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Service Commercial/Recreational Mobile Generator Sets Models: 7.5EOR/EORZ 10EOR/EORZ 15EOR/EORZ 20EOR/EORZ 6EFOR/EFORZ 9EFOR/EFORZ 12.5EFOR/EFORZ 16.5EFOR/EFORZ TP-6073 4/06a...
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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.
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Battery electrolyte is a diluted Accidental Starting Electromechanical equipment, sulfuric acid. Battery acid can cause including generator sets, transfer severe injury or death. Battery acid WARNING switches, switchgear, and accessories, can cause blindness and burn skin. can cause bodily harm and pose Always wear...
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Battery short circuits. Explosion Servicing the air cleaner. A sudden Carbon monoxide symptoms. can cause severe injury or death. backfire can cause severe injury or Carbon monoxide can cause severe Short circuits can cause bodily injury death. Do not operate the generator nausea, fainting, or death.
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Grounding electrical equipment. Fuel System Hazardous Noise Hazardous voltage cause severe injury or death. Electrocution CAUTION WARNING is possible whenever electricity is present. Turn off the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment...
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Testing live electrical circuits. Checking the coolant level. Moving Parts Hazardous voltage or current can coolant can cause severe injury or cause severe injury or death. Have death. Allow the engine to cool. WARNING trained and qualified personnel take Release pressure from the cooling diagnostic measurements live...
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NOTICE NOTICE Notice Hardware damage. The engine and Canadian installations only. NOTICE generator set may use both American standby service connect the output of Standard and metric hardware. Use the generator set to a suitably rated the correct size tools to prevent transfer switch in accordance with This generator set has been rounding of the bolt heads and nuts.
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Notes 10 Safety Precautions and Instructions TP-6073 4/06...
Obtain service from an authorized service distributor/ Information in this publication represents data available dealer to keep equipment in top condition. at the time of print. Kohler Co. reserves the right to x:in:001:002:a change this publication and the products represented...
Section 2 Scheduled Maintenance 2.1 General Maintenance Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts WARNING and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.
2.2 Lubrication System 2.3 Battery Charging Use oil that meets the American Petroleum Institute WARNING (API) classification of CD, CC/CD, or CC. Using unsuitable oil or neglecting an oil change may result in engine damage and a shorter engine life. Figure 2-1 for the recommended Society of Automotive Engineers (SAE) viscosity designation for various operating temperature ranges.
2.4 Belt Tension 2.5 Battery Adjust the tension of the alternator/fan belt so that finger Use a 12-volt battery with a minimum 625 CCA rating. pressure deflects the belt about 10--15 mm (0.4--0.6 in.). Do not perform maintenance on a maintenance-free See Figure 2-3.
2.6 Storage Procedure 2.6.3 Fuel System Prepare the fuel system for storage as follows: Perform the following storage procedure before taking a generator set out of service for three months or longer. Diesel-Fueled Engines Follow the engine manufacturer’s recommendations, if available, for fuel system and internal engine 1.
Section 3 Intake and Exhaust System 3.1 Air Cleaner Service 3.2 Exhaust System Inspection Replace the air cleaner element at the intervals shown in WARNING the service schedule. Service the air cleaner more often if the generator set operates under dusty or dirty conditions.
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Notes Section 3 Intake and Exhaust System TP-6073 4/06...
Section 4 Fuel System 4.1 Fuel Specifications Spin-on Fuel Filter: 1. Loosen the fuel filter by turning it counterclockwise. Use clean, good quality diesel fuel oil with a cetane Remove the fuel filter and use rags to clean up any number of 45 or greater.
Procedure to Bleed the Fuel System: 1. Fill the fuel tank. 2. Loosen the fuel filter vent screw. See Figure 4-3. 3. Toggle the start/stop switch until fuel, free of air bubbles, flows from the vent screw. Tighten the screw. 4.
4.4 Governor The centrifugal, mechanical-type governor maintains constant engine speed by automatically adjusting the fuel supply to the engine depending on load changes. The governor requires no regular service. The governor is factory-set during run-in and requires no further adjustment unless greatly varying load conditions are encountered or if poor governor control develops after extended usage.
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Notes Section 4 Fuel System TP-6073 4/06...
Section 5 Cooling System 5.1 General Note: Block heater damage. The block heater will fail if the energized heater element is not immersed The water-cooled engine uses a closed-loop cooling in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is system that includes an engine water pump which warm, and refill the radiator to purge the air from circulates the cooling water and an engine thermostat...
5.2.3 Procedure to Drain the Cooling 5.2.4 Procedure to Flush and Clean the System Cooling System For optimum protection, drain, flush, and refill the Use the instructions in the engine operation manual cooling system at the intervals listed in the service when available to flush and clean the cooling system.
5.2.5 Procedure to Refill the Cooling 6. Replace the pressure cap. System 7. Fill the coolant recovery tank to the low mark or approximately 1/4 full for tanks without marks. See the generator set spec sheet for coolant capacity. 8. Operate the generator set until the thermostat Note: Do not add coolant to a hot engine.
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Notes Section 5 Cooling System TP-6073 4/06...
Section 6 Controller Troubleshooting 6.1 Controller Sequence of Releasing the start/stop switch allows the switch to return to its neutral position. If the start/stop switch is Operation released before the engine starts, the K1 relay does not energize, which stops the engine startup sequence. This section describes controller operation during generator set starting, running, and stopping.
6.1.3 Stop 6.1.4 Automatic Safety Shutdowns Rock the start/stop switch on the controller front panel to The engine has two switches that monitor critical the STOP position and release the switch to stop the operating conditions: generator set. Release the switch to prevent energizing The High Engine Temperature (HET) switch closes the AH relay and unnecessarily heating the intake when engine coolant temperature approaches an...
6.2 Controller Circuit Board It is possible to check some controller circuit board components (relays) without removing them from the board. Check these relays before installing a new board and attempting startup. Use a high quality multimeter and follow the manufacturer’s instructions. To obtain accurate readings when testing, remove all the circuit board connectors and conformal coating (transparent insulation) from the component terminals.
6.3 Troubleshooting Flowchart Use the flow chart (Figure 6-3) to aid in troubleshooting the generator set. If the prescribed remedy does not correct the problem, replace the circuit board. Press the start switch Go to Does the engine crank? (local or remote). Is the K2 relay LED lit? Is the K3 relay LED lit? Check the controller fuse.
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Go to Does the engine start? Is 12-volt DC present at the fuel solenoid? (check wiring) Is the 10-amp fuse (BCA) functional? Does unit have fuel? Replace the fuse. Engine fault (check the fuel Replenish fuel supply. Is the K25 relay functional? supply, fuel feed pump, fuel injection pump, etc.).
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Does the engine continue Can the engine be stopped to run after the start by using the stop switch? switch is released? The generator set is functional. Did the K4 relay LED light? Does the K1 relay LED light? Is the fuel solenoid functional? Go to Are the local and...
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Is there AC output Is the voltage when the start Is AC output at the regulator button is HELD and correct voltage fuse functional? the unit is running? (e.g. 120-volts AC)? Replace the fuse. Is there 12VDC at the exciter field? Test the voltage Test the...
Section 7 Generator Troubleshooting 7.1 General 7.2 General Troubleshooting Before beginning the troubleshooting procedures, read To determine the cause of no- or low-AC output , refer to all the safety precautions at the beginning of this the following steps and the troubleshooting flow chart manual.
7.3 Separate Excitation — Separately exciting the generator can determine the presence of an inoperative voltage regulator or whether a running fault exists in the rotor and/or stator. generator component that appears functional while static (stationary) may exhibit a running open or short circuit while dynamic (moving).
7.4 PowerBoostt IIIE Voltage PowerBoostt IIIE Voltage Regulator Test Procedure: Regulators (7.5 and 10 kW 1. Connect the components as shown in Figure 7-5. Models) 2. Turn the variable transformer setting to zero. Plug The generator set is equipped with a PowerBoostt IIIE in the variable transformer.
7.5 PowerBoostt V Voltage PowerBoostt V Voltage Regulator Test Procedure: Regulators (15 and 20 kW 1. Connect the components as shown in Figure 7-7. Models) If a 200--240 volt power source is available, the step-up transformer is not required. The generator set is equipped with a PowerBoostt V voltage regulator.
7.6 Voltage Regulator Adjustment The factory sets the voltage regulator and, under normal Output Input circumstances, the regulator requires no further Green adjustment. However, if the voltage regulator has been Stab Volts replaced or tampered with, or if voltage/frequency V/HZ Sensing reconnection has been done, readjust the voltage Yellow...
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Voltage Regulator Adjustment Procedure: 1. Place the generator set controller start/stop switch in the STOP position. 2. Turn the volts/Hz and the stability potentiometers fully counterclockwise. Connect the voltmeter to the AC circuit or an electrical outlet. 3. Start the generator set and rotate the voltage adjustment potentiometer clockwise (increase voltage) or counterclockwise (decrease voltage) until the desired output voltage is achieved.
7.7 Brushes (EOR/EFOR Models) Replace brushes if they show excessive or uneven wear. The brushes provide a current path from the voltage Use a retainer wire (such as a paper clip) to contain the regulator to the collector rings. Because the brushes brushes during disassembly and reassembly.
7.8 Exciter Field (EORZ and EFORZ Models) Direct current from the battery magnetizes the exciter field. When the exciter armature rotates within the magnetized exciter field windings, an electrical current develops within the exciter armature. Test the exciter field according to the following procedure. Exciter Field Test Procedure: 1.
Exciter Armature Test Procedure: 1. Disassemble the alternator. Refer to Section 9. 2. With the alternator disassembled, disconnect the armature leads from the rectifier module AC terminals. Refer to Section 9. 3. With an ohmmeter on the R x 1 scale, check the resistance across the exciter armature leads.
2. Use an ohmmeter on the R x 100 scale to check the ohmmeter readings indicate the main field is resistance between the rectifier diodes as shown in inoperative. If the resistance test is inconclusive, Figure 7-17. The ohmmeter should show a low perform a megohmmeter test on the main field as resistance in one direction and, upon reversing the described in the next step.
7.12 Stator The stator produces electrical output (AC) as the magnetized main field rotates within the stator windings. The stator consists of a series of coils of wire laid in a laminated steel frame. The stator leads supply voltage to the AC load and exciter regulator. Leads 1, 2, 3, and 4 are the generator set output leads.
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5. Contact the ohmmeter leads and readjust the ohmmeter to zero ohms. Check the cold resistance of the stator windings by connecting the meter leads to the stator leads 1-2, 3-4, etc. See Section 1, Specifications, for the stator resistance values.
Section 8 Component Troubleshooting 8.1 Engine/Generator Components particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the WARNING equipment.
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To further check generator set components, disconnect Note: Before performing ohmmeter checks, disconnect the generator set battery to prevent damage to the battery and remove the wiring harness plugs from the ohmmeter. the controller circuit board. Use an ohmmeter to check continuity and to isolate inoperative components as described in Figure 8-2.
8.2.2 Panel Tests Test the panels with an ohmmeter as described in Kohler Co. offers three remote panels. The first has a Figure 8-5 or with a voltmeter as described in start/stop switch. The second has a start/stop switch Figure 8-6.
Section 9 Generator Disassembly/Reassembly 9.1 Disassembly Note: It is possible to connect the output leads in various positions different volt Disconnect all of the external connections—battery configurations. Mark leads 1, 2, 3, and 4 for correct reconnection. cables at the battery (negative (--) lead first), AC-output leads in the controller, remote start panel at the 8.
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13. Disconnect the P7 (FP and FN) and P6 (F1 and F2) 18. Remove the two alternator end vibromounts. See connectors. See Figure 9-4. Figure 9-6. 558865 1. Armature 2. Armature retaining bolt 3. Rotor leads 558864 1. P7 connector 4.
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21. Install a sling on the stator housing. 26. Clamp the rotor in a soft-jaw vise. Remove the eight Figure 9-7. bolts and remove the drive disc assembly from the rotor. See Figure 9-9. 22. Use a two-jaw puller to pull the end bracket/stator assembly from the bearing on the rotor shaft.
9.2 Reassembly 1. Clamp the rotor in a soft-jaw vise. Install the drive disc on the rotor with disc studs facing the rotor. Tighten the eight bolts to 38 Nm (28 ft. lbs). See Figure 9-9. Note: 7.5 kW models: Apply antiseize compound to the end of the rotor shaft.
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9. Connect the P6, P7, and F1 connectors. See 11. Install tie wraps to secure the wires as necessary. Figure 9-12. 12. Route output leads 1, 2, 3, and 4 through the 10. Brush-equipped models: Remove the brush conduit elbow on the top of the controller box. retainer from the brush holder.
Section 10 Wiring Diagrams Refer to the following wiring diagrams for suggested WARNING connection of generator sets. Follow the National Electrical Code (NEC) in all cases. WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set.
10.12Four-Lead Reconnection L0 (Neutral) The following drawing illustrates the reconnection of GRD. Ground four-lead generator sets. In all cases, follow the National Electrical Code (NEC) guidelines. Load Side NOTICE Single-Pole Circuit Voltage reconnection. Affix a notice to the generator set after Breaker reconnecting the set to a voltage different from the voltage on Line...
10.13Twelve-Lead Reconnection L0 (Neutral) The reconnection procedure that follows details voltage GRD. Ground reconnections only. If the generator set requires frequency changes, adjust the governor and voltage Load regulator. See the generator set service manual for Side information regarding frequency adjustment. Factory Two-Pole In all cases, follow National Electrical Code (NEC)
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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.
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex.
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kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter μF 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.
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.
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 Cast Iron or Steel Assembled into...
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)
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...
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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...
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For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-6073 4/06a 7 Jurong Pier Road Singapore 619159 E 2001 and 2006 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...
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