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Table of Contents

SUBJECT
Safety Precautions and Instructions ............ Glossary of Abbreviations .................... Reference Material .......................... Service Assistance ........................... Section 1. Introduction ......................
Specifications Generator Engine ................................ ..................................

PAGE
i vi ... ix
l-l l-l l-l l-l l-l l-4

SUBJECT
Belt Tension ................................ Sea Water Pump Belt ...................... Battery Charging Alternator Belt ............. Generator Service ........................... Wattage Requirements ....................... Storage Procedure .......................... Section 4. General Troubleshooting .......... Section 5. Controller Troubleshooting ........ Sequence of Operation (E-239563 Circuit Board) ............................... Starting.. .................................. Running ................................... Stopping ................................... Engine Safety Shutdown Switches. ............. Low Oil Pressure (LOP) Shutdown Switch .......................... High Water Temperature (HWT) and High Exhaust Temperature (HET) Shutdown Switch .......................... Overspeed Safety Shutdown (SDR) ............

PAGE
3-l 4 3-14 3-l 4 3-l 5 3-l 5 3-l 5

VIII

....................................

4-l 5-l
5-l 5-l 5-l 5-2 5-3 5-3

Accessories ................................ Service Views ...............................

Section 2. Operation ........................


Prestart Checks .............................. Controller ................................... Starting ..................................... Preheat Feature (Optional) 13.5/l 4/l 8.5/2OCCOZ and 11/11.5/15/17.5 CCFOZ Models Only Stopping ..................................... Circuit Protection ............................. Engine Safety Shutdown Remote Panels (Optional) Remote Start Panel Switches .............. ..................... ...........

2-l
2-l 2-l 2-2

........

2-2 2-2 2-3 2-3 2-4 2-4 2-5 2-6

5-3 5-3

Section 6. Generator/Controller Troubleshooting ............................


Controller Circuit Board .......................

6-l
6-l

......................... Remote Start and Twb-Meter Panel Remote Stat-t and Four-Meter General ..................................... ............................ ........................... .............................. System

Panel ...........

Section 3. Scheduled Maintenance ...........


Service Schedule Lubrication OilCheck.. Specifications

&I
3-1 3-2 3-4 3-4 3-4 3-4 3-5 3-6 3-6 3-6 3-6 3-7 3-8 3-9 3-9 3-9 3-11 3-11 3-l 1 3-12

................................

Oil Change ................................. Oil Filter Change ............................ Fuel System ................................. Specifications .............................. Fuel Filter .................................. Bleeding ................................... Air Intake Silencer Cleaner .................... Turbocharger (13.5/l 8.5/21 CCOZ and 11/15/16.5/18CCFOZ) ................... Servicing Mixing Elbow ....................... Governor .................................... Valve Adjustment. ............................ Cylinder Head Retightening ................... Cooling System ............................. Closed/Heat Exchanger .................... Siphon Break ...............................

7-l Separate Excitation ........................... 7-l Voltage Regulator Test-Powerboost V ........ 7-3 Test Procedure ............................. 7-4 Voltage Regulator Adjustment ................ 7-5 Adjustment Procedure ....................... 7-6 Exciter Field ................................. 7-6 Exciter Armature ............................. 7-8 Rectifier Module. ............................. 7-9 Generator Main Field (Rotor) .................. 7-9 Stator .................................... 7-10 Controller Circuit Board ...................... 7-l 4 Engine/Generator Components ............... 7-l 6 Fuel Solenoid ............................. 7-l 9 Fuel Pump ................................ 7-20 Section 8. Disassembly/Reassembly ......... 8-l Section 9. Wiring Diagrams .................. 9-l Section IO. Specifications Chart ............ IO-I Generator Models ........................... 1 O-l Engine Models .............................. 1O-5 ................................. Installation 1O-9 Common Hardware Application Guidelines, Specification G-585 ............. 1O-l 1 Common Hardware Application (G-585) ....... 1O-l 2 Common Hardware Identification ............. 1O-l 3 General Torque Specifications ............... 1 O-l 5

Section 7. Component Testing and Adjustment ............................

TP-5630 1 O/93

Table of Contents

Safety Precautions and Instructions


A generator set, like any other electro-mechanical device, can pose potential dangers to life and limb if improperly maintained or imprudently operated. The best way to prevent accidents is to be aware of the potential dangers and to always use good common sense. In the interest of safety, some general precautions relating to the operating of a generator set follow. Keep these in mind. This manual contains several types of safety precautions which are explained below.

EXHAUST SYSTEM

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death. DANGER The exhaust system must be leakproof and routinely inspected.
A

Danger is used to indicate the presence of a hazard that will cause severe personal injury, death, or substantial property damage if the warning is ignored.

WARNING

Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.

CAUTION

Caution is used to indicate the presence of a hazard that Morwcause minorpersonal injury or property damage if the warning is ignored. NOTE Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related. Safety decals are affixed to the generator set in prominent places to advise the operator or service technician of potentially hazardous situations. The decals are reproduced here to improve operator recognition and thereby increase decal effectiveness. For a further explanation of decal information, reference the accompanying safety precautions. Before operating or servicing the generator set, be sure you understand the message of these decals. Replace decals if missing or damaged.

Carbon monoxide can cause severe nausea, fainting, or death. Use the following precautions when installing and operating generator set. Carbon monoxide is particularly threatening in that it is an odorless, colorless, Be especially careful if tasteless, nonirritating gas. operating the generator when moored or anchored under calm conditions as gases may accumulate. If operating the set dockside, moor your craft so that the exhaust discharges on the lee side (the side sheltered from the wind), and always be mindful of others-make sure your exhaust is directed away from other boats and occupied buildings. Do not install exhaust outlet where exhaust can be drawn through portholes, vents, or air conditioners. If generator sets exhaust discharge hole is near to your crafts water line, DO NOT OVERLOAD CRAFT so as to close or restrict exhaust discharge hole. Carbon monoxide can cause severe nausea, fainting, or death. Diesel fumes can rapidly destroy copper tubing in diesel exhaust systems. Do not use copper tubing in diesel exhaust systems. Exhaust sulphur will cause rapid deterioration and this could result in exhaustiater leakage.
(Diesel Models on/)

Carbon monoxide can cause severe nausea, fainting, or death. In addition to routine inspection of the exhaust system, a carbon monoxide detector should be considered. Consult your boat builder or marina for installation of approved detectors. It is essential that all detectors be routinely inspected for proper operation.

TP-5630 1 O/93

Safety Precautions and instructions

ACCIDENTAL

STARTING

Accidental starting. Can cause severe injury or death. Disconnect battery cables before working on generator set (negative lead first and reconnect it last). Accidental starting can cause severe injury or death. Disconnect battery cables (remove negative lead first and reconnect it last) to disable generator set before working on any equipment connected to generator. The generator set can be started by remote start/stop switch unless this precaution is followed.

Flying projectiles can cause severe injury or death. Retorque all crankshaft and rotor hardware after servicing. When making adjustments or servicing generator set, do not loosen crankshaft hardware or rotor thru-bolt. If rotating crankshaft manually, direction should be clockwise only. Turning crankshaft bolt or rotor thru-bolt counterclockwise can loosen hardware and result in serious personal injury from hardware or pulley flying off engine while unit is running. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, and clothing away from belts and pulleys when unit is running. Replace guards, covers, and screens before operating generator set. Exposed moving parts can cause severe injury or death. Additional Precautions Regarding Sound Shield Equjpped Models: Some scheduled maintenance procedures require the generator set to be running while performing service. If the sound shield has been removed leaving belts and pulleys exposed, be especially careful of this area.

MOVING PARTS
r

WARNING

ENGINE BACKFIRE/FLASH

FIRE

A
Hazardous voltage.

WARNING

-3

Moving rotor.

b!!b

Can cause severe injury or death. Do not operate generator set without all guards and electrical enclosures in place. Fire. Can cause severe injury or death. Do not smoke or permit flame or spark to occur near fuel or fuel system.

WARNING at&
0

A sudden backfire can cause severe injury or death. Do not operate with air cleaner/silencer removed. (Diesel Models only.) A sudden flash fire can cause severe injury or death. Do not smoke or permit flame or spark to occur near fuel system. Keep the compartment and generator set clean and free of debris to minimize chances of fire. Wipe up all spilled fuel and engine oil.

Rotating parts. Can cause severe injury or death. Do not operate generator set without all guards, screens, or covers in place.

ii

Safety Precautions and Instructions

TP-5630 1 O/93

HAZARDOUS

NOISE

Hazardous backfeed voltage can cause severe injury or death. Do not connect to any building/marina
electrical system without connecting device and after building connections can cause serious working to repair through an approved Backfeed and/or may be prevent 1 main switch is open. a power

injury or death to utility outage connection to

CAUTION

personnel unlawful transfer

personnel in the vicinity. switch must

Unauthorized be

Hazardous noise. Can cause loss of hearing.


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

in some states and/or localities. installed of generator

A ship-to-shore

interconnection

set power and shore power.

FUEL SYSTEM HAZARDOUS SHOCK VOLTAGE/ELECTRICAL

WARNING

WARNING

Explosive fuel vapors. Can cause severe injury or death.

-9
Hazardous voltage.

Fib
Moving rotor.

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

Can cause severe injury or death.


Do not operate generator set without and electrical enclosures in place. all guards

Explosive fuel vapors can cause severe injury or death. All fuels are highly explosive in a vapor state. Use
extreme care when handling, storing, and using fuels. Store fuel 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 since spilled fuel may ignite on contact with hot parts or from ignition spark. Do not smoke or permit flame or spark to occur near potential sources of spilled fuel or fuel vapors. Keep fuel lines and connections tight and in good condition-dont replace flexible fuel lines with rigid lines. Flexible sections are used to avoid breakage due to vibration. electrical Should any fuel leakage, fuel accumulation, or sparks be noted, DO NOT OPERATE repaired before

Hazardous voltage can cause severe injury or death.


Wherever electricity is present, there is the hazard of electrocution. Take the same precautions with electrical appliances in your craft that you would observe in your home. Open main circuit breaker on all power sources before servicing equipment. Make sure unqualified persons, especially children, cannot gain access to your set-keep the compartment door locked or securely latched at all times. Be sure that generator is properly grounded. Never touch electrical leads or appliances with wet hands, when standing in water, or on wet ground as the chance of electrocution is especially prevalent under such conditions.

GENERATOR SET. Have systems resuming generator operation.

Hazardous voltage can cause severe injury or death.


The heat sink of the voltage regulator contains high voltage. Do not touch voltage regulator heat sink when testing or electrical shock will occur.

Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a
container to catch fuel when draining fuel system. Wipe up all spilled fuel after draining system.

(PowerBoost, PowerBoost Ill, and PowerBoost V Voltage Regulator Models only) Hazardous voltage can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment with tools Remove damage. Do not contact electrical connections or jewelry while adjustments are made. wristwatch,

Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Do not
modify the tank or propulsion engine fuel system. Craft must be equipped with a tank allowing one of the two pickup arrangements described. Tank and installation must conform to U.S.C.G. Regulations.

rings, and jewelry that can cause short circuits.

TP-5630 10193

Safety Precautions and Instructions

iii

BAlTERY

HOT PARTS

WARNING

WARNtNG

Sulfuric acid in batteries. Can cause severe injury or death.


Use protective permanent in clothing. goggles and clothes. Can cause

damage to eyes, burn skin, and eat holes

Hot coolant and steam. Can cause severe injury or death.


Before removing pressure cap stop generator, cap to relieve

Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can cause permanent
damage Always to eyes, burn skin, and eat holes in clothing. wear splash-proof safety goggles when working around the battery. If battery electrolyte is splashed in the eyes or on skin, immediately flush the affected area for 15 minutes with large quantities of clean water. In the case of eye contact, seek immediate medical aid. Never add acid

allow to cool and loosen pressure pressure.

WARNING

to a battery once the battery has been placed in service. Doing so may result in hazardous spattering of electrolyte.

Explosion can cause severe injury or death. Battery


gases can cause an explosion. Do not smoke or permit flame or spark to occur near a battery at any time, particularly when it is being charged. Avoid contacting terminals with tools, etc. to prevent burns and to prevent Remove sparks that could cause an explosion. wristwatch, rings, and any other jewelry before handling battery. Never connect negative (-) battery cable to positive (+) connection terminal of starter solenoid. Do not test battery condition by shorting terminals together or sparks could ignite battery gases or fuel vapors. Any compartment containing batteries must be well ventilated to prevent accumulation of explosive gases. To avoid sparks, do not disturb battery charger connections while battery is being charged and always turn charger off When before disconnecting battery connections. disconnecting battery, reconnect it last. remove negative lead first and

Hot engine and exhaust system. Can cause severe injury or death.
Do not work on generator set until unit is allowed to cool.

Hot parts can cause severe injury or death. Do not


touch hot engine parts. An engine gets hot while running and exhaust system components get extremely hot.

Hot coolant can cause severe injury or death. Allow engine to cool and release pressure from cooling system
before opening pressure cap. To release pressure, cover the pressure cap with a thick cloth then turn it slowly counterclockwise to the first stop. After pressure has been completely released and the engine has cooled, remove cap. If generator set is equipped with a coolant recovery tank, check coolant level at tank.

iv

Safety Precautions and Instructions

TP-5630 10193

NOTES

NOTE
Wipe up all spilled diesel fuel after bleeding system. Wash hands after any contact with fuel oil. (Diesel models only).

NOTICE
This generator set has been rewired from its nameplate voltage to:

NOTE HARDWARE DAMAGE! Engine and generator may make


use of both American heads and nuts. Standard and metric hardware. Be sure to use the correct size tools to prevent rounding of bolt

246242 Special attention should

NOTE
be given when checking for proper coolant level. After the coolant has been drained, it normally requires some time before complete refill of the engine water jacket takes place.

NOTICE
This is a positive terminal only. Do not attach negative lead!

NOTE ENGINE DAMAGE! Failure to bleed air from cooling

NOTICE
Check zinc anode every 100 hours or 3 months.

system may cause overheating to engine.

and subsequent

damage

NOTE When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available
American Standard in different hardness ratings. hardware uses a series of markings and metric hardware uses a numeric system to indicate hardness. Check markings on bolt head and nuts for proper identification.

NOTICE

Do not use as a step.


Standing on genset could impair operation of unit.

51

NOTE
High-mineral content sea water (salt water) can cause rapid destruction of all metals. Wipe up all salt water spillage on and around generator set and keep metal surfaces free from accumulated salt deposits.

TP-5630 10193

Safety Precautions and Instructions

Glossary of Abbreviations
Abbreviations are used throughout this manual. Normally in the text they will appear in complete form with the abbreviation following in parentheses the first time they are used. After that they will appear in the abbreviated form. The commonly used abbreviations are shown below. Abbreviation Description alternating current AC AHWT ALOP AM amp amps ANSI API approx. A/R A/S ASA assy. ASTM ATDC ATS aux. AWG AWM bhp bmep Btu C cc CCA CEC cfh cfm CID cm cmm co. contd. C.S.A. cu. in. cyl. dBA DC DCR deg. dept. dia. anticipatory high water temp. anticipatory low oil pressure amplitude modulation ampere amperes American National Standard Institute American Petroleum Institute approximate, approximately as required, as requested as supplied, as stated, as suggested American Standards Association assembly American Society for Testing Materials after top dead center automatic transfer switch auxiliary American Wire Gauge appliance wiring material brake horsepower brake mean effective power British thermal unit Celsius degree cubic centimeter cold cranking Amps. Canadian Electrical Code cubic feet per hour cubic feet per minute cubic inch displacement centimeter, centimeters cubic meters per minute company continued Canadian Standards Association cubic inch, cubic inches cylinder decibels direct current direct current resistance degree department diameter Abbreviation e.g. EMI etc. ext. F fl. oz. FM fs ft. ft. Ibs. ga. gal., gals. gal./hr. gph gpm gr. grd. HCHT HET Hg
H20 hp

Description example given electromagnetic interference etcetera, (and so forth) external Fahrenheit degree fluid ounce, fluid ounces frequency modulation full scale foot, feet foot pound, foot pounds gauge gallon, gallons gallons per hour gallons per hour gallons per minute grade ground high cylinder head temperature high exhaust temperature mercury (element) water horsepower hour high water temperature hertz (cycles per second) inside diameter inch(es) incorporated inch pounds internal internal-external International Standards Organization joule, joules Japanese Industry Standard kilogram, kilograms kilograms per square centimeter kilogram meter(s) kilometer, kilometers kiloPascal, kiloPascals kilometers per hour kilovolt kilovolt amperes

hr, hrs HWT Hz ID in. inc. in. Ibs. int. int.-ext. IS0 J JIS kg kg/cm2 kgm km kPa kph kV kVA

vi

Glossary of Abbreviations

TP-5630 1 O/93

Abbreviation kW kWH L LxWxH LED, LEDs lb., Ibs. Uhr. Umin. LOP LP LWT m m3 max. MCM mi. mil min. mJ MJ mm m3/min MPa mph MS mW MW N/A NEC NEMA NFPA Nm no., nos. NPT N/R

Description kilowatt, kilowatts kilowatt hour liter, liters length x width x height light emitting diode pound, pounds liter per hour, liters per hour liter(s) per minute low oil pressure liquefied petroleum low water temperature meter, meters cubic meter, cubic meters maximum one thousand circular mils. mile, miles one one-thousandth of an inch minimum millijoule, millijoules mega joule, mega joules millimeter, millimeters cubic meters per minute megaPascal miles per hour military standard milliwatt, milliwatts megawatt, megawatts not available National Electrical Code National Electrical Manufacturers Association National Fire Protection Association Newton meter, Newton meters number, numbers National Standard taper pipe thread per general use not required

Abbreviation OD OEM OS ov
OZ.

Description outside diameter original equipment manufacturer overspeed, oversize overvoltage ounce, ounces power factor potentiometer parts per million pounds per square inch pint, pints quart, quarts quantity reference radio frequency interference root mean square revolutions per inch Society of Automotive Engineers second, seconds silicon controlled rectifier specification square square centimeters square inch, square inches tachometer top dead center temperature telephone influence factor turbocharger Unified coarse thread (was NC) Unified fine thread (was NF) Underwriters Laboratories, Inc. undersize volt, volts volts alternating current volts direct current watt, watts

PF pot. ppm psi pt., pts. qt., qts. qty. ref. RFI rms rpm SAE sec. SCR spec, specs sqsq. cm sq. in. tach TDC temp. TIF turbo UNC UNF UL us V VAC VDC W

TP-5630 1 O/93

Glossary of Abbreviations

vii

Reference Material
It is recommended that the following Regulations and Standards be followed when installing Marine Generator Sets. IEEE 45 The Institute of Electrical and Electronics Engineers Inc. 345 East 47th Street New York, NY 10017 l-800-678-4333

PLEASURE CRAFT
Designed and manufactured to meet U.S. Coast Guard Title 33. U.S. Coast Guard Code of Federal Regulations Tile 33 Subparts l-Electrical Systems Subparts J-Fuel Systems Title 46 Subchapter F-Marine Engineering Part 58-Main and Auxiliary Machinery and Related Systems Order the above publications from: Superintendent of Documents U.S. Government Printing Office Washington, DC 20402 l-202-783-3238 Boating Safety Circular Commandant (G-BC) Boating Statistics (G-BP-l) U.S. Coast Guard Headquarters 2100 Second Street, S.W. Washington, DC 20593-0001 Boating Safety Hotline: l-800-368-5647 Underwriters Laboratories, Inc. (UL) Publications Stock 333 Pfingsten Road Northbrook, IL 60062 Marine Department: l-91 9-549-l 400 NFPA 302 National Fire Protection Association Batterymarch Park Quincy, MA 02269 I-800-735-01 00 Customer Service Society of Automotive Engineers (SAE) 400 Commonwealth Drive Warrendale, PA 15096 l-41 2-776-4970 American Boat and Yacht Council, Inc. (ABYC) 405 Headquarters Drive, Suite 3 Millersville, MD 21108 l-301 -923-3932 or l-301 -923-3953 ...
Reference Material

COMMERCIAL VESSELS
In order to use these generator sets for commercial applications where U.S. Coast Guard Title 46 Certificate is required, additional modifications will be necessary. U.S. Coast Guard Code of Federal Regulations Title 46 Subchapter F-Marine Engineering Part 58-Main and Auxiliary Machinery and Related Systems Subchapter J-Electrical Engineering Part 11l-Electrical SystemsGeneral Requirements Part 112-Emergency Lighting and Power Systems Subchapter T-Small Passenger Vessels (Under 100 Gross Tons) Part 182-Machinery Installation Part 183-Electrical Installation Order the above publications from: Superintendent of Documents U.S. Government Printing Office Washington, DC 20402 l-202-783-3238 American Bureau of Shipping (ABS) 65 Broadway New York, NY 10006 Order ABS publications from: American Bureau of Shipping Book Order Section 45 Eisenhower Drive P.O. Box 910 Paramus, NJ 97653-0910 Lloyds Register of Shipping 71 Fenchurch Street London, EC3M 4BS England Midwest Off ice: Lloyds Register of Shipping 100 South York Street, Room 226 Elmhurst, IL 60126 l-31 2-279-5414
TP-5630 10193

VIII

Service Assistance
See the Yellow Pages of your Telephone Generator-Electric for your closest Dealer or contact your local marina. KOHLER CO., Kohler, Wisconsin Phone 414-565-3381 Fax 414-565-3648 For Sales & Service in U.S.A. & Canada Phone l-800-544-2444 Provide ENGINE set. MODEL, numbers SPECIFICATION, from the generator SERIAL, nameplate and to 53044 Directory under Generator Kohler

receive current parts and information

for your generator

TP-5630 10193

Service Assistance

ix

Section I. Introduction
This manual covers and the repair operation, maintenance, current Service requirements therefore, inspect are minimal but are very important of your generator parts often. It set; is associated that perform an troubleshooting, Marine Generator of the alternating to the safe and efficient operation recommended Sets listed in Figure l-l.

Models 13.5/l 8.5/21 CCOZ


14/20/24CCCZ 11 /15/l 6.5/l 8CCFOZ

Voltage
100/200-l 20/240 (60 Hz) 120/208-277/480 (60 Hz broad range) 220-240, 100/200-11 o/220 (50 Hz) 11 O/l 90-240/416 (50 Hz broad range)

Phase
1

dealer/distributor your unit continues

authorized required servicing

service to assure

to meet USCG requirements. to read this manual, then

Please take a few moments 3 1 set in top condition. future reference. identification All information 3

carefully follow all service recommendations


See Figures 1-2, l-3,

to keep your and 1-4 for

Keep this manual aboard your craft for

and location of components. found in this publication to this literature without is based on data and the products notice and without

11.5/l 7.5/20 CCFOZ

available at time of printing. to make changes represented incurring obligation. at any time

Kohler Co. reserves the right

Figure 1-l. Generator Model Coverage

Specifications
Generator
Derating: Nameplate rating shown is at 25 C (77 F) and at 500 ft. (150 m) on units without sound shields. Units will derate at higher ambient temperatures and/or different altitudes. Consult factory for specific derating information. Several installation

Accessories
accessories or to add are available to finalize the and convenience to operation

service. All the most current information can be obtained by contacting your local Kohler dealer/distributor. Available accessories at the time of print of this publication are as follows.

Engine
The 13SCCOZ/ll CCFOZ and 14CCOZ/l1.5CCFOZ are powered by a Yanmar threecylinder, water-cooled, four-cycle diesel engine. The turbocharged, three-cylinder engine with heat exchanger The 18.5CCOZ/15CCFOZ powered four-cylinder four-cylinder 4JH2LT-K. The 21 CCOZ/l6.5CCFOZ, are powered four-cylinder by four-cycle 24CCOZ/2OCCFOZ a Yanmar and by a Yanmar is Model 3JH2LT-K.

LINE CIRCUIT BREAKERS


Line circuit breakers protect the generator overload. from extreme

PREHEATER
and 2OCCOZ/l7.5CCFOZ four-cylinder, are Air Intake Heater Kit provides limates water-cooled,

KITS
improved starting in cold

diesel engine. engine with heat

The turbocharged exchanger is Model

REMOTE CONNECTION/EXTENSION HARNESS

18CCFOZ water-cooled,

four-cylinder,

Provides additional controller connector increments-75

wiring between all remote panels and in 15 ft. (4.6 m) or 25 ft (7.6 m) One required for

diesel engine. The turbocharged engine with heat exchanger

and intercooled

ft. (22.6 m) maximum.

is Model 4JH2LHT-K. Heat exchanger cooling consists of heat exchanger with

each Remote Meter Panel Kit (see Section 2).

REMOTE WIRING HARNESS

(124NCH)

coolant recovery tank, thermostat, rubber impeller sea water pump, centrifugal type engine circulating pump, water-cooled exhaust manifold, and exhaust mixer.

This one-foot (0.3 m) wiring harness has a 6-pin connector on one end which is keyed to the controller box connector. The other end has pigtails for connection to customer supplied start switch, generator ON light, hourmeter, etc.

TP-5630 10193

Introduction

l-l

SEA WATER STRAINER


Available for in-line installation between seacock and seawater pump. Required to prevent sea-water entry into the engine when generator set is installed at or below water line.

SENDER KIT
Provides sender capability which is necessary to make remote meter panel gauges functional.

SOUND SHIELD
Provides highly effective silencing, ease of access for engine/generator service, low maintenance, excellent durability, and safety.

SHIP-TO-SHORE

SWITCH

Allows immediate switching to Kohler generator set power or shore power protecting your electrical system from the possibility of simultaneous connection of both power sources.

SILENCERS
Reduce engine exhaust noise. Super Silencer II is a tube type and Super Silencer III is a canister (lift) type.

1-2

Introduction

TP-5630 1 O/93

Notes

TP-5630 1 O/93

Introduction

l-3

Figure 1-2. Service Views-l3.5CCOZ/11CCFOZ,


l-4 Introduction

14CCOZ/ll SCCFOZ
TP-5630 10193

13.5CCOZ/ll

Service Views CCFOZ, 14CCOZ/11.5CCFOZ


Heat Exchanger Coolant (Fresh Water) Drain Sea Water Drain High Exhaust Temperature Safety Shutdown Switch AC Load Lead Connector Nameplate Remote Start Connector Mixing Elbow (Water Outlet/Exhaust Outlet) Coolant (Fresh Water Drain Battery Negative (-) 2 onnection Starter Solenoid Starter Motor Ground Lug (Equipment Ground) Battery Positive (+ Connection Sea Water (Drain b oint) Petcock Belt Guard Coolant (Fresh Water) Drain Battery Charging Alternator V-Belts Engine-Driven Water Pump Not Shown Air Intake Heater (optional Preheat Kit required to make air intake heater functional).

1. Controller 2. Air Intake Silencer 3. Fuel Solenoid 4. Lifting Eye 5. Lifting Eye 6. Fuel Injectors 7. Oil Fill 8. Water Temperature Sender (Optional) 9. Fuel Filter 10. Fuel Return Connector 11. Fuel Injection Pump 12. Oil Fill 13. Governor 14. Sea Water Pump (Water Inlet) 15. Oil Pressure Sender (Optional) 16. Lube Oil Filter 17. Oil Drain Valve and Hose 18. Oil Check 19. Fuel Feed Pump (Fuel Inlet) 20. Low Oil Pressure Safety Shutdown Switch 21. Coolant (Fresh Water) Drain 22. High Water Temperature Safety Shutdown Switch 23. Overflow Tube 24. Pressure Cap

TP-563010l93

Introduction

l-5

Figure 1-3. Service Views-l8.5CCOU15CCFOZ,


l-6 Introduction

2OCCOZIl7SCCFOZ

TP-5630 10193

Service Views (continued) 18.5CCOZ/l XCFOZ, 2OCCOZ/17.5CCFOZ


1. Controller 2. Nameplate 3. Air Intake Silencer 4. Lifting Eye 5. Fuel Solenoid 6. Fuel lniectors 7. Oil Fill a 8. Water Temperature Sender (Optional) 9. Fuel Filter 10. Fuel Return Connector 11. Oil Fill 12. Fuel Injection Pump 13. Governor 14. Sea Water Pump (Drain Point (Water Inlet) 15. Oil Pressure Sender (Optiona 1 ) 16. Oil Drain Valve and Hose 17. Lube Oil Filter 18. Oil Check 19. Fuel Feed Pump (Fuel Inlet) 20. Low Oil Pressure Safety Shutdown Switch 21. Coolant (Fresh Water) Drain 22. Overflow Tube 23. Pressure Cap 24. Lifting Eye 25. Heat Exchanger 26. Coolant (Fresh Water) Drain Sea Water Drain z. High Exhaust Temperature Safety Shutdown Switch 29: AC Load Lead Connector Remote Start Connector ::: Mixing Elbow (Water Outlet/ Exhaust Outlet) Coolant (Fresh Water Drain ::* Battery Negative (-) & onnection 34: Starter Solenoid 35. Starter Motor Battery Positive (+) Connection :;. Ground Lug (Equipment Ground) 38: piersater (Drain Point) Petcock !Z: Battery Charging Alternator Engine-Driven Water Pump ::. Belt Guard 43: High Water Temperature Safety Shutdown Switch Not Shown Air Intake Heater Coil (optional Preheater Kit required to make it fuctional).

TP-563010193

Introduction

1-7

Figure 1-4. Service Views--2lCCOZ/16SCCFOZ,

18CCFOZ,

24CCOU2OCCFOZ

l-8

Introduction

TP-5630

1 O/93

Service Views (continued) 21 CCOZII 6.5CCFOZ, 18CCFOZ, 24CCOZI2OCCFOZ


1. Controller 2. Nameplate 3. Air Intake Silencer 4. Lifting Eye 5. Fuel Solenoid 6. Fuel Injectors 7. Oil Fill 8. Water Temperature Sender (Optional) 9. Fuel Filter 10. Fuel Return Connector 11. Oil Fill 12. Fuel Injection Pump 13. Governor 14. Sea Water Pump (Drain Point (Water Inlet) 15. Oil Pressure Sender (Optiona 1 ) 16. Oil Drain Valve and Hose 17. Lube Oil Filter 18. Oil Check 19. Fuel Feed Pump (Fuel Inlet) 20. Low Oil Pressure Safety Shutdown Switch 21. Coolant (Fresh Water) Drain 22. Overflow Tube 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. Pressure Cap Lifting Eye Heat Exchanger Coolant (Fresh Water) Drain Sea Water Drain Coolant (Fresh Water) Drain Sea Water Drain High Exhaust Temperature Safety Shutdown Switch Mixing Elbow (Water Outlet/Exhaust Outlet) AC Load Lead Connector Remote Start Connector Battery Negative (-) Connection Starter Solenoid Starter Motor Battery Positive (+) Connection Ground Lug (Equipment Ground) Sea Water (Drain Point) Petcock V-Belts Battery Charging Alternator Belt Guard Engine-Driven Water Pump High Water Temperature Safety Shutdown Switch

TP-563010/93

Introduction

l-9

Section 2. Operation
Prestart Checks
To insure continued satisfactory operation, the following items should be checked before each start-up. Air Intake Silencer: Must be clean and properly installed to prevent unfiltered air from entering engine. See Section 3, Scheduled Maintenance. Battery: Remove caps and check the electrolyte level of each cell (batteries with filler caps only); add distilled water if necessary. Check to make sure it is connected correctly. Battery installation and connections must, meet Coast Guard Standards. Battery should be serviced by authorized personnel only. See Section 3, Scheduled Maintenance. Compartment: Keep the engine room or compartment clean and dry. Check for fuel or oil leaks. Check the condition of fuel system, exhaust piping, hoses, and muffler; have any faulty components repaired before getting underway. Open hatch to air out compartment and use ignition-protected bilge blowers, if required, to clear fumes from area before each start-up. If fuel leaks, fumes, exhaust gases, or electrical sparks are noted, arrange for qualified personnel to make necessary repairs before operating generator set. Fuel Level: Make sure the fuel tanks are full and the fuel system primed for operation. See Section 3, Scheduled Maintenance. Oil Level: Should be at or near FULL mark. Add oil as needed to bring level up to this range. See Section 3, Scheduled Maintenance. Cooling: The coolant level on closed-type heat exchanger systems can be checked using the coolant recovery tank. The ADD/COLD mark indicates full when cold and the FULL/HOT mark indicates full when hot. Maintain the coolant level between these marks. If cooling system has been drained and requires filling, open pressure cap on heat exchanger and add fresh coolant until level is just below overflowtube opening. See Section 3, Scheduled Maintenance. Sea-Water Pump Priming: The sea-water pump must be primed before initial start-up or whenever cooling sea water has been drained. To prime pump, close seacock and remove the hose from water-filter outlet. Fill hose and pump with clean water. Replace hose and open seacock. Check for pump operating on start-up by observing water discharge from exhaust outlet.

Controller
For identification of controller, see Figure 2-1. 1. Start-Stop/Preheat Switch: Used to start and stop generator set-refer to Starting and Stopping following. 2. Hourmeter: Records total generator set operating hours for reference in maintenance scheduling. 3. DC Circuit Breaker: The generator set will shut down automatically after fault. See Circuit Protection following. 4. AC Circuit Breaker (Optional): Will trip when a current overload is detected in the output circuit. Used to disconnect generator set during maintenance of craft wiring. To close circuit breaker(s), place in ON position. 5. Remote Start Connector: 6-pin connector on controller back panel allows connection of (optional) remote start kits.
TP-563010l93

Figure 2-1. Controller


Operation 2-1

Starting
Open manual fuel shut-off valve (if equipped). Start follow these guidelines motor from overheating. NOTE may result in damage to the starter generator set by placing controller start switch to START position or use remote start-stop switch.

Preheat Feature (Optional) 13.5/l 4/l 8.5/2OCCOZ and 1l/l 1.5/l 5/l 7.5CCFOZ Models Only
During cold-weather start switch energizing starts (below 23F [-5X]), to start generator place for set. or controller in STOP/PREHEAT position

If excessive failure

cranking

is encountered may cause

during possible

starting, filling of

to close seacock,

exhaust piping and silencer with sea water. This condition may further hinder generator starting and cause sea water entry into the engine cylinders through the exhaust valve. To correct this situation, from exhaust system close seacock at silencer and drain water plug before cranking is a the exhaust dealer/ drain

15-20 seconds This provides energize

before attempting

attempting to start generator set. If excessive

of the air heater coil.

Do not

chronic problem,
system) distributor. serviced

have the unit (including by an authorized

preheat feature

for more than 30 seconds

Kohler

damage may occur. If engine fails to start after the first attempt, close the seacock before attempting start-up. This will help prevent sea water from entering the engine cylinders through the exhaust valves. NOTE Do not crank engine continuously for more than IO seconds at a time. A 60-second cooldown period must be

Once the generator set is started, the seacock opened to allow passage of cooling water. NOTE

must be

Failure to open seacock after generator set is running will result in serious engine damage due to overheating and damage to the sea water pump impeller. NOTE Check that the marine ship-to-shore the proper position, if used. transfer switch is in

allowed between cranking attempts if the engine does not start. If the unit fails to start after three attempts, contact an authorized Kohler dealer/distributor for repair. Failure to

Stopping
Run generator set at no load for five minutes Place controller to allow Do not place STOP/PREHEAT position NOTE Start-Stop/Preheat Switch in or for more than 30 seconds engine cooldown. start switch to STOP

position and wait until generator set comes to a complete stop; or use remote start-stop switch.

damage may occur to preheat feature (if equipped).

2-2

Operation

TP-5630

1 O/93

Circuit Protection
AC Circuit Breakers (Optional): Will trip when a current
overload is detected in the output circuit. After removing by some of the electrical placing in ON position. for each model. load, reset AC circuit breaker(s)

Voltage Regulator Fuse (8Amp): Protects unit in case of


fault in the voltage regulator and/or generator circuit. After fault is corrected, replace with a new fuse of the same rating. Voltage regulator circuit is now functional.

Unit is now ready to be restarted.

Circuit breaker selection is based on voltage configuration

Battery Charging Fuse: A lo-amp


battery charging alternator, battery protects the controller set. circuit board and iftripped, and circuitry. After fault is corrected, functional.

fuse

protects

the

DC Circuit Breaker: A 1O-amp circuit breaker located on


the controller circuitry. If unitshutsdown, checkcircuitbreaker,

charging

regulator,

replace with a new circuit is now

fuse of the same rating. Battery charging

reset then restart the generator

Engine Safety Shutdown Switches


The engine is protected by safety shutdown switches NOTE The Low Oil Pressure switch does not act as a low oil level switch. The only way to protect against damage from low Engine safety shutdown switches become functional when unit comes up to speed and AC voltage is available and after a 5-l 0 second time delay. oil level is to check oil level regularly. which automatically reset after the problem is corrected or was the problem). the unit is allowed to cool (if overheating

High Water Temperature (HWT) of 230F (1lOC) *3 will


cause the unit to shut down.

High Exhaust Temperature (HET) of 215F (102C) 8


will cause the unit to shut down.

Low Oil Pressure (LOP) of 7.1 psi (49 kPa) or less will
shut down the unit.

Overspeed Safety Shutdown (SDR) (Optional) will cause unit to shut down at an engine speed of 2100 rpm
(70 Hz).

TP-5630 10193

Operation

2-3

Remote Panels (Optional)


Three remote panels are offered. The first

uses a

start/stop switch. The second has a start/stop switch and two gauges. The third incorporates four gauges. a start/stop switch and

Remote Start Panel


Remote equipped connection If difficulty can disconnect start with panel allows starting-stopping set. Generator on from a P P& for location remote of the generator a 6-pin sets are

IOA.

Fuse

connector

controller

of the kit. See Figure 2-2. with the remote operation for proper function. the J3/P3 connector. NOTE occurs, the switch Prior to testing,

be tested

See Figure 2-3.

I
d P2-3 T

K.2

Kl

Relay Circuit Board

C-

More troubleshooting

information

on remote start panels

is provided at the end of this section.

0
KOHLER GENERATOR START

. \

Gen. ON Light
L

Figure 2-3. Remote Start Panel

n STOP/PREHEAT c

,J
l-656

Figure 2-2. Remote Stat-t Panel

2-4

Operation

TP-5630 1 O/93

Remote Start and Two-Meter Panel


More troubleshooting Allows starting-stopping gauge, panel from a location and a water remote of the gauge. on kit. See generator Generator controller set. The illuminated gauges include an engine temperature of the

NOTE
information on remote start panels is provided at the end of this section.

oil pressure

sets come equipped with a 6-pin connector back for connection panel kit.

Figure 2-4 for remote start and two-meter

NOTE
Remote start panel will require a sender kit.

Start/Stop Switch: Rocker-type switch with ON light used


to start and stop the generator set. engine oil

Engine Oil Pressure Gauge: Measures


pressure. Normal engine operating

range is 40-60 psi

(276-414 kPa) for 60 Hz models. 50 Hz models will show a slightly lower pressure range. NOTE During the engine break-in period, it is normal for the engine to produce higher oil pressure readings.

Water Temperature Gauge: Measure


temperature. 170-195F If difficulty gauges, function. Normal (77-91 C). with remote operation engine

engine coolant operating range is

occurs,

the switch,

and gauge senders can be tested for proper Prior to testing, disconnect the J3/P3 connector.

See Figure 2-5.

Figure 2-5. Remote Start and Two-Meter Panel

l-762

Figure 2-4. Remote Start and Two-Meter Panel

Operation

2-5

Remote Start and Four-Meter Panel


Allows starting-stopping set. The from a location gauges remote include of the a DC generator voltmeter, illuminated

If difficulty gauges, function.

with

remote

operation

occurs,

the switch,

and gauge senders

can be tested for proper the J3/P3 connector.

Prior to testing, disconnect

See Figure 2-7. NOTE More troubleshooting information on remote start panels is provided at the end of this section.

engine oil pressure gauge, water temperature Generator with a 6-pin connector panel features. on controller

gauge, and generator running time hourmeter. sets come equipped back panel for connection remote start and four-meter

of the kit. See Figure 2-6 for

KOHLER MARINE OENERATCIRS

c
START

en
.. Iwr
I

I -

Sender

STOP

AK2
I

I Relay Circuit Board w

T K1
Figure 2-6. Remote Start and Four-Meter Panel

NOTE Remote start panel will require a sender kit. Start/Stop Switch: Rocker-type to start and stop the generator DC Voltmeter: Measures switch with ON light used set.
T P3-3 -2 J3-3

L.
Blue

voltage of starting battery(ies). range is 12-I 4 volts. Gauge: Measures engine oil

Normal battery operating Engine pressure. Oil Pressure engine

Normal

operating

range is 40-60 psi

(276-414 kPa) for 60 Hz models. 50 Hz models will show a slightly lower pressure range. NOTE
0

During

the engine

break-in

period,

it is normal for the

engine to produce higher oil pressure readings. Water Temperature temperature. (77-91 C). Hourmeter: Records total generator set operating hours Gauge: Measures engine coolant
b

Oil Pressure Gauge

Normal engine operating range is 170-l 95F

DC Voltmeter b

for reference in maintenance If difficulty gauges, function. with remote

scheduling. occurs, the switch, for proper Figure 2-7. Remote Start and Four-Meter Hourmeter l-940

operation

and gauge

senders

can be tested

Prior to testing, disconnect

the J3/P3 connector. Panel

See Figure 2-7.

2-6

Operation

F-5630

1 O/93

TROUBLESHOOTING

REMOTE

Generally, sender can be presumed good if it changes its resistance value as its respective pressure/temperature changes. Adefectivesenderwill to either be open or shorted.

START PANELS
To test water temperature controller resistance change complete. socket sender, connect ohmmeter See Figure

Water Temperature Sender Values

P3-1 and P3-2.

2-8 for I
I

by varying temperature.

Start generator set to set when test is

temperature.

STOP generator

Figure 2-8. Water Temperature Sender Resistance Oil Pressure Sender Values
0 15 30 45 psi osi psi psi 5-l 3 44-52 80-88 115-l 25 ohms ohms ohms ohms

To test oil pressure sender, connect ohmmeter to controller socket P3-1 and P3-3. See Figure 2-9 for resistances STOP generator set when test is complete. by varying pressure. Start generator set to change pressure.

Figure 2-9. Oil Pressure Sender Resistance Remarks


Ohmmeter on R x 1 scale.

Component
demote switch

Ohmmeter Connections
Remote switch: yellow/red wire terminal and black wire terminal (bottom and middle terminals). Press rocker switch to START position. Remote switch: grey/black wire terminal and black wire terminal (top and middle terminals). Press rocker switch to STOP position.

Results
Continuity-switch good. is

Ohmmeter

on R x 1 scale.

Continuity-switch good.

is

Component
Remote switch ON light*, Jauge lights, DC voltmeier, and hourmeter

Voltmeter Connections
Red test lead to P3-4 and black test lead to P3-1. Place controller rocker switch to START position. STOP generator set when test is completed.

Remarks
If 12-volts DC is present and component does not function after J3 is connected to controller P3, replace component.

Results
Voltmeter setting 12 volts or greater. Generator set does not need to be running, just cranking for this test. NOTE: Hourmeter is not illuminated. To further test components, connect to 12- volt battery. NOTE: Hourmeter is polarity sensitive. Voltmeter setting 12 volts or greater.

Water temperature

gauge

Red test lead to P3-4 (socket side) and black test lead to P3-2 (socket side). Start generator set for test. STOP unit when test is completed. Red test lead to P3-4 (socket side) and black test lead to P3-3 (socket side). Start generator set for test. STOP unit when test is completed. of gauge wiring and extension

If 0.5-l 2-volts DC is present and gauge does not function after J3 is connected to controller, replace gauge. If 0.5-l 2-volts DC is present and gauge does not function after J3 is connected to controller, replace gauge. harness before replacing

Oil pressure gauge

Voltmeter setting 12 volts or greater.

NOTE: Check continuity

components.

* See Remote Start Panel.

Figure 2-10. Troubleshooting Remote Start Panels


TP-5630 1 O/93 Operation 2-7

Section 3. Scheduled Maintenance


General
Schedule routine maintenance using the Service Schedule following and the hourmeter located on the controller (see Section 2, Operation). If the generator set will be subject to extreme operating conditions, service unit accordingly. Service intervals are located on the top rows of the Service Schedule chart. They include how often maintenance tasks need to be done. Each service item is to be repeated at the specified interval. For example, an item required at 50 hours will again need to be performed at 100 hours, 150 hours, etc. For continued satisfactory operation and longevity of the engine and generator set, proper maintenance and eventual overhaul by a competent mechanic is essential. While it is not possible to anticipate component failure, rough operation, metallic noises, and excessive oil consumption are among the indicators of potential problems. Do not ignore these conditions! NOTE Operate the generator set with one-third load or more applied at least once a month. Allow generator set to run about one hour to reach operating temperature. This prevents the formation of corrosion on internal engine components when exposed to the breakdown of exhaust gases and sea water for long periods of generator inactivity. If unit is to be out of service for several months, see Storage Procedure. NOTE High-mineral content sea water (salt water) can cause rapid destruction of metals. Even if protected by paint or oil coating, salt water will cause metal erosion. Wipe up all salt water spillage on and around generator set and keep metal surfaces free from accumulated salt deposits. NOTE HARDWARE DAMAGE! Engine and generator make use of both SAE and metric hardware. Be sure to use the correct size tools to prevent rounding of bolt heads and nuts. NOTE If generator set is operated with less than l/3 load and/or for short periods, service turbocharger every 25 hours. Accidental starting. Can cause severe injury or death. Disconnect battery cables before working on generator set (negative lead first and reconnect it last).

Accidental starting can cause severe injury or death. Disconnect battery cables (remove negative lead first and reconnect it last) to disable generator set before working on any equipment connected to generator. The generator set can be started by remote start/stop switch unless this jrecaution is followed.

WARNING

Rotating parts. Can cause severe injury or death. Do not operate generator set without all guards, screens, or covers in place. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from belts and pulleys when unit is running. Replace guards, covers, and screens before operating generator set. Exposed moving parts can cause severe injury or death. Additional Precautions Regarding Sound Shield Equipped Models: Some scheduled maintenance procedures require the generator set to be running while performing service. If the sound shield has been removed leaving belts and pulleys exposed, be especially careful of this area.

TP-5630 1 O/93

Scheduled Maintenance

3-1

Service Schedule
Before Starting After 66 Hours or One Month Every 100 Hrs. or 3 Months Every 160 Hrs. or 3 Months Every 300 Hrs. or 6 Months Every 600 Hours or Yearly

FUEL SYSTEM
Check the fuel oil level . . . . . . . . . . . . . . . X Fillfueltank _.._.........____....... X Remove sediment from fuel tank _. . . . . . . . . . . . . . . . . . . . . . . . _. _. _. . _. . . . . . Check for any abnormal fuel injection sound . . . . . . X (During Operation) Replace fuel filter element* . . . . . . . . . . . . _. . . . . . . . . . . . . . . . . . . . X . . . . . . . . (Break-in Period) Check the injection timing*#& @ . . _. . . . . . . . . . . . . . . . . . _ . ____. . . . . . . . . . . _ Check governor operation and adjustasnecessaty*&@ . . . . . . . .._..__............................ Check the fuel injection nozzles*#&@....................................................
...... .. .... ....... ..... X

............

X X X X

............ ............ ............

LUBRICATION SYSTEM
Check the oil level-crankcase ........ X Replace the oil-crankcase . . . . . _. ___. . . . . . _. . . . X (Break-in Replace the lube oil filter element* . . . . . . . . . . . . . . . X (Break-in . . . . . . _. __. . . _. . . . . _X (150 Hours) Period) .....................X Period)

X .................... Checkcoolantlevel..................X................................... Seawater outlet . . . . . . . . _ . _. . . . . . . . . X (During Operation) Inspect exhaust system components for cracks and corrosion (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and outlet flapper)*& . . . . . X Adjust the tension of engine waterpumpbelt* .._..._............._..._. X.....................X (Break-in Period) Adjust the tension of sea waterpumpbelt* . . . . . .._..__.............. X.....................X (Break-in Period) Check function of siphon break (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X X Flush cooling system *& . . . . . . . . . . . . _. . . . . . . . . . . . . . . . . . . . . . __. . _. . . . . . . _. . . .................... Replace the impeller of the x ......... x ........ seawaterpump*t.................................................... (Check) Check the thermostat function* .,. . . . . __. . . . . . ____. . . . . . . . . . . . _. . . . _. . . . __. . _. . . . . . . . . . . . . ___. . . . . X

COOLING SYSTEM

@ Should be performed by an authorized dealer/distributor. * Requires removal of sound shield (if installed). # Reference Engine Service Manual for procedure. & Read WARNING regarding Moving Parts found at the beginning of Section 3. t More often under silty or dirty water conditions.
T P-5630 1 Q/93

3-2

Scheduled Maintenance

Service Schedule (continued)


Before Starting After 60 Hours or One Month Every 100 Hrs. or 3 Months Every 160 Hrs. or 3 Months Every 300 HIS. or 6 Months Every 500 Hours or Yearly

AIR CLEANER, Etc. Check the exhaust gas condition . . . . . . X (During Operation) Inspect turbocharger compressor (135/185/2lCCOZ and 11/15/165CCFOZ)* @ . . . _. _. . . . . . . . . . . . . . . . . X Check for abnormal turbocharger rotor noise during operation (13.5/l 8.5/21 CCOZ and 11/15/16.5CCFOZ)*#& @ . . . . _. . _. . . . . . . . . . . . . _. . . . . . . . . . . __. . . __. . . . . . . . . . __. . . . . . . . . . . X (1500 Hrs.) Clean the intake silencer element* _. . . . . . . . . . . ___. . . . . . . . . . . . X . . . . . . . . . . . . . . . . . . . . . X (Replace) (Clean) Clean the exhaust/water mixing elbow* . . . . . . __. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Check the breather pipe* . . . . . . . __. _. . . . . . . . . . . _. . . . . . . . . _. _. _. . . . . . . . . . X Check turbo rotor shaft for wear (end play and radial tolerances) (13.5/l 8.5/21 CCOZ andll/l5/16.5CCOZ)#*@ . . . . . . . ..__.............................._.....I...... X (6000 Hrs.) ELECTRICAL SYSTEM Check electrolyte level in the battery . . . X (batteries with filler caps only) Check the electrical connections* . . . . . . . . . . . . . . . . X Adjust the tension of the alternator driving belt* _..____..___........_...._..... X................................. X (Break-in Period) Check the battery specific gravity . . . . . . . . _. _. . . . . . . . . . __. . . . . X (batteries with filler caps only) CYLINDER HEAD, Etc. Check for leakage of water and oil*& . . . X . . . . . . . . X Retighten the cylinder head bolts* . . . _. . . . . . . __. _ X . . . . . . . . . _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X (Two Years) (Break-in Period) Adjust intake/exhaust valve clearance* . . . . . . . __. . X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X (Break-in Period) Check mounting bolts and vibromounts fortightness*......................................................X Retighten all major nuts and bolts* ___. . . . . . . . __. __. . . . . . . . . . . . . . . . . . . . . . . . . . . . _. . . . . X REMOTE CONTROL SYSTEM, Etc. Check compartment condition (fuel, oil, or water leaks) . _. . . . . . . . X Test run generator set. . . . . . . . . . . _. _. _. . . . . . . . . . X (Monthly) Check the remote control operation . . . _. . . . . . . . . _ X _. . . . . . . . . . . . . __. . . . . . . . . . . . . . . . . X (Break-in Period) GENERATOR Blow dust out of generator*& . . . . . . . . _. . . . . . . . . _. ___. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X @Should be performed by an authorized dealer/distributor. * Requires removal of sound shield (if installed). # Reference Engine Service Manual for procedure. & Read WARNING regarding Moving Parts found at the beginning of Section 3.
TP-5630 1O/93 Scheduled Maintenance 3-3

Lubrication
Specifications
The selection of engine oil is very important to a diesel engine. If an unsuitable oil is used or an oil change is neglected, it may result in damage and a shorter engine life. Oil must meet the API (American Petroleum Institute) classification of CD, CC/CD, or CC. Recommended SAE (Society of Automotive Engineers) viscosity designation for given temperature ranges is listed in Figure 3-l.

System

S.A.E. Service 3rade 1. MIN Mark 2. MAX Mark Figure 3-2. Oil Level Check NOTE Do not check oil level when set is in operation. The engine must be stopped and on a level surface when checking oil. Most accurate oil reading is obtained by shutting down the generator and waiting several minutes before checking oil. NOTE Do not operate the set if the oil level is belowthe MIN mark or above the MAX mark.

Oil Change
"C-30-20-10 0 IO 20 30 40 "F I I I I I I "F 0 20 40 60 80 100F
Change oil for the first time after 50 hours or one month and then at the specified interval. Change oil more frequently under dirty, dusty conditions. Change oil while the engine is still warm. 1. To drain oil, remove end cap and place oil drain hose in a suitable container. See Figure 3-3 for location.

Operating Temperature ::i::::.:.:.i...Recommended Value 1.


+:w ..:\..:.: .....,.,.,:,,,,,,:,,,,:,,,, :~w.. ,:,,, ~~:w.~ . ....,.,:,,,,:,, .......,,,:,,,, ....... .,,_ ::,, ~.....W .. .. .. .. .. .,.,:,,,,: I.:.::.:.::.:.:: /: .,.,.,,,,,,,,,,,,,,,, ,,., ::::i:i:i::::~~i:i:iii:i:i :::::,,:,:,,,,,
.. ::::.:::i:::i::ii:i.iii:

r--i

L--J

Usable Limit

Figure 3-1. Engine Oil Selection NOTE Failure to observe these standards may cause inadequate lubrication/oil pressure and cold starting difficulties.

Oil Check
Check the oil level in the crankcase daily, or before each start-up, to insure that the level is in the safe range. To check oil level, remove dipstick and wipe the end clean, reinsert as far as possible, and remove. Level should be between MIN and MAX marks on the dipstick (Figure 3-2).
3-4 Scheduled Maintenance

2. Oil Drain Valve 1. Oil Drain Hose Figure 3-3. Oil Drain Hose (21CCOUi 6SCCFOZ Model Shown)
TP-5630 10193

2. Allow ample time for oil to drain. After draining process is complete, replace end cap on hose. NOTE If an electric oil drain pump is used, place the pump outlet hose into a suitable container. Remove oil fill cap. See Figure 3-4. Activate pump until all oil is removed. Fill with proper amount and type of oil, see Section 10, Specifications. Replace oil fill cap(s). Disconnect pump and install end cap on hose. Go to Step 5.

NOTE Do NOT pollute the environment. Dispose of used engine oil and other contaminants in a safe and approved manner.

Oil Filter Change


Replace the oil filter initially after 50 hours or one month and then at the specified interval or during every other oil change. Change more frequently if operating in dirty, dusty conditions. See Figure 3-5 and refer to the following procedure.

1. Oil Fill at Valve Cover 2. Oil Fill at Governor Figure 3-4. Oil Fill Locations (typical) (21 CCOUI 6.5CCFOZ Model Shown) 3. Remove oil fill cap. One is located near the top of the engine on the valve cover and one is located near the governor. See Figure 3-4. 4. If engine oil filter is to be replaced, see Oil Filter Change following. 5. Fill crankcase with proper amount and type of oil. See Section 10, Specifications. Replace oil fill cap(s). 6. Start generator set and check for oil leaks. 7. STOP generator set. Remove dipstick and wipe clean, reinsert as far as possible and remove to check oil level. Add oil, as necessary, to bring level up to MAX mark. NOTE Too high an oil level causes high oil consumption and carbonizing of the engine. Too low a level will damage the engine.
TP-5630 10193

1. Lube Oil Filter Figure 3-5. Lube Oil Filter (21 CCOZ/16SCCFOZ Model Shown)
1. Loosen oil filter by turning in a counterclockwise

direction. Remove oil filter and use rags to clean up spilled oil. Dispose of oil filter in a safe and approved manner. 2. Clean contact surface on oil filter adapter. 3. Lightly lubricate the gasket surface of the new filter with fresh engine oil. Thread filter on adapter until gasket makes contact; hand tighten an additional one-half turn. Wash hands after any contact with engine oil. If oil change is also being perfomed, skip Steps 4-5 and go back to Oil Change procedure. If oil change is not being performed, continue to Step4. 4. Start generator set and check for oil leaks. 5. STOP generator set. Remove dipstick and wipe clean, reinsert as far as possible, and remove to checkoil level. Add oil, as necessary, to bring level up to MAX mark.
Scheduled Maintenance 3-5

Fuel System
Specifications
Use a clean, good quality requirements Materials Cleanliness and pumps. Recommended fuel: No. 2-D diesel oil. No. 2-D diesel fuel oil with a The fuel must meet the Society of Testing D975. on diesel and cetane number of 45 or greater. of the American 4. Lightly lubricate the gasket surface of the new fuel filter with fresh fuel oil. Thread filter on adapter until gasket oil. makes contact; hand tighten an additional one-half turn. Wash hands after any contact with fuel

(ASTM) diesel fuel classification of the fuel is especially

5. Open fuel valve.


6. See Bleeding section following.

important

engines which have easily clogged, precision fuel injectors

United States ASTM/D975

United Kingdom BS2869 Class Al. NOTE Never store diesel fuel in galvanized

containers;

diesel

fuel and the galvanized coating react chemically to produce flaking which quickly clogs filters or causes failure of the fuel pump or injectors. Do not run the generator set out of fuel. Airwill be drawn into the fuel lines and the entire system will restarted. have to be bled before the unit can be

NOTE Avoid storing fuel over long periods of time. Take special precautions to keep all dirt, water, and other contaminants out of the fuel. Storage tanks containing diesel fuel contaminants with water may cause the growth of microbes. The presence of microbes will form a slime which will clog fuel filter and lines.

Figure 3-6. Fuel Filter Location (21 CCOU165CCFOZ Model Shown)

Bleeding
If the generator set engine runs out of fuel, if air leaks

Fuel Filter
The fuel filter can be cleaned compressed with fresh fuel oil and largely

develop in the suction side of the fuel system, or if the fuel filter is replaced, it will be necessary to bleed the entire system to prevent starting failures and/or erratic operation.

air. The useful life will be determined

by the quality and condition of the fuel used. Under normal conditions, the fuel filter element should be replaced at the specified interval. fuel filter. 1. Close fuel valve. 2. Loosen fuel filter by turning in a counterclockwise direction. Remove fuel filter and use rags to clean up spilled fuel oil. approved Dispose of fuel filter in a safe and See Figure 3-6. manner. Use the following procedure to service

NOTE
The priming procedure requires the battery to be connected so that engine cranking will occur. Do not allow engine/generator disconnect terminal). to start. To prevent engine starting, line 71 A from the starter motor solenoid (spade

Use the following

procedure to bleed fuel system. See Figure 3-7.

3. Clean contact surface on fuel oil filter adapter.

1. Loosen vent screw A at fuel filter.

3-6

Scheduled Maintenance

TP-5630 10193

2. Toggle the start/stop switch. Place the start/stop switch in the START position for a few seconds and then place the switch in the STOP position until fuel, free of air bubbles, flows from vent screw A. Tighten connection. 3. Loosen vent screw B at fuel filter. 4. Toggle the start/stop bubbles, connection. 5. Loosen vent screw C at fuel injection pump. 6. Toggle the start/stop bubbles, connection. flows from switch vent until fuel, free of air screw C. Tighten flows from switch vent until fuel, free of air screw B. Tighten

NOTE
Wipe up all spilled diesel fuel after bleeding system. Wash hands after any contact with fuel oil.

1. Fuel Filter 2. Fuel Injection Pump 3. Vent Screw A 4. Vent Screw B 5. Vent Screw C

Figure 3-7. Bleeding Fuel System

Air Intake Silencer Cleaner


A round polyurethane sound-absorbing type intake a silencer is employed to silence the intake air drawn into the cylinder silencing head from the intake port. Besides providing effect, the silencer also acts as an air cleaner. service schedule. or severely Clean more frequently Should the air silencer with dirt it contaminated if

Clean the air silencer at the specified interval shown in the appropriate become should following operating in dirty, dusty conditions. damaged be replaced. procedure.

See Figure 3-8 and refer to the

1. Release

the two spring

clips and remove

intake

silencer cover.

2. Remove
reasonable

element

from

cover

and inspect.

If in 1. Air Intake Silencer/Cleaner 2. Spring Clip

condition for cleaning, continue to Step 3 If damaged or in poor condition, skip Step 3 and go to Step 4.

for procedure. replace element;

Figure 3-8. Air Intake Silencer

TP-5630 1 O/93

Scheduled Maintenance

3-7

3. Wash the element in mild detergent and water solution. Rinse and allow to air dry. See Figure 3-9. 4. Wipe cover and base with a clean rag to remove any dirt. Check base for damage, replace as necessary. 5. Reassemble silencer element and cover assembly Make sure sealing to intake fit

base.

surfaces

properly and reattach spring clips. Air-intake silencer duct should be at the 5 oclock position end. pulley and replace as viewed from the generator

6. Remove screws from crankshaft

belt guard or ground shield (if so equipped).

l-776 I. Element

Figure 3-9. Washing Element

Turbot larger (13.5/l 8.5/21 CC02 am 11/I 5/l 6.5/l 8CCFOZ)


The compressor (blower) should be inspected at the in the Service following specified interval for build-up of carbon residue. All other inspection and service as described using and Yanmar use the must be performed 3-10 by an Authorized

turbocharger Service Manuals.

Service Schedule See

Dealer/Distributer Figure

procedure to inspect compressor.

1. Remove connector,

breather

hose

from

air-intake

silencer

if equipped.

2. Loosen

hose

clamp

on

air-intake

silencer

and

remove air-intake

silencer.

3. Inspect compressor (blower cleaning wheel) is required,

(blower)

housing of carbon

and impeller residue. service If

for build-up

contact an authorized cleaner.

Figure 3-10. Turbocharger Inspection (21 CCOZ/i 6SCCFOZ Model Shown) NOTE
Air intake silencer duct should be directed down and away from engine.

dealer/distributer

for proper cleaning.

Use a Yanmar

approved turbocharger

4. Place

air-intake

silencer

over

turbocharger

5. Attach breather hose to air-intake silencer connector,


if equipped.

compressor

housing inlet and tighten clamp.

3-8

Scheduled Maintenance

TP-5630 1 O/93

Servicing Mixing Elbow


Check mixing brush. Inspect elbow for carbon exhaust manifold build-up and corrosion threads for high inside the pipe. Clean residual carbon build-up with a wire mounting cracking and corrosion. temperature when exposed The mixing elbow combines vibration makes conducive to rapid deterioration and failure if not properly maintained. If any damage is detected with mixing elbow or other exhaust made to prevent leakage. components, engine replacement (carbon should be exhaust monoxide)

exhaust and cooling sea water. The mixture to engine conditions

Governor
The centrifugal, speed of fuel mechanical constant supplied governor serves to keep the to 1 engine amount by automatically to the engine adjusting according

changes in the load. No regular service is required on the unit. The governor is adjusted during run-in at the factory, and further adjustment should not be needed are encountl after extended unless greatly varying usage. 60 Hz generator sets are designed to operate in the range of 57-63 Hz (1800 rpm under full load and 1890 rpm under no load). 50 Hz generator sets are designed to operate in the range of 47-53 Hz (1500 rpm under full load and 1590 rpm under no load). To check speed, use frequency leads or use hand tachometer. meter connected to load Loosen locking nut on 1. Locking Nut 2. Speed Adjusting Screw Model Shown) load conditions

ered or if poor governor

control develops

speed adjusting screw; turn screw in clockwise direction to increase speed (and frequency). To decrease speed, turn screw counterclockwise. setting. See Figure 3-11. lighten locking nut at new

Figure 3-11. Governor


(21 CCOU16.5CCFOZ

Valve Adjustment
With poppet-type valve mechanism, each valve is spring

NOTE
The engine firing order is based on the No.1 piston being next to the flywheel, not the crankshaft pulley. 1. Remove rocker arm cover nuts and breather hose at rocker arm cover connection. Carefully pry rocker arm cover from cylinder head. Wipe excess oil from components using a clean rag.

held in the closed position until forced open by the action of the rocker arm in contact with the push rod which is moved by the tappet which rides on a lobe of the camshaft. Rocker arms have adjusting screws with locknuts for adjusting the valve shown clearance stem-to-rocker-arm valve clearance appropriate in the clearance. service Check the Valve intake/exhaust at the specified schedule. interval

of both intake and exhaust valves is 0.0079 in.

NOTE
Be careful not to damage gasket or mating surface.

(0.2 mm) with the engine cold.

TP-5630 1 O/93

Scheduled Maintenance

3-9

2. Locate intake valve of No. 1 cylinder (the second valve from the flywheel). See Figure 3-12 or 3-13. Remove the belt guard. Rotate crankshaft clockwise (facing pulley), using a wrench on one of the crankshaft pulley bolts, until intake valve of No. 1 cylinder begins to open. Continue rotation until timing mark numbered 1 on flywheel aligns with mark engraved on stator housing shown in Figure 3-14.

slight drag is felt on the feeler gauge as it is withdrawn. Tighten lock nut. See Figure 3-15.

3-Cylinder Engine:
Rotate crankshaft clockwise until intake valve of rotation aligns in Figure 2 on flywheel shown No. 2 cylinder begins to open. Continue until timing mark numbered with mark on stator housing

3-14. Adjust valves 3 and 6. See Figure 3-l 2.

4-Cylinder Engine:
Rotate crankshaft clockwise until timing mark numbered with 3-l 3. 4. With mating surfaces clean and gasket properly mark on stator until intake valve of rotation aligns in Figure 4 on flywheel shown No. 4 cylinder begins to open. Continue housing

3-14. Adjust valves 3, 6, 7, and 8. See Figure I-94c

Figure 3-12.3~Cylinder Valve Adjustment

aligned, install rocker arm and cover and nuts. Be certain that O-ring is properly seated in groove. 5. Install the belt guard.

I-94c

Figure 3-13.4~Cylinder Valve Adjustment

Figure 3-14. Timing Mark


3. Valves 1,2,4, and 5 can now be adjusted. See Figure 3-l 2 or 3-l 3. Use a feeler gauge to check clearance between rocker arm and valve stem. If necessary, screw until very loosen lock nut and move adjusting

I I 1. Locknut 2. Adjusting Screw 3. Feeler Gauge

l-777 4. Rock Arm 5. Push Rod 6. Clearance (Lash)

Figure 3-15. Valve Adjustment


TP-5630 10193

3-10

Scheduled Maintenance

Flying projectiles

can cause severe or servicing

injury or death. generator set, do If be in

WARNING i&s
0

Retorque all crankshaft and rotor hardware after servicing. When making adjustments not loosen rotating clockwise crankshaft only. Turning can hardware manually, crankshaft loosen or rotor thru-bolt. direction hardware should and result bolt or rotor thru-bolt or pulley flying off

I0

crankshaft

counterclockwise Rotating parts. Can cause severe injury or death. Do not operate generator screens, or covers in place.
L

serious personal injury from hardware engine while unit is running. all guards,
J

set without

Cylinder Head Retightening


Loosen and retighten cylinder-head interval. lighten to specifications Specifications or 3-17. bolts at the specified given in Section 10, It may be necessary to remove the rocker arm assembly to access some of the cylinder-head bolts. See the engine service manual for complete information. and use the sequence shown in Figure 3-l 6

1. Flywheel

Side of Cylinder

Head Sequence-

1. Flywheel

Side of Cylinder

Head Sequence-

Figure 3-16. Cylinder Head Tightening Three Cylinder

Figure 3-17. Cylinder Head Tightening Four Cylinder

Cooling System
Closed/Heat Exchanger
In a closed cooling system, the sea water does not circulate through the engine but circulates through the separate chambers within the heat exchanger to cool the engine water. ejected out Specifications It is then mixed with engine exhaust See Section the ,exhaust outlet. for coolant capacity (including and 10,

FliLlNG

AND CHECKING

Before filling the cooling system, verify that all petcocks are closed and all hose clamps are tight. If cooling system has been drained and requires filling, open pressure cap on heat exchanger and add fresh coolant until level is just Add additional coolant, as below overflow tube opening.

coolant

recovery tank), thermostat rating, and pressure cap rating. A solution of 50% ethylene glycol and 50% clean, softened water is recommended protection. to inhibit rust/corrosion and provide freezing

necessary, to coolant recovery tank. Fill to just below the HOT (full) mark. Maintain proper coolant level in coolant recovery tank. The COLD (add) mark indicates full when cold and the HOT (full) mark indicates full when hot. Coolant level should always be between these marks.

TP-5630 1 O/93

Scheduled Maintenance

3-11

NOTE

WARNING

High-mineral spillage

content

sea water (salt water) generator

can cause

rapid destruction

of all metals.

Wipe up all salt water set and keep metal salt deposits.

on and around

surfaces free from accumulated

FLUSHING AND CLEANING


Can cause severe injury or death.
Before removing pressure cap stop generator, cap to relieve I For optimum periodically Schedule. engine completely protection, drained, the cooling system should be flushed, and refilled, system models see Service

allow to cool and loosen pressure

Open petcocks and cooling Some drain.

located at heat exchanger, and let the system may have petcocks

block,

Hot coolant can cause severe injury or death. Allow


engine to cool and release pressure from cooling system before opening pressure cap. To release pressure, cover the pressure cap with a thick cloth then turn it slowly to the first stop. After pressure has been counterclockwise

located behind belt guard. will make draining easier. recovery tank. instructions.

Removal of the pressure cap Drain, clean, and flush coolant for badly

Chemical cleaners are available

rusted or corroded cooling system; follow manufacturers Flush system with clean water before filling coolant. with recommended

completely released and the engine has cooled, remove cap. If generator set is equipped with a coolant recovery tank, check coolant level at tank.

PRESSURE
Closed/heat exchanger

CAP
incorporate a

systems

NOTE Special attention should be given when checking for proper coolant level. After the coolant has been drained, it normally requires some time before complete refill of the engine water jacket takes place.

pressurized cap to raise the boiling point of the coolant and make use of higher operating temperatures. If leakage or malfunction occurs, replace with same rating type of cap. The pressure cap rating is found in Section 10, Specifications.

Siphon Break
A siphon break provision is used to prevent sea water manifold entry into the engine when the engine exhaust to function properly. Check the siphon break at the recommended interval for proper function. Generator set must not be running during servicing. NOTE Ambient water temperature and/or water salinity may require more frequent servicing.

outlet is located less than 9 in. (23 cm) above the water line when the craft is loaded to maximum capacity and is shut

down. When used in contaminated

waters or salt water,

the formation of corrosion may not allow the siphon break

3-12

Scheduled Maintenance

TP-5630 1 O/93

NOTE Numt 3ers in illustration refer to items below and not to dimensions.

l-94( 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Mounting Base Retaining Cap Reed Valve Assembly -.. Siphon Break Intake Strainer Seacock Sea Water Strainer Engine-Driven Sea Water Pump Coolant Recovery Tank Heat Exchanger (Locations Vary by Model) Exhaust Mixer Elbow Water Lock (Optional) Silencer Locate Coolant Recovery Tank at Same Height as Overflow on Exhaust Manifold Filler Neck 15. Pitch of Exhaust Hose 0.5 in. per ft. (1.3 cm per 30.5 cm) min. 16. Distance of Break above Waterline 1 ft. I___ . Siphon . (30.5 cm) min. 17. Distance of Silencer from Exhaust Mixer Elbow 10 ft. (3 m) max. 18. Vertical Lift of Silencer 4 ft. (1.2 m) max. 19. Pitch of Exhaust Hose 0.5 in. per ft. (1.3 cm per 30.5 cm) min. 20. Distance of Exhaust Outlet above Waterline 4 in. (10 cm) min. 21. Distance of Exhaust Mixer Elbow above Waterline. If less than 9 in. (23cm), siphon break is required.

Figure 3-18. Siphon Break (Threaded

Brass Type)

SIPHON BREAK (THREADED BRASS TYPE)


Remove the valve from the assembly rubber seal for wear and proper necessary. and examine replace the as seating;

NOTE Use two hose clamps on each end of all flexible hose connections.

exhaust

See Figure 3-l 8. To install, coat threads with

NOTE Data given also applies to side exhaust installations.

pipe sealant and tighten.

TP-5630 1 O/93

Scheduled Maintenance

3-13

Belt Tension
The belt tension should be checked initially at 50 hours or one month and then at the specified interval found in the If the tension is not within Service Schedule. specifications, adjust belt(s) as described below. 1. Remove belt guard. 2. Check belt tension at the midpoint of the longest span of the belt. (222-266 At this point, a used belt should deflect about 0.4-0.6 in. (IO-15 mm) with about 50-60 Ibs. N) of force. See Figure 3-19. A new belt

a+
0 #

WARNING

should be checked after 10 minutes of operation. If belt is not within specifications, If belt is within specifications, 3. Loosen adjusting 4. While prying screws. water pump outward, tighten go to Step 3.

go to Step 6.

sea

adjusting screws. 5. Recheck and adjust as necessary.

Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads
away from belts and pulleys when unit is running. Replace guards, covers, and screens set. before operating generator

6. Replace the belt guard.

3attery Charging Alternator Belt


1 Remove belt guard.

Sea Water Pump Belt

2. Check belt tension at the midpoint of the longest span of the belt. At this point, the belt should deflect about 0.4-0.6 in. (lo-15 mm) with about 22 Ibs. (10 kg) of force, see Figure 3-18. If belt is not within specifications, If belt is within specifications, go to Step 3.

go to Step 7. pivot

3. Loosen adjusting arm pivot screw, alternator screw, and alternator adjusting screw. 4. While prying adjusting 5. Tighten alternator outward, tighten

alternator

screw. adjusting arm pivot screw and alternator

pivot screw. 6. Recheck and adjust as necessary. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. il. Engine-Driven Water Pump Pulley Battery Charging Alternator Pulley Crankshaft Pulley Sea Water Pump Pulley Check Sea Water Pump Belt Tension Here Adjusting (Pivot) Screw Adjusting Screw Check Alternator Belt Tension Here Adjusting Screw Adjusting Arm (Pivot) Screw Alternator (Pivot) Screw 7. Reinstall the belt guard.

NOTE
If the battery is used while the craft is docked and the generator set is not running (i.e. auxiliary lights, two-way radio, etc.,) the battery will be drained and may not have enough powerto start the generator set later. Therefore, it may be necessary to connect a battery charger while the craft is docked and running on shore power.

Figure 3-19. Belt Tension (Typical)


3-l 4 Scheduled Maintenance

TP-5630 10193

Generator Service
Under normal conditions generator service will not be air to operation. indicates and Service excessive more frequently if bearing inspection damage generator service required on a regular basis. dusty and dirty conditions, the generator set operating rotor bearing If operating under extremely rotor end play or bearing lubrication. All use DRY compressed from corrosion or heat buildup. requires no additional service must be performed The rotor bearing is sealed by an authorized

blow out of the generator at frequent intervals.

Do this with and direct the stream of air in every 10,000 hours of

through the cooling slots at the end of the generator. The should be replaced

dealer/distributor.

Wattage Requirements
If the rated amperage capacity of the generator set is breaker, turn off some of the appliances and lights inside exceeded, the circuit breaker located on the controller will trip to protect the generator by having resulting too many against damage. This could be caused by a short in the AC circuit in the craft or simply appliances condition. on at the same time If the circuit breaker in an overload the craft to bring the load down within the rated amperage limits of the set. If this is done and the circuit breaker trips again after being reset, a short circuit is indicated. event, turn off the set and have a qualified locate and correct the cause of the short circuit. information regarding generator 10, Specifications. In this electrician For more

trips, the set may continue

running but there will be no AC Before resetting the circuit

set capacity, see Section

output to the protected circuit.

Storage Procedure
It is recommended that the craft be afloat at the time of generator set storage since unit must be started. set and run until operating 1. Start generator temperature is reached or about 15 minutes. STOP generator set. Drain oil from crankcase while engine is still warm. Refill crankcase with specified weight oil. NOTE Follow Steps 2-5 or 6-9. 2. Close seacock and remove hose at seacock. Place hose in a container of coolant/antifreeze. Container should have approx. antifreeze. l-2 U.S. gallons (3.7-7.5 L) of A mixture of 50% ethylene glycol and 50% NOTE If freezing temperatures will be encountered during storage, be sure antifreeze is capable of withstanding the lowest possible temperatures. Generally, a mixture of 50% ethylene glycol and 50% clean, softened water is sufficient. IO. Diesel fuel can be stored months. in fuel tank for several 7. Drain sea water from strainer and sea-water pump. 8. Open petcock on heat exchanger to only drain sea water. Use an air hose to blow out any remaining water, if necessary. Check coolant exchanger and add if necessary. level of heat

9. Drain sea water from exhaust water line.

clean, softened water is sufficient. 3. With a suitable container at exhaust outlet, run generator set until coolant is observed being discharged at exhaust outlet or until coolant mixture is used up. Do not allow coolant mixture to flow into waterways. STOP generator set.

11. Clean exterior of generator set and spread a light film of oil or silicon spray over any exposed which may be subject to rust or corrosion. surfaces

4. Connect hose to seacock. 5. Check coolant necessary.

Leave seacock closed. and add if

12. Tape to seal air inlet, exhaust pipe, and fuel tank cap. 13. Disconnect and remove battery. Battery should be

level of heat exchanger

6. Close seacock and drain all sea water out of cooling system.

placed in a warm, dry location for period of storage. Recharge once a month to maintain full charge. 14. Cover entire unit with a dust cover.

TP-5630 1 O/93

Scheduled Maintenance

3-15

Section 4. General Troubleshooting


Use the following tables as a quick reference in service unqualified dealers/distributors. personnel Improper repair failures. by troubleshooting remedies. The individual source problems. Generator of more detailed set faults can lead to additional are listed by specific groups and include likely causes and information needed to correct a problem is indicated. Installation Corrective knowledge These sources NOTE When Kl , K2, K3, K4 or K5 relays are receiving power, the corresponding whether It is LED will light. The LED does not indicate This conclusion analysis can deductive a continuity of generator the relay coil is energized.

include various sections of this manual, the Operation and Manual, and the Engine Service Manual. action and testing and in many cases electronic requires

only be reached through faults and by performing (see Section 7, Controller

of electrical that service

circuits.

test on the relay coil

recommended

only be done by authorized

Circuit Board).

TP-5630 10193

General Troubleshooting

4-l

Problem

Possible

Cause

Corrective

Action

Reference

ENGINE Will not crank (dead) Controller voltagesupply circuit breaker tripped Reset circuit breaker or replace fuse. Troubleshoot DC circuit and wiring. If circuit breaker failure continues, replace circuit breaker Check connections Section 7, Engine/ Generator Components Section 9, Wiring Diagrams

Battery disconnected or improperly connected Dead battery

Section 9, Wiring Diagrams

Check electrolyte level and specific gravity (batteries with filler caps only). Perform load test Clean or replace

Operation

Manual

Corroded or loose battery connections Defective starter Defective starter solenoid

Operation

Manual

Replace Check continuity of circuit. Bypass relay using jumper wire. If starter cranks, replace solenoid Check continuity

Engine Service Manual Section 7, Engine/ Generator Components Section 9, Wiring Diagrams Engine Service Manual Section 7, Component Testing Section 9, Wiring Diagrams Section 7, Component Testing Section 9, Wiring Diagrams Section 9, Wiring Diagrams Section 7, Component Testing

Defective start/stop switch

Open wiring, terminal, pin, foil, etc.

Check continuity

Remote start/stop switch not operating properly

Check wiring and connection to controller. If start/stop switch on controller functions, replace/ repair remote switch and/or wiring

4-2

General Troubleshooting

TP-5630 1 O/93

Problem

Possible

Cause

Corrective

Action

Reference

Will not start (cranks okay)

No fuel in tank

Replenish and bleed fuel system Check continuity and ground connection Replace fuel-feed pump Check air intake

Section 3, Fuel System

Defective fuel solenoid Defective fuel-feed pump Air intake restriction

Section 7, Fuel Solenoid

Section 7, Fuel Pump

Section 3, Air Intake Silencer/Cleaner Engine Service Manual Section 3, Fuel Filter Section 7, Controller Circuit Board Section 9, Wiring Diagrams

Engine malfunction Clogged fuel filter K2 relay coil defective (If LED2 is lit, relay is receiving power but may not be energized) Open wiring, terminal, or pin (P2 connector) K4 relay defective (K2 relay) must be energized Air in fuel system Water, dirt in fuel system Dirty or faulty injectors Improper compression Improper type of fuel

Troubleshoot

engine

Replace filter Check continuity

Check continuity

Section 9, Wiring Diagrams

Check relay coil continuity

Section 7, Controller Circuit Board Section 9, Wiring Diagrams Section 3, Fuel System

Bleed air Drain, flush fuel system Check injectors Check compression Use proper type of fuel; consult fuel supplier Use proper lube oil Test circuit board

Engine Service Manual Engine Service Manual Section 3, Fuel System

Improper type of crankcase lube oil Defective K4 relay contacts Weak or dead battery

Section 3, Lubrication System Section 7. Controller Circuit Board Operation Manual

Check electrolyte level and specific gravity (batteries with filler caps only). Perform load test

TP-5630 1 O/93

General Troubleshooting

4-3

Problem

Possible Cause

Corrective Action

Reference

Engine starts, but stops after start switch is released

No generator output voltage

Check AC voltage. Separately excite unit. Check stator and main field (rotor) continuity Check continuity

Section 9, Wiring Diagrams Section 7, Component Testing-Separate Excitation Section 9, Wiring Diagrams Section 9, Wiring Diagrams

Open wiring (Pi or P2 connector) Kl relay coil defective

Check continuity

Section 7, Controller Circuit Board Section 9, Wiring Diagrams Section 7, Stator Section 7, Component Testing-Engine/ Generator Components Engine Service Manual

If LED1 is not lit, Kl relay may not be receiving power from stator Bl/B2 winding No/low oil pressure (time delay of 5-10 seconds) Defective low oil pressure (LOP) shutdown

Check for power at relay

Check oil pressure, oil pump, and low oil pressure shutdown switch

Disconnect lead from LOP switch and isolate terminal. If engine continues to run, replace LOP switch. LOP switch contacts close at approx. 6.8 psi (47 kPa). NOTE: Verify proper engine oil pressure, before replacing LOP shutdown switch. Replace Check air intake Intake Silencer/Cleaner Check compression Section 3, Air

Hard starting

Stale or bad fuel Air intake restriction

Worn piston rings, valves, etc. Improper cooling (hot engine only) Air in fuel system Water, dirt in fuel system Dirty or faulty injectors Improper type of fuel

Engine Service Manual

Inspect cooling system

Section 3, Cooling System

Bleed air Drain, flush fuel system

Section 3, Fuel System

Check injectors Use proper type of fuel; consult fuel supplier

Engine Service Manual Section 3, Fuel System

4-4

General Troubleshooting

TP-5630 1 O/93

Problem Generator set shuts down by itself

Possible Cause
No fuel in tank Fuel line restriction

Corrective Action
Replenish Inspect fuel lines and tank Replace filter Check fuel feed pump

Reference

Clogged fuel filter Defective fuel feed pump Engine overloaded (hot engine only) Engine overheated (hot engine only)

Section 3, Fuel System Engine Service Manual

Reduce electrical

load

Section 3, Wattage Requirements Section 3, Service Schedule Engine Service Manual Section 9, Wiring Diagrams Section 7, Stator

Check air intake, carburetor adjustment, oil level, etc. Check AC voltage at rectifier (BRl) Check continuity of Bi/B2 stator leads Clean air intake

Loss of generator output voltage to Kl relay (LED1 not lit)

Air intake clogged

Section 3, Air Intake Silencer/Cleaner

No/low oil pressure

Check oil pressure, oil pump, and low oil pressure shutdown switch Reset circuit breaker. If breaker trips repeatedly, replace circuit breaker Bleed air

Engine Service Manual

Controller circuit breaker tripped

Section 7, Engine/ Generator Components Section 8, Wiring Diagrams Section 3, Fuel System

Air in fuel system Defective low oil pressure (LOP) shutdown

Disconnect lead from LOP switch and isolate terminal. If engine continues to run, replace LOP switch. LOP switch contacts close at approx. 6.8 psi (47 kPa). NOTE: Verify proper engine oil pressure, before replacing LOP shutdown switch. Disconnect lead from HWT switch and isolate terminal of lead. NOTE: Verify proper engine operating temperature before replacing HWT switch. If engine continues to run, replace HWT switch. HWT switch contacts close at approx. 203 F (95 C). Disconnect lead(s) from HET switch and isolate terminal of lead. NOTE: Verify proper operating temperature before replacing HET shutdown switches. If engine continues to run, replace defective switch. Shutdown switch contact closes at approx. 215 F (102C).

Defective high water temperature (HWT) safety shutdown switch

Defective high exhaust temperature safety shutdown switches

TP-5630 1 O/93

General Troubleshooting

4-5

Problem Will not carry load or runs rough

Possible Cause
Excessive load connected to generator Improper cooling (hot engine only) Governor not properly adjusted or defective (Engine not operating at rated rpm)

Corrective Action
Reduce electrical load

Reference
Section 3, Wattage Requirements

Inspect cooling system

Section 3, Cooling System

Check speed using tachometer or frequency meter. NOTE: Hz x 120/No. of rotor poles = rpm

Section 3, Governor

(Example: 60 x 120/4 = 1800)


Fuel line restriction Inspect fuel lines and tank Replace fuel filter Check fuel-feed pump Section 3, Fuel System Engine Service Manual

Dirty fuel filter Defective fuelfeed pump Excessive carbon build-up Valves not seating

Clean cylinder head

Engine Service Manual

Inspect valves and valve seats Check air intake

Engine Service Manual

Air intake restriction

Section 3, Air Intake Silencer/Cleaner Section 3, Fuel System

Improper type of fuel

Use proper type of fuel; consult fuel supplier Check injection timing

Incorrect fuel injection timing Vent in fuel tank cap obstructed Water, dirt, or air in fuel system Dirty or faulty injectors Improper cylinder top clearance Defective piston or piston ring Defective crankshaft bearing or piston pin bearing Improper valve clearance Improper compression Defective valve spring

Engine Service Manual

Clean cap in solvent, blow dry Drain, flush, fill, and bleed air in the system Check injectors Check clearance Section 3, Fuel System

Engine Service Manual Engine Service Manual

Check components

Engine Service Manual

Check components

Engine Service Manual

Adjust proper valve clearance Check compression Replace valve spring

Section 3, Valve Adjustment

Engine Service Manual Engine Service Manual

4-6

General Troubleshooting

TP-5630 10193

Problem Will not carry load or runs rough (contd)

Possible Cause
Defective injection pump Defective turbocharger Improper lube oil

Corrective Action
Check injection pump

Reference
Engine Service Manual

Check turbocharger Use proper viscosity oil Check engine speed using frequency meter or tachometer. NOTE: Hz x 120/No. of rotor poles = rpm

Engine Service Manual Section 3, Lubrication System Section 3, Governor

Lacks power

Governor not properly adjusted or defective (Engine not operating at rated rpm)

(Example: 60 x 120/4 = 1800)


Air intake restriction I Carbon build-up Clean carbon from cylinder heads Inspect cooling system Reduce electrical load Check air intake Section 3, Servicing Air Intake Silencer/Cleaner Engine Service Manual

Improper cooling Engine overloaded

Section 3, Cooling System Section 3, Wattage Requirements

Stale or bad fuel Fuel line restriction

Replace Check fuel lines and tank Replace fuel filter Check turbocharger Check cooling system Section 3, Fuel System Engine Service Manual Section 3, Cooling System

Dirty fuel filter Defective turbocharger

Overheats

Improper cooling (Check hoses for blockage and components for function.) Air intake restriction

Check air intake

Section 3, Servicing Cleaner

Air

Air heater (optional) malfunction Engine malfunction Defective fuel-feed pump

Check heater and relay Troubleshoot engine pump

Engine Service Manual Section 9, Wiring Diagrams Engine Service Manual Engine Service Manual

Check fuel-feed

TP-5630 1O/93

General Troubleshooting

4-7

Problem

Possible Cause

Corrective Action

Reference

Operates erratically

Air intake restriction

Check air intake

Section 3, Servicing Air Intake Silencer/Cleaner

Stale or bad fuel Governor not properly adjusted or defective (Engine not operating at rated rpm)

Replace Check engine speed using frequency-meter or tachometer. NOTE: Hz x 120/No. of rotor poles = rpm Section 3, Governor

(Example: 60 x 12014 = 1800)


Fuel line restriction Inspect fuel lines and tank. Check and replace as necessary Check and replace as necessary Retighten screws Operation and Installation Manual-Exhaust Systems Section 8, Disassembly/ Reassembly

Unit is noisy

Exhaust system leak

Broken or damaged vibro mounts Loose or vibrating sheet metal/housing Inadequate compartment clearances

Check clearances

Section 10, Specifications Chart-Generator Operation and Installation Manual-Compartment Size Operation and Installation Manual-Exhaust Systems

Exhaust piping or air inlets/outlets not securely installed No compartment sound insulation

Inspect for loose parts

Install sound shield Install fireproof insulation

Section 1. Accessories Instructions with Kit Operation and Installation Manual-Compartment Size Section 8, Disassembly/ Reassembly Engine Service Manual

Excessive vibrationengine/generator

Check main field (rotor), crankshaft, bearing, etc. (Disassembly of engine and/or generator may be required)

4-8

General Troubleshooting

TP-5630 1 O/93

Problem ELECTRICAL SYSTEM Battery will not charge

Possible Cause

Corrective Action

Reference

Loose or corroded connections Sulfated or worn-out battery

Clean and tighten connections Check electrolyte level and specific gravity (batteries with filler caps only) Test and replace, if necessary Adjust belt tension or replace belt Test and replace, if necessary Clean and tighten loose connections Check electrolyte level and specific gravity (batteries with filler caps only) Check starter solenoid Replace starter solenoid, as necessary Replace switch

Section 3, Battery

Operation

and Installation Manual

Defective alternator

Engine Service Manual

Loose or defective alternator belt Defective alternator voltage regulator

Section 3, Belt Tension

Section 7, Component Testing

Starter does not work properly

Loose or corroded connections Low battery output

Operation

and Installation Manual

Defective starter solenoid

Section 7, Component

Testing
Engine Service Manual Section 7, Component Testing Section 9, Wiring Diagrams Engine Service Manual Section 10, Specifications Chart-Installation Operation and Installation Manual-Electrical System

Defective start/stop switch Defective wiring Defective starter Battery cables undersize

Check wiring Replace starter Select proper size cable

TP-5630 1O/93

General Troubleshooting

4-9

Problem Starter cranks slowly

Possible Cause
Low battery output

Corrective Action
Check electrolyte level and specific gravity (batteries with filler caps only) Use proper viscosity oil Clean and tighten loose connections Repair/Replace starter

Reference
Operation and Installation Manual

Too heavy viscosity lube oil Loose or corroded wiring High starter current draw Battery cable undersize

Section 3, Lubrication System

Select proper size cable

Section 10, Specifications Chart-Installation Operation and Installation Manual-Electrical Systems

4-10

General Troubleshooting

TP-5630 1 O/93

Problem GENERATOR No generator output voltage

Possible Cause

Corrective Action

Reference

AC output circuit breaker open or defective

Check position of circuit breaker Check AC voltage on generator side of circuit breakers Reduce load Reset and attempt start-up Turn handle to proper position

Section 2, Circuit Protection Section 9, Wiring Diagrams

AC circuit breaker tripping due to overload on unit Transfer switch in OFF or other power source position

Section 3, Wattage Requirement

Section 9, Wiring Diagrams Operation and Installation Manual - Electrical Connections Section 9, Wiring Diagrams

No battery voltage to terminal (10) and (12) of voltage regulator during cranking Short circuit in vessel installation wiring causing circuit breaker to trip Open wiring, terminals or pin in exciter field (field flashing) Defective main field (rotor) (open, grounded, or shorted windings) Defective stator (open, grounded, or shorted windings) Open D5 or D8 diode

Check for 12 VDC at voltage regulator (10) and (12)

Reset circuit breaker. If breaker trips again, check vessel wiring. Check continuity

Section 9, Wiring Diagrams Vessel Wiring Diagram

Section 9, Wiring Diagrams

Test and/or replace

Section 7, Main Field (Rotor)

Test and/or replace

Section 7, Stator

Check for open or shorted diode (a good diode has high resistance one way and low resistance the other way, when tested with ohmmeter) Check continuity

Section 9 Wiring Diagrams Section 7, Circuit Board

Kl relay (normally closed) contacts open Defective voltage regulator Misadjusted voltage regulator

Section 9, Wiring Diagrams Section 7, Circuit Board Section 7, Separate Excitation Section 7, Voltage Regulator Test

Excite (main field) separately

TP-5630 1 O/93

General Troubleshooting

4-11

Problem Low generator output voltage

Possible Cause
Low engine rpm

Corrective Action
Check engine speed using frequency meter or tachometer. NOTE: Hz x 120/No. of rotor poles = rpm.

Reference
Section 3, Governor Adjustments

(Example: 60 x 120/4 = 1800)


Set overloaded Make sure capacity is not being exceeded Test and/or replace Section 3, Wattage Requirements Section 7, Main Field (Rotor) Section 7, Stator Section 7, Voltage Regulator Section 7, Voltage Regulator Section 7, Voltage Regulator Section 7, Voltage Regulator Section 7, Stator

Defective main field (rotor) Defective stator Defective voltage regulator Improperly adjusted voltage regulator

Test and/or replace Test and/or replace

Readjust

High generator output voltage

Defective voltage regulator Voltage regulator misadjusted Open or poor splice connection at terminals Vl-1 or V4-4 on 1-phase stator (regulator sensing); or poor pin connection at voltage regulator

Test and/or replace

Readjust

Check continuity

4-l 2

General Troubleshooting

TP-5630 1 O/93

Section 5. Controller Troubleshooting


Sequence of Operation (E-239563 Circuit Board)
The following test is the controller sequence of operation when starting, running, stopping, or during fault shutdown of the set. Use this section as a starting point for controller fault identification. Refer to Figure 5-1 for the a accompanying but uses wiring schematic. stator. Figure 5-1 illustrates Legend

1-phase 4-lead stator. The 3-phase generator a 12-lead See descriptions.

is identical for symbol

Starting
Close start/stop remote starting). K2 relay is energized Normally (LED2 lights). close to energize K3 switch between N and 47 (local or

open K2 contacts

relay (LED3 lights), controller hourmeter, exciter field.

K25 (fuel solenoid) relay, and generator armature

K3 relay normally open contacts close to energize K20 (starter) relay. K20 relay normally open contacts close to energize S relay (starter solenoid). S relay normally open contacts close to energize starter motor. K25 normally solenoid. Normally closed LOP contacts open. open contacts close to energize fuel

Running
When proper output is obtained from stator main field windings Bl/B2, Kl relay is energized (LED1 lights). After a 5-10 second time delay, K5 relay is energized (LED5 lights). NOTE Voltage to the Kl relay and K5 relay are rectified and regulated at 12 volts DC by bridge rectifier BRl and voltage regulator VR1

LED5 .r*

T&50 TB-6 0

ARMATURE

Figure 5-1. Sequence of Operation, l-Phase


TP-5630 1 O/93 Controller Troubleshooting

Stator

winding

Vl-V4

provides

voltage

sensing

source to the voltage regulator VR2 (PBV). Normally open Kl (A) contacts close to maintain

voltage to K2 relay (LED2 remains lit). Normally maintain hourmeter. Normally open Kl (B) contacts close to energize the (optional) oil pressure, coolant temperature, voltmeter, ON light. Normally water open K5 contacts and close to permit high high (LOP) and hourmeter gauges battery and generator open voltage K2 contacts remain closed to

to fuel

solenoid

and controller

temperature (HET),

(HWT),

exhaust

rL

K2

temperature

low oil pressure

switches to function. NOTE Low oil pressure (LOP) switch contacts engine develops proper oil pressure. open when

One set of normally closed Ki (C) contacts open to disconnect circuit to (+) connection of exciter fields (field flashing). A set of normally closed Ki (E) contacts open to disconnect circuit to (-) connection of exciter field (field flashing). Normally closed Ki (D) contacts open to deenergize K3 relay (LED3 goes out) and prevents accidental reenergizing of starter motor. K3 contacts open to deenergize K20 relay. K20 contacts open to deenergize S relay. S contacts open to deenergize starter motor. When the unit is running, start switch contacts N and 47 are opened by releasing start/stop rocker switch.
1 K4 i

Stopping
Close start/stop switch between remote). K4 relay is energized Normally deenergize closed (LED4 lights). open to deenergize contacts open to
TB-50 j

N and 43 (local or

K4 contacts

L-

K25 relay. K25 normally fuel solenoid.

open

ARMATURE

Normally open K4 contacts close to maintain ground to K4 relay. As unit is shutting down, Ki relay is deenergized

TE60

l-940

(LED1 goes out). Normally open Kl (A) contacts open to deenergize K2 relay (LED2 goes out). Normally closed K2 contacts close to ground circuit to K4 relay until unit comes to a complete stop. Figure 5-l. Sequence of Operation, (Continued) l-Phase

Controller Troubleshooting

TP-5630 1 O/S3

Legend A ALT BRl BV D FS GRD HET HWT HR HXT Kl K2 K3 Ampere Rating Battery Charging Alternator Bridge Rectifier (Supply Voltage) Battery Voltmeter Diode Fuel Solenoid Ground High Exhaust Temperature High Water Temperature Hourmeter High Exhaust Temperature AC Crank Disconnect Switch Relay (Circuit Board) Switch Switch K20 K25 LED LOP M OP Qi Q2 S SDR VRl VR2 WT K4 K5 Fault Shutdown Fault Shutdown (Circuit Board) Starter Relay/Solenoid Fuel Solenoid Relay Light Emitting Diode Low Oil Pressure Switch Starter Motor Oil Pressure Gauge Thyristor SCR (Silicone Starter Relay Overspeed Shutdown Relay Voltage Regulator Voltage Regulator Water Temperature PBV Gauge Controlled Rectifier) Relay (Circuit Board) Time Delay Relay

Engine Run Relay (Circuit Board) Engine Crank Control Relay (Circuit Board)

Engine Safety Shutdown Switches


Low Oil Pressure (LOP) Shutdown Switch
l

Normally closed K4 contacts open to deenergize K25 relay. K25 normally open contacts open to deenergize LOP K4 fuel solenoid.

When

low

oil

pressure

is

encountered,

shutdown switch contacts relay (LED4 lights).

close and energize

Normally open K4 contacts close to maintain ground to K4 relay. As unit is shutting down, Kl relay is deenergized (LED1 goes out). Normally open Kl (A) contacts open to deenergize K2 relay (LED2 goes out). Normally closed K2 contacts close to ground circuit to K4 relay until unit comes to a complete stop.

NOTE During cranking low oil pressure shutdown switch is deactivated until K5 relay is energized. This allows the engine to reach normal operating oil pressure. Normally closed LOP contacts open when unit develops adequate oil pressure.
l

Normally closed K4 contacts open to deenergize K25 relay. K25 normally open contacts open to deenergize fuel solenoid.

Overspeed Safety Shutdown (SDR)


When engine speed exceeds 70 Hz (2100 rpm), shutdown relay (SDR) on overspeed protection circuit board is energized. Normally open SDR K4 contacts close to complete circuit and energize relay (LED4 lights).

Normally open K4 contacts close to maintain ground to K4 relay. As unit is shutting down, Ki relay is deenergized (LED1 goes out). Normally open Kl (A) contacts open to deenergize K2 relay (LED2 goes out). Normally closed K2 contacts close to ground circuit to K4 relay until unit comes to a complete stop.

Normally closed K4 contacts open to deenergize K25 relay. K25 normally open contacts open to deenergize fuel solenoid.

High Water Temperature (HWT) and High Exhaust Temperature (HET) Shutdown Switch
l

Normally open K4 contacts close to maintain ground to K4 relay. As unit is shutting down, Ki relay is deenergized

When high temperature

is encountered

at one (or

(LED1 goes out). Normally open Kl (A) contacts open to deenergize K2 relay (LED2 goes out). Normally closed K2 contacts close to ground circuit to K4 relay until unit comes to a complete stop.

both) of these sources, the shutdown switch contacts close and energize K4 relay (LED4 lights).

TP-5630 1 O/93

Controller Troubleshooting

5-3

Section 6. Generator/Controller Troubleshooting


The flow chart is a guide to troubleshoot the generator set including the controller circuit board. Before beginning the troubleshooting procedures, read all safety precautions at Additional safety the beginning of this manual. precautions are included with the tests; DO NOT NEGLECTTHESE PRECAUTIONS.

Controller Circuit Board


The controller circuit board is equipped with LEDs (light emitting diodes) to indicate the presence of relay coil power and to aid in circuit board and generator fault detection. See Figure 6-I. When Kl , K2, K3, K4, or K5 relays are receiving power, the corresponding LED will light. The LED does not indicate whether the relay coil is energized. This conclusion can only be reached through deductive analysis of generator faults and by performing a continuity test on the relay coil (see Section 7, Controller Circuit Board). Use the following flow chart as an aid in troubleshooting the generator set. If the prescribed remedy does not correct the problem, the circuit board may have to be replaced. Where a check or test is referenced, go to that appropriate part of Section 7, Component Testing and Adjustment for detailed instructions.

TP-5630 1 O/93

GeneratorKontoller

Troubleshooting

6-1

30

LED3

E-239563
Dll R Pl-9

7qA
+i

6 PI-15 I P2-2 ,LD2 3 1

--

K5B Pl-13

PI -1

,L K4B 21, 3 II

Dl D4 u D6 R Pi-7 Pl-10 P2-8 P2-5 PI-2

P2-1

K2E 7y, PI -a K4C 4x1 5 h ,r DIO Ih 5

P2-3

KlB 31, 2 II

&KID ,-

P2-6 P2-9

Pl -5

D7 R

4$C Ih

DE R

P2-4 D4 u n KiE 5yl7 n P2-7

PI-12

PI-3

VI v GRD P1-6 ,L D3

Ri ,L LED5 b

5 cz K5A 2 KIA

R6 1

7:

Cl

R2 Ql R4 \r -4

Fi3 yQ2 c2 R5

LED1

Figure 6-1. Controller Circuit Board E-239563


6-2 Generator/Controller Troubleshooting TP-5630 10193

GENERATOR/CONTROLLER
Press start switch (Local or remote)

TROUBLESHOOTING
GotoA (next page)

Yes

Lrl

No

T
I I

No

Is K2 relay LED lit?

Yes

Is voltage present at K20 relay coil? Is K2 relay functioning properly?

I
0
K3 relay or Kl relay faulty. Replace circuit board

I
No
Replace circuit board

Is K3 relay functioning properly?

Q0
Yes

r
- Check condition/ connections of start/stop switch (N, 43, and 47). - Check battery condition and connections. - Check connections at PI-14. - Do all check okay?

&- 1
No Yes

Jr
No c functioning Is voltage present at S relay contact (starter motor side)?

Replace K20 relay

Replace S relay

Replace starter motor

TP-5630 1O/93

Generator/Contoller Troubleshooting

6-3

GENERATOR/CONTROLLER

TROUBLESHOOTING

(Contd.)

Does engine start?

Lrl
No

11

Is 12 Volts DC No
l

. present at
fuel solenoid? (check wiring)

Yes

Is 10 Amp. fuse okay?

Pl-8 connection - Check P4-14 connection - Replace circuit board (K2 relay defective)
- Check

6-4

Generator/Controller Troubleshooting

TP-5630 10193

GENERATOR/CONTROLLER
B+ Does engine continue to run after start switch is released? Yes -

TROUBLESHOOTING
Can engine be stopped by using stop switch? 1 No

(Contd.)
Yes 1 GENERATOR SET CHECKS OUT OKAY

+i No

4
Does Ki relay LED liaht? I

Yes

?l
Yes Does K5 relay LED light after 5-10 seconds of running time? I ----+ No I

No

9
No

Yes

Replace circuit board (K4 relay defective)

Is K25 relay functioning properly?

No I

Do local and remote start/stop switches function properly?

Yes
ti

-P

Yes
ti

. Does engine have proper oil pressure? Use a mechanical gauge to verify oressure.

0
Yes

No -

Replace defective SDR Circuit Board

Replace defective temperature switch(es> ;

GotoC (next page)

TP-5630 1 O/93

GeneratorKontoller

Troubleshooting

6-5

GENERATOR

TROUBLESHOOTING

Is there AC output when start button is HELD and unit is running? J No I

Yes

Is AC output at proper voltage? (e.g. 120 volts AC)

No

Test voltage regulator

clr Is there 12VAC output at Bl/B2 stator winding? Go to B at the beginning of preceding page No Test stator, main field (rotor) and exciter/armature
J

r---

f ----i

b
Yes 1

(OPTIONAL)

L ---

----

Separately excite generator set to determine if other components are defective. 1 Is AC output voltage at spec.? (See Section 7, Separate Excitation)

No

Test stator, main field (rotor), and exciter/armature

4 -l
Yes Test voltage regulator
6-6 Generator/Controller Troubleshooting TP-5630 10193

Section 7. Component Testing and Adjustment


This section is a guide for checking generator, controller, and some engine Follow the safety components precautions for improper operation. of this at the beginning manual during are all test included procedures. with the Additional tests; safety precautions OBSERVE THESE PRECAUTIONS!

Separate Excitation
To isolate the cause of no- or low-AC stator output to either the voltage regulator circuit or the generator components, separately excite the generator. See Figure 7-l.

Hazardous voltage can cause severe injury or death.


Wherever appliances electricity is present, there is the hazard of electrocution. home. before persons, Take the same precautions with electrical in your

in your craft that you would observe equipment. children, Make sure

The exciter field may be magnetized power source (12-volt automotive providing excitation

using an outsider DC battery). The separate

Open main circuit breaker on all power sources servicing especially unqualified cannot gain access to your

excitation test duplicates the role of the voltage regulator in current to the exciter field.

set-keep the compartment door locked or securely latched at all times. Be sure that generator is properly grounded. Never touch electrical leads or appliances with wet hands, when standing the chance of electrocution such conditions. While separately in water, or on wet ground as is especially prevalent under

WARNING

exciting the generator to determine

the

presence of a faulty voltage regulator, it is possible to determine if a running fault exists in the generator

Hazardous voltage.

1 Moving rotor.

components module).

(exciter, armature,

rotor, stator, and rectifier

Can cause severe injury or death.


Do not operate generator set without and electrical enclosures in place. all guards

A generator component that appears good while static (stationary) may exhibit a running open or short while dynamic (moving). This fault can be caused by centrifugal forces acting on the windings while rotating or by insulation breakdown as temperatures increase.

OUTPUT

VOLTAGE REGULATOR WIRING

&

NOOUTPUT

SEPARATE EXCITATION

NOOUTPUT

EXCITER CIRCUIT & RECTIFIER MODULE

ml
STATOR

111
Figure 7-1. Generator Troubleshooting
TP-5630 1 O/93

l-940

Component Testing and Adjustment

7-1

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.


Use protective permanent in clothing. goggles and clothes. Can cause
P5-1 000: 0000 I 0000 3 V/HZ VOLT 12

70

damage to eyes, burn skin, and eat holes

Sulfuric acid in batteries can cause severe injury or death. Sulfuric


damage Always acid in battery can cause permanent to eyes, burn skin, and eat holes in clothing. wear splash-proof safety goggles when working is splashed in the 1. LED 1 (1 wut) 2. LED 2 (Output) 3. LED 3 (Sensing) flush the affected area for 15 If battery electrolyte

around the battery.

eyes or on skin, immediately

minutes with large quantities of clean water. In the case of eye contact, seek immediate medical aid. Never add acid to a battery once the battery has been placed in service. Doing so may result in hazardous spattering of electrolyte.

Figure 7-2. PowerBoostTMV Voltage Regulator


2. Disconnect 3. Connect P6 (Fl, F2) connector. separate excitation circuit as shown in

Explosion can cause severe injury or death. Battery


gases can cause an explosion. flame or spark to occur particularly terminals sparks battery. wristwatch, Do not smoke or permit at any time, contacting Remove cable to Do not or Any Avoid near a battery

Figure 7-3. (Connect an ammeter and a 10 ampere fuse in series with Fl .) Note and record the ammeter reading. 4. The approximate ammeter reading should be battery voltage divided by the specified exciter resistance (cold).

when it is being charged. could cause an

with tools, etc. to prevent burns and to prevent that explosion. (-) battery rings, and any other jewelry Never connect negative before handling

Volts (Battery Voltage) Ohms (Exciter Resistance)

positive (+) connection test battery sparks compartment to prevent battery before reconnect condition containing

terminal of starter solenoid. by shorting terminals gases or fuel vapors. gases.

Amps = (Exciter Current)

together

could ignite battery accumulation charged

batteries must be well ventilated of explosive and always negative To avoid while off When

Specified values are found in Section IO, Specifications. 5. Start engine and check that ammeter remains stable. An increasing meter reading indicates a shorted exciter field. A decreasing meter reading to zero, or unstable reading, suggests a running open in exciter. If ammeter is stable, proceed to step 6. 6. Check for AC output across stator leads and compare to values in Section 10, Specifications. If output varies considerably from those listed, a faulty stator, is likely. Refer to

sparks, do not disturb battery charger connections is being disconnecting battery, it last. battery remove connections.

turn charger

disconnecting

lead first and

1. Disconnect Figure 7-2.

all leads from the voltage regulator. See

rotor, rectifier module, or armature this section for further information.

7-2

Component Testing and Adjustment

TP-5630 10193

7. If AC output is within specifications, the voltage regulator is probably defective. If there is no generator output during normal operation but output is available when the set is separately excited, the voltage regulator is probably defective.

NOTE Stator Output Voltages (with Separately Excited Generator) found in Section 10, SpecificationsGenerator are based on a battery voltage of 12 volts. Should actual battery voltage vary (11-14 volts), resulting values will also vary.

PowerBoost V Voltage Regulator

Disconnect P6 Connector (Fl/F2 leads) before separate excitation.

: : L; 7

10 Amp Fuse

Generator Frame

l-940

Figure 7-3. separate txcitatlon r;onnections

Voltage Regulator TestPowerboost M V


The PowerBoost voltage magnitude V voltage regulator monitors output to control current to the generator
l

Step-up Transformer, (1 .O Amp minimum) Variable Transformer, (1 .O Amp minimum)

1:2, 120 to 240 Volts

exciter field. The voltage regulator has an under-frequency unloading feature which is referred to as Volts-per-Hz (V/Hz). To determine if the voltage regulator is functioning properly, reduce engine speed (Hz) and watch for a corresponding drop in AC voltage. AC voltage should remain constant until engine speed drops below 57.5 Hz (on 60 Hz models) or 47.5 Hz (on 50 Hz models). When frequency function, output. drops below 57.5/47.5 perform To test the following the voltage Hz, AC voltage should decline. To further check the voltage regulator for proper test to check regulator the regulator following

O-140 Volts

250 Volt, 100 Watt Lamp AC Voltmeter 250 Volt (minimum) 1 Amp Fuse 1 SPST Switch, 1 Amp (minimum) 120 Volt AC Plug (200-240 Volt AC Plug optional) #I 4 AWG Copper Wire (minimum)

components

will be needed:

TP-5630 1 O/93

Component Testing and Adjustment

7-3

Test Procedure
1. Connect components as shown in Figure 7-4. If a the step-up 200-240 volt power source is available, transformer 2. Turn Volts is not required. potentiometer (pot.) fully counter-

3. Plug power cord into outlet. Turn power supply on. AC voltmeter should indicate power supply voltage of 200-240 volts. Lamp should be off. Slowly turn Volts adjustment pot. clockwise. The lamp should go on. If the light does not go on, the voltage regulator is defective and should be replaced. 4. Turn power supply off and disconnect power cord.

clockwise.

1. 2. 3. 4. 5. 6. 7.

Voltage Regulator PBV 250 Volt, 100 Watt Lamp AC Voltmeter 250 Volt (Minimum) Volts Potentiometer 1:2 Step-Up Transformer Single-Pole Single-Throw Switch I-Amp Fuse

8. 9. 10. 11. 12. 13. 14.

Black Wire White Wire 100-l 20 VAC 200-240 VAC (Optional) LED 3 (Sensing) LED 1 (Input) LED 2 (Output)

Figure 7-4. PowerBoost V Voltage Regulator Test

7-4

Component

Testing and Adjustment

TP-5630 10193

Voltage Regulator Adjustment


The PowerBoost N V voltage regulator monitors generator output to control current flow to the generator generator ouput under field. load PowerBoost V maintains

under a variety of load circumstances, no further with, or voltage/frequency readjust according regulator components and described

conditions. adjustment reconnection

Under normal is necessary. has been done, Voltage

However, if the regulator is replaced, has been tampered to the following procedure.

until the generator

engine speed drops to a preset level the

are identified in Figures 7-5 and 7-6 paragraphs.

(factory setting 57.5 Hz on 60 Hz models and 47.5 Hz on 50 Hz models). At this point (under factory settings) level sufficient to handle load. When the generator generator regulator output also returns to normal. regulator allows generator voltage and current to drop to a speed

in the following

NOTE Figure 7-5 illustrates a 3-phase connection. 1 (replaces are identical. l-phase 7) and 4 connection Diagrams. is to stator windings Remaining connections

returns to normal (60 Hz or 50 Hz) as load is accepted, The voltage operation is factory set for proper generator

(replaces 8). See 1 -phase schematic

in Section 9, Wiring

PowerBoost V Voltage Regulator 1

V/HZ VOLTS LED3 0

Sensing Leads (208-240 Volts nominal)

Main Field (Rotor)

Armature

i-l

Bl

B21

42 53 Stator Windings

6 l-940

Figure 7-5. PowerBoost V Voltage Regulator-3-Phase

Connection

TP-5630 1 O/93

Component Testing and Adjustment

7-5

Adjustment Procedure
1. With generator set off, turn remote rheostat (if equipped) to midpoint. Turn Voltage, Volts/Hz, and

Stability
voltmeter

pots. fully

counterclockwise.

Connect

to AC circuit or an electrical

outlet.

2. Start generator set. Rotate voltage adjustment pot. clockwise (decrease achieved.
V/HZ VOLT

(increase voltage)

voltage)

or counterclockwise output voltage is

until desired

3. Rotate stability pot. clockwise flicker is obtained.

until minimum

light

$ El
1

4. Readjust voltage adjustment pot. (if necessary).


I

5. Mechanical Governor:
TB

Adjust (factory

engine setting

speed 57.558

to desired

cut-in

frequency or on

Hz for 60 Hz models

47.5-48 Hz for 50 Hz. models) as measured frequency meter. See Section 3, Governor. 1. Stability Potentiometer 2. Volts/Hertz Potentiometer 3. Voltage Potentiometer 4. LED 1 5. LED 2 6. LED3

Figure 7-6. PowerBoost V Adjustments

6. Rotate volts/Hz adjustment pot. clockwise until voltage level begins to drop (as measured on voltmeter). When set to these specifications, the generator will attempt to maintain normal output until engine speed drops below the frequency (as load is applied). 7. Mechanical Governor: Readjust engine speed to normal (63 Hz/1890 rpm for 60 Hz or 52.5 Hz/l 575 rpm for 50 Hz). See Section 3, Governor. 8. Readjust voltage adjustment pot. (if necessary). set in Step5

NOTE
The voltage regulator is located in the generator junction box and is serviceable by removing six screws.

Voltage Adjustment Pot.-Adjusts generator within range of 190-270 volts (line-to-line).


Stability flicker. Pot.- Fine-tunes regulator to reduce

output

light 9. Readjust stability pot. (if necessary). (if equipped) to make final SET

Volts/Hz-Adjustment

determines

engine speed (Hz) at

10. Use remote

rheostat

which generator output voltage will begin to drop.

voltage adjustments.

STOP GENERATOR

Exciter Field
The exciter field is magnetized magnetized according exciter by DC voltage from the is rotated within the an electrical current 2. Check exciter field resistance by connecting an battery. When the exciter armature field windings, procedure. ohmmeter across exciter field Fi and F2. See Figure 7-7. The resistance found in Section an indicates reading for a cold exciter field is A low reading a high exciter reading field is short and indicate proves IO, Specifications.

develops within the exciter armature. Test the exciter field to the following

internal

indicates an open winding. field if ohmmeter 1. Disconnect generator starting battery (negative exciter leads Fi lead defective. first). Disconnect connector. and F2 at P6 readings If resistance

Repair or replace exciter test inconclusive,

perform a megohmmeter the next step.

test on field as described in

7-6

Component Testing and Adjustment

TP-5630 10193

3. Check exciter field for a grounded

WARNING

megohmmeter, instructions performing field winding

condition. Using a apply 500~volts DC to Fl or F2 lead manufacturerwhen of approximately the of to

and exciter field frame. See Figure 7-8. (Follow the ofthe megohmmeter this test.) A reading

500K ohms (l/2

megohm) and higher indicates indicates possible deterioration current flow

is good. A reading of less than 500K and

Moving rotor. I Can cause severe injury or death. Hazardous voltage.


Do not operate and electrical generator set without in olace. all guards

ohms winding

(approximately) insulation

ground. Repair or replacement necessary. PowerBoost THV Voltage Regulator enclosures

of the exciter field is

Hazardous voltage can cause severe injury or death.


Wherever appliances home. before electricity is present, there is the hazard of electrocution. Take the same precautions with electrical in your

in your craft that you would observe equipment. children, Make sure

Open main circuit breaker on all power sources servicing unqualified Disconnect P6 Connector (Fi/F2 Leads before Testing. cannot gain access to your

persons, especially set-keep latched at grounded. wet hands, the chance

the compartment door locked or securely all times. Be sure that generator is properly Never touch electrical leads or appliances with when standing in water, or on wet ground as of electrocution is especially prevalent under

such conditions.

PowerBoost N V Voltage Regulator

I I8 t I 8 I I I I I I I I

I Ohmmeter El P O

-E
l-940

Disconnect P6 Connector (Fi /F2 Leads)

:A,1

Figure 7-8. Megohmmeter Connections on Exciter Field

Figure 7-7. Checking Exciter Field Resistance

TP-5630 1 O/93

Component

Testing and Adjustment

7-7

Exciter Armature
The exciter armature supplies excitation current to the generator main field (through the rectifier module). Test the exciter armature as described in the following steps. The generator must be disassembled prior to performing this test. 1. With generator disassembled, disconnect armature leads from rectifier module AC terminals. 2. With an ohmmeter on the R x 1000 scale, check resistance across all three exciter armature leads. See Figure 7-9. The armature resistance is found in Section 10, Specifications. No continuity indicates an open armature winding. If the resistance test proves inconclusive, perform a megohmmeter test on the armature as described in the next step. NOTE Most ohmmeters will not provide accurate readings when measuring less than one ohm. The exciter armature can be considered good if a low resistance reading is obtained (continuity) and there is no evidence of shorted windings (heat discoloration). Ohmmeter instructions of the megohmmeter manufacturerwhen performing this test.) See Figure 7-10. A reading of approximately 500K ohms (l/2 megohm) and higher indicates the exciter armature is good. A reading of less than 500K ohms (approximately) indicates deterioration of winding insulation and possible current flow to ground. Repair or replacement of the exciter armature is necessary.

Windings

WARNING

Figure 7-9. Exciter Armature Ohmmeter Test Hazardous voltage.


1 Moving rotor.

Can cause severe injury or death. Do not operate generator set without all guards and electrical enclosures in olace. Hazardous voltage can cause severe injury or death. Wherever electricity is present, there is the hazard of electrocution. Take the same precautions with electrical appliances in your craft that you would observe in your home. Open main circuit breaker on all power sources before servicing equipment. Make sure unqualified persons, especially children, cannot gain access to your set-keep the compartment door locked or securely latched at all times. Be sure that generator is properly grounded. Never touch electrical leads or appliances with wet hands, when standing in water, or on wet ground as the chance of electrocution is especially prevalent under such conditions. 3. Check exciter armature for a grounded condition. Using a megohmmeter, apply 500-volts DC to either armature lead and the armature frame. (Follow the
7-8 Component Testing and Adjustment

Windings

I Shaft Connection Ohmmeter

-EL
Figure 7-10. Megohmmeter Connections on Exciter Armature

l-940

TP-5630 10193

Rectifier Module
The rectifier module (located electrically armature to DC which magnetizes between exciter main steps. armature and main field) converts the AC from the exciter the generator in the following field. Test the rectifier as described 1. Disconnect exciter armature

and main field leads

from rectifier module. 2. Using an ohmmeter on the R x 100 scale, check the coating from

resistance of rectifier diodes as shown in Figure 7-11. To test diode, carefully scrape insulation diode terminals terminals resistance ohmmeter direction. 1 and 2. The ohmmeter in one direction leads, a higher 1 and 2 and place ohmmeter leads on should show a low the in the other and, upon reversing resistance

Replace the rectifier

module if any of the

diodes tests differently

than described.

I-940 _ .-

.-... . 1. urocie lerminal 2. Diode Terminal

Figure 7-11. Testing Rectifier Module

Generator Main Field (Rotor)


The generator main field (magnetized by DC from the rectifier module) rotating within the stator windings induces AC in the stator windings. Test generator main field as described in the following steps. The generator must be disassembled prior to performing this test.

Hazardous voltage can cause severe injury or death.


Follow instructions of test equipment manufacturer when performing high voltage test on rotor or stator. Improper test procedure can damage equipment or lead to future generator failures. 1. With the generator disassembled, disconnect generator main field (rotor) windings from the rectifier module terminals F+ and F-. 2. Check the main field resistance ohmmeter by connecting an

WARNING

across main field F+ and F- leads. See

Hazardous voltage.

-P

Moving rotor.

B!b

Figure 7-12. The resistance reading for a cold main field is found in Section IO, Specifications. A low reading indicates an internal short and a high reading indicates field all guards defective. perform described an open winding. readings Repair or replace main indicate main field is as if ohmmeter

Can cause severe injury or death.


Do not operate and electrical generator set without in place.

If the resistance test proves inconclusive, a megohmmeter in the next step. test on the armature

enclosures

TP-5630 1 O/93

Component

Testing and Adjustment

7-9

3. Check the main field for a grounded condition. Using a megohmmeter, apply 500-volts DC to either main field lead and the main field frame. of the megohmmeter (Follow the The stator consists instructions performing manufacturerwhen laminated steel frame.

Stator
of a series of coils of wire laid in a The stator leads supply voltage to

this test.) See Figure 7-13. A reading of 500K ohms (i/2 megohm) and higher is good. A reading of less than indicates deterioration possible current flow of the main of to

the AC load and the exciter regulator. Prior to testing, windings, laminations. inspect the stator for heat discoloration lead wires, exposed coil in and varnished areas of frame

approximately 500Kohms winding ground.

indicates the mainfield insulation

(approximately) and

and visible damage to housing and exposed

Repair or replacement

field is

Check that the stator is securely fastened

necessary.

the stator housing.

CHECKING STATOR CONTINUITY AND RESISTANCE


1. Disconnect leads first). generator starting battery (negative

2. Disconnect all stator leads. 3. Adjust ohmmeter to zero ohms on R x 1 scale. Check
stator continuity by connecting meter leads to stator leads as shown in Figure 7-14 or 7-15. There must be continutiy individual winding. Ohmmeter between leads of an

__!E!Figure 7-12. Ohmmeter Connections on Main Field

There must be NO continuity separate windings.

between

leads of

There must be NO continuity between any winding lead and ground on the stator housing or frame laminations.

4. Contact ohmmeter

leads and readjust ohmmeter to zero ohms. Check cold resistance of stator windings by connecting meter leads to stator leads of an individual winding (Bl-B2, Vl-1, l-2, etc.: l-phase; Bl-82, l-4,2-5, etc.: 3-phase). Typical statorwinding resistances If the stator are shown in Section 10, Specifications. resistance test proves inconclusive, test on stator as described

perform a megohmmeter in the next step.

NOTE
Most ohmmeters will not provide accurate readings when measuring less than one ohm. The stator can be considered good if a low resistance reading Megohmmeter (continuity) is obtained and there is no evidence of shorted windings (heat discoloration).

NOTE
Since ohmmeters from l-940 Section do vary in their accuracy, use data as a IO, Specifications-Generator

Figure 7-13. Megohmmeter Connections on Main Field


7-10 Component Testing and Adjustment

reference for approximate readings. Ohmmeter readings must be taken at room temperature or about 70 F (21 C).

TP-5630 10193

NOTE
Stator resistance temperature. Should any of the stator readings vary considerably during the previous checks, the stator must be repaired or replaced. will vary directly with increased

7-17. (Follow the instructions of the meghommeter manufacturerwhen performing this test.) Repeat test on other leads until all stator windings have been tested. A reading of approximately 500K ohms (l/2 megohm) and higher indicates the stator is good. A reading indicates possible of less than 500K deterioration current flow to ohms (approximately) insulation Repair and or of winding

ground.

replacement

of the stator is necessary.

WARNING

-2
Hazardous voltage.

vb
Moving rotor.

Can cause severe injury or death.


Do not operate generator set without and electrical enclosures in place. all guards

m$-J 6-ia r-3


3 4 55 66 Vl v4 W t_?_ l-940 A. Continuity/Resistance Between B. No Continuity Between Points C. No Continuity Between Points Points A B f

Hazardous voltage can cause severe injury or death.


Follow instructions of test equipment manufacturer when performing high voltage test on rotor or stator. Improper test procedure can damage generator failures. equipment or lead to future

5. Check stator for a grounded condition. Using a megohmmeter, apply 500-volts DC to any stator lead from winding and stator frame. See Figure 7-16 or

NOTE: Perform tests on all statorwindings.

Figure 7-14. Stator Windings, l-Phase

l-940

A. Continuity/Resistance Between Points B. No Continuity Between Points C. No Continuity Between Points NOTE: Perform tests on all stator windings.

Figure 7-15. Stator Windings, 3-Phase


Component Testing and Adjustment 7-11

TP-5630 1 O/93

PowerBoost

V Voltage Regulator

LED1

LED2

0 a lol

Sensing Leads (208-240 Vqlts nominal)


V/HZ LED3 0 VOLTS

Voltage Regulator Power

Main Field (Rotor) Rectifier Module U I

Armature

1 Stator Windings

Figure 7-16. Megohmmeter Connections on Stator, l-Phase

7-l 2

Component Testing and Adjustment

TP-5630 1O/93

PowerBoost

V Voltage Regulator

Sensing Leads (208-240 Vtts nominal)

V/HZ LED3 0

VOLTS F2

Voltage Regulator Power Supply Leads

Exciter Field Stator Windings

Main Field (Rotor)

Armature

MoaUe LF%zFFr
Bl B21 4 2 53 Stator Windings 6 Megohmmeter 12;11 P 9 U Connection l-940

Figure 7-17. Megohmmeter Connections on Stator, 3-Phase

TP-5630 1 O/93

Component Testing and Adjustment

7-l 3

Controller Circuit Board


It is possible components installing tests from the board. are to check (relays) some controller circuit board the and manufacturers conformal instructions. To obtain accurate from pages. without removing the component readings when testing, remove all circuit board connectors coating (transparent insulation) component terminals. controller Use the following chart and see the on the following

These checks should be made prior to

a new board and attempting start-up. Most of the in Section 4, General referenced Use a high quality multimeter and follow

circuit board schematic

Troubleshooting.

E-239563 Circuit Board


Ohmmeter Connections
Kl coil terminals (See relay schematic)

Component
Kl Relay Coil

Remarks
Ohmmeter RxlOscale on

Results
If good-approx. 160 ohms. Low resistance (continuity)shorted coil. High resistance-open coil. If good-approx. 160 ohms. Low resistance (continuity)shorted coil. High resistance-open coil. If good-approx. 400 ohms. Low resistance (continuity)shorted coil. High resistance-open coil. If good-approx. 125 ohms. Low resistance (continuity)shorted coil. High resistance-open coil. If good-approx. 510 ohms. Low resistance (continuity)shorted coil. High resistance-open coil.

K2 Relay Coil

K2 coil terminals (See relay schematic)

Ohmmeter RxlOscale

on

K3 Relay Coil

K3 coil terminals (See relay schematic)

Ohmmeter on Rx loscale

K4 Relay Coil

K4 coil terminals (See relay schematic)

Ohmmeter RxiOscale

on

K5 Relay Coil

K5 coil terminals (See relay schematic)

Ohmmeter RxiOscale

on

7-14

Component Testing and Adjustment

TP-5630 10193

P2 0 0 000 OQQ l5.l

PCB ASSY E-23%63

E-239563
Dll R Pl-9

Pl-15

xD*

3__ 1

K5B Pl -13

,L K4B 211 3 I1

Di D4 u D6 R Pl-7 Pl-10 P2-6 P2-5 Pi-2

K2E 7x1 Pl-6 K4C 4Ul 5 h DlO Ih 5

KlB P2-3 311-2----

KlD

P2-6 P2-9

P2-4 D4 u KlE 5yl7 P2-7

Pl-12

Pl-3 VRl VI v GRD Pi-6 ,L D3

Rl ,L LED5 ::

5 CI K5A 2 KlA

:) R6 1

-4 Cl

R2 Ql R4 h 7:

R3 ;rcctz C2 R5

,L LED1 t

Y-51 79

Figure 7-18. Controller Circuit Board Testing


Component Testing and Adjustment 7-15

TP-5630 1 O/93

Engine/Generator
With the generator checked. set battery connected, the wiring can be harness and some engine/generator Place the controller position in the prescribed components

Components
each component component. using a DC voltmeter. This will verify that the switches function and 12 volts DC is present at each

or remote start/stop switch

and check for 12 volts DC at

Component
Hourmeter and wiring

Voltmeter Connections
Red test clip to (+) terminal. Black test clip to (-) terminal. Place controller or remote switch in START position. None (see Remarks)

Remarks
Voltmeter setting 12-volts DC reading indicates wiring harness is okay.

Results
If good-12-volts DC or greater. To determine if hourmeter is good, proceed to next step.

Disconnect hourmeter leads and apply 12-volts DC to hourmeter.

If good-hourmeter operate.

will

NOTE: Hourmeter is
polarity sensitive. Bl and B2 stator auxiliary winding Disconnect Bl/B2 leads. Connect AC voltmeter to leads. NOTE: Voltage can only be measured momentarily since unit will not continue to run after start switch is released. STOP generator. Red test clip to red lead of solenoid and black test clip to engine block (ground). Place controller switch to START position. STOP generator set. Voltmeter setting 20volts AC or greater. Start generator set and allow to reach proper speed. Reading of 12-l 5 volts indicates Bl/B2 winding is good.

Fuel solenoid

Voltmeter setting 12 volts or greater. If lead can not be disconnected, cut leads and crimp on fully insulated push-on terminals. To determine if fuel solenoid is good, proceed to next step. Disconnect red and white leads at push-on terminals. Apply 12-volts DC to red lead and momentarily apply 12volts DC to white lead. NOTE: Apply voltage only momentarily to white lead to prevent fuel solenoid damage. This coil draws 50 amps and is intended only to pull in solenoid.

If good-12-volts DC reading indicates wiring is okay.

None (see Remarks)

If good-fuel solenoid plunger will energize when voltage is applied to white lead and remain held in after white lead is disconnected as long as red lead has voltage applied to it.

7-16

Component Testing and Adjustment

TP-5630 1 O/93

Legend
K20

Electrical Contacts

Actuator

Starter Relay/ Solenoid

Fuel Solenoid FS SiRD Ground HET High Exhaust Temp. Shutdown Switch Hourmeter HR HWT High Water Temp. Shutdown K25 Switch

Fuel Solenoid Relay LOP Low Oil Pressure Shutdown Switch Starter Motor M Starter Relay s

Start

Rocker Switch Electrical Contacts and Actuator Positions NOTE


Rocker switch closed electrical contacts are opposite from rocker switch actuated position.

7nA

71A I K25 I I K20 FP

HET

LOP I B2_ -

LJ

Exciter

Figure 7-19. Wiring Harness Connections with E-239563 Circuit Board


TP-5630 1 O/93

Component Testing and Adjustment

7-l 7

Component
Controller switch

Ohmmeter Connections P2-6 and P2-4

Remarks
Ohmmeter on R x 1000 scale. Place rocker switch in START position.

Results
If good-zero ohms (continuity). Any resistance other than zero or very low ohmsreplace switch. If good-zero ohms (continuity). Any resistance other than zero or very low ohmsreplace switch. If good-85 ohms. Low resistance-shorted C relay coil and/or wiring. High resistance-open C relay and/or wiring. If good-400 ohms. Low resistance-shorted K25 relay coil and/or wiring. High resistance-open K25 relay and/or wiring. If good-approx. 0.5-0.6 ohms at 805F (275C).

P2-6 and P2-5

Ohmmeter on R x 1000 scale. Place rocker switch in STOP position.

K20 relay
coil and wiring

Pl-4 and Pl-9

Ohmmeter on R x 1 scale

K25 relay
coil and wiring

Pl-8 and Pi-9

Ohmmeter on R x 1 scale

Starter solenoid (S relay)

P4-22 and battery (+) cable. NOTE: J4 and P4 must be disconnected to perform this test. Battery positive (+) cable and PI-14 NOTE: J4 and P4 must be connected to perform this test. P7 (FP/FN) NOTE: Disconnect P7 connector for this test.

Ohmmeter on R x 1 scale

Controller 1Oamp circuit breaker and wiring

Ohmmeter on R x 1000 scale

If good-zero or very low ohms. No reading (infinity)-open circuit or circuit breaker tripped.

Exciter field windings

Ohmmeter on R x 1 scale. Disconnect exciter field leads to voltage regulator at P6.

If good-see Section 10, Specifications. Low resistanceexcitershorted. High resistance-exciteropen.

Exciter armature windings

Disconnect armature leads from rectifier. Connect ohmmeter to two armature leads. Repeat test on third lead.

Ohmmeter

on R x 1 scale

If good-see Section 10, Specifications. Low resistance-armature windings shorted. High resistance-armature windings open.

Main field (rotor)

Disconnect rotor F+ and F- leads from rectifier. Connect ohmmeter F+ and F- leads.

Ohmmeter

on R x 1 scale

to

If good-See Section IO, Specifications. Low resistance-rotor windings shorted. High resistance-rotor windings open.

7-18

Component Testing and Adjustment

TP-5630 1 O/93

Component Bl /B2 stator windings

Ohmmeter Connections P8-4 and P8-5 NOTE: P8 and J8 must


be disconnected to perform this test.

Remarks Ohmmeter on R x 1 scale

Results If good-see Section 10,


Specifications. Low resistance-Bl/B2 windings shorted. High resistance-Bl/B2 windings open.

Pl ground connection

,Pl-9 and ground

Ohmmeter

on R x 1 scale

If good-zero (continuity).

ohms

Any other reading indicates a poor


ground connection.

Low oil pressure (LOP) safety shutdown switch

Pl -15 and engine block (ground) NOTE: J4 and P4 must be connected to perform this test.

Ohmmeter on R x 1000 scale. This test is not conclusive until the temperature shutdown switches are checked. Ohmmeter scale on R x 1000

If good-zero ohms (continuity). Then, disconnect LOP switch lead and isolate terminal. Meter reading should show an open circuit. If good-open circuit. Any continuity suggests that temperature switch(es) are defective. Disconnect individual leads to determine which switch is defective.

High exhaust temperature (HET), high water temperature (HWT) safety shutdown switches

Pi -15 and engine block (ground) NOTE: LOP switch lead should be removed and isolated. NOTE: J4 and P4 must be connected to perform this test.

Fuel Solenoid
The fuel solenoid serves to pull the injector pump lever to the fuel onposition when energized. The fuel solenoid is spring loaded to return the injector-pump lever to the fuel off position when de-energized. The generators use a three-lead fuel solenoid. This

Current (amps) and resistance readings are shown in Figure 7-20. Resistance readings can be taken to determine if the solenoid windings are open or shorted. These tests must be made with fuel solenoid disconnected from engine wiring harness.

solenoid has a white lead (P) which energizes the pull-in coil only during cranking. During operation the red lead energizes the holdcoil ground. and the black lead is the common

Figure 7-20. Fuel Solenoid Readings

TP-5630 1 O/93

Component Testing and Adjustment

7-19

In addition to the ohmmeter test, check for smooth, non-binding movement of plunger. It is important that the linkage between the fuel solenoid and the fuel injection pump lever be properly plunger adjusted coil. to allow the solenoid adjustment may is lf the fuel solenoid to fully compress. Improper

Fuel Pump
The fuel pump transfers fuel from a source to the injection pump The fuel pump can be tested using the following procedure. 1. Remove the two leads at the bottom of the fuel pump. The pump terminals Figure 7-22. are labeled (-) and (+). See

cause burn-out of the pull-in

removed or the setting is suspected to be incorrect, the following procedure and see Figure 7-21.

use

1. Remove linkage to allow fuel solenoid plunger to be manually compressed. 2. With fuel solenoid and check solenoid lever should injection fully compressed, pump align linkage Fuel pump lever

lever for travel. and injection

2. Connect Disconnect

inlet

side

of pump

to

a fuel

source.

should fully compress be 0.05

outlet hose from fuel filter and place hose

in. (1.6 mm) before

end in a container to catch fuel. 3. Connect positive positive terminal (+) terminal of fuel pump. of 12 V battery Connect (-) terminal to of

contacts (internal full open) stop. NOTE Fuel solenoid must compress (bottom) fully or burn-out of fuel solenoid pull-in coil will occur. 3. If alignment is not correct, check linkage and

negative

terminal

of fuel pump to negative

battery. You should hear pump operate and see fuel discharged from pump outlet. If pump does not operate, replace pump.

mounting brackets. Loosen locknuts and adjust ball joint length in or out to attain proper alignment. Tighten locknut.

1. Fuel Solenoid 2. Ball Joints 3. Locknuts

1. 2. 3. 4.

Negative terminal Positive Terminal Fuel Inlet Fuel Outlet

Figure 7-21. Fuel Solenoid Linkage

Figure 7-22. Fuel Pump

7-20

Component Testing and Adjustment

TP-5630 1 O/93

Section 8. Disassembly/Reassembly
Disconnect all external connections-battery cables at battery (negative lead first), AC-output sea-water exhaust precautions procedures. leads in controller,

WARNING

remote start panel at controller P3 connector, water line at pump, fuel line at fuel pump filter inlet, and line at listed mixing during elbow. Observe all safety the disassembly/reassembly

Hazardous voltage.
NOTE Several procedure models are covered in this manual, may vary and the

1 Moving rotor.

Can cause severe injury or death.


Do not operate and electrical generator set without in place. all guards

for disassembly

due to product

updates and assembly variations. NOTE The voltage Remove regulator is located in the controller voltage removing box. controller cover to service regulator. the voltage

enclosures

Adjustments are possible without regulator from the controller.

Hazardous voltage can cause severe injury or death.


The heat sink of the voltage Do not touch voltage regulator regulator contains high voltage. heat sink when

HARDWARE

DAMAGE!

NOTE Engine and generator

make use

testing or electrical (PowerBoost,

shock will occur. Ill, and PowerBoost V Voltage

of both SAE and metric hardware. Be sure to use correct size tools to prevent rounding of bolt heads and nuts.

PowerBoost

Regulator Models only.)

Disassembly
1. Remove end panel from generator end of unit. Loosen four screws and lift off cover. See Figure 8-l 2. Disconnect P4 (22-pin) connector from J4. Remove bolt to disconnect ground strap. Disconnect P8, P7, and P6 connectors. See Figure 8-2.

1. Generator End Panel 2. Controller Cover

1, 2. 3. 4. 5.

P4 (22-Pin) Connector Ground Strap P7 (2-Pin) Connector P6 (2-Pin) Connector P8 (6-Pin) Connector

Figure 8-1. Covers


TP-5630 1O/93

Figure 8-2. Connectors


Disassembly/Reassembly 8-l

NOTE Output leads can be connected in various positions for different volt configurations. Mark leads for proper reconnection. 3. Disconnect the generator output leads from circuit from breaker and neutral stud (LO). Remove four controller mount locknuts. hole of controller See Figure 8-3. Lift controller leads through box. rubber mounts while guiding bottom

field

(rotor)

leads

through

armature

bores.

See

Figure 8-5.

1. 2. 3. 4.

Armature Retaining Armature Rectifier Board Rotor Leads

Bolt

Figure 8-5. Removing Armature


6. Remove two vibromount bolts. Raise generator end and place wood block under locator plate. Lower generator until locator plate is supported by wood block. Remove four overbolts from end bracket. See Figure 8-6.

1. Controller Mount Locknut 2. Neutral Stud (LO)

Figure 8-3. Removing Controller 4. Remove tie wraps from wire harness as necessary.
Remove four bolts to remove exciter field. See Figure 8-4.

NOTE
Hoist capcity should be rated one-half ton or greater.

Figure 8-4. Removing Exciter Field 5. Remove three bolts and spacers from rectifier board.
Disconnect main field (rotor) leads from rectifier board positive/negative terminals. Remove bolt and washer. Remove armature from shaft, guiding main 1. 2. 3. 4. Locator Plate Wood Block Vibromount Bolts Overbolts

Figure 8-6. Supporting Generator


TP-5630 1 O/93

8-2

Disassembly/Reassembly

7. Remove two bolts and starter cover.

9. Remove eight metric bolts to remove drive disc/rotor assembly from flywheel. See Figure 8-9.

Figure 8-7. Removing Stator Cover 8. Install sling centered on stator housing. Use two-jaw
puller to pull end bracket/stator assembly from bearing on main field (rotor) shaft. See Figure 8-7. (End bracket can separate from stator during removal.) Remove stator assembly from main field.

1. Drive Discs (Two Used) 2. Main Field (Rotor)

Figure 8-9. Removing Main Field (Rotor)


10. Clamp rotor in a soft-jaw vise. Remove eight bolts

and remove drive discs from rotor. See Figure 8-10.

Figure 8-10. Removing Drive Discs Figure 8-8. Removing Stator Assembly

TP-5630 10193

Disassembly/Reassembly

8-3

11. Remove eight slot-head four bolt spacers.

bolts. Remove the fan and

Figure 8-11. Removing Fan

Reassembly
1. Apply Loctite 271 to threads of eight slot-head and install fan and four bolt spacers. 2. Clamp main field (rotor) in a soft-jaw vise. Install two drive discs and tighten eight bolts to 30 ft. tbs. (40 Nm). 3. Install rotor/drive disc assembly on flywheel using bolts 4. Inspect O-ring in end bracket bearing bore and replace O-ring if damaged. Use a sling to support stator assembly while installing over rotor. Be careful not to damage rotor. Check that alignment marks on end frame and stator as well as stator and locator plate are aligned. See Figure 8-13. Install overbolts and tighten to 30 ft. Ibs. (40 Nm). four

eight bolts and washers. Tighten bolts to 20 ft. Ibs. (27 Nm). Use a strap wrench to prevent rotor from

1. End Frame/Stator Alignment Marks 2. Stator/Locator Plate Alignment Marks

Figure 8-13. Installing Stator

Figure 8-12. Installing Main Field (Rotor)


6-4 Disassembly/Reassembly

5. Install starter cover on stator housing using two bolts.

TP-5630 1 O/93

6. Use hoist to raise generator end. Remove wood block under locator plate. Lower generator and install bolt, large washer, three small washers (one at locknut), and locknut in each vibromount. Tighten mount bolts to 20 ft. Ibs. (28 N.m). 7. Apply anti-seize compound to keyed end of rotor shaft. Bring rotor leads through bores in armature while installing armature on shaft. Check keyway of shaft and key of armature for damage. Install armature retaining bolt and washer. 8. Install rotor leads to rectifier board at positive and negative terminals using screws and lockwashers. NOTE Position lockwashers against rectifier board. 9. Install three spacers and bolts to mount rectifier board to armature. 10. Install exciter field using four bolts and washers. Field leads are at top. 11. Install tie wraps to secure wires as necessary. 12. Bring output leads through bottom of controller box. Check that grommet is intact and there are no sharp

edges exposed that could damage wiring. Install box on rubber mounts and install four locknuts. Connect leads to circuit breaker and neutral stud (LO) as marked during disassembly. NOTE Generator set nameplate can be checked to verify original voltage configuration. See Section 9, Wiring Diagrams for more information regarding voltage reconnection. 13. Connect P4 (22-pin), P6, P7, and P8 connectors. Connect ground strap using bolt, washer, and lockwasher (install lockwasher against ground strap). 14. Install controller cover. 15. Install end panel with louvered openings down. 16. Reconnect all external connections-exhaust line to mixing elbow, fuel line to fuel pump filter inlet, water line to sea-water pump, remote start panel to controller P3 connector, AC output leads in controller, and battery cables to battery (negative lead last). 17. Open seacock and fuel valve.

TP-5630 10193

Disassembly/Reassembly

8-5

Section 9. Wiring Diagrams


Electra Switch
2-Wire Generator Sets Ll 3-Wire Generator Sets

To Generator

To Load To Load

Kraus NaimletYAmerican Solenoid (Early Rectangular Design)


P-Wire Generator Sets 3-Wire Generator Sets

To Load To Load

Kraus NaimetYAmerican Solenoid (Newer Round Design)


2-Wire Generator Sets 3-Wire Generator Sets

To Generator

To Load To Load Figure 9-l. Marine Manual (Ship-to-Shore) Transfer Switch


TP-5630 1 O/93 Wiring Diagrams 9-l

TP-5399-5

This Page Intentionally Left Blank.

9-2

Wiring Diagrams

TP-5630 10193

Kraus NaimetVAmerican Solenoid


4-Wire, three phase Generator Sets

To Generator Set

Ll L2

L3

LO
t-940

To Load

Figure 9-2. Manual (Ship-to-Shore) Transfer Switch

TP-5630 10193

Wiring Diagrams

9-3

12 YOCT

SCHEMATIC

LEGEND

229073-D Figure 9-3. Wiring Diagram-Schematic (13.5/l 8.!$21 CCOZ and 11/l 5/l 6.5CCFOZ) (Equipped with A-258296 Voltage Regulator)

9-4

Wiring Diagrams

TP-5630 1 O/93

NOTE :

CONNECTOR PIN INSERTION

SHOWN FROM END.

REMOTE

PANEL

SACK VIEW OF PANEL (2 AND 4 GAUGE REMOTE

PANEL)

GENERATOR

CONNECTIONS

FOR VOLT - RECONNECTABLE CONFIGURATIONS-SEE ADV-5857

229073-D

Figure 9-4. Wiring Diagram-Point-to-Point Wiring (13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ) (Equipped with A-258296 Voltage Regulator)

TP-5630 1O/93

Wiring Diagrams

9-5

lPOLT

SCHEMATIC

LEGEND AH -AIR HEATER RELAY BV - BA-ITERY VOLT METER FP - FUEL PUMP FS - FUEL SOLENOID HR - HOUR METER Kl -AC CRANK DISCONNECT RELAY K2- ENGINE RUN RELAY K3 - ENGINE CRANK RELAY K4 - FAULT SHUTDOWN RELAY K5 - FAULT SHUTDOWN TIME DELAY RELAY K20 - STARTER RELAY/SOLENOID K25 - FUEL SOLENOID RELAY M - STARTER MOTOR OP - OIL PRESSURE GAUGE OPS - OIL PRESSURE SENDER S - STARTER RELAY SDR - OVERSPEED SHUTDOWN RELAY TDR - TIME DELAY RELAY VRl -VOLTAGE REGULATOR WT- WATER TEMPERATURE GAUGE WTS - WATER TEMPERATURE SENDER -OPTIONAL

229937-D

Figure 9-5. Wiring Diagram-Schematic (13.5/18.5/21 CC02 and II/l 5/l 6.5/l BCCFOZ) (Equipped with B-258296 Voltage Regulator)
Q-6 Wiring Diagrams TP-5630 1 O/93

REMOTE

PANEL

NOTE : CONNECTOR SHOWN PIN INSERTION END.

FROM

BACK VIEW OF PANEL

CONTROLLER VOLTAGE REGULATOR (POWER BOOST 5)

LYY

IIT
2 P
P7 SEE GENERATOR CONNECTIONS

FOR VOLTRECONNECTABLE CONFIGURATIONS - SEEADV-5857

229937-D Figure 9-6. Wiring Diagram-Point-to-Point Wiring (13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ) (Equipped with B-258296 Voltage Regulator)

TP-5630 1 O/93

Wiring Diagrams

9-7

12 OLi

SCHEMATIC

I -

vo+-J

P4 -6

Figure 9-7. Wiring Diagram-Schematic (14/20/24CCOZ and 11.5/17.5/2OCCFOZ) (Equipped with A-258296 Voltage Regulator)
9-8 Wiring Diagrams TP-5630 1 O/93

J3

-_-

M
I

I I

225652-D Figure 9-8. Wiring Diagram-Point-to-Point Wiring (14/20/24CCOZ and 11.5/17.5/2OCCFOZ) (Equipped with A-258296 Voltage Regulator)

TP-5630 1 O/93

Wiring Diagrams

9-9

12

OLT

SCHEMATIC

*Ill/

I r

229938-D

Figure 9-9. Wiring Diagram-Schematic (14/20/24CCOZ and 11.5/17.5/2OCCFOZ) (Equipped with B-258296 Voltage Regulator)
9-10 Wiring Diagrams

TP-5630 1 O/93

NOTE : CONNECTOR SHOWN PIN INSERTION END. REMOTE PANEL

FROM VOLTAGE REGULATOR (POWER BOOST 5) I

BACK VIEW OF PANEL (2AND 4 GAUGE REMOTE

PANEL)

GENERATOR CONNECTIONS

229938-D

Figure 9-10. Wiring Diagram-Point-to-Point Wiring (14/20/24CCOZ an! 11.5/17.5/2OCCFOZ) (Equipped with B-258296 Voltage Regulator)
Wiring Diagrams 9-11

TP-5630 10193

TP-5592/TP-5630
12 VOLT

SCHEMATIC

+! I I !

13.5CCOZ,18.5CCOZ, and 21 CCOZ Wiring Diagram-Schematic (Specs: PA-1 26136, PA-1 26137, and PA-1 26138)
11194

TP-5592/TP-5630

CUSTOMER

SUPPLIED

WIRING

CONTROu.ER

13.5CCOZ,18.5CCOZ, and 21 CC02 Wiring Diagram-Point-to-Point (Specs: PA-1 26136, PA-1 26137, and PA-1 26138)
11194

7
LED3

50

E-239563
PI-9

A* +-I

6 PI-15 I P2-2

,L PI-1

D2

3 -1

KSB PI-13

,L K4B 21, 3 I,

Dl D4 u R D6 R PI -7 PI-IO P2-8 P2-5 PI -2 P2-6 P2-9

P2-1

K2E 7u,

__I_/
P2-3 KIB 31, 2 ,I PI-5 D7 R 4vyc Ih 2 D8 R PI-12 D4 u I KIE 5yl7 PI-3

I?,

P24 P2-7

PI-6

zt

Cl

R2 01 R4 jr 7: c2 RS ,L ;: LED1

Figure 9-11. Controller Circuit Board E-239563


S-l 2 Wiring Diagrams TP-5630 1 O/S3

Four-Lead Reconnectable (Single-Phase) Generator Sets Where Generator Output Can Be Reconnected for 100-120 Volt or IOO-120/200-240 Volt, 60 Hz; or 100-l 20 Volt,lOO-120/200-240 Volt, or 200-220-240 Volt, 50 Hz
To illustrate the proper reconnection of 4-lead generator sets, the following information is provided. In all cases, the National Electrical Code (NEC) should be followed.

NOTE When a generator set is reconnected to a voltage different than nameplate voltage, notice should be placed on the unit indicating this change. A decal (part no. 246242) is available for this purpose from authorized Kohler dealers/distributors. Jumper lead not used. Circuit breaker MUST be a circuit breaker manufacturer two-pole circuit breaker. Two single-pole circuit breakers do not conform to NEC requirements when supplying a 200-240 volt load. This is true even if they are mechanically attached together. Leads Ll and L2 are different phases and must never be connected together.

ILoad Side

FE i> c> H

1: Factory Two-Pole Circuit Breaker

x_ j Line -O Side

4 3 2 1 Stator Leads
I

100-l 20/200-240 Volt, 3 Wire 50 Hz 100-l 20 Volt 100-l 20 Volt 200-240 Volt

LO-L1 LO-L2 LO-L2

60 Hz 100-l 20 Volt 100-l 20 Volt 200-240 Volt

Figure 9-13. IOO-120/200-240 Volt Configuration LO (Neutral) > L_ Side 6 H Single-Pole Circuit Breaker @Ground Load Side H Line Side B B LO GRD. Ll

Single-Pole Circuit Breaker

100-l 20 Volt. 2 Wire 4 3 2 1 Stator Leads

4 3 2 1 Stator Leads 60 Hz 100-l 20 Volt 100-l 20 Volt 50 Hz 100-l 20 Volt 100-l 20 Volt

r T

Tape to insulate from ground

200-220-240 Volt, 2 Wire

LO-L1 LO-L2

LO-L1

60 Hz not used

50 Hz 200-220-240 Volt sets equipped with

Figure 9-14.200-220-240 Volt Configuration* * Only available on generator B-258296 voltage regulator.

Figure 9-12.100-120 Volt Configuration*


TP-5630 10193

Wiring Diagrams

9-13

12 LEAD STATOR 60 Hz - 120/208V. OR 139/24OV. 3 PH. 4 WIRE LOW WYE 50 Hz - 120/208V. OR 11O/l 90 V. 3 PH. 4 WIRE LOW WYE

12 LEAD STATOR 60 Hz - 120/24OV. 3 kH. 4 WIRE DELTA 50 Hz - 110/22OV. 3 PH. 4 WIRE DELTA

Li

12

12 LEAD STATOR 60 Hz - 277/48OV. 3 PH. 4 WIRE HIGH WYE 50 Hz - 220/38OV. 3 PH. 4 WIRE HIGH WYE

60 HZ - 100-120/200-240X 50 HZ - IOO-120/200-240V.

- 1 PH. 3 WIRE - 1 PH. 3 WIRE

Figure 9-15. Voltage Reconnections

with 12-Lead Stator

9-14

Wiring Diagrams

TP-5630 1 O/93

Section IO.

Specifications Chart
21ccoz 13.5ccoz 11CCFOZ 18.5CCOZ 1SCCFOZ 16.5CCFOZ 18CCFOZ

Generator Models

Dimensions (L) (W

in. (mm) 36.6 (930) 22.2 (564) 26 (660) 41.3 (1049) 25.8 (655) 27.5 (699) 680 (308) N/A 86.78172.32 (1422/l 185) 21 O/l 75 (5946/4955) 41.3 (1049) 22.2 (564) 26.4 (671) 44.8 (1138) 25.8 (655) 28.0 (711) 765 (347) 870 (395) 115.91/96.59 (1899/l 582) 21 O/l 75 (5946/4955) 25 continuous, 30 intermittent (three minutes or less) and 1.5 in. (38 mm) 41.3 (1049) 22.2 (564) 26.4 (671) 44.8 (1138) 25.8 (655) 28.0 (71) 790 (358) 895 (405) 115.91/96.59 (1899/l 582) 21 O/l 75 (5946/4955)

0-U (L) w/sound shield (W) w/sound shield (H) w/sound shield w/ sound shield (wet) Ibs. (kg)

Weight (wet) Ibs. (kg) Air Requirements-CFM (Vmin.) - Combustion 60 Hz/50 Hz Cooling 60 Hz/50 Hz Operation (max.) for vibration

Angular

(in all directions) Minimum Clearances

cooling (top, front, rear, and sides) (without sound shield) Fuel Consumption 60 Hz U.S. gal./hr. (Uhr.) (fuel consumption LOAD 25% 50% 75% 50 Hz U.S. gal./hr. (Uhr.) based on CCFOZ63 voltage configuration) 0.38 (1.8) 0.54 (1.9) 0.72 (2.7) 0.93 (3.5) based on CCOZ63 voltage configuration) 0.48 (1.8) 0.71 (2.7) 0.93 (3.5) 1.19 (4.5)

0.63 (2.4) 0.90 (3.4) 1.24 (4.7) 1.63 (6.2)

0.67 (2.5) 0.98 (3.7) 1.37 (5.2) 1.77 (6.7)

- 100% Fuel Consumption (fuel consumption LOAD 25% 50% 75%

0.50 (1.9) 0:72 (2.7) 1 .OO (3.8) 1.38 (5.2) four pole, rotating field flexible disc brushless exciter 1800/l 500 4 PowerBoost +2% *5% V

0.53 (2.0) 0.77 (2.9) 1.05 (4.0) 1.40 (5.3)

- 100% Generator Type Coupling Type Excitation Type Shaft RPM (60/50 Hz) Number of Output Leads Voltage Regulator Voltage Regulation Frequency Regulation

TP-5630 1 O/93

Specifications

Chart

1 O-l

Generator Models (continued)


21 cc02 13.5ccoz 11CCFOZ 18.5CCOZ 15CCFOZ 16.5CCFOZ 1 BCCFOZ

Exciter Field Voltage/Current Readings at Rated Voltage (Hot) No Load (63 Hz) Full Load (60 Hz) (Cold) (Cold) (Cold) Resistance 410.7 12/l .8 5.8 0.5 4.3 6/l .O 11/l .8 5.8 0.5 3.0 6/l .O 1512.3 5.8 0.5 3.0 (21 CCOZ/l6.5CCFOZ) 4.0 (18CCFOZ) Stator Output Voltages with Separately Excited Generator, Using 135 180 17 0.12 1.50 0.07 95 125 12 0.07 1.30 0.06 95 125 12 0.07 1.30 0.06 12-Volt Battery (60 Hz only) * l-2, 3-4 (Vl -V4) - 55-66 - Bl -B2 Stator Resistance (Cold) - l-2, 3-4 (Vl -V4) 55-66 Bl -B2

Exciter Field Resistance Exciter Armature

Main Field (Rotor) Resistance

To limit battery current and prevent damage to the generator, use a 1 O-ohm, 1O-watt resistor in series with the 12-volt battery to obtain the following values. are available only with models equipped with B-25896

NOTE:

Straight 100-200 volt configurations voltage regulator Power Boost TM V.

1 O-2

Specifications

Chart

TP-5630 1 O/93

Generator Models (continued)


14ccoz 11.5CCFOZ 2occoz 17.5CCFOZ 24CCOZ POCCFOZ

Dimensions (L) -((w>

in. (mm) 36.6 (930) 22.3 (567) 26 (660) 43 (104993) 25.8 (655) 28.3 (718) 690 (313) 785(356) 86.78/72.32 (1422/l 185) 210/175 (5946/4955) (Vmin.) 115.91/96.59 (1899/l 582) 21 O/l 75 (5946/4955) 25 continuous, 30 intermittent for vibration and (three minutes or less) 1.5 in. (38 mm) 115.91/96.59 (1899/l 582) 21 O/l 75 (5946/4955) 41.3 (1049) 22.3 (567) 26.4 (671) 46.5 (1181) 25.8 (655) 28.8 (730) 775 (352) 880 (399) 41.3 (1049) 22.3 (567) 26.4 (671) 46.5 (1181) 25.8 (655) 28.8 (730) 800 (363) 905 (411)

(H) (L) w/sound shield (W) w/sound shield (H) w/sound shield

Weight (wet) Ibs. (kg) w/ sound shield (wet) Ibs. (kg) Air Requirements-CFM Combustion 60 Hz/50 Hz

Cooling 60 Hz/50 Hz Operation (max.)

Angular

(in all directions) Minimum Clearances

cooling (top, front, rear, and sides) (without sound shield) Fuel Consumption 60 Hz U.S. gal./hr. (Uhr.) (fuel consumption based on CCOZ63 voltage configuration) LOAD 25% 50% 75% 0.48 (1.8) 0.71 (2.7)

0.93 (3.5) - 100% 1 .I9 (4.5) Fuel Consumption 50 Hz U.S. gal./hr. (Uhr.) (fuel consumption based on CCFOZ63 voltage configuration) 25% 50% 75% 100% 0.38 (1.8) 0.54 (1.9) 0.72 (2.7) 0.93 (3.5)

0.63 (2.4) 0.90 (3.4) 1.24 (4.7) 1.63 (6.2)

0.67 (2.5) 0.98 (3.7) 1.37 (5.2) 1.77 (6.7)

LOAD -

0.50 (1.9) 0.72 (2.7) 1 .OO (3.8) 1.38 (5.2) four pole, rotating field flexible disc brushless exciter 1800/l 500 12 PowerBoost V *2% *5%

0.53 (2.0) 0.77 (2.9) 1.05 (4.0) 1.40 (5.3)

Generator Type Coupling Type Excitation Type Shaft RPM (60/50 Hz.) Number ofoutput Voltage Regulator Voltage Regulation Frequency Regulation Leads

TP-5630 1 O/93

Specifications

Chart

1 O-3

Generator Models (continued)


14ccoz 11 .SCCFOZ 2occoz 17.5CCFOZ 24CCOZ POCCFOZ

Exciter Field Voltage/Current Readings at Rated Voltage (Hot) 6/0.9 17/2.6 (Cold) (Cold) (Cold) Using 70 90 9 0.04 1.3 0.05 70 90 9 0.04 1.3 0.05 5.8 0.5 4.3 8/l .4 1312.0 5.8 0.5 3.0 8/l .4 1612.4 5.8 0.5 3.0 No Load (63 Hz) Full Load (60 Hz) Resistance

Exciter Field Resistance Exciter Armature

Main Field (Rotor) Resistance Stator Output Voltages with Separately

Excited Generator,

12-Volt Battery (60 Hz only) * - l-4, 2-5, 3-6, 7-l 0, 8-11, 9-l 2, 7-8 o/l -V4) 110 - 55-66 125 - Bl -B2 12 Stator Resistance (Cold) - l-4, 2-5, 3-6, 7-10, 8-11, 9-12, 7-8 (vl-V4) - 55-66 - Bl -B2 0.06 1.5 0.06

To limit battery current and prevent damage to the generator, use a 1O-ohm, 1O-watt resistor in series with the 12-volt battery to obtain the following values. are available only with models equipped with B-25896

NOTE:

Straight 100-200 volt configurations voltage regulator Power Boost TM V.

1 O-4

Specifications

Chart

TP-5630 1 O/93

Engine Mddels
13.5ccoz 11CCFOZ 18.5CCOZ 1SCCFOZ 21 cc02 16.5CCkOZ 18CCFOZ

Engine Manufacturer Engine Model Number of Cylinders Cylinder Cylinder Block Material Head Material

Yanmar 3JH2LT-K 3

Yanmar 3JH2LT-K 4 cast iron cast iron 2 compression/l stamped forging forged steel centrifugal, mechanical 3.31 (84) x 3.39 (86) oil

Yanmar 3JH2LT-K 4

Piston Rings Crankshaft Connecting Governor Bore x Stroke in. (mm) Displacement CID (L) 87.26 (1.43) 17.79:1 20/l 6.5 Compression Ratio Horsepower 60/50 Hz RPM 60/50 Hz Direction of Rotation (as viewed from generator Lubrication System Lube Oil Capacity (w/filter) Oil Recommendation (API) Engine Firing Order Rod

116.6 (1.91) 16.99:l 27.5/22.5 1800/l 500 Counterclockwise pressure

116.6 (1.91) 16.99:l 37127.5

end) 5.0 (4.7) l-3-2 6.1 (5.8) CD 1-3-4-2 17 21 2844 271 (200 25) direct injection 12 Volt, negative ground 500 CCA, 100 Amp Hr. 50 Amps @ 12 Volts Diesel, ASTM/D975-66T, No. 1-D or No. 2-D electric solenoid fuel shutoff ft. (m) 2.36 (2.23) electric 4.0 (1.2) 3.15 (3.0) .85 (.8) 50% ethylene glycol; 50% clean, softened water 195F (90X) 12.8 psi (88.3 kPa) 1.8 kW, gear-reduction automotive (cold) 0.0079 (0.2) 0.0079 (0.2) 3.15 (3.0) 6.1 (5.8) 1-3-4-2 17 rl 2844 271 (200 25)

(#l cylinder nearest to flywheel) Fuel Injection Timing (BTDC) 17 Fuel Injection Pressure psi (kg/cm sq.) 2844 +71 (200 25) Combustion System (min.) Battery Voltage Battery Recommendation Battery Charging Fuel Recommendation Fuel System Fuel Pump Prime Pump Fuel Pump Lift (recommended) Coolant Capacity U.S. qts. (L) Coolant Recovery Tank qts. (L) Recommended Coolant Thermostat Pressure Cap Rating Starter Motor Intake/Exhaust in. (mm) Valve Clearance

(alternator)

type 0.0079 (0.2)

TP-5630 10193

Specifications

Chart

1 O-5

Engine Models (continued)


21 cc02 13.5ccoz 11CCFOZ 18SCCOZ 1 SCCFOZ 16.5CCFOZ 18CCFOZ

Belt Tension (force) Cylinder Head Torque 29 (39) ft. Ibs. (Nm) 58 (79) 30 (41) 20 (27) Housing 30 (41) 30 (41) (;53 (736) 3/8 ID/l/4 NPT 3/8 ID/l/4 NPT Initial ft. Ibs. (Nm) Final ft. Ibs. (Nm) (2-step intervals) Bolt Torque

0.38 in. (10 mm) @ 22 Ibs. (10 kg) 29 (39) 58 (79) 30, (41) 20 (27) 29 (39) 58 (79) 30 (41) 20 (27)

Flex Plate to Rotor Bolt Torque Flex Plate to Flywheel ft. Ibs. (Nm) Generator

Adapter Plate to Flywheel

Bolt Torque ft. Ibs. Over Bolt Torque ft. Ibs. Inlet Water Line Hose ID in. (mm) (sea-water pump inlet) Outlet Water Line Hose ID in. (mm) (mixing elbow outlet) Fuel Inlet (Fuel Pump Inlet) Fuel Return Size/Type

30 (41) 30 (41) (z) (736) 3/8 ID/l/4 NPT 3/8 ID/l /4 NPT

30 (41) 30 (41) & (&) 3/8 ID/l/4 3/8 ID/l/4 NPT NPT

1 O-6

Specifications

Chart

TP-5630 1 O/93

Engine Models (continued)


14ccoz 11 .SCCFOZ 2occoz 17.5CCFOZ 24CCOZ POCCFOZ

Engine Manufacturer Engine Model Number of cylinders Cylinder Cylinder Block Material Head Material

Yanmar 3JH2LT-K 3

Yanmar 3JH2LT-K 4 cast iron cast iron 2 compression/l stamped forging oil

Yanmar 3JH2LT-K 4

Piston Rings Crankshaft Connecting Governor Bore x Stroke in. (mm) Displacement Compression CID (L) Ratio 87.26 (1.43) 17.79:1 20/l 6.5 Rod

forged steel centrifugal, mechanical 116.6 (1.91) 16.99:1 37127.5 3.31 (84) x 3.39 (86) 116.6 (1.91) 16.99:1 275122.5 1800/l 500 Counterclockwise end) pressure 5.0 (4.7) l-3-2 17 6.1 (5.8) CD l-3-4-2 17 21 2844 k71 (200 35) direct injection 12 Volt, negative ground 500 CCA, 100 Amp Hr. 50 Amps @ 12 Volts Diesel, ASTM/D975-66T, No. 1-D or No. 2-D electric solenoid fuel shutoff electric 4.0 (1.2) 3.15 (3.0) 3.15 (3.0) 2.36 (2.23) 0.85 (.8) 50% ethylene glycol; 50% clean, softened water 195F (90X) 12.8 psi (88.3 kPa) 1.8 kW, gear-reduction automotive (cold) 0.0079 (0.2) 0.0079 (0.2) 0.0079 (0.2) type 6.1 (5.8) l-3-4-2 17 21 2844 k71 (200 25)

Horsepower 60/50 Hz RPM 60/50 Hz Direction of Rotation (as viewed from generator Lubrication System Lube Oil Capacity (w/filter) Oil Recommendation Engine Firing Order (API)

(#l cylinder nearest to flywheel) Fuel Injection Timing (BTDC) Combustion System Fuel Injection Pressure psi (kg/cm sq.) 2844 *71 (200 25) Battery Voltage Battery Recommendation (min.) Battery Charging (alternator) Fuel Recommendation Fuel System Fuel Pump Prime Pump Fuel Pump Lift (recommended) Coolant Capacity U.S. qts. (L) Coolant Recovery Tank qts. (L) Recommended Thermostat Pressure Cap Rating Starter Motor Intake/Exhaust Valve Clearance in. (mm) Coolant ft. (m)

TP-5630 10193

Specifications

Chart

1 O-7

Engine Models (continued)


14ccoz 11 .SCCFOZ 2occoz 17.5CCFOZ 24CCOZ 16.5CCFOZ

Belt Tension (force) Cylinder Head Torque 29 (39) 58 (79) 30 (41) 20 (27) Housing 30 (41) 30 (41) (Z) (736) l/4 NPT l/4 NPT Initial ft. Ibs. (Nm) Final ft. Ibs. (Nm) (2-step intervals) ft. Ibs. (Nm) Flex Plate to Flywheel Bolt Torque

0.38 in. (10 mm) @ 22 Ibs. (10 kg)

29,(39)
58 (79) 30 (41) 20 (27)

29 (39) 58 (79) 30 (41) 20 (27)

Flex Plate to Rotor Bolt Torque

ft. Ibs. (Nm) Generator Adapter Plate to Flywheel Bolt Torque ft. Ibs. Over Bolt Torque ft. Ibs. Inlet Water Line Hose ID in. (mm) (sea water pump inlet) Outlet Water Line Hose ID in. (mm) (mixing elbow outlet) Fuel Pump Inlet Thread Size Fuel Return Thread Size

30 (41) 30 (41) (;59 (736) l/4 NPT l/4 NPT

30 (41) 30 (41) (;59 &). l/4 NPT l/4 NPT

1 O-8

Specifications

Chart

TP-5630 1 O/93

Installation
Motor Starting Requirements Motor Requirements l/4 HP
l/3 HP l/2 HP 314 HP 1 HP 2 HP 3 HP

Cooling Water Hose ID Running Watts


330 400 600 750 1100 2000 3000 All Models 1 (25) 3 (76)

Starting (In-Rush) Watts


750 1000 1500 2000 3300 4000 5000

Water Pump Inlet ID in. (mm)

Mixing Elbow Hose ID in. (mm)

Battery Cable Size Cable Size (AWG) At 32F At 75F (24C) (8C)
0 1 2 2 4 6 6 8

Fuel Pump Lift and inlet/Return Size ID Fuel Pump Recommended Lift ft. (m)
4 (1.2)

Distance Between At 0F Generator Set (-18C) and Battery


40 Feet (12.2 m) 30 Feet (9.1 m) 25 Feet (7.6 m) 20 Feet (6.1 m) 15 Feet (4.6 m) 10 Feet (3.0 m) 5 Feet (1.5 m) 2.5 Feet (0.8 m) 0 0 1 2 2 4 6 8

Model
All Models

Fuel Inlet/ Return Size in.


l/4 NPT

Model
13.5CCOZ (1 -PH) 18.5ccoz (1 -PH) 21 CCOZ (1 -PH) 14CCOZ (3-PH) 20CCOZ (3-PH) 24CCOZ (3-PH) 11CCFOZ (1 -PH) 15CCFOZ (1 -PH) 16.5CCFOZ (1 -PH) 1aCCFOZ (1 -PH) 11.5CCFOZ (3-PH) 17.5CCFOZ (3-PH) 20CCFOZ (3-PH)

Wattage
13,500 I 8,500 21,500 14,000 20,000 24,000 11,000 15,000 16,500 I 8,000 11,500 17,500 20,000

Will Operate Air Conditioner of Size Indicated


Three Three Three Three Three Three Three Three Three Three Three Three Three 13,500 13,500 13,500 13,500 13,500 13,500 13,500 13,500 13,500 13,500 13,500 13,500 13,500 BTU BTU BTU BTU BTU BTU BTU BTU BTU BTU BTU BTU BTU

Power to Spare for Lighting Appliances, Tools


7,800 I 2,800 15,300 8,300 14,300 16,400 5,300 9,300 i 0,800 12,300 5,800 11,800 14,300

TP-5630 10193

Specifications

Chart

1 O-9

Installation (continued)
Appliance Average Wattage Ratings (60 Hz) Motor Starting Watts
Pilot 800

Electrical Appliance
Automatic Blender Broiler Depthometer Drill, 3/8 Dryer, Hair Fan, Air Circulating Food, Mixer Heater, Space Heater, Water Iron Light Bulbs Pan, Frying Percolator, Radar Coffee

Running Watts
150-250 50-250 600 1350 25-l 000

Blanket, Electric

600 50-200 400

350 850-I 200 25-l 00 235 750-l 500 1500 900-l 200 (as indicated) 1200 650 750-l 500 50-l 00 100-200 1000-l 500 250 300-750

Radio Radiophone Range, Electric (per element) Soldering Gun Television Toaster Water System 500-l 500

750-l 200 300-l 250

1 O-l 0 Specifications

Chart

TP-5630 1 O/93

Common Hardware Application Guidelines, Specification G-585


Starting Manuals hardware late 1991, will contain references many Parts Catalogs common (see hardware Hardware and Service entries and References) of 112 the bolt/screw preferred method.
l

diameter

beyond

the nut is the

Spiit Lock Washers: Split lock washers will no longer be


device. For hardware up to l/2 in a whiz nut (serrated flange) will be used. with preloading Torque The

instead of part numbers for common hardware.

used as a locking diameter hardware

Kohler

Specification guidelines.

G-585

gives

common

locking method used for hardware above l/2 in diameter will be SAE flat washers bolt/screw. other torque specifications
l

application the following

Use the information

below and on is made.

(torque) of the and

pages to identify proper fastening techniques

See General

Specifications

when no specific reference for reassembly

in the service literature. When hardware size

Common Hardware Entries:

Bolt/Screw Length: When bolt/screw length is not given,

(diameter and threads per inch) is given but no indication of type of additional hardware is shown, use the illustration in Figure 1O-2 as a guide.

use Figure 1 O-l as a guide. As a general rule, a minimum length of one thread beyond the nut and

a maximum length

Preferred

Nut/Bolt Clearance
Min. 1 Full Thread

l/2 Bolt Diameter

Beyond Top of Nu

Unacceptable

Nut/Bolt Clearance

Below Top of Nut

Figure 10-I. Acceptable Bolt Lengths


Specifications Chat-l 1 O-11

TP-5630 1 O/93

Common Hardware Application (G-585)


Steps for common hardware application:
1. Determine 2. Determine entry hole type: exit hole type: round, or slotted. fixed female thread (weld nut), round, or slotted. if hardware is greater than l/2 inch in

For round .and slotted exit holes, determine diameter, or l/2 inch in diameter or less. ameter takes a standard

nut and SAE washer.

Hardware that is greater than 7/2 inch in diHardware 7/2 inch or less in diameter

can take a properly torqued whiz nut. See the diagram below. 3. Follow these SAE washer rules after determining exit hole type:

a. Always use a washer between hardware and a slot. b. Always use a washer under a nut (see 2. above for exception). c. Use a washer under a bolt when the female thread is fixed (weld nut). 4. Refer to the diagram below, which depicts the preceding hardware configuration possibilities.

Entry Hole Types I Cap Screw

Standard Nut And SAE washer: Greater


Than l/2 Dia. Hardware

Whiz Nut:
/ Exit Hole Types Up To And Including Dia. Hardware l/2

Figure 1O-2. Acceptable Hardware Combinations

1 O-12 Specifications

Chart

TP-5630 10193

Common Hardware Identification


Common hardware has many different head, drive, and page. This is a guide for identification hardware used is shown. purposes. Not all grade (hardness) styles. Some ofthe more common types are shown in Figure 1O-3, below, and in Figure 1O-4, next generator

Screws/Bolts/Studs
HEAD STYLES

Hex. Head or Machine Head

Hex. Head or Machine Head

Hex. Head or Machine Head with Washer

Flat Head

Round Head

Pan Head

Socket Head Cap or Allen Head Cap

Socket Head or Allen Head Shoulder Bolt

Sheet Metal Screw

Stud

DRIVE STYLES

Hex.

Hex. and Slotted

Phillips

Slotted

Hex. Socket

GRADE (HARDNESS) American Standard Metric o(c)00


Grade 5 Grade 8 Grade 8/9
6.8 8.8 10.9 12.9

(>a@@
Grade 2

SAMPLE DIMENSIONS American Standard


Major Thread Diameter In Fractional -..---Inches Or Screw Number Size U-y Threads lLLength Per Inch In Inches

Metric
Major Thread Diameter In Millimeters/ Distance M8-1 25 x 20 7 --Length Between Threads In Millimeters

In Millimeters

Figure 10-3. Screws/Bolts/Studs

TP-5630 1 O/93

Specifications

Chart 1 O-l 3

Nuts
STYLES

Hex. Head

Lock Nut or Nylock Nut

Square Nut

Cap Nut or Acorn Nut

Wing Nut

GRADE (HARDNESS) American Standard Metric

Grade 2

Grade 5

@@@@ 6.8

8.8

10.9

12.9

SAMPLE DIMENSIONS American


Major Thread Diameter In Fractional I Inches Or Screw Number Size

Standard
-Threads Per Inch

l/4-20

Metric
Major Thread Diameter In Millimeters~ M8-1 25 I Distance Between Threads In Millimeters

Washers
STYLES

Plain Washer

Split Lock Washer or Spring Washer

Spring Washer or Wave Washer

External Tooth Lock Washer

Internal Tooth Lock Washer

Internal-External Tooth Lock Washer

GRADE (HARDNESS)
There is no marking to identify hardness. black Usually hardened washers have a finish.

oxide or black phosphate finish rather than a zinc (silver-colored) SAMPLE DIMENSIONS Plain Washers

Internal Dimension I

9&2X5+X&6

Thickness

External Dimension

Lock Washers
58 t Internal Dimension

Figure 10-4. Nuts and Washers


1 O-l 4 Specifications Chart

TP-5630 1 O/93

General Torque Specifications


The values given are for clean, dry threads.

Assembled in Cast Iron or Steel

Assembled

in Aluminum

OQ@ Size
8-32 1O-24 1O-32 l/4-20 I/4-28 5/l 6-l 8 5/i 6-24 318-l 6 318-24 7/l 6-l 4 7/l 6-20 1.12-l 3 l/2-20 9116-12 9/l 6-l 8 518-l 518-l 314-l 314-l 1 8 0 6

<:(-J Grade 5
25 40 40 115 (2.8) (4.5) (4.5) (13) 165 (18.6) 200 (22.6) 350 360 50 60 80 105 115 165 (40) (41) (65) (80) (108) (142) (155) (224) 150 (17) 70 (7.9)

Measurement
in. Ibs. (Nm) in. Ibs. (Nm) in. Ibs. (Nm) in. Ibs. (Nm) in. Ibs. (Nm) in. Ibs. (Nm) in. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm) ft. Ibs. (Nm)

Grade 2
20 32 32 70 85 150 22 25 35 45 50 70 75 100 110 140 (2.3) (3.6) (3.6) (7.9) (9.6) (17) (30) (35) (45) (54) (65) (95) (105) (136) (149) (190)

Grade 8

Grade 2 or 5
20 (2.3) 32 (3.6)

140 (15.8) 250 (28.2) 270 (30.5) 35 (45) 40 (54) 55 (75) 75 (105) 80 105 125 165 180 230 245 325 (110) (140) (165) (224) (244) (312) (322) (440)

165 (18.6)

175 (237) 230 (312) 260 (353) 330 (447) 350 (475) 470 (637)

150 (203) 200 (271)

SAMPLE DIMENSIONS American Standard


Major Thread Diameter In Fractional I Inches Or Screw Number Size l/4-20 Threads X1 I -..._Per Inch Length in Inches

TP-5630 1 O/93

Specifications

Chart 1 O-15