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Service Manual, 5ERKM (TP

1. 5 6 able of Contents afet Precautions anc nstructions 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 SAVE THESE INSTRUCTIONS This manual has several types offsatety precautions and instructions Danger Warning Caution and Notice DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6079 3 00 Accidental Starting A WARNING Jas Accid
2. fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuelto the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do notoperate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when draining the fuel system Wipe up spilled fuel after draining the system TP 6079 3 00 Hazardous Noise CAUTION
3. z K20 STARTER SOLENOID RELAY BAT ji K25 IGNITION SHUTDOWN RELAY BATTERY AC 11 4 PENES LOL LOW OIL LEVEL SWITCH CHARGING BCP P4 22 7 9 d P PLUG NC VOLTAGE M i 71A P4 4 SM STARTER MOTOR REGULATOR BATTERY SS STARTER SOLENOID GND 555 STOP START SWITCH FOR VOLT RECONNECTABLE VADSCVOETAGETDUST CONFIGURATIONS SEE GG 250000 GM11960 TP 6079 3 00 Reconnection and Wiring Diagrams 33 Notes 34 Reconnection and Wiring Diagrams TP 6079 3 00 Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB CCW CEC cfh cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only
4. i N K25 30 10 41 588 14 4 12 BCP 24 22 0 l o 14 N REMOTE GENERATOR P9 CONNECTIONS PIN EBG 2 70 CHTR 37A P4 6 P4 11 14P P4 12 10P SS 14N EBG 70 P4 13 LEGEND ADS ANTI DIESEL SOLENOID X j BCR BATTERY CHARGING REGULATOR CHTR CHOKE HEATER INSULINK 1 9 DE DIODE 33 P10 3 EBG ENGINE BLOCK GROUND 44 P10 4 d F FUSE B2 P11 2 J FP FUEL PUMP L Bt 11 1 GND CONTROLLER BOX GROUND VOLTAGE YEL HR HOUR METER REGULATOR IGN IGNITION RED N J CONNECTOR JACK BATTERY ORG homma K1 AC CRANK DISCONNECT RELAY CHARGING BRUSH K2 ENGINE START RUN RELAY COIL GRYS N NP eJ f ENGINE CRANK RELAY BK N E Q K4 FAULT SHUTDOWN RELAY gt lama 14N BCR i d J Y Ben L F2 P10 2 PEP P113 K5 FAULT SHUTDOWN TIME DELAY RELAY 10 1 Pl0 2 y N 14N CHTR P11 4 lt K6 CRANK INTERLOCK RELAY ir C L F1 P10 1 M gi N P4 14 C I Fra 15 CH lt BLUE RED BLK WHT BLUE WHT
5. Is there continuity between N and 47 while pressing the start stop switch Y Yes Replace or repair Replace the fuse Y the wiring harness _ Is there 12 volts Yes at P1 14 Y No Is voltage present at the starter relay Is the start stop No switch functional Replace the circuit board Is voltage present at the starter No Replace the Replace the No start stop switch K20 relay Replace or Replace the starter repair the relay starter motor Figure 4 3 Troubleshooting the Relay Controller Circuit Board 1 of 4 TP 6079 3 00 Controller Troubleshooting 11 GotoB next page Does the engine start gt Y Is the K4 relay LED lit Y Is there continuity between Nos 12 volts DC present ves gt Is the fuel P4 5 and N at the fuel pump pump working P9 2 i Yes Is there continuity Y between P1 9 and P9 1 Troubleshoot the engine refer to the engine service manual Y Is there continuity Y Go to C between P9 2 and P1 8 Replace the No next page fuel pump Y Yes Is there continuity Y between P2 8 and N Is there continuity bet
6. 19 0 168 Generator adapter to engine bolts 14 9 132 Engine oil drain boss inside generator adapter Generator adapter to exhaust manifold Spark plug 47 5 420 13 6 120 12 17 106 150 Specifications 1 1 6 Service Views SERVICE VIEW 6 10 xum 1 Controller Spark plug Hourmeter Air intake silencer Start Stop switch Carburetor Nameplate top Oil drain valve Input fuse Oil check Battery charging fuse Fuel feed pump Voltage regulator fuse Fuel inlet AC circuit breaker Extended shaft generator specification available Remote start connector nonservice side Engine battery charging voltage regulator Lifting eye End bracket cover plate Muffler PowerBoost IIIE voltage regulator oO ONOU POD a Figure 1 1 5ERKM 4EFRKM Service Views 2 Specifications TP 6079 3 00 2 1 General A WARNING KS 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 reconne
7. Y Does the engine have proper oil level Replace the circuit board inoperative K4 relay Y Replace the switch Fill the engine crankcase with the specified amount of oil See Section 1 2 Figure 4 5 Troubleshooting the Relay Controller Circuit Board 3 of 4 TP 6079 3 00 Controller Troubleshooting 13 Is there output when the start button is held and the unit is running No Is there approximately 12 VDC at the brushes gt Is there 12 volts output at Yes Replace the No the B1 B2 stator winding circuit board Separately excite the generator set to determine if other components are inoperative See Section 5 1 2 Separate Excitation Y Is the stator Replace the functional circuit board Is there AC output voltage No the stator Replace Is the stator and rotor functional Is the voltage regulator fuse functional No Replace inoperative components Is the voltage regulator functional Replace the fuse Replace the voltage regulator Figure 4 6 Troubleshooting the Relay Controller Circuit Board 4 of 4 14 Controller Troubleshooting TP 6079 3 00 Gener
8. TEE 413 50 mds 4 1 4 Low Oil Level LOL Safety Switch 4 2 Controller Circuit Board TP 6079 3 00 B able of Contents 4 3 Troubleshooting 11 Generator Troubleshooting 15 bd General De ea tea 15 5 1 1 General Troubleshooting 15 5 1 2 Separate Excitation 16 5 2 PowerBoost Voltage Regulators 17 5 2 1 Voltage Regulator Test 17 5 2 2 Voltage Regulator Adjustment 18 5 3 JRO Suspen yi ada Pee e 19 o dici nun 20 5 5 Brushes zv qm EE EE 21 Component Troubleshooting 23 61 Engine Generator Components 23 6 2 Remote Panel optional 25 Generator Disassembly Reassembly 27 7 1 Disassembly 27 7 2 Collector Ring and Bearing Replacement 30 7 8 30 Reconnection and Wiring Diagrams 31 8 1 Reconnection Diagram 100 120 V 60 S DORZ aa sus ie eis 32 8 2 Reconnection Diagram 100 120 200 240 V 60 amp DO HZ ea 32 8 3 Reconnection Diagram 220 240 V 50 Hz 32 8 4 Remote Start Panel 32 8 5 Wiring Diagram 5ERKM 4EFRKM 33 Abbreviations A 1 ark Gem dele SER Rr A 3 UNUS 4
9. 3 Follow these SAE washer rules after determining exit hole type a Alwaysuse a washer between hardware and a slot b Always use a washer under a nut see 2 above for exception Use a washer under a bolt when the female thread is fixed weld nut 4 Refer to Figure 2 which depicts the preceding hardware configuration possibilities 4 B Bo Cap screw Entry hole types Standard nut and SAE washer Whiz nut or spiralock up to 1 2 in dia hardware Weld nuts above 1 2 in dia hardware Exit hole types App 0 lorque Specifications Use the following torque specifications when service oiled threads Increase values by 1596 for nonplated literature instructions give no specific torque values threads All torque values are 0 10 The charts list values for new plated zinc phosphate or American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into Torque Aluminum Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5 1 8 16 2 9 26 2 9 26 6 8 60 81 72 13 6 120 14 9 132 240 18 27 0 20 39 0 29 43 0 32 60 0 44 66 0 49 81 0 60 91 0 67 113 0 83 128 0 94 199 0 147 222 0 164 259 0 191 283 0 209 Metric Fasteners Torque Specifications Measured in Nm ft Ib Assembled into Cast Iron or Steel Assembled into Alumi
10. Disconnect the power to the battery charger if equipped 2 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch TP 6079 3 00 WARNING LI b W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment 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 fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Generator Disassembly Reassembly 27 Disassembly Procedure 1 2 10 11 12 13 Place the start stop switch in the STOP position Disconnect the generato
11. Hex Head Bolts partial thread M931 06040 60 M931 06055 60 M931 06060 60 M931 06070 60 M931 06075 60 M931 06090 60 M931 08035 60 M931 08040 60 M931 08040 82 M931 08045 60 M931 08050 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 10040 60 M931 10045 60 M931 10050 60 M931 10055 60 M931 10060 60 M931 10065 60 M931 10070 60 M931 10080 60 M931 10090 60 M931 10100 60 M931 12045 60 M931 12050 60 M931 12055 60 M931 12060 60 M931 12065 60 M931 12080 60 M931 12090 60 M931 12100 60 M931 12110 60 M931 16090 60 M931 20065 60 M931 20120 60 M931 20160 60 M931 22090 60 M931 22120 60 M931 22160 60 M931 24090 60 M931 24120 60 M931 24160 60 This metric hex bolt s hardness is grade 10 9 TP 6079 3 00 Dimensions M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M8 1 25 x 35 M8 1 25 x 40 M8 1 25 x 40 8 1 25 x 45 M8 1 25 x 50 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 M10 1 50 x 40 M10 1 50 x 45 M10 1 50 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 50 x 90 M10 1 50 x 100 M12 1 75 x 45 M12 1 75 x 50 M12 1 75 x 55 M12 1 75 x 60 M12 1 75 x 65 M12 1 75 x 80 M12 1 75 x 90 M12 1 75 x 100 M12 1 75 x 110 M16 2 00 x 90 M20 2 50 x 65 M20 2 50 x 120 M
12. LEDA lights The generator set shuts down as described in Section 4 1 3 4 2 Controller Circuit Board The controller circuit board has light emitting diodes LEDs that indicate the presence of relay coil power When any of the relays K1 K5 receives power the corresponding LED lights NO3 13901 9NINNNY N39 ASSY 6 10516 6079 3 00 4 3 Troubleshooting Use the following flow chart as an aid in troubleshooting the wires between components Always disconnect the main circuit board and the entire generator set Ifthe external components remote start stop switches the prescribed remedy does not correct the problem the engine gauge panel dry relay contact kits etc before circuit board may have to be replaced Use this chart for performing troubleshooting procedures component testing only Always check the continuity of i GotoA ress the start switch Does the engine crank next page local or remote Check the battery condition and connections Does the K2 relay LED light while cranking Isthe relay LED lit Yes Is voltage present atthe K20 relay Y P1 4 connector The K relay is faulty Replace No the circuit board The 2 relay is faulty Replace the circuit board Is the 10 amp controller fuse functional
13. The voltage regulator monitors the output voltage of the generator set The 10 amp regulator fuse protects the alternator stator windings power supply 55 33 from excessive current draw because of an inoperative voltage regulator or a downstream short Ifthe regulator s 10 amp fuse blows the generator set will shut down Verify that the regulator fuse is functional before proceeding with the test i O H H 9O HH TP 598653 1 Voltage potentiometer 2 Stability potentiometer 3 Volts Hz potentiometer Figure 5 3 PowerBoost Voltage Regulator 5 2 1 Voltage Regulator Test Perform the following test to check the regulator output Use the following components to test the voltage regulator e Variable transformer 0 140 volts 0 5 amp minimum e Plug 120 volts AC e Lamp 120 volts 100 watts e AC voltmeter e Insulated copper wire 14 AWG minimum TP 6079 3 00 Regulator Test Procedure 1 Connect the components as shown in Figure 5 4 2 Turn the variable transformer setting to zero Plug in the variable transformer 3 Turn the variable transformer on Slowly increase the variable transformer to 100 volts The testlamp should light If the lamp does not light turn the voltage adjustment potentiometer pot clockwise If the lamp still does not light the voltage regulator is inoperative Replace the voltage regulator An inoperative voltage regulator causes a generator no low output condition
14. kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display Id shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 229 bytes 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 MQ milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg mounting MW megawatt A 2 Appendix mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns O C opt O S OSHA ON 02 PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly rms milli
15. substrate semiconductor cogeneration communications port connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust external F fglass FHM fl oz flex freq FS ft ft Ibs ft min 9 gal gen genset GFI gnd gov gph gpm gr gr wt Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge
16. 05012 20 M3 0 50 x 10 M3 0 50 x 12 M4 0 70 x 20 5 0 80 x 10 5 0 80 x 12 Flat Head Machine Screws M965A 05016 20 M5 0 80 x 16 Part No Hex Nuts M934 03 50 M934 04 50 M934 05 50 M982 05 80 M6923 06 80 M934 06 64 M982 06 80 M6923 08 80 M934 08 60 M982 08 80 M6923 10 80 M982 10 80 M6923 12 80 M982 12 80 M982 14 80 M6923 16 80 M982 16 80 M982 18 80 M934 20 80 M982 20 80 M934 22 80 M982 22 80 M934 24 80 M982 24 80 Washers Part No M125A 03 80 M125A 04 80 M125A 05 80 M125A 06 80 M125A 08 80 M125A 10 80 M125A 12 80 M125A 14 80 M125A 16 80 M125A 18 80 M125A 20 80 M125A 24 80 Dimensions M3 0 50 M4 0 70 5 0 80 5 0 80 6 1 00 6 1 00 6 1 00 M8 1 25 M8 1 25 M8 1 25 M10 1 50 M10 1 50 M12 1 75 M12 1 75 M14 2 00 M16 2 00 M16 2 00 M18 2 50 M20 2 50 M20 2 50 M22 2 50 M22 2 50 M24 3 00 M24 3 00 ID 3 2 4 3 5 3 6 4 8 4 10 5 13 0 15 0 17 0 19 0 21 0 25 0 OD 7 0 9 0 10 0 12 0 16 0 20 0 24 0 28 0 30 0 34 0 37 0 44 0 Type Standard Standard Standard Elastic Stop Spiralock Std green Elastic Stop Spiralock Standard Elastic Stop Spiralock Elastic Stop Spiralock Elastic Stop Elastic Stop Spiralock Elastic Stop Elastic Stop Standard Elastic Stop Standard Elastic Stop Standard Elastic Stop Bolt Thick Screw 0 5 0 8 4 1 0 5 1 6 6 1 6 M8 2 0 M10 2 5 M
17. 1 oil control Mechanical 85 x 63 3 35 x 2 48 0 357 21 79 Compression ratio 8 1 1 Horsepower 60 50 Hz 11 5 8 RPM 60 50 Hz 3600 3000 Lubrication system Splash Lube oil capacity L U S qts 2 0 2 1 Oil recommendation API SC or SH Battery voltage standard DC 12 Battery CCA recommendation 250 min Governor Bore x stroke mm in Displacement L CID Battery charging 10 amps Starter motor Bendix automotive type 1 3 Fuel Fuel System Specifications Fuel recommendation Unleaded 87 octane Electric 0 9 3 13 8 24 1 2 0 3 5 6 35 0 25 Fuel pump Fuel pump max lift m ft Fuel pump operating kPa psi Fuel pump inlet hose ID mm in TP 6079 3 00 Specifications 1 4 Generator Component Specifications Hot exciter field voltage current readings at rated voltage No load 63 Hz volts amps 10 1 4 4 Full load 60 Hz volts amps 50 5 8 5 Cold main field rotor resistance ohms 3 7 Stator output voltages with separately excited generator using 12 volt battery 60 Hz only 1 2 3 4 33 44 VAC 55 66 VAC B1 B2 VAC Cold stator resistance 1 2 3 4 33 44 ohms 55 66 ohms B1 B2 ohms 1 5 Torque Component Torque Nm in Ib Rotor bolt 23 1 204 Generator overbolts 13 6 120 Mounting plate to end bracket bolts Lift eyebolts 6 8 60
18. 2 50 1 2 13 x 2 75 1 2 13 x 3 00 1 2 13 x 3 50 1 2 13 x 4 00 1 2 13 x 4 50 1 2 13 x 5 50 1 2 13 x 6 00 1 2 20 x 75 1 2 20 x 1 25 1 2 20 x 1 50 5 8 11 x 1 00 5 8 11 x 1 25 5 8 11 x 1 50 5 8 11 x 1 75 5 8 11 x 2 00 5 8 11 x 2 25 5 8 11 x 2 50 5 8 11 x 2 75 5 8 11 x 3 75 5 8 11 x 4 50 5 8 11 x 6 00 5 8 18 x 2 50 3 4 10 x 1 00 3 4 10 x 1 25 3 4 10 x 1 50 3 4 10 x 2 00 3 4 10 x 2 50 3 4 10 x 3 00 3 4 10 x 3 50 1 8x2 25 1 8 x 3 00 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 X 25 127 1 062 Dimensions Type 1 8 Standard 6 32 Whiz 8 32 Whiz 10 24 Whiz 10 32 Whiz 1 4 20 Spiralock 1 4 28 Spiralock 5 16 18 Spiralock 5 16 24 Spiralock 3 8 16 Spiralock 3 8 24 Spiralock 7 16 14 Spiralock 1 2 13 Spiralock 7 16 20 Spiralock Spiralock 5 8 11 Standard 3 4 10 Standard 1 2 20 Standard Bolt ID OD Thick Screw 125 250 022 4 156 375 049 6 188 438 049 8 219 500 049 10 281 625 065 1 4 344 687 065 5 16 406 812 065 3 8 469 922 065 7 16 531 1 062 095 1 2 656 1 312 095 5 8 812 1 469 134 3 4 2 000 134 1 6079 3 00 Metric Hex head bolts are hardness grade 8 8 unless noted Part No
19. 4 Slowly increase the variable transformer to 120 volts The lamp should go out and stay out as the voltage increases If the lamp remains lit turn the voltage adjustment pot counterclockwise If the lamp still remains lit replace the voltage regulator A voltage regulator that is inoperative causes a generator high voltage output condition 5 Turn the variable transformer to zero and unplug the AC cord Note For applications requiring fine voltage adjustment connect a remote rheostat to voltage regulator terminal 66 TP 598654 120 volts AC Variable transformer AC voltmeter Voltage regulator PowerBoost IIIE Stator rotor connections for reference only Lead color 120 volt 100 watt lamp Figure 5 4 PowerBoost Voltage Regulator Test Generator Troubleshooting 17 5 2 2 Voltage Regulator Adjustment The factory sets the voltage regulator and under normal circumstances the regulator requires no further adjustment However if the voltage regulator has been replaced or tampered with or if voltage frequency reconnection has been done readjust the voltage regulator according to the following procedure See Figure 5 5 The following paragraphs describe the voltage regulator components TP 598655 Optional remote rheostat Voltage adjustment pot
20. 75 5 16 18 x 88 5 16 18 x 1 00 5 16 18 x 1 25 5 16 18 x 1 50 5 16 18 x 1 75 5 16 18 x 2 00 5 16 18 x 2 25 5 16 18 x 2 50 5 16 18 x 2 75 5 16 18 x 3 00 5 16 18 x 4 50 5 16 18 x 5 00 5 16 18 x 5 50 5 16 18 x 6 00 5 16 18 x 6 50 5 16 24 x 1 75 5 16 24 x 2 50 5 16 24 x 75 5 16 24 x 2 00 5 16 24 x 2 75 3 8 16 x 62 3 8 16 x 75 3 8 16 x 88 3 8 16 x 1 00 3 8 16 x 1 25 3 8 16 x 1 50 3 8 16 x 1 75 3 8 16 x 2 00 3 8 16 x 2 25 3 8 16 x 2 50 3 8 16 x 2 75 3 8 16 x 3 00 3 8 16 x 3 25 3 8 16 x 3 50 3 8 16 x 3 75 3 8 16 x 4 50 3 8 16 x 5 50 3 8 16 x 6 50 A 6 Appendix Part No Dimensions Hex Head Bolts cont X 6238 14 X 6238 16 X 6238 21 X 6238 22 X 6024 5 X 6024 2 X 6024 8 X 6024 3 X 6024 4 X 6024 11 X 6024 12 X 129 15 X 129 17 X 129 18 X 129 19 X 129 20 X 129 21 X 129 22 X 129 23 X 129 24 X 129 25 X 129 27 X 129 29 X 129 30 X 463 9 X 129 44 X 129 51 X 129 45 X 129 52 X 6021 3 X 6021 4 X 6021 2 X 6021 1 273049 X 6021 5 X 6021 6 X 6021 7 X 6021 12 6021 11 6021 10 6021 9 6239 1 6239 8 6239 2 6239 3 6239 4 6239 5 6239 6 792 1 792 5 792 8 3 8 24 x 75 3 8 24 x 1 25 3 8 24 x 4 00 3 8 24 x 4 50 7 16 14 x 75 7 16 14 x 1 00 7 16 14 x 1 25 7 16 14 x 1 50 7 16 14 x 2 00 7 16 14 x 2 75 7 16 14 x 6 50 1 2 18 x 75 1 2 13 x 1 00 1 2 13 x 1 25 1 2 13 x 1 50 1 2 13x 1 75 1 2 13 x 2 00 1 2 13 x 2 25 1 2 13 x
21. Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Electrical Shock A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Hazardous voltage Backfeed to the utility system can cause severe injury death or property damage Connect the generator set to the building s electrical system only through an approved device and after the building s main switch is opened Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of
22. PowerBoost IIIE voltage regulator Stabilizer pot Volts Hz pot Stator rotor connections for reference only DC output Rotor 10 amp fuse AC power input aux Main 2 and 1 Control Stator Sensing Main 3 and 4 Figure 5 5 PowerBoost Voltage Regulator Voltage Adjustment Pot adjusts the generator output within the range of 100 130 volts Stabilizer Pot fine tunes regulator circuitry to minimize AC voltage fluctuation Volts Hz Pot allows the voltage to drop if the load imposed on the generator causes the engine speed to fall below a predetermined frequency roll off point This reduction of voltage results in a decrease of starting kW load allowing the governor to recover the engine speed 18 Generator Troubleshooting Voltage Regulator Adjustment Procedure 1 Stop the generator set 2 Turn the remote rheostat if equipped to the midpoint Turn the voltage and stabilizer pots fully counterclockwise Connectthe voltmeter to the AC circuit or an electrical outlet 3 Start the generator set 4 Adjust the generator frequency using a frequency meter Set the no load speed at 52 5 Hz for 50 Hz operation or 63 Hz for 60 Hz operation Rotate the voltage adjustment pot clockwise to increase the voltage or counterclockwise to decrease the voltage to achieve the desired output voltage 5 Connect a 120 volt light bulb to the AC plug on the generator set 6 Rotate the st
23. dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention ifthe condition of affected persons does not improve within minutes of breathing fresh air Installing the exhaust tail pipe Carbon monoxide can cause severe nausea fainting or death Install the exhaust system tail pipe to prevent the drawing of discharged exhaust gases into the vehicle interior through windows doors air conditioners and other openings Do not use flexible tail piping because it could crack and allow lethal exhaust fumes to enter the vehicle Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the vehicle s occupants install a carbon monoxide detector Consult the coach builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times TP 6079 3 00 Fuel System A WARNING
24. meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext ISO J JIS k K kA KB kg hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 219 bytes kilogram Append kg cm kilograms per square centimeter kgm kilogram meter kg m kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm KQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour
25. repair instructions for 5ERKM and 4EFRKM model generator sets controllers and accessories Refer to the engine service manual for generator set engine service information This manual may be used for models not listed on the front cover Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever TP 6079 3 00 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 section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe prescribed intervals Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service Before installing a mobile generator set obtain the most current installation manual from your local distributor dealer Only qualified persons should install the generator set x in 001 002 a ntroduction i ervice Assistance Service Information Please contact a local authorized distributor dealer for sales service or other information about Kohler Generator Divisio
26. 12 2 5 M14 3 0 M16 3 0 M18 3 0 M20 4 0 M24 Append AF7 6079 3 00 Kohler Co 2000 All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Web site www kohlergenerators com Fax 920 459 1646 U S A Sales Fax 920 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
27. 20 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 Part No Dimensions Hex Head Bolts full thread M933 04006 60 M933 05050 60 M933 06010 60 M933 0601 4 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06040 60 M933 06050 60 M933 08016 60 M933 08020 60 M933 08025 60 M933 08030 60 M933 10012 60 M961 10020 60 M933 10020 60 M933 10025 60 M933 10030 60 M933 10030 82 M961 10035 60 M933 10035 60 M933 12016 60 M933 12020 60 M933 12025 60 M933 12025 82 M933 12030 60 M933 12040 60 M933 12040 82 M961 14025 60 M933 14025 60 M961 16025 60 M933 16025 60 M933 16030 82 M933 16035 60 M933 16040 60 M933 16050 60 M933 16050 82 M933 16060 60 M933 18050 60 M933 18060 60 M4 0 70x6 M5 0 80 x 50 M6 1 00 x 10 M6 1 00 x 14 M6 1 00 x 16 M6 1 00 x 20 M6 1 00 x 25 M6 1 00 x 40 M6 1 00 x 50 M8 1 25 x 16 M8 1 25 x 20 M8 1 25 x 25 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 50 x 30 M10 1 50 x 30 M10 1 25 x 35 M10 1 50 x 35 M12 1 75 x 16 M12 1 75 x 20 M12 1 75 x 25 M12 1 75 x 25 M12 1 75 x 30 M12 1 75 x 40 M12 1 75 x 40 M14 1 50 x 25 M14 2 00 x 25 M16 1 50 x 25 M16 2 00 x 25 M16 2 00 x 30 M16 2 00 x 35 M16 2 00 x 40 M16 2 00 x 50 M16 2 00 x 50 M16 2 00 x 60 M18 2 50 x 50 M18 2 50 x 60 Pan Head Machine Screws M7985A 03010 20 M7985A 03012 20 M7985A 04020 20 M7985A 05010 20 M7985A
28. 7 Install the coverplate torque it to 6 8 Nm 38 maximum as soldered 60 In Ib 8 Install the fuel line and fuel pump 9 Guide the leads from the stator through the bottom opening of the controller Secure the controller 10 Reconnect the leads from the stator to the controller using the reverse procedure of that listed in Section 71 Refer to Section 8 Reconnection and Wiring Diagrams 11 Connect the generator set starting battery the positive lead first 12 Test the generator operation VIEW A A 1 Collector ring leads 2 Keyways Figure 7 5 Rotor Assembly 30 Generator Disassembly Reassembly TP 6079 3 00 Reconnection and Wiring Diagrams WARNING Pa or Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Disconnect the power to the battery charger if equipped 2 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these pr
29. American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audio visual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute TP 6079 3 00 CG CID CL cm cmm CMOS cogen COM conn cont CPVC crit CRT CSA CT Cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter cubic meters per minute complementary metal oxide
30. E ADV 5857 8 2 Reconnection Diagram 8 4 Remote Start Panel 100 120 200 240 V 60 amp 50 Hz Stop 10 amp Local O fuse switch 0 100 120 200 240V 60Hz 100 120 200 240V 50Hz VN VVV 43 N P2 5 LO NEUTRAL GROUND Relay circuit board L1 2 3 2 7 FACTORY TWO POLE CIRCUIT BREAKER 70 47 Grey A A Black P3 4 P3 5 J3 4 J3 5 Violet P3 6 J3 6 3 2 4 1 STATOR LEADS Stop O a Yellow Red 100 120 200 240 VOLT 3 WIRE ADV 5857 G Hourmeter 32 Reconnection and Wiring Diagrams TP 6079 3 00 8 5 Wiring Diagram 5ERKM 4EFRKM REMOTE PANEL OPTIONAL CONTROLLER SCHEMATIC CRANKING BATTERY P3 CONNECTIONS P1 CONNECTIONS PN N P2 9 PIN 1 44 8 5 J4 2 Bi 011 1 7C 24 3 K20 86 70 2 3 J11 3 47 2 7 11 2 43 2 8 wen K25 86 VOLTAGE 1 GND 2 REGULATOR o 70 03 4 J11 4 M J11 CONNECTIONS PIN 1 B1 1 3 AN P2 CONNECTIONS Be F126 RIO 02 2 PIN 1 70 HM 9 FP P1 5 4 FN P1 12 70 P3 4 47 555 48 SSS P11 CONNECTIONS N 655 PIN 1 1 47 P3 5 48 P3 6 N P3 1 FP FN 7 EU Er N X ON
31. Seal leaks as needed e Ensure that the carbon monoxide detector is 1 in the vehicle 2 functional and 3 energized whenever the generator set operates m op 001 003 TP 6079 3 00 WARNING LI b W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment 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 fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels 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 drainin
32. Service Commercial and Recreational Mobile Generator Sets Models 5ERKM 4EFRKM E Tu 622001 KOHLER mmm CENERATORS INTERNATIONALLY REGISTERED KOHLER POWER SYSTEMS me se Precautions and instructions Ed EIE UNE ieu rand ER MUR ud EUR Service Information Product Information Specifications 11 General iul EUER 1 2 Engine ib opine DRE 1 3 rr 1 4 1 5 Torque nasse HH 1 6 Service Views Scheduled Maintenance 21 General edat 2 2 Lubrication 2 3 Air Intake System 2 4 Exhaust System Fuel System 34 GONE al xac ea 3 2 3 3 Carburetor Troubleshooting 3 3 1 Hard Starting 882 Stalling i 20 2 3 3 3 Flooding 3 8 4 0 3 8 5 Leaking 3 4 Governor 3 5 60 and50 Hz Conversions Controller Troubleshooting 4 1 Sequence of Operation 4 1 1 SIA TP 4 1 2
33. Stator Leads Description Output coil Output coil Control wires from 3 and 4 Voltage regulator power source Controller power source Figure 5 7 Stator Coil Lead Description Before testing the stator inspect it for heat discoloration and visible damage to the exposed coil windings and varnished areas of the frame laminations Be sure the stator is securely fastened in the stator housing The stator produces electrical output AC as the magnetized main field rotates within the stator windings Testthe condition ofthe stator according to the following procedure Leads 1 2 3 and 4 are the generator output leads Leads 33 44 and 55 are the voltage regulator supply and sensing leads The output of leads B1 and B2 is the control voltage for the controller Stator Test Procedure 1 Place the generator start stop switch in the STOP position 2 Disconnect the generator set engine starting battery negative lead first 3 Checkthe generator output lead connections See Reconnection and Wiring Diagrams 4 Disconnect all of the stator leads to isolate the windings To check the stator continuity set the ohmmeter on the R x 1 scale Check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 5 8 Perform the stator tests on all of the stator windings 20 Generator Troubleshooting Note When taking an ohmmeter reading using lead 55 make the connection prior t
34. ability pot clockwise until the light bulb flickers minimally Readjust the voltage to achieve the desired output voltage 8 Disconnect the 120 volt light bulb 9 Turn the volts Hz pot completely clockwise to decrease the Hz roll off point See Figure 5 6 Volts AC 48 50 52 54 56 5 Frequency Hz 60 Hz Models 50 Hz Models f Counterclockwise to increase Hz roll off Clockwise to decrease Hz roll off Figure 5 6 Volts Hz Roll Off Chart TP 6079 3 00 10 Set the engine speed to 47 5 Hz for 50 Hz generator sets and 57 5 Hz for 60 Hz generator sets for the desired cut in frequency 11 Slowly turn the volts Hz pot counterclockwise until the frequency matches that of the engine frequency 47 5 or 57 5 Hz or until the voltage just begins to drop 12 Reset the engine speed to the normal frequency 50 Hz or 60 Hz 13 Recheck the AC voltage output and stability as described in steps 4 7 14 Stop the generator set 5 3 Rotor The two pole rotor creates the magnetic field needed to sustain alternating current in the stator windings Before testing inspect the rotor for visible damage to pole shoes insulation exposed coil windings and collector ring surfaces Check the rotor bearing for noisy operation excessive wear radial or axial movement and or heat discoloration Replace the rotor as necessary Collector rings acqu
35. ator Troubleshooting 5 1 General Before beginning the following troubleshooting procedures read all the safety precautions at the beginning of this manual The following tests include additional safety precautions OBSERVE THESE PRECAUTIONS A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is present atthe voltage regulator heat sink To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator PowerBoost PowerBoost Ill and PowerBoost V voltage regulator models only Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contac
36. ches 32 00 Maximum eccentricity mm in 0 08 0 003 Maximum out of round mm in 0 01 0 0002 1 Unsolder the collector ring leads from the collector ring terminals Figure 7 6 Collector Ring Dimensions 2 Remove the collector rings with a 3 jaw puller 3 Remove the bearing with a 3 jaw puller 7 3 Reassembly 4 Press the new bearing onto the rotor shaft 1 Apply antiseize compound to the tapered shaft of the engine 5 Align the collector ring keyway with the keyway on the rotor shaft See Figure 7 5 2 Align the rotor onto the engine shaft and secure the rotor with the rotor bolt Torque the rotor bolt to 6 Press the new collector rings onto the rotor shaft 23 1 Nm 204 in Ib Note The new collector rings must be turned 3 Carefully slide the stator assembly over the rotor down to a finish of 32 microinches using a lathe and commutator stones Turn down 4 Install the end bracket and torque the overbolts to the collector rings on the rotor shaft See 13 6 Nm 120 in Ib See Figure 7 2 Figure 7 6 5 Feed the brush leads inside the stator housing up 7 Solder the leads onto the collector ring terminals through the opening Secure the brush holder The connection is not to exceed 9 65 mm 0 38 in using the original screws beyond the collector rings See Figure 7 5 6 Remove the brush retainer wire and check the 8 Test to ensure continuity at the collector rings brush alignment See Section 5 5
37. cting 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 Disconnect the power to the battery charger if equipped 2 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place Servicing the generator set when itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Note See the generator set operation manual for the service schedule and other service not included in this manual TP 6079 3 00 Scheduled Maintenance 2 2 Lubrication System Use oil that meets the American Petroleum Institute API classification of SC or SH Using unsuitable oil or neglecting an oil change may result in engine damage that is not covered by the engine warranty Figure 2 1 shows the recommended Society of Automotive Engineers SAE viscosity designation for given operating temperatur
38. ctional zero ohms continuity Any resistance other than zero or very low ohms replace the switch If the switch is functional zero ohms continuity Any resistance other than zero or very low ohms replace the switch Connect the ohmmeter to the P1 4 and P1 9 leads K20 relay coil and wiring Place the ohmmeter on the R x 1 scale If functional 85 ohms Low resistance shorted K20 relay coil and or wiring High resistance open K20 relay and or wiring Connect the ohmmeter to the battery positive cable and the P1 14 lead Note Connect the J4 and P4 leads to perform this test Controller 10 amp fuse and wiring Place the ohmmeter on the Rx 1000 scale Figure 6 2 Engine Generator Component Testing Relay Controller 24 Component Troubleshooting If functional zero or very low ohms No reading infinity open circuit or blown fuse TP 6079 3 00 Component Main field rotor Ohmmeter Connections Disconnect the P10 and P11 connectors and connect the ohmmeter to P10 1 and P10 2 leads Procedure Place the ohmmeter on the R x 1 scale Results Low resistance indicates shorted rotor windings High resistance indicates an open in the rotor windings See Specifications B1 B2 stator windings Connect the ohmmeter to the P11 1 and P11 2 leads Note Disconnect P11 and J11 to perform this test Place the ohmmeter on the R x 1 scale Low resistance indicat
39. d Nuts 8 1 25 x 20 Length In Millimeters Screws and Bolts Distance Between Threads In Millimeters Major Thread Diameter In Millimeters TP 6079 3 00 Major Thread Diameter In Fractional Inches Or Screw Number Size Metric Number stamped on hardware 5 8 shown Plain Washers 9 32 x 5 8 x 1 16 L Thickness External Dimension Internal Dimension Lock Washers 5 8 NEN Internal Dimension Append AL5 Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Hex Head Bolts Grade 5 X 465 17 X 465 6 X 465 2 X 465 16 X 465 18 X 465 7 X 465 8 X 465 9 X 465 10 X 465 11 X 465 12 X 465 14 X 465 21 X 465 25 X 465 20 X 125 33 X 125 23 X 125 3 X 125 31 X 125 5 X 125 24 X 125 34 X 125 25 X 125 26 230578 X 125 29 X 125 27 X 125 28 X 125 22 X 125 32 X 125 35 X 125 36 X 125 40 X 125 43 X 125 44 X 125 30 X 125 39 X 125 38 X 6238 2 X 6238 10 X 6238 3 X 6238 11 X 6238 4 X 6238 5 X 6238 1 X 6238 6 X 6238 17 X 6238 7 X 6238 8 X 6238 9 X 6238 19 X 6238 12 X 6238 20 X 6238 13 X 6238 18 X 6238 25 Dimensions 1 4 20 x 38 1 4 20 x 50 1 4 20 x 62 1 4 20 x 75 1 4 20 x 88 1 4 20 x 1 00 1 4 20 x 1 25 1 4 20 x 1 50 1 4 20 x 1 75 1 4 20 x 2 00 1 4 20 x 2 25 1 4 20 x 2 75 1 4 20 x 5 00 1 4 28 x 38 1 4 28 x 1 00 5 16 18 x 50 5 16 18 x 62 5 16 18 x
40. e ranges Do not mix different oil brands Incompatibility could cause a breakdown of lubricating ingredients and reduce engine protection Kohler Winter 10W 30 m 5W 20 5130 Al BERN BEER Kohler Command 80 0 30 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Figure 2 1 Recommended SAE Viscosity Grades Scheduled Maintenance 3 2 3 Air Intake System Atthe interval specified in the service schedule inspect clean or replace the air filter element 2 4 Exhaust System WARNING Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected Exhaust System Check for exhaust leaks and blockages Check the muffler and piping condition and check for tight exhaust system connections 4 Scheduled Maintenance Inspect the exhaust system components exhaust manifold exhaust line exhaust clamps and muffler for cracks and corrosion e Check for 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 Checkthe exhaust gas color If the exhaust is blue or black contact your local distributor dealer e Visually inspect for exhaust leaks Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaustleak
41. ecautions to prevent the starting of the generator set by the remote start stop switch TP 6079 3 00 WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Reconnection and Wiring Diagrams 31 8 1 Reconnection Diagram 100 120 V 60 amp 50 Hz 8 3 Reconnection Diagram 220 240 V 50 Hz 100 120V 60Hz 100 120V 50Hz JUMPER 220 240V 50Hz LEAD L1 GRD GRD LO NEUTRAL LO NEUTRAL u LO NEUTRAL 0 GRD GROUND GROUND GROUND L1 L2 FACTORY LOAD ONE POLE ONE POLE TWO POLE SIDE P4 CIRCUIT CIRCUIT OR 2 BREAKER BREAKER ONE POLE Ir CIRCUIT BREAKERS JUMPER LEAD 1 4 2 3 2 4 STATOR LEADS 100 120 VOLT STATOR LEADS 2 WIRE STATOR LEADS 100 120 VOLT 3 WIRE 200 240 VOLT 2 WIR
42. electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove wristwatch rings and jewelry before servicing the equipment Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is present at the voltage regulator heat sink To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator PowerBoost PowerBoost Ill and PowerBoost V voltage regulator models only afety Precautions and Instructions III Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building campground electrical system only through an approved device and after the building campground main Switch is opened Backfeed connections can cause serious injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a transfer switch to prevent interconnection of the generator set power and other sources of power Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic mea
43. ental 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 Disconnectthe power to the battery charger if equipped 2 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the batter
44. es shorted B1 B2 windings High resistance indicates an open in the B1 B2 windings See Specifications P1 ground connection Connect the ohmmeter to the P1 9 and ground Place the ohmmeter on the R x 1 scale If functional zero ohms continuity Any other reading indicates a poor ground connection Low oil level LOL safety shutdown switch Connect the ohmmeter to the P4 6 and engine block ground Place the ohmmeter on the R x 1000 scale The oil level in the engine must be drained for this test Replace the engine oil after this test Figure 6 3 Engine Generator Component Testing Relay Controller 6 2 Remote Panel optional Kohler Co offers a remote panel with a start stop switch and a hourmeter for connection to the generator set Component Start stop switch START u E Ohmmeter Connections Remote switch yellow red wire terminal and black wire terminal Remote switch grey black wire terminal and black wire terminal fo 00000 5 TOTAL HOURS STOP KOHLER GENERATORS IN C2 Figure 6 4 Remote Start Panel Troubleshooting TP 6079 3 00 If functional zero ohms continuity Then disconnect LOL switch lead and isolate the terminal Meter reading should show an open circuit If difficulty with the remote operation occurs test the switch See Figure 6 4 and Section 84 for troubleshooting t
45. g the fuel system Wipe up spilled fuel after draining the system 3 1 General In most installations both the generator set and the vehicle s engine operate from a common fuel tank with a dual dip tube The generator set s dip tube may be shorter than the vehicle engine s dip tube With this arrangement fuel may not be available to the generator set when the fuel supply is low See Figure 3 1 for a fuel system schematic TP 6079 3 00 Fuel System 3 2 Fuel Pump Electric fuel pumps draw fuel from the fuel tank through a filter and supply clean fuel at the proper pressure and quantity to the generator set engine carburetor Fuel Pump Test Procedure 1 Connect the inlet side of the pump to a fuel source 2 Disconnect the outlet hose from the fuel filter and place the end in a container to catch the fuel 3 Disconnect the P9 connector 4 Connect the positive terminal 70 of the fuel pump to the positive terminal 4 of a 12 volt battery 5 Connect the negative terminal N of the fuel pump to the negative terminal of the battery The pump should operate and fuel should discharge from the pump outlet Ifthe pump does not operate replace the pump Vehicle s engine Generator set fuel pump 1 Dual dip tubes 2 Fuel filter 3 Fuel tank Figure 3 1 Fuel System Schematic Typical Fuel System 5 3 3 Carburetor Troubleshooting This section is for fuel related problems and basic carburetor troublesh
46. he remote start stop switch Procedure Place the ohmmeter on the R x1 scale Place the rocker switch in the START position Place the ohmmeter on the R x1 scale Place the rocker switch to the STOP position N Results Continuity indicates a functional switch No reading indicates an inoperative switch Replace the switch Continuity indicates a functional switch No reading indicates an inoperative switch Replace the switch QUOD 229 43 47 70 226965 Component Troubleshooting 25 Notes 26 Component Troubleshooting TP 6079 3 00 Generator Disassembly Reassembly 7 1 Disassembly Disconnect the external connections battery cables at the battery negative lead first AC output leads in the controller remote start panel at the controller P3 connector and the fuel line at the fuel pump filter inlet Observe all of the safety precautions listed during the disassembly reassembly procedures A WARNING 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 equipment connected to the set disable the generator set as follows 1
47. idelines 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 General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance Unacceptable Nut Bolt Clearance CES C 3 1 1 2 of bolt diameter 2 Min 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths TP 6079 3 00 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
48. ions and Instructions Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove wristwatch rings and other jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire WARNING Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed 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 ll Safety Precautions and Instructions Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Ha
49. ire a glossy brown finish in normal operation Do not attempt to maintain a bright newly TP 6079 3 00 machined appearance Wipe the collector rings with a dry lint free cloth Use a commutator stone to remove the groves on the collector rings Do not use emery or carborundum paper or cloth Remove all carbon dust from the generator Remove the black or pitted surface of the collector rings using a lathe Check the rotor for continuity and resistance Lift the brushes and measure the rotor resistance between the two collector rings See Section 5 5 Note When checking rotor resistance with the rotor installed brushes must not be in contact with rotor collector rings Use a brush retainer on brushes for accurate resistance readings Note Use the values in Section T as a reference for rotor resistance readings Take readings at room temperature or about 21 70 F Rotor resistance will vary directly with increase in temperature To check whether the rotor is shorted to ground touch one ohmmeter lead to either collector ring and the other lead to the rotor poles or shaft The meter should register no continuity Repair or replace the rotor if the previous tests detect any faults Generator Troubleshooting 19 5 4 Stator The stator consists of a series of coils of wire laid in a laminated steel frame The stator leads supply voltage to the AC load and exciter regulator See Figure 5 7 for coil lead description
50. n IGN and hourmeter HR The normally closed K1 contacts open ending the flashing by preventing battery voltage to the main field and The K6 relay energizes The normally open K6 contacts close latching the K6 relay on The normally closed K6 contacts open preventing inadvertent starter engagement by disabling the the relay The relay deenergizes LED3 off The contacts open deenergizing the K20 relay The K20 contacts open deenergizing the starter relay and starter motor At the same time the K1 relay energizes the time delay for the K5 relay starts After 5 10 seconds the K5 relay energizes LED 5 lights The normally open K5 contacts close permitting the function of the engine safety shutdown switch Controller Troubleshooting 9 4 1 3 Stop Close the start stop switch between N and 43 local or remote The K4 relay energizes LEDA lights The normally closed K4 contacts open disabling the fuel pump FP choke heater CHTR antidiesel solenoid ADS and ignition IGN The normally open K4 contacts close latching the circuit to the K4 relay until the generator set comes to a complete stop 2 gt 2 E m 2 SARA R D d Figure 4 2 GM10516 Controller Circuit Board 10 Controller Troubleshooting 4 1 4 Low Oil Level LOL Safety Switch When the oil level is low the LOL shutdown switch contacts close energizing the K4 relay
51. n products To locate a local authorized distributor dealer inside the U S A and Canada Look onthe product or in the information included with the product e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Generator Division web site at www kohlergenerators com e Call 1 800 544 2444 To locate a local authorized distributor dealer outside the U S A and Canada Look on the product or in the information included with the product e Consult the telephone directory under the heading Generators Electric e Visit the Kohler Generator Division web site at www kohlergenerators com e Contact the nearest regional office Africa Europe Middle East London Regional Office Langley Slough England Phone 44 1753 580 771 Fax 44 1753 580 036 Australia Australia Regional Office Queensland Australia Phone 617 3893 0061 Fax 617 3893 0072 China China Regional Office Shanghai People s Republic of China Phone 86 21 6482 1252 Fax 86 21 6482 1255 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 2284270 91 80 2284279 Fax 91 80 2284286 Japan Japan Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 ii Introduction Latin America Latin America Regional Office Lakeland Florida U S A Phone 941 619 7568 Fax 941 701 7131 South East Asia Singapore Regional Office Singapore Republic of Singapore Ph
52. ndle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System WARNING Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected 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 or vehicle Do not obstruct the exhaust outlet when parking your vehicle The exhaust gases must discharge freely to prevent carbon monoxide from deflecting into the vehicle 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
53. nt path from the voltage regulator to the collector rings Because the brushes carry a low current inspect them every 3000 hours Abrasive dust on the collector rings could shorten the life of the brushes Excessive arcing at the brushes could damage the voltage regulator Weak springs damaged collector rings sticking brushes a loose holder or poor brush contact can cause arcing at the brushes See Figure 5 10 for brush component identification The brushes must be free to move within the holder and be held in contact by the springs When properly positioned spring pressure on the brush surface will cause the brush to wear evenly The brushes must ride 100 on the collector rings or arcing will occur and cause burned rings or failure of the voltage regulator Figure 5 9 shows the correct positioning of the brushes Add or remove alignment shims as necessary to center the brushes on the collector rings TP 598657 1 Correct position 2 Brush holder 3 Incorrect position 4 Generator collector rings Figure 5 9 Brush Positioning TP 6079 3 00 Replace brushes if they show excessive or uneven wear Use a retainer wire such as a paper clip to contain the brushes during disassembly and reassembly Push the brushes into the brush holder until the retainer wire can be inserted into the brush keeping hole Replace brushes when they are worn
54. num Size mm Grade 5 8 Grade 8 8 Grade 10 9 Grade 5 8 or 8 8 M6 x 1 00 M8 x 1 25 13 6 M8 x 1 00 21 0 M10 x 1 50 27 0 M10 x 1 25 39 0 M12 x 1 75 47 0 M12 x 1 50 65 0 M14 x 2 00 74 0 M14 x 1 50 100 0 M16 x 2 00 115 0 M16 x 1 50 141 0 104 M18 x 2 50 155 0 114 M18x 1 50 196 0 145 315 A 4 Appendix TP 6079 3 00 Hardware Identification Screw Bolts Studs Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head with Washer Gy Lock or Elastic Grade 5 Flat Head FHM gr Square Grade 8 Round Head RHM Cy Cap or Acorn Grade 8 9 Hex Socket Head Pan Head gn Wing Hex Socket Head Cap or Allen Head Cap Hex Socket Head or Allen Head Shoulder Bolt mM q Sheet Metal Screw Washers Washer Styles Plain Stud Split Lock or Spring Drive Styles Hex Spring or Wave External Tooth Lock Hex and Slotted Internal Tooth Lock Phillips Slotted Dr au e e Hex Socket Internal External Tooth Lock Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company 1 4 20x 1 Threads Per Inch Sample Dimensions American Standard Screws Bolts Studs and Nuts L Length In Inches Screws and Bolts Metric Screws Bolts Studs an
55. o the in line fuse 5 Check the cold resistance of the stator windings by connecting the meter leads to the stator leads 1 4 2 5 3 6 etc See Section 1 Specifications for the stator resistance values 6 Perform a megohmmeter test on the stator as described in step 7 Note Consider the stator functional if the resistance reading continuity is low and there is no evidence of shorted windings heat discoloration Note The stator resistance varies directly with increased temperature If the stator readings vary considerably during the previous checks repair or replace the stator 7 Check the stator for a grounded condition using a megohmmeter Apply 500 volts DC to any stator lead from each winding and the stator frame Follow the instructions of the megohmmeter manufacturer when performing this test Repeat the test on the other leads until all of the stator windings have been tested A reading of approximately 1 5 megohms and higher indicates the stator is functional A reading of less than approximately 1 5 megohms indicates deterioration of the winding insulation and possible current flow to ground if so replace the stator Between Leads Continuity 1and2 4 55 and 66 B1 and B2 1 and 3 4 33 44 55 1 and 55 B1 and B2 4 and B1 and B2 55 and B1 and B2 Any stator lead and ground Figure 5 8 Stator Continuity TP 6079 3 00 5 5 Brushes The brushes provide a curre
56. on SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier 5 sec second Sl Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s sq square sq cm square centimeter sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations U F underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal U S undersize underspeed UV ultraviolet UN undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6079 3 00 Hardware Application Gu
57. one 65 264 6422 Fax 65 264 6455 Product Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Number Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Number Serial Number TP 6079 3 00 1 1 General The 5ERKM and 4EFRKM units are powered by a one cylinder air cooled four cycle gasoline engine Kohler Co develops all Kohler mobile generator set ratings using accepted reference conditions of 25 C 77 F and pressure of 98 9 kPa 29 2 in Hg dry barometer ISO 3046 and ISO 8528 1 include reference conditions and output calculations Obtain technical information bulletin TIB 101 on ratings guidelines for complete ratings definitions 1 2 Engine Engine Specifications Engine manufacturer Kohler Engine model 512 Number of cylinders 1 Cylinder block material Aluminum Cylinder head material Aluminum 2 compression Piston rings
58. ooting See Figure 3 2 for carburetor component identification Note When troubleshooting the fuel system it is important to have an adequate fuel supply A lean or rich fuel condition can reduce power output and cause poor acceleration Symptoms of a lean condition e Hard starting e Stalling e Hunting Symptoms of a rich condition Hard starting Stalling Percolation Flooding Leaking carburetor If a rich condition occurs remove the air cleaner element and observe the choke plate to ensure that it is fully open The choke will not fully open until the engine is warm If the choke does not fully open test the bi metallic strip and the choke pull off See Figure 3 2 Replace components as necessary Choke Pull off Vacuum Solenoid Test Procedure 1 Remove the vacuum hose that is connected to the back of the choke pull off vacuum solenoid 2 Push and hold the choke linkage into the choke pull off vacuum solenoid 3 Seal the vacuum port on the back of the solenoid and release the choke linkage If the choke linkage moves back to the original location while the vacuum port is sealed replace the choke pull off vacuum solenoid 6 Fuel System Bi metallic Strip Test Procedure 1 Start and run the generator set until it reaches normal operating temperature 5 10 minutes 2 If the choke plate lever can be rotated counterclockwise adjust or replace the bi metallic strip 598642 Choke pull off Bi me
59. p 44 YEL RE CONNECTIONS If 5 PIN BC ORG GRY P4 CONNECTIONS A EN NIE s _ aa EN 7C 3 3 S US SEINEN EINEN nun K20 30 1A 37 37A 45 73 7 71A 37 P1 15 2 d ut e fi Nal NC IRURE 4 43 P1 13 71A 55 14 70 NJ Qo tP CO C 45 1 7 NC NIC 2 12 1 1 555 F3 RED Ri LED47 37A LOL CAN KA I lo C 6 N C ORG VN j fe 45 05 AA AN EN lai A 4 4 GRY 47 03 5 ENGINE WN 1 03 2 BC BCR K6 po P10 CONNECTIONS J10 CONNECTIONS 1 F1 2F2 PIN 1 BLK 14P J4 11 K4 N K25 85 D21 19 P1 8 70 04 13 2 X H4 K20 85 S 444 YEL g gt 333 WHT 73 ADS K20 87 1 2157 42 73 apg 45 PS Las P INSULINK1 d dd GND INSULINK1 Se K25 87A CHTR CHARGING V EBG COL IGN N P1 10 lt gt LK m LO L1 Fi F2 O LINE INPUT BATT SEE 10A CHRG GENERATOR F1 15A CONNECTIONS 47 P2 4 1 70 P2 1 55 P10 5 N P1 9 ON 04 14 NN K20 85
60. p 7 16 Generator Troubleshooting 7 Remove the jumper wire and reverse the positive and negative leads on the rotor Repeat step 5 Ifthe ammeter is stable ground the negative lead at its new location on the rotor to the engine block Replace the rotor if the ammeter reading fluctuates 8 Check for AC output across the stator leads and compare the measured output to the values in Specifications If the output varies considerably from those listed a faulty stator rotor rectifier module or armature is the likely cause If there is no generator output during normal operation but output is available when the generator set is separately excited the voltage regulator may be inoperative Note See Specifications for the stator output voltages with separately excited generator These specifications are based on 12 volts at the battery Should the battery voltage vary the resulting stator output values will also vary TP 598652 Brushes Collector rings Main field rotor Jumper lead Engine ground Voltage regulator Terminal P10 1 Terminal P10 2 10 amp fuse DC ammeter 12 volt battery DC Figure 5 2 Separate Excitation Connections TP 6079 3 00 5 2 PowerBoost Voltage Regulators The generator set is equipped with a PowerBoost voltage regulator See Figure 5 3
61. r short circuit while dynamic moving Centrifugal forces acting on the windings during rotation or insulation breakdown as temperatures increase can cause short circuits Note It is not necessary to separately excite the generator if there is AC output with flashing voltage Separate Excitation Procedure 1 Disconnect all of the leads from the voltage regulator 2 Disconnect the P10 F1 F2 connector 3 Connect a separate excitation circuit as shown in Figure 5 2 Connect an ammeter and a 10 amp fuse in series with F1 Note and record the ammeter reading 4 Divide the battery voltage by the exciter resistance cold to determine the exciter current Disconnect the resistor leads and determine the exciter current value using an ohmmeter See Section 1 3 Specifications for the normal values Battery Voltage Current Exciter Resistance 12 VDC Example 3 7 Ohms 3 2 Amps 5 Start the engine and check that the ammeter remains stable An increasing meter reading indicates a shorted rotor A decreasing meter reading to zero or unstable reading suggests a running open in the rotor If the ammeter is stable continue with step 6 6 With a jumper wire ground the negative lead from the rotor to the engine block An increased current reading or a fluctuating reading indicates a grounded rotor winding Replace the rotor if the ammeter reading fluctuates f the ammeter is stable continue with ste
62. r set engine starting battery the negative lead first Remove the controller cover Disconnect the P4 22 pin connector from J4 Disconnect the controller ground strap engine side Note It is possible to connect the output leads in various positions for different voltage configurations Mark the leads for correct reconnection Disconnect the generator output leads 1 2 3 and 4 from the circuit breaker and the neutral stud LO Disconnect the P11 FP and FN and P10 F1 and F2 connectors Lift the controller from the rubber mounts while guiding the leads through the bottom hole of the controller box Remove the fuel pump and fuel inlet line from the generator See Figure 7 1 Remove the coverplate Push the brushes into the holder Secure the brushes into position by sliding a retainer into the brush keeping holes Refer to Section 5 5 Remove the brush holder and carefully slide the leads out of the stator housing See Figure 7 2 Remove the generator side vibromount nuts 28 Generator Disassembly Reassembly 14 15 16 17 18 Tilt the generator set up and brace it with a block of wood See Figure 7 3 Remove the end bracket overbolts Use a rubber mallet to separate the end bracket from the stator housing See Figure 7 3 Carefully remove the stator assembly from the generator adaptor plate Loosen the rotor bolt finger tighten and back off two turns St
63. rike the bolt with a hammer until the rotor is freed from the engine tapered drive shaft Do not damage the bolt threads or the bolt head See Figure 7 4 1 Controller 2 Fuel pump FV 277000 Figure 7 1 Fuel Pump and Controller Removal TP 6079 3 00 19 18 17 16 Generator adapter plate bolt quantity 4 Generator adapter Brush holder assembly Brush holder shim Rotor bolt Hardened washer Generator overbolt quantity 4 Retainer wire Brush assembly mounting screws quantity 2 Bracket brush holder m 15 14 201 191 1 11 Fan guard 12 Fan guard bolts quantity 2 13 End bracket 14 Pipe plug 15 End drive fitting for marine application only 16 End bracket bearing 17 O ring 18 Stator assembly 19 Rotor assembly Figure 7 2 Alternator Components FV 277000 1 End bracket 2 Rubber mallet 3 Block of wood Figure 7 3 Raising the Generator TP 6079 3 00 FV 277000 1 Mallet 2 Rotor bolt Figure 7 4 Rotor Removal Generator Disassembly Reassembly 29 7 2 Collector Ring Bearing Minimum diameter mm in 57 15 2 250 Replacement Maximum finish microin
64. surements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove rings wristwatch and jewelry 2 Stand ona dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under Hot Parts WARNING 7 5 5 D Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools IV Safety Precautions and Instructions 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 Combustible materials Fire can cause severe injury or death A hot exhaust system can ignite adjacent combustible materials Do not locate electrical wiring fuel lines or combustible materials above the exhaust muffler Exercise caution when parking your vehicle to prevent the exhaust system and hot exhaust gases from starting grass fires Combustible materials Fire can cause severe injury or death A hot generator set can ignite debris in the compartment Keep the compartment and generator set clean and free of debris and combustible ma
65. t electrical connections with tools or jewelry while making adjustments or repairs Remove wristwatch rings and jewelry before servicing the equipment TP 6079 3 00 5 1 1 General Troubleshooting To determine the cause of no or low AC output refer to the following steps and the troubleshooting flow chart Figure 5 1 Verify the operation of the alternator components before replacing the controller board or voltage regulator General Troubleshooting 1 Check the condition of the voltage regulator s 10 amp fuse 2 If the fuse is functional separately excite the generator See Section 5 1 2 The separate excitation test duplicates the role of the voltage regulator by providing excitation current to the rotor Generator has no or low output Check for flashing voltage at the brushes Separately Troubleshoot controller Generator has output Test voltage regulator and wiring excite generator Generator has no output Test rotor Test stator TP 598651 Figure 5 1 General Troubleshooting Generator Troubleshooting 15 5 1 2 Separate Excitation By separately exciting the generator to determine the presence of a faulty voltage regulator it is possible to determine if a running fault exists in the rotor and or stator A generator component that appears functional while static stationary may exhibit a running open o
66. tallic strip Choke linkage Choke plate lever Figure 3 2 Fuel System Exploded View 3 3 1 Hard Starting A flooded engine an improperly adjusted or inoperative choke or a dirty carburetor lean condition can cause hard starting 3 3 2 Stalling A dirty carburetor can cause stalling Clogged idle air bleeds idle air passages or an idle discharge port can cause stalling because of a lean condition To remedy this condition clean or adjust the carburetor TP 6079 3 00 3 3 3 Flooding Flooding occurs from a float level set too high an inoperative bi metallic strip an inoperative choke pull off a sticking choke plate or float or a fuel inlet needle held off its seat either by improper seating or dirt particles A punctured or leaking float admitting fuel becomes gas logged causing a heavy float high fuel level and flooding 3 3 4 Hunting A low fuel level because of an improperly adjusted float a clogged main jet restricted main jet passages or an improperly sized main jet for the application can cause hunting To remedy this condition clean adjust or replace inoperative components An incorrect throttle linkage adjustment a binding throttle linkage a sticking throttle shaft or a loose throttle shaft in the throttle body or bore can cause inconsistent idle speed 3 3 5 Leaking Carburetor Loose fuel connections a cracked carburetor body a sticking fuel inlet needle or an inoperative float can ca
67. terials to minimize the possibility of fire Do not block the fuel oil drain opening in the generator set mounting tray Cut a corresponding hole in the subfloor if used for the drain opening Moving Parts WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware Servicing the generator set when itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set TP 6079 3 00 NOTICE This generator set has been rewired from its nameplate voltage
68. 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 TP 6079 3 00 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 installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 NOTICE This generator set does not comply with United States Coast Guard USCG requirements and must not be used for marine applications For marine installations use only generator sets specified for marine use USCG Regulation 33CFR183 requires that a generator set must be ignition protected when used in a gasoline fueled environment afety Precautions and Instructions V Notes VI Safety Precaufions and Instructions TP 6079 3 00 This manual provides troubleshooting and
69. to half of their original size TP 598658 1 Brush holder 2 Retainer paper clip 3 Mounting screw 4 Alignment shim s 5 Brush 6 Spring Figure 5 10 Brush Holder Generator Troubleshooting 21 Notes 22 Generator Troubleshooting TP 6079 3 00 Component Troubleshooting 6 1 Engine Generator Components See Figure 6 1 through Figure 6 3 for engine generator component testing With the generator set battery connected check the wiring harness and the engine generator components listed in the following tables Check each component using a multimeter to verify that the switches function and that voltage is present at each component Component Hourmeter and wiring Voltmeter Connections Connect the red test lead to the hourmeter positive terminal Connect the black test lead to the hourmeter negative terminal Procedure Set the voltmeter to 12 volts DC or greater Start the generator set Results A 12 volt DC reading indicates the wiring harness is functional None see procedure Disconnect the hourmeter leads and apply 12 volts DC to the hourmeter The hourmeter is polarity sensitive If functional hourmeter operates Stator auxiliary winding B1 and B2 Figure 6 1 TP 6079 3 00 Connect the AC voltmeter leads to the B1 and B2 windings at connector P11 Stop the generator set Set the voltmeter to 20 volts AC or greater Crank the generator set and allo
70. use aleaking carburetor Adjust repair or replace the affected components 3 4 Governor The factory adjusts the governor and_ further adjustments should not be necessary Note Never tamper with the governor settings to increase the generator output Overspeeding can cause equipment parts to exceed design limitations resulting in component failure TP 6079 3 00 3 5 60 and 50 Hz Conversions To convert the generator set to 50 or 60 Hz follow the procedure below Governor 50 or 60 Hz Conversion Procedure 1 Adjust the generator frequency by adjusting the generator speed adjusting screw Using a frequency meter set the no load speed at 52 5 Hz for 50 Hz operation or 63 Hz for 60 Hz operation 2 Adjust the voltage regulator volt Hz roll off point Refer to Section 5 2 2 1 Generator speed adjusting screw Figure 3 3 Governor 60 Hz to 50 Hz Conversion Fuel System 7 Notes 8 Fuel System TP 6079 3 00 Controller Troubleshooting 4 1 Sequence of Operation This section describes the controller sequence of operation during the generator start run stop and fault shutdown modes and describes the relay testing procedures Use this section as a starting point for controller fault identification Use the LEDs on the controller circuit board to assist in the troubleshooting process An illuminated LED indicates that the respective relay is receiving power the LED does not indicate whether that relay is energized or
71. w the set to reach its rated speed Engine Generator Component Testing Relay Controller A reading of 12 15 volts AC indicates a functional B1 B2 winding Component Troubleshooting 23 To further check the generator set components disconnect the battery and remove the wiring harness plugs from the controller circuit board Use an ohmmeter to check the continuity of the components and to isolate inoperative components Refer to Figure 6 2 and Figure 6 3 WARNING Hazardous voltage Moving rotor Can cause severe injury or death Note Before performing ohmmeter checks disconnect the generator set battery to prevent damage to 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 wristwatch rings and jewelry before servicing the equipment Ohmmeter Connections Connect the ohmmeter to the P2 6 and P2 4 leads Component Start stop switch Connect the ohmmeter to the P2 6 and P2 5 leads the ohmmeter Procedure Place the ohmmeter on the R x 1000 scale Place the rocker switch in the START position Place the ohmmeter on the R x 1000 scale Place the rocker switch in the STOP position Results If the switch is fun
72. watt 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 packed accessory 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 pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw relay root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanizati
73. ween P1 8 and P1 14 Yes Yes Y Y Disconnect the P2 connector Is there continuity between Is there continuity across the P2 5 and N P1 P4 and P9 connectors No Y Check the wiring for open circuits Replace the remote start stop switch Check the connectors for open circuits Y Replace the start stop switch Figure 4 4 Troubleshooting the Relay Controller Circuit Board 2 of 4 12 Controller Troubleshooting TP 6079 3 00 to run after the start switch is released Does the engine continue gt Does using the stop switch stop the engine No No Y Did the K4 relay LED light Does the K1 relay LED light Yes of running time Does the K5 relay LED light after 5 10 seconds Yes Y No Is the LED lit Replace the circuit board the K5 relay Yes Y The generator set is functioning properly No Is the start stop switch functional Replace the start stop switch Y Is the LOL switch functional is inoperative Replace the circuit board the K6 relay is inoperative Y Go to D next page
74. working properly Unfold and use the wiring diagram in Section 8 5 to follow the sequence of operation in this section mb JUU STOP START AC CIRCUIT BREAKE 1 2 Dundee ge PBIIIE voltage regulator K20 relay K25 relay Controller circuit board Fuses Start stop switch Hourmeter Figure 4 1 Controller TP 6079 3 00 4 1 1 Start Press the start stop switch to the START position to close the start stop switch between N and 47 local or remote The K2 relay energizes and LED2 illuminates The normally open K2 contacts close energizing the relay LED3 lights fuel pump FP choke heater CHTR antidiesel solenoid ADS ignition IGN hourmeter HR and the main field FP and FN Flashing of the main field occurs when the K2 contacts close The normally open K3 contacts close energizing the K20 relay The normally open K20 contacts close energizing the starter relay SR The SR normally open contacts close energizing the starter motor SM 4 1 2 Run The bridged rectifier BR1 receives AC voltage 12 15 volts through the B1 and B2 windings of the stator The K1 relay energizes LED1 lights The normally open K1 contacts close maintaining voltage to the K2 relay allowing the function of the fuel pump FP choke heater CHTR antidiesel solenoid ADS ignitio
75. y 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 neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permitflames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove wristwatch rings and other 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 atety Precaut

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