement parts for John Deere diesel fueled 3029 series e
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35. 3 Use Figure 5 1 Figure 5 2 Figure 5 3 and Figure 5 4 to determine the generator set voltage configuration Note the original voltage and reconnect as needed Route leads through current transformers CTs and connect them according to the diagram for desired phase and voltage Note Position current transformers CT1 CT2 and CTS with the dot or HI side toward the generator set Section 5 Generator Set Reconnection 41 1 9 eunBi4 uonoeuuooeH 195 100 120 2 60HZ 220 240V 50HZ 220 240 50HZ 100 120 200 50 2 2 2 3 AA 4 Mul AM 5 1 2 3 AAA 4 1 7 L li Lw 18 J 1 L CS Qu 2 12 1 1 H 1 0 GRD GRD 10 NEUTRAL 0 NEUTRAL O NEUTRAL 10 NEUTRAL 0 NEUTRAL gt LO LO p 0 10 0 GRD GRD GRD GRD GRD GROUND GROUND GROUND GROUND GROUND s 11 12 LOAD 2 74 SIDE 4 CIRCUI 2 BREAKER o o LINE LINE SIDE SID x gt 1 4 2 ki 1 4 2 3 2 4 1 de do nw 1 STATOR LEADS STATO EADS 00 STATOR LEADS STATOR LEADS 200 240 VOLT 20 1 2 WIRE 5 ADC2100 REGULATORS PERMANENT 2100 R 5 LD REGULATORS 1919 41 80 1 H VS 8S AGV 5 pjer4 punom pue zouben MA 0
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37. Adjust the stability pot Determine the source of H Tighten of instability Are there load clockwise to just the point current spikes connections No Does the voltage regulator check out okay See Section 3 4 2 No Contact service department for assistance Figure 3 3 Troubleshooting Generator Set Unstable Voltage TP 6349 6 07 the load disturbance and check for faulty equipment Refer to the generator set controller operartion manual or the respective parts catalog for the list of related literature Section 3 Alternator Troubleshooting 27 3 4 2 Voltage Regulator Test The generator set is equipped with a wound field voltage regulator See Figure 3 4 4 gd 6349 3 12 volt battery or DC voltage supply Voltage regulator 12 pin plug pin insertion end shown 250 volt 100 watt lamp 200 240 VAC optional 1 amp fuse Single pole single throw switch 1 2 step up transformer White wire 100 120 VAC Black wire Potentiometer 1 Zooouoosom Figure 3 4 Voltage Regulator Test with User Fabricated Adapter Harness The voltage regulator monitors output voltage magnitude to control the current to the exciter
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42. Communication module circuit board and or gauge driver circuit board Figure 6 19 Communication Module Circuit Board Location and Connection 54 Section 6 Accessories TP 6161 1 08 6 31 Communication Modules Circuit Board Versions GM47242 Circuit Board This is the communication module for all models except the 450 500REOZVB models and is superceded by GM49791 1 See Figure 6 20 H DC mc DC I gt mo mo 11 11 sm sm 00 GM47242 a 1 P9 connector 10 position 2 SW2 DIP switches set to open position 3 TB5 Terminal connectors 4 P8 connector 24 position Figure 6 20 Communication Circuit Board GM47242 GM49791 1 Circuit Board This is the communication module for all models and includes the gauge driver provision needed to drive the oil pressure and water temperature gauges for some models requires application software version 1 23 or later See Figure 6 21 GM49791 2 Circuit Board This is the interface circuit board with the gauge drivers required on the 450 500REOZVB models only For communication purposes replace GM49791 2 with GM49791 1 GM49791 2 is mounted in the communication module location but does not provide the communication function See Figure 6 22 6 32 Circuit Boards Views Figure 6 20
43. 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 exhaustfumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely 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 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 Fuel System WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive
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45. MADE IN USA Field Serviceable Element replaceable cartridge element 1 year warranty Warranty Full Factory Warranty Heaters are guaranteed against failure due to leaks of Heater Body Element Faucet Aerator with excellent spray pattern supplied Assembly for a period of FIVE YEARS with unit 220 s High Temperature Limit Switch protects against element Hands Free sensor and metering faucet compatible burn out with reset button SUGGESTED SPECIFICATION Tankless Water Heater shall be an Eemax Model with vac to heat 0 5 GPM Rw rating volage a temperature rise of degrees F Unit shall have amperage ABS UL 94Vo rated cover Element shall be replaceable cartridge insert Unit shall have a replaceable filter in the inlet connector and a flow regulator in the outlet connector Element shall be iron free nickel chrome material Heater shall be fitted with 38 compression nuts and sleeves to elimi nate need for soldering Heater shall be installed upright with water connections on top only Hot water storage tanks prohibited Unit shall be Eemax or approved equal NOTE Refer to rating chart for product information NOTE Flow Activated 0 5 GPM OPERATING PRESSURE 25 PSI 150 PSI OPTIONAL FLEX CONNECTOR ACCESSORY FC Stainless steel braid reinforced flexible water connector 1 3 8 C x 1 2 FIP 16 faucet supp
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47. 00060 A 5 G 02 02 ALR op oa A Su 00060 f ON Part No 334083 290020 336020 352323 352324 BLK GM10411 GM10412 M912 08025 60 X 6086 6 X 6306 111 334084 222995 BLK 222999 290020 GM15301 X 25 45 X 50 41 X 6304 16 334085 222995 BLK 222999 290020 GM15301 X 25 45 X 50 41 X 6304 85 334086 290020 336020 352323 352324 BLK GM10411 GM10412 M912 08025 60 X 6086 6 X 6306 117 334087 222995 BLK 222999 290020 GM15301 X 25 45 X 50 41 X 6304 85 334088 290020 336020 352323 352324 BLK GM10411 GM10412 M912 08025 60 X 6086 6 X 6306 117 334089 222996 BLK 222999 290020 360763 GM15301 X 6086 6 X 6304 88 X 6308 1 Description Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Cover side Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit
48. 1 BUS 2 2 BUS FOR 457 4S7 4V7 459 4V9 4 4V7 459 4 9 4511 511 4 11 4513 4515 4037 40 9 4AU10 4 11 4813 4515 4UAT 4039 4AU10 USE 3 BUS FOR 4UA13 AND 4UA16 USE 2 BUS FOR 4UA13 AND 4UA16 GROUND BUS 10 11 12 4 5 6 10 11 12 1 10 4 6 10 12 4 5 6 CURRENT TRANSFORMERS CT1 CT3 1 7 2 8 3 9 1 7 2 8 3 9 6 7 4 8 5 9 1 7 2 8 5 1 12 10 D H GROUND BUS B D H GROUND BUS B D H GROUND BUS B D GROUND BUS GROUND BUS B D H GROUND BUS NOTE CURRENT TRANSFORMER DOT OR HI RD GENERATOR TORQUE TERMINAL BOARD HARDWARE TO 45 Nm 84 FT LBS 2 Figure 1 6 Reconnection Decal 6349 6 07 Section 1 GM39792 B Specifications 17 Notes 18 Section 1 Specifications TP 6349 6 07 This section contains generator set troubleshooting diagnostic and repair information Use the chart on the following pages 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 TP 6349 6 07 Section 2 Troubleshooting Maintain a record of repairs and adjustments performed on the equip
49. Install the hardware attaching the drive discs to the flywheel Do not final tighten at this time Note Some applications use hardened washers Do not substitute with non hardened washers Hoist the alternator and engine slightly to remove the wood block s from under the flywheel housing Align the alternator assembly and the skid Lower the alternator and tighten the vibromount mounting bolts Remove the chains or slings from the alternator Final tighten the drive discs to the flywheel Torque the hardware to specifications Mount the rotating rectifier assembly hub and magnetic actuator to the rotor shaft using two screws Torque to specifications Section 4 Alternator Disassembly Reassembly 24 Replace the diode assembly plates and varistor if removed The diode assembly plates are color coded The positive diode assembly is blue and the negative diode assembly is red See Figure 4 20 GM32507 TP 6349 4 AC terminals Diode terminal F red Diode terminal F blue Maristor Mounting screws Magnetic actuator Figure 4 20 Rotating Rectifier Assembly Hub and 25 1 2 3 4 5 6 7 8 9 Components Reconnect the wiring to the three AC terminals and terminals of the rotating rectifier assembly hub See Figure 4 21 Torque to specifications GM32507 TP 6349 4 AC terminal no 1 AC terminal no 2 AC terminal no 3 Blue diode terminal no 3 connect to AC ter
50. Local Starting Move the generator set master switch to the RUN position to start the generator set at the controller Normal Operation Note The alarm horn sounds and the Not in Auto lamp lights when the generator set master switch is not in the AUTO position Section 2 Operation 17 Note transient start stop function of the 16 light controller prevents accidental cranking of the rotating engine If the generator set master switch is momentarily placed in the OFF RESET position and then is returned to the RUN position the generator set slows to 750 rpm 25 Hz and recranks before returning to rated speed Automatic Starting Move the generator set master switch to the AUTO position to allow startup by an automatic transfer switch or a remote start stop switch Refer to the wiring diagrams for remote switch connection information The engine cranks up to 30 seconds continuously or 75 seconds cyclically crank 15 seconds rest 15 seconds crank 15 seconds etc before shutting down on an overcrank fault Note The engine ECM may limit the crank cycle even if the controller is set to a longer time period Select the cyclic or continuous cranking mode on the controller circuit board See Section 1 2 7 DIP switches Stopping Run the generator set without load for 5 minutes to ensure adequate engine cooldown To stop the generator set place the generator set master switch in the OFF RESET position and wait until the
51. 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 applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw 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
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53. Terminal Strip 1 Description Terminal strip for connecting generator set accessories such as an emergency stop switch a remote start stop switch audiovisual alarms etc Refer to the wiring diagrams for information on connecting accessories to the TB1 terminal strip Terminal strip for selecting the remote start stop switch inputs and prime power mode Communication module connection for remote serial annunciator RSA or network communication RS 485 communication connection for Modbus to download new application program software or for connecting the remote serial annunciator CAN engine communication connection Figure 1 7 Controller Terminal Strips Connections GM28725 TB1 TB1A terminal strip TB3 TB1B terminal strip TB2 terminal strip P8 annunciator panel lamp and RSA communication module connections P21 for Modbus RS 485 communication connection P22 for CAN engine communication connection SW1 DIP switch 8 positions P7 RSA communication module connection Fuses Figure 1 8 Controller DIP Switches TP 6161 1 08 1 2 7 DIP Switches The controller circuit board contains eight DIP switches see Figure 1 9 Switch Position Description Open Closed Overspeed selection 60 Hz 70 Hz Temperature Cooldown Cooldown Cooldown Enable Disabled Functional Crank Mode Selection Cyclic Continuous Engine Comm Setting
54. Weekly Circuit breakers fuses Monthly Wire abrasions where subject to motion Quarterly Safety and alarm operation Six Months Tighten control and power wiring connections Yearly Transfer switch main contacts Yearly Voltage sensing device relay adjustment Yearly Wire cable insulation breakdown 3 Years or 500 Hours Engine and Mounting General inspection Weekly Governor operation lubricate moving parts Monthly Air cleaner service Six Months Choke carburetor adjustment Six Months Governor oil mechanical governor only Yearly Ignition components Yearly Injector pump and injector flow rate pressure spray pattern Yearly Valve clearance 3 Years or 500 Hours Bolt torque 3 Years or 500 Hours Remote Control System etc Compartment condition Weekly Remote control Monthly Run generator set Monthly Alternator General inspection Weekly Rotor and stator Yearly Bearing condition Yearly Exciter Yearly Voltage regulator Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier disconnected Yearly Blow dust out of alternator 2 Years or 300 Hours General Condition of Equipment Any condition of vibration leakage noise temperature or deterioration Wee
55. 12 tolerance Early alternators with part numbers GM33000 xx have resistance values of 17 2 ohms 14 Section 1 Specifications TP 6349 6 07 1 4 Specifications Electrical Values Use the values shown in Figure 1 2 and Figure 1 3 during alternator testing Hot Exciter Field No Load Readings at Rated Voltage Alternator Model Volts Amps 4P4W 4P5W 4P5BW 4P7W 4P7BW 4P8W 4P10W 4S7W 4S9W 4S11W 4S13W 4S15W 4UA7W 4UA9W 4UA10W 4UA13W All values are at 25 C 77 F Figure 1 2 Exciter Field Voltage Current Values Stator output voltages with separately excited alternator using a 12 volt battery gt 150 Volts gt 300 Volts Stator main windings volts Stator auxiliary winding volts All values are at 25 C 77 F Figure 1 3 Stator Output Voltages TP 6349 6 07 1 5 Specifications Torque Values Use the torque values shown in Figure 1 4 during alternator assembly For assembly torque values not shown use the guidelines in Appendix C General Torque Specifications Component Torque Value 20 60 10 8 Nm 8 ft Ib 80 300 45 Nm 34 ft Ib 20 170 61 Nm 45 ft Ib 180 300 115 Nm 85 ft Ib 20 170 26 4 Nm 19 5 ft Ib 180 300 35 Nm 28 ft Ib 180 300 95 Nm 70 ft Ib Stator to generator adapter 5 180 300 95 Nm 70 ft Ib 180 300 9 5 Nm 7 ft Ib 180 300 45 Nm 34 ft Ib 180 300
56. 56 Section 6 Accessories TP 6161 1 08 Appendix Abbreviations The following list contains abbreviations that may appear in this publication A amp adj ADV Ah AHWT alt Al ANSI AO AR AS ASE ASME assy ASTM 5 auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk htr bps br BTDC Btu Btu min C cal CAN CARB CB cc CCA CCW CEC cert cfh TP 6161 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
57. 6304 79 334772 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 82 334773 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 83 334774 222908 222909 290020 324313 354518 364484 364495 BLK 364508 X 6086 6 X 6128 3 X 6304 88 334775 222908 222909 290020 324313 354518 364484 364495 BLK 364508 X 6086 6 X 6128 3 X 6304 89 25 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Washer spring 39 ID x 81 i
58. 71 2 Kit Parts List Description Battery Charger 24 Volt Decal connection Fuse 5 A 250 V Connector plug 12 position Clip speed Fuse 25 A 125 V Transformer 120 240 V 26 6 V Decal warning connection Clip cable Holder fuse Spacer Lamp 120 V 33 W Decal Strip terminal Ammeter 0 15 DC Module SCR Fuse 7 A 250 V Voltmeter 0 50 V DC Harness wiring 12 24 V float chargers Marker strip Marker strip Retainer Block terminal Nut captive 6 32 Box battery charger Door silkscreen Decal battery charger 3 5 x 5 in PCB assembly Charger assembly battery Charger battery automatic Washer lock 262 ID x 743 in OD Washer lock 172 ID x 595 in OD Washer lock 146 ID x 53 in OD Washer lock 146 ID x 285 in OD Screw slotted pan head machine Screw slotted pan head machine Screw slotted pan head machine Screw cross recess pan head machine Screw slotted pan head machine Screw slotted pan head machine Screw cross recess round machine Screw cross recess pan head machine Screw slotted pan head machine Screw cross recess machine Screw Phillips hex crimptite Nut hex machine screw 6 32 Qty a lt lt APH Ny Part 292864 233966 239298 241605 257442 262389 262395 262397 262399 263156 287948 291208 292387 292940 292941 292946 292948 292957 29
59. 934 04 50 6086 6 6128 3 6304 51 334735 222908 222909 290020 324314 354518 364484 364491 934 04 50 6086 6 6128 3 6304 52 334736 222908 222909 290020 324314 354518 364484 364491 934 04 50 6086 6 6128 3 6304 54 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex Amm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex 4mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex 4mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circui
60. Bracket circuit breaker Spacer 281 x 500 x 375 steel Insulator Bus load Bracket circuit breaker Tag ground Bus line Channel insulating Washer plain 406 ID x 1 in OD Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 250 A Breaker circuit Screw slotted pan head machine Marker wire Marker wire Marker wire Nut hex 3 8 16 zinc ININN N P E 3 HAHAHA 222835 222908 222909 265861 290020 324313 336632 354518 360763 GM13940 X 25 118 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 163 X 6304 95 X 6308 1 X 750 14 X 750 15 X 750 16 X 83 7 Line Circuit Breaker Dual 450 350 19646 1 Cover side Bracket circuit breaker Bracket circuit breaker Relay protective Transformer curr 400 5 round Insulator Bus load Tag ground Bus line Plate Bracket circuit breaker Spacer 375 ID x 75 OD x 5 in Screw slotted round head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 450 A Breaker circuit 350 A Screw pan head machine 40 o bb 0 OD 2 222835 222908 222909 227266 248874 290020 324313 354518 365606 GM19468 GM19660 X 400 104 X 51 53 X 6086 6 X 6128 3 X 6304 167 X 6304 168 X 6308 2 Description Qty Part No Line Circuit Breaker
61. Charger Malfunction Engine Ground Alarm Terminal Strip Figure 6 6 Float Equalize Battery Charger Connections 6 1 9 Line Circuit Breaker The line circuit breaker interrupts generator output if an overload or short circuit occurs Use the line circuit breaker to manually disconnect the generator set from the load during generator set service See Figure 6 7 Figure 6 7 Line Circuit Breaker Section 6 Accessories 49 6 1 10 Low Fuel Switch Some gaseous fueled models offer a low fuel pressure switch as part of the Engine Prealarm Senders kit The low fuel pressure switch connects to the same terminal as the low fuel level switch on diesel or gasoline fueled models See Figure 6 8 and Figure 6 9 See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification Note The subbase fuel tank or main tank may include the low fuel level switch The fuel tank supplier typically provides the low fuel level switch LOW FUEL SWITCH OPTIONAL LOCATED IN MAIN TANK AS PROVIDED BY FUEL TANK SUPPLIER GROUND GM16088A A Figure 6 8 Low Fuel Switch Level or Pressure Switch Rating 12 volts DC minimum 0 5 amp minimum Wiring Recommendation mm ft 30 5 100 153 500 305 1000 Gauge Figure 6 9 Switch Rating and Wiring Recommendation 6 1 11 Remote Annunciator Kit M A remote annunciator
62. Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit Qty GY Ny 9 3 lt Ny G N 0 6 Part 334135 222996 BLK 222999 290020 360763 GM15301 X 6086 6 X 6304 98 X 6308 1 334136 290020 336020 352323 352325 BLK X 6086 6 X 6306 122 334137 222999 360973 BLK 365608 365627 GM15301 X 6086 6 X 6304 105 334138 290020 336020 352323 352325 BLK X 6086 6 X 6306 126 334139 222999 360973 BLK 365608 365627 GM15301 X 6086 6 X 6304 110 334140 290020 336020 352323 352325 BLK X 6086 6 X 6606 126 334141 222999 360973 BLK 365608 365627 GM15301 X 6086 6 X 6304 113 334142 222996 BLK 222998 290020 336020 365608 X 6086 6 X 6306 138 TP 6116 2 02 Description Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Screw HC special thread length Washer spring 46 ID x 875 in OD Washer spring 39 ID x 81 in OD Breaker circuit Nut
63. Decal power breaker 1 GM15301 Cover side 1 9 17668 Screw cross recess pan head machine 4 X 49 2 Breaker circuit 100 A 480 V 4 pole 1 X 6250 5 Line Circuit Breaker 90 A GM17678 KA1 Bracket circuit breaker 1 222908 Bracket circuit breaker 1 222909 Insulator 2 290020 Bus load 1 324313 Tag ground 1 354518 Decal power breaker 1 GM15301 Bracket circuit breaker 2 GM17634 Cover side 1 GM17638 BLK Nut hex 5mm 4 M934 05 50 Washer plain 344 ID x 875 in OD 6 X 25 75 Washer spring 39 ID x 81 in OD 3 X 6086 6 Standoff insulator 1 4 20 1 5 in 2 X 6128 3 Breaker circuit 1 X 6304 54 Marker wire 1 X 750 14 Marker wire 1 X 750 15 Marker wire 1 X 750 16 Nut hex 5 16 18 3 X 82 6 Line Circuit Breaker 90 A W 12 V S T GM17678 KA2 Bracket circuit breaker 1 222908 Bracket circuit breaker 1 222909 Insulator 2 290020 Bus load 1 324313 Tag ground 1 354518 Decal power breaker 1 GM15301 Bracket circuit breaker 2 GM17634 Cover side 1 GM17638 BLK Nut hex 5mm 4 M934 05 50 Washer plain 344 ID x 875 in OD 6 X 25 75 Washer spring 39 ID x 81 in OD 3 X 6086 6 Standoff insulator 1 4 20 x 1 5 in 2 X 6128 3 Breaker circuit 1 X 6304 55 Marker wire 1 X 750 14 Marker wire 1 X 750 15 Marker wire 1 X 750 16 Nut hex 5 16 18 3 X 82 6 Line Circuit Breaker 100 A GM17678 KA3 Bracket circuit breaker 1 222908 Bracket circuit breaker 1 222909 Insulator 2 290020 Bus load 1 324313 Tag ground 1 354518 De
64. G G 00 05 6 0 ch Part 334098 222996 222999 365608 365627 GM15301 X 6086 6 X 6304 103 X 6308 1 334099 290020 336020 352323 352325 BLK GM10413 GM10414 GM10415 X 6086 6 X 6306 124 334100 222999 360973 BLK 365608 365627 GM15301 X 6086 6 X 6304 103 X 6308 1 334101 290020 336020 352323 352325 BLK GM10413 GM10414 GM10415 X 6086 6 X 6306 124 334102 222999 360973 BLK 365608 365627 GM15301 X 6086 6 X 6304 108 334103 290020 336020 352323 352325 BLK GM10413 GM10414 GM10415 X 6086 6 X 6306 124 334104 222999 360973 BLK 365608 365627 GM15301 X 6086 6 X 6304 111 Description Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus
65. Insert valve 6 6 6 224168 Valve intake standard 3 3 6 224193 Valve intake OS 0 381 mm AR AR 6 224197 Valve intake OS 0 762 mm AR AR 7 GM21434 Insert valve 6 6 8 224156 Valve exhaust 3 3 8 224153 Valve exhaust OS 0 381 mm AR AR 8 224151 Valve exhaust OS 0 762 mm AR AR 20 TP 6141 12 03 Group 10 Filter 8 Dipstick See Group 21 cD 35802 Var PartNo Description 4004 4006 5939 1 223604 Filter 1 1 1 GM34935 Filter oil 1 2 223443 Dipstick 1 1 1 3 223454 O ring 1 1 1 4 223502 Nipple threaded 1 4 GM21435 Guide dipstick 1 1 5 Nut 1 2 in 1 1 1 Common hardware procure locally TP 6141 12 03 21 Group 11 Starter Motor 6141_11 Part No Description 3008 1 GM21436 Starter 1 6 GM40186 Cover d 7 10 1 8 Screw 3 8 in x 1 1 8 in 2 9 1 Common hardware procure locally X Not sold separately Group 11b Starter Motor Components CD40138 Item Part No Description 3008 1 GM40185 Solenoid 1 2 Shifter 1 3 Brush kit 1 4 GM40184 Starter motor drive 1 5 1 Contact factory Dart number 22 6141 12 03 Group 12 Exhaust Manifold CDL1053B Qty Var Item Part No Description 2802D 1 336726 Nut hex 2 2 Washer 10 x 18 x 2 500 mm 6 3 Stud 9 525 x 48 500 mm 2 4 Screw 3 8
66. The auxiliary fault lamp flashes or lights continuously to indicate different conditions Figure 1 3 describes the auxiliary fault lamp conditions Lamp Illumination Generator Condition Flashing Continuous Auxiliary Delay Shutdown Lamp lights and the engine shuts down 5 seconds after high oil temperature P1 13 low coolant level P1 10 2 wire sender or P1 14 3 wire switch or auxiliary delay shutdown P1 15 faults if equipped occur These fault conditions are inhibited during the first 30 seconds after crank disconnect Auxiliary Immediate Shutdown Lamp lights and the engine shuts down if activated by customer supplied sensing devices connected to auxiliary immediate shutdown ports P1 17 and P1 18 Emergency Stop Switch Reset Lamp lights if the optional emergency stop switch is reset while the generator set master switch is in the AUTO or RUN position Place the generator set master switch in the OFF RESET position to clear this fault Low Fuel Shutdown 125RZG only Lamp lights and the engine shuts down if activated by the low fuel pressure shutdown switch connected to the Auxiliary Immediate Shutdown port P1 17 Place the generator set master switch in the OFF RESET position to clear this fault No AC Output Lamp flashes if the controller senses no AC output with the unit running except during first 10 seconds after startup When the controller senses AC output the flashing stops and the lamp is unlit
67. e The voltage regulator requires low power and has tight average voltage regulation e The safeguard circuit breaker kit collapses the generator set s main field during a sustained heavy overload or short circuit TP 6349 6 07 Section 1 Specifications 13 1 3 Specifications Resistance Values Alternator Model 4P4W 4P5W 4P5BW 4P7W 4P7BW 4P8W 4P10W 4S7W 4S9W 4S11W 4S13W 4S15W 4UA7W 4UA9W 4UA10W 4UA13W Alternator Leads 12 Three Phase Nominal Stator Main Winding milliohm Stator Aux Winding ohms 2 3 Rotor Main Field ohms 2 1 2 3 1 8 Exciter Field Winding ohms Exciter Armature ohms 1 9 1 5 1 5 2 5 1 9 1 4 1 2 1 0 1 9 1 2 1 5 1 0 4P4W 4P5W 4P5BW 4P7W 4P7BW 4P8W 4P10W 4S7W 4S9W 4S11W 4S13W 4S15W 4UA7W 4UA9W 4UA10W 4UA13W 2 3 2 1 2 3 1 8 1 9 88 1 5 55 1 5 61 5 2 5 45 4 1 9 36 6 1 4 30 8 1 2 15 9 1 0 28 3 1 9 17 6 1 2 18 8 1 5 12 1 1 0 4Q4W 4Q5W 4Q7W 4Q8W 4Q10W 4V7W 4V9W 4V11W 4 Single Phase 30 50 5 2 4 35 34 7 1 9 40 25 8 1 7 45 23 6 1 6 55 17 5 1 3 75 16 3 1 4 95 10 6 1 1 110 6 7 1 1 All resistance values are at 25 C 77 F with
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69. 10 Se 8 06 X OL OM pigog oj jexoeuq 1eBueu ew juno uou pue asoy Bulpnjoxa ejjoid ieusinBunxe jo Sepis puo q e ou ezis 1eusinBunxe uo juepuedep si jo UIPIM pue syoq e B60 91 6 0 8 junoW S3ZIS mg 12049945 Jexoeuq y ut ou yno smasos poom Duo 018 pnis Ajeunoes 1expeJq Junoy 53216 Puno spnis e1euM SEM 0 se pinous 1exoeJq J usin6unx eut 00 uey 559 jou jnq u usin6unx jo a A JO 92 0 B3IL A snu Dufueu e ey Jn SNOLLONYLSNI ONLLNDOW FE uo selon 10 peBpoisip Ajeyueprooe eq yiu 1eusmBunxe ul Ayejnoned woe ayy S JEJ D A 58591216 18 uossino se qusnquioo je inod sues 5 snos s nbino 5 2046 osneo uo jueyaui Se 115 estin jn8g L sainjuia
70. 336020 354518 364484 364510 912 08025 60 6086 6 6128 3 6306 111 6116 2 02 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit
71. 4 297981 16 X 25 118 8 X 6086 6 8 X 83 7 000 PA 336807 1 X 202 35 PA 294992 294981 294988 GM16657 TT 847 GM17244 KP1 226245 238582 238898 246114 254822 292800 292879 292940 354483 GM17206 GM17207 GM17234 1 GM17236 M934 04 50 M934 05 50 X 22 7 X 22 9 X 284 31 X 468 3 X 6216 1 A N O N O N Q N Go 43 Kit Parts List Description Cable 15 Ft Remote Mounting Terminal pin male 20 24 AWG Terminal spade male Terminal fast on male Block terminal Marker strip Connector cable Terminal socket female 20 24 AWG Strip terminal Strip marker Box remote cable mounting Cover remote cable mounting Box assembly 15 ft remote mounting Harness wiring 15 ft extension Nut hex 4mm Nut hex 5mm Washer lock 172 ID x 333 in OD Washer lock 20 ID x 373 in OD Grommet round Cable tie nylon Screw Phillips hex crimptite Cable 25 Ft Remote Mounting Terminal pin male 20 24 AWG Terminal spade male Terminal fast on male Block terminal Marker strip Connector cable Terminal socket female 20 24 AWG Strip terminal Strip marker Box remote cable mounting Cover remote cable mounting Box assembly 25 ft remote mounting Harness wiring 25 ft extension Nut hex 4mm Nut hex 5mm Washer lock 172 ID x 333 in OD Washer lock 20 ID x 373 in OD Grommet round Cable tie ny
72. 9 5 Nm 7 ft Ib End bracket grease vent screw 180 300 9 5 Nm 7 ft Ib Rotating rectifier assembly Mounting bolts AC exciter armature nuts F1 F2 main field nuts Ground lug assembly nuts Drive discs to rotor shaft bolts Fan to rotor flange bolts End bracket to stator bolts Terminal block to stator bolts Terminal block link nuts End bracket grease fitting 20 300 6 6 Nm 58 in Ib 20 300 1 8 Nm 16 in Ib 20 300 2 9 Nm 26 in Ib Alternator adapter to flywheel housing bolt torque 20 300 See chart following Drive discs to flywheel bolt torque 20 300 See chart following Figure 1 4 Torque Values Section 1 Specifications 15 1 6 Adapter to Flywheel Housing Torque Values 20 40 kW Alternator 30 60 kW 50 60 kW John Deere Hardware Type 3 8 16 grade 8 bolt Torque Nm ft Ib 53 39 GM 3 8 16 grade 8 bolt 53 39 John Deere 3 8 16 grade 8 bolt M10 grade 10 9 bolt 53 39 60 125 kW 60 180 kW 135 150 kW GM 3 8 16 grade 8 bolt 53 39 John Deere 3 8 16 grade 8 bolt 53 39 7 16 14 grade 8 bolt 60 44 M10 grade 10 9 bolt 65 48 DDC Series 50 60 Gas 7 16 14 grade 8 bolt 60 44 150 275 kW 200 kW 200 230 kW 200 300 kW 230 300 kW DDC Series 50 60 Gas 7 16 14 grade 8 bo
73. Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 1 5 in Breaker circuit 350 A 240 V 3 pole Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 350 A 240 V 3 pole Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A 600 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Washer plain 203 ID x 75 in OD Screw slotted pan head machine Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A 600 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD
74. Figure 6 21 and Figure 6 22 show the differences between the communication circuit boards and the interface circuit board with gauge drivers The SW2 DIP switches should be set to the open position unless the instructions supplied with the kit indicate another configuration TP 6161 1 08 C21 cis CO c 77777 2 2 D2 D3 D4 05 3 CO GM47242 1 P9 connector 10 position 2 SW2 switches set to open position 3 TB5 Terminal connectors 4 P8 connector 24 position Figure 6 21 Communication Circuit Board GM49791 1 021 cis Ce 088 and 23 D2 D3 D4 05 Ratna ear 000 GM47242 1 P8 connector Figure 6 22 Gauge Driver Circuit Board GM49791 2 Section 6 Accessories 55 Notes
75. SION einjeJeduje Buiseajout uo yams uedo e 3 921 01 4 091 s uneg e uoto y u31IAS 20 8360 4 1 72 IIO Ut 8 HAS U OWL 330815002 uonedissiq 24 66 22 52 eudiy 0 081 4 206 e1nje1odiue 0 04 01 2 0 3 891 01 3 06 WON 0 2 0 2 92 3 44 000701 enjeA juayaoxg e snonunuo 40 10 510941 7 suondo 5105095 11361854 pojeibojuj s n A JOJ 8845 aeg g uoisueulg 94 1 16 21 6 jo 5936 215 9 pue sooueisip o 9 8 uo 90463901 1 10 S9U2IMS VA 001 10 06 UMA SIUN 30 uou 30 uoga 1 SMY 22 pue suogeinBijuoo paziubooaJ 1f jo SUN 30 DMY 818 S 9218 UMA 2 p ziu6o3 J 1n u payddns aq ued Jo se Je papeus ui payloads esiwJeujo ssajun Bunesques au ujBue se Jayem Buipueosap uo pejeJqieo uonenyoy ABIO UM VJO UM Ug uM UJOPIIS UM UJgPIB UAA I9APIIS
76. Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Cover side Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit 400 A 240 V 3 pole Screw slotted pan head machine Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine Line Circuit Breaker Insulator Bracket circuit breaker Cover side Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Kit Parts List Qty cn 02 cn Om Part 334090 222996 222999 290020 360763 15301 6086 6 6304 88 6308 1 334091 222996 BLK 222999 290020 360763 GM15301 X 6086 6 X 6304 92 X 6308 1 334092 352323 352325 BLK GM10413 GM10414 X 6086 6 X 6306 120 334093 222996 BLK 222999 290020 360763 GM15301 X 6086 6 X 6304 92 X 6308 1 334094 352323 352325 BLK GM10413 GM10414 X 6086 6 X 6306 120 334095 222996 BLK 222999 290020 360763 GM15301 X 6086 6 X 6304 6 X 6308 1 334096 222996 BLK 222999 290020 360763 GM15301
77. See selections for DIP switch 4 and DIP switch 5 below Value 0 Value 2 Value 0 Value 4 Value 0 Value 8 Open Open MDEC Comm Closed Isochronous Open Open Closed MDEC Comm Closed Governor VSG Closed Engine Comm Setting Modbus Address Bit 0 Modbus Address Bit 1 Modbus Address Bit 2 No ECM J1939 Communication 3 AJA 4 01 Figure 1 9 Switch Functions Note After setting switches to the generator set application be sure to power down and then power up the controller disconnect the battery and then reconnect the battery of the generator set or use the prime power switch if equipped The controller will NOT acknowledge the DIP switch change until after generator set controller is powered up Push down the end of the DIP switch near the OPEN label to open the switch or push down the other end to close it See Figure 1 10 OPEN 1 Push this side down to open circuit Figure 1 10 DIP Switch Open Position Modbus is a registered trademark of Schneider Electric TP 6161 1 08 Typically the factory default settings have all the DIP Switches in the closed position except the crank mode selection switch SW3 which is open for cyclic cranking The overspeed selection switch SW1 is open on 50 Hz units Be sure to select the corr
78. Standoff insulator 1 4 20 x 1 5 in Breaker circuit 300 A 600 V 3 pole Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw slotted pan head machine Qty T PPR Ahhh 3 hihi Part 334030 222908 222909 222910 290020 324314 354518 GM10527 BLK GM15301 X 25 45 51 45 51 47 6086 6 6128 3 6304 3 334032 222908 222909 222910 290020 324313 354518 GM10528 BLK X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 15 334033 222908 222909 222910 222949 BLK 290020 324313 354518 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 15 334034 222908 222909 222910 222949 BLK 290020 324313 354518 360763 X 6086 6 X 6128 3 X 6304 18 X 6308 1 334035 222908 222909 222910 222950 BLK 290020 324313 354518 360763 X 6086 6 X 6128 3 X 6304 89 X 6308 1 TP 6116 2 02 Description Line Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in
79. TP 6116 2 02 Qty EENEG zl CO hi Mi Part 334807 222908 222909 290020 324313 336020 354518 364484 364510 912 08025 60 6086 6 6128 3 6306 112 334808 222908 222909 290020 324313 336020 354518 364484 364510 912 08025 60 6086 6 6128 3 6306 117 334809 222908 222909 290020 324313 336020 354518 364484 364510 912 08025 60 6086 6 6128 3 6306 118 334810 222908 222909 290020 324313 336020 354518 364484 364511 6086 6 6128 3 6306 120 334811 222908 222909 290020 324313 336020 354518 364484 364511 6086 6 6128 3 6306 121 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Screw slo
80. 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 battery 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 Seekimmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service asthis may resultin hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and I
81. X 6086 6 X 6304 96 X 6308 1 334097 290020 352323 352325 BLK GM10413 GM10414 X 6086 6 X 6306 120 15 Kit Parts List Description Line Circuit Breaker Cover side Bracket circuit breaker Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Qty Mi CO N
82. X 6306 93 GM14030 KA2 222908 222909 290020 324314 336020 354518 GM14299 BLK GM14300 X 6128 3 X 6306 96 Ny bi vk P 0 p P 0 p 4242p a4 2242p Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Cover side Bracket circuit breaker Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Cover side Bracket circuit breaker Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bus line Bus line Cover side Bracket circuit breaker Screw socket head cap Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bus line Bus line Cover side Bracket circuit breaker Screw socket head cap Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker 80 A Breaker circuit 80 A 480 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker 80 A W 12 V S T Decal power breaker Cover side Screw cross recess pan head machine Brea
83. 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 HxW xD height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext IO 5 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 53 kilo 1000 kelvin kA kiloampere KB kilobyte 219 bytes KBus Kohler communication protocol kg kilogram kg cm k
84. frequency adjustment information 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 Equipment damage Verify that the voltage ratings of the transfer switch line circuit breakers and other accessories match the selected line voltage WARNING Lee aS Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Turn the generator set master switch and switchgear engine control 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 preventthe starting ofthe generator set by an automatic transfer switch or a remote start stop switch Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the gene
85. hex 7 16 14 Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Screw HC special thread length Washer spring 46 ID x 875 in OD Washer spring 39 ID x 81 in OD Breaker circuit Nut hex 7 16 14 Line Circuit Breaker Bracket circuit breaker Insulator Cover side Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit TP 6116 2 02 Qty o G O O N Q G D N zk N D N O N GO cc L G G N Part No 334143 222999 360973 BLK 365608 365627 GM15301 X 6086 6 X 6304 117 334144 222996 BLK 222998 290020 336020 365608 X 6086 6 X 6306 138 334145 222999 360973 BLK 365609 365627 GM15301 GM16793 X 6086 20 X 6086 6 X 6304 120 X 70 13 334146 222996 BLK 222998 290020 336020 365609 X 6086 6 X 6306 140 334147 222999 360973 BLK 365609 365627 GM15301 GM16793 X 6086 20 X 6086 6 X 6304 122 X 70 13 334149 222999 290020 360973 BLK 365609 X 6086 6 X 6304 126 334150 222996 BLK 222998 290020 336020 365609 X 6086
86. interconnection Contact 10 circuit dry Washer lock 172 ID x 595 in OD Spacer 282 ID x 5 OD x 531 in Screw Phillips hex crimptite Nut hex machine screw 8 32 Dry Contact 10 SPDT 10 Grommet round Cover dry contact Harness wiring FRII rem volt reg Vibromount Box dry contact Contact 10 circuit dry PCB assembly 10 relay dry contact Customer connection assembly Diagram accessory interconnection Harness wiring controller connection Ten relay dry contact 6 2000 kW Washer lock 172 ID x 595 in OD Spacer 282 ID x 5 OD x 531 in Bolt hex cap Screw cross recess round head machine Nut flange spiralock 1 4 20 Nut flange whiz 8 32 Screw Phillips hex crimptite Nut hex machine screw 8 32 Spacer 25 OD 5 in Control Module Day Tank Day Tank Electronic Sensor float Module power Harness wiring extension Harness wiring 6 15 kW 1 phase Switch float 1 pole Connector jack 9 position Connector plug 9 position Pump motor assembly Grommet Fitting hose connector 90 deg Hose Clamp 1 in hose Day Tank Electronic Sensor float Module power Harness wiring extension Harness wiring 6 15 kW 1 phase Switch float 1 pole Connector jack 9 position Connector plug 9 position Pump motor assembly Grommet Fitting hose connector 90 deg Hose Clamp 1 in hose 46 Qty Part No 273913 243319 273934 273935 282829 328912 336394 354246 A 27393
87. load Tag hang Cover side Tag ground Bus line Bus line Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Qty N NN NNUU NNM NNUU 5 A Part 334073 222908 222909 222910 290020 324313 336020 352295 354518 364510 GM10167 M912 08025 60 X 6086 6 X 6128 3 X 6306 112 334074 222908 222909 222910 290020 324313 336020 352295 BLK 354518 364510 GM10167 M912 08025 60 X 6086 6 X 6128 3 X 6306 118 334075 222908 222909 222910 324313 354518 360970 BLK 365606 365627 X 6086 6 X 6128 3 X 6304 109 X 6308 2 334076 222908 222909 222910 290020 324313 336020 352326 BLK 354518 364511 GM10168 GM10169 X 6086 6 X 6128 3 X 6306 125 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Bus line Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket ci
88. nv 1 NONLOTYH a assv12 auanod V OAS SNDINIHD LIndOMd Y 4444 19 444 assnow e no anbiwiyo ynpoid e eesueAind nee e sunojunxe np sed ise 909 e euoueAel 906 np eunp yole oe e j 2 Op e nbsnf uogoejoud eun p jned sen c e zz ep nu nee opz ej N S ano VvINa 35 Y LNVNALYVdd 580131 631 139 3604 3 SVd IN 591 s oooje sei nee suep se qnjos sepinbi s p osneo s l uns asin yn d 4444 e 252 ai ep mad seinjeledule sep ue eunpoJd es ep ejqndeosns nee eeuejuejsui uonesuode EI uossino 6 sop osneo ue juejjoul 1004 4444 no 444 essnow e neo e eosueA nd nea e sinejounxe p 1 stewel 18 V sesse o ep qN uos sunejounxe 89 sayap imod eesiuolep nea ep nee e sinejunxe se 2429 OLZA enbuyeje xnej INS Joen s
89. round head machine screw relay rms rnd ROM rot rpm RS RTU scfm SCR 5 sec Sl SI EO sil SNMP SPDT SPST spec specs sq Sq cm sq in SS std stl tach root 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 fluor
90. slotted pan head machine Screw slotted round head machine Tubing heat shrink Tubing heat shrink Screw Phillips hex crimptite Nut hex machine screw 10 32 Nut hex machine screw 6 32 Qty YUYUN N S 4 Ny Part 326767 151511 201620 152 233966 239298 257442 262389 262395 262397 262399 263156 268015 287948 291208 292387 292938 292940 292941 292946 292947 292948 292957 292961 292962 295010 295314 298810 325593 5 325996 326780 326782 326784 326767 262375 262378 680 729 22 11 22 12 22 18 22 25 22 6 283 1 283 11 283 2 468 12 49 25 49 26 49 39 49 6 50 1 50 3 51 11 51 15 51 30 51 53 6079 2 6081 3 6216 1 70 3 71 2 6116 2 02 Description Battery Charger 12 Decal connection 250 Connector plug 12 position Clip speed Fuse 25 A 125 V Transformer 120 240 V 29 5 V Decal warning connection Clip cable Holder fuse Spacer Lamp 120 V 33W Decal Strip terminal Ammeter 0 15 A DC Voltmeter 0 25 V DC Module SCR Fuse 7 A 250 V Harness wiring 12 24 V float chargers Marker strip Marker strip Retainer Block terminal Nut captive 6 32 Box battery charger Door silkscreen Nameplate battery charger PCB assembly
91. 01 aJaupe aseald Bugs 0 Jamad 29000251 5929 950 6 lqiisnquuo3 Jo jo MIA ue BU 92415 514100 195 YOHWMS fase op sabueuo jnsol5u 00 0001 0 0 ue s eualpu p nnb 2 sr Bursa I9 9 ayy j 5 SIQewwey pue j5np 0 9 1009 uls SILA 81061009 YINMS jo e yOu 104 se 56014 5 suorjeordde 50032204 JOJ 4SN Aq ajes sv Ayesauad si 15 559 snovas ui SIUI YUM 2 01 dos pow si uiBuo 12014 H dois 1601 194 ayy wo adueysip ay pue xz suo LQ 5 01 Gurpjo22e Su 10169 SIUL 0500 0 HALY 920849 6 794010 Bua uo spu d p iueunsnt d LAN nt lqe1od Joy sjeuajew ae 520595 p A01dde JSN pue uoneJedo u 181541 J9 00 104 unojng uornaniisur jonpood poJInbo St Dunsai 5902 Jo 0 00991985 SWIN o qeotjdde aui pue 122121291
92. 1 7 GM21424 Bearing kit standard 3 3 3 7 GM21469 Bearing kit 0 25 mm US AR AR AR As Required X Not sold separately 32 TP 6141 12 03 Group 25 Oil Pump See Group 21 CD42124 Item Part No Description 5001 9928 1 GM21477 Oil pump kit 1 1 2 Nut 1 2 1 0 1 1 3 224035 O ring 1 1 4 223511 O ring 1 1 5 336458 O ring AR AR 7 GM21478 Tube oil 1 1 8 223512 O ring AR AR 9 Not used 1 1 10 223631 Gear 1 1 11 224274 Screw cap 1 1 12 Washer lock 3 8 in 1 1 Common hardware procure locally AR As Required TP 6141 12 03 33 Group 26 Front Plate Code 9922 Code 9923 See Group 8a RS MA Ht Zap 1 d Z 1 Z7 D n A Uu K Jo CD35803A CD39158 NEM LU Qty Var Item Part No Description 1 22 fe 26 Part No Description 1 3622 1 GM21479 Gasket 1 1 2 Washer 3 8 5 5 1 Nut 1 2 in 20UNF 1 1 3 224333 Screw 5 2 336447 Washer thrust 1 1 3 GMS32735 Bolt 5 3 223729 Gear 1 1 4 GM21480 Plate also order items 6 and 7 1 1 4 223984 Bushing 1 1 5 GM21481 Washer AR AR 5 224186 Pin 1 1 6 1223442 Screw set 8 8 6 336446 Washer thrust 1 1 7 223445 Screw set 2 2 7 224267 Washer 1 1 8 224335 Stud 3 3 8 224260 Screw hex head 1 1 9 Nut 5 16 in 18UNC 3 3 Common hardware procure locally Common hardware procure locally AR As Req
93. 1 364422 Harness wiring engine 1 328915 Flexible Exhaust Connector 5 in NPT PA 364420 Diagram interconnection 1 354246 Gasket exhaust 1 364384 Screw cross recess round machine 4 X 51 11 Adapter flexible exhaust 1 364424 Conduit convoluted 1 X 6003 69 Controller Connection Kit GM17032 KA1 Customer connection assembly 1 GM13984 Diagram accessory interconnection 1 GM16088 Contact Kit Dry Harness wiring controller connection 1 GM17033 Screw cross recess round head machine 6 X 51 3 Dry Contact 1 SPDT 273912 Spacer 25 OD 5 in 6 X 712 9 Grommet round 249919 Box dry contact 1 273942 Cover dry contact 1 273943 Harness wiring switchgear 1 273944 Vibromount 4 282829 Connector Kits Flexible Exhaust Diagram interconnection 1 328912 Flexible Exhaust Connector GM19877 KP1 SECH ae Adapter flexible exhaust 1 GM19876 2 9945 Clamp exhaust 1 GM22535 PCB assembly 1 relay dry contact 1 C 294301 Screw hex cap 1 M931 08035 60 Screw Phillips hex crimptite 4 X 6216 1 Nut hex elastic stop 1 M982 08 80 Nut hex machine screw 8 32 4 X 70 12 Flexible Exhaust Connector GM22425 KP1 I A Clamp exhaust pi 81 in 1 276949 Dry Contact 1 SPDT 10A GM17068 KP1 Adpater flexible exhaust 1 GM22426 mm eech SET Flexible Exhaust GM22876 KP1 Cover dry contact 1 273943 Adapter flexible exhaust 1 276946 Wiring harness switchgear 1 273944 Clamp exhaust 1 GM22535 Vibromount 4 282829 Screw hex cap 1 M
94. 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 12040 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 03012 20 M7985A 04010 20 M7985A 04016 20 M7985A 04020 20 M7985A 04050 20 M7985A 04100 20 M7985A 05
95. 1 single pole single throw SPST 1 amp minimum Plug 120 volt AC 200 240 volt AC plug optional Stranded copper wire 218 AWG WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place TP 6349 6 07 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 Voltage Regulator Test Procedure 1 Connect the components as shown in Figure 3 4 If a 200 240 volt power source is available the step up transformer is not required 2 Turn 1 kOhm potentiometer fully counterclockwise See Figure 3 4 item 11 3 Plug the power cord into the outlet 4 Turn the power supply on The 100 watt lamp should be off If 100 watt lamp is lit replace the voltage regulator It is acceptable for the lamp to briefly illuminate at powerup 5 Slowly turn the 1 kOhm potentiometer clockwise The 100 watt lamp should light Replace the voltage regulator if the 100 watt lamp does not light 3 4 3 Voltage Regulator Adjustment The voltage regulator is factory set and under normal circumstances requires further adjustment However if the voltage regulator has been replaced or tampered with or if voltage frequency re
96. 12 V 900cca 1 12 V Dry Battery dry charge Battery 12 V 900 1 12 V Wet Battery wet charge Battery Battery Battery Battery Battery Battery wet charge Qty ch Part PAD 292865 233966 262397 287948 291208 292387 292940 292946 292948 292957 292958 298810 325596 B 262375 C 262378 D 292865 X 22 12 X 22 18 X 22 25 X 22 6 X 49 25 X 49 26 X 49 39 X 49 6 X 50 1 X 51 11 X 51 15 X 51 30 X 51 9 X 6216 1 71 2 336828 336814 336827 336830 336814 336826 343286 336814 336827 352359 336814 336826 352667 336814 336825 225290 225289 256985 256984 324493 324367 324494 324368 324588 324586 6116 2 02 Description Batter Battery dry charge Battery Battery dry charge Battery Battery wet charge Battery Battery wet charge Battery Battery dry charge Blanket Kits Exhaust Manifold Exhaust Manifold Blanket Blanket insulating manifold Exhaust Manifold Blanket Blanket insulating manifold Blanket insulating manifold Blanket insulating turbo Blanket insulating elbow Exhaust Manifold Blanket Blanket insulating manifold Blanket insulating manifold Blanket insulating turbo wrap Blanket insulating elbow Blanket insulating manifold Exhaust Manifold Blanket Blanket insulating manifold Blanket insulating elbow Blanket insulating manifold Blanket
97. 280991 PA 279883 1 291285 Description Line Circuit Breaker Breaker circuit 1400 A 600 V 3 pole Line Circuit Breaker Breaker circuit 1600 A 600 V 3 pole Line Circuit Breaker Breaker circuit 1800 A 600 V 3 pole Line Circuit Breaker Breaker circuit 200 A 600 V 3 pole Line Circuit Breaker Breaker circuit 2500 A 600 V 3 pole Line Circuit Breaker Breaker circuit 500 A 600 V 3 pole Line Circuit Breaker Breaker circuit 600 A 600 V 3 pole Line Circuit Breaker Breaker circuit 700 A 600 V 3 pole Line Circuit Breaker Breaker circuit 800 A 600 V 3 pole Line Circuit Breaker Breaker circuit 900 A 600 V 3 pole Line Circuit Breaker Breaker circuit 1000 A 600 V 3 pole Line Circuit Breaker Breaker circuit 1200 A 600 V 3 pole Line Circuit Breaker Breaker circuit 1400 A 600 V 3 pole Line Circuit Breaker Breaker circuit 1600 A 600 V 3 pole Line Circuit Breaker Breaker circuit 2000 A 600 V 3 pole Line Circuit Breaker Breaker circuit 2500 A 600 V 3 pole Breaker Kits Line Circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 225 A 600 V 3 pole Line Circuit Breaker
98. 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Washer plain 203 ID x 75 in OD Screw slotted pan head machine Breaker circuit 200 A 600 V 3 pole Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Washer plain 203 ID x 75 in OD Screw slotted pan head machine Breaker circuit 225 A 600 V 3 pole Line Circuit Breaker Cover side Bracket circuit breaker Insulator Washer plain 203 ID x 75 in OD Screw slotted pan head machine Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine TP 6116 2 02 Qty 00060 PM P ch ch 00060 Q N 00 O OO Part No 334112 222999 290020 3609
99. 4 Prime power operation Figure 2 1 16 Light Controller TB2 Terminal Strip Prime Power Starting prime power mode provides local starting only at the controller The AUTO position no longer functions as a remote start When the generator set master switch is in the OFF RESET position the controller functions are inoperative Move the generator set master switch to the AUTO position to start the generator set Do not start the generator set with the master switch in the RUN position because the alarm horn will sound Note Move the generator set master switch to the AUTO position to return controller functions to normal Prime Power Stopping Move the generator set master switch to the OFF RESET position to stop the generator set and power down the controller Note The controller functions are inoperative when the generator set master switch is in the OFF RESET position 2 3 3 Emergency Stopping Activate the controller emergency stop switch if equipped or the optional remote emergency stop switch for immediate shutdown Use the emergency stop switch es for emergency shutdowns only Use the generator set master switch for normal shutdowns TP 6161 1 08 unit shuts down stop lamp lights H operator activates either the local remote emergency stop switch Use the following procedure to restart the generator set after shutdown by an emergen
100. 4 1 General ne eo Das PM Rae a 39 4 2 ie radere Ur ados ens 42 4 3 Beassembly s aO Mey ea a a A 44 Appendix A Abbreviations 53 Appendix B Common Hardware Application Guidelines 55 Appendix C General Torque Specifications 56 Appendix D Common Hardware Identification 57 TP 6349 6 07 Table of Contents 3 Notes 4 Table of Contents TP 6349 6 07 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
101. 4 20 x 1 5 in Breaker circuit 125 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Kit Parts List Qty Part No 334791 222908 222909 290020 324314 336020 354518 364484 364497 X 6086 6 X 6128 3 X 6306 97 334792 222908 222909 290020 324314 336020 354518 364484 364497 X 6086 6 X 6128 3 X 6306 99 334793 222908 222909 290020 324314 336020 354518 364484 364497 X 6086 6 X 6128 3 X 6306 100 334794 222908 222909 290020 324314 336020 354518 364484 364497 X 6086 6 X 6128 3 X 6306 102 334795 222908 222909 290020 324314 336020 354518 364484 364497 X 6086 6 X 6128 3 X 6306 103 27 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Bracket cir
102. 4 50 X 6024 5 7 16 14 x 75 X 6024 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2 13 x 1 25 X 129 19 1 2 13 x 1 50 X 129 20 1 2 13 x 1 75 X 129 21 1 2 13 x 2 00 X 129 22 1 2 13 x 2 25 X 129 23 1 2 13 x 2 50 X 129 24 1 2 13 x 2 75 X 129 25 1 2 13 x 3 00 X 129 27 1 2 13 x 3 50 X 129 29 1 2 13 x 4 00 X 129 30 1 2 13 x 4 50 X 463 9 1 2 13 x 5 50 X 129 44 1 2 13 x 6 00 X 129 51 1 2 20 x 75 X 129 45 1 2 20 x 1 25 X 129 52 1 2 20 x 1 50 X 6021 3 5 8 11 x 1 00 X 6021 4 5 8 11 x 1 25 X 6021 2 5 8 11 x 1 50 X 6021 1 5 8 11 x 1 75 273049 5 8 11 x 2 00 X 6021 5 5 8 11 x 2 25 X 6021 6 5 8 11 x 2 50 X 6021 7 5 8 11 x 2 75 X 6021 12 5 8 11 x 3 75 X 6021 11 5 8 11 x 4 50 X 6021 10 5 8 11 x 6 00 X 6021 9 5 8 18 x 2 50 X 6239 1 3 4 10 x 1 00 X 6239 8 3 4 10 x 1 25 X 6239 2 3 4 10 x 1 50 X 6239 3 3 4 10 x 2 00 X 6239 4 3 4 10 x 2 50 X 6239 5 3 4 10 x 3 00 X 6239 6 3 4 10 x 3 50 X 792 1 1 8 x 2 25 X 792 5 1 8 x 3 00 X 792 8 1 8 x 5 00 Part No Hex Nuts X 6009 1 X 6210 3 X 6210 4 X 6210 5 X 6210 1 X 6210 2 X 6210 6 X 6210 7 X 6210 8 X 6210 9 X 6210 10 X 6210 11 X 6210 12 X 6210 15 X 6210 14 X 85 3 X 88 12 X 89 2 Washers Part No X 25 46 X 25 9 X 25 48 X 25 36 X 25 40 X 25 85 X 25 37 X 25 34 X 25 26 X 25 15 X 25 29 Dimensions ID 125 156 18
103. 4 in 1 Common hardware procure locally 30 TP 6141 12 03 6141 12 03 CD37218A Group 21c Oil Cooler Var Part No Description 5906 5939 1 GM21409 Clamp 8 8 2 GM21463 Hose 2 2 3 336462 Line 1 1 4 336461 Line 1 1 5 336463 Hose 2 2 6 GM21464 Nipple threaded d 6 GM32733 Adapter 1 7 21465 Cooler oil 1 1 8 GM21466 Packing 1 1 9 Screw 3 8 2 3 8 grade 8 1 1 10 336466 1 1 11 336467 Washer 1 1 12 Washer 10 18 2 5 1 1 4 Common hardware procure locally 31 Group 22 Piston Qty Var Item Part No Description 9915 9917 4814 1 GM21472 Piston liner kit 3 1 GM21476 Piston liner kit 3 3 2 360066 Ring kit 1 1 1 3 x Piston 1 1 1 4 GM21473 Liner cylinder 1 1 4 x Liner cylinder 1 5 223419 O ring kit 1 1 1 6 GM21474 Shim 0 05 mm AR AR AR 6 GM21475 Shim 0 1 mm AR AR AR AR As Required X Not sold separately Qty Var Item Part No Description 9916 9918 4814 1 GM21470 Connecting rod kit includes items 2 4 5 3 1 GM21467 Rod connecting includes item 2 3 1 GMS32734 Rod connecting includes items 2 3 3 2 223528 Screw 2 2 2 GM17477 Screw 2 3 GM21468 Piston pin kit includes items 4 6 3 3 4 GM21471 Ring snap 2 4 223479 Ring snap 2 2 5 IX Pin piston order item 1 1 5 IX Pin piston order item 3 1 1 6 X Bushing 1
104. 4 x Bearing ball order item 21 1 5 x Seal order item 21 1 6 223553 Impeller 1 7 223560 Gasket 1 8 GM21402 Cover 1 9 Plug pipe 1 2 in 14 NPT 1 10 GM21403 Fitting union 1 4 in 18 NPT x 54mm 1 11 352067 Tube 2 12 Screw cap 3 8 in x 1 1 2 in SAE grade 8 1 13 Washer 10 x 18 x 2 500 mm 1 14 Screw cap 3 8 in x 1 3 8 in SAE grade 8 1 15 Washer 10 500 x 18 x 1 600 mm 1 16 223628 Gasket 1 17 Screw cap 3 8 in x 2 in SAE grade 8 1 18 Washer locker 3 8 in 3 19 Nut 3 8 in 1 20 Screw cap 3 8 in x 3 1 2 in 2 1 21 GM21404 Kit pump repair Common hardware procure locally X Not sold separately 6 TP 6141 12 03 6141 12 03 Group 26 Thermostat See Group 6141 Part Description Var 2110 360013 GM21508 GM32722 GM21406 360116 GM21407 GM21408 10 GM21409 11 336463 12 GM15403 13 223595 O ring Screw cap 3 8 in x 1 1 8 in Washer 10 x 18 x 2 500 mm Cover also order items 1 7 and 12 Gasket Gasket water bypass tube Gasket Clamp Clamp Hose Plug pipe Thermostat 82 deg C Common hardware procure locally _ _ ch Group 2c Fan Belt Item Part No Description Var 2401 1 GM11846 Belt fan Group 3 Vent Tube CDA36501 Var Item Part No Description 2902
105. 6 1 88 01 v26 9n axa 99 5 001 dx3 08 01 Figure 4 24 4SW 4 Alternator Components 60 kW IMS 170 kW 6349 6 07 Section 4 Alternator Disassembly Reassembly 51 00022 49 MINORE ATHAdSSV OLVNYILTY 9A MENTIS MI SUY SNDISNG Ei Eum AIBWASS 30010 SNLVIDH 313 QVO SIN3TWAInD3 HSI19N3 Jay 5 5 G 3 130119 v sv 505 9 ISN OOHIH 4188355 H3dOHd 304 Nit 40 STIA NO 031319395 LON 3Hv ONY dX3 SV 031511 J3uv SH3HSVM ONY SIAN SW3H2S 35N3dX3 D 301415 DINI O3183SNI SI 80104 340438 40108 OL 3 15 9 3 81200 20019 Addy 969 9 Had 50431 Alunni Z 21 9 Yad 43419345 ISIMYIHLO SS31Nn CL S310N bm gt 7709 08 01090 8 81925 37425 2 2 NOSIS 4 0 NOSS 5871 gz 2 Dl 300401 08 90 2860 dX3 2 09 02090 6 TWANIINH L 0931 01414 NIV 096 MOISIMVA TNIV SL 5971 921 6 OL 3nbuoL 0S S0 rE6N dx3 08 90 VSZLIN 43 oe 0coco cesh SE1 NI Z anoal 2 og 90 cg86lN ATBN3SSV 30010 5 OINI QN38 HO LON 1 38 15011 G39vWva 581 14 56 OL 3nDHOL 035 3 0 N338 Sei ONLI SILY MGHOS TIVISNI 3SIMH3HIO X
106. 7 GM12536 KA1 290020 336020 352323 GM10411 GM10412 GM12539 BLK M912 08025 60 X 25 118 X 6086 6 6306 117 83 7 GM12537 KA1 290020 336020 352323 GM10413 GM10414 GM12537 B GM12540 BLK X 25 118 X 6086 6 X 6306 120 83 7 G O Q G D G O O N O D N G G O O N O G D Kit Parts List Description Qty Part No Line Circuit Breaker 450 630 GM12537 KA2 Insulator 2 290020 Tag hang 1 336020 Bracket circuit breaker 1 352323 Bus line 3 GM10413 Bus line 3 GM10414 Bus line 3 GM10415 Line circuit breaker base parts 1 GM12537 B Cover side 1 GM12540 BLK Washer plain 406 ID x 1 in OD 6 X 25 118 Washer spring 39 ID x 81 in OD 3 X 6086 6 Breaker circuit 1 X 6306 124 Nut hex 3 8 16 zinc 3 X 83 7 Line Circuit Breaker 700 800 A GM12538 KA1 Bracket circuit breaker 1 222998 Insulator 4 290020 Tag hang 1 336020 Cover side 1 GM12333 BLK Bus line 3 GM12336 Washer plain 406 ID x 1 in OD 6 X 25 118 Washer spring 39 ID x 81 in OD 3 X 6086 6 Breaker circuit 1 X 6306 136 Nut hex 3 8 16 zinc 3 X 83 7 12 V Shunt Trip 300 400 A UL GM12606 KA1 Breaker circuit 1 X 6304 138 24 V Shunt Trip 300 400 A UL GM12606 KA2 Breaker circuit 1 X 6304 139 Auxiliary Switch 300 400 A UL GM12606 KA3 Breaker circuit 1 X 6304 140 12 V Shunt Trip 450 1200 A UL 12607 1 c
107. Alarm Reporting Unit NA 9 24 UPS NA Water Systems SECTION 9 2 ELECTRICAL Section 9 2 Electrical 9 2 1 Kohler Standby Generator Model 40REOZJB Tag na SHOP DRAWING REVIEW RAWING HAS BEEN REVIEWED FOR GENERAL CONF AANGE WITH THE DESKIN CONCEPT ONLY SUCH REVIEW THE COM ONSIBILITY 18 ASSUMED FOR OR DETAILS m Submission He U NO COMMENT A cf Project No 29842 0 2 AMEND RESUBMIT 57 MC ae REIECTEO Dale M SES Zf DILLON CONSULTING LIMITED KOHLER POWER SYSTEMS Operation Industrial Generator Sets eh Models 20 2250 kW Controllers Decision Maker 3 16 Light Software Code Version 1 10 or higher Decision Maker 1 mum POVVER SYSTEMS NATIONALLY REGISTERED TP 6161 1 08f California Proposition 65 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 s
108. Bracket 18 Nut 5 16 in 19 Screw cap 5 16 in x 3 4 in Common hardware procure locally TP 6141 12 03 37 Group 51a Alternator Var Item Part No Description 3123 1 Screw 5 16 in 1 3 8 in 1 2 Washer 11 32 in x 3 4 in x 0 120 in 1 3 GM21517 Shield 1 4 Washer lock 8 100 mm 2 5 Nut 5 16 in 1 6 GM21518 Harness wiring 1 7 Screw cap 5 16 in x 3 3 4 in 1 8 GM21519 Alternator 1 9 GM21520 Sheave 1 10 Nut lock 5 2 11 Nut lock M6 1 Common hardware procure locally 38 TP 6141 12 03 Group 51b Alternator Brackets CDP45566 See Group 51a Var Item Part No Description 6218 1 Screw 3 8 in 3 1 2 in 2 2 Washer 10 5 18 1 6 2 3 GM21493 Bracket 2 4 GM21494 Spacer 2 5 Nut lock 3 8 in 2 6 Screw cap 3 8 in x 2 in SAE grade 8 1 7 Washer lock 3 8 in 1 8 224099 Strap d Common hardware locally TP 6141 12 03 39 AA Ze 2 4 See Group 51a TP 6141 12 08 Alternator Components Group 51c 2 x f gt 0 m Var 3123 Description Regulator GM21522 Diode GM21521 Item Part No 40 Appendix Common Hardware Identification Screw Bolts Studs Hex Head or Machine Head Hex Head W Grade 2 Hex Head or Machine Head i Y wi
109. Breaker Transformer curr 150 5 round Crct brkr 20 150 kW Washer plain 156 ID x 375 in OD Screw cross recess pan head machine Jumper two terminal Breaker circuit 4 5 A 240 V 3 pole Bus Bar Kits Bus Bar Bracket upper support Bracket support LS Bracket support RS Bus Insulator lug Tag ground Washer plain 203 ID x 75 in OD Washer plain 193 ID x 5 in OD Qty AA AA AA bb AA oR AR AAA BARA ARRAS hi Part 255128 22 6 49 2 796 4 255129 22 6 49 2 796 6 255130 22 6 49 2 796 2 255131 22 6 49 2 796 3 272745 22 6 49 2 796 4 272746 22 6 49 2 796 3 272747 22 6 49 2 796 1 272748 22 6 49 2 796 6 275595 22 6 49 2 796 2 255139 246886 591 25 9 49 2 6076 2 796 2 222966 222962 275457 275458 275459 275562 354518 25 45 25 92 41 Kit Parts List Description Bus Bar Bracket upper support Bracket upper support Insulator panel Bracket support LS Bracket support RS Bus Insulator lug Tag ground Washer plain 281 ID x 625 in OD Washer plain 193 ID x 5 in OD Bus Bar Bracket upper support Bracket support Insulator panel Bracket support Channel insulating Bracket support RS Bus Insulator lug Tag ground Washer plain 193 ID x 5 in OD Bus Bar Suppo
110. Breaker circuit 150 A 600 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 150 A 600 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 400 A 240 V 3 pole Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 400 A 240 V 3 pole Screw slotted pan head machine TP 6116 2 02 Qty 2 Part 334036 222908 222909
111. Breaker circuit 1 X 6304 92 Screw slotted pan head machine 4 X 6308 1 Nut hex 3 8 16 zinc 3 X 83 7 Line Circuit Breaker 400 A GM12379 KA3 Bracket circuit breaker 1 222999 Insulator 2 290020 Cover side 1 GM12333 BLK Bus line 3 GM12335 Decal power breaker 1 GM15301 Washer plain 406 ID x 1 in OD 9 X 25 118 Washer spring 39 ID x 81 in OD 6 X 6086 6 Breaker circuit 1 X 6304 96 Screw slotted pan head machine 4 X 6308 1 Nut hex 3 8 16 zinc 3 X 83 7 Line Circuit Breaker 450 A GM12380 KA1 Bracket circuit breaker 1 222999 Insulation CB 2 365627 Cover side 1 GM12334 BLK Bus line 3 GM12336 Washer plain 406 ID x 1 in OD 6 X 25 118 Washer spring 46 ID x 875 in OD 6 X 6086 20 Washer spring 39 ID x 81 in OD 3 X 6086 6 Breaker circuit 1 X 6304 100 Nut hex 3 8 16 zinc 3 X 83 7 Line Circuit Breaker 500 A GM12380 KA2 Bracket circuit breaker 1 222999 Insulation CB 2 365627 Cover side 1 GM12334 BLK Bus line 3 GM12336 Decal power breaker 1 GM15301 Washer plain 406 ID x 1 in OD 6 X 25 118 Washer spring 46 ID x 875 in OD 6 X 6086 20 Washer spring 39 ID x 81 in OD 3 X 6086 6 Breaker circuit 1 X 6304 103 Nut hex 3 8 16 zinc 3 X 83 7 TP 6116 2 02 Description Line Circuit Breaker 600A Bracket circuit breaker Insulation CB Cover side Bus line Decal power breaker Washer plain 406 ID x 1 in OD Washer spring 46 ID x 875 in OD Washer spring 39 ID x 81 in OD Break
112. Does not require manual reset Overvoltage Shutdown Lamp lights and the engine shuts down immediately if an overvoltage condition arises if equipped with overvoltage shutdown kit Underfrequency Shutdown Lamp lights and the engine shuts down if the engine speed drops below 5 of the nominal engine speed 1710 for 1800 rpm or 1425 for 1500 rpm for a continuous 60 second period Figure 1 3 Auxiliary Fault Lamp Operation 1 2 3 Fuses 1 2 4 Analog Meters and Gauges The fuses listed in Figure 1 4 protect the generator set Figure 1 5 describes the meters and gauges located on circuitry microprocessor controllers 3 amp remote annunciator fuse protects the dry contact kit if equipped 3 amp controller fuse protects the controller circuit board speed sensor and lamp circuit board 15 amp engine and accessories fuse protects engine starting circuitry and accessories AC voltmeter Meter displays the AC output voltage Use the selector switch to choose the output lead circuits AC ammeter Meter displays the AC output amperage Use the selector switch to choose the phase currents Figure 1 4 Controller Fuses DC voltmeter Meter displays the voltage of the starting battery ies Frequency Meter displays the frequency Hz of the meter generator set output Hourmeter Hourmeter records the generator set total operating hours for reference in maintenance scheduling pressure Gau
113. Drive Discs to Flywheel Torque Values 16 1 8 Terminal Block Reconnection Decal 80 300 kW 17 Section 2 Troubleshooting sQ eei Isa S SS 19 Section 3 Alternator Troubleshooting 25 31 WEE CILE 25 3 2 General Troubleshooting 25 3 3 Separate Excitation ee T FERE is 25 3 4 Wound Field Voltage Regulators 26 3 4 1 Unstable Voltage Troubleshooting 26 3 4 8 Voltage Regulator 28 3 4 3 Voltage Regulator 29 3 54 cExciter Field mit eue ea ns eds Sa 30 3 6 Exciter Armature issus ee EN ve er eibi demere pe ele 31 3 7 Rotating Rectifier Assembly RRA Varistor 32 cot e ento au d MERC M 33 E e ONIS d fera 33 3 10 Sensor Test reiri sisa eae ere ree eu RR 35 3 11 Interface Circuit Board 0 11718 36 Section 4 Alternator Disassembly Reassembly 39
114. Dual 200 A 150 A GM19665 KA1 Cover side Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Relay protective Transformer curr 400 5 round Insulator Bus load Tag ground Plate Washer plain 203 ID x 75 in OD Washer plain 344 ID x 875 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 200 A Breaker circuit 150 A Nut hex 5 16 18 Line Circuit Breaker 600 A Bracket circuit breaker Bracket circuit breaker Relay protective Transformer curr 500 5 round Bus load Cover side Bus line Insulation CB Plate Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 600 A Screw pan head machine 222835 222908 222909 222910 227266 248874 290020 324313 354518 GM19468 X 25 45 X 25 75 X 50 41 X 6086 6 X 6128 3 X 6304 161 X 6304 162 X 82 6 GM19674 KA1 222909 222910 227266 248875 324313 360970 BLK 365606 365627 GM19468 X 6086 6 X 6128 3 X 6304 169 X 6308 2 A 2 2 2 ae f N QO N QO OQ N Line Circuit Breaker Dual 225 175 19678 1 Cover side Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Relay protective Transformer curr 500 5 round Insulator Bus load Plate Washer plain 203 ID x 75 in OD Screw slotted pan head ma
115. GM15301 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 13 334029 222908 222909 222910 290020 324313 354518 GM10528 BLK GM15301 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 85 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw cross recess pan head machine Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 225 A 240 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 225 A 600 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 225 A 600 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Washer spring 39 ID x 81 in OD
116. Gauge restriction Air cleaner kit 20 2000 kW Coupling pipe 1 8 x 1 3 16 in Air Cleaner Restriction Indicator Gauge restriction Air cleaner kit 20 2000 kW Qty Part No 274608 267428 273113 X 216 24 326237 273113 328005 273113 D 228 343513 273377 GM10756 KA1 273113 276552 360975 TT 1207 GM11490 KA1 267428 GM11489 TT 1207 X 216 24 GM11491 KA1 GM11489 TT 1207 Alarm Kits Inner Subbase Fuel Tank Leak Inner Tank Leak Alarm Bracket support Insert threaded Box Harness wiring leak alarm 6 15 kW Harness wiring leak alarm 200 400 kW Fuse 5 A 250 V Connector plug 4 position Connector plug 4 position Connector jack 4 position Connector jack 4 position Lens red Switch float 1 pole Vibromount Fuse holder inline Plate silkscreen Screw mounting Bracket leak alarm Box assembly Sensor leak Plate assembly PCB assembly A V 1 light annunciator Grommet round Screw cross recess round machine Spacer 25 OD 5 in Screw hex washer head drill TP 6116 2 02 Ry PM Sak ch P h 0 ch ch ch nnn nin ch pu 226203 224871 225948 225949 226200 226207 239298 239408 239408 239411 239411 253241 255600 259919 269216 276800 292828 336505 224861 226201 276799 292883 284 15 51 11 712 9 794 2 Kit Parts List Description Inner Tank Leak Alarm Bracket support Insert threaded Box Harness wiring le
117. Interface Circuit Board GM11718 Verify connection and continuity of the wires shown in Figure 3 25 and Figure 3 26 Check the wires for broken strands and damaged insulation including cuts and chafing Check the terminals for corrosion and loose electrical connections Repair and or replace any defective wiring Circuit Board Connection Component Connection P6 1 TB3 1 P6 2 TB3 7 P6 3 TB4 4 P6 4 P1 16 P6 5 P1 20 P6 6 none T1 Stator main field 55 T2 Stator main field 66 T3 Exciter field IB F T4 Exciter field IB F Figure 3 25 Interface Circuit Board Connections TP 6349 6 07 P6 CONNECTIONS PIN 1 E12 TB3 1 N TB3 7 EOV TB4 4 38 1 16 58 1 20 EXCITER FIELD ig 0 lt KE Gi 12 LEAD dt 66 STAT 66 F1 EXCITER FIELD F2 EXCITER FIELD GM35944 B Figure 3 26 Interface Circuit Board Diagram with Wound Field Alternator Dothe checks shown in Figure 3 27 Shut down the unit If the circuit board is still suspected of questionable after performing the start and run checks function after the circuit board wiring checks out okay replace with a known good circuit board and test the generator set for functionality Connections Display Check Possible Causes P6 E12 and P6 N connections 12 VDC supply from 550 Check
118. J U JI UO JOU jsnui Je e9u SIU L ONINSVM snoues 10 yyeap ul 1nseJ Aew uejs s eu punoJB anpe eui eq LSNA Pee y L N JO 27 pue 1 YOO jeur y slo s 94 p nous 1 Z LNO LND AYNLVeAdN SL HOIH 1 5 O23 s ou JNOYOOUY OM SU JO euo BIA eje dxoeq ay JO puey Jamo uBnoJui pinous pun y Ague 16 S10jonpuoo 2 JYIM doup jeuoniodoud aq Wan Ag0Z 022 H3JddOO 1 peiddns jenjoe ay J SOA OpZ pae sjejeeu oul s uoul g 6 07 56 5645 ez ze 2 8148 n 99 9985 Loi 99 99 45 ve on Sr 22 2 9848 6 0 2 0046 88 06 064 81 62 08 0845 89 89 2266 09 LZ 0945 3215 or ly 96 en ur ELT 31 ViddOHddV OL 62 Llp en oe io 2442648 or Lv 95 16 Vv 800745 ez 0 808 802648 Ee ve or ar DEL NCC BERGL SONIS 62 y Lb 92 0 u 20645 AMLN3 SHIM e 00022 PE 204 AW ECON SLINN dS dO SONILVY paea eui Aq pej2ejoud Oo GZ 0 dn asn 10 9215 eyeudoudde ay J
119. M934 05 50 X 6128 3 X 6304 61 GM14029 KA10 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 X 6304 79 GM14029 KA11 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 934 05 50 6128 3 6304 82 GM14029 KA12 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 X 6304 83 a 0 Mi 2022p P Mi zb ch P 2022p Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5 Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Brac
120. N Lower the alternator assembly to a horizontal position Attach the hoisting hooks to the adapter as shown in Figure 4 12 Suspend the alternator assembly Before lowering the alternator assembly place boards along the edge of the end bracket Maintain a25 mm 1 in clearance underneath the center of the end bracket to allow for rotor shaft clearance Figure 4 12 Supporting Alternator Assembly TP 6349 6 07 Section 4 Alternator Disassembly Reassembly 45 10 Fasten the lifting eye and hoist hook to the rotor flange See Figure 4 13 Hoist the rotor to a vertical position taking care not to damage windings laminations or bearing Figure 4 13 Hoisting Rotor 11 12 13 46 Suspend the rotor over the alternator assembly Lowerthe rotor into the stator Be extremely careful while lowering the rotor to avoid damaging the exciter field assembly stator windings or rotor laminations See Figure 4 14 align rotor bearing into end bracket Place the fan over the rotor flange and the torque bolts to specifications 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
121. Nm 100 ft Ib See Figure 3 7 im L 5 GM18401 J 4 32 blade retention bolts nuts 136 Nm 100 ft Ib 5 12 hub boss cap screws 102 Nm 75 ft Ib 6 3 bushing cap screws 43 Nm 32 ft Ib Figure 3 7 Fan Hardware Location and Torque 7 Retorque the 12 qty hub boss cap screws to 102 Nm 75 ft There are six screws on each side of the fan 8 Retorque the 3 gty bushing cap screws to 43 Nm 32 ft Ib 9 Replace the fan guards screens and covers that were removed to access the radiator fan hardware 10 Checkthat the generator set master switch is in the OFF position 11 Reconnect the generator set engine starting battery negative lead last 12 Reconnect power to the battery charger if equipped 30 Section 3 Scheduled Maintenance 13 Place the generator set master switch to the RUN position to start the generator set Refer to the respective generator set operation manual as needed 14 Listen and observe the fan operation 15 Immediately shut down the generator set if abnormal noise or fan assembly vibration is observed Correct the problem and go back to step 13 16 After several minutes of generator set operation without abnormal noise or vibration shut down the generator set by placing the generator set master Switch to the OFF RESET position 3 9 Radiator Fan Bearing Lubrication
122. S3ILNVYVD S31 53 3HlN3 SIHdWOO A sallonidWi SSLLNVYVD 631 881001 un no eun e sop uonisodxe eun e uonesiynn asieanew eun e e uoneoyipou eun e snp sjnejop sed ojAnoo eu 27 YNZLONILX31 4 YNOd 3NIOIHO 8303 4 S30 36110 1 1036 10 1 3HOON3 183 gien 306 31 IS eles xnenjosjop no sinejep sap 890919 epoued ep sinoo ny jeuoep el e sue 0 xis ep epoued eun ep sinejounxe s s SNY 9 121 ne ep ep xoip esse 9 e das e 4444 19 444 essnoui e 9558 2 e t sli A nd nea no nea e STaNNVIN a NOILVSITILO Q TANNYN AAA ETF EE ECS SESE ESET gag SJeuejsej 10 6 195 Buisn eoejins pijos e peunbeJ ji jexoeiq poeAojdde ue io ieusinBunxe y peusiuin
123. STOP lamp and shuts down the unit Before restarting the generator set reset emergency stop switch by replacing the glass piece and reset the generator set by placing the master switch in the OFF RESET position The switch holds a single replacement glass piece which is available as a service E na BRASS 9 CT Figure 6 11 Emergency Stop TP 6161 1 08 6 1 13 Remote Serial Annunciator The remote serial annunciator monitors the condition of the generator set from a location remote from the generator set If a generator alarm condition occurs the remote annunciator alerts the operator through visual and audible signals using a 5 485 controller connection See Figure 6 12 Requires a controller communication module kit installed in the controller See Figure 6 13 Overcrank Not In Auto High Engine Temp Common Fault Low Oil Pressure Battery Charger Battery Voltage Overspeed On Higli Blink Low Emergency Stop Low Level Low Coolant Temp Low Fuel Alarm Silenced Generator ID Location EPS Supplying Load System Ready RSA 1000 Generator Running Communication Status Figure 6 12 Remote Serial Annunciator RSA CH GM32644 B 1 Communication circuit board GM47242 or GM49791 1 Note Circuit board GM 49791 2 is a
124. Standoff insulator 1 4 20 x 1 5 in Breaker circuit 200 A 600 V 3 pole Qty Ph sch Mi P N N Ny CO GN gt Ny A ANOU gt gt P EP PA A NNa Part 334046 222908 222909 222910 222949 BLK 290020 324313 354518 360763 X 6086 6 X 6128 3 X 6304 5 X 6308 1 334047 222908 222909 222910 222950 BLK 290020 324313 354518 360763 X 6086 6 X 6128 3 X 6304 5 X 6308 1 334048 222908 222909 222910 290020 324313 354518 GM10528 BLK X 25 45 50 41 6086 6 6128 3 6304 9 334049 222908 222909 222910 222949 290020 324313 354518 25 45 50 41 6128 3 6304 9 334050 222908 222909 222910 290020 324313 354518 GM10528 BLK X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 14 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 225 A 600 V 3 pole L
125. The following procedure applies only to 1200 2000 kW generator sets Lubricate the radiator fan shaft and idler shaft bearings at every engine oil change to avoid bearing damage Lubricate the bearings every 200 hours of operation when the generator set runs in ambient temperatures below 29 C 85 F or when the generator set runs in a dusty and or humid environment Lubrication and Drive Belt Adjustment Procedure Lubricate the fan shaft and idler shaft bearings with a lithium complex base multi purpose grease with antirust and extreme pressure additives having a minimum dropping point of 204 C 400 Use Mobil Mobilith AW2 NLGI Grade 2 or equivalent 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the generator set engine starting battery ies negative lead first and disconnect power to the battery charger 3 Remove the belt guards to expose the fan shaft and idler shaft bearings 4 Inject grease into the two bearings on the fan shaft block and the two bearings on the idler shaft block using a grease gun until a 3 6 mm 0 13 0 25 in grease column shows atthe bearing pressure relief port See Figure 3 8 Note The fan shaft and idler shaft bearings have pressure relief ports to prevent bearing damage caused by overlubrication TP 6161 1 08 5353 3 1 Grease fittings
126. UM I9A UM P9 UM ON 9UON pesn SI juo pesn ULI OM 1601 IUO Z umosg ngum ong sg pow E E poH owon s 10918 XLIB IIMA 4 0 5 702130 uo peseq 2 pue g 1 TSOJON ON S YBIY pue O N S Janaj uaym AjUO pesn aq ULI 5 OM 900 eouejsip Q WNWIUIW 2 188 0 pun Jo pue WNWIUIW 2 1 2 8 ed 7 2 SaYyBry eouejsip 8 6 1 V Al dnog 4 9 VA 02 SIYIPMS 1445 5 1548 199951 41 0 9945 ssajujejs ul pue p SadAL 40109 ON S pue Ap O N S aq ULI sJ A9 OM 1601 900 9 0N Sara UOHeNjoe eouejsip P L e2ue sip E 9 9 pun jo pue 2 4140 9441 7 2 5 o ouglsIp 2
127. X 6128 3 Breaker circuit 1 X 6304 61 Marker wire 1 X 750 14 Marker wire 1 X 750 15 Marker wire 1 X 750 16 Nut hex 5 16 18 6 X 82 6 Line Circuit Breaker 225 A W 12 V S T GM17679 KA10 Bracket circuit breaker 1 222908 Bracket circuit breaker 1 222909 Insulator 2 290020 Bus load 1 324313 Tag ground 1 354518 Bus line 3 364498 Decal power breaker 1 GM15301 Bracket circuit breaker 2 GM17634 Cover side 1 GM17638 BLK Nut hex 5mm 4 M934 05 50 Washer plain 344 ID x 875 in OD 12 X 25 75 Washer spring 39 ID x 81 in OD 6 X 6086 6 Standoff insulator 1 4 20 x 1 5 in 2 X 6128 3 Breaker circuit 1 X 6304 79 Marker wire 1 X 750 14 Marker wire 1 X 750 15 Marker wire 1 X 750 16 Nut hex 5 16 18 6 X 82 6 35 Kit Parts List Description Line Circuit Breaker 250 Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5mm Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Qty Part No GM17679 KA11 O NONA 3 3 N 7 222909 290020 324313 354518 364498 GM15301 GM17634 GM17638 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 82 X 750 14 X 750 15 X 750 16 X 82 6 Line Circuit Breaker 250 A W 12 V S T GM17679 KA12 Bracket circuit breaker Bracket circu
128. adjustment if equipped Oil pressure gauge Hourmeter Emergency stop switch if equipped Section 1 Specifications and Features 11 16 light controller with communications has a new circuit board GM28725 that is different in appearance and has additional functions from the earlier versions but is a direct replacement for earlier version circuit boards including A 336415 Features of the new circuit board include the following items New Application Program Software Contact your local authorized distributor for application program updates when instructed to do so during troubleshooting and or when adding specific accessories Refer to TT 1285 Program Loader Software instruction for additional download information Red circuit board previous versions are green Terminal strips TB1 TB2 and TB3 SWh switch 8 switches Communication connector P21 for Modbus to 1 2 1 Annunciator Panel Lamps Figure 1 2 lists the annunciator lamps included on each controller and describes the lamp functions download new application program software or to connect the remote serial annunciator using RS 485 communications Requires RS 485 to RS 232 converter for downloading application program e Communication connector P22 for J1939 engine communication Lamp Description Air damper This light is not used on current standard products Auxiliary fault Flashes or lights upon fault detection Figure
129. battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie 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 1 08 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 cylinde
130. battery and or connections controller Check P6 connector and wiring P6 3B and P6 5B connections 1 8 VDC output Check controller interconnection P1 connector and wiring start and run unit for this test Check T3 and T4 connections field wires Check F1 and F2 winding and connections at exciter field Field overvoltage fault display on 550 P6 EOV connection Check if P6 EOV is grounded controller T1 and T2 PMG connections 200 230 VAC stator output Check T1 and T2 PMG connections start and run unit for this test Check 55 and 66 winding and connections at stator F4 and F connections DC voltage values are Check T3 and T4 connections field wires alternator dependant Check F1 and F2 winding and connections at exciter field Figure 3 27 Interface Circuit Board GM11718 Testing TP 6349 6 07 Section 3 Alternator Troubleshooting 37 Notes 38 Section 3 Alternator Troubleshooting TP 6349 6 07 Section 4 Alternator Disassembly Reassembly WARNING 4 1 General Before beginning disassembly carefully read all safety precautions at the beginning of this manual Please observe these precautions and those included in 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 or Figure 4 2 to help understand component descriptions and general c
131. battery charger control Charger assembly battery Charger battery automatic Charger battery circuit board Washer lock 262 ID x 743 in OD Washer lock 172 ID x 595 in OD Washer lock 146 ID x 53 in OD Washer lock 146 ID x 285 in OD Screw slotted pan head machine Screw slotted pan head machine Screw slotted pan head machine Screw cross recess pan head machine Screw slotted pan head machine Screw slotted pan head machine Screw cross recess round machine Screw cross recess pan head machine Screw slotted pan head machine Screw cross recess machine Screw Phillips hex crimptite Nut hex machine screw 6 32 TP 6116 2 02 Qty NN EN ch P Ai hh ch Part PAD 292862 233966 239298 241605 257442 262389 262394 262397 262399 263156 287948 291208 292387 292940 292941 292942 292945 292948 292958 292961 292962 295010 295314 298810 325593 SD 325596 325608 C 262377 D 292862 TT 680 TT 729 X 22 12 X 22 18 X 22 25 X 22 6 X 49 25 X 49 26 X 49 39 X 49 6 X 50 1 X 50 3 X 51 11 X 51 15 X 51 30 X 51 9 X 6216 1 X 71 2 Kit Parts List Description Battery Charger 12 Volt Decal connection Fuse 5 A 250 V Connector plug 12 position Clip speed Fuse 25 125 V Transformer 120 240 V 29 5 V Decal warning connection Clip cable Holder fuse Spacer Lamp 120 V 33 W Decal S
132. block Terminal block link Section 4 Alternator Disassembly Reassembly 41 Perform following steps prior to disassembling the generator set 1 5 Disconnect negative lead first remove the starting batteries from the work area to prevent a fire hazard Disconnect AC powered accessories such as the battery charger block heater and fuel transfer pump Shut off the fuel supply Drain the fuel system as necessary by emptying the fuel into proper containers Remove any fuel containers from the work area to prevent a fire hazard Ventilate the work area to clear fumes Disconnect the fuel cooling and exhaust systems as necessary to tilt the generator set Disconnect the output leads or load circuit cables at the generator set 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 the generator set nameplate or spec sheet for weight Remove the junction box panels 4 2 Disassembly 1 42 Remove the two mounting screws Disconnect all controller to engine and engine to alternator harnesses and wiring Disconnect the speed sensor wiring Remove the junction box and the controller as a unit Remove the fan guard Remove the rotating rectifier assembly housing Remove the alternator rodent guard on the end bracket if equipped Remove the speed sensor from the end bracket
133. cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6161 1 08 Accidental Starting WARNING Pa or Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or 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
134. connections including multiple battery configurations After reconnecting the battery cables coat the terminals with petroleum jelly silicon grease or other nonconductive grease Note Some units require a reflective heat shield insulative sleeve on the battery cables and other wires that are fastened to the starter solenoid This sleeve is a conductive material and must be secured approximately 25 mm 1 in away from the exposed cable terminal EZ 273000 J 1 To positive 4 terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 3 10 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection 32 Section 3 Scheduled Maintenance 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 3 11 24 Volt Engine Electrical System Single Starter Motor Typical Battery Connection KW 272000 B 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor 3 To positive terminal on second starter solenoid 4 To ground terminal on or near second starter motor Figure 3 12 24 Volt Engine Electrical System Dual Starter Motors Typical Battery Connections TP 6161 1 08 3 10 1 Cleaning Clean the battery and cables and tig
135. contact kits may connect to a specific output connection on the controller Figure 6 4 shows some typical dry contact kits mounted on an assembly panel for 450 kW and larger generator sets Typical 10 and 14 relay contact kit output connections include e Overspeed e Overcrank e High engine temperature e Low oil pressure 48 Section 6 Accessories e Low water temperature e Auxiliary fault e Anticipatory high engine temperature e Anticipatory low oil pressure e Emergency stop Additional connections available with the 20 relay kits include e Battery charger fault e Low battery voltage e Low fuel level e Engine trouble e Notin AUTO e System ready e Common fault e Overcrank e Crank terminate e Cooldown 270 365569 1 10 relay kit 2 20 relay kit Figure 6 4 Dry Contact Kits shown mounted on assembly panel for 450 kW and larger generator sets TP 6161 1 08 6 1 66 Engine Senders Alert the user of low water temperature approaching low oil pressure and approaching high engine temperature Kits for gas fueled models include a low fuel pressure switch 6 1 7 FASTCHECK Diagnostic Tester M The FASTCHECK diagnostic tester simulates engine operation to identify faults in the controller and engine circuitry Use the FASTCHECK when trou
136. day tank 6 60 kW Fuse 5 A 250 V Relay 120 VAC 15 Cover conduit box Fuse holder inline Box junction Harness wiring engine 125 180 kW Bracket relay Box controller Pump motor assembly Washer lock 146 ID x 53 in OD Washer lock 172 ID x 333 in OD Fitting hose connector 90 deg Hose Clamp 1 in hose Screw slotted pan head machine Screw slotted pan head machine Coupling non metallic Conduit convoluted Nut hex machine screw 6 32 Day Tank Electronic Sensor float Module power Harness wiring day tank 80 400 kW Harness wiring 6 15 kW 1 phase Switch float 1 pole Connector jack 9 position Connector plug 9 position Pump motor assembly Grommet Fitting hose connector 90 deg Hose Clamp 1 in hose Day Tank Relay Control Coupling conduit elbow Coupling conduit elbow Fuse 5 A 250 V Relay 120 VAC 15A Cover conduit box Fuse holder inline Box junction Harness wiring motor Harness wiring engine 125 180 kW Switch float Bracket relay Box controller Pump motor assembly Washer lock 146 ID x 53 in OD Washer lock 172 ID x 333 in OD Fitting hose connector 90 deg Hose Clamp 1 in hose Screw slotted pan head machine Screw slotted pan head machine Coupling non metallic Conduit convoluted Nut hex machine screw 6 32 TP 6116 2 02 Qty 44 ch ch ch ch ch bi zk ch ch ch ch
137. engine Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater Drive Belts Check the belt condition and tension of the radiator fan water pump and battery charging alternator belt s Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold exhaust line flexible exhaust clamps silencer and outlet pipe for cracks leaks and corrosion e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace the exhaust clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed Fuel Level Check the fuel level and fill the tank s regular
138. fault exists in the rotor and or stator A alternator component that appears good while static stationary may exhibit a running open or short circuit while dynamic moving Short circuits can be caused by centrifugal forces acting on the windings during rotation or insulation breakdown as temperatures increase 1 Disconnect all of the leads from the voltage regulator 2 Disconnect the FP FN connector 3 Disconnect the exciter field winding leads Connect an ohmmeter to the exciter field winding and measure the resistance Section 3 Alternator Troubleshooting 25 4 Connect separate excitation circuit as shown in Figure 3 2 Connect a DC ammeter in series with FP Note and record the ammeter reading The approximate ammeter reading should be battery voltage divided by the specified exciter field winding resistances cold See Section 1 Specifications for the values Example 12 Volts Battery Voltage 0 99 amps Exciter Field 121 Ohms Winding Current Exciter Field Winding Resistance Voltage regulator DC ammeter Battery Ground to alternator frame Exciter armature field winding Figure 3 2 Separate Excitation Connections 5 Move the generator set master switch to the RUN position to start the generator set 6 Check the ammeter values Unstable ammeter reading An in
139. foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and Instructions 5 Battery gases cause severe injury or death Battery gases can cause an explosion Do not smoke or permitflames or sparksto occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away 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 conn
140. gauge driver and is not a communications circuit board Figure 6 13 16 Light Controller with Installed Comm Module controller top view TP 6161 1 08 6 1 14 Run Relay Kit The run relay kit includes three sets of contacts that energize only during generator set operation The run relay kit can control air intake louvers radiator louvers alarms and other signaling See Figure 6 14 Figure 6 14 Run Relay Kit 6 1 15 Safeguard Breaker The safeguard breaker senses output current on each generator phase and shuts offthe AC voltage regulator if a sustained overload or short circuit occurs Itis nota circuit breaker and does not disconnect the generator set from the load See Figure 6 15 X NIN Figure 6 15 Safeguard Section 6 Accessories 51 6 2 Accessory and Prime Power Terminal Strip Connections M The 16 light controller circuit board has terminal strips for use in connecting a controller connection kit Do not connect accessories directly to the controller terminal strips Connect accessories to either a controller connection kit or dry contact kit Connectthe dry contact kit s to the controller connection kit Connect alarms battery chargers remote switches other accessories to the dry contact kit relay s The 16 light controller has two terminal strips TB1 and TB2 on the controller circuit board and prime power choices are made on TB2 See Figure 6 16 f
141. high and low marks Note Air pockets often form in the engine water jacket when the coolant system is refilled Check the coolant level in the coolant recovery tank after each generator set operation and add coolant as necessary until the coolant level stabilizes Then check the coolant at the interval specified in the service schedule 14 Reenergize the block heater if equipped 3 8 Radiator Fan Bolt Retorque Adapted from Service Bulletin SB 683 12 07a The radiator fan bolts must be initially checked after approximately 8 hours of operation and then rechecked after each 100 hours of operation This scheduled service is required on all 1500 2800REOZDC unit mounted radiator models using a 2743 mm 108 in diameter fan Perform the scheduled service steps in the order shown Required Tools e Socket wrench sets American Standard and Metric sizes e Torque wrench up to 203 Nm 150 ft Ib Procedure 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the power to the battery charger if equipped Section 3 Scheduled Maintenance 29 3 Disconnect the generator set engine starting battery ies negative lead first 4 Remove the fan guards screens and covers as necessary to access the radiator fan hardware 5 Inspect the blades for cracks or other damage Verify that all hardware is present Replace needed 6 Retorque the 32 qty blade retention bolts nuts to 136
142. in x 1 1 4 in SAE grade 8 4 5 GM21443 Manifold exhaust 1 6 GM21444 Gasket 3 Common hardware procure locally CD36530A Var Part No Description 2802T 1 336724 Screw hex head 6 2 Washer 10 x 18 x 2 500 mm 6 3 GM21445 Manifold exhaust 1 4 GM21446 Gasket 3 Common hardware procure locally TP 6141 12 03 23 Group 13 See Group 8 Var PartNo Description 1501 1 Screw 1 2 in x 1 1 2 in 4 2 GM21447 Flywheel d 3 223613 Gear flywheel ring 1 Common hardware procure locally Group 13b Flywheel Housing See Group 8a PartNo Description 1418 1453 1 GM21448 Housing d 1 GM32730 Housing 1 2 224268 Plug pipe AR 3 Screw cap 5 8 in x 3 in SAE grade 8 2 3 Screw cap 5 8 in x 2 1 2 in 2 4 Screw 3 8 in x 1 3 8 grade 8 8 8 5 Screw cap 5 8 in x 5 1 2 in SAE grade 8 2 2 6 360582 Plug 1 1 7 223558 Gasket 1 1 8 223583 Seal 1 1 Common hardware procure locally AR As Required 24 TP 6141 12 03 Group 14 Fuel CD42106 Var Item Part No Description 3710 GM21449 Pump fuel GM17555 O ring 44 12 x 2 616 Washer 11 32 in x 11 16 in x 0 065 in Screw cap 5 16 in x 7 8 in GM21450 Clip GM21451 Hose GM21452 Line fuel GM17494 Washer sealing GM21453 Nut Common h
143. installations only For standby service connect the output of the generator set to a suitably rated transfer switch accordance with Canadian Electrical Code Part 1 Safety Precautions and Instructions 9 Notes 10 Safety Precautions and Instructions TP 6349 6 07 This manual provides troubleshooting repair instructions for the generator set models listed on the front cover using wound field 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 injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference TP 6349 6 07 Introduction The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe pres
144. 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 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 8 Safety Precautions and Instructions 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 into a utility electrical system can cause severe injry or death to utility personnel working on power
145. line Clamp hose 5 1 in D W In Base Daytank Elec Control Module power Wiring harness extension Wiring harness 6 15 kw 1 phase Switch float 1 pole Pump motor assembly Sensor float Fitting hose connector 90 deg Hose Clamp hose 5 1 in Day Tank Relay Control Module Coupling conduit elbow Pump motor assembly Box assembly controller Switch float Connector 90 deg 1 2 in ID hose Hose Clamp hose 5 1 in Screw slotted pan head machine Day Tank Relay Control Module Coupling conduit elbow Pump motor assembly Box assembly controller Switch float Connector 90 deg 1 2 in ID hose Hose Clamp hose 5 1 in Screw slotted pan head machine Qty Part No 343678 156327 156327 224869 224873 239298 241950 266469 269216 274883 279875 343676 A 290024 A 343677 X 214 22 X 22 25 X 22 7 X 391 13 X 422 30 X 426 10 X 50 3 X 51 12 X 567 1 X 6003 10 X 71 2 GM10410 KA1 156327 279745 A 290024 A 343677 GM10440 M934 05 50 X 391 13 X 422 36 X 426 10 GM10432 KA1 224825 224881 224884 255600 A 290024 GM10430 X 391 13 X 422 30 X 426 10 GM17211 KA1 156327 A 290024 A 343677 GM16906 X 391 13 X 422 30 426 10 50 3 GM17212 KA1 156327 A 290024 A 343677 GM16907 X 391 13 X 422 30 426 10 50 3 NY s NY Mi zk ch ch ch ch ch Mi Ny ch a NN ch
146. 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 andfollowthe 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 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 Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools 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 caus
147. lqisnquuo2 Jo ajqeluwey Jo 9jes Aled 5 JO JooJduoisojdxa aen sjeuajeur pue a qnsnquioo 0 paywit se suty yons suoneot dde ease snopsezey Joy 10 snoues ynso 514 9 20500 0 eJn re4 e2ueuejuteu pue uotjej ejsur 5 unang jonpojd ajqeoydde ay pue opo Jeoui2e a aouep 40228 1915 ut paj ejsu pue aq jsnu sjonpoJd sway 5 lupe odu 2997 262 098 4 1909 26 098 jet Bulyooisas Adde ay 8 pejdaooe jou 541019 dijs pue Jeurejuoo au u predasd 146133 wnay wnay 10 jueuruedeg suJnjas JNO 9 002 Ienu jO 5 OF o dn swa 32015 uo padae 5 N3399 038 uonenjoe 9 9 20 p Z JO Wun e eq jsnui ways Jo pug uun 10 105485 1 uoneuuoju 20 6205495 suec joejuoo
148. needed 3 13 2 Cooling System Prepare the cooling system for storage as follows 1 Check the coolant freeze protection using a coolant tester Section 3 Scheduled Maintenance 35 2 Add replace coolant necessary to ensure adequate freezing protection Use the guidelines included in the engine operation manual 3 Run the generator set for 30 minutes to redistribute added 3 13 3 Fuel System Prepare the fuel system for storage as follows Diesel Fueled Engines 1 Fill the fuel tank with 2 diesel fuel 2 Condition the fuel system with compatible additives to control microbial growth 3 Change the fuel filter separator and bleed the fuel System See the engine owner s manual Gasoline Fueled Engines 1 Add stabilizer to the fuel system Follow the manufacturer s recommended procedure 2 Runthe generator set for 15 minutes to ensure that the stabilized fuel reaches the carburetor 3 Place the generator set master switch in the OFF RESET position 4 Close the fuel valve Gas Fueled Engines 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the generator set until the engine stops 4 Place the generator set master switch in the OFF RESET position 3 13 4 Internal Engine Components Gas Gasoline Fueled Engines If you have access to a fogging agent or SAE 10 oil prepare the pistons and cylinders for storage as follows 1 Whi
149. or fuel injectors dirty or faulty diesel only Clean test and or replace the inoperative fuel injector t Eng S M Fuel filter restriction Clean or replace the fuel filter Eng O M Fuel solenoid inoperative Troubleshoot the fuel solenoid Eng S M x Fuel pressure insufficient gas only Check the fuel supply and valves S S Gen O M x Fuel injection timing out of adjustment diesel only Adjust the fuel injection timing Eng S M Alternator AC output circuit breaker open Reset the breaker and check for AC voltage at the generator side of the circuit breaker Transfer switch test switch in the OFF position Move the transfer switch test switch to the AUTO position ATS O M Transfer switch fails to transfer load Move the ATS test switch to the AUTO position Troubleshoot the transfer circuit and time delays ATS O M S M Wiring terminals or pin in the exciter field open Check for continuity Section 3 W D Main field rotor inoperative open or grounded Test and or replace the rotor Section 3 Stator inoperative open or grounded Test and or replace the stator Section 3 Vibration excessive Tighten loose components Voltage regulator digital settings incorrect digital controller only Adjust the voltage regulator Section 3 Voltage regulator inoperative Replace the voltage regulator fuse If t
150. outlet before working on the block heater electrical connections Handling the capacitor Hazardous voltage can cause severe injury or death Electrical shock results from touching the charged capacitor terminals Discharge the capacitor by shorting the terminals together Capacitor excited models only 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 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 andfollowthe 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 8 Safety Precautions and Instructions WARNING Airborne particles Can cause severe injury or blindness Wearprotective goggles and c
151. pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex 4mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex 4mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex 4mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 24 Qty P Roop A hh A P P Naa Part 334752 253225 364492 1 49 2 334753 364493 BLK X 49 2 X 6250 4 334754 344905 364492 1 49 2 334755 364493 49 2 6250 16 334756 253226 364492 49 2 334757 364493 BLK X 49 2 X 6250 5 334758 222908 222909 290020 324313 354518 364484 364494 BLK M934 04 50 X 6086 6 X 6128 3 X 6304 54 334759 222908 222909 290020 324313 354518 364484 364494 BLK M934 04 50 X 6086 6 X 6128 3 X 6304 55 334760 222908 222909 290020 324313 354518 364484 364494 BLK M934 04 50 X 6086 6 X 6128 3 X 6304
152. poys 1eusinBulxe si asn 0 peoedxe eq 14 6 oym euo uy si usinBunx3 weoy 4444 pue 444v pue 1SIIN N3NHQ 7IHO WO3 AVMV SYSHSINONILXS 8413 4334 jeusinBunxe un Ajjenied e uaaa uolso dx ue pinoo dn pjinq 0650 4 LNO LON SI 3913 JHL di 3AV3130 Sauls 3HL OLNI YAHSINONILXS NV MOSHA H3A3N 39V4d S 3NOANV OLNI 5 9 V 2810 EELER OL SONIHL LNVLYOdINI NOILONGOULNI ENEE MERA ea eR hie emt 20 9 660217574 US ul WO MMM 0 58 65 0869 799 008 4 6 669 002 euoug 1800 02166 STHASSNYL 18 O d 4 1121 PU uo Queen Jeaf euo SUOnon sut JO 1800 6 156 TV apen Lg 0 d O eju si Jo uoneBtiqo ay jo aouewiopad 8 yorum Jauo nok pue 20905 5141 188 Ajssasdxa uey sayo Augen Aue M Jo eumsse oj uosjed 290 Jo Aue Jou diop nod oi jou suoisn oxe Jo
153. provides convenient monitoring of the generator set s condition from a remote location See Figure 6 10 The remote annunciator includes an alarm horn alarm silence switch lamp test and the same lamp indicators except air damper as the 16 light controller plus the following lamps Line Power lamp illuminates to indicate that the commercial utility is the power source Generator Power lamp illuminates to indicate that the generator set is the power source 50 Section 6 Accessories PREALARM _ HIGH ENGINE 7 7 TEMPERATURE HIGH ENGINE gt BATTERY gt UNE 7 TEMPERATURE 2 CHARGER FAULT 5 POWER PREALARM _ Lowo 7 7 PRESSURE gt LOW OIL y 77 LOW BATTERY GENERATOR _ PRESSURE VOLTAGE POWER 77 LOW WATER EMERGENCY 77 AUXILARY SYSTEM TEMPERATURE STOP FAULT V7 READY GENERATOR 2 SWITCH NOT IN AUTO Low FUEL OVERCRANK RA SILENCE NORMAL ALARM LAMP TEST Remote Annunciator wei 25025 e FBA 1 10 AMP 14 Relay Dry Contact Box Figure 6 10 Remote Annunciator with 14 Relay Dry Contact Box 6 1 12 Remote Emergency Stop Kit M The emergency stop kit shuts down the generator set from a remote location in an emergency See Figure 6 11 Activating the emergency stop switch lights the EMERGENCY
154. recess pan head machine 32 Qty Part No GM14027 KA12 1 1 4 1 GM14297 BLK GM15301 X 49 2 X 6250 4 GM14027 KA13 1 1 1 4 344905 GM14296 BLK GM15301 X 49 2 GM14027 KA14 1 1 4 1 GM14297 BLK GM15301 X 49 2 X 6250 16 GM14027 KA15 1 1 1 4 253226 GM14296 BLK GM15301 X 49 2 GM14027 KA16 1 1 4 1 1 1 4 1 1 1 1 4 1 1 4 1 1 1 4 1 GM14297 BLK GM15301 X 49 2 X 6250 5 GM14027 KA2 GM14297 BLK GM15301 X 49 2 X 6250 1 GM14027 KA3 269252 GM14296 BLK GM15301 X 49 2 GM14027 KA4 GM14297 BLK GM15301 X 49 2 X 6250 2 GM14027 KA5 258928 GM14296 BLK GM15301 X 49 2 GM14027 KA6 GM14297 BLK GM15301 X 49 2 X 6250 6 GM14027 KA7 253224 GM14296 BLK GM15301 X 49 2 GM14027 KA8 GM14297 BLK GM15301 X 49 2 X 6250 3 GM14027 KA9 258381 GM14296 BLK GM15301 X 49 2 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Bracket circuit breaker Decal power breaker Nut hex 4mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Bracket circuit breaker Decal power breaker Nut hex 4mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator
155. refer to Figure 1 12 L1 AMPS L112 VOLTS 12 AMPS 12 13 VOLTS 10 13 L3 AMPS _ VOLTS U 0 7 USE LOWER METER SCALES RESET VOLTAGE RUN OFF AUTO ADV 5849E B Voltage adjustment control Fault lamp 10 amp controller fuse DC voltmeter Water temperature gauge Oil pressure gauge Frequency meter AC voltmeter AC ammeter Scale lamps upper lower Selector switch Hourmeter Generator set master switch Figure 1 12 Expanded Decision Maker 1 Controller Figure 1 13 and Figure 1 14 describe the controls and indicators located on the controller Item Description Hourmeter Item Description AC ammeter Meter displays the AC output amperage Use the selector switch to choose the phase currents Hourmeter records the generator set total operating hours for reference in maintenance scheduling pressure gauge Gauge displays the engine oil pressure Scale lamps upper lower Lamps indicate which AC voltmeter and or ammeter scales to read AC voltmeter Meter displays the AC output voltage Use the selector switch to choose the output lead circuits DC voltmeter Meter displays the voltage of the starting battery ies Fault lamp Lamp illuminates during engine shutdown if the engine shuts down because of one of the following faults high engine temperature low water level low oil pressure overcrank or ov
156. rotor main field winding leads from the RRA See Figure 3 13 Keep each lead electrically separated from the other leads and any metal components GM32507 TP 6349 4 1 AC terminals 2 Diode terminal F 3 Diode terminal F 4 Varistor Figure 3 13 RRA Connections 2 Use an ohmmeter on the R x 100 scale to check the resistance between the RRA diodes as shown in Figure 3 14 The ohmmeter should show a low resistance in one direction and upon reversing the ohmmeter leads a high resistance in the other direction Replace the diode assembly plates service part set if any of the six diodes test differently than described Note Disconnect leads from rectifier module before performing test DI GM31963 TP 6349 4 1 Ohmmeter 2 Diodes 3 diodes per plate 3 Diode ground connection 4 Diode terminal Figure 3 14 Diode Assembly Plate part of RRA Test 3 Replace the varistor if there is evidence of heat damage Replace the diode assembly hub if any damage is evident TP 6349 6 07 3 8 Rotor The rotor magnetized by DC from the rotating rectifier assembly rotating within the stator induces AC in the stator windings Testthe rotor main field as described in the following steps Disassemble the alternator prior to performing this test See Section 4 Alternator Disassembly Reassembly for the procedure Generator Rotor Test Procedure 1 With the alternator disassembled disconnect the rotor mai
157. rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 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 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 Section 3 Scheduled Maintenance 31 to this section general battery information maintenance All generator set models use a negative ground with a 12 volt or 24 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator set spec sheet for battery capacity recommendations for replacement purposes The wiring diagrams provide battery connection information See Figure 3 10 Figure 3 11 and Figure 3 12 for typical battery
158. 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 6349 6 07 Appendix Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See Appendix C General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance Unacceptable Nut Bolt Clearance 1 1 2 of bolt diameter 2 Min 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths TP 6349 6 0
159. shun 679767 ERAN 2 001 20 VA 02 1845 19936 88811615 OLE N eung eue iod 54 SHOA ICON 40 0 peo eAnsisey yoUMS 3 P 5 1291070919 s d L 1 014 Water Systems SECTION 9 1 HEATING VENTILATION amp AIR CONDITIONING Section 9 1 Heating Ventilation amp Air Conditioning 9 1 11 Eemax Tankless Water Heaters Model SP3208 Tag NA SINGLE POINT CODE COMPLIANT HANDWASHING HEATERS instant Comfort ndless Savings ELECTRIC TANKLESS WATER HEATERS MODELS Volts SP2412 120V SP3012 120V SP3512 120V 5 3208 208 5 4208 208 SP35 240V SP48 240V SP55 240V SP3277 277V SP4277 Shonna Malls Office and Tenant Spaces Commercial Buildings restaurant e Modular Buildings Modular Offic s Public Hand Washing Service Stations Schools s Concessions Stands Stadiums Ke ADVANCED TECHNOLOGY e HIGHEST EFFICIENCY DESIGNED DURABILITY 9 06 arget outlet temperature 105 110 MADE IN USA QUALITY FEATURES s On Demand Hot Water no delay Cut Energy Waste flow switch activates heater only on demand no standby heat loss 99 efficient Continuous Hot Water no storage capacity to run out e Reduces Insta
160. solely on the level in the coolant recovery tank Add fresh coolant until the level is just below the overflow tube opening of the filler neck 28 Section Scheduled Maintenance 3 7 2 Cooling System Component Inspection To prevent generator set shutdown or damage caused by overheating e Keep the cooling air inlets clean and unobstructed e Inspect the radiator s exterior for obstructions Remove dirt and foreign material using a soft brush or cloth to avoid damaging the radiator fins e Check the hoses and connections for leaks Replace any cracked frayed or spongy hoses e Check the condition and tension of the radiator fan and water pump belt s Follow the belt tension procedure in this manual and or the engine operation manual e Checkthe pressure cap seal and replace a cracked or deteriorated cap Remove dirt and other debris from the pressure cap and filler neck The pressure cap raises the boiling point of the coolant enabling higher operating temperatures Replace a leaking pressure cap with one rated for the same pressure The pressure cap rating usually appears on the pressure cap 3 7 3 Cooling System Drainage Procedure For optimum protection drain flush and refill the cooling system at the intervals listed in the service schedule Note Dispose of all waste materials oil fuel coolant filters and gaskets in an environmentally safe manner 1 Deenergize the block heater if equipped 2 Re
161. 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 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 6349 6 07 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
162. suonet ay os jenuenbesuoo JO jejuepiout uopeyw Jo uorsnjoxe Jo sjse Up UE ue Buoj moy uo suopeyw JOU op 591216 S39VIAVO WILNSNOASNOO VIN3QIONI OL 318 1 38 dHOO TWHS ON NI 3 O8V 31916 500134 JWL SHL OL 34V ONY 350 YOd SS3NLId 40 SSILNVYYVM JON 108 S3ILNVHNVM TWV eoueuejureu Jo Jadoiduul suonipuoo eJnsodxe uoneleye uoneogipoui Bunins jou 5 Que eA SIUL YSHSINONILXS SHL 35 O 0350 338 3AVH SLYVd LN3IW3OV Id3H AYOLOVA ATNO dl HO ONV 51 WAS M3dWVl A3MO TVNIOIMO JHL 4 peoejdei saysinBuyxe Jo aq sjoajep yons Aue ponad Aueuew ay Buung aseyoind jo apep Sip 9 xis JO ponad 104 diusueubuow pue oj sy SJUBUEM x ALNVHSVM HV3A 9 QALIW SYSHSINONILXS Suis 112 epiXoiq uoqieg ssej5 Aq jeotwayyg 4443 8 444 56 2 je21u8u2 19M ISIN 4938 M JOJEAA 1 9 10 IV nNVN S YSNMO sed 1 05 eu uoddns je sei IS
163. touch hot engine parts The engine and exhaust system components become extremely hot during operation WARNING ES 4 Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do notreplace flexible fuellines with rigidlines 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 manufactu
164. 0 IN3H S NI 32NY vH 587 13 WN SLL OL INOYOL D 156282 4108 40 Qv3H 19 5 6062 ZB S60ZL LESIN JOSNASSY OL ove NATIO d 3808 8 81905 B S3lv1d SMOLVOO1 3S3HL NI HOWLLY 3IVNINE3L Liste 40 Lcrecl STS9 OL 50931 0134 7990 HILO c 1 682 14 5 9 8 N334138 31v201 296129 dx3 08 90 92 1 amg NMOHS 59 50 31 30010 SNIA331S 034 131110 0931 3dnlvWsw s3ll3X3 HOWLIY ONY S WNINE3L TIVISNI LJvHS Wows Z rO 5 05 OL 60431 H3lloX3 Worl Wil CERN 5 01 353 1 NI NMOHS 9 or Y Y NOILO3S 1108 40 Qv3H 8 586062 8 28 lt 8021 1 dX3 09200 00226 8228 ALY ONISN NOILYNINHL 133904 ENH NI 380036 2 6 lt 82 ogee 81 22 un 28 01 3nouoL 8 08 90 5 1 dx3 09 91090 lt LNO 01931 1413 NIV NMOHS Sy 50931 30010 SNIA331S 3M8 5871 13 821 WN 5 01 3noHoL 8 6 Gc x g 09 52001 280 91 15 Gg YN SLL OL 3nDHOL 8 156 52 NMOHS LK 5 ONISNOH TAHNAT LL6LENS Q3 N3l23X3 3 9 3 4 804 V AIA 335 8 MJA 335 18 01080 00068 1 896189
165. 0 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 175 A 600 V 3 pole Kit Parts List Qty pARo ENEE Ph ch NNa Ph ch A hb bh Ph ch ch Ny aaaN P P b i A Part 334041 222908 222909 222910 290020 324314 354518 GM10527 BLK X 25 45 X 251 17 X 50 41 X 6086 6 X 6128 3 X 6304 10 334042 222908 222909 222910 290020 324314 354518 GM10527 BLK X 51 47 X 6086 6 X 6128 3 X 6304 55 334043 222908 222909 222910 290020 324313 354518 GM10528 BLK X 51 47 X 6086 6 X 6128 3 X 6304 58 334044 222908 222909 222910 290020 324313 354518 GM10528 BLK 51 47 6086 6 6128 3 6304 58 334045 222908 222909 222910 290020 324314 354518 GM10527 BLK X 25 45 50 41 6086 6 6128 3 6304 12 11 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker
166. 01 v46 9N 08 01 9621 09 9200 ecen dX3 08 0 969H dxa 08 01 2 08 01 6 08 01 44218 1581 14 96 Sr OL SINN 184355 0 089 TIY 300801 310N Figure 4 25 4UAW Alternator Components 180 300 kW TP 6349 6 07 52 Section 4 Alternator Disassembly Reassembly Appendix Abbreviations The following list contains abbreviations that may appear in this publication A amp adj ADV Ah AHWT alt Al ANSI AO AR AS ASE ASME assy ASTM 5 auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk htr bps br BTDC Btu Btu min C cal CAN CARB CB cc CCA 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
167. 010 20 M7985A 05012 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 M5 0 80 x 10 M5 0 80 x 12 M5 0 80 x 16 M5 0 80 x 20 M5 0 80 x 25 5 0 80 x 30 M5 0 80 x 80 M5 0 80 x 100 6 1 00 x 100 Flat Head Machine Screws M965A 04012 SS M965A 05012 SS M965A 0501 6 20 965 06012 20 4 0 70 12 5 0 80 12 5 0 80 16 6 1 00 x 12 3 Metric continued Part No Hex Nuts M934 03 50 M934 04 50 M934 04 B M934 05 50 M934 06 60 M934 06 64 M6923 06 80 M982 06 80 M934 08 60 M6923 08 80 M982 08 80 M934 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 125 03 80 125 04 80 125 05 80 125 06 80 125 08 80 125 10 80 125 12 80 125 14 80 125 16 80 125 18 80 125 20 80 125 24 80 Dimensions M3 0 50 M4 0 70 M4 0 70 M5 0 80 M6 1 00 M6 1 00 M6 1 00 M6 1 00 M8 1 25 M8 1 25 M8 1 25 M10 1 50 M10 1 25 M10 1 50 M10 1 50 M10 1 50 M12 1 75 M12 1 25 M12 1 75 M12 1 75 M14 2 00 M16 2 00 M16 2 00 M18 2 5 M18 2 50 M
168. 02050 226 2 8 0 2 08 65080 1 6 4 REECH E 3 H MJA 33S 14 5 OLNI 1835 ONY 0931 aaao 5 3075 sg1 14 S MN 018 OL 51108 0 01 g 108 8 0 001 3718 4355 59510 50100 00089 INV ve on 20 HI Xlddv 2559 Ol HOldd HIOTO Add 9312 HUN Slug3d laid ISnO 40 3408 1319788 ONS 3578 W3lno 12 18 01040 0006 8 8961 20 m A 868 9 I3wOvag om 3016 THHS 801915 OL HLY 4003 1 230 582 988 lt 0 7 90 5 dX3 08 80 t 68A NMOHS Dr XIBN3SSY YOLOY Leg 0 9 dX3 08 09080 dx3 2 08 90 211 55 90 476 81 08 90 VSz IW dX3 08 90 c69h NMOHS MM Ob 18 155 501915 1659 aNo L AGIA dX3 09
169. 03 02090 O9BLEND TWIN SL MOSER 07314 NIWA 151 2 08 90 9578 aos xz AGIA 531914 ASSY 30010 961 5 RO Ont SNOLN2O1 3S3HL NI jO HO 205061 STS OL 50931 HOlOH 0134 sel WII 6 682 IJwHS 9 SNH N33M138 319201 SC gz WN 62 OL 3nO030L 2 90 2860 aos 9 9 NOH93S 581 91 WN 8 OL 3nouoL 2 09 50 7864 50 961 7WNINB3L N3llDx3 1 TWNINAL 30010 30010 Lou 91 OL 20001 NAOHS Sv SOv31 30000 HOWL SNIA331S 1371100 0 31 5 80108 66 dX3 08 02001 6N 5 201 3S3HL NI ONY STvNIAH3L 11915 14 5 JO WD Ni zoros GTG OL 50737 SHNLWWaY 6 WIL e gsc x 09200 002868 UNN ALH ONISN M3idv 153004 NI 340235 2 6 80 199824 591 861 WN 99 OL 300801 IE 08 90 vSz dx3 09 91090 NAOHS SY 54 31 30010 6 SNIA331S IME 929 9 581 Fez WN 992 OL 51708 3NOYOL v lt 5 52 dx3 9 08 02001 6668 CH NMOHS gp 035 9 65 lt 2 9 09 0 lt 001 1 lt 6 50 dx3 09
170. 06090 6 NMOHS 01 375 TAIHA a NMOHS t 395 ONISNOH 133HMA14 55 80 26491 dX3 08 90 952 NMOHS dX3 08 90 f c69H 08 90 8 11 dX3 0s 0 090 c6n 08 90 6 591 96 WN en OL SINN ATBAASSY om TV 310N 375 W3ldvOv HODVHJN3O Figure 4 23 4QW Alternator Components 20 60 kW TP 6349 6 07 50 Section 4 Alternator Disassembly Reassembly 56602 A9 WSHGCERD wu a AYO JlHLIN SINSTWAInO3 34v NI SNOISNINIG 401915 OLNI 031435 S 80108 330438 ANH 80108 OL 3AUVIN3A3Hd 160 dX3 8 200 20019 Xlddv v Sv 889 9 350 dOHL3 ATBMW3SSv Haddad 804 40 5718 NO 931519395 LON ONY dX3 Sv 031511 Jav 5 5 ONY SION SM3HOS 3SN3dX3 565 9 50 31 031312345 3SIMH3HIO SS3TNI 21 INDHOL L AIBN3SSv 901 ONS Hv3N 3Wvu4j 301415 NO 319201 QNS W330 S6ctvE y 804 HU 0734 ASP 021 08 37905 1935 2 09 02090 5 TINNIAH3L Qv31 91313 AIGNASSY 30010 ONIVIOH O9BIEND 2 08 80 vSZLN 3800 EN WN Ar OL 3nouoL 08 90 786 1225 2 2 35 e WN OL 3noHOl E 09 50 286 d
171. 1 223491 O ring 1 2 223551 Fitting elbow 1 3 336475 Clamp 1 4 GM32723 Tube 1 5 Screw 5 16 1 2 in 1 6 Washer 8 4 16 1 6 1 7 GM32724 1 Common hardware procure locally 8 TP 6141 12 03 Group 4a Camshaft CD42113 Var Item Part No Description 9914 4607 1 GM21411 Camshaft kit 1 1 2 223407 Key woodruff 1 1 3 Camshaft i 1 4 223611 Tappet 8 8 5 352246 Bushing 1 1 6 Screw 3 8 1 grade 8 2 2 7 223610 Plate 1 1 8 Notused Gear spur 1 1 9 223609 Gear 1 1 Common hardware procure locally X Not sold separately TP 6141 12 08 9 Group 46 Valve Train CS See Item 8 3 CD37239A See Group 9b Var Part No Description 4903 9901 1 223480 2 2 2 GM32725 Shaft rocker arm 1 2 GM21412 Shaft rocker arm 1 3 223634 Washer 2 2 4 223632 Spring 2 2 5 GM32726 Screw self locking 3 5 Screw 3 8 x 2 1 2 in SAE grade 8 3 6 223756 Washer 3 7 223633 Support 3 7 360112 Support 3 8 223592 Arm rocker 6 6 9 GM21413 Rod push 6 6 10 223611 Tappet 6 6 Common hardware procure locally 10 TP 6141 12 03 Group Rocker Cover CD39613A Item Part No Description 1105 Label GM21414 Screw with washer GM21415 Cover GM21416 Gasket 336435 Cap filler X Not sold separately O N
172. 1 3 describes auxiliary fault conditions High engine temperature Lights if the engine has shut down because of high engine temperature The shutdown occurs 5 seconds after the engine reaches temperature shutdown range Low oil pressure Lamp lights if the generator set shuts down because of insufficient oil pressure The shutdown occurs 5 seconds after the engine reaches temperature shutdown range Overspeed Lamp lights if the generator set shuts down because the governed frequency on 50 60 Hz models exceeds 60 70 Hz Overcrank Cranking stops and the lamp lights if the engine does not start after 30 seconds of continuous cranking or 75 seconds of cyclic cranking See Section 2 3 1 Normal Operation Note The engine ECM may limit the crank cycle even if the controller is set to a longer time period Cranking stops and the overcrank lamp lights after 25 seconds if the starter or engine does not turn locked rotor The overcrank lamp flashes if the speed sensor signal is absent for longer than one second Low water temperature Lights if water temperature falls below the minimum preset temperature This lamp may require an optional prealarm sender kit in order to function Battery charger fault Lights if the battery charger malfunctions This lamp requires an optional battery charger Emergency stop Lights and the generator set shuts down if the optional emergency stop switch is energized either locall
173. 100 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 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 x 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 7 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
174. 13 4 Internal Engine Components Gas Gasoline Fueled Engines 36 3 13 5 EEN 36 3 13 6 Battery vd ose ve LG oe 36 Section 4 Troubleshooting ve SS ere Rc RE REGE Re EX e rex Re eee ee rote es 37 Section 5 Generator Set Reconnection 41 Section 6 Accessories 47 6 1 ee s uuu pu a sa ua EE 47 6 1 1 Audiovisual Alarm 47 6 1 2 Common Failure Relay Kit M 47 6 1 8 Controller Connection Kit M 47 6 1 4 Dry Contact Kit Single Relay M 48 6 1 5 Dry Contact Kits 10 14 and 20 Relay M 48 6 1 6 Engine Prealarm Senders 49 6 1 7 FASTCHECK Diagnostic Tester 49 6 1 8 Float Equalize Battery Charger Kit with Alarm Option M 49 6 4 9 Line Circuit Breaker 49 6 1 10 Low Fuel Switch M 50 6 1 11 Remote Annunciator Kit M 50 6 1 12 Remote Emergency Stop Kit M 50 6 1 13 Remote Serial Annunciator 51 6114 Run
175. 14 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 74 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Kit Part
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177. 2 4 275471 4 275561 4 X 6086 5 4 X 6207 8 GM10155 KA3 4 275474 4 X 6086 5 4 X 6207 5 GM10155 KA4 4 275469 8 X 6086 5 8 X 6207 8 GM10155 KA5 4 275470 4 X 6086 5 4 X 6207 9 GM10155 KA6 4 297981 8 X 6086 5 GM10155 KA7 4 297983 8 X 6086 5 Kit Parts List Description Bus Lug 350mcm 06 2wire Term Bracket lug restrainer Washer plain 406 ID x 1 in OD Washer spring 39 ID x 81 in OD Lug terminal aluminum Nut hex 3 8 16 zinc Bus Lug 600mcm 02 2wire Term Lug terminal aluminum Washer plain 406 ID x 1 in OD Washer spring 39 ID x 81 in OD Nut hex 3 8 16 zinc Bushing Adapter for Silencer Adapter Bushing Bushing reducer Cable Computer PC Cable Cable multiconductor Connector Cable DB9M DB9F null modem Controller communications kits Cables For Remote Controller Kit Cable 5 Ft Remote Mounting Terminal pin male 20 24 AWG Terminal spade male Terminal fast on male Block terminal Marker strip Connector cable Terminal socket female 20 24 AWG Strip terminal Strip marker Box remote cable mounting Cover remote cable mounting Box assembly 51 remote mounting Harness wiring 5 ft extension Nut hex 4mm Nut hex 5mm Washer lock 172 ID x 333 in OD Washer lock 20 ID x 373 in OD Grommet round Cable tie nylon Screw Phillips hex crimptite Qty Part No GM10155 KA8 275469 X 25 118 X 6086 6 X 6207 8 X 83 7 GM10155 KA9
178. 2 Pressure relief port 3 Radiator assembly 4 shaft grease fittings 5 Fan shaft grease fittings Figure 3 8 Radiator Fan Bearings and Pressure Relief Ports Typical 5 Remove excess grease from the bearing pressure relief ports 6 Inspect the fan drive belt and replace if itis damaged or worn Check the fan belt tension using a poly V belt tension gauge and adjust the tension if necessary See Figure 3 9 New Belt Used Generator Set Model N Ibf N Ibf 2450 2890 1650 1910 1200 2000 kW 550 650 370 430 A belt is considered used after 50 hours of service Figure 3 9 Poly V Belt Tension Specifications 7 Reinstall the belt guards using the original hardware 8 Reconnect the generator set engine starting battery ies negative lead last 9 Test run the generator set for a few minutes and listen for belt noise squeal indicating a slipping belt Stop the generator set If the belt slips after the belt tension procedure clean the pulley surfaces and repeat the belt tension procedure If slippage continues replace the fan belt TP 6161 1 08 3 10 Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles clothing Battery acid may cause blindness and burn skin Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur ne
179. 20 2 50 M20 2 50 M22 2 50 M24 3 00 M24 3 00 M30 3 50 ID 3 2 4 3 5 3 6 4 8 4 10 5 13 0 15 0 17 0 19 0 21 0 25 0 OD 7 0 9 0 10 0 12 0 16 0 20 0 24 0 28 0 30 0 34 0 37 0 44 0 Type Standard Standard Brass Standard Standard Std green Spiralock Elastic Stop Standard Spiralock Elastic Stop Standard Standard Spiralock 5 Elastic Stop Standard Standard Spiralock Elastic Stop Elastic Stop Spiralock Elastic Stop Standard Elastic Stop Standard Elastic Stop Standard Standard Elastic Stop Standard Bolt Thick Screw 4 5 6 8 10 12 14 16 M18 30 20 40 24 OO This metric hex nut s hardness is grade 8 A 4 Appendix TP 6141 12 03 6141 12 03b Service Parts Industrial Generator Sets Models Accessories 20 230 kW Diesel powered KOHLER POWER SYSTEMS 99001 A KOHLER mu POWER SYSTEMS NATIONALLY REGISTERED TP 6116 2 02c Table of Contents Table of Contents 1 Introducton nnn 2 How to Find Service Part Numbers 2 Kit Description Number Sequence 2 Air Cleaner Restriction Indicator Kit 3 Alarm Kits Inner Subbase Fuel Tank Leak 3 Alarm Kits Subbase Tank Low Fuel 3 Alarm Panel Kit Remote A
180. 222909 290020 324313 336020 354518 GM17634 GM17637 BLK GM17637 BLK X 25 75 X 6086 6 X 6128 3 X 6306 99 X 750 14 X 750 15 X 750 16 X 82 6 GM17682 KA3 222908 222909 290020 324313 336020 354518 GM17634 GM17637 BLK X 25 75 X 6086 6 X 6128 3 X 6306 102 X 750 14 X 750 15 X 750 16 X 82 6 GM17682 KA4 222908 222909 290020 324313 336020 354518 364510 GM10167 GM17634 GM17637 BLK M912 08025 60 X 25 75 X 6086 6 X 6128 3 6306 111 750 14 750 15 750 16 82 6 h GA Ny 6116 2 02 Description Line Circuit 225 250 Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bus line Bus line Bracket circuit breaker Cover side Screw socket head cap Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker 300 400 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bus line Bus line Bracket circuit breaker Cover side Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire M
181. 222910 290020 324313 354518 GM10528 BLK X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 10 334037 222908 222909 222910 222949 BLK 290020 324313 354518 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 10 334038 222908 222909 222910 324313 354518 360970 BLK 365606 365627 X 6086 6 X 6128 3 X 6304 104 X 6308 2 334039 222908 222909 222910 222949 BLK 290020 324313 354518 360763 X 6086 6 X 6128 3 X 6304 7 X 6308 1 334040 222908 222909 222910 222950 BLK 290020 324313 354518 360763 X 6086 6 X 6128 3 X 6304 7 X 6308 1 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Terminal fast on male 2 AWG Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 150 A 600 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 2
182. 22909 Bus load 1 324313 Tag ground 1 354518 Cover side 1 360969 Cover side 1 364496 Bus line 3 364509 Insulation CB 2 365627 Washer spring 39 ID x 81 in OD 13 X 6086 6 Standoff insulator 1 4 20 x 1 5 in 2 X 6128 3 Breaker circuit 1 X 6304 116 Screw pan head machine 4 X 6308 2 Line Circuit Breaker GM12343 KA1 Bracket circuit breaker 1 222908 Bracket circuit breaker 1 222909 Insulator 2 290020 Bus load 1 324313 Tag ground 1 354518 Cover side 1 364494 BLK Bus line 3 364498 Nut hex 5mm 4 M934 05 50 Washer spring 39 ID x 81 in OD 4 X 6086 6 Standoff insulator 1 4 20 x 1 5 in 2 X 6128 3 Breaker circuit 1 X 6304 80 Line Circuit Breaker GM12344 KA1 Bracket circuit breaker 1 222908 Bracket circuit breaker 1 222909 Insulator 2 290020 Bus load 1 324313 Tag ground 1 354518 Cover side 1 364494 BLK Bus line 3 364498 Nut hex 5mm 4 M934 05 50 Washer spring 39 ID x 81 in OD 4 X 6086 6 Standoff insulator 1 4 20 x 1 5 in 2 X 6128 3 Breaker circuit 1 X 6304 84 Line Circuit Breaker 225 A GM12345 KA1 Bracket circuit breaker 1 222999 Insulator 2 290020 Cover side 1 GM12332 BLK Decal power breaker 1 GM15301 Nut hex 5mm 4 M934 05 50 Breaker circuit 225 A 600 V 3 pole 1 X 6304 16 Line Circuit Breaker 225 A W 12 V S T GM12345 KA2 Bracket circuit breaker 1 222999 Insulator 2 290020 Cover side 1 GM12332 BLK Nut hex 5mm 4 M934 05 50 Breaker circuit 225 A 600 V 3 pole 1 X 6304 15 Line Circui
183. 24314 354518 GM10527 BLK X 25 45 X 251 16 50 41 6086 6 6128 3 6304 9 334054 222976 49 2 6250 2 334055 222976 49 2 6250 3 334056 222976 BLK X 49 2 X 6250 4 334057 222976 BLK X 49 2 X 6250 5 334058 222976 BLK X 49 2 X 6250 6 334059 222976 BLK X 49 2 X 6250 1 TP 6116 2 02 Description Line Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Terminal fast on male 4 AWG Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Br
184. 27 GM11950 BLK GM16793 GM19468 GM23472 X 51 53 X 6086 20 X 6086 6 X 6138 3 X 6304 114 X 6304 170 X 70 13 X 750 14 X 750 15 X 750 16 N I CD CD N G G Line Circuit Breaker Dual 350 300 GM19771 KA1 Relay protective Transformer curr 800 5 round Insulator Bus load Bracket circuit breaker Bus line Channel insulating Plate Cover side Bracket circuit breaker mounting Screw slotted round head machine Washer spring 39 ID x 81 in OD Breaker circuit 300 A Breaker circuit Screw slotted pan head machine Marker wire Marker wire Marker wire Line Circuit Breaker 1800 A Bag air Relay protective Transformer curr 2000 5 round Box circuit breaker Support and bus Screw slotted round head machine Breaker circuit 1800 A Line Circuit Breaker Breaker circuit 3000 A 600 V 3 pole Line Circuit Breaker Breaker circuit 3000 A 600 V 3 pole Line Circuit Breaker Breaker circuit 4000 A 600 V 3 pole Line Circuit Breaker Breaker circuit 4000 A 600 V 3 pole Breaker Safeguard Circuit Kits Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 4 A 240 V 3 pole TP 6116 2 02 227266 248878 290020 324313 328353 360763 GM13940 GM19468 GM19819 GM23472 X 51 53 X 6086 6 X 6138 3 X 6304 171 X 6304 95 X 6308 1 X 750 14 X 750 15 X 750 16 GM19875 KA1 224796 22
185. 2958 292961 292962 295010 295314 298810 325593 SD 325596 325607 C 262378 D 292864 TT 680 X 22 12 X 22 18 X 22 25 X 22 6 X 49 25 X 49 26 X 49 39 X 49 6 X 50 1 X 50 3 X 51 11 X 51 15 X 51 30 X 51 9 X 6216 1 X 71 2 Description Battery Charger 24 Volt Decal connection Decal warning connection Spacer Lamp 120 V 33 W Decal Strip terminal Module SCR Fuse 7 A 250 V Voltmeter 0 50 V DC Harness wiring 12 24 V float chargers Nut captive 6 32 Door silkscreen PCB assembly PCB assembly Charger assembly battery Washer lock 262 ID x 743 in OD Washer lock 172 ID x 595 in OD Washer lock 146 ID x 53 in OD Washer lock 146 ID x 285 in OD Screw slotted pan head machine Screw slotted pan head machine Screw slotted pan head machine Screw cross recess pan head machine Screw slotted pan head machine Screw cross recess round machine Screw cross recess pan head machine Screw slotted pan head machine Screw cross recess machine Screw Phillips hex crimptite Nut hex machine screw 6 32 Battery Heater Kit Battery Heater 12 V Heater battery wrap Heater battery pad Battery Heater 24 V Heater battery wrap Heater battery pad Battery Heater 24 V Heater battery wrap Heater battery pad Battery Heater 110 120 V Heater battery wrap Heater battery pad Battery Heater 110 120 V Heater battery wrap Heater battery pad Battery Kits Starting Battery
186. 3 pe jo 51104 uonenjse i EN 94 3940 4 ou ut 2 e2 axe sionpoud Jo uontJado pue aui 1022 121215 pue jsnu 5121 020 suia Jo 20 Jo dn W s sjujog a lanes 0 was 5 9n 0989 061 098 Xea uo INU youn jeroads pue 1805 62 098 91 Ce 8845 sanas 008 571 hag SN ni 20 si aiqeisnip safseys 20159 1468 882058 5009 paida2oe jou 505018 70 70 2 dus 5 pajsntpy v puoi vz 3Nn qeuiGuo pue jeurejuoo jeurbss0 ay ur predaad 3 000 out unay raquinu uonezuotumy vonios Witt 301 1984 10490 INO LIOI 158 0 S ep OE 01 un 201 VO SUNIY 4 mon sterne 008 571 lt S S 51 Vogt 102 55 91 v2qie2 ab 09 12215 ssa BIS 10 55228 8891 08 32918 uoneurnoju euoritppy JO SIOSUBS 51089 19261402 E SUMIM 91851 ainjesadwa 0 568 001 uo 2502 UadO e d k ng ne 4 3 541 O 3 091 80496 e
187. 304 11 334006 222908 222909 222910 290020 324313 354518 GM10528 BLK GM15301 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 11 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Decal power breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 400 A 240 V 3 pole Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Decal power breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 400 A 240 V 3 pole Screw slotted pan head machine Line Circuit Breaker Cover side Breaker circuit 40 A 600 V 3 pole Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Cover side Breaker circuit 60 A 600 V 3 pole Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Cover side Breaker circuit 80 A 480 V 3 pole Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Cover side Breaker circuit 100 A 480 V 3 pole Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Ins
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189. 334018 222908 222909 222910 290020 324313 354518 GM10528 BLK GM15301 51 47 6086 6 6128 3 6304 57 334019 222974 258928 GM15301 X 49 2 334020 222908 222909 222910 290020 324314 354518 GM10527 BLK GM15301 X 25 45 X 251 16 X 50 41 X 6086 6 X 6128 3 X 6304 8 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw cross recess pan head machine Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 175 A 240 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Decal power breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 350 A 240 V 3 pole Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Decal power breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 350 A 240 V 3 pole Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit brea
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191. 349 6 07 2005 2007 by Kohler All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 Service Parts Engine Engine Models John Deere 3029DF 3029TF 3029TF270 Generator Models 20ROZJB 20 40REOZJB 20DSJB 20 40DSEJB TP 6141 12 03b Table of Contents Description Page Description Page Introd ction Jte eA ataqa at 1 Group 11b Starter Motor Components 22 Number Significance 1 Group 12a Exhaust Manifold 23 How to Find Part Numbers 1 Group 13a Flywheel 24 Specification Number Index 2 Group 13b Flywheel Housing 24 Group 1 AirIntake 5 Group 14 25 Group 2a Water Pump 6 Group 15 26 Group 2b Thermostat 7 Group 18 Timing Gear 28 Group 2c Fan Belt 7 Group 21a 29 Group 3 Vent T be b
192. 354518 GM17634 GM17637 BLK X 25 75 X 6086 6 X 6128 3 X 6306 96 X 750 14 X 750 15 X 750 16 X 82 6 Ou iN scr Ni ca Ri mk x N ONWA T ai Sk NY Gy OO N k u a NS a ch Description Line Circuit Breaker 125 Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Cover side Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 1 5 in Breaker circuit 125 A Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker 150 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker 175 200 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bus line Bus line Bracket circuit breaker Cover side Screw socket head cap Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Qty Part No GM17682 KA2 222908
193. 36020 352326 BLK 354518 364511 GM10168 GM10169 X 6086 6 X 6128 3 X 6306 125 334070 222908 222909 222910 290020 324314 336020 352293 BLK 354518 X 251 16 X 6086 6 X 6128 3 X 6306 97 334071 222908 222909 222910 290020 324313 336020 352295 BLK 354518 X 6086 6 X 6128 3 X 6306 97 334072 222908 222909 222910 290020 324313 336020 352295 BLK 354518 X 6086 6 X 6128 3 X 6306 97 13 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus
194. 364510 M912 08025 60 X 6086 6 X 6128 3 X 6306 118 334463 222908 222909 222910 290020 324313 336020 352295 BLK 354518 X 6086 6 X 6128 3 X 6306 99 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Screw socket head cap Washer spring 3
195. 36917 364498 X 25 45 X 50 41 X 6128 3 X 6304 161 X 6304 162 Line Circuit Breaker Dual 225 A175 GM19641 KA2 Cover side Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Bus line Washer plain 203 ID x 75 in OD Screw slotted pan head machine Standoff insulator 1 4 20 x 1 5 in Breaker circuit 225 A Breaker circuit 175 A 2 EE 222833 222908 222909 222910 290020 324314 364498 25 45 50 41 6128 3 6304 165 6304 166 39 Kit Parts List Description Qty Part No Line Circuit Breaker Dual 350 250 GM19642 KA1 Cover side Bracket circuit breaker Bracket circuit breaker Spacer 281 x 500 x 375 steel Insulator Bus load Bracket circuit breaker Tag ground Channel insulating Washer plain 406 ID x 1 in OD Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 250 A Breaker circuit Screw slotted pan head machine Marker wire Marker wire Marker wire Nut hex 3 8 16 zinc A N P Ph P P 222833 222908 222909 265861 290020 324313 336632 354518 GM13940 X 25 118 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 163 X 6304 95 X 6308 1 X 750 14 X 750 15 X 750 16 X 83 7 Line Circuit Breaker Dual 350 250 GM19645 KA1 Cover side Bracket circuit breaker
196. 38 AAO 138 031511 NOLLVINHOJNI 3H L SAVH 6919 699 008 1 3384 1101 5 TVOINHO3L YNO TVO 35 314 20 YO 15 AHL O L ONLLV133 5 5800 3AVH SYINDAY dl 29009 11 HOONGHLYON NALSONIdd 666 SSAIMOLVYOSVT SYSALIMMYSGNN SNLLISM 09 21810313 LN3WNHSAOO 1 201 WO343 18 SI NOILVOIMENd SIHL 3009 0313 TVNOILLVN JHL AO 1931 V1 SHLHLIM 58009 1v201 30 58 HO 530002 2 ANY 1VONVIA NI SNOILONYLSNI 3H L INHO NOO LSNW NOLLVTTV LSNI SHL S39Vd ONIMOTIOS JHL NO SNOILONYLSNI SNI LV J3dO NOILVTIVLSNI 3H L OL 40 38Snvo38 SSOVNVG 718V 38 LON H3 LV3H SIHL 30 JHL H3ASOSJIVHM AVM NI N338 SVH NOIS3Q JHL 4 38 1 JHL NOLLVeH3dO ONY NOILVTIVLSNI H3dO3d NO 3 1LV3HH3 LVM SIH L HO AJNVSSHVAM 3OVIAVO Als3dO3d ATIGOS 50014535 ANY ATH3dOSd ALVYAdO LON TIIM LINN O3MO1104 LON S314 134 5 JHL sl 31V3H H31VM 31V3adO TIVLSNI OL 119 330338 ATINASYVO SIH L S3ILl TIBI SNOdS33 YSINNSNOS H3 TVLSNI 5
197. 38M NOH SYAHSINONILXS 4334 1eusinBunxe Ajyenied e uaaa ue asnes pinos dn pjing 1680 4 1 LON SI 5813 AHL 31 Q3QN311VNf li 1 2017 OLNI YSHSINONILXS NV 8074 S 3NOANV OLNI YSHSINONILXS 2011 V 398VHOSIG H3JA3N OL SONIHL 1 4 SRS a SU TEAR HE RENE 816 pue siio 10 ejqejefoA M e qusnquioo pue Joyesado aui o 1ueuudinbe E211 98 pesn eq spinbii ujed 5 1 pue use Op V To D 5 54414 53813 JO AYNLOld 30 SAdAL 5995719 53415 dO 53557719 ANY S3dAL Sadly Jo SadA uo pesn e pue 2 10 payes SWOS JO 89215 pue 68 0 pejeJ pue pas si usin6unx3 JO sesse jo Buipuejsiepun ue 1eusinBunxe Aue 10 esn eAgoege pue J dold o MOY pue aen SI 1I OP ONNVO
198. 39 240V 50 HZ 120 208V 60 HZ 277 480 50 HZ 240 416V 1 129 OPTIONAL DROOP L1 23 N 12 Pe wv en COMP CT 74 294 5 1 1 2 1 PAL C5 e S o 5 CT WIRING FOR 20 50 KW 10 pu E DECISION MAKER 340 10 11 CONTROLLER WHEN SPECIFIED 5 bo va bp 26 12 KEP ib C OPTIONAL DROOP 2 vo 511 v9 qup 077 9 46 v8 3 e 3 OPTIONAL DROOP CTS TN P d m 0 CTS CTS E en 5 v8 2 8 b SM 1 3 M 2 9 1 METER SCALE Be C SCALE 9 C1 METER SCALE 183 ue vz o LAMP JUMPER 183 velvz Lo LAMP JUMPER L3 9 10 LAMP JUMPER 5 CURRENT TRANSFORMER DOT OR H1 CURRENT TRANSFORMERS NOT USED ON ALL SETS TOWARD GENERATOR PHASE ROTAT L1 L2 TION P L5 uonoeuuooeH 196 9 1919 41 80 1 09289 006 zZISISAO 09 6 8 941614 12 LEAD ALTERNATOR 5 WIRE 60 HZ 100 200 60 HZ 120 240V 50 HZ 100 200V SINGLE PHASE 12 LEAD ALTERNATOR 5 WIRE 60 HZ 240V 50 Hz 220V MARINE ONLY SINGLE PHASE 12 LEAD ALTERNATOR 4 WIRE DELTA 60 HZ 120 240V 50 HZ 110 220
199. 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Qty Part No GM17679 KA3 222908 222909 290020 324313 354518 364498 GM15301 GM17634 GM17638 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 65 X 750 14 X 750 15 X 750 16 X 82 6 N O N P G gt A Line Circuit Breaker 150 A W 12 V S T GM17679 KA4 Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5 Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker 175 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5mm Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 222908 222909 290020 324313 354518 364498 GM15301 GM17634 GM17638 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 66 X 750 14 X 750 15 X 750 16 X 82 6 GM17679 KA5 222908 222909 290020 324313 354518 364498 GM15301 GM17634 GM1763
200. 39776 Decal notice neutral bonded 1 239789 Tag instruction 1 255798 Decal 1 255882 Screw hex head machine special thread 4 273736 Guard generator 1 274596 Decal electrical equipment 2 25 x 2 8 1 343292 Washer lock 391 ID x 681 in OD 4 X 22 10 Conduit convoluted 1 X 6003 17 48 Description CSA Decal caution Decal notice neutral bonded Tag instruction Decal Guard generator Decal electrical equipment 2 25 x 2 8 Screw hex head machine special thread Washer lock 391 ID x 681 in OD Conduit convoluted CSA Decal caution Decal notice neutral bonded Tag instruction Decal Screw 1 2 13 x 4 Decal electrical equipment 2 25 x 2 8 Guard generator CSA Washer lock 521 ID x 884 in OD Conduit convoluted CSA With Rodent Guards Decal caution Decal notice neutral bonded Tag instruction Decal Screw 1 2 13 x 4 Decal electrical equipment Guard generator Screen fan Washer lock 521 ID x 884 in OD Plug button Conduit convoluted Conauit Screw hex washer head drill CSA Approval 4P Decal caution Decal notice Tag instruction Decal caution standby service connect Screw hex head machine special thread Guard generator Decal electrical equipment 2 25 x 2 8 Washer lock 391 ID x 681 in OD Plug button Conduit convoluted Nut flange spiralock 3 8 16 CSA Approval 4S Decal caution Decal notice Tag instruction Decal caution standby
201. 419919 AHL SNILO3NNOO SXV31 NOILVTIVLSNI 1531 dN MOOH 1791419919 Q3390Hd 3904 8 38 LSNW TIV ALON uselos Jay 1 lul EES LON OQ Bumy uolsseidwoo LON OQ ONLL LIJ uoisseJdui05 LD 4 4 Sjexood QISIA pue DButd nB aay snonunuoo si OM JO lnulul e JO e je euo SIU Aq Jou pue ujoq uedo An GT L48 0 uejuBn suy uorssedduioo 64016 pun inu uoisseJduroo ueju n uorsseiduioo 5 j exe jueseud 81 ee J suonoeuuoo Syed 10 6 By xoeuo n si Buiquinid je z 1 sesodind eoueuejureui aq o jun siu s did pue aju uo eA eA eq Bunejosi 161 YOUMS os ay Bunoeuuoo auojeq edid y suq p edid Ajddns out 1 UNY 3 LON uo ssaJjs J9pJo ui 886604 ino pue jejur y UM p uBije
202. 5 BLK 222999 290020 GM15301 X 25 45 X 50 41 X 6304 13 TP 6116 2 02 Description Line Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Breaker circuit 225 A 600 V 3 pole Line Circuit Breaker Cover side Bracket circuit breaker Insulator Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine TP 6116 2 02 Qty
203. 500 19 1 snssap ne spaid 9292 ce ap Jnejneu eun e snss p nb e ep in lounx l 19 816 alos un p said aouaigjaid ep senbsu sep mb sop ejgsseooe 295 aidoid inb un suep jesu snayourxa 7 Sjmeuod s jueuje2uoo uonemossy uonoejoid 914 jeuoneN Vd4dN 0 euuou e Jessa uonoedsur uonejejsui e 2014 8181610 LA 15 e un nb suie 8 9 04 02 no sep Jaujenua 1nad 8 enbejd ej ins enbipui wou anejounxe epie e ej nod ep SjueDe sep jauuosiad esodsip jeso 1nejnquisip ejsieioeds un Jed sanjaya yop uonesipn seide ep e ejep ep e sue XIS
204. 509 365627 6086 6 6128 3 6304 104 6308 2 334784 222908 222909 324313 354518 364484 364496 364509 365627 6086 6 6128 3 6304 108 6308 2 334785 222908 222909 324313 354518 364484 364496 364509 365627 6086 6 6128 3 6304 109 6308 2 6116 2 02 Description Line Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Bracket circuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Bracket circuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circui
205. 54 Connector 1 287850 Hood strain relief 2 287851 Box 1 287869 Nut dress 1 4 40 4 287873 Cap 1 287874 Connector cable 1 292800 Connector 24 position 1 295145 PCB assembly test fast check 1 B 287848 Control assembly 1 B 291930 49 Kit Parts List Description Fill Cap Kit 2 inch Locking 2 in Locking Fill Cap Cap sealed fill Pipe 2 in NPT x 2 00 in Flange Kits Weld on Weld On Flange 6 in Flange weld on Gasket exhaust ring 6 in Washer plain 812 ID x 1 469 in OD Screw hex head machine Nut hex 3 4 10 zinc Fuel Filters Fuel Water Separator Fuel line flexible Filter assembly fuel water separator Fitting elbow 5 8 18 x 1 4 in Fitting elbow 5 8 18 x 3 8 in Fuel Line Kits Flexible Flexible Fuel Lines Fuel line flexible Fuel line flexible Fuel line Cap 1 4 NPT pipe Fitting elbow 7 16 20 x 1 8 in Fitting elbow oil line Fitting union Flexible Fuel Lines Fuel line flexible Fuel Line flexible Cap pipe Fitting half union Fitting half union Fitting half union Elbow oil line connection Flexible Fuel Lines Line 25 OD steel fuel Bracket mounting Fuel line flexible Fuel line flexible Cap 1 4 NPT pipe Cap pipe Connector half union Fitting elbow 7 8 14 Clamp insulated 5 in Fitting union Flexible Fuel Lines Line 25 OD steel fuel Bracket mounting Fuel line flexible Fuel line flexible Cap 1 4 NPT pipe Cap pipe Connector hal
206. 57 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex 4mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Qty hb DMA hi Ah A hb E G hi A S P E hh A
207. 6 X 22 18 X 400 28 X 6216 1 X 70 12 GM17069 KP1 243319 273934 273935 282829 336394 A 273936 294303 GM13984 GM16088 GM17033 TT 723 X 22 18 X 400 28 X 465 7 X 51 3 X 6210 2 X 6210 4 X 6216 1 X 70 12 X 712 9 ORADHA h CD Qa a8 O PO P P OD HH sch O 224809 224814 224825 224881 224884 255600 299186 299187 A 290024 X 284 35 X 391 13 X 422 30 X 426 10 224810 224815 224825 224881 224884 255600 299186 299187 A 290024 X 284 35 X 391 13 X 422 30 X 426 10 Mi ch ch ch ch ES ch ch ch ch ch ch Description Day Tank Electronic Sensor float Module power Harness wiring extension Harness wiring 6 15 kW 1 phase Switch float 1 pole Connector jack 9 position Connector plug 9 position Pump motor assembly Grommet Fitting hose connector 90 deg Hose Clamp 1 in hose Day Tank Relay Control Coupling conduit elbow Coupling conduit elbow Harness wiring day tank 6 60 kW Fuse 5 A 250 V Relay 120 VAC 15A Cover conduit box Fuse holder inline Box junction Harness wiring engine 125 180 kW Switch float Bracket relay Box controller Pump motor assembly Washer lock 146 ID x 53 in OD Washer lock 172 ID x 333 in OD Fitting hose connector 90 deg Hose Clamp 1 in hose Screw slotted pan head machine Screw slotted pan head machine Coupling non metallic Conduit convolute
208. 6 X 6306 117 334481 290020 336020 352323 352324 912 08025 60 6086 6 6306 118 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Breaker circuit Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw slotted pan head machine Line Circuit Breaker Breaker circuit 30 A 600 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 30 A 600 V 4 pole Line Circuit Breaker Breaker circuit 40 A 600 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 40 A 600 V 4 pole Line Circuit Breaker Breaker circuit 50 A 600 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 50 A 600 V 4 pole Line Circuit Breaker Breaker circuit 60 A 600 V 3 pole Cover side Screw cross recess pan head machine Line C
209. 6 X 6306 142 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Breaker circuit 70 A 600 V 3 pole Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 70 A 600 V 4 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 1 5 in Breaker circuit 125 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insula
210. 6 kPa 1 4 oz in 2 6 4 cm 2 5 water column the generator set uses the primary fuel Contact an authorized service distributor dealer for kit availability Manual Changeover A manual changeover fuel system allows manual changeover from gasoline to natural gas or LP gas or from natural gas or LP gas to gasoline Typically the combination system uses gas as the primary preferred fuel and gasoline in emergencies If the primary fuel is unavailable an empty fuel tank or fuel supply disruption the system uses gasoline toggle switch on the generator set controls the fuel choice and energizes either a fuel solenoid and electric fuel pump for gasoline or a fuel valve for gas Pull out the control cable for gasoline and push in the control cable for gas 3 6 5 Carburetor Adjustment Before adjusting the carburetor verify that the engine compression and ignition system meet specifications Do not adjust the carburetor to compensate for other engine disorders Ifthe engine speed is incorrect adjust the electronic governor to achieve 1800 rpm at 60 Hz or 1500 rpm at 50 Hz Adjustthe carburetor if governor adjustment alone does not result in the desired engine speed Adjusting the carburetor affects the engine fuel mixture Routine carburetor adjustment is not necessary However if the carburetor is removed or tampered with the carburetor may require adjustment to achieve optimum engine performance Some engines have
211. 60 M931 10140 60 M931 10180 60 M931 10235 60 M931 10260 60 M960 10330 60 M931 12045 60 M960 12050 60 M960 12050 82 M931 12050 60 M931 12050 82 M931 12055 60 M931 12060 60 M931 12060 82 M931 12065 60 M931 12075 60 M931 12080 60 M931 12090 60 M931 12100 60 M931 12110 60 This metric hex bolt s hardness is grade 10 9 TP 6141 12 03 Dimensions M5 0 80 x 55 M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M6 1 00 x 145 M6 1 00 x 150 M8 1 25 x 35 M8 1 25 x 40 M8 1 25 x 45 M8 1 25 x 50 M8 1 25 x 55 M8 1 25 x 55 M8 1 25 x 60 M8 1 25 x 70 M8 1 25 x 70 M8 1 25 x 75 M8 1 25 x 80 M8 1 25 x 90 M8 1 25 x 95 M8 1 25 x 100 M8 1 25 x 110 M8 1 25 x 120 M8 1 25 x 130 M8 1 25 x 140 M8 1 25 x 150 M8 1 25 x 200 M10 1 25 x 40 M10 1 50 x 40 M10 1 50 x 45 M10 1 50 x 50 M10 1 25 x 50 M10 1 50 x 55 M10 1 50 x 60 M10 1 50 x 65 M10 1 50 x 70 M10 1 50 x 80 M10 1 25 x 80 M10 1 50 x 90 M10 1 50 x 90 M10 1 50 x 100 M10 1 50 x 110 M10 1 50 x 120 M10 1 50 x 130 M10 1 50 x 140 M10 1 50 x 180 M10 1 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 16
212. 6242 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 For standby service connect the output of the generator set to a suitably rated transfer switch accordance with Canadian Electrical Code Part 1 TP 6161 1 08 Introduction This manual provides operation instructions for 20 2250 kW generator sets equipped with the following controllers e Decision Maker 3 16 Light e Decision Maker 1 Wiring diagram manuals are available separately Refer to the engine operation manual for generator set engine scheduled maintenance 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 injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required ser
213. 7 Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nut and SAE washer Hardware 1 2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut See Figure 2 3 Follow these SAE washer rules after determining exit hole type a Always use a washer between hardware and a slot b Always use a washer under a nut see 2 above for exception c Use a washer under a bolt when the female thread is fixed weld nut 4 Refer to Figure 2 which depicts the preceding hardware configuration possibilities Ce S lt O K A 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 55 Appendix General Torque Specifications American Standard Fasteners Torque Specifications 8 32 Assembled into Cast Iron or Steel Torque Measurement Nm in Ib Grade 2 Grade 5 Grade 8 10 24 Nm in Ib 10 32 Nm in Ib 1 4 20 Nm in Ib 1 4 28 Nm in Ib
214. 7 283869 467 4 51 5 256505 233955 283869 467 4 51 5 273845 292364 292467 293906 222655 222654 940 Kit Parts List Description Qty Part No End Cap Kits Skid Skid End Caps 275463 End cap skid 2 275460 Skid End Caps 275464 End cap skid 2 GM19839 Skid End Caps 324923 End cap skid front 1 324889 End cap skid rear 1 324891 Skid End Caps 336217 End cap skid 44 58 in 2 336216 Skid End Caps 352644 End cap skid 30 58 in 2 352589 Skid End Caps 4S7 352645 End cap skid 30 58 in 2 352643 Skid End Caps W Cable Entry 364413 Endcap skid 1 364512 Skid End Cap W Cable Entry 364414 Endcap skid 1 364513 Skid End Caps W Cable Entry GM10232 KA1 End cap skid 1 GM10233 Skid End Caps W Cable Entry GM11922 KA1 End Cap Skid w Cable Entry 1 GM10650 Skid End Cap GM15456 KA1 Enclosure skid 2 GM15453 Skid End Cap GM16287 KA1 Enclosure skid 2 GM15373 Skid End Cap GM16288 KA1 Enclosure skid 2 GM15375 Skid End Caps GM21057 KA1 End cap skid 2 GM17759 KCB Skid End Caps GM21057 KA2 End cap skid 2 364050 KCB Skid End Caps GM21057 KA3 End cap skid 2 364239 KCB Skid End Caps Enclosure skid GM21057 KA4 2 GM20810 KCB FASTCHECK and Wire Harness Kit FASTCHECK And Harness PA 272766 Cover 1 254409 Decal FASTCHECK 3 x 4 in 1 255405 Wiring harness for FRII relay circuit 1 255915 Nut dress cap 1 4 40 1 269174 Clip alligator 2 269952 Insulator rotor 1 269953 Insulator rotor 1 2699
215. 7 1 4 20 x 38 X 465 6 1 4 20 x 50 X 465 2 1 4 20 x 62 X 465 16 1 4 20 x 75 X 465 18 1 4 20 x 88 X 465 7 1 4 20 x 1 00 X 465 8 1 4 20 x 1 25 X 465 9 1 4 20 x 1 50 X 465 10 1 4 20 x 1 75 X 465 11 1 4 20 x 2 00 X 465 12 1 4 20 x 2 25 X 465 14 1 4 20 x 2 75 X 465 21 1 4 20 x 5 00 X 465 25 1 4 28 x 38 X 465 20 1 4 28 x 1 00 X 125 33 5 16 18 x 50 X 125 23 5 16 18 x 62 X 125 3 5 16 18 x 75 X 125 31 5 16 18 x 88 X 125 5 5 16 18 x 1 00 X 125 24 5 16 18 x 1 25 X 125 34 5 16 18 x 1 50 X 125 25 5 16 18 x 1 75 X 125 26 5 16 18 x 2 00 230578 5 16 18 x 2 25 X 125 29 5 16 18 x 2 50 X 125 27 5 16 18 x 2 75 X 125 28 5 16 18 x 3 00 X 125 22 5 16 18 x 4 50 X 125 32 5 16 18 x 5 00 X 125 35 5 16 18 x 5 50 X 125 36 5 16 18 x 6 00 X 125 40 5 16 18 x 6 50 X 125 43 5 16 24 x 1 75 X 125 44 5 16 24 x 2 50 X 125 30 5 16 24 x 75 X 125 39 5 16 24 x 2 00 X 125 38 5 16 24 x 2 75 X 6238 2 3 8 16 x 62 X 6238 10 3 8 16 x 75 X 6238 3 3 8 16 x 88 X 6238 11 3 8 16 x 1 00 X 6238 4 3 8 16 x 1 25 X 6238 5 3 8 16 x 1 50 X 6238 1 3 8 16 x 1 75 X 6238 6 3 8 16 x 2 00 X 6238 17 3 8 16 x 2 25 X 6238 7 3 8 16 x 2 50 X 6238 8 3 8 16 x 2 75 X 6238 9 3 8 16 x 3 00 X 6238 19 3 8 16 x 3 25 X 6238 12 3 8 16 x 3 50 X 6238 20 3 8 16 x 3 75 X 6238 13 3 8 16 x 4 50 X 6238 18 3 8 16 x 5 50 X 6238 25 3 8 16 x 6 50 A 2 Appendix Part No Dimensions Hex Head Bolts cont X 6238 14 3 8 24 x 75 X 6238 16 3 8 24 x 1 25 X 6238 21 3 8 24 x 4 00 X 6238 22 3 8 24 x
216. 7266 291548 361991 361993 X 51 53 X 6304 177 PA 279889 282049 PA 347596 1 347594 PA 347597 1 347595 PA 347599 1 347598 ch EH Ei ch ch waa Awa woo 255127 X 22 6 X 49 2 X 796 1 AL Kit Parts List Description Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 3 A 240 V 3 pole Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 5 A 240 V 3 pole Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 4 5 A 240 V 3 pole Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 3 5 A 240 V 3 pole Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 3 A 240 V 3 pole Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 3 5 A 240 V 3 pole Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 4 A 240 V 3 pole Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 5 A 240 V 3 pole Safeguard Breaker Washer lock 146 ID x 285 in OD Screw cross recess pan head machine Breaker circuit 4 5 A 240 V 3 pole Safeguard
217. 73 BLK 365609 X 6086 6 X 6304 125 334113 222996 BLK 222998 290020 336020 365609 X 6086 6 X 6306 141 334114 222995 BLK 222999 290020 X 25 45 X 50 41 X 6304 14 334115 290020 336020 352323 352324 BLK GM10411 GM10412 912 08025 60 6086 6 6306 112 334116 222995 BLK 222999 290020 X 25 45 X 50 41 X 6304 15 334117 222995 BLK 222999 290020 X 25 45 X 50 41 X 6304 86 334118 290020 336020 352323 352324 BLK GM10411 GM10412 M912 08025 60 X 6086 6 X 6306 118 334119 222996 BLK 222999 290020 360763 X 6086 6 X 6304 89 X 6308 1 Description Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Washer spring 39 ID x 81 in OD Breaker circuit 400 A 240 V 3 pole Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Co
218. 8 219 281 244 406 469 531 656 812 25 127 1 062 1 8 6 32 8 32 10 24 10 32 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 1 2 13 7 16 20 1 2 20 5 8 11 3 4 10 1 2 20 250 375 438 500 625 687 812 922 1 062 1 312 1 469 2 000 Standard Whiz Whiz Whiz Whiz Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Standard Standard Standard Bolt Thick Screw 022 4 049 6 049 8 049 10 065 1 4 065 5 16 065 3 8 065 7 16 095 1 2 095 5 8 134 3 4 134 1 6141 12 03 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 M931 06070 SS M931 06075 60 M931 06090 60 M931 06145 60 M931 06150 60 M931 08035 60 M931 08040 60 M931 08045 60 M931 08050 60 M931 08055 60 M931 08055 82 M931 08060 60 M931 08070 60 M931 08070 82 M931 08075 60 M931 08080 60 M931 08090 60 M931 08095 60 M931 08100 60 M931 08110 60 M931 08120 60 M931 08130 60 M931 08140 60 M931 08150 60 M931 08200 60 M931 10040 82 M931 10040 60 M931 10045 60 M931 10050 60 M931 10050 82 M931 10055 60 M931 10060 60 M931 10065 60 M931 10070 60 M931 10080 60 M931 10080 82 M931 10090 60 M931 10090 82 M931 10100 60 M931 10110 60 M931 10120 60 M931 10130
219. 8 3123 3029DF 50Hz 1299 5906 9915 9916 9928 a 1 9932 9910 3123 6218 3123 3029 60 Hz 1299 5906 9917 9918 9928 1 1 9932 9910 6547 3123 6218 3123 3029 50 Hz 1299 5906 9917 9918 9928 5 1 9932 9910 6585 3123 6218 3123 30297 2270 1299 5939 4814 4814 5001 3622 9706 9706 9702 6547 3123 6218 3123 6141 12 03 Notes TP 6141 12 03 CD36569A Group 1 Air Intake Description 1712 1 222765 Screw cap 2 2 Washer 10 500 x 18 x 1 600 mm 2 3 GM21398 Intake air 1 4 223532 Gasket 1 5 Not used 1 6 Not used 1 Common hardware procure locally CD36012A Var PartNo Description 1710 1710 1 Screw cap 3 8 x 1 1 8 in grade 8 2 2 2 Washer lock 3 8 in 2 2 3 GM21399 Tube also order items 7 and 8 1 3 GM32721 Duct air 1 4 223532 Gasket 1 1 5 GM21400 1 1 6 336706 Clamp hose 2 2 7 360174 Fitting 1 8 Sealant Loctite 592 AR Common hardware procure locally AR As Required Loctite is a registered trademark of Loctite Corporation TP 6141 12 03 5 Group 2 Water Pump CD42101 on XA d EA p e G CD41102 Var PartNo Description 2020 1 GM21401 Pump water 1 2 223659 Pulley 1 3 x Housing order item 1 1
220. 8 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 69 X 750 14 X 750 15 X 750 16 X 82 6 P sch EA Mi N Oy NS sch Ny ch 6116 2 02 Description Qty Part No Line Circuit Breaker 175 A W 12 V GM17679 KA6 Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5 Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker 200 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5mm Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 O N O N B A G N Oy k 4 Ny Gy P sch a NS 222908 222909 290020 324313 354518 364498 GM15301 GM17634 GM17638 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 70 X 750 14 X 750 15 X 750 16 X 82 6 GM17679 KA7 222908 222909 290020 324313 354518 364498 GM15301 GM17634 GM17638 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 74
221. 8 Terminal Block Reconnection Decal 80 300 kW terminal block shown Figure 1 5 Figure 1 6 provide the voltage reconnection combinations and terminal block hardware torque values ENGINE END X Figure 1 5 Load Connections TOP VIEW OF ALTERNATOR TERMINAL BOARD GM39937 TERMINAL BOARD RECONNECTION DIAGRAM LO GROUND BUS TERMINAL BOARD TERMINAL BOARD LOCATION 12 24 LEAD STATOR CONNECTIONS 6 LEAD STATOR 4 LEAD STATOR HIGH WYE 380V 416V 480V LOW WYE 208V 240V DELTA 120V 240V DOGLEG 120V 240V 600V WYE SINGLE PHASE ONLY 120V 240V H 13 CONN BUS QTY CONN 805 CONN BUS QTY CONN BUS QTY CONN CONN BUS QTY 47 1 104 NOTE 1 0 2 2 1 5 8 1 0 6 9 1 3 L3 NOTE 1 OPEN 0 1 7 L1 NOTE2 OPEN 2 8 L2 OPEN OPEN OPEN 3 9 L3 NOTE2 3 12 1 6 7 L1 NOTE 1 OPEN 0 4 8 L2 NOTE 1 OPEN 0 0 2 11 1 5 9 L3 NOTE 1 0 1 7 L1 1 0 2 8 12 1 0 3 5 9 11 1 L1 OPEN 2 L2 OPEN 0 OPEN 0 OPEN 1 8 L3 0 0 0 NOTE 1 4 L2 OPEN 0 1 L1 NOTE 1 OPEN 0 NOTE 1 OPEN 0 0 0 0 NOTES 1
222. 83 292887 639 22 7 712 9 72 4 SO PO PO 3 3 E Ph hi 11849 1 1 GM11849 GM11850 KP1 1 GM11850 Description Battery Charger Ring lock switch Tab ID grd Decal connection Fuse 5 A 250 V Clip speed Fuse 25 A 125 V Transformer 120 240 V 26 6 V Decal warning connection Clip cable Fuse holder Switch toggle 1 pole Spacer Lamp 120 V 33 W Decal Heatsink Strip terminal Ammeter 0 15 DC Module SCR Resistor 04 05 ohm 35 W Fuse 7 A 250 V Voltmeter 0 50 V DC Marker strip Marker strip Retainer Block terminal Nut captive 6 32 Box battery charger Nameplate battery charger Wiring harness engine 18 kw relay Diagram wiring Door silkscreened battery charger Charger battery PCB assembly PCB assembly Charger battery automatic Charger battery circuit board Washer lock 262 ID x 469 in OD Washer lock 262 ID x 743 in OD Washer lock 172 ID x 595 in OD Washer lock 146 ID x 53 in OD Washer lock 146 ID x 285 in OD Terminal ring male 16 14 AWG Terminal ring male 10 12 AWG Terminal ring male 16 14 AWG Cable tie Screw slotted pan head machine Screw slotted pan head machine Screw slotted pan head machine Screw cross recess pan head machine Screw slotted pan head machine Screw slotted pan head machine Screw cross recess round machine Screw cross recess pan head machine Screw
223. 9 wun 1 81 py FE V2Z 3Nn i 99 8 5 2 uonisog 6ununow 07 ul6u 1 xew pue 884 JO 61802 SS 91 pasapso jeisads 1snuu 84018 je0 j SS 9 6 spun 2 uey ssa spun uo jeuondo 618400 560 9015 8010 ased u uejs owes 5 816 09 UMA ulBu l 24 UBY sun ION bununow 7 06 dn seuojiMs yue ut Jo dn dot yue u 27501 848496 aunjesadwal S 008 S1 sepnioul 5 5 eiqeysnfpy 008 57 008 57 Seles d 8 621 ON upang uononasul 009 826 008 1 lqe giAJ sun Japuas jonpojd Aq paurejsns 5 pejreda pjey aq jou ysnw 5 08495 MO Buueas JodeA pinbi yue ue sluiod pue samua Je2ui aa syonpoid Jno jo 940 4 eui ensue 0 suq p
224. 9 274432 274434 274741 275453 275598 354518 22 12 25 73 25 92 6086 6 GM12552 KA1 274659 274661 336009 336010 854518 GM12553 M934 08 60 X 25 118 X 25 92 X 6086 6 X 794 2 X 83 7 GM14031 KA1 275457 275458 275459 854518 GM14301 GM14302 X 25 45 X 25 92 X 781 11 GM17814 KA1 201620 83 201620 84 201620 94 201620 95 233269 275454 275455 275456 854518 GM17815 GM17816 X 25 68 X 25 73 X 25 75 X 25 92 X 6086 6 X 781 10 X 781 11 X 82 6 OO OO gt E M EE AAA C2 ORRORDANMHA MHA P 00 274693 4 275473 4 6207 7 6116 2 02 Description Bus Lug Bracket lug restrainer Bracket lug restrainer Washer plain 391 ID x 875 in OD Lug terminal aluminum Bus Lug Bracket lug restrainer Washer plain 391 ID x 875 in OD Lug terminal aluminum Bus Lug Bracket lug restrainer Washer plain 391 ID x 875 in OD Lug terminal aluminum Bus Lug Bracket lug restrainer Lug terminal aluminum Bus Lug Lug terminal aluminum Washer plain 391 ID x 875 in OD Bus Lug Lug terminal aluminum Washer plain 391 ID x 875 in OD Bus Lug Lug terminal aluminum Washer plain 391 ID x 875 in OD Bus Lug Lug terminal aluminum Bus Lug Lug terminal aluminum Bus Lug 3 0 08 1 Wire Term Bracket lug restrainer Lug terminal aluminum Bus Lug 750mcm 3 0 3 Wire Term Lug term
225. 9 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Qty P pp P 424 ch pop R22 254 ch Part 334464 222908 222909 222910 290020 324313 336020 352295 BLK 354518 X 6086 6 X 6128 3 X 6306 100 334465 222908 222909 222910 290020 324313 336020 352295 BLK 354518 X 6086 6 X 6128 3 X 6306 102 334466 222908 222909 222910 290020 324313 336020 352295 BLK 354518 X 6086 6 X 6128 3 X 6306 103 334469 222908 222909 222910 290020 324313 336020 352295 BLK 354518 364510 M912 08025 60 X 6086 6 X 6128 3 X 6306 117 334470 222908 222909 222910 290020 324313 336020 352295 BLK 354518 364510 M912 08025 60 X 6086 6 X 6128 3 X 6306 118 TP 6116 2 02 Description Line Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit brea
226. 90020 360763 GM15301 X 6086 6 X 6304 90 X 6308 1 334132 290020 336020 352323 352325 BLK GM10413 GM10414 X 6086 6 X 6306 122 334133 222996 BLK 222999 290020 360763 GM15301 X 6086 6 X 6304 94 X 6308 1 334134 290020 336020 352323 352325 BLK GM10413 GM10414 X 6086 6 X 6306 122 Description Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker
227. 90deg Clamp hose 25 70 in Screw slotted pan head machine Coupling non metallic Conduit convoluted Nut hex machine screw 6 32 TP 6116 2 02 224875 156327 156327 224873 239298 241950 266469 269216 274883 275559 279875 A 224874 A 290024 X 202 12 X 202 30 X 22 25 X 22 7 X 386 102 X 391 20 X 426 9 X 51 12 X 567 1 6003 10 71 2 ch ch ch ch Description Transfer Pump 120 V 60 Hz Coupling conduit elbow Coupling conduit elbow Fuse 5 A 250 V Relay 120 VAC 15 A Cover conduit box Fuse holder inline Box junction Harness wiring motor Harness wiring engine 125 180 kW Bracket relay Box controller Pump motor assembly Bushing reducing 1 4 x 1 2 Bushing reducing 1 4 x 3 8 Washer lock 146 ID x 53 in OD Washer lock 172 ID x 333 in OD Hose Fitting hose connector 90deg Clamp hose 25 70 in Screw slotted pan head machine Coupling non metallic Conduit convoluted Nut hex machine screw 6 32 Fuel Tank Kits Day Day Tank 10 Gallon Economy Tank day Motor pump Pump Coupling pump drive Sensor float Switch Day Tank 10 Gallon Economy Tank day Motor pump Pump Coupling pump drive Sensor float Pan rupture basin Switch basin Switch float Switch Day Tank 25 Gallon Economy Tank day Motor pump Pump Coupling pump drive Switch Sensor float Day Tank 25 Gallo
228. 91 02 1919 41 80 1 uonoeuuooeH 196 Jomgiauep uonoes 99489 5 PUNOM 09 02 pue jueueuued 008 02 2 5 n a 12 LEAD ALTERNATOR 5 WIRE SINGLE PHASE 60 HZ 100 200V 60 HZ 120 240V 50 HZ 100 200V 50 HZ 110 220V SOME SETS NOT RATED FOR SINGLE PHASE SEE MANUALS NOT USED OPTIONAL COMP CT DROOP V7 12 LEAD ALTERNATOR 5 Wl RE SINGLE PHASE 60 HZ 240V 50 HZ 220V MARINE ONLY CT3 NOT USED 12 LEAD ALTERNATOR 4 WIRE DELTA 60 HZ 120 240V 50 HZ 110 220V E OVB 11 LO 11 NE P Q 0 8 7 10 x SCH ien P 8 5 7 7 S 2 7 SE LO ex geg SL OPTIONAL S 1 72 22 01 98007 L1 DANN rein cn 2 6 O 12 8 9 TAPE TO INSULATE 7 FROM GROUND Tos 1 5 5 y METER SCALE 1 METER SCALE METER SCALE Vo 21 013 ue vz o LAMP JUMPER 183 ue 7 LAMP JUMPER 09210 LAMP JUMPER 12 LEAD ALTERNATOR 4 WIRE LOW WYE 12 LEAD ALTERNATOR 4 WIRE WYE 6 LEAD ALTERNATOR 4 WIRE WYE 60 HZ 120 208 50 HZ 110 190 60 HZ 220 380V 50 HZ 220 380V 60 HZ 347 60 7 127 220 50 HZ 115 200 60 HZ 240 416V 50 HZ 230 400V L1 60 HZ 1
229. 931 08035 60 Contact 1 A 273945 Nut hex elastic stop 1 M982 08 80 PCB assembly 1 relay dry contact 1 C 294301 Flexible Exhaust Connector PA 276943 Customer connection assembly 1 GM13984 Adapter flexible exhaust 1 276946 Harness wiring controller connection 1 GM17033 Adapter flexible exhaust 1 276946 Single relay dry contact 20 2000 kW 1 TT 1304 Clamp exhaust 3 15 in 1 276948 Bolt hex cap 2 X 125 3 Clamp exhaust 3 15 in 1 276948 Screw cross recess round head machine 6 X 51 3 Pipe 3 NPT 1 X 533 1 Nut flange whiz 8 32 14 X 6210 4 Hose flexible exhaust 1 X 797 33 Nut flange spiralick 5 16 18 2 X 6210 7 Flexible Exhaust Connector PA 276944 Screw Phillips hex crimptite 4 X 6216 1 Adapter flexible exhaust 1 276947 Nut hex machine screw 8 32 4 70 12 exhaust 4 81 1 276949 25 OD sm 9 Flexible Exhaust Connector PA 276945 Clamp exhaust 4 81 in 1 276949 Adapter flexible 1 276951 Pipe 4 NPT 1 X 549 3 Hose flexible 1 X 797 35 Flexible Exhaust Connector PA 324932 Adapter flex exhaust 1 324932 Flexible Exhaust Connector PA 336809 Clamp exhaust 4 81 in 1 276949 Adapter flexible exhaust 1 336801 Pipe 5 NPT 1 X 707 1 Hose flexible exhaust 1 X 797 40 TP 6116 2 02 45 Kit Parts List Description Contact Kit Dry 10 Relay Dry Contact 10 SPDT Grommet round Cover dry contact Harness wiring FRII rem volt reg Vibromount Diagram interconnection Box dry contact Diagram
230. ABOVE YOUR HEATER IS STILL NOT FUNCTIONING PLEASE CALL THE TECHNICAL SUPPORT LINE AT EEMAX 1 800 543 6163 PLEASE HAVE THE FOLLOWING INFORMATION AVAILABLE 1 ORDER REF NUMBER ULL rating label on the front cover of unit 2 SERIAL NUMBER inside unit on backplate 7 Water Systems SECTION 9 1 HEATING VENTILATION amp AIR CONDITIONING Section 9 1 Heating Ventilation amp Air Conditioning 9 1 12 Fire Extinguisher Model WBDL S20 Tag NA UO2 8Jj X9J9UJE MMM uo SOSW HV 81988 1eusinBunxe Jeloeds e u S uopewoju SASN eu uonippe uogerod1o5 10 Jno sieusinBunxe u peu je ayqeyeae W 699465 geq vHSO Aq peinbel sy 310N pjoo esneo pinos US uelis pue jeppe 5 526 y 1 Seale peuijuoo ul pasiouexe 8 ueB xo sein MO ye mous 40 sajonaed se 51 opixoig uoqieo 82994 uiui Aou eJeuM suol sJeusinBunxe joe qns jou o Bulyooo Sait 10 esa loeo sjeusinBunxa 55810 jeo jd dod
231. Battery connections loose corroded or incorrect Verify that the battery connections are correct clean and tight Section 3 Battery weak or dead Recharge or replace the battery The spec sheet provides recommended battery CCA rating Section 3 S S Starter starter solenoid inoperative Replace the starter or starter solenoid Eng S M Engine harness connector s not locked tight Disconnect the engine harness connector s then reconnect it to the controller W D High water temperature switch inoperative Replace the inoperative switch Gen S M or W D Fault shutdown Reset the fault switches and troubleshoot the controller Section 2 High exhaust temperature switch inoperative Replace the inoperative switch Gen S M or W D Sec Section numbered section of this manual ATS Automatic Transfer Switch Eng Engine Gen Generator Set I M Installation Manual O M Operation Manual S M Service Manual S S Spec Sheet W D Wiring Diagram Manual Have an authorized service distributor dealer perform this service 1919 41 80 1 Bunoous lqnoil p uonoes Trouble Symptoms Does but does start Starts hard No or low output voltage Stops suddenly Lacks power Overheats pressure High fuel consumption Excessive or abnormal noise Probable Causes Recommended Actions Section
232. Bearing Alternator 3 4 3 Refer to the generator set service manual for bearing maintenance information 3 5 Diesel Fuel Systems 3 5 1 Bleeding Air from Fuel System Bleed air from the fuel system after fuel system maintenance such as replacing the fuel filter s using the hand prime pump kit when equipped The hand prime fuel pump eliminates the need for cranking the engine to bleed air from the fuel system Note Bleed air from the fuel system according to the engine manufacturer s instructions Trapped air in the fuel system causes difficult starting and or erratic engine operation Note Correct any fuel leaks encountered during the priming procedure 1 Place the fuel valves in the fuel system prime position Close the fuel valve located between the pipe tee and the engine Open the fuel valves on each side of the fuel prime pump See Figure 3 1 24 Section 3 Scheduled Maintenance Open this Valve Close this Valve Open this Valve Valve Open Valve Closed PK 272000 H Figure 3 1 Hand Prime Pump with Valve Positions for Fuel Priming Generator Set Without a Fuel Water Separator Shown Note The illustration shows a generator set without a fuel water separator The valve location and position for a generator set equipped with fuel water separator is similar 2 Loosen the bleed screw at the engine Refer to the engine operation manual for loc
233. Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 225 A 600 V 3 pole Kit Parts List Qty E P P Ah A hihi ch hb P bh ch ch hihi Part 279884 291111 279885 291668 279886 291733 279887 282050 279888 282048 279890 274543 279891 274544 279892 274489 279893 274490 279894 274491 279895 274492 279896 274493 279897 274494 279898 274533 279899 274534 279900 274535 334001 222908 222909 222910 290020 324313 354518 GM10528 BLK GM15301 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 16 334002 222908 222909 222910 290020 324313 354518 GM10528 BLK GM15301 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 16 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Decal power breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker
234. Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Decal power breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 150 A 600 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 150 A 600 V 3 pole Qty P P P k sch Ny N Mi A 5 Di Ny p ch PDN Part No 334003 222908 222909 222910 222949 BLK 290020 324313 354518 360763 GM15301 X 6086 6 X 6128 3 X 6304 88 X 6308 1 334004 222908 222909 222910 222950 BLK 290020 324313 354518 360763 GM15301 X 6086 6 X 6128 3 X 6304 88 X 6308 1 334005 222908 222909 222910 290020 324313 354518 GM10528 BLK GM15301 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6
235. Bracket circuit breaker Insulator Bus load Tag ground Cover side Bracket circuit breaker Decal power breaker Nut hex 4mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit TP 6116 2 02 Qty Part No GM14028 KA6 222908 222909 290020 324314 354518 GM14298 BLK GM14300 GM15301 M934 04 50 X 6128 3 X 6304 58 GM14029 KA1 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301
236. Bus load Tag ground Cover side Bracket circuit breaker Decal power breaker Nut hex 4mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Bracket circuit breaker Decal power breaker Nut hex 4mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Bracket circuit breaker Decal power breaker Nut hex 4mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Qty Part No GM14028 KA1 222908 222909 290020 324314 354518 GM14298 BLK GM14300 GM15301 M934 04 50 X 6128 3 X 6304 51 GM14028 KA2 222908 222909 290020 324314 354518 GM14298 BLK GM14300 GM15301 M934 04 50 X 6128 3 X 6304 52 GM14028 KA3 222908 222909 290020 324314 354518 GM14298 BLK GM14300 GM15301 M934 04 50 X 6128 3 X 6304 54 GM14028 KA4 222908 222909 290020 324314 354518 GM14298 BLK GM14300 GM15301 M934 04 50 X 6128 3 X 6304 55 GM14028 KA5 222908 222909 290020 324314 354518 GM14298 BLK GM14300 GM15301 M934 04 50 X 6128 3 X 6304 57 2242p a 2242p 4222p P Ny Mi zb 0 5 Ny 6116 2 02 Description Line Circuit Breaker Bracket circuit breaker
237. CY 2 i XD 1 METER SCALE oa METER SCALE 2 ya METER SCALE 2219 SIT 733 ue 7 0 LAMP JUMPER 185 7 LAMP JUMPER L3 TO PT3 H2 we vr Lo LAMP JUMPER NOTES CURRENT TRANSFORMER DOT OR H1 TOWARD GENERAT CURRENT TRANSFORMERS NOT USED ON ALL SEIS PHASE ROIATION L1 L2 13 1919 41 80 1 uonoeuuooeH 195 uonoes 9489 0008 0896 t S GENERATOR CONNECTIONS 12 LEAD ALTERNATOR 3 WIRE SINGLE PHASE 12 LEAD ALTERNATOR 4 WIRE DELTA 10 OR 12 LEAD ALTERNATOR 4 WIRE LOW WYE 60 HZ 100 200V 60 HZ 120 240V 2 v8 60 AZ 120 208V 50 HZ 110 190V 60 HZ 120 240 50 uz 110 220V 1 60 HZ 127 220V 50 HZ 115 200V v8 50 HZ 100 200V 12 v7 60 HZ 139 240V 50 HZ 120 208V 50 HZ 110 220V an ta OBHONAL 18 43 12 SOME SETS RATED FOR DROOP SINGLE PHASE SEE MANUALS COMP CT L1 TL 72 2 1 METER SCALE 7 lt 3 NOT USED YP LAMP JUMPER SU 2 1 2 JA BR We w OPTIONAL 1415 N SE T DROOP 5 d e m vo E 2 5 312 7 LO 712 id TB Sch 17 AAA 5 LO xen Us 1 5 10 12 apt Taya T4 x 2 VB Vi 1
238. Hex Head W Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head FHM Square Grade 8 Grade 8 9 Hex Socket Head Metric Cap or Acorn Round Head RHM Pan Head Wing Number stamped on hardware 5 8 shown Washers Washer Styles Hex Socket Head or Allen w Head Shoulder Bolt Plain Sheet Metal Screw Stud ax Drive Styles Hex Socket Head Cap or 3 Alen Head Split Lock or Spring Spring or Wave External Tooth Lock Hex Internal Tooth Lock Internal External Tooth Lock L Hex Slotted A Phillips Slotted e Hex Socket Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company Sample Dimensions American Standard Screws Bolts Studs and Nuts Plain Washers 1 4 20 x 1 9 32 x 5 8 x 1 16 Met L Length In Inches Screws and Bolts Threads Per Inch Major Thread Diameter In Fractional Inches Or Screw Number Size ric Screws Bolts Studs and Nuts M8 1 25 x 20 TP 6349 L Length In Millimeters Screws and Bolts Distance Between Threads In Millimeters Major Thread Diameter In Millimeters 6 07 L Thickness External Dimension Internal Dimension Lock Washers Internal Dimension Appendix 57 Notes 58 Appendix TP 6349 6 07 6
239. ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker 450 A Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Bus line Insulation CB Decal power breaker Bus line Bracket circuit breaker Cover side Washer plain 344 ID x 875 in OD Washer spring 46 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machined Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker 90 100 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A Marker wire Marker wire Marker wire Nut hex 5 16 18 38 Qty Part No GM17680 KA3 222908 222909 290020 324313 354518 364508 GM15301 GM17634 GM17639 BLK X 25 118 X 25 75 X 6086 6 X 6128 3 X 6304 96 X 750 14 X 750 15 X 750 16 X 82 6 GM17681 KA1 222908 222909 324313 354518 364509 365627 GM15301 GM17633 GM17634 GM17636 BLK X 25 75 X 6086 20 X 6086 6 X 6128 3 X 6304 100 X 6308 2 X 750 14 X 750 15 X 750 16 X 82 6 GM17682 KA1 222908 222909 290020 324313 336020
240. Jo SU YUM 40220 pod jood uo suaysinBuyxea LEZ ogy asn 15 0 pue si se ay ay uosi d au pyojnb unooo 5 sue qoid 084 Su s id y JO ayejdaweu uo pejeorput uey Jejeus seole pesn pinous 12 Jou nedas puo q juawdinbs au inq ayy usinBunx jueBe siy jo aen Heie Jo jou 51 30 uetoisAud e peouepadxe sl 8018 4 Aue J ue eq ejdung 4o peseq 40 ogy paseq oipioe 94 104 snouosiod uou ese fug JO aseo ssajasn JO 5591 ainssaid 2501 esneo pjnoo jo junoue Hews sebum 1004 158 jou oq pad
241. Megohmmeter Connections on Exciter Field Winding TP 6349 6 07 A reading of approximately 500 kOhms 1 2 megohm and higher indicates the exciter field winding is good A reading of less than approximately 500 kOhms indicates deterioration of the exciter field winding insulation and possible current flow to ground Replace the exciter field winding 3 6 Exciter Armature The exciter armature supplies excitation current to the main field windings through the rotating rectifier assembly RRA Test the exciter armature as described in the following steps Exciter Armature Test Procedure 1 Disassemble the alternator See Section 4 Alternator Disassembly Reassembly for the procedure 2 With the alternator disassembled disconnect the armature leads from the RRA AC terminals 3 With an ohmmeter on the R x 1 scale check the resistance across the exciter armature leads See Figure 3 11 See Section 1 Specifications for the armature resistance No continuity indicates an open armature winding If the resistance test is inconclusive perform a megohmmeter test on the exciter armature as described in the next step TP 6349 3 4 Ohmmeter 5 Exciter armature 6 Exciter field winding 1 Rotor main field 2 Stator main windings 3 Rotating rectifier assembly RRA Figure 3 11 Exciter Armature Resistance Test Section 3 Alternator Troubleshooting 31 Note Consider the exci
242. NI ZOTO E SESZ OL S31V1d 3HLO INO ONY NI 20 0 1 SFOOL OL assy 2000 0 31 07315 INO WIL c zL 8z X 08800 O0zzcf Aen BEL Kon 13320d ANH NI 3Nn23S e eaec x lJwHS 8 190820 N33AI38 319201 ETS 591 24 WN eg OL 31080 08 90 46 Lh 2 08 91080 666 5 SY 50757 30010 NMOHS Sv 50737 2000 c SNIA331S 038 NOLLVOOT 141119 avd 14 5 HOIOH H31dvOv 2 5 01 201 3S3HL NI HOWL ONY SD TIVISNI LIVHS ON3 NI 20702 ere OL SGV31 3HniviWev e esz x 08 05001 260 NAOHS 01235 G 6 Sc x dx3 6 08 08001 1688 assy o OH 1 AGIA NMOHS MY 08 65 80108 Y 455 on NS MIA NMOHS M 08 A ATBWGSSV 01415 dX3 09 05001 26 8 55 01 6 9 Z 08 01 08 01 vSzLIN AXA 08 01 69 axa 08 01 2694 dx3 2 08 01 69 axa O8 DL VSZLlN 1 11 72 AN SF Ol SINN 1184155 9NI ANNOYS TY 360801 23108 NMOHS cf 385 HOlvud3N35 NMOHS 3 5 SNISNOH T33HM 14 5 c l LL 395 KEE 581 wu 082 WN 62 OL v 68 52 dX3 9 09 0200 6 591 14 sr UN 19 OL 3noHOL E 8 108 ZB S 001 EEGA 909 9 Yad EZE 52510 q 421162 dX3 09 08001 6
243. O ejqeo e pejsi TN peyejnsul sy xeulez INOA Ee MOOHS 40 339NvG GIOAV OL 140 S 9877 888 JHL 3315 38 NOLLVTIVLSNI 3H1 NO AYYOM 330438 VINYA L3TNI OL 15 a 3A1VA 1311nO dN MOOH TVOI319373 INSTRUCTIONS FOR TROUBLESHOOTING YOUR WATER HEATER Everything you need to know about troubleshooting your Eemax unit is contained in this fully illustrated guide If you still have problems after reading and carrying out the instructions in this manual then please call the Eemax technical support department on the toll free number below and we will be happy to help PHONE TOLL FREE 800 543 6163 SP MODELS SP MODELS Water outlet inlet Top out in U L Rating label Model Order UP indicator light This is how your Eemax SP model should look when mounted correctly on the wall Any other mounting configuration is wrong and the unit will not work Check to see if you have SP model on the U L rating label on the front cover of your Eemax unit If the unit is mounted correctly and still does not produce hot water then have a look to see if the indicator light comes on when the hot water faucet is fully opened If the l
244. R 222661 STANDBY NAMEPLATE KOHLER CO KOHLER Wi USA ERIA 1 Kit numbers Figure 1 Generator Accessory Nameplate 2 2 Use the Index at the end of this catalog to find the location of the kit number in the Kit Parts List Example Safeguard breaker kit 272748 is on page 41 3 Locate the service part description in the list of parts following each kit Read across to the part number Example Circuit Breaker 5 A 240 V 3 pole is part number X 796 6 Safeguard Breaker ae 272748 Washer lock 146 ID x 285 in OD 22 6 Screw cross recess pan head machine X 49 2 Breaker circuit 5 A 240 V 3 pole X 796 6 1 1 Part description 2 Part number Figure 2 Kit Parts List Kit Description Number Sequence This publication lists the kit names in alphabetical order and arranges kits numerically under the kit name TP 6116 2 02 Description Air Cleaner Restriction Indicator Kit Air Cleaner Restriction Indicator Fitting 45deg street elbow Gauge restriction Coupling pipe 1 8 x 1 3 16 in Air Cleaner Restriction Indicator Gauge restriction Air Cleaner Restriction Indicator Gauge restriction Bushing reducing 1 8 x 3 8 in NPT Air Cleaner Restriction Indicator Gauge restriction Air Cleaner Restriction Indicator Gauge restriction Washer nylon 878 ID x 1 132 in OD Adapter bushing Air cleaner kit 20 2000 kW Air Cleaner Restriction Indicator Fitting 45deg street elbow
245. Relay Kit iore what buds 51 6 1 15 Safeguard Breaker 51 6 2 Accessory and Prime Power Terminal Strip Connections M 52 6 3 Communication Module Kit and Gauge Driver Circuit Board 54 6 3 1 Communication Modules Circuit Board Versions 55 6 3 2 Circuit Boards Views 55 Appendix A Abbreviations 57 4 Table of Contents TP 6161 1 08 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 A CAUTION Caution indicates the presence of a hazard that will or can
246. X 750 14 X 750 15 X 750 16 X 82 6 Line Circuit Breaker 200 A W 12 V S T GM17679 KA8 Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5 Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 TP 6116 2 02 EA 222908 222909 290020 324313 354518 364498 GM15301 GM17634 GM17638 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 75 X 750 14 X 750 15 X 750 16 X 82 6 Description Line Circuit Breaker 225 A Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5 Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker 300 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Decal power breaker Bracket circuit breaker Cover side Washer plain 406 ID x 1 in OD Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circ
247. X3 0g S0 vSZ LN 3 TNNIMHSL SUDA z 038 30010 ame WNIWH3L 30010 SH1 NI zz ee OL 2 08 50 ag ozoso ccew v 08 480 486 7 09 00180 1267 qi3H N3llOX3 2 9168 9 H MIA 335 3NI1 H31N32 18 01060 0008 3 BSB LEWD JOH Qv31 AYAN 1431 OL 319201 3 40078 TWNINSGL 71030 5 8 80 00 00088 LYN ANS IHB TI AMO 6 40 Wil v Alddv 711843559 OL HIOTO 180 Nv319 HUN 519830 1410 1500 JO 3808 1359788 GN3 2170 83100 NV312 SNLINDOIN 1 804 SYVMdYVH 557 98 00189 09 00140 1 5 8 Tesee mue serana 1 0 9 oeme miw WRA CO s Gr SHOLOT amp ISN HIONI 0991 89 8 ri 13897 b 8 4 ew anoo 8 8 089 96 4 129 9 186068 9 6 sz x axa 08 00101 61 9 3 m 08 01 521 91 08 01 269 18 020890 0008 34 OWN 3150440 61 11 4o01B SIONN 31 201 MOOT TWNINSIL 16230 YOOTE vNIWN3L BISLENS 37895 Xz SNOLV201 3S3H1 NI HOWLIY 19 8 LWHS 40 WOHJ
248. ak alarm 6 15 kW Harness wiring detector 120 V Fuse 5 A 250 V Connector plug 4 position Connector jack 4 position Lens red Switch float 1 pole Vibromount Fuse holder inline Plate silkscreen Screw mounting Bracket leak alarm Box assembly Sensor leak Plate assembly PCB assembly A V 1 light annunciator Grommet round Screw cross recess round machine Spacer 25 OD 5 in Screw hex washer head drill Low Fuel Level Alarm Wiring harness float switch Bracket leak alarm Harness low fuel level alarm Box assembly Dwg assembly low fuel alarm Nut hex 4mm Qty Part No 226204 224871 225948 225949 226200 226208 239298 239408 239411 253241 255600 259919 269216 276800 292828 336505 A 224861 A 226201 A 276799 A 292883 X 284 15 X 51 11 X 712 9 X 794 2 GM10409 KA1 224856 336505 GM10397 GM10407 GM10409 M934 04 50 PADMA ch lt ch ch ch ch ch ch Mi ch Alarm Kits Subbase Tank Low Fuel Low Level Fuel Alarm Switch low fuel level Harness wiring float switch Low Level Fuel Alarm Switch low fuel level Harness wiring float switch Low Level Fuel Alarm Switch low fuel level Harness wiring float switch Low Fuel Level Switch Harness wiring float switch Switch low fuel level Low Fuel Level Switch Harness wiring float switch Switch low fuel level Low Fuel Level Switch Harness wiring float switch Switch low fu
249. aker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Cover side Breaker circuit 50 A 600 V 3 pole Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Terminal fast on male 4 AWG Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A 600 V 3 pole TP 6116 2 02 Qty A hihi A A Ph ch hihi E Eh A E ppp Part 334016 222908 222909 222910 290020 324314 354518 GM10527 BLK GM15301 51 47 6086 6 6128 3 6304 54 334017 222908 222909 222910 290020 324313 354518 GM10528 BLK GM15301 51 47 6086 6 6128 3 6304 57
250. ar a battery at any time particularly when itis charging Do not dispose ofa battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases 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 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
251. ardware procure locally GQ N N Nia TP 6141 12 03 25 Group 15 Fuel Filter See Group 5 28 CDP45119 26 TP 6141 12 03 Group 15 Fuel Filter Qty Var Item Part No Description 1 35DD 1 GM17543 Kit 1 1 2 222772 Kit 1 1 3 275501 Filter fuel 1 3 996545 Filter fuel also order 15 1 336661 4 222773 kit 1 1 5 360048 Kit 1 1 6 2731 Kit sediment bowl 1 7 Retainer 1 1 8 Retainer order 1 4 1 1 9 Seal order item 2 1 1 10 Retainer order item 1 or 4 1 d 11 Filter head order 1 1 1 12 360178 O ring 2 2 13 Plug pipe M12 x 1 5 2 13 360015 Plug 2 14 Drain plug order item 1 4or 5 1 1 15 GM17445 Seal 1 1 16 Filter element order item 3 1 1 17 Retainer order item 1 or 4 1 18 O ring order item 2 or 6 1 19 Wing nut order item 6 1 20 O ring order item 2 or 6 1 21 Nut order item 6 1 22 Lock Washer order 6 1 23 Washer order item 6 1 24 Bowl sediment order 6 1 25 O ring order item 6 or 2 or 5 1 26 Gasket order item 6 or 2 or 5 1 27 Drain plug order item 6 or 5 1 28 Screw order item 6 1 29 O ring order item 6 or 2 or 5 1 Common hardware procure locally TP 6141 12 03 27 Group 18 Timing Gear Cover CD37324A lem PartNo Description 4499 1 Screw 3 8 in x 2 in
252. arker wire Nut hex 5 16 18 Line Circuit Breaker 450 630 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bus line Bus line Bus line Bracket circuit breaker Cover side Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit 1200 A 600 V 3 pole TP 6116 2 02 Qty Part No GM17682 KA5 222908 222909 290020 324313 336020 354518 364510 GM10167 GM17634 GM17637 BLK M912 08025 60 X 25 75 X 6086 6 X 6128 3 6306 117 750 14 750 15 750 16 82 6 GM17683 KA1 222908 222909 290020 324313 336020 354518 364511 GM10168 GM17634 GM17635 BLK X 25 75 X 6086 6 X 6128 3 6306 120 750 14 750 15 750 16 82 6 GM17683 KA2 222908 222909 290020 324313 336020 354518 364511 GM10168 GM10169 GM17634 GM17635 BLK X 25 75 X 6086 6 X 6128 3 6306 124 750 14 750 15 750 16 82 6 GM17879 KA1 222996 BLK 222998 290020 336020 365609 GM15301 X 6086 6 6305 134 ON E 2 2 Ny Gy N gt N
253. ation of the bleed screw s The bleed screw allows air to be expelled from the fuel system when the hand prime pump is operated 3 Rotate hand prime pump handle counterclockwise until fuel flows from the bleed screw Stop pumping 4 Tighten the bleed screw Wipe up any fuel leakage 5 Place the fuel valves in the normal operation position Open the fuel valve located between the pipe tee and the engine Close the fuel valves on each side of the fuel prime pump TP 6161 1 08 3 52 Subbase Inner Fuel Tank Alarm This kit provides for both audible and visual alarm from a location remote from the generator set if a leak is detected in the inner fuel tank of the double wall subbase fuel tanks See Figure 3 2 If the inner tank is leaking a sensor installed in the outer tank sends an electrical signal to the alarm plate when the sensor becomes immersed in the fuel collecting in the outer tank If aleak is detected the alarm horn will sound and the fault lamp will light The alarm horn is quieted by moving the alarm switch to the SILENCE position the alarm lamp remains lit until the fault is corrected See Figure 3 3 for troubleshooting information Inner Tank O Fuel Leak Alarm Alarm Normal 12 Silence S FF 273000 D Figure 3 2 Inner Fuel Tank Leak Alarm 20 300 kW Model Shown Alarm Fl
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255. bleed petcocks if equipped Close the air bleed petcocks when coolant begins to flow from them 4 Add coolant additives or water pump lubricants according to the engine manufacturer s recommendations in the engine operation manual 5 Fill the cooling system with the recommended coolant antifreeze mixture of 5096 ethylene glycol and 5096 clean softened water to inhibit rust corrosion and prevent freezing Note A coolant solution of 5096 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 A coolant solution containing less than 5096 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution containing more than 5096 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Refer to the engine operation manual for recommendations regarding the coolant mixture to use in extreme temperatures TP 6161 1 08 6 Replace the pressure cap 7 Fill the coolant recovery tank to the low mark 8 Operate the generator set until the thermostat opens when the upper cooling system hose warms 9 Stop the engine and allow it to cool 10 Remove the pressure cap 11 Add coolant to bring the coolant level to just below the overflow tube opening of the filler neck 12 Replace the pressure cap 13 Maintain the coolant level in the coolant recovery tank between the
256. bleshooting startup problems or to test and troubleshoot the controller when it is removed from the generator set Perform tests without starting the generator set FASTCHECK functions are listed below refer to Figure 6 5 to identify LEDs and switches Figure 6 5 FASTCHECKe Diagnostic Tester LEDs on the FASTCHECKe illuminate to indicate the energizing of the following circuits AC Voltage Regulator Battery Connection correct polarity Engine Ignition gas gasoline Engine Crank Engine Antidieseling Engine Malfunction Alarm and or Alarm Shutdown Fuel Solenoid diesel Switches on the FASTCHECK simulate the following Anticipatory High Engine Coolant Temperature Anticipatory Low Engine Oil Pressure Engine Crank Engine Overspeed Engine Running High Engine Coolant Temperature Low Engine Coolant Temperature Low Engine Oil Pressure Low Fuel TP 6161 1 08 6 18 Float Equalize Battery Charger Kit with Alarm Option M The float equalize battery charger with alarm option provides battery charging to the engine starting battery ies and connects to the controller for fault detection Battery chargers for 12 or 24 volt models are available as a generator set accessory See Figure 6 6 See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification Low Voltage Controller Terminal Strip
257. cal kWth kilowatt thermal liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male ms cubic meter m hr cubic meters per hour m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 229 bytes MCCB molded case circuit breaker MCM one thousand circular mils meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQmillionm MOhm MQmegohm 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 58 Appendix MTBO mtg MTU MW mW nat 5 02 D 2 pot psig pt PTC PTO PVC qt qty R rad
258. cal power breaker 1 GM15301 Bracket circuit breaker 2 GM17634 Cover side 1 GM17638 BLK Nut hex 5mm 4 M934 05 50 Washer plain 344 ID x 875 in OD 6 X 25 75 Washer spring 39 ID x 81 in OD 3 X 6086 6 Standoff insulator 1 4 20 x 1 5 in 2 X 6128 3 Breaker circuit 1 X 6304 57 Marker wire 1 X 750 14 Marker wire 1 X 750 15 Marker wire 1 X 750 16 Nut hex 5 16 18 3 X 82 6 TP 6116 2 02 Kit Parts List Description Qty Part No Line Circuit Breaker 100 A W 12 V S T GM17678 KA4 Bracket circuit breaker 1 222908 Bracket circuit breaker 1 222909 Insulator 2 290020 Bus load 1 324313 Tag ground 1 354518 Decal power breaker 1 GM15301 Bracket circuit breaker 2 GM17634 Cover side 1 GM17638 BLK Nut hex 5mm 4 M934 05 50 Washer plain 344 ID x 875 in OD 6 X 25 75 Washer spring 39 ID x 81 in OD 3 X 6086 6 Standoff insulator 1 4 20 x 1 5 in 2 X 6128 3 Breaker circuit 1 X 6304 58 Marker wire 1 X 750 14 Marker wire 1 X 750 15 Marker wire 1 X 750 16 Nut hex 5 16 18 3 X 82 6 Line Circuit Breaker 125 A GM17679 KA1 Bracket circuit breaker 1 222908 Bracket circuit breaker 1 222909 Insulator 2 290020 Bus load 1 324313 Tag ground 1 354518 Bus line 3 364498 Decal power breaker 1 GM15301 Bracket circuit breaker 2 GM17634 Cover side 1 GM17638 BLK Nut hex 5mm 4 M934 05 50 Washer plain 344 ID x 875 in OD 12 X 25 75 Washer spring 39 ID x 81 in OD 6 X 6086 6 Standoff insulator 1 4 20 x 1 5 in 2
259. chine Standoff insulator 1 4 20 x 1 5 in Breaker circuit 225 A Breaker circuit 175 A 222835 222908 222909 222910 227266 248875 290020 324314 GM19468 X 25 45 X 50 41 X 6128 3 X 6304 165 X 6304 166 N P CA N Line Circuit Breaker Dual 800 600 GM19767 KA1 Relay protective Transformer curr 800 5 round Bus lead Bracket circuit breaker Bus line Insulation CB Cover side Plate Bracket circuit breaker mounting Screw slotted round head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Breaker circuit 600 A Marker wire Marker wire Marker wire 227266 248878 324313 328353 365609 365627 GM11950 BLK GM19468 GM23472 X 51 53 X 6086 6 X 6138 3 X 6304 118 X 6304 170 X 750 14 X 750 15 X 750 16 L Sk lt lt 6116 2 02 Description Qty Part No Line Circuit Breaker Dual 700 600 GM19767 KA2 Relay protective Transformer curr 800 5 round Bus load Bracket circuit breaker Bus line Insulation CB Cover side Screw HC special thread length Plate Bracket circuit breaker mounting Screw slotted round head machine Washer spring 46 ID x 875 in OD Washer spring 39 ID x 81 in OD Breaker circuit Breaker circuit 600 A Nut hex 7 16 14 Marker wire Marker wire Marker wire 227266 248878 324313 328353 365609 3656
260. citer armature 7 Exciter field windings Figure 3 16 Megohmmeter Connections on Rotor Main Field 3 9 Stator The stator consists of a series of coils of wire windings laid in a laminated steel frame The stator leads supply voltage to the AC load and voltage regulator Before testing the stator inspect it for heat discoloration and visible damage to the housing lead wires and exposed and varnished areas of the frame laminations Be sure the stator is securely fastened in the stator housing The stator produces electrical output AC as the magnetized main field rotates within the stator windings Test the condition of the stator according to the following procedure Section 3 Alternator Troubleshooting 33 Leads 1 4 single phase leads 1 12 three phase are the alternator AC outputleads Leads 55 and 66 are the voltage regulator supply and sensing leads Refer to Figure 3 17 Figure 3 18 three phase Figure 3 19 and Figure 3 20 single phase when performing the following tests Between Leads Continuity 1 and 4 2 and 5 3 and 6 7 and 10 8 and 11 9 and 12 55 and 66 1 and 2 5 3 6 7 10 8 11 9 12 1 and 55 66 Any stator lead and ground Rotor main field Sensing leads 208 240 volts nominal Voltage regulator power supply leads Stator main windings Ohmmeter Rotating rectifier assembly RRA Excit
261. cket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Bus line Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Terminal fast on male 4 AWG Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A Kit Parts List Qty D 5 AHH R22 254 ch 42542 lt lt ma k ch P pp Part 334067 222908 222909 222910 290020 324313 336020 352295 BLK 354518 364510 GM10167 M912 08025 60 X 6086 6 X 6128 3 X 6306 117 334069 222908 222909 222910 290020 324313 3
262. 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 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
263. connection has been done readjust the voltage regulator according to the following procedure voltage regulator components are identified and described in the following paragraphs Figure 3 6 illustrates the voltage regulator features Figure 3 7 identifies the voltage regulator connections to the P40 socket Note Frequency reconnection Refer to the respective generator set spec sheet to determine if engine frequency speed is fixed or field convertible Stability Potentiometer Potentiometer fine tunes the regulator circuitry to reduce light flicker TP 6349 6 07 Volts Hz Potentiometer Potentiometer adjustment determines the engine speed Hz at which the alternator output begins to drop Voltage Adjustment remote only Use the generator set controller voltage adjustment control to adjust the alternator output See the respective generator set operation manual for further information DB IG 4 gato UT LST 17 LL Qi e Zeus 2 9 bc c D 1 zl R73 SET ES des Ca us m el mm a bp ri te 4 TEEN A Raj 1 LED1 red shutdown 2 LED2 green output 3 12 pin socket P40 4 Stability potentiometer 5 Volts Hz potentiometer Figure 3 6 Voltage Regulator Features Description Function Remote voltage adjustment TB4 V7 sensing input TB4 V8 sensing input Exc
264. creasing meter reading indicates a shorted exciter field decreasing meter reading to zero or unstable reading suggests a running open in the exciter 26 Section 3 Alternator Troubleshooting Stable ammeter reading If the ammeter 15 stable continue with the next step 7 Use a voltmeter and check for AC output across the stator main windings and compare it to the values in Section 1 Specifications If the stator main windings output varies considerably from those listed a faulty stator rotor rotating rectifier assembly or exciter armature is likely 8 Place the generator set master switch to the OFF RESET position to stop the generator set If the AC output is not within specifications the voltage regulator is probably defective If there is no alternator output during normal operation but output is available when the generator set is separately excited the voltage regulator is probably defective Note See Section 1 Specifications for the stator output voltages with separately excited alternator These specifications are based on a battery voltage of 12 Should the battery voltage vary 11 14 volts the resulting stator output values will also vary 3 4 WoundField Voltage Regulators 341 Unstable Voltage Troubleshooting Before replacing the voltage regulator use the flowchart in Figure 3 3 to troubleshoot the generator set when unstable voltage is detected The remaining parts of this section give addit
265. cribed intervals Maintenance work must be performed by appropriately skiled 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 550 controller Figure 1 lists the available literature part numbers Manual Description Literature Part No Voltage Reguator Spec Sheet G6 58 TP 6200 550 Controller Operation Manual 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 Consult the Yellow Pages under the heading Generators Electric Visit the Kohler KohlerPower com Power Systems website at Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Zl Senia 122 12 rue des Hauts Flouviers 94517 Thiais Cedex France Phone 33 1 41 735500 Fax 33 1 41 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 12 Service As
266. cuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit TP 6116 2 02 Qty S P HA A P RON Ny A P GS hi A P P MH A Part 334766 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 69 334767 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 70 334768 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 74 334769 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 75 334770 222908 222909 290020 324313 354518 364484 364494 BLK 364498 M934 05 50 X 6086 6 X 6128 3 X 6304 78 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side B
267. cuit breaker Bracket circuit breaker Bracket circuit breaker Cover side Insulator Bus load Tag ground Bus line Decal power breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw slotted pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 200 A 600 V 3 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Qty ch P P ch ch hihi A P appa 5 A 5 gt gt hb P hihi Part 334025 222908 222909 222910 290020 324313 354518 GM10528 BLK GM15301 X 25 45 X 50 41 X 6128 3 X 6304 8 334026 222974 BLK 269250 GM15301 X 49 2 334027 222908 222909 222910 222950 BLK 290020 324313 354518 360763 GM15301 X 6086 6 X 6128 3 X 6304 92 X 6308 1 334028 222908 222909 222910 290020 324313 354518 GM10528 BLK
268. cuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A 28 Qty N A MH A MHA APA
269. cy stop switch Refer to Section 2 3 5 Controller Resetting After a Fault Shutdown to restart the generator set following a fault shutdown Emergency Stop Switch Resetting Procedure 1 Investigate the cause of the emergency stop and correct the circuit or wiring problem s 2 If the remote emergency stop switch was activated reset the switch by replacing the glass piece If the controller mounted emergency stop switch if equipped was activated reset the controller emergency stop switch by rotating the switch clockwise until it springs back to its original position Note The controller auxiliary fault lamp lights if the generator set master switch is in the RUN or AUTO position during the resetting procedure 3 Toggle the generator set master switch to the OFF RESET position and then to the RUN or AUTO position to restart the generator set The generator set does not crank until the resetting procedure is completed 2 3 4 Fault Shutdowns The generator set shuts down automatically under the fault conditions listed in Figure 2 2 2 3 5 Controller Resetting After a Fault Shutdown Use the following procedure to restart the generator set after a fault shutdown Refer to Section 2 3 3 Emergency Stopping to reset the generator set after an emergency stop 1 Move the controller alarm horn switch to the SILENCE position If equipped the audiovisual annunciator alarm horn and lamp are activated Move the audiovisual ann
270. d Nut hex machine screw 6 32 Day Tank Relay Control Coupling conduit elbow Coupling conduit elbow Harness wiring day tank 6 60 kW Fuse 5 A 250 V Relay 120 VAC 15A Cover conduit box Fuse holder inline Box junction Harness wiring engine 125 180 kW Switch float Bracket relay Box controller Pump motor assembly Washer lock 146 ID x 53 in OD Washer lock 172 ID x 333 in OD Fitting hose connector 90 deg Hose Clamp 1 in hose Screw slotted pan head machine Screw slotted pan head machine Coupling non metallic Conduit convoluted Nut hex machine screw 6 32 Qty A ca 2x ch nnn nin iin 2 N ch ch nnn nin iin Part 224813 224816 224825 224881 224884 255600 299186 299187 290024 284 35 391 13 422 30 426 10 224850 156327 156327 224873 239298 241950 266469 269216 274883 275559 279746 279875 224874 290024 22 25 22 7 391 13 422 31 426 10 50 3 51 12 567 1 6003 10 71 2 224851 156327 156327 224873 239298 241950 266469 269216 274883 275559 279746 279875 224874 290024 22 25 22 7 391 13 422 30 426 10 50 3 51 12 567 1 6003 10 71 2 6116 2 02 Description Day Tank Electronic Coupling conduit elbow Coupling conduit elbow Switch float Harness wiring
271. d s inu ou ss sepinbr 3 sjayoap neen Jeided 8104 Se qnsnquioo S3WAVHO X034 01014 S3dAL S3SSV1O 30 SASSV19 13 63441 S d s slinn JUOS 8 8 enbsu un juenjnsuoo je sunaisnid 8 assejo n s eun e juos Sjnejounxe seuiuexe sep 9p e ep ue 59100 9 59158 1008 p 5 ep sesse o Sep aiqejeeid eouessieuuoo eun esoddns inejournxe unp je eeudoidde uonesynn no enis 169 Woupua janb uye ep enbroejeuBrs enbejd e jns jueunBy SUOHONASU S a9 1 S 4nejounxe 1004 eouenbesuoo ue eun 14929 yop eouefunp seo ue jnejounxe un Jasin p eijqndeosns jauuosued 9 VHSO ej seide q enbipoued ep ejnsuoo 1nod 668028 81581 inb eyos ue ue au Zejin9A jueseid suep jueunBi uomneuuojul eipuejduio2 je n yelaap 192 epqndeosns auuosied nol NOLLOnGO3LNI
272. d bracket located 180 from the grease fitting Use a grease gun and fill with Chevron SRI2 or equivalent lithium based grease until the grease is visible at the vent sight hole Wipe excess grease from the end bracket 1 Flywheel studs Replace the vent sight hole screw and torque to specifications See Figure 4 16 Figure 4 17 Flywheel Studs 18 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 discs over the studs When the drive discs are about 25 mm 1 in over studs install spacers if so equipped See Figure 4 18 GM33000A A 1 Grease fitting 2 Vent sight screw Figure 4 16 Applying Grease to UA Alternator 1 Drive discs 2 Studs 3 Spacers Figure 4 18 Installing Spacers Loctite is a registered trademark of Loctite Corporation TP 6349 6 07 Section 4 Alternator Disassembly Reassembly 47 19 20 21 22 23 48 Move the alternator necessary to align the adapter and the flywheel housing Fasten and final tighten the adapter to the flywheel housing using bolts and hardened lock washers See Figure 4 19 Torque the bolts to specifications 3 083 R8371 17 Figure 4 19 Aligning Adapter to Flywheel Housing
273. d head machine Reactive Droop Compensator Transformer curr 400 5 round Nameplate engraved rheostat Rheostat includes rheo and knob Screw slotted round head machine Reactive Droop Compensator Transformer curr 600 5 round Nameplate engraved rheostat Rheostat includes rheo and knob Screw slotted round head machine Reactive Droop Compensator Transformer curr 1000 5 round Nameplate engraved rheostat Rheostat includes rheo and knob Screw slotted round head machine Reactive Droop Compensator Transformer curr 1600 5 round Nameplate engraved rheostat Rheostat includes rheo and knob Screw slotted round head machine Reactive Droop Compensator Transformer curr 2500 5 round Nameplate engraved rheostat Rheostat includes rheo and knob Screw slotted round head machine own own own ch A Emergency Stop Switch Kit Local Emergency Stop Button Switch emergency stop pushbutton Decal emergency stop Ere Emergency Stop Switch Kit Remote Remote Emergency Stop Switch Rod glass 1 Switch emergency stop 1 Remote emergency stop 6 1600 kW 1 TP 6116 2 02 Part No GM19978 KA3 239776 239789 255798 255882 273738 343292 347232 X 22 4 X 301 24 6003 17 6210 12 256496 233951 283869 467 4 51 5 256497 233952 283869 467 4 51 5 256498 233953 283869 467 4 51 5 256499 233954 283869 467 4 51 5 256500 23395
274. ded Test and or replace the rotor Gen S M Stator inoperative open or grounded Test and or replace the stator Gen S M Vibration excessive Tighten loose components Voltage regulator digital settings incorrect digital controller only Adjust the voltage regulator Sec 2 Menu 11 Voltage regulator inoperative Replace the voltage regulator fuse If the fuse blows again troubleshoot the voltage regulator Gen S M Voltage regulator out of adjustment Adjust the voltage regulator Gen S M Crankcase oil type incorrect for ambient temperature Change the oil Use oil with a viscosity suitable for the operating climate Oil level low Restore the oil level Inspect the generator set for oil leaks Low oil pressure shutdown Check the oil level 1919 41 80 1 Sec Section numbered section of this manual ATS Automatic Transfer Switch Eng Engine Gen Generator Set I M Installation Manual O M Operation Manual S M Service Manual S S Spec Sheet W D Wiring Diagram Manual Have an authorized service distributor dealer perform this service Section 5 Generator Set Reconnection WARNING change the voltage of 10 12 lead generator sets use the following voltage reconnection procedure Adjust the governor and voltage regulator for frequency changes Consult the generator set service manual for
275. dified 16 light microprocessor controllers with switchgear applications These nonstandard controllers may have remote start and no time delay for engine cooldown circuitry Consult the switchgear literature for configuration function Note Some 1 A CVOLTS A C AMPERES A 27 LOWER METER SCALES VOLTAGE EMERGENCY STOP S oom TOTAL HOURS ONLY NN Tw N N AN BATTERY TF PREALARM 2 HIGH ENGINE 5 7 TEMPERATURE HIGH ENGINE l gt AUXILIARY HIGH BATTERY _ TEMPERATURE FAULT PREALARM LOW OIL 4 LOW OIL 1 PRESSURE LOW Ol BATTERY y AIR PRESSURE _ Fi DAMPER LOW WATER EMERGENCY LOW BATTERY gt SYSTEM _ TEMPERATURE STOP VOLTAGE 7 READY GENERATOR LOW FUEL OVERSPEED OVERCRANK SWITCH 25 A 2 NOT IN AUTO RUN OFF RESET AUTO SILENCE RMAL ALARM 16 Fuses inside controller Selector switch Frequency meter AC voltmeter Controller TB1 and TP2 terminal strips on circuit board AC ammeter Scale lamps upper lower Lamp test Alarm horn Figure 1 1 16 Light Decision Maker 3 Controller TP 6161 1 08 Annunciator panel lamps Alarm silence switch Generator set master switch ADV 5849A DC voltmeter Water temperature gauge Voltage
276. diys sjeusinBunxe 2589 Su3HSInoNILX3 NOS3VO ANY 55712 TVOIIN3HO LAM 1112 1 NOHLO VH 58919 AUG IVOIW3HO ANG AND KE LEEFER SEENEN sraysinBuyxa 4 4444 JO 443 PM ISIN 816 108 0 peufisep jou si 905 euj pue 510 rewiue 10 gpaw 0 2 ue jo uonppe UHA 4 0p 0 pe128104d J usin6unx 3 4 092 po eui ILON DNO oui 3H3HM SNOILIGNOD Sien 1 NI SH3HSIDnONILX 383 3M 35 1 ANY Loarans LON oq pue seju S elqnsnquioo uo y 10 se uons Jojeredo oym yuawdinbs 1 sat uo pesn aq 10 pas pue O je IREM Ko 10 s1eusinBunxo We 1S N aen 19A9N GE 2 55815 pue y 55812 2 SE UNXe eseu spinbii Gebeu ISIN 2 29 01828 IPPON pue jured fo euiosec SI Way jo ay 2 55215 au 550128 usejs pai y uo ayejdaweu y jueudi
277. druff 1 1 8 GM21422 Bearing kit standard 3 3 8 GM21423 Bearing kit 0 25 mm US AR AR 9 GM21424 Bearing kit standard 3 3 10 GM21425 Bearing kit thrust standard 1 1 10 GM21426 Bearing kit thrust 0 25 mm US AR AR 11 GM21427 Washer thrust standard 1 1 11 GM21428 Washer thrust 0 1 mm OS AR AR 12 223583 Seal rear 1 1 13 223472 Pin 1 1 14 224056 Sleeve AR AR 15 224007 Ring AR AR X Not sold separately AR As Required 18 TP 6141 12 08 Group 8b Crankshaft Pulley See Group 8a CD40401 See Group 2c Item Part No Description 1330 1 Screw 1 2 1 3 4 grade 8 14 2 352035 Spacer 1 3 GM21429 Sheave pulley 1 4 GM21430 Key shaft 5 16 in x 1 1 8 in 1 5 Screw 3 8 160 Common hardware procure locally AR As Required TP 6141 12 03 19 Group 9a Cylinder Head and Valves Var Item Part No Description 5105 9902 1 224164 Screw cap 14 14 2 GM21431 Head cylinder 1 1 3 223448 Cap 2 2 4 GMS32729 Gasket cylinder head 1 4 GM21432 Gasket cylinder head 1 5 Plug pipe 1 2 14 6 360174 Fitting also order 7 1 7 223746 O ring 1 Common hardware locally AR As Required Group 9b Valves CD37204 Item Part No Description 1 224184 Lock 12 12 2 224176 Rotator 6 6 3 223455 Spring 6 6 4 224243 Seal 6 6 5 GM21433
278. e 56 1 06 in Clamp insulated 75 in Fuel Lines For Fuel Water Separator Fuel line flexible Fuel line flexible Cap pipe Fitting half union Fitting half union Fitting half union Connector 1 2 union Flexible Fuel Lines Fuel line flexible Fuel line Fuel line flexible Cap pipe 3 8 in NPT Clamp hose 38 88 in Elbow oil line 90 deg vibra seal Elbow oil line 90 deg vibra seal Fitting straight union Flexible Fuel Lines Fuel line Fuel line flexible Fuel line flexible Cap pipe 3 8 in NPT Clamp hose 38 88 in Elbow oil line 90 deg vibra seal Elbow oil line 90 deg vibra seal Fitting straight union Qty Part No 352371 273629 273631 344210 X 268 3 X 426 18 X 447 7 X 695 2 352489 273629 273631 X 268 3 X 447 10 X 447 7 X 695 2 364134 2 X 268 3 1 X 386 36 1 X 386 81 1 X 391 20 1 4 hi ck 391 25 426 9 364314 1 125 08 80 1 M933 08016 60 1 268 8 1 268 9 1 386 112 1 391 13 1 391 30 1 422 21 4 426 3 1 672 31 GM10959 KA1 324481 324967 X 268 8 X 296 10 X 296 13 X 296 2 X 296 25 GM19461 KA1 273615 273616 GM21201 X 268 9 X 426 18 X 447 23 X 447 9 X 695 2 GM19461 KA2 273631 324608 GM21201 X 268 9 X 426 18 X 447 23 X 447 9 X 695 2 k aap aaa ch lt lt Ky sao ch ch Ai ki s TP 6116 2 02 Description Flexible Fuel Lines Fuel li
279. e Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 TP 6161 1 08 Section 1 Specifications and Features 11 The specification sheets for each generator set provide specific generator and engine information Refer to the respective specification sheet for data not supplied in this manual Consult the generator set service manual installation manual engine operation manual and engine service manual for additional specifications Introduction 1 2 16 Light Controller Features The 16 light controller can operate in either the normal mode or the prime power mode The prime power mode allows reduced controller current draw in applications without a battery charger minimizing battery drain by the controller circuitry See Section 2 3 2 Prime Power Mode Operation for more information Figure 1 1 shows the 16 light level 1 controller The 16 light controller features include annunciator panel lamps analog meters switches and controls and fuses and terminal strips For identification and an explanation of the functions see Sections 1 2 1 through 1 2 7 installations use mo
280. e is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaustfumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely 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 exhaustgases Carbon monoxide 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 notimprove within minutes of breathing fresh air Fuel System WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Th
281. e snd no jeseddey NOUO3dSNI uonejrejsui AN ejepouep N NOILO3dSNIO 3H1SIO3M aN M3AV1Vg M3SSdHd N3SlA 8341 AL 18 0 SVd IN V 5391131 SAG laf WLNOZIMOH L1N3N3AnON M3WIHdWi 13 S33NOlOd 531 UG SNOA 50714 531 SdWWvid 530 35 8 Nad 1 V LNVLSSY 2 31180939 3114009 v1 YHL 13 LONG L e1joje1idsoJ anbsew un uonoajo4d sep ejqissod 15 eppueou un juegequoo juenbsu un ed e je 5 88 uonesinn 58 08 euoz e 29 98 zenoe d G puaidal 6 juejjie uns 8 ino ze no8J uleje naj 5 p Sjue nuq no sai Jassadsip SUE zeloj A9 SnoA 00 006 snoa sues siew 5 naj enb e zeoueAy jejuozuou ep un iuenjoege ue uos 1004 s 2313S e e51Je sod ue sunofno jueva ug
282. e Primary Secondary Emergency Venting e Manhole Spillbox Combination for Filling Dipping Primary Tank Access Manhole Spillbox has Large 72 Litre Capacity 3 4 Drain Back Port 2 Dip Port Lockable Cover Stainless Steel Hinge Two 4 N P T Couplings c w M I Plugs Containment Inspection Port Approved Lift Lugs Identification Name Plate Structural Saddle Base Support Grounding Lug Gauge Stick and Dip Chart Installation and Maintenance Manual Specifications Primary Fittings ULC S601 93 UL 142 Class 150 Secondary Blast ULC S653 94 UL 142 1 2044 SSPC SP6 Pipe Coatings Schedule 40 A53 GR B Top Coat High Build Urethane 25000 fior br o for po 325 laan Water Systems SECTION 9 1 HEATING VENTILATION amp AIR CONDITIONING Section 9 1 Heating Ventilation amp Air Conditioning 9 1 10 Fuel Tank Level Switch Model LS 800 Tag NA EENS teen Kee Yous j28uu07 4 1 OUI weis odo Legge Sudie Steeg au nid uoJ8n pue yue un esu 9 Buidno2 pasur uonsod ut 1 r 0611 29090 12 5 jeddn ur 2015 2 uono s Jaddn Jlelsur oj eq ysnw peoy Samog auo e 01 1 Gey pernd Apus
283. e battery connections are correct clean Generator set O M incorrect and tight Battery weak or dead Recharge or replace the battery The spec sheet Generator set provides recommended battery CCA rating O M S S Starter starter solenoid inoperative Replace the starter or starter solenoid Eng S M Engine harness connector s not locked tight Disconnect the engine harness connector s then W D reconnect it to the controller High water temperature switch inoperative Replace the inoperative switch Engine S M or Fault shutdown Reset the fault switches and troubleshoot the controller Generator set High exhaust temperature switch inoperative Replace the inoperative switch Engine S M or Air cleaner clogged Clean or replace the filter element Eng O M Compression weak Check the compression Eng S M Engine overload Reduce the electrical load See the generator set spec S S sheet for wattage specifications Exhaust system leak Inspect the exhaust system Replace the inoperative I M exhaust system components Exhaust system not securely installed Inspect the exhaust system Tighten the loose exhaust 1 System components Governor inoperative Adjust the governor t Governor literature Valve clearance incorrect Adjust the valves Eng S M Vibration excessive Tighten all loose hardware Ignition system inoperative gas gasoline only Check the i
284. e drivers required for some models not confuse the function of these circuit boards See the Introduction section and refer to Tech Tools Engine Electronic Module ECM for the latest applications LEGEND CONTROLLER BOARD CMB COMMUNICATION MODULE BOARD TBIA 21 9 61 5 FRR ss IPA INDICATOR PANEL ASSEMBLY P PLUG TB1 TB2 CONTROLLER BOARD TERMINAL BLOCK TBS COMMUNICATION INTERFACE BOARD TERMINAL BLOCK 24 d ENGINE HARNESS ES 3 TB5 CONNECTIONS PIN N C 2 N C SW2 1N A SW2 2N A SW2 3N A SW2 4N A gt GM21340 REF 3 ATS POSITION RETURN GM32632 REF 4 USER INPUT 1 RETURN 5 USER INPUT 2 RETIRN SW2 SETTINGS 6 USER INPUT 3 RETURN CMB 7 8 DES 9 ATS POSITION INPUT 10 USER INPUT 1 11 USER INPUT 2 12 USER INPUT 3 HIGH BATTERY VOLTAGE CONTACTS ON BATTERY CHARGER GM35318 REF Ribbon cable 10 position Ribbon cable 24 position Connector 6 position Indicator panel board existing NC PART OF GM49791 1 ASSEMBLY GM32644 E
285. e fan bearings 1200 2000 kW 200 Hours or Six Months Air ducts louvers Yearly Coolant Yearly Heat exchanger Yearly Louver motors and controls Yearly Radiator exterior Yearly Water supply to heat exchanger Yearly Exhaust Line Drain condensate trap Weekly Leakage Weekly Insulation fire hazards Quarterly Flexible connector s Six Months Excessive back pressure Yearly Hangers and supports Yearly DC Electrical System Battery charger operation charge rate Monthly Battery electrolyte level Monthly Battery specific gravity charge state Monthly Recharge after engine start Monthly Remove corrosion clean and dry battery and rack x Monthly Clean and tighten battery terminals x x Quarterly Tighten DC electrical connections x Six Months e Follow procedures and frequencies indicated in the engine manufacturer s maintenance manual If not indicated follow this service schedule Some items may not apply to all generator sets R Replace as necessary X Action Service more frequently if operated in dusty areas 22 Section 3 Scheduled Maintenance TP 6161 1 08 Service Schedule continued System Component AC Electrical System Action Visually Inspect Check Change Interval Controller lamp test Weekly General Inspection
286. e fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donot operate the generator set in the presence of fuel TP 6161 1 08 leaks fuel accumulation 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 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 Fuel tanks Explosive f
287. e generator set master switch to the OFF RESET position 2 Disconnect the generator set engine starting battery negative lead first 3 Disconnect the FP FN leads 4 Checkthe exciter field resistance by connecting an ohmmeter across exciter field FP and FN leads See Figure 3 9 See Section 1 Specifications for resistance reading for a cold exciter field winding TP 6349 6 07 1 Voltage regulator 2 Ohmmeter 3 Exciter field winding 4 Exciter armature Figure 3 9 Exciter Field Winding Resistance Test A low reading indicates an internal short and a high reading indicates an open winding Repair or replace the exciter field winding if the ohmmeter readings indicate an inoperative exciter field winding If the resistance test is inconclusive perform a megohmmeter test on the exciter field winding as described in the next step 5 Check the exciter field winding for a short to ground condition See Figure 3 10 Use a megohmmeter to apply 500 volts DC to the FP or FN lead and the exciter field winding frame Follow megohmmeter manufacturer s instructions for using the megohmmeter TP 6349 3 4 Exciter armature 5 Exciter field winding 1 Voltage regulator 2 Ohmmeter 3 Ground to exciter frame Figure 3 10
288. e in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Section 3 Scheduled Maintenance 21 3 3 Service Schedule Action Visually Check Change System Component Interval Fuel Day tank level Weekly Flexible lines and connections Weekly Fuel level switch Weekly Main tank supply level Weekly Solenoid valve operation Weekly Transfer pump operation Weekly Water in system remove Weekly Filter s Quarterly Gasoline supply Six Months Fuel piping Yearly Tank vents and return lines for obstructions Yearly Lubrication Oil level Weekly Crankcase breather Quarterly Change oil Replace filter s First 50 Hours Then Every 250 Hours Cooling Radiator fan bolt torque 1500 2800REOZDC with unit mounted radiator Initially 8 Hours Then Every 100 Hours Air cleaner to room enclosure Weekly Block heater operation Weekly Coolant level Weekly Flexible hoses and connectors Weekly Water pump s Weekly Fan and alternator belts Monthly Coolant temperature protection level Six Months Lubricat
289. e severe burns Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Checkthe coolant level atthe tank ifthe generator set has a coolant recovery tank Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation TP 6349 6 07 Moving Parts WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place WARNING Airborne particles Can cause severe injury or blindness Wearprotective goggles and clothing when using power tools hand tools or compressed air TP 6349 6 07 Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator setengine and can cause personal injury Retorque all crankshaft and r
290. eaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit TP 6116 2 02 Qty 3 ch lt lt h NY Ny 6 0 0 pop P a wh lt lt NY tt Part 334062 222908 222909 222910 290020 324314 336020 352293 354518 251 16 6086 6 6128 3 6306 96 334063 222908 222909 222910 290020 324313 336020 352295 BLK 354518 X 6086 6 X 6128 3 X 6306 96 334064 222908 222909 222910 290020 324313 336020 352295 BLK 354518 X 6086 6 X 6128 3 X 6306 96 334065 222908 222909 222910 290020 324313 336020 352326 BLK 354518 364511 GM10168 X 6086 6 X 6128 3 X 6306 120 334066 222908 222909 222910 290020 324313 336020 352295 BLK 354518 364510 GM10167 M912 08025 60 X 6086 6 X 6128 3 X 6306 111 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bra
291. econds after the fault The level low coolant level shutdown does not function during the first 5 seconds after startup Shutdown occurs 5 seconds after the fault The low oil pressure shutdown does not function during the first 5 seconds after startup Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Low oil pressure Shutdown occurs after 30 seconds of continuous cranking Shutdown occurs 30 seconds after startup if there is no AC output Overcrank Overspeed Shutdown occurs immediately when the governed frequency on the 50 and 60 Hz models exceeds 70 Hz Figure 2 3 Fault Shutdowns TP 6161 1 08 Under normal operating conditions the generator 5 alternator requires no normal service Consult the prestart checklist in Section 2 1 for a list of routine checks 3 1 Alternator Service When operating the generator set under dusty or dirty conditions use dry compressed air to blow dust out of the alternator while the generator set is running Direct the stream of air through openings in the generator set end bracket 3 2 Engine Service Perform engine service at the intervals specified in the engine manufacturer s service literature Contact an authorized service distributor dealer to obtain service literature Note Have maintenance work including battery service performed by appropriately skilled and suitably trained maintenance perso
292. ect DIP switch configuration for each generator set application Overspeed Frequency DIP Switch 1 The generator set overspeed frequency is set using DIP switch 1 Select 70 Hz for 60 Hz voltages and 60 Hz for 50 Hz voltages Temperature Cooldown DIP Switch 2 The generator set will continue to run during a five minute cooldown cycle or shut down immediately The choice is made using DIP switch 2 Engine Cranking DIP Switch 3 The controller is factory set for cyclic cranking change to the continuous cranking mode use DIP switch 3 Engine Configuration DIP Switches 4 and 5 See Figure 1 9 for the DIP switch positions based on engine configurations regarding non ECM MDEC and J1939 engine communication selections Modbus Address DIP Switches 6 8 Each Modbus device requires a unique address Address numbers are created using a binary number system with DIP switches 6 8 Figure 1 11 shows the DIP switch position for each address number DIP Switches 6 7 8 Value 4 Value 8 Open Open Open Modbus Address Value 2 Closed Open Open Open Closed Open Closed Closed Open Open Open Closed Closed Open Closed Open Closed Closed Closed Closed Closed Figure 1 11 Modbus Device Address Section 1 Specifications and Features 15 1 3 Expanded Decision Maker 1 Controller For identification of the expanded controller s indicators and controls and their functions
293. ection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire WARNING 7 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 6 Safety Precautions and Instructions Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Servicing the 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 prevention procedures Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected
294. el Low Fuel Level Switch Harness wiring float switch Switch low fuel level 224696 1 224800 1 224856 224697 1 224801 1 224856 224698 1 224802 1 224856 292282 1 224856 1 292269 292283 1 224856 1 292270 292284 1 224856 1 292271 292285 1 224856 1 292272 Kit Parts List Description Qty Part No Alarm Panel Kit Remote Audio Visual Remote A V Alarm Panel Lens red Screw Plate silkscreened PCB assembly AV 1 light annunciator Plate assembly Customer connection assembly Diagram accessory interconnection Harness wiring controller connection AV alarm gensets with 550 controller Washer lock 172 ID x 333 in OD Screw cross recess round head machine Stud self clinching 8 32 x 875 in Nut flange whiz 8 32 Spacer 25 OD 5 in Spacer 25 OD 5 in Nut hex machine screw 8 32 Remote Alarm Lens red Screw mounting Plate silkscreened PCB assembly A V 1 light annunciator Plate assembly Annunciator panel 1 light Washer lock 172 ID x 333 in OD Spacer 25 OD 5 in Nut hex machine screw 8 32 Battery Charger Kits Battery Charger 12 V Float Equal Battery charger 12V 6A float equalize Battery Charger 24 V Float Equal Battery charger 24 float equalize GM17070 KP1 253241 292828 292936 A 292883 A 292887 GM13984 GM16088 GM17033 TT 1300 X 22 7 X 51 3 X 6205 3 X 6210 4 X 712 9 X 712 9 X 72 4 292856 253241 292828 292936 2928
295. emote start ground Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Remote start Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Crank mode selection open cyclic crank ground continuous crank Connect TB2 9 to TB2 9A for continuous cranking leave TB2 9 open cyclic cranking see starting instructions in Section 2 Operation Crank mode ground Figure 6 17 16 Light Controller TB2 Terminal Strip TP 6161 1 08 Terminal 1 1 1 Ground Emergency stop relay Connect emergency stop across terminals 1 1 1A Emergency stop relay 4 coil negative side Connect emergency stop across terminals TB1 1 and 1A Ground terminal Overcrank OC signal Auxiliary AUX signal Common fault prealarm line 1 audiovisual alarm or common fault relay activated by OC 12 AUX 26 LWT 35 HET 36 LOP 38 OS 39 40 ALOP 41 and LF 63 faults Common fault prealarm line 2 audiovisual alarm or common fault relay activated by AUX 26 HET 36 LOP 38 OS 39 and ES 48 faults Low water temperature LWT signal High engine temperature HET signal Low oil pressure signal Overspeed OS signal Anticipatory high engine temperature signal Anticipatory low oi
296. ep ai XI019 eun p e ep ejoqui s 2 91 01849 snos sjejedde sep sinejunxe 1esinn Yez 262 062 072 sejepow Op e euneuedns 1se nee suep seJniojuo sep Uuonenueouoo e Is 700 np uoisouoo ep un lqiuul ep apie e 2 nejunxe 4 OFZ APPON 9IA18S ue SIL jue e sesunsseJd je SAGIA 1 06 Snssop i souuonueu 4444 no 344v essnoui jo nee e no nee e sin jounx3 SLNVANA 530 331304 SHOH 5 531 enbseJd 158 snayounxa Is 10188944 ap uonelnuinoo sun g ojins es med uoisojdxe oun 5 1581 133 3116 3ONVTIIBA3nS SNVS YASSIVT 311 134 NN SIVINVP Nn noTano 39VSIA 31 4118 YNIL NILXI 193 31213918IQ SIVINV SN SVd SN V SLNVIHOdMI SLNIOd SSE RCE PE EE EE TEES Water Systems SECTION 9 2 ELECTRICAL TABLE OF CONTENTS Section 9 2 Electrical Section Manufacturer amp Description Make Model 9 2 1 Kohler Standby Generator Kohler 40REOZJB 9 2 2 Automatic Transfer Switches Thomson Technology NA TS873A0200A 9 2 3 Protalk
297. er DDR Place the switch in the DIAGNOSTIC DATA READER position Plug the DDR into the control box The DDR displays the stored failure codes e Useapersonal computer software package available from the manufacturer with a translator to access stored codes Follow the instructions provided with the software TP 6161 1 08 Code Active code A code flashing on the SEL lamp indicates a fault currently exists Inactive code A code flashing on the CEL lamp indicates a previous fault occurrence The ECM memory stores inactive codes with time date identification and the following information e First occurrence of each diagnostic code in engine operating hours e Last occurrence of each diagnostic code in engine operating hours e Total time in seconds that the diagnostic code was active 3 12 Engine Control Systems Some generator sets use an engine control system Access the control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting engine Use the following data for general informational purposes only See the Engine Service Manual for complete information regarding operation troubleshooting Contact an authorized service distributor dealer for service or diagnostic equipment Engine Control Features Engine control is an advanced technology electronic engine control system The system optimizes control of critical engine functions and pr
298. er circuit Nut hex 3 8 16 zinc Line Circuit Breaker 700 A Bracket circuit breaker Insulation CB Cover side Bus line Decal power breaker Washer plain 406 ID x 1 in OD Washer spring 46 ID x 875 in OD Washer spring 39 ID x 81 in OD Breaker circuit Nut hex 3 8 16 zinc Line Circuit Breaker 800 A Bracket circuit breaker Insulation CB Cover side Bus line Decal power breaker Washer plain 406 ID x 1 in OD Washer spring 46 ID x 875 in OD Washer spring 39 ID x 81 in OD Breaker circuit Nut hex 3 8 16 zinc Line Circuit Breaker 225 250 A Insulator Tag hang Bracket circuit breaker Bus line Bus line Cover side Screw socket head cap Washer plain 406 ID x 1 in OD Washer spring 39 ID x 81 in OD Breaker circuit Nut hex 3 8 16 zinc Line Circuit Breaker 300 400 A Insulator Tag hang Bracket circuit breaker Bus line Bus line Line circuit breaker base parts Cover side Washer plain 406 ID x 1 in OD Washer spring 39 ID x 81 in OD Breaker circuit Nut hex 3 8 16 zinc TP 6116 2 02 Qty Part No GM12380 KA3 222999 365627 GM12334 BLK GM12336 GM15301 X 25 118 X 6086 20 X 6086 6 X 6304 108 X 83 7 GM12380 KA4 222999 365627 GM12334 BLK GM12336 GM15301 X 25 118 X 6086 20 X 6086 6 X 6304 111 X 83 7 GM12380 KA5 222999 365627 GM12334 BLK GM12336 GM15301 X 25 118 X 6086 20 X 6086 6 6304 116 83
299. er armature Exciter field winding JO Om Figure 3 18 Stator Ohmmeter Connections 3 Between Leads Continuity 1 2 3 and 4 55 and 66 1 and 3 4 33 44 1 and 55 Any stator lead and ground Figure 3 19 Stator Continuity Single Phase 34 Section Alternator Troubleshooting Rotor main field Sensing leads 208 240 volts nominal Stator main windings Voltage regulator power supply leads Ohmmeter Rotating rectifier assembly RRA Exciter armature ONDAN Exciter field winding Figure 3 20 Stator Ohmmeter Connections Single Phase Stator Test Procedure 1 Move the generator set master switch to the OFF RESET position 2 Disconnect the generator set engine starting battery negative lead first 3 Check the alternator output lead connections Refer to wiring diagram manual and or generator set operation manual 4 Disconnect all the stator leads to isolate the windings To check the stator continuity set the ohmmeter on the R x 1 scale Check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 3 20 Perform the stator tests on all of the stator windings For single phase alternators use Figure 3 19 For three phase alternators use Figure 3 17 5 Contact the ohmmeter leads and readjust the ohmmeter to zero ohms Check the cold resistance of the stator wind
300. erator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Moving Parts 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 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 offthe main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing
301. ere 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 cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when draining the fuel system Wipe up spilled fuel after draining the system 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 90psi 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 TP 6349 6 07 Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muf
302. erspeed See Section 2 4 3 Fault Shutdowns for additional shutdown information Frequency meter Meter displays the frequency Hz of the generator set output Generator set master switch Switch functions as the controller reset and generator set operation switch Figure 1 13 Controls and Indicators 16 Section 1 Specifications and Features Selector switch Switch selects the generator set output circuits to measure When switched to a position with three circuit labels the meters display the amperage on the lead shown in the upper label and the voltage between the two leads shown in the lower label The AC ammeter and voltmeter function only with the switch in the ON position Voltage adjustment control Control fine tunes 5 the generator set output voltage Water temperature gauge Gauge displays the engine coolant temperature 10 amp controller fuse Fuse protects the controller circuitry from short circuits and overloads Figure 1 14 Controls and Indicators continued TP 6161 1 08 2 1 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the
303. escent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer TP 6161 1 08 TP 6161 1 081 2004 2005 2006 2007 2008 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 Service Industrial Generator Sets e Models 20 300 kW Alternators Fast Response Wound Field Alternator SHOP D DRAWING RE REVIEW 4 Sub SEE RESUBMIT A 432 4 DILLON CONSULTING LIMITED 29001 kone POWER Siet EMS KOHLER G POWER SYSTEMS 6349 6 07b California Proposition 65 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 kit
304. essories with the M notation are available on models with 16 light microprocessor controllers 611 Audiovisual Alarm M An audiovisual alarm warns the operator of fault shutdowns and prealarm conditions except battery charger fault and low battery voltage from a remote location Audiovisual alarms include an alarm horn an alarm silence switch and a common fault lamp See Figure 6 1 Note Use the audiovisual alarm with a dry contact kit Front View Side View Figure 6 1 Audiovisual Alarm TP 6161 1 08 Section 6 Accessories 6 1 2 Common Failure Relay Kit M The common failure relay kit provides one set of contacts to trigger user provided warning devices if a fault occurs The common failure relay faults are user defined Connect up to three common failure relay kits to the controller output See Figure 6 2 See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification Figure 6 2 Common Failure Relay Kit 6 1 3 Controller Connection Kit M The controller connection kit allows easy connection of controller accessories without accessing the controller terminal strip The kit uses a 165 cm 65 in wiring harness to link the controller terminal strip s with a remote terminal strip located in the generator set junction box With the exception of a few terminals the remote terminal strip is identical to that of the controller C
305. et 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 5 Introduction u RARE PRU A RC aetna 9 Abbreviations aq RE ip tu ER 9 List of Related Materials 9 Service Assistance a u pide 10 Section 1 Specifications and Features 11 1 r trod ctiOm poke seed EE ade Ek 11 1 2 16 9 Controller Features 11 1 2 1 Annunciator Panel Lamps 12 1 2 2 Auxiliary Fault Lamp 13 1 2 3 20565 An Ze RARE RR REPE aed 13 1 2 4 Analog Meters and Gauges
306. ether Engine Backfire Flash Fire WARNING 7 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 6 Safety Precautions and Instructions Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Servicing the 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 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 monoxid
307. f this manual ATS Automatic Transfer Switch Eng Engine Gen Generator Set I M lInstallation Manual O M Operation Manual S M Service Manual S S Spec Sheet W D Wiring Diagram Manual Have an authorized service distributor dealer perform this service If the unit has a 550 controller refer to the 550 controller operation manual for voltage regulator settings Go to Menu 20 Factory Setup and verify that the application software code version is correct for the generator set model and alternator voltage Notes 24 Troubleshooting TP 6349 6 07 Section 3 Alternator Troubleshooting 3 1 General Before beginning the troubleshooting procedures read all the safety precautions at the beginning of this manual The following tests include additional safety precautions OBSERVE THESE PRECAUTIONS WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Flectrocution is possible whenever electricity is present the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances
308. f union Fitting elbow 7 8 14 Clamp insulated 5 in Fitting union 50 Qty Part No A 32 16 16 mere Mi ch oa apa ch ch sch lt lt ch sch ch ch ch ch sch yuk 224684 224683 219 9 343613 343609 343611 25 29 6239 4 88 12 10958 1 343603 GM10571 447 1 447 9 273618 273614 273615 273616 268 3 447 10 447 7 695 2 324925 324481 324967 268 8 296 10 296 13 296 2 447 21 336864 273631 273643 336863 344205 268 3 268 8 296 11 447 8 672 10 695 2 336866 273631 273916 336863 344205 268 3 268 8 296 11 447 8 672 10 695 2 Description Flexible Fuel Lines Line flexible fuel 37 inch Line 25 OD steel fuel Fuel line flexible 1 4 NPT pipe Clamp hose 38 88 in Fitting elbow oil line Fitting union Flexible Fuel Lines Line flexible fuel 37 inch Line 25 OD steel fuel Cap 1 4 NPT pipe Fitting elbow 7 16 20 x 1 8 in Fitting elbow oil line Fitting union Flexible Fuel Lines Cap 1 4 NPT pipe Fuel line flexible Fuel line flexible Fitting hose connector 90deg Fitting hose connector 90deg Clamp hose 25 70 in Flexible Fuel Lines Washer plain Screw hex cap Cap pipe Cap pipe 3 8 NPT Fuel line flexible Fitting hose connector 90 deg Fitting hose connector 90deg Fuel line flexible Clamp hos
309. ference during installation if the bearing will be removed Use a hydraulic press to remove the bearing if needed 22 Place the alternator assembly on the adapter end in order to remove the adapter and end bracket from the stator Fasten chains to the adapter and lower to a horizontal position Fasten the hoist hook to the end bracket eye and lift to a vertical position See Figure 4 9 23 Remove the adapter mounting bolts Fasten the hoist hooks to the end bracket and raise the stator assembly slightly Tap adapter loose by using a rubber mallet 24 Lower the stator assembly Remove the end bracket mounting bolts Separate the end bracket from the stator by tapping loose with a rubber mallet 25 Remove the exciter field winding from the end bracket 4 3 Reassembly Follow the general guidelines in the following procedure In addition Figure 4 23 Figure 4 24 and Figure 4 25 at the end of this section may provide some detailed help during the reassembly procedure When torque specifications are not shown in Section 1 Specifications use the guidelines shown in Appendix C General Torque Specifications 1 Attach the exciter field to the end bracket with four mounting bolts Torque to specifications 2 Place the stator in a vertical position with the end bracket side up 1 Hoist hook 3 End bracket Note The end bracket side of the stator has four 2 Hoist hook 4 Adapte
310. field windings The voltage regulator has an underfrequency unloading feature that is referred to as volts per Hz 2 To determine if the voltage regulator is functioning reduce the engine speed Hz if possible and watch for a corresponding drop in the AC voltage The AC voltage should remain constant until the engine speed drops below 57 5 Hz on 60 Hz models or 47 5 Hz on 50 Hz models When the frequency drops below either 57 5 or 47 5 Hz the AC voltage should decline Perform the following test to check the voltage regulator output 28 Section 3 Alternator Troubleshooting The following components will be needed to test the voltage regulator e 12 volt battery or DC power supply isolated e Step up transformer 1 2 120 volts to 240 volts 1 0 amp min e 1 kOhm 1 2 watt potentiometer e Variable transformer 0 140 volts 1 0 amp min e Voltage regulator adapter harness see Figure 3 5 make from 1 plug part no GM11858 10 terminals part no 337137 10 leads 18 ga 610 mm 24 in long EES R59 R63 088 864 l R73 A cal Ri me CC N GM31850 E 1 241618A BB X 6295B AW Voltage regulator 12 pin socket 2 GM11858 12 pin plug 3 337173 terminal 10 female 0 99 mm 0 39 in diameter Figure 3 5 Voltage Regulator Adapter Harness e Lamp 250 volt 100 watt e Fuse 1 amp Switch
311. figure the installation to electrically ground the generator set transfer switch and related equipment electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution 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 Safety Precautions and Instructions 7 Welding the generator set Can cause severe electrical 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 equipment grounding conductor with circuit conductors and connect
312. fler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Electrical Shock DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place 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 CAUTION Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Con
313. fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donot operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation TP 6349 6 07 Explosive fuel 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 Fuel tanks Explosive fuel vapors can cause sev
314. g 1 1 1 25 GM21508 O ring 1 1 1 26 GM21509 Switch temperature 1 1 1 27 GM21510 Harness wiring 1 1 1 28 GM32784 Solenoid valve coil 1 1 Common hardware procure locally Serial Number Contingent Fuel Line Use the engine serial number to verify item16 Find your serial number on the engine nameplate and choose the fuel filter line from the chart below Model Variation Serial Number Part Number 29 266666 and before GM21507 419 After PE3029T266666 GM32738 029 028590 and before GM21507 2 QUIBIT After PE3029T028590 GM32738 TP 6141 12 03 13 Group 5b Fuel Injection Nozzle CDP45007 14 TP 6141 12 08 Group 5b Fuel Injection Nozzle Qty Var Item Part No Description 1603 1641 16TR 16TT 164 1 GM21511 Nozzle injection 3 3 1 GM21512 Nozzle injection 3 3 1 360017 Nozzle injection 3 2 GM21513 Fitting tee 1 1 1 1 1 3 x Washer order item 10 1 1 1 1 1 4 223517 Nut tube 1 1 1 1 1 5 224257 Plug AR AR AR AR AR 6 x Washer order item 10 1 1 1 1 1 7 x Packing order item 10 1 1 1 1 1 8 223660 Plug AR AR AR AR AR 9 224188 Screw cap 3 3 3 3 3 10 GM21515 O ring kit AR AR 10 GM21516 O ring kit AR AR AR AR As Required X Not sold separately TP 6141 12 03 15 Group 7 Cylinder Block THRA au T See Group 10 4 Kal 1 ia ge 5 H 6141 12 03 Gr
315. ge measures the engine oil pressure gauge Scale lamps Lamps indicate which AC voltmeter and or upper lower ammeter scales to read Water Gauge displays the engine coolant temperature temperature gauge Figure 1 5 Analog Meters and Gauges TP 6161 1 08 Section 1 Specifications and Features 13 1 2 5 Switches and Controls Figure 1 6 describes the switches and controls located on microprocessor controllers Alarm horn Horn sounds if any fault or prealarm condition exists except emergency stop battery charger fault high battery voltage or low battery voltage Place the generator set master switch in the AUTO position before silencing the alarm horn See controller resetting procedure in Section 2 3 5 Controller Resetting After a Fault Shutdown Alarm Switch silences the alarm during service Place silence the generator set master switch in the AUTO switch position before silencing the alarm horn To avoid reactivating the alarm horn restore all alarm horn Switches controller remote annunciator and audiovisual alarm to their normal positions after correcting the fault See controller resetting procedure in Section 2 3 5 Controller Resetting After a Fault Shutdown Emergency Switch if equipped immediately shuts down the stop switch generator set in emergency situations Reset the emergency stop switch after shutdown by pulling the knob slightly outward Use the emergency stop switch for emergency shutd
316. generator set stops completely Note The generator set continues to run during a 5 minute cooldown cycle if a remote switch or automatic transfer switch signals the engine to stop Note The controller circuit board DIP switches allow disabling the engine cooldown function 2 3 2 Prime Power Mode Operation The controller can operate in either the normal mode or the prime power mode n prime power mode the controller draws less current when the generator set master switch is in the OFF RESET position minimizing the battery drain Use the prime power mode for installations that do not have a battery charger to help prevent discharging the battery when the generator set is not operating Moving the generator set master switch to the OFF RESET position disables all controller functions Moving the generator set master switch to the AUTO position restores controller functions 18 Section 2 Operation Enabling and Disabling the Prime Power Mode To enable the prime power mode use jumpers to connect TB2 1P to TB2 2P 2 to TB2 4P and TB2 3 to TB2 4 To deactivate the prime power mode remove these jumpers See Figure 1 7 Figure 1 8 and Figure 2 1 Terminal Purpose Prime power operation Prime power operation Remote start ground Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Remote start Connect transfer switch or remote start switch to TB2 3 and TB2
317. gnition system spark plugs spark plug Eng O M wires etc Sec Section numbered section of this manual ATS Automatic Transfer Switch Eng Engine Gen Generator Set M Installation Manual O M Operation Manual S M Service Manual S S Spec Sheet W D Wiring Diagram Manual Have an authorized service distributor dealer perform this service If the unit has a 550 controller refer to the 550 controller operation manual for voltage regulator settings Go to Menu 20 Factory Setup and verify that the application software code version is correct for the generator set model and alternator voltage Trouble Symptoms Does but does start Fuel System Starts hard No or low output voltage Stops suddenly Lacks power Overheats pressure High fuel consumption Excessive or abnormal noise Probable Causes Recommended Actions Section or Publication Reference Air in fuel system diesel only Bleed the diesel fuel system Eng O M Bunoouse qnoj p 22 Ether canister empty or system inoperative if equipped diesel only Replace or repair the ether starting system Eng O M Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position Fuel feed or injection pump inoperative diesel only Rebuild or replace the injection pump Eng S M Fuel
318. gt Description Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit 1200 A 600 V 3 pole Kit Parts List Qty Part No 1 1 2 1 3 3 1 GM17880 KA1 222996 BLK 222998 290020 336020 365609 X 6086 6 X 6305 135 Line Circuit Breaker Dual 125 A 100 GM19636 KA1 Cover side Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Washer plain 203 ID x 75 in OD Spacer 375 ID x 75 OD x 5 in Screw slotted pan head machine Screw slotted round head machine Standoff insulator 1 4 20 x 1 5 in Breaker circuit 100 A Breaker circuit 125 A Marker wire Marker wire Marker wire SS 0 ET COP HH GO HK SH 222833 222908 222909 222910 290020 324314 354518 364498 X 25 45 X 400 104 X 50 41 X 50 46 X 6128 3 X 6304 159 X 6304 160 X 750 14 X 750 15 X 750 16 Line Circuit Breaker Dual 200 A 150A GM19641 KA1 Cover side Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Diagram wiring Bus line Washer plain 203 ID x 75 in OD Screw slotted pan head machine Standoff insulator 1 4 20 x 1 5 in Breaker circuit 200 A Breaker circuit 150 A 1 1 1 2 4 1 1 2 8 8 2 1 1 222833 222908 222909 222910 290020 324314 3
319. he fuel Fuel pressure insufficient gas only Check the fuel supply and valves Sec Section numbered section of this manual ATS Automatic Transfer Switch Eng Engine Gen Generator Set I M lInstallation Manual O M Operation Manual S M Service Manual S S Spec Sheet W D Wiring Diagram Manual Have an authorized service distributor dealer perform this service Fuel injection timing out of adjustment diesel only Adjust the fuel injection timing p uonoeS Or Trouble Symptoms Does not crank Cranks but does not start Starts hard No or low output voltage Stops suddenly Lacks power Overheats Alternator pressure High fuel consumption Excessive or abnormal noise Probable Causes Recommended Actions Section or Publication Reference AC output circuit breaker open Reset the breaker and check for AC voltage at the generator side of the circuit breaker Transfer switch test switch in the OFF position Move the transfer switch test switch to the AUTO position ATS O M Transfer switch fails to transfer load Move the ATS test switch to the AUTO position Troubleshoot the transfer circuit and time delays ATS O M S M Wiring terminals or pin in the exciter field open Check for continuity Gen S M W D Main field rotor inoperative open or groun
320. he fuse blows again troubleshoot the voltage regulator Section 3 Voltage regulator out of adjustment Adjust the voltage regulator Section 3 Sec Section numbered section of this manual ATS Automatic Transfer Switch Eng Engine Gen Generator Set I M lInstallation Manual O M Operation Manual S M Service Manual 20 9 6vE9 dL S S Spec Sheet W D Wiring Diagram Manual Have an authorized service distributor dealer perform this service If the unit has a 550 controller refer to the 550 controller operation manual for voltage regulator settings Go to Menu 20 Factory Setup and verify that the application software code version is correct for the generator set model and alternator voltage 20 9 6v 9 dl Bunoous lqnoijl p uono s Trouble Symptoms Does not Cranks but does not start Starts hard No or low output voltage Stops suddenly Lacks power Overheats pressure High fuel consumption Excessive or abnormal noise Probable Causes Recommended Actions Section or Publication Reference Crankcase oil type incorrect for ambient temperature Change the oil Use oil with a viscosity suitable for the operating climate Oil level low Restore the oil level Inspect the generator set for oil leaks Low oil pressure shutdown Check the oil level Sec Section numbered section o
321. he unit and then remove the bung from the fitting Now replace the fitting and with the faucet open fully see if the light comes on now with water flowing through the unit SP MODELS INLET 0 5 gpm flow regulator The little black bung as ol J inlet filter SS E If the heater now turns on with water flowing call Eemax at 1 800 543 6163 Describe what you have done and we will send you a selection of bungs to replace the one which you have removed This will allow the unit to turn but will also control the flow rate to give you the correct rise in temperature If the heater still does not work proceed to step 4 STEP FOUR You will require a multimeter voltmeter to carry out the next tests DANGER TURN OFF THE BREAKER BEFORE PROCEEDING WITH THE NEXT TESTS Set the meter to the single Ohms setting Do not measure continuity this will not work The Ohm symbol The upside down horse shoe Remove the heater cover at the end of the black heater body there are two threaded silver rods with brass nuts on them where the wires go Take a reading of the ohms value between these two rods If the reading is less than 20 ohms on the Rx 1 scale or the Rx 10 scale the element is good if itis much greater eg 10 000 ohms or if you get a reading on the Rx 1K scale then you must replace the element contact Eemax Tel 1 800 543 6163 for replacement eleme
322. hould indicate approximately 12 volts DC If the speed sensor is emitting a signal check the continuity of the speed sensor leads wires 2 16 and Section 3 Alternator Troubleshooting 35 24 between the controller connector and lead terminals at speed sensor If the speed sensor is not emitting a signal test the speed sensor using the following procedure 1 Connect the speed sensor voltmeter and DC voltage source as shown in Figure 3 23 TP 5353 7 1 DC Voltmeter 2 12 Volt Battery or DC Power Supply 3 Sensing Surface Figure 3 23 Speed Sensor Test 2 Touchthe sensing surface with a flat piece of iron or steel at least 4 cm 1 4 cu in in size 3 The voltmeter test reading should equal the source voltage 4 Remove the iron or steel from the sensing surface and observe a no voltage reading on the voltmeter 3 11 Interface Circuit Board GM11718 The 550 controller has an integral voltage regulator Circuit board GM11718 interfaces between the wound field alternator and 550 controller voltage regulator See Figure 3 24 for an illustration of the circuit board The circuit board is typically located in the junction box 36 Section 3 Alternator Troubleshooting There is no field test for this circuit board Use the following information to help troubleshoot the circuit board GM11718B F Figure 3 24
323. hten the battery terminals according to the service schedule recommendations Clean the battery by wiping it with a damp cloth Keep electrical connections dry and tight If corrosion exists disconnect the cables from the battery and remove the corrosion with a wire brush Clean the battery and cables with a solution of baking soda and water Do not allow the cleaning solution to enter battery cells Flush the battery and cables with clean water and wipe the battery with a dry cloth 3 10 2 Electrolyte Level Inspection Check the electrolyte level and specific gravity of batteries that have filler caps Maintenance free batteries do not require electrolyte level checking or specific gravity testing Check the electrolyte level at the specified interval Remove the filler caps and verify that the electrolyte level reaches the bottom of each filler hole See Figure 3 13 Refill as necessary with distilled water or clean tap water Do not add fresh electrolyte Tighten the filler caps After adding water during freezing temperatures run the generator set 20 30 minutes to mix the electrolyte and the water to prevent battery damage from freezing 1 Filler caps 2 Electrolyte level Figure 3 13 Battery Electrolyte Level Inspection 3 10 3 Specific Gravity Check Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell of batteries with filler caps Holding the hydrometer vertically read the numbe
324. ify the groups of parts that make up the engine The intersection of the engine model and the group numbers is the variation number corresponding to the components of that engine Note the variation number STEP 2 Find the page number of the group in the Table of Contents and turn to that page or page forward until you find the group Use the drawings and itemized text to locate the part and its part number Specification Number Index i Group Title x N 5 5 a O p c xX 5 S x 9 9 2 8 5 lt 9 9 5 E 00 Je x 4 lt 40 Q lt 2 9 E 2 2 E E 2 2 S 2 qoum 70258100 Group 1 2 2b 2c 3 4a 4b 4c 5b 7 8 8b Variation Number Engine Model 3029DF 60 Hz 1712 2020 2110 2401 2902 9914 9901 1105 1603 1603 9906 9919 1330 3029DF 50Hz 1712 2020 2110 2401 2902 9914 9901 1105 1641 1641 9906 9919 1330 3029TF 60 Hz 1710A 2020 2110 2401 2902 9914 9901 1105 16TR 16TR 9906 9919 1330 3029TF 50 Hz 1710A 2020 2110 2401 2902 9914 9901 1105 16TT 16TT 9906 9919 1330 3029 270 1710 2020 2110 2401 2902 4607 4903 1105 164H 164H 4607 4702 1330
325. ight comes on turn to page 5 If the light does not come on turn to page 3 i i i i i i i i i i i The Indicator light does not come when the hot water faucet is opened STEP ONE Is the circuit breaker switched on at the breaker panel YES Goto Step two NO Run water at the hot faucet for a couple of minutes before turning on the breaker Turn on breaker STEP TWO The unit won t switch on unless enough water is flowing through the heater You will need a flow rate of about 0 5 gallons per minute 1 2 gpm Measure the flow rate Take a 1 gallon milk container and using only water from the hot outlet time how long it takes to fill Longer than 2 minutes and you probably do not have enough water flow to turn on the unit Open all water valves as much as possible If this does not work try unscrewing the aerator situated on the end of your faucet Now run the water with the faucet open fully if the indicator light still does not illuminate then proceed to step 3 Aerator Fits on the end of the faucet lt Male female threaded adapter on top of SS 1 aerator flow restrictor maybe removed to increase flow Pd Zomme FOUR 5 In the brass outlet fitting there is a flow restrictor This is a little black bung Shut the water off to t
326. ilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical kWth kilowatt thermal liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male ms cubic meter m hr cubic meters per hour m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 229 bytes MCCB molded case circuit breaker MCM one thousand circular mils meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQmillionm MOhm MQmegohm mph MS ms m sec MTBF metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mean ti
327. in water or on wet ground because these conditions increase the risk of electrocution 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 Safety Precautions and Instructions 7 Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments 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
328. inal aluminum Washer plain 406 ID x 1 in OD Washer spring 39 ID x 81 in OD Nut hex 3 8 16 zinc Bus Lug 600mcm 02 4 Wire Term Lug terminal aluminum Washer plain 406 ID x 1 in OD Washer spring 39 ID x 81 in OD Nut hex 3 8 16 zinc Bus Lug 350mcm 06 1 Wire Term Bracket lug restrainer Bracket lug restrainer Washer spring 515 ID x 1 06 in OD Lug terminal aluminum Bus Lug 500 04 1 Wire Term Bracket lug restrainer Washer spring 515 ID x 1 06 in OD Lug terminal aluminum Bus Lug 350mcm 06 2 Wire Term Bracket lug restrainer Washer spring 515 ID x 1 06 in OD Lug terminal aluminum Bus Lug 600mcm 04 1 Wore Term Bracket lug restrainer Washer spring 515 ID x 1 06 in OD Lug terminal aluminum Bus Lug 600mcm 02 2 Wire Term Lug terminal aluminum Washer spring 515 ID x 1 06 in OD Bus Lug 750mcm 3 0 3 Wire Term Lug terminal aluminum Washer spring 515 ID x 1 06 in OD TP 6116 2 02 Qty Part No 274694 4 275471 4 275561 8 X 25 18 4 X 6207 8 274695 4 275474 8 X 25 18 4 X 6207 5 274696 4 275469 16 X 25 18 8 X 6207 8 274697 4 275470 4 X 6207 9 274698 4 297981 16 X 25 18 274699 4 297983 16 X 25 18 274700 4 297582 16 X 25 18 274778 4 297981 274779 4 297983 GM10155 KA1 4 275473 4 X 6207 7 GM10155 KA10 4 297983 16 X 25 118 8 X 6086 6 8 X 83 7 GM10155 KA11 4 297582 16 X 25 118 8 X 6086 6 8 X 83 7 GM10155 KA
329. ine Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Terminal fast on male 4 AWG Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A 600 V 3 pole Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 40 A 600 V 4 pole Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 60 A 600 V 4 pole Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 80 A 480 V 4 pole Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 100 A 480 V 4 pole Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 50 A 600 V 4 pole Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 30 A 600 V 4 pole Qty NAAA P oa hihi L Sak Part 334051 222908 222909 222910 290020 324313 354518 GM10528 BLK X 25 45 X 6086 6 X 6128 3 X 6304 86 X 6308 1 334052 222908 222909 222910 290020 324314 354518 GM10527 BLK X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 15 334053 222908 222909 222910 290020 3
330. ing and adjustment screw 3 Connect a manometer to check the fuel supply pressure on the carburetor side of the regulator downstream of any fuel system equipment accessories The recommended fuel supply pressures are shown on the generator set spec sheet 4 Adjust the fuel supply pressure with the generator set running at full load Rotate the adjustment screw on the fuel regulator until the pressure indicated by the manometer matches the specified pressure Use the lower pressure value if the generator set still provides good response and full power Lower than specified pressures may result in poor response to load changes or lack of power 5 Reinstall the cover plug TP 6161 1 08 3 6 4 Fuel System Changeover Kits Automatic Changeover A changeover fuel system kit provides automatic changeover from natural gas to LP gas vapor or from LP gas vapor to natural gas The primary and backup fuels each have a secondary fuel regulator and a fuel valve Typically the primary fuel is natural gas the backup fuel is LP gas vapor When the generator set starts the primary fuel valve opens and the backup fuel valve closes The primary fuel line has a vacuum switch in series with a relay connected to the start run circuit When the primary fuel pressure drops below 0 6 kPa 1 4 oz in or 6 4 cm 2 5 water column a relay opens the backup fuel valve and closes the primary fuel valve When the primary fuel pressure rises above 0
331. ings by connecting the meter leads to the stator leads 1 2 3 4 etc See Section 1 Specifications for the stator resistance values Ifthe stator resistance test is inconclusive perform a megohmmeter test on the stator as described in the next step TP 6349 6 07 Note Consider the stator good if the resistance reading continuity is low and there is no evidence of shorted windings heat discoloration Note When taking ohmmeter reading using lead 55 make the connection prior to the in line fuse Note The stator resistance varies directly with increased temperature 6 If of the stator readings vary during the previous checks replace the stator 7 Check the stator for a short to ground condition using a megohmmeter See Figure 3 21 and Figure 3 22 Rotor main field Sensing leads 208 240 volts nominal Voltage regulator power supply leads Stator main windings Ground to stator frame Megohmmeter Rotating rectifier assembly RRA Exciter armature Exciter field winding Apply 500 volts DC to any stator lead from each winding and the stator frame Follow the megohmmeter manufacturer s instructions for using the megohmmeter Repeat the test on the other leads until all the stator windings have been tested OPNI PYN Figure 3 22 Megohmmeter Connections on Stator A reading of 500 kOhms 1 2 megohm and higher Three Phase indica
332. insulating turbo Blanket insulating manifold Exhaust Manifold Blanket Blanket insulating turbo wrap Blanket insulating manifold Blanket insulating manifold Blanket insulating elbow Insulating blanket Exhaust Manifold Blanket Blanket exhaust manifold Exhaust Manifold Blanket Exhaust blanket Exhaust Manifold amp Turbo Blanket Exhaust blanket Qty Part No 324589 2 324587 336070 2 225289 336071 2 256984 336692 1 324586 336693 1 324587 275477 1 275480 275478 275482 275485 276547 276548 275479 275517 275518 275519 276562 276563 275483 275481 275484 275486 276523 276989 276558 275519 276559 276560 276562 276564 GM10220 KA1 1 GM10223 GM21241 KA1 1 GM21037 GM21241 KA2 1 GM21242 Saa ee Cee ch ch sch ch Kits 1 Line Breaker circuit 500 600 V 3 pole Line Circuit Breaker Breaker circuit 600 A 600 V 3 pole Line Circuit Breaker Breaker circuit 700 A 600 V 3 pole Line Circuit Breaker Breaker circuit 800 A 600 V 3 pole Line Circuit Breaker Breaker circuit 900 A 600 V 3 pole Line Circuit Breaker Breaker circuit 1000A 600 V 3 pole Line Circuit Breaker Breaker circuit 1200 A 600 V 3 pole TP 6116 2 02 PA 253176 1 290861 PA 279878 1 291441 PA 279879 1 290862 PA 279880 1 290863 PA 279881 1 290933 PA 279882 1
333. ional and more detailed information about the individual checks tests mentioned in the flowchart TP 6349 6 07 Unstable voltage Does engine speed fluctuate Yes Is the fuel filter clean Yes Y Is the speed sensor okay Yes Y Is the fuel injection pump okay Yes Are the fuel injectors okay Yes Y Is the fuel injection timing okay Yes Y Does engine speed still No fluctuate Yes Y Refer to the engine governor and ECM systems technical literature Clean replace Adjust replace Rebuild replace Clean test replace Adjust timing Is voltage stable No Yes Voltage regulator checks out okay Does the regulator LED flicker No Y Are the main connections tight Yes Are the wiring and connectors okay Yes Tighten connections or replace harness No Turn the stability pot fully clockwise then slowly rotate counterclockwise connections Are there load current spikes No Yes Does the voltage change Yes Y Are the circuit breaker connections tight Replace the voltage regulator
334. ircuit 1 6304 141 24 V Shunt Trip 450 1200 A UL GM12607 KA2 Breaker circuit 1 X 6304 142 Auxiliary Switch 450 1200 A UL GM12607 KA3 Breaker circuit 1 X 6304 143 12 V Shunt Trip 80 630 A IEC GM12608 KA1 Breaker circuit 1 X 6306 143 24 V Shunt Trip 80 630 A IEC GM12608 KA2 Breaker circuit 1 X 6306 144 Auxiliary Alarm Switch 80 630 A IEC GM12608 KA3 Breaker circuit 1 X 6306 145 12 V Shunt Trip 700 1250 A IEC GM12609 KA1 Breaker circuit 1 X 6306 146 24 V Shunt Trip 700 1250 A IEC GM12609 KA2 Breaker circuit 1 X 6306 147 Auxiliary Alarm Switch 700 1250 A IEC GM12609 KA3 Breaker circuit 1 X 6306 148 Line Circuit Breaker GM14027 KA1 Breaker circuit 30 A 600 V 3 pole 1 269250 Cover side 1 GM14296 BLK Decal power breaker 1 GM15301 Screw cross recess pan head machine 4 X 49 2 Line Circuit Breaker GM14027 KA10 Cover side 1 GM14297 BLK Decal power breaker 1 GM15301 Screw cross recess pan head machine 4 X 49 2 Circuit breaker 70 A 600 V 4 pole 1 X 6250 8 Line Circuit Breaker GM14027 KA11 Breaker circuit 80 A 480 V 3 pole 1 253225 Cover side 1 GM14296 BLK Decal power breaker 1 GM15301 Screw cross recess pan head machine 4 X 49 2 31 Kit Parts List Description Line Circuit Breaker Cover side Decal power breaker Screw cross recess pan head machine Breaker circuit 80 A 480 V 4 pole Line Circuit Breaker Breaker circuit 90 A 480 V 3 pole Cover side Decal power breaker Screw cross recess
335. ircuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 60 A 600 V 4 pole Line Circuit Breaker Breaker circuit 70 A 600 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 70 A 600 V 4 pole Qty ch pa a Part 334483 352323 352325 6086 6 6306 120 334484 290020 336020 352323 352325 BLK X 6086 6 X 6306 121 334642 222908 222909 222910 222950 BLK 290020 324313 354518 360763 X 6086 6 X 6128 3 X 6304 93 X 6308 1 334718 269250 364489 X 49 2 334719 364490 X 49 2 X 6250 1 334720 269252 364489 X 49 2 334721 364490 X 49 2 X 6250 2 334722 258928 364489 X 49 2 334723 364490 X 49 2 X 6250 6 334724 253224 364489 X 49 2 334725 364490 X 49 2 X 6250 3 334726 258381 364489 X 49 2 334727 364490 X 49 2 X 6250 8 21 Kit Parts List Description Line Circuit Breaker Breaker circuit 80 A 480 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 80 A 480 V 4 pole Line Circuit Breaker Breaker circuit 90 A 480 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross reces
336. it breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit TP 6116 2 02 Qty P RO2M P A Ny P P CS MHA bi A P P Gy Ny hi vk A Part 334742 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 65 334743 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 66 334744 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 69 334745 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 70 334746 222908 222909 290020 3243
337. it breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5 Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 gt 222908 222909 290020 324313 354518 364498 GM15301 GM17634 GM17638 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 83 X 750 14 X 750 15 X 750 16 X 82 6 Line Circuit Breaker 125 A W 12 V S T GM17679 KA2 Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5mm Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 36 P sch Ny EA h gt 222908 222909 290020 324313 354518 364498 GM15301 GM17634 GM17638 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 62 X 750 14 X 750 15 X 750 16 X 82 6 Description Line Circuit Breaker 150 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Nut hex 5mm Washer plain 344 ID x 875 in OD Washer spring
338. iter field output Remote voltage adjustment Overvoltage controller output signal Not used Exciter field output TB11 7N battery negative Safeguard circuit breaker battery positive OJIN 0 OQ N Voltage regulator power supply Voltage regulator power supply Figure 3 7 Voltage Regulator P40 Connections Section 3 Alternator Troubleshooting 29 Voltage Regulator Adjustment Procedure Figure 3 8 illustrates the wiring connections necessary for the voltage regulator adjustment procedure Fi F F2 F AC 5 ar Sensing leads Stator main windings Rotor main field Voltage regulator power supply leads Rotating rectifier assembly RRA Exciter armature Exciter field winding Voltage regulator P40 socket Figure 3 8 Voltage Regulator Connection 1 Verify that the generator set master switch is in the OFF RESET position 2 Turn the Volts Hz and the stability potentiometers fully counterclockwise Connect the voltmeter to the AC circuit or an electrical outlet 3 Move the generator set master switch to the RUN position 4 Change the voltage adjustment control located at the generator set controller until the desired output voltage is achieved 5 Rotate the stability potentiometer clockwise until light flicker minimizes 6 Readj
339. itions shown in Figure 2 3 and cannot be restarted until the fault condition is corrected Reset the controller after a fault shutdown 20 Section 2 Operation The fault lamp does not stay lit after the generator set shuts down on a fault condition 2 4 4 Controller Resetting After a Fault Shutdown Use the following procedure to restart the generator set after a fault shutdown 1 Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch See the Safety Precautions at the beginning of this section before proceeding 2 Correct the cause of the fault shutdown See the Safety Precautions at the beginning of this section before proceeding 3 Startthe generator set by moving the generator set master switch to RESET OFF and then to RUN 4 Verify that the cause of the shutdown has been corrected by test operating the generator set 5 Reconnect the generator set to the load using the line circuit breaker or automatic transfer switch 6 Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Fault Description High engine Shutdown occurs 5 seconds after the fault The temperature high engine temperature shutdown does not function during the first 5 seconds after startup Note The high temperature shutdown functions only when the coolant level is in the operating range Low coolant Shutdown occurs 5 s
340. ker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A 600 V 3 pole Qty o L O G Ny y N ONN bh A NN 5 GY k sch Ky s Ny A P bh I hihi Part No 334021 222908 222909 222910 290020 324314 354518 GM10527 BLK GM15301 X 25 45 X 51 45 X 51 47 X 6086 6 X 6128 3 X 6304 2 334022 222908 222909 222910 222949 BLK 290020 324313 354518 360763 GM15301 X 6086 6 X 6128 3 X 6304 4 X 6308 1 334023 222908 222909 222910 222950 BLK 290020 324313 354518 360763 GM15301 X 6086 6 X 6128 3 X 6304 4 X 6308 1 334024 222908 222909 222910 290020 324313 354518 GM10528 BLK GM15301 X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 8 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A 600 V 3 pole Line Circuit Breaker Cover side Breaker circuit 30 A 600 V 3 pole Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Bracket cir
341. ker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Screw socket head cap Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Screw socket head cap Washer spring 39 ID x 81 in OD Breaker circuit TP 6116 2 02 Qty Mi zl EA pop Ny 02 a Part 334471 222908 222909 222910 290020 324313 336020 352294 354518 364511 6086 6 6128 3 6306 120 334472 222908 222909 222910 290020 324313 336020 352294 BLK 354518 364511 X 6086 6 X 6128 3 X 6306 121 334473 222908 222909 222910 290020 324313 336020 352326 BLK 354518 364511 X 6086 6 X 6128 3 X 6306 120 334474 222908 222909 222910 290020 324313 336020 352326 BLK 354518 364511 X 6086 6 X 6128 3 X 6306 121 334480 290020 336020 352323 352324 BLK M912 08025 60 X 6086
342. ker circuit 80 A 480 V 4 pole Line Circuit Breaker 90 A Breaker circuit 90 A 480 V 3 pole Decal power breaker Cover side Screw cross recess pan head machine Line Circuit Breaker 90 A W 12 V S T Decal power breaker Cover side Screw cross recess pan head machine Breaker circuit with shunt trip Qty Part No GM14030 KA3 222908 222909 290020 324314 336020 354518 GM14299 BLK GM14300 X 6128 3 X 6306 99 GM14030 KA4 222908 222909 290020 324314 336020 354518 GM14299 BLK GM14300 X 6128 3 X 6306 102 GM14030 KA5 222908 222909 290020 324314 336020 354518 364510 GM10167 GM14299 BLK GM14300 M912 08025 60 X 6128 3 X 6306 111 GM14030 KA6 222908 222909 290020 324314 336020 354518 364510 GM10167 GM14299 BLK GM14300 M912 08025 60 X 6128 3 X 6306 117 GM17677 KA1 1 253225 1 GM17667 BLK 4 X 49 2 GM17677 KA2 1 GM15301 1 GM17668 BLK 4 X 49 2 1 X 6250 4 GM17677 KA3 1 344905 1 GM15301 1 GM17667 BLK 4 X 49 2 GM17677 KA4 1 GM15301 1 GM17668 BLK 4 X 49 2 1 X 6250 16 TP 6116 2 02 Mi vk 3p 0 bi x p38 02 Ny Description Qty Part No Line Circuit Breaker 100 A GM17677 KA5 Breaker circuit 100 A 480 V 3 pole 1 253226 Decal power breaker 1 GM15301 Cover side 1 GM17667 BLK Screw cross recess pan head machine 4 X 49 2 Line Circuit Breaker 100 A W 12 V GM17677 KA6
343. ket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Kit Parts List Qty Part No GM14029 KA2 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 X 6304 62 GM14029 KA3 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 6304 65 GM14029 KA4 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 X 6304 66 GM14029 KA5 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 X 6304 69 GM14029 KA6 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 X 6304 70 P Mi Ny P 0 Ny P Gy Ny P 0 33 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5 Standoff insulator 1 4 20 x 1 5 in Breake
344. kly Ensure that system is set for automatic operation x Weekly Interior of equipment room or outdoor weather housing x Weekly Follow procedures and frequencies indicated in the engine manufacturer s maintenance manual If not indicated follow this service schedule Some items may not apply to all generator sets R Replace as necessary X Action Service more frequently if operated in dusty areas Do not break manufacturer s seals or internally inspect these devices Megger is a registered trademark of Biddle Instruments TP 6161 1 08 Section 3 Scheduled Maintenance 23 3 4 Alternator Bearing Service Have an authorized service distributor dealer perform service 3 4 1 20 300 kW Models Replace the end bracket bearing every 10 000 hours of operation in standby and prime power applications Service the bearing more frequently if the annual inspection indicates excessive rotor end play or bearing damage Replace the tolerance ring if equipped following end bracket removal The sealed end bracket bearing requires no additional lubrication 3 4 2 350 2000 kW Models with Single Bearing Alternator The alternator bearing requires lubrication at intervals specified in the generator set technical manual Use Chevron SRI or equivalent high quality grease with a lubrication temperature range of 30 to 175 22 to 350 F 1250 2000 kW Model with Two
345. l pressure ALOP signal Battery voltage fuse 1 protected Accessory power supply Customer may also provide separate accessory power source 48 Emergency stop ES signal 56 Air damper AD switch 60 System ready signal 61 Battery charger fault Connect battery charger alarm contact to activate fault lamp active low if used 62 Low battery volts Connect battery charger alarm contact to activate fault lamp active low if used 63 Low fuel LF fault Connect fuel level sensor to activate fault lamp active low if used 70C Generator in cool down mode signal 70R Generator in running mode signal 80 Not in auto signal Connect jumper across terminals 1 and 1A if emergency stop switch is not used Use aremote annunciator and or audiovisual alarm kit as an indicator with a dry contact kit connected to controller terminal strip TB1 TB1A and TB3 TB1B Figure 6 18 16 Light Controller TB1 TB1A and TB3 TB1B Terminal Strips TP 6161 1 08 Section 6 Accessories 53 6 3 Communication Module Kit and Driver Board When a remote serial annunciator RSA is connected to a Decision Maker 3 controller a communication module circuit board is required See Figure 6 19 for location and connection The communication module circuit board location may also be occupied by interface circuit board with gaug
346. le the engine is running spray a fogging agent or SAE 10 engine oil into the air intake for about two minutes until the engine stops 2 Place the generator set master switch in the OFF RESET position 36 Section 3 Scheduled Maintenance If a fogging agent is not available perform the following 1 Remove the spark plugs 2 Pour 15 cc 0 5 oz of engine oil into each spark plug hole Ignition System Damage Refer to the engine operation manual for ignition system precautions before cranking the engine while the spark plug wires are disconnected 3 Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders 4 Reinstall the spark plugs and torque them to specifications 3 13 5 Exterior 1 Clean the exterior surface of the generator set 2 Seal all engine openings except for the air intake with nonabsorbent adhesive tape 3 To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake 4 Mask electrical connections 5 Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion 3 13 6 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the battery ies negative lead first 3 Clean the battery Refer to Section 3 10 1 for the battery cleaning proced
347. line Insulation CB Decal power breaker Screw HC special thread length Washer spring 46 ID x 875 in OD Washer spring 39 ID x 81 in OD Breaker circuit Nut hex 7 16 14 Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Decal power breaker Screw HC special thread length Washer spring 46 ID x 875 in OD Washer spring 39 ID x 81 in OD Breaker circuit Nut hex 7 16 14 Qty co CO 0 mpl k Ny ml OO GO O O N GQ Part No 334105 222996 BLK 222998 290020 336020 365608 X 6086 6 X 6306 136 334106 222999 360973 BLK 365608 365627 GM15301 X 6086 6 X 6304 111 334107 222996 BLK 222998 290020 336020 365608 X 6086 6 X 6306 136 334108 222999 360973 BLK 365608 365627 GM15301 X 6086 6 X 6304 116 334109 222999 360973 BLK 365609 365627 GM15301 GM16793 X 6086 20 X 6086 6 X 6304 119 X 70 13 334110 222996 BLK 222998 290020 336020 365609 X 6086 6 X 6306 139 334111 222999 360973 BLK 365609 365627 GM15301 GM16793 X 6086 20 X 6086 6 X 6304 121 X 70 13 TP 6116 2 02 Description Line Bracket circuit breaker Insulator Cover side Bus line Washer spring
348. llation Cost no T 4 P relief needed check local codes Easy installation only one cold water line need be brought to lavatory integral 98 compression fittings on top no sweat connections Mounts on wall at point of use Integral Flow Restrictor Built in to ensure proper temperature rise Complies with U S Federal regulations Faucet Aerator with excellent spray pattern supplied with unit Hands Free sensor and metering faucet compatible Prevents Legionella Bacteria Growth Reduces Liming Calcification and Sedimentation Complies with Handicap Requirements Ni Chrome Element a unique patented flow path ensures optimum heat transfer and extended element life Compact Size dimensions 10 75 x 5 25 x 2 875 weight 3 Ibs Field Serviceable Element replaceable cartridge element 1 year warranty Warranty Full Factory Warranty Heaters are guaranteed against failure due to leaks of Heater Body Element Assembly for a period of FIVE YEARS s High Temperature Limit Switch protects against element burn out with reset button i i CODE COMPLIANT HANDWASHING HEATERS Instant Comfort Endless Sauings ELECTRIC TANKLESS WATER HEATERS MODELS Volts kW SP2412 120V 2 4kW SP3012 120V 3 0kW SP3512 120V 3 5kW SP3208 208V 3 0kW SP4208 208V 4 1kW SP35 240V 3 5kW SP48 240V 4 8 55 240V 5 5kW SP3277 277V 3 0kW SP4277 277V 41kW
349. lon Screw Phillips hex crimptite Cable 40 Ft Remote Mounting Terminal pin male 20 24 AWG Terminal spade male Terminal fast on male Block terminal Marker strip Connector cable Terminal socket female 20 24 AWG Strip terminal Strip marker Box remote cable mounting Cover remote cable mounting Box assembly 40 ft remote mounting Harness wiring 40 ft extension Nut Hex 4mm Nut hex 5mm Washer lock 172 ID x 333 in OD Washer lock 20 ID x 373 in OD Grommet round Cable tie nylon Screw Phillips hex crimptite 44 Qty Part No GM17244 KP2 226245 238582 238898 246114 254822 292800 292879 292940 354483 GM17206 GM17207 GM17234 2 GM17238 M934 04 50 M934 05 50 X 22 7 X 22 9 X 284 31 X 468 3 X 6216 1 GM17244 KP3 226245 238582 238898 246114 254822 292800 292879 292940 354483 GM17206 GM17207 GM17234 3 GM17240 M934 04 50 M934 05 50 X 22 7 X 22 9 X 284 31 X 468 3 X 6216 1 GM17244 KP4 226245 238582 238898 246114 254822 292800 292879 292940 354483 GM17206 GM17207 GM17234 4 GM17242 M934 04 50 M934 05 50 X 22 7 X 22 9 X 284 31 X 468 3 X 6216 1 BRHNONOH Q Q N Q N G ae ND O N O HH HW OQ N Q N G ae BRHNONOH HH HW Q N Q N G Description 5 Ft Cables For Remote Mounting Block terminal Block terminal Box remote connection Marker strip Strip marker C
350. lothing when using power tools hand tools or compressed air 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 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 Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools 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 This generator set has been rewired from its nameplate voltage to 24
351. lt 85 63 DDC Series 40 3 8 16 grade 8 bolt 53 39 John Deere 3 8 16 grade 8 bolt 53 39 7 16 14 grade 8 bolt 85 63 M10 grade 10 9 bolt 65 48 Kohler Branded D200 D250 D300 7 16 14 grade 8 bolt 85 63 M10 grade 10 9 bolt 65 48 DDC Series 60 Diesel 7 16 14 grade 8 bolt 1 7 Drive Discs to Flywheel Torque Values 20 40 kW 30 60 kW 50 60 kW 85 63 Hardware Sequence Bolt hardened washer Alternator Engine John Deere Hardware Type 3 8 16 grade 8 stud Torque Nm ft Ib 53 39 Hardware Sequence Stud spacer hardened washer grade 8 nut GM John Deere 3 8 16 grade 8 stud 53 39 60 125 kW 80 180 kW 135 150 kW GM John Deere 3 8 16 grade 8 stud 53 39 Stud spacer hardened washer nut DDC Series 50 60 Gas 1 2 13 grade 8 bolt 60 44 150 275 kW 200 230 kW DDC Series 50 60 Gas 1 2 13 grade 8 bolt 130 96 Bolt hardened washer DDC Series 40 3 8 16 grade 8 stud 53 39 Stud spacer hardened washer grade 8 nut John Deere 1 2 13 grade 8 bolt 130 96 Kohler Branded 1 2 13 grade 8 bolt 130 96 200 300 kW Bolt hardened washer D200 D250 D300 M12 grade 10 9 bolt 1 2 13 grade 8 bolt 122 90 130 96 230 300 kW DDC Series 60 Diesel 16 Section 1 Specifications TP 6349 6 07 1
352. ly EX176 O 3 8 x 3 8 C 16 faucet supply 177 RATINGS OF SINGLE POINT UNITS 1 Cold water feed only MODEL VOLTS kW AMPS WIRE SIZE SP2412 120V 2 4kW 20A SP3012 120V 5 3512 120V 3 5kW 29A SP3208 208V RISE RECOMMENDED electrical supply Co gt 5 4208 208 4 1kW 19 7 5 35 240V 3 5kW 14 6A SPECIFICATIONS Dimensions 10 75 x 5 25 x 2 875 Weight 3 Ibs Materials Cover ABS UL rated 94Vo Color White Element Replaceable cartridge insert Pipe Fittings 3 8 compression at top of unit UL Listed E86887 M U S Patent 5 4 762 980 and 4 960 976 277 Engineer Architect REMOVABLE FILTER of LISTED EEMAX SUBMITTAL Job Name Customer Location SPECIAL INQUIRIES FOR UNITS FOR UNIQUE Contractar Representative DESIGN APPLICATIONS ARE WELCOME CALL SERVICE OUR TECHNICAL SERVICE DEPT PEDE 1 800 543 6163 Single Point Model SP Option Quantity kW Voltage AMPS GPM www eemax com Eemax Inc 353 Christian Street Oxford CT 06478 Telephone 203 267 7890 TOLL FREE 1 800 543 6163 FAX 203 267 7975 9 6 92 00 XV4 0682 192 202 919 69 008 L 131 82790 LO J0JXO 5 uensuuO ese ouj ALVG NOILVTIVLSNI 191435 SNIT1V9 3304
353. ly to ensure adequate fuel supply TP 6161 1 08 Section 2 Operation Ignition System Ensure that the ends of all spark plug wires are properly seated onto the coil distributor and the spark plug Lamp Test Press the lamp test button if equipped to verify that all controller LEDs illuminate Oil Level Maintain the oil level at or near not over the full mark on the dipstick Keep the oil level in the mechanical governor if equipped at or near the full level Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set 2 2 Generator Set Exercising Operate the generator set under load once each week for one hour Perform the exercise in the presence of an operator if the generator set does not have a programmed exercise mode or an automatic transfer switch with an exercise option During the exercise period apply a minimum of 35 load based on the nameplate standby rating unless otherwise instructed in the engine operation manual The operator should perform all of the prestart checks before starting the exercise procedure Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks 2 3 16 Light Controller Features 2 3 1
354. maintain concentric alignment of the individual drive disks during installation See Figure 4 15 Note The user supplied pins should be no smaller than 0 025 mm 0 001 in of the disc hole diameter Section 4 Alternator Disassembly Reassembly 3 090 R8348 19 Install alignment pins or bolts here Rolled corner Burr side 120 total position drive disk hex hole at the stator bottom position or within 60 CW or from the stator bottom position 5 Hex hole Figure 4 15 Aligning and Mounting Drive Disks TP 6349 6 07 14 Attach the drive disc s to end of rotor shaft with the 17 Apply Loctite 271 red to stud threads and hole burr side toward the alternator fan and with the install into flywheel as shown in Figure 4 17 Install hex hole at the stator bottom position or within 60 studs completely into flywheel Apply Loctite No clockwise CW or counterclockwise CCW of the 242 blue to stud threads on nut side 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 15 Attach a hoist to the 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 the alternator to the top 16 UA alternator only Remove the vent sight hole screw from the en
355. manufacturer s instructions Figure 3 15 shows typical test results Number of Floating Beads Battery Condition Overcharged Fully charged A good charge A low charge A dead battery Figure 3 15 Bead Type Test Interpretation 3 10 4 Charging Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application The engine battery charging alternator charges the battery only while the generator set is running Note If the generator set is in a temporary prime power application in which the generator set has periods of inactivity the controller circuitry may drain the battery If there is no power source for a battery charger place the controller in the prime power mode if equipped or disconnect the battery from the generator set 3 11 Detroit Diesel Engine Control Systems Some generator sets equipped with Detroit Diesel engines use a DDEC MDEC system Access the DDEC control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting the engine Note DDC MTU engines with MDEC requires the following method e Useapersonal computer software package available from the manufacturer with a translator to access stored codes Follow the instructions provided with the software Use the following data for informational purposes only Consult the engine literature for complete information regarding operatio
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357. me between failure 54 Appendix MTBO mtg MTU MW mW nat 5 02 D 2 pot 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 applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pou
358. ment 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 19 Trouble Symptoms Does crank Contr Cranks but does not start Starts hard No or low output voltage Stops suddenly Lacks power Overheats pressure High fuel consumption Excessive or abnormal noise Probable Causes Recommended Actions Section or Publication Reference x Controller circuit board s inoperative Replace the controller circuit board Bunoouse qnoj p 02 Controller fault Troubleshoot the controller Generator set O M Controller fuse blown Replace the blown controller fuse If the fuse blows again troubleshoot the controller Controller master switch inoperative Replace the controller master switch Controller master switch in the OFF RESET position Move the controller master switch to the RUN or AUTO position Generator set O M Cooling Sys Engine start circuit open Move the controller master switch to the RUN position to test the generator set Troubleshoot the auto start circuit and time delays Generator set O M W D ATS O M S M Air openings clogged Clean the air openings Coolant level low Restore the coolant to normal operating level Generator se
359. minal no 3 Blue diode terminal no 2 connect to AC terminal no 2 Blue diode terminal no 1 connect to AC terminal no 1 Diode terminal F red connect to main field F Diode terminal F blue connect to main field F Varistor connect to diode terminals F and F Red diode terminal no 1 connect to AC terminal no 1 Red diode terminal no 2 connect to AC terminal no 2 Red diode terminal no 3 connect to AC terminal no 3 Figure 4 21 Rotating Rectifier Assembly Hub Electrical Connections TP 6349 6 07 26 Attach the speed sensor to the end bracket using 27 Replace the alternator rodent guard on the end two screws Adjust the air gap See Figure 4 22 bracket if equipped 28 Replace the rotating rectifier assembly housing 29 Install the fan guard 30 Reinstall the junction box and controller 31 Reconnect all controller to engine and engine to alternator harnesses and wiring Reconnect the speed sensor wiring Refer to the respective wiring diagram manual as required 32 Replace the junction box panels 5 33 Reconnect the fuel cooling and exhaust systems that were disconnected during disassembly 0 36 0 71 mm Reconnect the output leads or load circuit cables at 6 014 0 029 in the alternator Open the fuel supply valve 34 Reconnect the starting batteries negative lead last Connect any AC powered accessories such as the battery charger block heater fuel transfer
360. mote 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 battery 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 Seekimmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service asthis may resultin hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction
361. move the pressure cap to allow the entire system to drain and prevent air pockets from restricting coolant flow through the engine block 3 Open the radiator and or engine block coolant drain valve s and allow the system to drain 4 If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease refer to Section 3 7 4 Cooling System Flush and Clean Procedure If the cooling system does not have mineral deposits go to Section 3 7 5 Cooling System Refilling Procedure TP 6161 1 08 3 7 4 Cooling System Flush and Clean Procedure Use the instructions in the engine operation manual when available to flush and clean the cooling system Otherwise use the following procedure and the cooling system cleaner manufacturer s instructions 1 Flush the cooling system with clean water 2 f the inside of the radiator still has mineral deposits use a radiator cleaner to remove the remaining deposits following the manufacturer s instructions 3 Drain clean and flush the coolant recovery tank 3 7 5 Cooling System Refilling Procedure See the generator set spec sheet for coolant capacity Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled 1 Remove the pressure cap 2 Close radiator and or engine block coolant drain valve s and tighten cooling system hose clamps 3 Open the air
362. n Economy Tank day Motor pump Pump Coupling pump drive Switch basin Switch float Switch Sensor float Pan rupture basin Day Tank 50 Gallon Economy Tank day Sensor float Motor pump Pump Coupling pump drive Switch Kit Parts List Qty nnn ch ch lt lt sch vk ch sch sch ch ch vk ch sch vk ch sch ch ch ch ch sch Part 274781 156327 156327 239298 241950 266469 269216 274883 275558 275559 279875 274818 290024 202 12 202 30 22 25 22 7 386 102 391 20 426 9 51 12 567 1 6003 10 71 2 274602 274602 352898 352899 352900 354367 354417 274603 274603 352898 352899 352900 354367 354369 354370 354371 354417 274604 274604 352898 352899 352900 354417 354418 274605 274605 352898 352899 352900 354370 354371 354417 354418 354419 274606 274606 352897 352898 352899 352900 354417 51
363. n OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Bracket circuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine 26 Qty N OG a aN AM a hi sch ai apaan ANONO MAA A Part No 334776 222908 222909 290020 324313 354518 364484 364495 BLK 364508 X 6086 6 X 6128 3 X 6304 92 334777 222908 222909 290020 324313 354518 364484 364495 BLK 364508 X 6086 6 6128 3 6304 93 334778 222908 222909 290020 324313 354518 364484 364495 364508 6086 6 6128 3 6304 96 334779 222908 222909 290020 324313 354518 364484 364495 1 364508 6086 6 6128 3 6304 97 334780 222908 222909 324313 354518 364484 364496 364509 365627 6086 6 6128 3 6304 100 6308 2 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Bracket circuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Bracket ci
364. n and troubleshooting See List of Related Materials in the Introduction section Contact an authorized service distributor dealer for service or diagnostic equipment 34 Section 3 Scheduled Maintenance 3 11 1 Features The DDEC MDEC system optimizes control of critical engine functions and protects against serious engine damage resulting from conditions such as the following e Low coolant level e Low coolant pressure e High coolant temperature e Low oil pressure e High oil temperature The major components of the DDEC MDEC system include the electronic control module ECM and engine sensors The DDEC control box is located in the generator set junction box 3 11 2 DDEC Engine Diagnostics The DDEC engine protection system monitors engine sensors and electronic components and recognizes system malfunctions Critical faults light the check engine CEL and stop engine SEL lamps on the control box ECM memory software logs malfunction codes Consult the engine operation manual or engine service manual to identify the stored failure code See Figure 3 16 for the DDEC control box features DIAGNOSTIC REQUEST A ff 2 um Z STOP CHECK ENGINE ENGINE 343591 Figure 3 16 DDEC Control Box Access the stored codes in one of three ways e Place the switch in the DIAGNOSTIC REQUEST position The CEL or SEL flashes to identify the failure e Use a hand held diagnostic data read
365. n field from the rotating rectifier assembly RRA terminals F and F 2 Check the rotor main field resistance by connecting an ohmmeter across leads field F and F See Figure 3 15 See Section 1 Specifications for the resistance values 4 Ohmmeter 5 Exciter armature 6 Exciter field winding 1 Rotor main field 2 Stator main windings 3 Rotating rectifier assembly Figure 3 15 Rotor Resistance Test A low reading indicates an internal short and a high reading indicates an open winding Repair or replace the rotor main field if the ohmmeter readings indicate the rotor main field is inoperative If the resistance test is inconclusive perform a megohmmeter test on the rotor main field as described in the next step TP 6349 6 07 3 Check the rotor main field for a short to ground condition by using megohmmeter Apply 500 volts DC to either rotor main field lead and the main field frame Follow the megohmmeter manufacturer s instructions for using the megohmmeter See Figure 3 16 A reading of 500 kOhms 1 2 megohm and higher indicates the rotor main field is good A reading of less than 500 kOhms indicates deterioration of the rotor main field winding insulation and possible current flow to ground Replace the rotor 1 Rotor main field 2 Stator main windings 3 Ground to stator frame 4 Rotating rectifier assembly 5 Megohmmeter 6 Ex
366. n or Publication Reference x Controller circuit board s inoperative Replace the controller circuit board Gen S M Controller fault Troubleshoot the controller Gen S M Controller fuse blown Replace the blown controller fuse If the fuse blows again troubleshoot the controller Section 2 W D Controller master switch inoperative Replace the controller master switch Controller master switch in the OFF RESET position Move the controller master switch to the RUN or AUTO position Section 2 Engine start circuit open Move the controller master switch to the RUN position to test the generator set Troubleshoot the auto start circuit and time delays Section 2 W D Gen I M S M ATS O M S M Cooling Sys Controller interface to engine ECM Check engine ECM and electrical wiring Eng S M W D Air openings clogged Clean the air openings Coolant level low Restore the coolant to normal operating level Section 3 Cooling water pump inoperative Tighten or replace the belt Replace the water pump Eng O M or S M High temperature shutdown Allow the engine to cool down Then troubleshoot the cooling system Sec 3 Eng O M Low coolant level shutdown if equipped Restore the coolant to normal operating level Section 3 Electrical System DC circuits Thermostat inoperative Replace the thermostat Eng S M
367. natural gas fuel by performing the fuel conversion procedure Some models require a different fuel kit when changing gas fuels Consult your local generator set distributor dealer for additional information Fuel conversion may decrease generator set output and affect exhaust emissions Consult your local generator set distributor dealer for additional information Fuel Conversion Procedure When converting the generator set to operate with LP gas remove the internal spring from the secondary regulator Install the spring to operate the generator set on natural gas Note Not all fuel regulators require spring and retainer removal for fuel conversion A hang tag on the fuel regulator identifies the conversion procedure LP Fuel Conversion Procedure Use the following steps to remove the internal spring from the fuel regulator 1 Remove the fuel regulator cover plug See Figure 3 5 26 Section Scheduled Maintenance w 1 Fuel regulator 2 Spring 3 Adjustment screw 4 Cover plug P 3 Figure 3 5 Fuel Regulator Typical 2 Remove the adjustment screw and spring from the fuel regulator Save the adjustment screw and spring for possible conversion back to natural gas 3 Reinstall the cover plug Natural Gas Fuel Conversion Procedure Use the following steps to convert the generator set to natural gas 1 Remove the fuel regulator cover plug See Figure 3 5 2 Replace the spr
368. ncy of 18 Hz Continued low engine speed causes an overcrank fault condition Overcrank Overspeed Overspeed shuts down the unit immediately when governed frequency on 50 60 Hz models exceeds 60 70 Hz Note The controller circuit board DIP switches allow 50 Hz 60 Hz shutdown or 60 Hz 70 Hz shutdown selection Overvoltage if Overvoltage shuts down the unit and lights the equipped auxiliary lamp when voltage is at least 15 over the nominal voltage for longer than 2 seconds Note Overvoltage can damage sensitive equipment in less than 1 second Provide separate overvoltage protection for online equipment requiring faster shutdowns Figure 2 2 Fault Shutdowns 3 Correct the cause of fault shutdown See the Safety Precautions section of this manual before proceeding 4 Startthe generator set by moving the generator set master switch to the OFF RESET position and then to the RUN position If equipped the audiovisual annunciator alarm horn sounds and lamp goes out 5 Verify that the cause of the shutdown was corrected by test operating the generator set 6 Reconnect the generator set to the load by using the line circuit breaker or the automatic transfer switch Note Place the generator set master switch in the AUTO position before silencing the alarm horn Section 2 Operation 19 7 Move generator set master switch to the AUTO position for startup by remote transfer switch or remote start
369. nds 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 scfm SCR 5 sec Sl SI EO sil SNMP SPDT SPST spec specs sq Sq cm sq in SS std stl tach root 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
370. ne flexible Fuel line flexible Bracket mounting Washer lock 521 ID x 884 in OD Cap pipe 3 8 3 8 Clamp hose 38 88 Elbow oil line 90 deg vibra seal Elbow oil line 90 deg vibra seal Clamp insulated 5 in Flexible Fuel Lines Fuel line flexible Fuel line flexible Bracket mounting Washer lock 656 ID x 1 058 in OD Cap pipe 1 2 in NPT Cap pipe 3 8 in NPT Clamp hose 38 88 in Elbow oil line 90 deg vibra seal Elbow oil line 90 deg Clamp insulated 5 in Fuel Pump Kits Auxiliary Auxiliary Fuel Pump 12 VDC Pump fuel Lead wire Qty Part No GM22835 KA1 336863 GM22836 GM22837 X 22 4 X 268 9 X 268 9 X 426 18 X 447 14 X 447 15 X 672 10 GM22835 KA2 336863 GM22836 GM22837 X 22 43 X 268 8 X 268 9 X 426 18 X 447 15 X 447 8 X 672 10 Ll lll mer PA 324405 1 229051 2 229056 Fuel Pump Kits Subbase Transfer Tank Transfer Pump 120 V 60 Hz Coupling conduit elbow Coupling conduit elbow Harness wiring day tank 6 60 kW Fuse 5 A 250 V Relay 120 VAC 15A Cover conduit box Fuse holder inline Box junction Harness wiring engine 125 180 kW Bracket relay Box controller Pump motor assembly Bushing reducing 1 4 x 1 2 in NPT Bushing reducing 1 4 x 3 8 in NPT Washer lock 146 ID x 53 in OD Washer lock 172 ID x 333 in OD Hose Fitting hose connector
371. ngines Refer to the Specification Number Index for generator models and specifications covered This manual includes the following main sections e Table of Contents Lists the sections of this catalog e Introduction and other information sections Contains introductory material followed by sections on specification numbers part numbers and hardware e Index Indexes generator set specifications and their groups e Group Parts Lists List part numbers of parts in the groups Number Significance This catalog uses a variety of numbering systems A description of these follows e Group Number group consists of parts needed to perform one or more related functions For example Group 1 is the Engine Air Intake group TP 6141 12 03 e Variation Number group might have several variations Parts comprising each variation perform the same function but parts lists vary For example a 50 Hz fuel injection pump and a 60 Hz fuel injection pump perform the same function However they are constructed of different parts Each of these differences necessitates the assignment of a group variation number e Part Number The part number identifies an individual assembly subassembly component or accessory kit How to Find Part Numbers Follow these steps to identify a part STEP 1 Turn to the Specification Number Index The first column lists engine models grouped by generator set model The headings across the top ident
372. nnel familiar with generator set operation and service WARNING x 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 TP 6161 1 08 Section 3 Scheduled Maintenance 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 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 WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures ar
373. nnn nin iin Part 224852 156327 156327 224869 224873 239298 241950 266469 269216 274883 275559 279875 224874 290024 22 25 22 7 391 13 422 30 426 10 50 3 51 12 567 1 6003 10 71 2 224877 224814 224825 224880 224884 255600 299186 299187 290024 284 35 391 13 422 31 426 10 224878 156327 156327 239298 241950 266469 269216 274883 275558 275559 279746 279875 274818 290024 22 25 22 7 391 13 422 31 426 10 50 3 51 12 567 1 6003 10 71 2 Kit Parts List Description Day Tank Relay Control Coupling conduit elbow Coupling conduit elbow Switch float Harness wiring day tank 6 60 kW Fuse 5 A 250 V Relay 120 15 A Cover conduit box Fuse holder inline Box junction Bracket relay Harness wiring Sea Ray 4 6 5 kW marine Pump motor assembly Box assembly controller flexible Washer lock 146 ID x 53 in OD Washer lock 172 ID x 333 in OD Fitting hose connector 90 deg Hose Clamp 1 in hose Screw slotted pan head machine Screw slotted pan head machine Coupling non metallic Conduit convoluted Nut hex machine screw 6 32 In Base Day Tank Relay Control Coupling conduit elbow Switch float Pump motor assembly Box assembly controller Bracket daytank controller mounting Nut hex 5mm Fitting hose connector 90 deg Hose flex fuel
374. nstructions 5 Battery gases cause severe injury or death Battery gases can cause an explosion Do not smoke or permitflames or sparksto occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away 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 tog
375. nt Kits Normal with Riser and Cap 90 Vent Kits Pressure Release 90 Voltage Regulator 91 Voltage Regulator Relocation Kit 91 Wiring Shunt 91 leie EE 92 Introduction This manual contains parts lists of optional accessory kits installed on Kohler diesel powered industrial generator sets This manual does not include controller cooling and some fuel system kits See the chart below for parts catalogs containing parts lists of these kits Additional Generator Set Parts Catalogs Parts Catalog Generator Set Model Number 20 200ROZJREOZJ TP 5408 135 200ROZJ 6081 only TP 5828 Controllers TP 6009 20 170ROZK TP 6029 200REOZP TP 6048 20ROZJB 20 230REOZJB TP 6142 How to Find Service Part Numbers Follow the step by step instructions below to determine the correct service part number An example is given with each step Example Need new circuit breaker for the generator set safeguard breaker kit 1 Determine the accessory kit number for the needed service part Refer to the generator set nameplate to identify the kit number installed on your generator set See Figure 1 for an example of the nameplate Example 272748 Safeguard Breaker OD ACCESSORIES 272748 SAFEGUARD BREAKER 274739 RAD COOLING 105DEG 276423 DEC 3 CONTROLLE
376. nt components Radiator cooled models have a radiator with a pressure and coolant recovery tank City water cooled models have a heat exchanger and an expansion surge tank with a pressure cap 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 Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank Note Engine damage Bleed the air from the cooling system to prevent overheating and subsequent engine damage Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater 3 7 4 Coolant Level Check Check the coolant level in the coolant recovery tank if equipped Maintain the coolant level between the high and low marks Note Periodically check the coolant level by removing the pressure cap Do notrely
377. nts PAGE SIX The Indicator light comes but there is no heat or the water temperature is low STEP ONE The water flow is too high Reduce the water flow using the faucet with experimentation you should notice an increase in temperature Make sure the aerator supplied with the heater is attached to the faucet these are integral to the proper performance of your heater If you do not have the special Eemax aerator call Eemax at 1 800 543 6163 and we will send you one STEP TWO Make sure that the unit is connected to the voltage supply specified on the U L rating label on the front cover of the heater and no other STEP THREE Take a resistance reading of the element To do this follow instructions on page five PAGE SEVEN Other possible solutions STEP ONE Make sure the printed circuit board is mounted in the correct position This is the top set of mounting holes see diagram below Failure to mount the board in the correct position will cause element burn out and may cause further damage to your heater This board may have been incorrectly moved when serviced previously The correct mounting holes 1 for the on an SP model E Board mounted in correct position STEP TWO Inspect the inlet filter see diagram on page four for location Make sure it is free from debris pipe dope or anything else which may hinder water flow IF HAVING CARRIED OUT ALL THE TESTS LISTED
378. oat Switch Switch Position Position Observation Open The alarm horn and the lamp are not energized The alarm horn and lamp activate when a fuel leak occurs If the alarm switch is moved to the silence position the lamp stays on until the fuel leak fault is corrected Closed The alarm horn sounds to alert the user that the alarm horn switch is not in the normal position and that the alarm horn will not sound should a fuel leak occur Figure 3 3 Inner Fuel Tank Leak Alarm Troubleshooting TP 6161 1 08 Resetting Procedure Use the following procedure to reset the alarm after a fault alarm 1 Move alarm switch to the SILENCE position to stop alarm horn Lamp will remain lit 2 Disconnect generator set from load with line circuit breaker or automatic transfer switch 3 Repair or replace the inner fuel tank 4 Move generator set master switch to the OFF RESET position and then to the RUN position for startup Alarm horn sounds and lamp goes out 5 Reconnect generator set to load via line circuit breaker or automatic transfer switch 6 Move generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Move alarm switch to the NORMAL position 3 6 Gas Gasoline Fuel Systems This section describes fuel systems that are not covered in the engine operation manual or engine service manual 3 6 1 Gaseous Fuel System Concept The gase
379. oftware Operation Manual TT 1405 TP 6347 Figure 1 Related Literature Several engine manufacturers provide engines with electronic controls These electronic controls indicate fault codes in addition to the generator set controller Use Figure 2 for literature part numbers relating to the identifying engine fault codes For the latest literature part numbers see the respective Parts Catalog Literature Part Description 30 kW and 80 125 kW GM 80 200 kW John Deere 4045 6068 275 500 kW Kohler Branded Engines 135 275 kW DDC Series 50 60 Gas 230 450 kW DDC Series 60 230 450 kW DDC Series 60 450 500 kW DDC Series 2000 650 1000 kW DDC Series 2000 650 1000 kW Engine Operating DDC MTU Series 2000 1 P 9502 instructions ADEC 1250 2250 kW Engine Operating DDC MTU Series 4000 6503 instructions ADEC 1350 2000 kW TP 6215 Engine ECM Service Manual TP 6285 Engine Operation Manual TP 6218 Engine Operation Manual Natural Gas Generator Set Engine Operator s Guide DDEC IV Application and Installation Manual TP 5830 TP 6056 TP 5611 Engine Operator s Guide DDEC IV ECM TP 6361 Troubleshooting Guide Engine Operating TP 6375 instructions MDEC Engine Operating DDC MTU Series 4000 P 6237 instructions MDEC Figure 2 Related Engine Literature Introduction 9 Tech Tools Use your SecurlD to access
380. onfiguration of the alternator Use the disassembly procedure as a guideline to help take apart the alternator The disassembly procedure provides important information to minimize disassembly time and indicates where special configurations exist which may require taking notes The reassembly procedure includes important alignment steps and provides special torque specs WARNING X a Accidental starting Can cause severe injury or death xf 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 setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe powertothe 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 TP 6349 6 07 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
381. onnect all accessories except the emergency stop kit to the connection kit terminal strip Section 6 Accessories 47 6 1 4 Dry Contact Kit Single Relay M The single relay dry contact kit uses one set of contacts to trigger customer provided warning devices if a fault condition occurs Connect any controller fault output connection from the TB1 terminal strip to the single relay kit Use the single relay dry contact kit as a common fault relay for signaling any of the following common fault conditions e Emergency Stop e Auxiliary e Overspeed e Low Oil Pressure e High Engine Temperature Connect a maximum of three dry contact kits to a single controller output See Figure 6 3 Figure 6 3 Single Relay Dry Contact Kit Typical 6 1 5 Dry Contact Kits 10 14 and 20 Relay M Dry contact kits allow monitoring of the generator set system and provide the ability to activate warning devices and other customer provided accessories Available kits include 10 14 or 20 sets of relay contacts for connecting customer provided devices to desired generator set functions The 20 relay kits can be used on 450 kW and larger generator sets The 10 relay and 20 relay kits provide normally open and normally closed contacts The 14 relay kit provides normally open contacts only Warning devices lamp and or audible alarms and other accessories typically connect to the controller output connections listed below A total of three dry
382. onnector cable Connector 24 position Connector jack 24 position Harness wiring control panel Box remote connection Remote connection 20 2000 kW Grommet 2 1 8 x 2 1 2 Screw cross recess round machine Screw cross recess pan head machine Screw slotted round head machine Cap Mushroom Cap Mushroom Cap vent Charging Prime Power Prime Power Charging Packing thermal compound Boot Diode 90 A Harness wiring 80 180 KW John Deere Bracket diode mounting Screw slotted pan head machine Nut hex machine screw 10 32 Prime Power Charging Packing thermal compound Boot Diode 90 A Bracket diode mounting Harness wiring 20 60 kW John Deere Screw slotted pan head machine Nut hex machine screw 10 32 Prime Power Charging Packing thermal compound Wiring harness 80 180 kW John Deere Bracket diode mounting Washer plain 219 ID x 5 in OD Screw slotted pan head machine Nut hex machine screw 10 32 Prime Power Charging Packing thermal compound Bracket diode mounting Wiring harness 20 60 kW John Deere Washer plain 219 ID x 5 in OD Screw slotted pan head machine Nut hex machine screw 10 32 Communications Kits RS 232 Communication Cable multiconductor ribbon PCB assembly I O RS232 Dec 340 Controller communications kits Washer lock 172 ID x 333 in OD Spacer 25 OD 937 in Qty ch ch aap aan ch DO Pop aaa aa Pop Aaa a
383. op Switch Kit Local 49 Emergency Stop Switch Kit Remote 49 End Cap Kits Skid 49 FASTCHECK and Wire Harness 49 Fill Cap Kit 2 inch 49 Flange Kits Weld on 50 Fuel Filters cri aea ctr gon 50 Fuel Line Kits Flexible 50 Fuel Pump Kits Auxiliary 51 Fuel Pump Kits Subbase Transfer 51 Fuel Tank Kits 40 222 2 51 Fuel Tank Kits Subbase Double Wall 53 TP 6116 2 02 Fuel Tank Kits Subbase Single Wall 61 Gauge Kits Fuel Pressure 61 Gauge Kits Manifold 62 Gauge Kits Oil Temperature 62 Gauge Kits Subbase Fuel Tank 62 Governor Kits Isochronous 62 Governor Kits Non Paralleling 64 Governor Kits Paralleling 64 Guard Kits Rodent 65 Harness kite 67 Heater Kits Controller 67 Heater Kits Generator
384. or Publication Reference Engine ECM Troubleshoot engine ECM and electrical Air cleaner clogged Clean or replace the filter element Compression weak Check the compression Engine overload Reduce the electrical load See the generator set spec sheet for wattage specifications Exhaust system leak Inspect the exhaust system Replace the inoperative exhaust system components 7 Exhaust system not securely installed Inspect the exhaust system Tighten the loose exhaust system components Governor inoperative Adjust the governor Valve clearance incorrect Adjust the valves t Vibration excessive Tighten all loose hardware Fuel System Ignition system inoperative gas gasoline only Check the ignition system spark plugs spark plug wires etc Air in fuel system diesel only Bleed the diesel fuel system Ether canister empty or system inoperative if equipped diesel only Replace or repair the ether starting system Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position Fuel feed or injection pump inoperative diesel only Rebuild or replace the injection pump Fuel or fuel injectors dirty or faulty diesel only Clean test and or replace the inoperative fuel 7 Fuel filter restriction Clean or replace the fuel filter Fuel solenoid inoperative Troubleshoot t
385. or controller configurations See Figure 6 17 Figure 6 18 for controller terminal strip identification Lower the controller circuit board panel until itis lying flat when connecting the dry contact kits to the controller TB1 terminal strip Route dry contact relay leads through the controller grommet and guide loops to the circuit board terminal strip Place the controller circuit board panel flat to ensure adequate slack in the dry contact relay leads For specific information on accessory connections refer to the accessory wiring diagrams in the Wiring Diagram Manual and the instruction sheet accompanying the kit Note Not all terminals are used for all generator sets see appropriate wiring diagrams for specific generator set models Note To use the prime power mode use jumpers to connect TB2 1P to TB2 2P 2 3 to TB2 4P and TB2 3 to TB2 4 To deactivate the prime power mode remove these jumpers 52 Section 6 Accessories N elle 2 1 336415 1 1 TB1A terminal strip 2 TB2 terminal strip 3 TB3 TB1B terminal strip Figure 6 16 TB1 and TB2 Terminal Strips on the 16 Light Controller Prime power operation Prime power operation R
386. or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6349 6 07 Accidental Starting WARNING Pa or Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or 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 re
387. otor hardware after servicing Do notloosen the crankshaft hardware or rotorthrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt rotor thrubolt counterclockwise can loosen the hardware Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Canadian
388. oup 7 Cylinder Block Qty Var Item Part No Description 4607 9906 1 GM21417 Block cylinder 1 1 2 Screw 3 8 1 grade 8 2 2 3 223610 Plate 1 1 4 223407 Key woodruff 1 1 5 X Camshaft order kit part number GM21411 1 1 6 223611 Tappet 1 6 7 GM21418 Orifice 3 3 8 223472 Pin dowel 4 4 9 352064 Pin dowel 2 2 10 Screw cap 3 8 in x 2 1 4 in 2 2 11 Stud 3 8 in x 47 mm 1 1 12 360517 Cap AR AR 13 360518 Bushing i 1 14 X Spring order item 32 1 1 15 X Valve order item 32 1 1 16 223639 Screw cap 8 8 17 GM21419 Washer 8 17 224089 Washer 8 18 223503 Cap bearing 3 19 223516 Cap 1 20 336458 O ring 1 1 21 x Block cylinder 1 1 22 Plug pipe 3 8 in 1 1 23 Screw 1 2 in x 1 2 in 1 1 24 223638 Nipple threaded 1 1 25 224268 Plug pipe 4 4 26 Plug pipe 1 4 in 18 1 1 27 Plug pipe 1 2 14 1 1 28 223802 Plug pipe 1 28 Plug pipe 1 4 in 1 29 Plug pipe 1 in 11 5 1 1 30 Nut 3 8 in 16UNC 1 1 31 352246 Bushing d 1 2 GM21420 Valve kit AR AR 33 223435 Valve drain AR AR Common hardware procure locally AR As Required X Not sold separately TP 6141 12 03 17 Group 8 Crankshaft CD40036 Var Item Part No Description 4702 9919 1 GM21421 Crankshaft 1 1 2 223422 Seal 1 1 3 223607 Slinger oil 1 d A Not used 1 1 5 223615 1 1 6 Crankshaft 1 1 7 223407 Key woo
389. ous fuel system uses a fuel valve with a solenoid to control the fuel flow to the fuel regulator The generator set mounted regulator reduces the fuel pressure as fuel passes to the carburetor See Figure 3 4 Primary regulator supplied by gas supplier or customer Pressure gauge Solenoid valve Secondary regulator Carburetor Figure 3 4 Fuel Regulator and Valve Typical Section 3 Scheduled Maintenance 25 The carburetor mixer controls the ratio of fuel to under varying load and speed conditions Because the carburetor receives fuel in a gaseous state it does not have to vaporize the fuel When switching from natural gas to LP gas or LP gas to natural gas verify that the electronic governor maintains the rated engine speed 1800 rpm at 60 Hz or 1500 rpm at 50 Hz If the engine speed is incorrect refer to the generator set service manual for the governor adjustment procedure 3 6 2 LP Liquid Withdrawal Fuel System Concept With the LP liquid withdrawal fuel system pressurized liquid LP fuel passes from the tank to a vaporizer The vaporizer converts the liquid fuel to gas before sending it to the carburetor The system also includes a fuel valve that shuts off the fuel flow when the engine stops Contact an authorized service distributor dealer for availability 3 6 3 LP Gas Natural Gas Conversion for Straight Gas Fuel System Most models operate on either LP gas or
390. ovides protection against serious engine damage The major components include the engine control module engine sensors and control box located in the generator set junction box See Figure 3 17 for the John Deere engine control box features DIAGNOSTIC SHUTDOWN OVERRIDE M WARNING STOP ENGINE D 2 GM30962 A Figure 3 17 John Deere Engine Control Box TP 6161 1 08 See Figure 3 18 for the Kohler branded D300 D350 D400 D450 and D500 engine control box features 8 A A d IGNITION d DIAGNOSTIC REQUEST DIAGNOSTIC Figure 3 18 Kohler Branded Engine Control Box GM23666 3 13 Storage Procedure Perform the following storage procedure before taking a generator set out of service for three months or longer Follow the engine manufacturer s recommendations if available for fuel system internal engine component storage 3 13 1 Lubricating System Prepare the engine lubricating system for storage as follows 1 Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature 2 Stop the generator set 3 With the engine still warm drain the oil from the crankcase 4 Remove and replace the oil filter 5 Refill the crankcase with oil suited to the climate 6 Run the generator set for two minutes to distribute the clean oil 7 Stop the generator set 8 Check the oil level and adjust if
391. owns only Use the generator set master switch for normal shutdowns The local emergency stop switch is standard on selected generator sets Generator Switch functions as the controller reset and set master generator set operation switch Refer to Switch Section 2 3 1 Normal Operation Section 2 3 2 Prime Power Mode Operation and Section 2 3 5 Controller Resetting After a Fault Shutdown Lamp test Switch displays the controller indicator lamps switch Selector Switch selects the generator set output circuits to switch measure When switched to a position with three circuit labels the meters display the amperage on the lead shown in the upper label and the voltage between the two leads shown in the lower label The AC ammeter and voltmeter function only with the switch in the ON position Voltage Control fine tunes 5 the generator set output adjustment voltage Used with 20 400 kW permanent control if magnet wound field alternator models only The equipped voltage adjustment on 350 2000 kW pilot excited models is located in the generator junction box Figure 1 6 Switches and Controls Modbus is a registered trademark of Schneider Electric 14 Section 1 Specifications and Features 1 2 6 Terminal Strips Two terminal strips are mounted on the controller circuit board See Figure 1 7 and Figure 1 8 Refer to Section 2 3 2 Prime Power Mode Operation for information on enabling prime power mode
392. pan head machine Line Circuit Breaker Cover side Decal power breaker Screw cross recess pan head machine Breaker circuit with shunt trip Line Circuit Breaker Breaker circuit 100 A 480 V 3 pole Cover side Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Cover side Decal power breaker Screw cross recess pan head machine Breaker circuit 100 A 480 V 4 pole Line Circuit Breaker Cover side Decal power breaker Screw cross recess pan head machine Circuit breaker 30 A 600 V 4 pole Line Circuit Breaker Breaker circuit 40 A 600 V 3 pole Cover side Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Cover side Decal power breaker Screw cross recess pan head machine Circuit breaker 40 A 600 V 4 pole Line Circuit Breaker Breaker circuit 50 A 600 V 3 pole Cover side Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Cover side Decal power breaker Screw cross recess pan head machine Circuit breaker 50 A 600 V 4 pole Line Circuit Breaker Breaker circuit 60 A 600 V 3 pole Cover side Decal power breaker Screw cross recess pan head machine Line Circuit Breaker Cover side Decal power breaker Screw cross recess pan head machine Circuit breaker 60 A 600 V 4 pole Line Circuit Breaker Breaker circuit 70 A 600 V 3 pole Cover side Decal power breaker Screw cross
393. 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 22 Speed Sensor Air Gap TP 6349 6 07 Section 4 Alternator Disassembly Reassembly 49 et 0 wel UNDE ASSV IMA nu 313 AY 21014 SIN3TVAIDD3 NI SNOISNAaWIa S HOLVIS DINI 431438 SI 40104 0438 4010Y OL Zull HS 1504 81200 20019 ddy v SV 985 0 ISN QOHL3M AlBW3ssv dddOHd 804 Ividilv 40 5118 NO 031319395 ION 349 4 3 Sv 041511 Su3HSVM ONY SINN 543825 3SN3dX3 468 0 Hid SAYIT 3lvNINE3L 7031312395 3SIMd3HlO 5531 01 21 9 1 25310 803 NOOO L MIA 804 OLIN 08 80 1015521 1581 1 491 e 861 ez 1300 d TE ma so vecum SoM 5 WN 8 86 0 ez Sem 9 ac 79 Tee 092 reg se m 962 WN voz 82 4 80 122 ee svscew 0134 3311253 H 6 8 50 85 Lead 03097 3191 BELHAS 0 80 21 9 woen LOSEEND ii a 4219 3 11314 INNOM I MOY 09 0 3725 1235 AJEWESS 30011 dx3 2
394. r mounting bosses Figure 4 9 Removing Alternator Adapter 44 Section 4 Alternator Disassembly Reassembly TP 6349 6 07 3 Position the end bracket housing eye opposite the stator mounting bracket during reassembly See Figure 4 10 9 Rotor shaft bearing installation Use a hydraulic press bearing heater or heavy rubber mallet and a 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 Place the end bracket on the stator and use bolts to align the holes Use a rubber mallet to mount the end bracket flush with the stator 1 End bracket lifting eye 2 Stator mounting bracket 1 Stator mounting bracket hd 3 Adapter lifting eye 2 End bracket lifting eye Figure 4 10 Attaching End Bracket on Stator 4 Attach the end bracket to the stator using the original hardware Torque to specifications 5 Attach the hoist hooks to the end bracket and suspend the stator Place the adaptor on the floor and lower the stator to within 12 7 6 4 mm 1 2 1 4 in of the adapter lip See Figure 4 11 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 finish tightening the bolts Torque to specifications
395. r 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 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 gove
396. r circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Cover side Bracket circuit breaker Decal power breaker Nut hex 5mm Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Cover side Bracket circuit breaker Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Cover side Bracket circuit breaker Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A 34 Qty Part No GM14029 KA7 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 X 6304 74 GM14029 KA8 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 X 6304 75 GM14029 KA9 222908 222909 290020 324314 354518 364498 GM14298 BLK GM14300 GM15301 M934 05 50 X 6128 3 X 6304 78 GM14030 KA1 222908 222909 290020 324314 336020 354518 GM14299 BLK GM14300 X 6128 3
397. r on the glass bulb at the top of the electrolyte level the number adjacent to the pointer If the hydrometer used does not have a correction table consult Figure 3 14 TP 6161 1 08 Determine the specific gravity and electrolyte temperature ofthe battery cells Locate the temperature in Figure 3 14 and correct the specific gravity by the amount shown battery is fully charged if the specific gravity is 1 260 at an electrolyte temperature of 26 7 C 80 F Maintain the specific gravities between cells within 0 01 of each other Charge the battery if the specific gravity is below 1 215 at an electrolyte temperature of 26 7 C 80 F Example No 1 Temperature below 26 7 C 80 F Hydrometer Reading 1 250 Acid Temperature 6 7 C 20 F Subtract 024 Specific Gravity Corrected Specific Gravity is 1 226 1 250 024 1 226 Example No 2 Temperature above 26 7 C 80 F Hydrometer Reading 1 235 Acid Temperature 37 8 C 100 F Add 008 Specific Gravity Corrected Specific Gravity is 1 243 1 235 008 1 243 The temperature correction amounts to about 004 4 points of specific gravity for each 5 5 C 10 F change in temperature 1 787 Figure 3 14 Specific Gravity Temperature Correction Section 3 Scheduled Maintenance 33 Note Some battery testers have four or five beads in a test tube Draw electrolyte into the tube as with the battery hydrometer described in this section Use the tester
398. r set after completing the voltage 5 Setthe phase selector switch to the L1 L2 position adjustment Replace the controller cover 1 phase or 3 depending on generator set connection Connect a voltmeter across leads L1 and L2 if the controller has no meters 46 Section 5 Generator Set Reconnection TP 6161 1 08 6 1 Accessories Several electrical accessories controls help finalize installation add convenience to operation and service and establish state andlocal code compliance Accessories vary with each generator set model and controller Select factory installed and or shipped loose accessories Kit and installation instruction part numbers change Obtain the most current accessory information from your local authorized service distributor dealer This section illustrates several accessories available at the time of print of this publication Accessory kits generally include installation instructions See the wiring diagrams manual for electrical connections not shown in this section See the installation instructions and drawings supplied with the kit for information on the kit mounting location The instructions provided with the accessory kit supersede these instructions where there are differences general run and DC wiring in separate conduit Use shielded cable for all analog inputs Observe all applicable national state and local electrical codes during accessory installation Note The acc
399. rator setas 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 TP 6161 1 08 Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Reconnect the generator set stator leads to change the output phase or voltage Refer to the following procedure and the connection schematics shown in Figure 5 1 Figure 5 2 Figure 5 3 and Figure 5 4 Follow the safety precautions at the front of this manual and in the text and observe National Electrical Code NEC guidelines Voltage Reconnection Procedure 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the generator set engine starting battery negative lead first Disconnect power to the battery charger if equipped
400. rcuit breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Cover side Bus line Insulation CB Decal power breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Bus line Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Breaker circuit 200 A 600 V 3 pole Qty P GO AM CO S CO Ny h AHH gt P Ai Part 334078 222908 222909 222910 324313 354518 360970 BLK 365606 365627 GM15301 X 6086 6 X 6128 3 X 6304 103 X 6308 2 334079 222908 222909 222910 290020 324313 336020 352326 BLK 354518 364511 GM10168 GM10169 X 6086 6 X 6128 3 X 6306 124 334080 222908 222909 222910 324313 354518 360970 BLK 365606 365627 GM15301 X 6086 6 X 6128 3 X 6304 108 X 6308 2 334081 222908 222909 222910 290020 324313 336020 352326 BLK 354518 364511 GM10168 GM10169 X 6086 6 X 6128 3 X 6306 124 334082 22299
401. rcuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Bracket circuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Bracket circuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bus load Tag ground Bracket circuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Screw pan head machine Qty Part 334781 222908 222909 324313 354518 364484 364496 364509 365627 6086 6 6128 3 6304 101 6308 2 334782 222908 222909 324313 354518 364484 364496 364509 365627 6086 6 6128 3 6304 103 6308 2 334783 222908 222909 324313 354518 364484 364496 364
402. reaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Qty 2232p a J N sch lt lt Ny x P sch Ny 2 Part 334801 222908 222909 290020 324313 336020 354518 364484 6086 6 6128 3 6306 97 334802 222908 222909 290020 324313 336020 354518 364484 6086 6 6128 3 6306 99 334803 222908 222909 290020 324313 336020 354518 364484 6086 6 6128 3 6306 100 334804 222908 222909 290020 324313 336020 354518 364484 6086 6 6128 3 6306 102 334805 222908 222909 290020 324313 336020 354518 364484 6086 6 6128 3 6306 103 334806 222908 222909 290020 324313
403. rer s instructions Section 4 Alternator Disassembly Reassembly 39 6349 4 Screw Elastic stop nut Stator Exciter field winding Elastic stop nut Adapter End bracket Varistor Ball bearing Magnetic actuator Rotating rectifier assembly cover Rotor Speed sensor Screw Alternator fan Screw Plain washer Plain washer Screw Screw Screw Rotating rectifier assembly hub Screw Drive discs 2 Screw Plain washer Hardened washer Nut Terminal Screw Diode assembly plates 2 pieces red and blue Equipment ground decal ZDON AWN Figure 4 1 4PW 4QW Alternator Components 20 60 kW 40 Section 4 Alternator Disassembly Reassembly TP 6349 6 07 Screw Exciter field assembly End bracket Magnetic actuator Speed sensor Screw Screw Rotating rectifier assembly hub Screw Nut Diode assembly plates 2 pieces red and blue Elastic stop nut Elastic stop nut ONDAN Figure 4 2 4SW 4VW and 4UAW Alternator Components 60 kW IMS 300 kW TP 6349 6 07 Varistor Rotating rectifier assembly cover Screw Plain washer Screw Screw Plain washer Terminal Equipment ground decal Stator Adapter Ball bearing Rotor TP 6349 4 Alternator fan Plain washer Screw Drive discs with 4SW AVW and 4 with 4UAW Hardened washer Screw Screw Plain washer Nut Terminal
404. rnor gallons per hour gallons per minute grade gross equipment ground gross weight HxW xD height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext IO 5 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 57 kilo 1000 kelvin kA kiloampere KB kilobyte 219 bytes KBus Kohler communication protocol kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechani
405. rt main bus Bracket upper support Bracket lower support Bracket support Channel insulating Insulator lug Lead Tag ground Bus assembly Washer plain 391 ID x 875 in OD Washer plain 193 ID x 5 in OD Screw self threading Screw hex washer head drill Nut hex 3 8 16 zinc Bus Bar 20 60 kW Deutz Bracket upper support Bracket support LS Bracket support RS Bus Tag ground Insulator lug Washer plain 203 ID x 75 in OD Washer plain 193 ID x 5 in OD Bus Bar 60 100 kW 4S Bracket upper support Bracket upper support Insulator panel Bracket support LS Bracket support RS Bus Insulator lug Tag ground Washer plain 281 ID x 625 in OD Washer plain 266 ID x 1 in OD Washer plain 193 ID x 5 in OD Washer spring 39 ID x 81 in OD 42 Qty Part No C2 ADAH P A OD DOR S Ro wae Cre seti 222967 222963 222964 233269 275454 275455 275456 275598 354518 X 25 68 X 25 92 222968 222963 222965 233269 274432 274434 274741 275453 275598 354518 X 25 92 222970 274659 274660 274661 336008 336009 336010 336011 354518 336007 25 18 25 92 67 107 794 2 83 7 GM10154 KA1 222962 275457 275458 275459 354518 GM10218 X 25 45 X 25 92 GM10156 KA1 222963 222964 233269 275454 275455 275456 275598 354518 X 25 68 X 25 73 X 25 92 X 6086 6 cO OQ NN O
406. s 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 TP 6349 6 07 Table of Contents Safety Precautions and Instructions 5 Introd cti n Er HET 11 List of Related Materials 11 Service Assistance ouo aps dE Saiwa ua ENS 12 Section 1 Specifications 13 It hee ee hamid os 13 1 2 Wound Field Alternator 13 1 3 Specifications Resistance Values 14 1 4 Specifications Electrical Values 15 1 5 Specifications Torque Values 15 1 6 Alternator Adapter to Flywheel Housing Torque Values 16 1 7
407. s List Qty h b i hc A Part 334747 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 75 334748 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 78 334749 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 79 334750 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 82 334751 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 83 23 Kit Parts List Description Line Circuit Breaker Breaker circuit 80 A 480 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 80 A 480 V 4 pole Line Circuit Breaker Breaker circuit 90 A 480 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit with shunt trip Line Circuit Breaker Breaker circuit 100 A 480 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 100 A 480 V 4
408. s over the studs if equipped to separate the alternator from the engine See Figure 4 5 3 093 1 Drive disc removal R8348 22 2 End bracket support Figure 4 6 Alternator Support Drive Discs and Fan 1 Drive discs Removal Figure 4 5 Separating Generator and Engine 15 Usea stud remover and remove the studs from the flywheel if damaged 16 Set the alternator assembly on the floor in a horizontal position Remove the support slings or chains 17 To remove the rotor assembly attach the hoist hook to the adapter and lift the alternator assembly to avertical position See Figure 4 6 Place boards along the edge of the end bracket to prevent damage to the rotating rectifier assembly hub and magnetic actuator Lower the rotor assembly 18 Remove the drive discs and fan from the alternator assembly See Figure 4 6 19 Fasten the lifting eye and hoist hook to the rotor flange Hoist the rotor carefully to avoid damaging the exciter armature or exciter field winding See Figure 4 7 1 Hoist hook locations Figure 4 7 Rotor Removal TP 6349 6 07 Section 4 Alternator Disassembly Reassembly 43 20 Place a pallet or other wooden surface under the rotor and slowly lower the rotor to a horizontal position Take care not to damage the windings laminations or bearing See Figure 4 8 21 Make note of the bearing location dimensions from the rotor shaft end for re
409. s pan head machine Breaker circuit with shunt trip Line Circuit Breaker Breaker circuit 100 A 480 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Cover side Screw cross recess pan head machine Breaker circuit 100 A 480 V 4 pole Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex 4mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex 4mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Nut hex 4mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 22 Qty P A P apa P Part 334728 253225 364489 49 2 334729 364490 49 2 6250 4 334730 344905 364489 49 2 334731 364490 49 2 6250 16 334732 253226 364489 49 2 334733 364490 49 2 6250 5 334734 222908 222909 290020 324314 354518 364484 364491
410. sealed carburetors that are not adjustable TP 6161 1 08 Gasoline Carburetor Adjustment Refer to the engine operation manual or engine service manual for gasoline carburetor adjustment information Gaseous Carburetor Fuel Mixer Adjustment Procedure Use the following procedure to adjust the carburetor fuel mixer 1 Start the generator set and run it at approximately half load 2 Adjust the engine fuel mixture screw Figure 3 6 until the engine runs smoothly 3 Apply varying loads and readjust the carburetor as necessary to achieve smooth engine performance at all load levels 4 Stop the generator set 1 Fuel adjusting screw 2 Lean 3 Rich Figure 3 6 Fuel Mixture Adjustment Typical 3 6 6 Fuel System Maintenance Gasoline Models Clean or replace the fuel filter at the specified interval Service the filters more frequently if the engine runs roughly as a clogged fuel filter can cause rough engine operation Some models use a disposable inline fuel filter which must be replaced Other models have a fuel pump with an integral fuel filter that requires cleaning at the specified interval Gaseous Models This fuel system requires no regular maintenance Section 3 Scheduled Maintenance 27 3 7 Cooling System The cooling system maintenance information applies to radiator cooled models and city water cooled heat exchanger models cooling systems function similarly even though they use differe
411. service connect Guard generator Decal electrical equipment 2 25 x 2 8 Screw hex head machine special thread Washer lock 391 ID x 681 in OD Plug button Conduit convoluted Nut flange spiralock 3 8 16 Qty Part No 273742 1 239776 1 239789 1 255798 1 255882 1 274597 1 343292 4 352415 4 22 10 1 6003 17 347233 1 239776 1 239789 1 255798 1 255882 4 273738 1 343292 1 347232 4 22 4 1 6003 17 347741 239776 239789 255798 255882 273738 343292 347237 347412 22 4 301 24 6003 17 6003 87 794 2 GM19978 KA1 239776 239789 255798 255882 273736 274596 343292 X 22 10 X 301 24 X 6003 17 X 6210 9 GM19978 KA2 239776 239789 255798 255882 274597 343292 352415 X 22 10 X 301 24 X 6003 17 X 6210 9 hao BS sch sch Jr echt sch ech ech Mi Ah Phi A P ch Sch scht Sch ech cb ch zech 6116 2 02 Description Qty CSA Approval Decal caution 1 Decal notice 1 Tag instruction 1 Decal caution standby service connect 1 Screw hex head machine special thread 4 Decal electrical equipment 2 25 x 2 8 1 Guard generator CSA 1 Washer lock 521 ID x 884 in OD 4 Plug button 1 Conduit convoluted 1 Nut flange spiralock 1 2 13 4 Droop Compensator Kits Reactive Reactive Droop Compensator Transformer curr 300 5 round Nameplate engraved rheostat Rheostat includes rheo and knob Screw slotted roun
412. sistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 6349 6 07 Section 1 Specifications 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 wound field alternator is identified with a W as the last digit Example Gen Model 4S11W 1 2 Wound Field Alternator Concept The alternator is a 4 pole rotating field unit with a brushless wound field WF excitation system The generator set excitation system uses a wound exciter field and a three phase exciter armature The rotating rectifier assembly RRA is rated for over five times full load vol
413. stop switch If equipped move the audiovisual annunciator alarm switch to NORMAL 8 Move the controller alarm horn switch to the NORMAL position 2 4 Expanded Decision Maker 1 Controller 2 4 1 Generator Set Starting Local Starting Move the generator set to the RUN position to immediately start the generator set Automatic Starting Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or the remote start stop switch connected to controller terminals TB1 3 and TB1 4 Note The controller allows up to 30 seconds of continuous cranking before overcrank shutdown occurs Note The engine ECM may limit the crank cycle even if the controller is set to a longer time period 2 4 2 Generator Set Stopping Local Stopping 1 Run the generator set at no load for 5 minutes to ensure adequate engine cooldown 2 Move the generator set master switch to the OFF RESET position The engine stops Automatic Stopping 1 The automatic transfer switch ATS or other device disconnects the load from the generator set 2 The generator set continues to run for a presettime if the ATS is equipped with an engine cooldown time delay 3 The ATS opens the connection between controller terminals TB1 3 and TB1 4 The generator set shuts down if the generator set master switch is in the AUTO position 2 4 3 Fault Shutdowns The generator set shuts down automatically under the fault cond
414. t Breaker 225 A W 24 V S T GM12345 KA3 Bracket circuit breaker 1 222999 Insulator 2 290020 Cover side 1 GM12332 BLK Decal power breaker 1 GM15301 Nut hex 5mm 4 M934 05 50 Breaker circuit 1 X 6304 81 Line Circuit Breaker 250 A GM12345 KA4 Bracket circuit breaker 1 222999 Insulator 2 290020 Cover side 1 GM12332 BLK Decal power breaker 1 GM15301 Nut hex 5mm 4 M934 05 50 Breaker circuit 1 X 6304 85 30 Description Qty Part No Line Circuit Breaker 250 A W 12 V S T GM12345 KA5 Bracket circuit breaker 1 222999 Insulator 2 290020 Cover side 1 GM12332 BLK Nut hex 5mm 4 M934 05 50 Breaker circuit 1 X 6304 86 Line Circuit Breaker 250 A W 24 V S T GM12345 KA6 Bracket circuit breaker 1 222999 Insulator 2 290020 Cover side 1 GM12332 BLK Nut hex 5mm 4 M934 05 50 Breaker circuit 1 X 6304 87 Line Circuit Breaker 300 A GM12379 KA1 Bracket circuit breaker 1 222999 Insulator 2 290020 Cover side 1 GM12333 BLK Bus line 3 GM12335 Decal power breaker 1 GM15301 Washer plain 406 ID x 1 in OD 9 X 25 118 Washer spring 39 ID x 81 in OD 6 X 6086 6 Breaker circuit 1 X 6304 88 Screw slotted pan head machine 4 X 6308 1 Nut hex 3 8 16 zinc 3 X 83 7 Line Circuit Breaker 350 A GM12379 KA2 Bracket circuit breaker 1 222999 Insulator 2 290020 Cover side 1 GM12333 BLK Bus line 3 GM12335 Decal power breaker 1 GM15301 Washer plain 406 ID x 1 in OD 9 X 25 118 Washer spring 39 ID x 81 in OD 6 X 6086 6
415. t O M Cooling water pump inoperative Tighten or replace the belt Replace the water pump Eng O M or S M High temperature shutdown Allow the engine to cool down Then troubleshoot the cooling system Generator set O M Eng O M Low coolant level shutdown if equipped Restore the coolant to normal operating level Generator set O M Thermostat inoperative Replace the thermostat Eng S M Sec Section numbered section of this manual ATS Automatic Transfer Switch Eng Engine Gen Generator Set I M Installation Manual O M Operation Manual S M Service Manual 20 9 6vE9 dL S S Spec Sheet W D Wiring Diagram Manual Have an authorized service distributor dealer perform this service If the unit has 550 controller refer to the 550 controller operation manual for voltage regulator settings Go to Menu 20 Factory Setup and verify that the application software code version is correct for the generator set model and alternator voltage 20 9 6v 9 dl LG Bumoous lqnoil uonoes Trouble Symptoms Section Publication Probable Causes Recommended Actions Reference Excessive or abnormal noise does not start Starts hard Does not crank Cranks but No or low output voltage Lacks power Overheats pressure High fuel consumption Electrical System Battery connections loose corroded or Verify that th
416. t breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 90 100 A TP 6116 2 02 Qty Ny P 2242p P h Ny 4 Part 334786 222908 222909 324313 354518 364484 364496 364509 365627 6086 6 6128 3 6304 111 6308 2 334787 222908 222909 324313 354518 364484 364496 364509 365627 6086 6 6128 3 6304 112 6308 2 334788 222908 222909 290020 324314 336020 354518 364484 364497 6086 6 6128 3 6306 93 334789 222908 222909 290020 324314 336020 354518 364484 364497 6086 6 6128 3 6306 94 334790 222908 222909 290020 324314 336020 354518 364484 364497 6086 6 6128 3 6306 96 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 1 5 in Breaker circuit 90 100 A Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Tag ground Bracket circuit breaker Cover side Washer spring 39 ID x 81 in OD Standoff insulator 1
417. t breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Qty P ROAM Aa P y A bb Ahh hh A N A Part 334737 222908 222909 290020 324314 354518 364484 364491 934 04 50 6086 6 6128 3 6304 55 334738 222908 222909 290020 324314 354518 364484 364491 934 04 50 6086 6 6128 3 6304 57 334739 222908 222909 290020 324314 354518 364484 364491 934 04 50 6086 6 6128 3 6304 58 334740 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 61 334741 222908 222909 290020 324314 354518 364484 364491 364498 934 05 50 6086 6 6128 3 6304 62 6116 2 02 Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circu
418. tage and three times full load current with added surge protection See Figure 1 1 The 0 25 average voltage regulator is powered by a stator auxiliary winding providing an independent power source for the exciter field In addition a rare earth permanent magnet is embedded in the exciter field for positive voltage buildup during startup The voltage regulator has volt Hz stability and voltage adjustments WF alternator sets offer the following advantages e Very good recovery characteristics because the auxiliary power for the voltage regulator comes from an independent stator winding that actually boosts the alternator s output during heavy loads Rotor main field Main alternator Stator auxiliary winding Stator main windings Exciter field winding Exciter armature Exciter alternator Rotating rectifier assembly RRA and surge suppressor varistor Voltage regulator Engine starting battery Safeguard circuit breaker optional e The inherent ability to support short circuit current allowing system coordination for tripping downstream branch circuit breakers gt e For the duration of a short circuit in the load 5 the output voltage drops and the amperage momentarily rises to 60096 1000 of the generator set s rated current Figure 1 1 WF Alternator
419. ter armature good if the resistance reading continuity is low and there is no evidence of a shorted winding heat discoloration 4 Check the exciter armature for a short to ground condition Use a megohmmeter to apply 500 volts DC to either armature lead and the armature frame Follow the megohmmeter manufacturer s instructions for using the megohmmeter See Figure 3 12 A reading of approximately 500 kOhms 1 2 megohm and higher indicates the exciter armature is good A reading of less than approximately 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground Replace the exciter armature 6349 3 5 Ground to armature frame Rotor main field Stator main windings Rotating rectifier assembly 6 Exciter armature RRA 7 Exciter field winding Megohmmeter Figure 3 12 Megohmmeter Connections on Exciter Armature 3 7 Rotating Rectifier Assembly RRA Varistor The RRA converts the AC from the exciter armature to DC which magnetizes the main field windings Test the RRA as described in the following steps The RRA consists of two diode assembly plates and varistor attached to the diode assembly hub The diode assembly plates are available only as a set when ordering service parts 32 Section 3 Alternator Troubleshooting Rotating Rectifier Assembly RRA Test Procedure 1 Disconnect the exciter armature and the
420. tes the stator is good A reading of less than 500 kOhms indicates deterioration of the stator winding insulation and possible current flow to ground Repair or replace the stator 3 10 Speed Sensor Test Follow the procedure outlined below to determine if the speed sensor overspeed fault is emitting a signal 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 the test leads Do not disconnect the speed sensor leads 1 Move the generator set master switch to the OFF RESET position 2 Connect a DC voltmeter between positive lead wire 24 at speed sensor and ground wire 2 The voltmeter should indicate approximately 8 10 volts DC 3 Move the generator set master switch to the RUN position to start the generator set Rotor main field Sensing leads 208 240 volts nominal Stator main windings Voltage regulator power supply leads Ground to stator frame Megohmmeter Rotating rectifier assembly RRA Exciter armature Exciter field winding Figure 3 21 Megohmmeter Connections on Stator Single Phase TP 6349 6 07 With generator set running connect the DC voltmeter negative probe to the O terminal wire 16 white on the speed sensor Place the voltmeter positive probe on positive terminal wire 24 red The voltmeter s
421. th Washer Lock or Elastic Grade 5 Flat Head FHM Square Grade 8 Grade 8 9 Hex Socket Head Metric Round Head RHM Cap or Acorn Pan Head Wing Number stamped on Hex Socket Head Cap or Washers hardware 5 8 shown Allen Head Cap Washer Styles Hex Socket Head or Allen Head Shoulder Bolt Plain Sheet Metal Screw Split Lock or Spring Stud Spring or Wave Drive Styles External Tooth Lock Hex Internal Tooth Lock Hex and Slotted Internal External Tooth Lock Phillips Slotted Hex Socket Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company Sample Dimensions American Standard Screws Bolts Studs and Nuts Plain Washers 1 4 20 x 1 L Length In Inches Screws and Bolts Thickness Threads Per Inch External Dimension Major Thread Diameter In Fractional Inches Or Screw Number Size Internal Dimension Metric Screws Bolts Studs and Nuts M8 1 25 x 20 Lock Washers Length In Millimeters Screws and Bolts 5 8 Distance Between Threads In Millimeters NEN Internal Dimension Major Thread Diameter In Millimeters TP 6141 12 03 Appendix 1 Appendix B Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Dimensions Hex Head Bolts Grade 5 X 465 1
422. the KOHLERnet and click on Tech Tools button to find the following topics Software used by generator set controllers including updates and documentation references Service Assistance e Network Communications provides basics to terms protocols standards wiring configurations and model e Engine Electronic Contro Module ECM has information about electronic devices provided by the engine manufacturer to manage engine data For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler KohlerPower com Power Systems website at Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 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 10 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 Offic
423. tor Decal power breaker Washer plain 203 ID x 75 in OD Screw slotted pan head machine Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insulator Bus line Decal power breaker Washer spring 39 ID x 81 in OD Breaker circuit Screw slotted pan head machine Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Qty G N 02 02 O WWW P P G N G 02 02 Part No 334128 222996 BLK 222998 290020 336020 365608 X 6086 6 X 6306 137 334129 222995 BLK 222999 290020 GM15301 X 25 45 X 50 41 X 6304 87 334130 290020 336020 352323 352324 BLK GM10411 GM10412 M912 08025 60 X 6086 6 X 6306 119 334131 222996 BLK 222999 2
424. tor 1 4 20 x 1 5 in Breaker circuit Qty CO Ph h i Ph aa NNa fa P a sch lt lt Ny P Sk ss Part 334151 222999 360973 365608 365627 GM15301 X 6086 6 X 6304 108 334358 222974 BLK 258381 GM15301 X 49 2 334359 222976 BLK X 49 2 X 6250 8 334453 222908 222909 222910 290020 324314 336020 352293 BLK 354518 X 6086 6 X 6128 3 X 6306 99 334454 222908 222909 222910 290020 324314 336020 352293 BLK 354518 X 6086 6 X 6128 3 X 6306 100 334455 222908 222909 222910 290020 324314 336020 352293 BLK 354518 X 6086 6 X 6128 3 X 6306 102 334456 222908 222909 222910 290020 324314 336020 352293 BLK 354518 X 6086 6 X 6128 3 X 6306 103 19 Kit Parts List Description Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circ
425. trip terminal Ammeter 0 15 A DC Voltmeter 0 25 V DC Module SCR Fuse 7 A 250 V Harness wiring 12 24 V float chargers Marker strip Marker strip Retainer Block terminal Nut captive 6 32 Box battery charger Door silkscreen Nameplate battery charger PCB assembly battery charger alarm PCB assembly battery charger control Charger assembly Charger battery automatic Washer lock 262 ID x 743 in OD Washer lock 172 ID x 595 in OD Washer lock 146 ID x 53 in OD Washer lock 146 ID x 285 in OD Screw slotted pan head machine Screw slotted pan head machine Screw slotted pan head machine Screw cross recess pan head machine Screw slotted pan head machine Screw slotted pan head machine Screw cross recess round machine Screw cross recess pan head machine Screw slotted pan head machine Screw cross recess machine Screw Phillips hex crimptite Nut hex machine screw 6 32 Qty N lt lt P Mi 4 4 4 4 4 sch sch Ny Part PAD 292863 233966 239298 241605 257442 262389 262394 262397 262399 263156 287948 291208 292387 292940 292941 292942 292945 292948 292958 292961 292962 295010 295314 298810 325593 SD 325596 325609 B 262374 C 262377 D 292863 TT 680 X 22 12 X 22 18 X 22 25 X 22 6 X 49 25 X 49 26 X 49 39 X 49 6 X 50 1 X 50 3 X 51 11 51 15 51 30 51 9 6216 1
426. tted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 225 A 600 V 3 pole Line Circuit Breaker Breaker circuit 30 A 600 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Breaker circuit 40 A 600 V 3 pole Cover side Screw cross recess pan head machine Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Washer plain 203 ID x 75 in OD Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 200 A 600 V 3 pole Qty E EP PA A A A pa a pa a E EP PA A Ny Ny A A Part No 334812 222908 222909 290020 324313 336020 354518 364484 364511 X 6086 6 X 6128 3 X 6306 124 334813 222908 222909 290020 324313 336020 354518 364484 364511 X 6086 6 X 6128 3 X 6306 125 335052 222908 222909 222910 290020 324314 354518 GM10527 SD X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 15 360486 269250 360440 BLK X 49 2 360598 269252 360440 BLK X 49 2 360755 222908 222909 222910 290020 324313 354518 GM10528 BLK X 25 45 X 50 41 X 6086 6 X 6128 3 X 6304 13 29 Kit Parts List Description Qty Part No Line Circuit Breaker GM12342 KA1 Bracket circuit breaker 1 222908 Bracket circuit breaker 1 2
427. uaurepide1 esiejeui un eAno4de auuosied eun 15 sanbelpseo ep 5u s 1d no Sep op seule 591 suep inejoumnxe ep enbnejeufBis enbejd e ins enb snjd soi seoedsa sep suep 5961 Sed LLZL uojeH ai 19 eu1e2uoo jueuiedinbe _ ISsne med H Stew 159 in jounx juebe no un suep oouessieu zueu sd sei ins 296 anbiwiyo un 169 zenbiunuuioo enbis ud jiojuooutp JeiueJd ny 460 soon 591 1004 sjuejuu jueAned y ldind gt 2eoujounxe e no synpojd sujeoje no 98y s pe spnpoid s sipu senbixoj sed juos eu soes seq eipueouip 522 ue AOA je uolss id eun 1eujenue jned eyed is np eDjeuoep eun unejounxe sed 29159 N ep ne sijduue juos sJnejounxe sag 3NO8MVO Y 13 X 35510 V 12
428. udio Visual 3 Battery Charger Kits 4 Battery Heater 2 4 2 2 41 2 6 Battery Kits Starting 6 Blanket Kits Exhaust Manifold 7 Breaker Kits Circuit in NEMA 1 7 Breaker Kits Line 7 Breaker Safeguard Circuit Kits 41 Bus Bar las 41 Bus L g 42 Bushing Adapter for Silencer 43 Cable Computer 43 Cables For Remote Controller 43 Cap 44 Charging Prime Power 44 Communications Kits eee 44 Connection Kit Terminal 45 Connector Kits Flexible Exhaust 45 Gontact Kit eet etait es 45 Contact Kit Dry 10 Relay 45 Control Module Day 46 Converter Kits Decision Maker 340 48 Cover Radiator Cap 48 CSA For Reconnectible Generators Kits 48 Droop Compensator Kits Reactive 49 Emergency St
429. uejsip ej xoeq pues 7 yeas eui 5 y nd pue 1u6udn jeusinBunxe eui pio seoueijsip Bunuejs pue seunpeooud oyioeds peynsuoo eq jsnu ejejdeueu sieusiBunxe eous ou Burzeenbs pue ay ajesado sususinBuyxe ejqeuod puey jo senbiuuoe 21524 eui Jesn out pepuejul einjeu jo 0 941 310 ISN 01 Een y y j o eg slguoiss jojd Aq eq pinous eBue V su ui pue ayejdaweu uo suononuisut eui o Ausdod 1eusinBunxe nok asp euoud Alana eq pinoys euoud 99 Sly 39v pyoinb jews pews eq 0 5 H ue e e9 Z BUOAIAAS auld 10 8572 NI eui uo pajejs BU S 1UBI A eu eui jeusinBunxe y yam pezunsseud si y JJ Be N3339 ui eq s amp ew e Pinoys eJnjejeduie oj enp Aea eu paxoeuo eq
430. uel 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 cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when draining the fuel system Wipe up spilled fuel after draining the system 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 90psi 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 TP 6161 1 08 Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the gen
431. uired CD39157 See Group 8a PartNo Description 1 1 223652 Screw 1 2 336447 Washer thrust 1 3 223432 Gear 1 4 223606 Bushing 1 5 224186 1 6 336446 Washer thrust 1 34 TP 6141 12 03 Group 39a Cylinder Head Gasket Set Code 9932 Qty Var Item Part No Description 1 9706 1 GM21482 Gasket kit Group 39b Overhaul Gasket Set Qty Var Part Description 9932 9706 1 21483 Gasket kit TERIS 35 TP 6141 12 08 Group 42 Short Block CD40908 Part No Description GM32736 1 GM21484 Short block assembly Short block assembly 9702 9910 1 E TP 6141 12 03 Group 50 Turbocharger amp Oil Lines a qui l Trap due qe V 2 CD37609 Var PartNo Description 6547 65BS 1 336477 Fitting tee 1 1 2 223457 Fitting 1 1 3 336721 Clamp 1 1 4 GM21485 Hose hydraulic 1 1 5 GM21486 Gasket 1 1 6 GM21487 Turbocharger 1 6 GM21488 Turbocharger 7 Washer lock 8 100 mm 8 Screw cap 5 16 in x 7 8 in 9 GM21489 Clamp 10 GM21490 Line oil 11 GM21409 Clamp 12 GM21491 Hose 13 336475 Clamp 14 GM21492 Fitting hose EE sch ch ch lt lt sch ch sch lt P P 15 Screw 3 8 7 8 16 Washer 10 5 18 1 6 mm 17 GMS32737
432. uit Marker wire Marker wire Marker wire Nut hex 5 16 18 Line Circuit Breaker 350 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Washer plain 406 ID x 1 in OD Washer plain 344 ID x 875 in OD Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Marker wire Marker wire Marker wire Nut hex 5 16 18 Kit Parts List Qty Part No GM17679 KA9 222909 290020 324313 354518 364498 GM15301 GM17634 GM17638 BLK M934 05 50 X 25 75 X 6086 6 X 6128 3 X 6304 78 X 750 14 X 750 15 X 750 16 X 82 6 GM17680 KA1 222908 222909 290020 324313 354518 364508 GM15301 GM15301 GM17634 GM17639 BLK X 25 118 X 25 75 X 6086 6 X 6128 3 X 6304 88 X 750 14 X 750 15 X 750 16 X 82 6 GM17680 KA2 222908 222909 290020 324313 354518 364508 GM15301 GM17634 GM17639 BLK X 25 118 X 25 75 X 6086 6 X 6128 3 X 6304 92 X 750 14 X 750 15 X 750 16 X 82 6 gt ONWANDAABwOAAHYHA N N3 A VP OO Mi G3 37 Kit Parts List Description Line Circuit Breaker 400 A Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bus line Decal power breaker Bracket circuit breaker Cover side Washer plain 406 ID x 1 in OD Washer plain 344
433. uit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Bus line Screw socket head cap Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag hang Cover side Tag ground Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 125 A 20 Qty vk pnp N P CO N P CO CO N N h i lt ch Part No 334457 222908 222909 222910 290020 324314 336020 352293 BLK 354518 364510 M912 08025 60 X 6086 6 X 6128 3 X 6306 111 334458 222908 222909 222910 290020 324314 336020 352293 BLK 354518 364510 M912 08025 60 X 6086 6 X 6128 3 X 6306 112 334459 222908 222909 222910 290020 324314 336020 352293 BLK 354518 364510 M912 08025 60 X 6086 6 X 6128 3 X 6306 117 334460 222908 222909 222910 290020 324314 336020 352293 BLK 354518
434. ulator Bus load Tag ground Cover side Decal power breaker Washer plain 203 ID x 75 in OD Terminal fast on male 2 AWG Screw cross recess pan head machine Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit 150 A 240 V 3 pole Qty N gt CH Ny k 5 M gt gt A Ab Se EN N A bh hh NNa Part 334008 222908 222909 222910 222949 BLK 290020 324313 354518 360763 GM15301 X 6086 6 X 6128 3 X 6304 6 X 6308 1 334009 222908 222909 222910 222950 BLK 290020 324313 354518 360763 GM15301 X 6086 6 X 6128 3 X 6304 6 X 6308 1 334011 222974 BLK 269252 GM15301 X 49 2 334012 222974 BLK 253224 GM15301 X 49 2 334013 222974 BLK 253225 GM15301 X 49 2 334014 222974 BLK 253226 GM15301 X 49 2 334015 222908 222909 222910 290020 324314 354518 GM10527 BLK GM15301 X 25 45 X 251 17 X 51 45 X 51 47 X 6086 6 X 6128 3 X 6304 1 TP 6116 2 02 Description Line Bracket circuit breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Cover side Decal power breaker Screw slotted pan head machine Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit bre
435. unciator alarm switch to SILENCE to stop the alarm horn The audiovisual annunciator lamp stays lit 2 Disconnect the generator set from the load by using the line circuit breaker or the automatic transfer switch TP 6161 1 08 High engine The high engine temperature shutdown shuts temperature down the unit 5 seconds after a fault The shutdown does not function during the first 30 seconds following startup Note The high temperature shutdown functions only when the coolant level is in the operating range Low coolant The low coolant level shutdown shuts down the level unit 5 seconds after the fault The shutdown if equipped does not function during the first 30 seconds following startup Low oil The low oil pressure shutdown shuts down the pressure unit 5 seconds after fault detection The shutdown does not function during the first 30 seconds following startup Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Overcrank shuts down the unit after 45 seconds of continuous cranking Shutdown occurs after 75 seconds of cyclic cranking crank 15 seconds reset 15 seconds crank 15 seconds etc for a total of 75 seconds Shutdown occurs after 15 seconds if the engine or starter does not turn locked rotor Note The controller has an automatic restart function The generator set attempts to restart if the engine speed drops below 390 rpm output freque
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437. ure 4 Place the battery in a cool dry location 5 Connect the battery to a float equalize battery charger or charge it monthly with a trickle battery charger Refer to the battery charger manufacturer s recommendations Maintain a full charge to extend battery life TP 6161 1 08 This section contains generator set troubleshooting diagnostic and repair information 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 list of common problems possible causes of the problem recommended corrective actions and references to detailed information or repair procedures TP 6161 1 08 Section 4 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 4 Troubleshooting 37 p 86 1919 41 80 1 Trouble Symptoms Does but does start Starts hard Controller No or low output voltage Stops suddenly Lacks power Overheats pressure High fuel consumption Excessive or abnormal noise Probable Causes Recommended Actions Sectio
438. us line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Nut hex 5mm Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Line Circuit Breaker Bracket circuit breaker Bracket circuit breaker Insulator Bus load Tag ground Bracket circuit breaker Cover side Bus line Washer spring 39 ID x 81 in OD Standoff insulator 1 4 20 x 1 5 in Breaker circuit Kit Parts List Qty Mi k Mi a P RO Ny ch G3 Ny Ny A P P k Ny A Sos earns E Part 334771 222908 222909 290020 324313 354518 364484 364494 364498 934 05 50 6086 6 6128 3
439. ustthe voltage adjustment control located at the generator set controller until the desired output voltage is achieved 30 Section 3 Alternator Troubleshooting 7 If the engine has a speed adjustment governor adjust the engine speed to the specified cut in frequency as measured on the frequency meter The factory setting is 57 5 58 Hz for 60 Hz models and 47 5 48 Hz for 50 Hz models Note Some engines do not permit engine speed adjustment 8 Rotate the volts Hz potentiometer clockwise until the voltage level as measured on the voltmeter begins to drop When the regulator is set to these specifications the alternator will attempt to maintain normal output until the engine speed drops below the frequency set in step 7 as load is applied 9 Readjust the engine speed to 1800 rpm for 60 Hz models or1500 rpm for 50 Hz models 10 Readjust the voltage adjustment control located at the generator set controller until the desired output is achieved 11 Readjust the stability potentiometer until light flicker minimizes 12 Move the generator set master switch to the OFF RESET position 3 5 Exciter Field Direct current from the battery magnetizes the exciter field winding When the exciter armature rotates within the magnetized exciter field windings an electrical current develops within the exciter armature Test the exciter field winding according to the following procedure Exciter Field Test Procedure 1 Place th
440. ver side Bus line Insulation CB Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Insulator Tag hang Bracket circuit breaker Cover side Bus line Bus line Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Bracket circuit breaker Cover side Bus line Insulation CB Washer spring 39 ID x 81 in OD Breaker circuit Kit Parts List Qty 0000 O N GO 00060 O N Q O O N G 00 O Q N 0 Part 334120 222996 222999 290020 360763 6086 6 6304 93 334121 290020 336020 352323 352325 GM10413 GM10414 X 6086 6 X 6306 121 334122 222996 BLK 222999 290020 360763 X 6086 6 X 6304 7 X 6308 1 334123 222999 360973 BLK 365608 365627 X 6086 6 X 6304 104 334124 290020 336020 352323 352325 BLK GM10413 GM10414 GM10415 X 6086 6 X 6306 125 334125 222999 360973 BLK 365608 365627 X 6086 6 X 6304 109 334126 290020 336020 352323 352325 BLK GM10413 GM10414 GM10415 X 6086 6 X 6306 125 334127 222999 360973 BLK 365608 365627 X 6086 6 X 6304 112 17 Kit Parts List Description Line Circuit Breaker Cover side Bracket circuit breaker Insulator Tag hang Bus line Washer spring 39 ID x 81 in OD Breaker circuit Line Circuit Breaker Cover side Bracket circuit breaker Insula
441. vice atthe prescribed intervals Maintenance work must be performed by appropriately skiled and suitably trained maintenance personnel familiar with generator set operation and service Abbreviations This publication makes use of numerous abbreviations Typically the word s are spelled out along with the abbreviation in parentheses when shown for the first time in a section Appendix A Abbreviations also includes many abbreviation definitions List of Related Materials Separate literature contains communication and software information for the 16 Light Controller with communications not provided in this manual Figure 1 lists the available literature part numbers Modbus is a registered trademark of Schneider Electric TP 6161 1 08 Communication and Software Manual Description 16 Light Controller Spec Sheet Literature Part No G6 30 Decision Maker 1 Controller G6 29 Spec Sheet Multiple Part Numbers Contact your Distributor Dealer Generator Set Controller Wiring Diagram Manual Modbus Communications Protocol Operation Manual TP 6113 TP 6009 TT 1285 TT 1377 TT 1310 Service Parts Controllers Program Loader Software Installation Remote Serial Annunciator RSA Controller Service Replacement Monitor IIl Converters Connections and Controller Setup Monitor Software Spec Sheet G6 76 Monitor Converter G6 79 Modbus Ethernet Spec Sheet 7 Monitor S
442. vo E2 LO 7 duo mi RS CT1 T9 IL METER SCALE r1 15 de 5 GC METER SCALE 0 JUMPER vd V9 vz o LAMP JUMPER 10 OR 12 LEAD ALTERNATOR 4 WIRE WYE 4 LEAD ALTERNATOR 4 WIRE WYE c NYE 60 HZ 220 380V 50 HZ 220 380V 60 HZ 220 380V 50 HZ 220 380V 60 HZ 2400 2160V 60 FZ 4160 7200V 60 HZ 240 416V 50 HZ 230 400V 60 HZ 240 416V 50 HZ 230 400V 50 17 1905 3300V 60 FZ 7200 12470V 60 HZ 277 480V 50 HZ 240 416V 60 HZ 277 480V 50 HZ 240 416V 50 HZ 3810 6600V 60 FZ 7620 15200 60 HZ 347 600V 60 HZ 7970 13800V P rre a 2 50 HZ 6550 11000 m RN Tg 5 ti OPTIONAL DROOP OPTIONAL 5 2 DROOP 2 T2 11 TO 2 E1 5 gt T2 b CT SV 12 TO 2 2 Q E1 1 d 17 Ts 18 ex Ta US 7 Ex Tiy 22 110 DROOP 3 PTI T5 d 2 10 112 vo Lo 0 3 T 4 vo e 25 x2 7 TO PT1 H1 LO in L1 gt V7 5 ga x E v8 T9 PT2 a L2 T3 e CT3 HI xT S 2 7 H 5 13 2 v8 S B L3 v9 vg amp t PTS 15 3 T3 E all TO 2 L3 25 3 5 2 2 1 5 15 025 va v LO vo METER SCALE 13 METER SCALE METER SCALE zE LAMP JUMPER 10 LAMP JUMPER 89 7 JUMPER 3 SINGLE PTS 3 PHASE P
443. when standing in water or on wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment 3 2 General Troubleshooting To determine the cause of no or low AC output refer to the following steps and the troubleshooting flow chart Figure 3 1 1 Check the condition of the voltage regulator 10 amp fuse located in the junction box 2 If the fuse is good separately excite the alternator see Section 3 3 The separate excitation test duplicates the role of the voltage regulator in providing the excitation current to the rotor 3 If voltage regulator failure is suspected go to Section 3 4 Wound Field Voltage Regulators TP 6349 6 07 Alternator has no output Separately excite Alternator has output alternator Test voltage regulator amp wiring Alternator has no output Exciter circuit and rectifier module Test rotor Test stator Figure 3 1 General Troubleshooting 3 3 Separate Excitation By separately exciting the alternator to determine the presence of a faulty voltage regulator it is possible to determine if a running
444. y or from a remote location The local emergency stop switch is standard on selected models Generator switch not in auto Lights when the generator set master switch is in the RUN or OFF RESET position High battery voltage Lights if the battery voltage rises above preset level An optional battery charger is required for the lamp to function Low battery voltage Lights if the battery voltage drops below a preset level This lamp requires an optional battery charger in order for the lamp to function Low fuel warning Lights if the fuel level in tank approaches empty This lamp requires a low fuel sensor in the fuel tank in order to function On gas fueled systems this lamp lights if the gas line pressure drops below a preset level Prealarm high engine temperature Lights if the engine temperature approaches the shutdown range This lamp may require an optional prealarm sender kit Prealarm low oil pressure Lights if the engine oil pressure approaches the shutdown range This lamp may require an optional prealarm sender kit in order to function System ready Lights when the generator set master switch is in the AUTO position and the system senses no faults Indicates that the generator set is ready for operation Figure 1 2 Annunciator Panel Lamps Modbus is a registered trademark of Schneider Electric 12 Section 1 Specifications and Features TP 6161 1 08 1 2 2 Auxiliary Fault Lamp

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