Kohler 40COZ/33CFOZ Service Manual
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Kohler 40COZ/33CFOZ Service Manual

Kohler 40COZ/33CFOZ Service Manual

Marine generator set
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Service
Marine Generator Sets
Models:
40COZ/33CFOZ, 40EOZ/33EFOZ
50COZ/40CFOZ, 50EOZ/40EFOZ
65COZ/50CFOZ, 65EOZ/55EFOZ
80EOZ/70EFOZ, 99EOZ/80EFOZ
125EOZ/100EFOZ, 150EOZ/125EFOZ
Controllers:
Decision-Makert 3+
Decision-Makert 1 Standard
Decision-Makert 1 Expanded
TP-5737 5/01b

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Summary of Contents for Kohler 40COZ/33CFOZ

  • Page 1 Service Marine Generator Sets Models: 40COZ/33CFOZ, 40EOZ/33EFOZ 50COZ/40CFOZ, 50EOZ/40EFOZ 65COZ/50CFOZ, 65EOZ/55EFOZ 80EOZ/70EFOZ, 99EOZ/80EFOZ 125EOZ/100EFOZ, 150EOZ/125EFOZ Controllers: Decision-Makert 3+ Decision-Makert 1 Standard Decision-Makert 1 Expanded TP-5737 5/01b...

  • Page 2: Product Identification Information

    Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ..........Inside front cover Safety Precautions and Instructions .
  • Page 4 Table of Contents, continued Section 5 Decision-Makert 3+ Troubleshooting ..........Decision-Makert 3+ Controller .
  • Page 5 Table of Contents, continued 7.14 Governor Adjustment ..........7.14.1 Mechanical Governor .

  • Page 7: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting Battery INSTRUCTIONS. Electromechanical equipment, including generator sets, WARNING WARNING transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act Accidental starting.
  • Page 8 Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms. fire can cause severe injury or death. Carbon monoxide can cause severe severe injury or death. Battery gases Do not smoke or permit flames or nausea, fainting, or death. Carbon can cause an explosion.
  • Page 9 Operating the generator set. Carbon The fuel system. Explosive fuel Pipe sealant. Explosive fuel vapors monoxide can cause severe nausea, vapors can cause severe injury or can cause severe injury or death. fainting, or death. Carbon monoxide death. Vaporized fuels are highly Fuel leakage can cause an explosion.
  • Page 10 Hazardous Voltage/ Testing voltage regulator. Hot Parts Hazardous voltage cause Electrical Shock severe injury or death. High voltage WARNING is present at the voltage regulator heat sink. To prevent electrical shock do not WARNING touch the voltage regulator heat sink when testing the voltage regulator.
  • Page 11 Moving Parts Tightening the hardware. Flying Notice projectiles can cause severe injury or death. Loose hardware can cause NOTICE WARNING the hardware or pulley to release from the generator set engine and can cause This generator set has been personal injury.
  • Page 12 Notes Safety Precautions and Instructions TP-5737 5/01...

  • Page 13: Introduction

    Information in this publication represents data available distributor/dealer to keep equipment in top condition. at the time of print. Kohler Co. reserves the right to change this publication and the products represented x:in:001:002:a Service Assistance Please contact a local authorized distributor/dealer for...
  • Page 14 Notes Service Assistance TP-5737 5/01...

  • Page 15: Section 1 Specifications

    Section 1 Specifications 1.1 Introduction Generator Component Specification Value The spec sheets for each generator set provide specific Controller/battery electrical system 12 or 24 volts DC generator and engine information. Refer to the respective spec sheet for data not supplied in this Generator field resistance (F+/ F--): manual.

  • Page 16: Accessories

    1.3.1 Remote Annunciator Kit A remote annunciator allows convenient monitoring of Kohler Co. offers several accessories to finalize the the generator set’s condition from a remote location. installation and to add convenience to operation and See Figure 1-1. The flush-mounted annunciator panel service.

  • Page 17: Safeguard Breaker

    1.3.2 Safeguard Breaker 1.3.4 Run Relay Kit The safeguard breaker senses output current on each The run relay kit energizes only when the generator set generator phase and shuts off the AC voltage regulator is running. Typically, the three sets of contacts control in the event of a sustained overload or short circuit.

  • Page 18: Fastcheck Diagnostic Tester (Microprocessor Controller Only)

    1.3.5 FASTCHECK Diagnostic Tester (Microprocessor Controller Only) â The FASTCHECK diagnostic tester simulates engine operation to identify faults in the controller and engine â circuitry. Use the FASTCHECK when troubleshooting startup problems or to test and troubleshoot the controller when the controller is removed from the generator.

  • Page 19: Section 2 Operation

    Section 2 Operation 2.1 Fast-Responset II Concepts The generator excitation system uses a permanent magnet exciter with a silicon controlled rectifier (SCR) assembly that controls the amount of DC current fed to the generator field. This type of system uses a voltage regulator that signals the SCR assembly through an optocoupler.

  • Page 20: Prestart Checklist

    Coolant Level. Check the coolant level according to 2.4 Marine Inspection the cooling system maintenance information. Kohler Co. recommends that all boat owners have their Drive Belts. Check the belt condition and tension of the vessels—especially the exhaust system attached to the water pump and battery charging alternator belt(s).

  • Page 21: Decision-Makert 3+ 16-Light Microprocessor Controller Operation

    2.7 Decision-Makerä 3+ 16-Light Microprocessor Controller Operation Figure 2-3 identifies the Decision-Makert 3+ 16-light controller’s indicators and controls and their functions. 1. Fuses (inside controller) 10. Lamp test ADV-5849 P1 2. Frequency meter 11. Generator set master switch 3. AC voltmeter 12.

  • Page 22: Controls And Indicators

    2.7.1 Controls and Indicators Lamp test switch The switch tests the controller indicator lamps. The following table describes the controls and indicators Low oil pressure The lamp illuminates if the located on the controller. lamp generator set shuts down because of low oil pressure.

  • Page 23: Fuses And Terminal Strips

    2.7.2 Fuses and Terminal Strips Name Description Auxiliary prealarm The lamp illuminates when The following table describes the controller circuit board lamp customer-provided sensing fuses and controller terminal strips. devices activate the pump. Emergency stop The lamp illuminates and the Name Description lamp...

  • Page 24: Auxiliary Fault Lamp Conditions

    2.7.3 Auxiliary Fault Lamp Conditions 2.7.4 Starting the Generator Set The following descriptions define the possible auxiliary The following procedures describe starting the fault lamp conditions. generator set. Local Starting (Nonautomatic). Move the generator Flashing Lamp Conditions set master switch to the RUN position to start the generator set at the controller.

  • Page 25: Prime Power Mode Operation

    Note: The generator set continues running during 2.7.7 Fault Shutdowns a 5-minute cooldown cycle if a remote The generator set shuts down automatically under the switch or automatic transfer switch signals following fault conditions and cannot be restarted until the engine to stop. the fault condition is corrected.

  • Page 26: Controller Resetting Procedure (Following Fault Shutdown)

    2.7.8 Controller Resetting Procedure 2.7.9 Resetting the Emergency Stop (Following Fault Shutdown) Switch Use the following procedure to restart the generator set Use the following procedure to restart the generator set after a fault shutdown. Refer to Resetting the after an emergency stop switch shutdown. Refer to the Emergency Stop Switch in this section to reset the Controller Resetting Procedure in this section to restart generator set after an emergency stop.

  • Page 27: Expanded Decision-Makert 1 Controller Operation

    2.8 Expanded Decision-Makert 1 Controller Operation For identification of the expanded controller’s indicators and controls and their functions, refer to Figure 2-5. ADV-5849E-B 1. Frequency meter 8. Voltage adjustment potentiometer 2. AC voltmeter 9. Fault lamp 3. AC ammeter 10. 10-amp controller fuse 4.

  • Page 28: Starting The Generator Set

    2.8.2 Starting the Generator Set 2.8.5 Controller Resetting Procedure (Following Fault Shutdown) The following procedure describes the actions required to start the generator set. Use the following procedure to restart the generator set after a fault shutdown. Local Starting. Move the generator set to the RUN position to immediately start the generator set.

  • Page 29: Standard Decision-Makert 1 Controller Operation

    2.9 Standard Decision-Makert 1 2.9.2 Starting the Generator Set Controller Operation The following procedures describe the actions required to start the generator set. For identification of the standard basic controller’s indicators and controls and their functions, refer to Local Starting. Move the generator set master switch Figure 2-6.

  • Page 30: Fault Shutdowns

    2.9.4 Fault Shutdowns 2.9.5 Controller Resetting Procedure (Following Fault Shutdown) The generator set shuts down automatically under the following fault conditions and cannot be restarted until Use the following procedure to restart the generator set the fault condition is corrected. The system automatically after a fault shutdown.

  • Page 31: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance 3.1 General Maintenance WARNING WARNING Rotating parts. Can cause severe injury or death. Accidental starting. Operate the generator set only when Can cause severe injury or death. all guards, screens, and covers are in place. Disconnect the battery cables before working on the generator set.

  • Page 32: Generator Bearing

    3.2 Generator Bearing 3.3.3 Fuel System Prepare the fuel system for storage as follows: Replace the end bracket bearing every 10,000 hours of operation. Service more frequently if bearing inspection Diesel-Fueled Engines indicates excessive rotor end play or bearing damage from corrosion or heat buildup.

  • Page 33: Section 4 General Troubleshooting

    Section 4 General Troubleshooting This section contains generator set troubleshooting, NOTICE diagnostic, and repair information. Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic). Use the following chart as a quick troubleshooting Do not substitute clear glass-type fuses for ceramic fuses.
  • Page 34 TP-5737 5/01 Section 4 Troubleshooting...
  • Page 35 TP-5737 5/01 Section 4 Troubleshooting...
  • Page 36 TP-5737 5/01 Section 4 Troubleshooting...

  • Page 37: Section 5 Decision-Makert 3+ Troubleshooting

    Section 5 Decision-Makert 3+ Troubleshooting 5.1 Decision-Makert 3+ Controller contains the logic schematic showing input/output circuits reference troubleshooting. This For external features, see Section 2, Operation. information deals directly with 16-light Figure 5-1 through Figure 5-11 show the locations of microprocessor.
  • Page 38 A-336415-L 1. K2 relay: control relay (crank) 9. LED4 (K4 relay) 2. K3 relay: control relay (run) 10. P1 connector (DC harness) 3. K4 relay: emergency stop 11. LED3 (K3 relay) 4. LED1 12. P2 connector (AC harness) 5. Microprocessor chip 13.

  • Page 39: Decision-Maker 3+ Circuit Board Terminal/Connector Identification

    5.1.1 Decision-Maker 3+ Circuit Board Description Terminal/Connector Identification 1 Output to K1 relay (crank relay), wire 71 2 Ground for speed sensor, wire 2 Terminal Wire Description 3 Output to safeguard breaker terminal, wire 70 (and 1A Emergency stop relay (K4) coil K5 relay if equipped with electronic governor) 1 Ground—emergency stop relay (K4) 4 Not used...
  • Page 40 Description Description 1 Ground (--), front panel, wire 2 1 Ground (--), front panel, wire 2 2 Not used 2 Not used 3 Not used 3 Not used 4 Input from generator set master switch, auto 4 Output from generator set master switch, auto position, wire 46 position, wire 46 5 Not used...
  • Page 41 Common Fault Indicator Activated By: Connect AV Alarm or Common Fault Relay Kit System Ready Common Fault /Prealarm (Line 2) (--) Low Battery Common Fault /Prealarm (Line 1) (--) E.STOP Emergency Running Mode Low Fuel Stop Cool-Down Mode Battery Charger Fault Prime Power Operation Crank Mode Remote Switch...
  • Page 42 120 VAC for Crank Disconnect Panel Lamps Auxiliary Immediate Shutdown Switch Safeguard Circuit Magnetic Breaker Pickup Voltage Anticipatory (Low) Oil Pressure Reg. AUX. Auxiliary AUX PRE Auxiliary Prealarm Alternator Ign. B+ Anticipatory (High) Water Temperature Flash Battery Charger Fault Engine Air Damper E.
  • Page 43 Anticipatory (Low) Oil Pressure AUX. Auxiliary AUX PRE Auxiliary Prealarm AHET Anticipatory High Engine Temperature Anticipatory (High) Water Temperature Battery Charger Fault Engine Air Damper Emergency Stop Fuel Solenoid High Engine Temperature High Water Temperature Low Battery Volts Low Fuel Low Oil Pressure Low Water Temperature Not-In-Auto...
  • Page 44 ADV-6122-B Figure 5-12 Logic Schematic, Decision-Makerä 3+ Section 5 Decision-Makert 3+ Troubleshooting TP-5737 5/01...

  • Page 45: Fault Shutdowns, Decision-Maker 3+ Controller

    5.1.2 Fault Shutdowns, Figure 5-13 to identify fault conditions. Consult the Engine Service Manual for detailed information on Decision-Maker 3+ Controller correcting engine-related faults. To reset the set after a If the generator set does not start or stops running fault shutdown, see Section 2, Operation.

  • Page 46: Microprocessor Controller Relay Descriptions

    5.2 Microprocessor Controller Relay Descriptions A description of the controller and generator relays follows. Use this information to troubleshoot the generator set in conjunction with the troubleshooting microprocessor controller flowcharts on the following pages. Use the troubleshooting section following and the respective wiring diagram for additional information.

  • Page 47: Troubleshooting

    To quickly check the condition of the components WARNING mentioned in the following flowcharts, use an ohmmeter to read resistance between the designated terminal and ground. See Figure 5-16. With the ohmmeter on the R x 1 scale, a reading of less than one ohm (continuity) indicates that the component may be inoperative.

  • Page 48: Fuses

    5.3.2 Fuses and resume operation. If the fuse blows again, use Figure 5-17 to identify the faulty component(s). The following chart lists the possible causes of blown controller fuses F1, F2, and F3. If a fuse blows, replace it Blown F1 fuse (remote annunciator: 3 amp) Inoperative dry contact kit Remaining accessories connected to TB1-42A Inoperative audio/visual alarm...
  • Page 49 Engine does not crank with the generator set master switch in the RUN position. Press the lamp test Is the battery fully charged? button. Do lamps light? Check the P3/P4 harness and connections. Are the connections okay? Charge the battery and attempt restart.
  • Page 50 Engine cranks but does not start. Is fuel low? Add fuel. Is LED3 lit? Replace the circuit board. Check the engine starting circuit. Check for battery voltage at the fuel solenoid/injector pump/electronic Are the controller panel lights lit? governor Does the engine starting circuit check out okay? Check for battery voltage at the Repair or replace governor controller (on diesel units).
  • Page 51 Controller instrumentation not functioning properly. Is there a loose input or component lead connection at the AC fuse Secure the connection. terminal block or at the component? Is there a blown 1.5-amp fuse at the AC Replace the fuse. fuse terminal block? See Figure 5-21. Instrumentation is inoperative.
  • Page 52 3-187 1. P4-6 (+) connection 2. P4-1 (--) connection Figure 5-24 Checking Input to Lamp Circuit Board Engine starts and runs, but overcrank lamp flashes. Note: The overcrank lamp flashes if the speed sensor signal is absent longer than one second. Adjust the speed sensor air gap to Is the speed sensor air gap greater 0.014-0.028 in.

  • Page 53: Fastcheck Features And Operation

    0 + --- 3-100 TP-5353-6 R12758-3 1. Speed sensor 4. Wire 2: black 2. Wire 16: white/clear 5. Air gap: 0.36--0.71 mm (0.014--0.028 in.) 3. Wire 24: red 6. Actuator cup Figure 5-26 Speed Sensor Air Gap 5.4 FASTCHECK Features and BATT—(battery) lamp: Operation Lights when the test battery(ies) or DC power...

  • Page 54: Application

    Switches: 5. Clip the red (+) and black (--) harness leads to a battery(ies) or DC power supply of proper voltage LOP—low oil pressure for the generator set (12 or 24 volts). Adjust the HWT—high water (engine) temperature output voltage to 1-2 volts above battery voltage when using a DC power supply.

  • Page 55: Overcrank

    8. Simulate engine malfunctions pressing 5.4.5 Controller Speed Sensor Circuitry â FASTCHECK fault switches. The corresponding To check the controller’s ability to respond to signals fault lamp on the controller should light during each from the speed sensor, perform the following test: simulated engine malfunction.

  • Page 56: Generator Condition Indicator Terminal (Tb1 Terminal Strip)

    5.4.6 Generator Condition Indicator Note: Because of the absence of AC output, the auxiliary lamp flashes during the controller Terminal (TB1 Terminal Strip) testing on 16-light microprocessor controllers. The NOT-IN-AUTO lamp illuminates whenever Remote accessories (audiovisual alarm, remote the generator set master switch is not in the annunciator, dry contact kits, etc.) may be connected to AUTO position on 16-light microprocessor the controller TB1 terminal strip to signal the condition of...
  • Page 57 Indicator Switch Position/Remarks Check For Voltage Between System Ready Master switch in AUTO position; engine switch in OFF TB1-42A (+) and TB1-60 (--) position. High (Engine) Water Master switch in RUN position; engine switch in RUN TB1-42A (+) and TB1-36 (--) Temperature (HWT) position;...
  • Page 58 Notes Section 5 Decision-Makert 3+ Troubleshooting TP-5737 5/01...

  • Page 59: Section 6 Decision-Makert 1 Controller Troubleshooting

    Section 6 Decision-Makert 1 Controller Troubleshooting 6.1 Decision-Makert 1 and Decision-Makert 1 Expanded Relay Controller The following text covers the relay controller sequence of operation during generator start, run, stop, and fault shutdown modes. Use this information as a starting point for controller fault identification.
  • Page 60 Relay Contact Relay Contact Function Relay Energizes/Action: Normal Position Action K2 relay and LED2 lights K10 relay (with F-254717) or K5 relay (with E-254717, engine Open Close components (fuel system, governor, ignition, etc.), K4 relay, and LED4 lights St ti Starting: Close the start/stop switch t t/ t it h...
  • Page 61 Starter 15 amp 10 amp Off/Reset Remote Start NOTE Auto D Overcrank, Overspeed, LWL, HET, and LOP drive the fault shutdown circuit. D Fault latch provided by K1 normally open contacts. D Overcrank shutdown is only driven by D Crank disconnect driven by AC and speed sensor input.
  • Page 62 ADV-6120-A Figure 6-5 Decision-Makerä 1 Relay Controller with E-254717 Circuit Board Section 6 Decision-Makert 1 Controller Troubleshooting TP-5737 5/01...
  • Page 63 ADV-6120-D Figure 6-6 Decision-Makerä 1 Relay Controller with F-254717 Circuit Board TP-5737 5/01 Section 6 Decision-Makert 1 Controller Troubleshooting...
  • Page 64 ADV-6121- Figure 6-7 Decision-Makerä 1 Expanded Relay Controller with E-254717 Circuit Board Section 6 Decision-Makert 1 Controller Troubleshooting TP-5737 5/01...
  • Page 65 ADV-6121-C Figure 6-8 Decision-Makerä 1 Expanded Relay Controller with F-254717 Circuit Board TP-5737 5/01 Section 6 Decision-Makert 1 Controller Troubleshooting...

  • Page 66: Relay Controller

    6.2 Relay Controller WARNING following charts reference troubleshooting individual problems. Before beginning any troubleshooting procedure, read all safety precautions at the beginning of this manual and those Moving rotor. Hazardous voltage. included in the text. Do not neglect these precautions. Can cause severe injury or death.
  • Page 67 E-254717-A F-254717- 1. K5 relay (fault latch) 7. P1 connector 1. LED1 6. K4 relay (crank) 2. K1 relay (fault) 8. K2 relay (run) 2. K1 relay (fault) 7. P1 connector 3. K3 relay (crank/run) 9. LED2 3. K3 relay (crank/run) 8.
  • Page 68 Does the Go to engine start? Does the engine Unit shuts down on overcrank. crank for 30 Troubleshoot the engine using the seconds and engine service manual then shut down? Is 12-volts DC Check for 12-volts present at the Is the Is the K1 Is the K2 DC at 70.
  • Page 69 The engine runs but The engine starts but cannot be stopped by shuts down after 30 the start/stop switch seconds or more? Check the condition/connections of the start/stop switch (local or Is the K3 relay remote). See the Wiring LED3 lit? Diagrams.
  • Page 70 Notes Section 6 Decision-Makert 1 Controller Troubleshooting TP-5737 5/01...

  • Page 71: Section 7 Component Testing And Adjustment

    Section 7 Component Testing and Adjustment 7.1 Generator Troubleshooting WARNING Use the following flowchart to troubleshoot the generator set when detecting no or high voltage. The remaining parts of this section give additional and more detailed information about the individual checks/tests Hazardous voltage.
  • Page 72 No output voltage is safeguard circuit Place the safeguard circuit detected breaker in the ON position? breaker to the ON position Do a flashlight test on the photo transistor board. (See Section 7.3, LED Circuit Board Test) If no voltage is detected, If high voltage is detected, remove the G and F+ (red) check for battery voltage at...
  • Page 73 Remove G and F+ (red) Turn safeguard circuit breaker to High output voltage is leads from the OFF position. Does output detected assembly. Does output voltage remain high? voltage remain high? Turn the safeguard circuit If no voltage is detected, Replace the breaker to the ON position.

  • Page 74: Generator Testing

    7.2.1 No Output On Any Phase WARNING No Output On Any Phase Test Procedure 1. Check the safeguard breaker, if equipped. If the safeguard breaker is open, close the breaker and, Moving rotor. Hazardous voltage. with the set running, check the AC voltmeter for AC Can cause severe injury or death.
  • Page 75 VOLTAGE ADJUSTMENT RHEOSTAT SELECTOR SWITCH V/Hz 60 Hz AC AMPS AC VOLTAGE REGULATOR CIRCUIT BOARD STAB. SAFEGUARD CONTROL BREAKER RELAY CONTACTS V/HZ 50 Hz 50 Hz SOLENOID 60 Hz STARTER 12 LEAD STATOR BATTERY MAGNETS EXCITER ARMATURE GENERATOR FIELD F--- PHOTO SCR ASSEMBLY TRANSISTOR...

  • Page 76: Overvoltage

    7.2.2 Overvoltage 7.3 LED Circuit Board Test Overvoltage Test Procedure The following procedure provides testing information for the LED circuit board. Certain steps require that the Note: If overvoltage occurs, disconnect the harness generator set be running. While the generator set is not plug at the voltage regulator.
  • Page 77 Testing the photo transistor circuit board. Hazardous 4. With generator running, observe voltage can cause severe injury or death. When the end approximately 1--2 volts DC at 3B (+) and 5B (--) at cover is removed, do not expose the photo transistor circuit the LED board.

  • Page 78: Scr Assembly And Photo Transistor Board

    7.4 SCR Assembly and Photo Testing the SCR assembly and photo transistor board requires the following components: Transistor Board Light bulb with socket, one 120-volt/110-watt. Switch, double-pole/single-throw (DPST), 120-volt 7.4.1 Concept and Equipment 10-amp minimum. The SCR assembly mounts behind the exciter armature Fuse, 1 amp, in holder.
  • Page 79 4. Shield the photo transistor board from all other light WARNING sources during this test. Direct the test light to the photo transistor board. If both components are working, the test fixture light bulb lights when the external light source is applied to the photo transistor board.

  • Page 80: Automatic Voltage Regulator (Avr) Operation And Adjustment

    7.5 Automatic Voltage Regulator 4. Start the generator set. With the generator running at no load, observe light bulb flicker. Excessive light (AVR) Operation and bulb flicker indicates poor stability. Adjustment 5. Adjust the stability potentiometer until minimum The AVR monitors output voltage amplitude and flicker is obtained.
  • Page 81 Voltage Regulator Test 1. Close the safeguard breaker, if equipped. 2. Disconnect the wiring harness connector from the voltage regulator and check for continuity between the voltage sensing leads V7 and V8 (pins 4 and 10). See Figure 7-11. If the circuit between V7 and V8 is open, repair or replace it.

  • Page 82: Stator

    7.6 Stator Note: When replacing the rotor or stator, use a skewed (slanted) rotor with a straight stator per original manufacturer. Stator Test Procedure 1. Check the generator output leads for proper connections. See Section 9, Wiring Diagrams. 2. Check the stator windings for: 3-100 a.

  • Page 83: Generator Field

    7.7 Generator Field 6. Using a megohmmeter, apply 500 volts DC to the F+ or F-- lead and the rotor shaft. See Figure 7-15. Follow the instructions of the megohmmeter WARNING manufacturer when performing this test. A reading of approximately 5--7 kOhms and higher indicates the field winding is functional.

  • Page 84: Exciter Armature

    WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the generator. Hot parts can cause severe injury or death. Avoid touching the generator set field or exciter armature.
  • Page 85 8. Repair or replace the rotor. Repair the AC leads if this test indicates the leads are shorted to ground. Solder and insulate any splices used. Use new sleeving when tying the leads to the shaft or the heat sink. Replace the rotor assembly if this test shows the armature is shorted to ground.

  • Page 86: End Bracket Removal And Replacement

    7.9 End Bracket Removal and End Bracket Replacement Replacement Reverse the order of the disassembly to reinstall the end bracket/exciter field assembly. See Section 8, Disassembly/Reassembly for more information. Note: Loosen the generator junction box before removing the end bracket. Remove the six junction box mounting screws and pull the junction box away from the engine to remove the end bracket.

  • Page 87: Speed Sensor Test

    7.10 Speed Sensor Test 2. Touch the sensing surface with a flat piece of iron or steel at least 4.1 cm (1/4 cubic inch) in size. The The following procedure determines if the speed sensor voltmeter test reading should equal the source voltage.

  • Page 88: Testing

    WARNING Moving rotor. Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage.

  • Page 89: Final Adjustment

    generator sets and reverse the direction of the 6. Apply resistive load (1.0 power factor) until generator load line through the current reaching rated current. transformer or reverse the transformer leads 7. Adjust the reactive droop compensator rheostat to on unit no. 1. achieve a 4% droop (decrease) in voltage.

  • Page 90: Gauge Senders

    7.13 Gauge Senders 7.13.2 Water Temperature Sender Testing The resistance of the oil pressure and water temperature sender output signals varies as the The water temperature sender is a single function, respective pressure and temperature change. Use the single-terminal type. See Figure 7-22. resistance change for verification of sender function.

  • Page 91: Governor Adjustment

    7.14 Governor Adjustment 7.14.2 Electronic Governor—Barber- Colman Dyna 2500 125- -150 kW John Deere Engine-Powered 6081 7.14.1 Mechanical Governor Some sets are equipped with Barber-Colman Dyna Note: Before checking and adjusting engine 2500 electronic governors. Because this is an speed, make sure the engine reaches its electronic device, no mechanical drive or hydraulic normal operating temperature.
  • Page 92 TP-5353-7 1. Actuator 2. Linkage Figure 7-26 Throttle Actuator (Barber-Colman Dyna 2500, John Deere 6076 Shown) The Barber-Colman control unit is equipped with switches S1 and S2. Before making governor adjustments, verify that S1 and S2 are in the correct KC250000B-A positions for your application.
  • Page 93 Preliminary Adjustment Procedure 4. With the engine running at no load, finalize the “I”, “D”, and gain adjustments. 1. Place the generator set master switch in the OFF position. Do not run the generator set. 5. Slowly turn the gain adjustment potentiometer clockwise (CW) until the output shaft and linkage 2.
  • Page 94 7.14.3 Electronic Governor, See Figure 7-28 for nonparalleling generator sets or Figure 7-29 for paralleling generator sets. Barber-Colman Dyna 70025 using electronic control unit interprets the signal from the Stanadyne D Series Injection magnetic pickup to control the current input to the Pump 35- -99 kW John Deere throttle actuator.
  • Page 95 Note: Follow this procedure carefully to prevent engine overspeed and damage to the generator or other load. 3. Turn the droop adjusting screw counterclockwise until it stops. Only paralleling generator sets use the droop adjustment. Note: Turn the droop adjusting screw clockwise (CW) two full turns.
  • Page 96 Governor Calibration for Paralleling Droop Adjustment Procedure Generator Sets 1. Place the generator set master switch in the RUN or TEST position to start the generator set. Calibration Procedure 2. Use the run speed potentiometer to set the engine 1. Place the generator set master switch in the OFF rpm to the desired no load speed (frequency) on position.

  • Page 97: Disassembly

    Section 8 Disassembly/Reassembly Before beginning the generator set disassembly WARNING procedure, carefully read all safety precautions at the beginning of this manual. Please observe these precautions and those included in the text during the disassembly/ reassembly procedure. The following procedures cover many models and some Accidental starting.
  • Page 98 Perform the following steps before disassembling the WARNING generator set. Remove the Generator Set from Service 1. Disconnect the generator set engine starting Hot engine and exhaust system. battery, negative (--) lead first and remove the Can cause severe injury or death. starting batteries from the work area to prevent fire hazard.
  • Page 99 EM-273000- 1. Voltage regulator terminal strip 9. End bracket cover 2. Voltage regulator panel 10. Skid 3. Voltage regulator 11. Generator fan guard 4. Voltage regulator wiring harness 12. Drive discs 5. Junction box cover 13. Stud 6. Junction box panel 14.
  • Page 100 F--- B-257657-Y 1. LED circuit board cover 8. Exciter field assembly 2. LED circuit board 9. Rotor assembly 3. Photo transistor board 10. SCR assembly 4. Insulating washer 11. Generator set fan 5. Insulator 12. Drive discs 6. Magnetic actuator 13.
  • Page 101 8.1 Disassembly the floor in a vertical position. See Figure 8-5. Before lowering the assembly, place boards along 1. Disconnect all controller-to-engine and engine-to- the edge of the end bracket to prevent damage to generator set harnesses and wiring. Disconnect the photo transistor board.
  • Page 102 11. Fasten the lifting eye and hoist hook to the rotor flange. Carefully hoist the rotor to avoid damaging the exciter armature or exciter field magnets. See Figure 8-6. 12. While the rotor is suspended, remove the photo transistor board and actuator cup. Remove the F3, G, and AC leads from the SCR assembly.
  • Page 103 15. Remove the generator set adapter mounting bolts. 2. Place the stator in a vertical position with the end Fasten the hoist hooks to the end bracket and raise bracket side up. the assembly slightly. Bump the generator set Note: The end bracket side of the stator has four adapter loose by using a rubber mallet.
  • Page 104 5. Attach the hoist hooks to the end bracket and suspend the stator. Place the generator set adapter on the floor and lower the stator to within 12.7--6.4 mm (0.05--0.25 in.) of the adapter lip. See Figure 8-11. 3-087 R8348-14 Figure 8-12 Supporting Generator Set Assembly 3-083 R8348-7...
  • Page 105 WARNING Moving rotor. Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Installing the photo transistor circuit board. Hazardous voltage can cause severe injury or death. Ensure that the foil side of the photo transistor circuit board, the end of the shaft, and the threaded holes are clean and free of metal particles and chips.
  • Page 106 12. Suspend the rotor over the generator set assembly. Lower the rotor field into the stator. Be extremely careful while lowering the rotor to avoid damaging the exciter armature, field magnets, stator windings, or rotor laminations. See Figure 8-16. Carefully align the rotor bearing to the end bracket.
  • Page 107 18. Move the generator set as necessary to align the generator set adapter and flywheel housing. Fasten and final tighten the adapter to the flywheel housing using bolts and hardened lock washers. See Figure 8-19. Torque the bolts to the value given in Section 1, Specifications, Generator.
  • Page 108 Notes TP-5737 5/01 Section 8 Disassembly/Reassembly...
  • Page 109 Section 9 Wiring Diagrams WARNING WARNING Hazardous voltage. Moving rotor. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working on the generator set.
  • Page 110 Notes Section 9 Wiring Diagrams TP-5737 5/01...
  • Page 129 Terminal Purpose Terminal Purpose Ground—emergency stop relay (K4)—connect Prime power operation emergency stop across terminals TB1-1 and Prime power operation 1A * Remote start ground—connect transfer Emergency stop relay (K4) coil; negative switch or remote start switch to TB2-3 and side—connect emergency stop across TB2-4 terminals TB1-1 and 1A *...

  • Page 130: Generator Set Frequency Change And Adjustment

    9.1 Voltage Reconnection Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator 9.1.1 Introduction set as follows: (1) Move the generator set master switch to the OFF position.
  • Page 131 Reconnection Notes Note: Position the current transformers with the dot or HI side CT mark toward the generator set. Some generator sets have no current transformers. Note: Phase Rotation: A = L1, B = L2, and C = L3. WITH DIGITAL Note: All 12-lead generator sets are reconnectable.
  • Page 132 Reconnection Notes Note: Position the current transformers with the dot or HI side CT mark toward the generator set. Some generator sets have no current transformers. Note: Phase Rotation: A = L1, B = L2, and C = L3. Note: All 12-lead generator sets are reconnectable. The 6-lead, 600-volt generator set is not reconnectable.
  • Page 133 Note: Position the current transformers with the 6. If the controller has meters, set the phase selector dot or HI side CT marking toward the switch to the L1-L2 position (1-phase or 3-phase generator set. configuration depending generator connection). Connect a voltmeter across leads L1 Note: Only generator sets equipped with AC meter and L2 if the controller has no meters.
  • Page 134 Disconnecting the electrical load. Hazardous voltage can Figure 9-24. The generator set should shut down cause severe injury or death. Disconnect the generator set overvoltage fault approximately from the load by opening the line circuit breaker or by 2 seconds. disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads.
  • Page 135 9.3 Generator Set Frequency 9.3.2 Frequency Adjustment Change and Adjustment Check the frequency meter for a no-load reading of 63 Hz for 60 Hz operation and 53 Hz for 50 Hz operation to determine correct frequency operation. Check for 50 9.3.1 Frequency Change and 60 Hz operation at no load if the generator set is...
  • Page 136 Notes 122 Section 9 Wiring Diagrams TP-5737 5/01...
  • Page 137 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity Fahrenheit, female ABDC after bottom dead center cubic inch displacement fglass. fiberglass alternating current centerline flat head machine (screw) analog to digital centimeter fl.
  • Page 138 kg/cm kilograms per square milliwatt rnd. round centimeter microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat. gas natural gas right side kilojoule National Bureau of Standards room temperature vulcanization...
  • Page 139 Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.
  • Page 140 Appendix C General Torque Specifications Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated literature instructions give no specific torque values. threads. All torque values are +0%/--10%. The charts list values for new plated, zinc phosphate, or American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel...
  • Page 141 Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)
  • Page 142 Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
  • Page 143 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Hex Nuts M931-06040-60 M6-1.00 x 40 M933-04006-60 M4-0.70 x 6 M934-03-50 M3-0.50 Standard...
  • Page 144 Appendix F Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed. Enter hours to the operating hours on your generator set and the dates nearest quarter hour. OPERATING HOURS SERVICE RECORD DATE HOURS TOTAL...
  • Page 148 Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Kohlerr Power Systems Asia Pacific Headquarters TP-5737 5/01b 7 Jurong Pier Road Singapore 619159 E Kohler Co., 1997, 2001. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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