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Kohler TP-5353 Service Manual

Industrial generator sets
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Service
Industrial Generator Sets
Models:
20-300 kW
TP-5353 8/94c

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Summary of Contents for Kohler TP-5353

  • Page 1 Service Industrial Generator Sets Models: 20-300 kW TP-5353 8/94c...

  • Page 2: Table Of Contents

    ......Section 4. General Troubleshooting ..General Troubleshooting Chart ....TP-5353 8/94 Table of Contents...

  • Page 3: Subject Page

    Early 20-100 kW Detroit Diesel-Powered Models) ....... . 7-27 Table of Contents TP-5353 8/94...

  • Page 4: Safety Precautions And Instructions

    Before operating or servicing the generator set, be sure you understand the messages of these decals. Replace decals if missing or damaged. TP-5353 8/94 Safety Precautions and Instructions I...
  • Page 5 Carbon monoxide is particularly dangerous because it is an odorless, colorless, tasteless, nonirritating gas. Be aware that it can cause death if inhaled for even a short time. II Safety Precautions and Instructions TP-5353 8/94...
  • Page 6 Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaust leakage. Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. TP-5353 8/94 Safety Precautions and Instructions III...
  • Page 7 6-8 ounces per square inch (10-14 inches water column). Do not use test solutions that contain ammonia or chlorine, since the soap will not bubble for an accurate leakage test. IV Safety Precautions and Instructions TP-5353 8/94...
  • Page 8 When generator set is used for standby power, use an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply. TP-5353 8/94 Safety Precautions and Instructions V...
  • Page 9 Electrical backfeed into a utility electrical system can cause serious injury or death to utility personnel working on transmission lines. Heavy Equipment VI Safety Precautions and Instructions TP-5353 8/94...
  • Page 10 An engine gets hot while running and exhaust system components get extremely hot. WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on generator set until it is allowed to cool. TP-5353 8/94 Safety Precautions and Instructions VII...
  • Page 11 Screws and nuts are available in different hardness ratings. American Standard hardware uses a series of markings and metric hardware uses a numeric system to indicate hardness. Check markings on bolt head and nuts for identification. VIII Safety Precautions and Instructions TP-5353 8/94...

  • Page 12: Introduction

    All information in this publication represents data Equipment service requirements are minimal but are available at time of printing. Kohler Co. reserves the very important to safe and efficient operation; therefore, right to change this literature and the products inspect parts often and perform required service at the represented without incurring obligation.

  • Page 14: Section 1. Specifications

    The SCR field in the event of a sustained heavy overload or short assembly sends full exciter power to the main field. The circuit. generator then sustains up to 300% of its rated current. TP-5353 8/94 Specifications 1-1...
  • Page 15 9. Safegaurd Breaker (Optional) 3. SCR Assembly 10. AC Voltage Regulator 4. Exciter Generator 11. LED Board 5. Exciter Field Magnets 12. Photo Transistor Board 6. Exciter Armature 13. Stator 7. Optical Coupling Figure 1-1. Alternator Schematic 1-2 Specifications TP-5353 8/94...

  • Page 16: Specifications

    Electronic governor magnetic pickup air gap 200-300 kW 1/4 turn out (cold) 2.5 volts AC minimum Magnetic pickup output voltage during cranking Generator adapter to flywheel housing bolt see chart following torque Drive disks to flywheel torque see chart following TP-5353 8/94 Specifications 1-3...

  • Page 17: Engine

    1) Stud/spacer (after drive disc)/hardened washer/nut 2) Hardened washer/bolt 3) Stud/spacer (before drive disc)/hardened washer/nut Engine Turbocharger Specifications (30, 80, and 100 kW Ford Powered) Specification Turbocharger Axial End Play 0.0043 in. (0.11 mm) Turbocharger Radial Play 0.0075 in. (0.19 mm) 1-4 Specifications TP-5353 8/94...
  • Page 18 20-60 kW Detroit Diesel Powered 11.5-18.5 psi (79-128 kPa) 80/100 kW Detroit Diesel Powered 5.5-10.5 psi (38-72 kPa) 125-180 kW Detroit Diesel Powered 11.5-18.5 psi (79-128 kPa) 200-300 kW Detroit Diesel Powered 11.5-18.5 psi (79-128 kPa) TP-5353 8/94 Specifications 1-5...
  • Page 19 25 psi (172 kPa) 138-162 50 psi (345 kPa) 92-114 75 psi (517 kPa) 50-80 100 psi (690 kPa) 21-50 (in ohms ±10%) Water Temperature Sender 100° F (38° C) 160° F (71° C) 220° F (104° C) 1-6 Specifications TP-5353 8/94...

  • Page 20: Accessories

    14-Relay Dry Contact Box PCB ASSY A- -320639 INPUT CONTACT RATINGS: 10A @120VAC RES. LOAD .01A @28VDC MIN. LOT NO. 10A @28VDC MAX. FBA- -1 10 AMP A-293983 Figure 1-2. Remote Annunciator with 14-Relay Dry Contact Kit TP-5353 8/94 Specifications 1-7...
  • Page 21 Surface Mount Flush Mount A-258782 A-256452 Dry Contact Kit A-256472 Figure 1-3. Remote Annunciator with 10-Relay Dry Contact Kit 1-8 Specifications TP-5353 8/94...
  • Page 22 High Engine Temperature Low Oil Pressure Low Water Temperature Auxiliary Fault Air Damper (if equipped) Anticipatory High Engine Temperature Anticipatory Low Oil Pressure A-292887 Emergency Stop Figure 1-4. Audio/Visual Alarm A-273936 Figure 1-5. Ten-Relay Dry Contact Kit TP-5353 8/94 Specifications 1-9...
  • Page 23 (on TB1 terminal strip), the kit is typically used to signal the following fault TP-5352-1 conditions: Emergency Stop Figure 1-8. Line Circuit Breaker Auxiliary Overspeed Low Oil Pressure High Engine Temperature 1-10 Specifications TP-5353 8/94...
  • Page 24 However, alarms and other signalling devices can also be connected to the contacts. See Figure 1-10. A-222654 TP-5352-1 Figure 1-11. Emergency Stop Kit 273705 Figure 1-10. Run Relay Kit TP-5353 8/94 Specifications 1-11...
  • Page 25 For specific information on Anticipatory High Engine Coolant accessory connections refer to Figure 1-13, the Temperature accessory wiring diagram, and the instruction sheet Low Engine Oil Pressure accompanying each kit. High Engine Coolant Temperature 1-12 Specifications TP-5353 8/94...
  • Page 26 NOTE: Not all terminals are used for all generator sets (see appropriate wiring diagrams for specific generator set model) † Normally closed contacts * Use a remote annunciator and/or A/V alarm kit as an indicator with a dry contact kit connected to controller terminal strip TB1 TP-5352-1 Figure 1-13. Controller TB1 Terminal Strip Connection TP-5353 8/94 Specifications 1-13...

  • Page 28: Section 2. Operation

    See the automatic exercise option, run the generator set under appropriate controller section for specific starting load once a week for one hour with an operator present. instructions. Make all prestart checks before starting the exercise TP-5353 8/94 Operation 2-1...

  • Page 29: 16-Light Controller (Level 1) Operation

    15. System Ready Lamp 32. Fuses (Inside Controller) 16. Generator Switch Not in Auto Lamp 33. Controller TB1 Terminal Strip (on Circuit Board) 17. Scale Lamps (Upper/Lower) Figure 2-1. 16-Light Microprocessor Controller (Standard and Oversize Meterbox Models) 2-2 Operation TP-5353 8/94...

  • Page 30: Features

    (governed frequency devices connected to auxiliary immediate- exceeding 70 Hz). shutdown ports (P1-17 and P1-18). 10. Battery Charger Fault (if battery charger equipped and connected). Lamp lights if battery charger malfunctions. TP-5353 8/94 Operation 2-3...
  • Page 31 (controller, remote annunciator, or audio/visual senses no faults. alarm) to normal position after fault shutdown is corrected to avoid reactivating alarm horn. See Controller Resetting Procedure following. 23. Voltage Adjustment. Fine adjustment for generator output voltage. 2-4 Operation TP-5353 8/94...
  • Page 32 (if equipped). 1. TB1 Terminal Strip D 3-Amp Controller (F2). Fuse protects 2. Fuses controller circuit board, speed sensor, and lamp Figure 2-2. TB1 Terminal Strip on Controller circuit board. Circuit Board TP-5353 8/94 Operation 2-5...

  • Page 33: Starting

    (cyclic or continuous) selection is made on the controller circuit board terminal strip. For cyclic cranking, leave circuit board terminal TB1-9 open. Continuous cranking is achieved by running a jumper between circuit board terminal TB1-2 (ground) and terminal TB1-9. 2-6 Operation TP-5353 8/94...

  • Page 34: Resetting Emergency Stop Switches

    3. If controller air damper light is on, reset air damper Figure 2-3. Air Damper Lever (Detroit Diesel on engine by rotating air damper lever as shown in Powered) Figure 2-3 and the air damper light will go out. TP-5353 8/94 Operation 2-7...
  • Page 35 Check for oil level at engine. overvoltage protection to on-line equipment requiring faster shutdowns. High Engine Temperature. Shutdown occurs 5 seconds after fault. High engine temperature shutdown will not function during first 30 seconds after start-up. 2-8 Operation TP-5353 8/94...
  • Page 36 8. Move controller alarm horn switch to the NORMAL breaker or automatic transfer switch. position. 3. Correct cause of fault shutdown. See Safety Place generator master switch in the AUTO Precautions section of this manual before position before silencing alarm horn. proceeding. TP-5353 8/94 Operation 2-9...

  • Page 37: 6-Light Controller (Level 2) Operation

    21. DC Voltmeter 10. Alarm Horn 22. Fuses (Inside Controller) 11. Alarm Silence Switch 23. Controller TB1 Terminal Strip (on Circuit Board) 12. Voltage Adjustment Pot Figure 2-4. 6-Light Microprocessor Controller (Standard and Oversize Meterbox Models) 2-10 Operation TP-5353 8/94...

  • Page 38: Features

    (P1-15) faults (if so equipped) occur. restart function. The generator set will attempt to These conditions are inhibited during first 30 restart if the engine speed drops below 13 Hz. seconds after crank disconnect. Decreased engine speed causes an overcrank condition. TP-5353 8/94 Operation 2-11...
  • Page 39 (if equipped). 12. Voltage Adjustment. Fine adjustment for generator output voltage. D 3-Amp Controller (F2). Fuse protects controller circuit board, speed sensor, and lamp circuit board. D 15-Amp Engine and Accessories (F3). Fuse protects engine/starting circuitry accessories. 2-12 Operation TP-5353 8/94...

  • Page 40: Starting

    (cyclic or continuous) selection is made on the Circuit Board controller circuit board terminal strip. For cyclic cranking, leave circuit board terminal TB1-9 open. Continuous cranking is achieved by running a jumper between circuit board terminal TB1-2 (ground) and terminal TB1-9. TP-5353 8/94 Operation 2-13...

  • Page 41: Stopping

    The generator set will not crank until the resetting NOTE procedure is completed. Use the emergency stop switch(es) for emergency shutdowns only. Use the generator master switch to stop the generator set under normal circumstances. TP-5633-2 Figure 2-6. Air Damper Lever (Detroit Diesel Powered) 2-14 Operation TP-5353 8/94...
  • Page 42 15% or more over nominal voltage. Low water temperature/auxiliary lamp will light. NOTE Sensitive equipment may suffer damage in less than one second of an overvoltage condition. Install separate overvoltage protection to on-line equipment requiring faster shutdowns. TP-5353 8/94 Operation 2-15...

  • Page 43: Paralleling Engine Gauge Box Controller Operation (Switchgear)

    A connection plug is used to connect the refer to Figure 2-7 and the following descriptions. generator set governor, crank relays, safety switches (high 2-16 Operation TP-5353 8/94...

  • Page 44: Features

    Speed switch settings are situations. Reset switch after shutdown by rotating adjustable for crank and overspeed. switch clockwise. Use the emergency stop switch for emergency shutdowns only. Use the TP-5353 8/94 Operation 2-17...

  • Page 45: Manual Controller Operation

    9. Selector Switch 3. Frequency Meter 10. Start/Stop Switch 4. AC Voltmeter 11. Voltage Adjustment Pot 5. AC Ammeter 12. 10-Amp Fuse 6. Oil Pressure Gauge 13. Scale Lamps (upper/lower) 7. Water Temperature Gauge Figure 2-8. Manual Controller 2-18 Operation TP-5353 8/94...

  • Page 46: Features

    When switched to a position with three circuit lead labels, amperage is measured on the upper lead and voltage is measured between the lower two leads. ammeter and voltmeter will not register with switch in the OFF position. TP-5353 8/94 Operation 2-19...

  • Page 47: Stopping

    The fault lamp will not stay lit after the unit shuts down on coolant level shutdowns will not function during the first a fault condition. 5 seconds after start-up. Overspeed. Unit shuts down immediately if governed frequency exceeds 70 Hz (2100 RPM) on 50 and 60 Hz models. 2-20 Operation TP-5353 8/94...

  • Page 48: Section 3. Scheduled Maintenance

    The generator set can be started by automatic transfer switch or remote start/stop switch unless these precautions are followed. TP-5353 8/94 Scheduled Maintenance 3-1...

  • Page 49: Oil Requirements (30, 80, And100 Kw Ford Powered)

    Manual for oil specifications. drain hose. 10. Wipe up any spilled oil and dispose of rags in a 4. Place generator master switch to RUN position fireproof container. Properly dispose of oil (microprocessor controller) or START position container. 3-2 Scheduled Maintenance TP-5353 8/94...

  • Page 50: Turbocharger Service Schedule (30, 80, And 100 Kw Ford Powered)

    Add the correct metallic surfaces to prevent rust or corrosion. amount of gas stabilizer to the fuel and follow all TP-5353 8/94 Scheduled Maintenance 3-3...

  • Page 52: Section 4. General Troubleshooting

    OFF position (if equipped) Generator problem such as Test and/or replace Section 6—Generator/Controller defective voltage regulator or Troubleshooting other internal fault Section 7—Component Testing and Adjustment Not applicable to generator sets equipped with manual controller. TP-5353 8/94 General Troubleshooting 4-1...
  • Page 53 Move switch to proper position Section 2—Operation OFF/RESET position* (RUN or AUTO) Emergency stop switch Check reason for emergency Section 2—Operation activated (local or remote)* shutdown; reset switch Not applicable to generator sets equipped with manual controller. 4-2 General Troubleshooting TP-5353 8/94...

  • Page 54: Section 5. Controller Troubleshooting

    4. Controller DC Ground Terminal 10. Control Panel Harness Connector (P2) 5. AC Fuse Terminal Block (TB3) 11. Controller Main Circuit Board 6. CT/Meter Scale Terminal Block (TB2) 12. P3/P4 Harness Figure 5-1. Microprocessor Controller TP-5353 8/94 Controller Troubleshooting 5-1...
  • Page 55 12. P1 Connector (DC Harness) 6. K3 Relay: Control Relay (Run) 13. P2 Connector (AC Harness) 7. LED2 (K2 Relay) 14. Fuse: 3 Amp (F1) Remote Annunciator 8. LED3 (K3 Relay) Figure 5-2. Microprocessor Controller Circuit Board Components 5-2 Controller Troubleshooting TP-5353 8/94...

  • Page 56: Circuit Board Terminal Identification (Tb1)

    Active low circuits may be checked for proper operation by placing ground on terminals so designated. Common alarm triggered by High Engine Temperature, High Engine Temperature Prealarm, Low Oil Pressure, Low Oil Pressure Prealarm, Low Water Temperature, Overcrank, Overspeed, Low Fuel, and Auxiliary Faults. TP-5353 8/94 Controller Troubleshooting 5-3...
  • Page 57 TB1-32 Output Logic Logic P3-16 Input Engine Air Damper Logic PHET (40A) Switch TB1--1A TB1--40 Output P2-4 P1-18 P1--8 P1-16 Input TB1-56 TB1--42A P3--8 P3-10 Output G-292806-S Figure 5-3. Microprocessor Controller Connections (TB1 Terminal Strip) 5-4 Controller Troubleshooting TP-5353 8/94...
  • Page 58 Low Fuel Low Oil Pressure PHET Low Water Temperature Not In Auto Overcrank PLOP Overspeed Safeguard Circuit Breaker SYS RDY System Ready Water Level Switch Input Output G-292806-S Figure 5-4. Microprocessor Controller Connections (P1 and P2) TP-5353 8/94 Controller Troubleshooting 5-5...
  • Page 59 Controller Circuit Board Off/Reset Generator Control Switch Switch Logic Grd. Horn Silence Auto AUTO OFF/ RESET Lamp Test Alarm Horn Controller 16-Light LED Indicators G-292806-S Figure 5-5. Microprocessor Controller to 16-Light LED Indicator Connections (P3) 5-6 Controller Troubleshooting TP-5353 8/94...
  • Page 60 ADV-5618-D Figure 5-6. Logic Schematic, 1-Phase/3-Phase Models TP-5353 8/94 Controller Troubleshooting 5-7...
  • Page 61 ADV-5619-H Figure 5-7. Logic Schematic, 3-Phase/600-Volt Models 5-8 Controller Troubleshooting TP-5353 8/94...

  • Page 62: Fault Shutdowns-Microprocessor Controller

    Emergency stop switch(es) are disconnected from controller terminals TB1-1 or 1A Multiple Lamps Light (where illumination may only appear Main circuit board F1 (3 amp) fuse blown. F1 fuse supplies battery dim) voltage to a remote annunciator and/or dry contact kit. TP-5353 8/94 Controller Troubleshooting 5-9...

  • Page 63: Paralleling Engine Gauge Box Controller (Switchgear)

    If the speed sensor is operating and the terminal on until power is removed or the overspeed reset button strip is wired correctly the speed switch is defective. is pushed. The test button lowers the overspeed setting 5-10 Controller Troubleshooting TP-5353 8/94...

  • Page 64: Manual Controller

    Then it is rectified and regulated to speed and voltage decrease enough to 12 volts DC by the BR1 rectifier and VR1 de-energize the K1 relay. K1 normally open voltage regulator. contacts open and the fault lamp turns off. TP-5353 8/94 Controller Troubleshooting 5-11...

  • Page 65: Engine Safety Shutdown Switches

    K4 relay until the unit comes to a complete stop. D Fault lamp is energized until the generator speed and voltage decreases enough to de-energize K1 relay. K1 normally open contacts open and the fault lamp turns off. 5-12 Controller Troubleshooting TP-5353 8/94...
  • Page 66 S-ADV-5664-C Figure 5-9. Manual Controller TP-5353 8/94 Controller Troubleshooting 5-13...

  • Page 68: Section 6. Generator/Controller Troubleshooting

    D Energizes ignition, fuel solenoid, fuel pump, 3. K2 Relay 4. LED2 choke, and instrumentation. 5. LED3 D Energizes generator voltage regulator, LED3 6. K3 Relay Figure 6-2. Main Circuit Board Relays lights when energized during crank and run TP-5353 8/94 Generator/Controller Troubleshooting 6-1...

  • Page 69: Troubleshooting Microprocessor Controller

    3 and 4 on controller circuit board. If conditions. the generator does not start, proceed with the controller troubleshooting procedure outlined in the following pages. 6-2 Generator/Controller Troubleshooting TP-5353 8/94...

  • Page 70: Fuses

    Blown F2 fuse (controller: 3 amp) Battery connections reversed Shorted DC supply to indicator panel Shorted controller circuit board Blown F3 fuse (engine and accessories: 15 amp) Defective engine electrical components Defective overvoltage board Defective panel lamps, engine gauges TP-5353 8/94 Generator/Controller Troubleshooting 6-3...

  • Page 71: Engine Will Not Crank

    Voltage at fuse indicates fuse is good. Is voltage present? Check fuse. Is fuse okay? Check P1 connector/harness. Replace fuse. If fuse blows Check if battery connections again, refer to Fuses are loose or reversed. earlier in this section. 6-4 Generator/Controller Troubleshooting TP-5353 8/94...

  • Page 72: Engine Cranks, But Will Not Start

    Is P2 harness and replace harness defective? connector pins. Is harness. harness defective? Repair or replace harness. Replace circuit board. Replace circuit board. 3-187 1. Fuse Terminal Figure 6-4. Checking Condition of Fuse F2 TP-5353 8/94 Generator/Controller Troubleshooting 6-5...

  • Page 73: Controller Instrumentation

    (TB3) or at component? Blown 1.5-amp fuse at AC fuse terminal block Replace the fuse. (TB3)? See Figure 6-5. Instrumentation is defective. Replace or repair component. TP-5353-6 1. AC Fuse Terminal Block Figure 6-5. AC Fuse Terminal Block 6-6 Generator/Controller Troubleshooting TP-5353 8/94...

  • Page 74: Lamp Circuit Board

    For these lamps to function requires circuit board. connection of air damper and auxiliary prealarm leads between circuit boards). Replace ribbon connector. 3-187 1. P4-8 (+) Connection 2. P4-20 (--) Connection Figure 6-6. Checking Input to Lamp Circuit Board TP-5353 8/94 Generator/Controller Troubleshooting 6-7...

  • Page 75: Overcrank Lamp

    (0.36-0.71 mm) 3-100 R12758-3 TP-5353-6 1. Speed Sensor 4. Wire 2: Black 2. Wire 16: White/Clear 5. Air Gap: 0.014-0.028 in. (0.36-0.71 mm) 3. Wire 24: Red 6. Actuator Cup Figure 6-7. Speed Sensor Air Gap 6-8 Generator/Controller Troubleshooting TP-5353 8/94...

  • Page 76: Fastcheckâ Features And Operation

    L.O.P and A.W.T.—anticipatory (high) water temperature H.W.T. circuits will start timing after engine has been running for 30 seconds. Engine shutdown should occur 5 seconds after pushing fault switch. TP-5353 8/94 Generator/Controller Troubleshooting 6-9...

  • Page 77: Operation

    On 6-light controllers â Figure 6-9. FASTCHECK Connections the low water temperature/auxiliary lamp will flash. The NOT IN AUTO lamp is illuminated whenever the generator master switch is not in the AUTO position on 16-light microprocessor controllers. 6-10 Generator/Controller Troubleshooting TP-5353 8/94...
  • Page 78 â position. Move the FASTCHECK engine switch to OFF position. Move generator master switch to RUN position. Observe IGN., CRK., and REG. lamps light. â Within 5 seconds, move the FASTCHECK engine switch to RUN. TP-5353 8/94 Generator/Controller Troubleshooting 6-11...
  • Page 79 Flashing AUX lamp indicates proper operation of all Auxiliary functions Emergency Stop (local/remote) (if Master switch in RUN position; engine Not Applicable equipped) switch in RUN position; remove switch lead connected to controller terminals TB1-1 or 1A. 6-12 Generator/Controller Troubleshooting TP-5353 8/94...
  • Page 80 See Overcrank earlier in this section Not Applicable Auxiliary Prealarm (Common Fault) Master switch in RUN position; engine TB1-42 (+) and TB1-32 (--) switch in RUN position; hold toggle switch to L.W.T., H.W.T., or L.O.P. TP-5353 8/94 Generator/Controller Troubleshooting 6-13...

  • Page 81: Manual Controller

    The Do not operate generator set without all guards and generator set can be started by automatic transfer electrical enclosures in place. switch or remote start/stop switch unless these precautions are followed. 6-14 Generator/Controller Troubleshooting TP-5353 8/94...

  • Page 82: Troubleshooting Manual Controller

    K3 relay or K1 D Check starter solenoid D Check battery relay faulty— on starter motor (if so condition replace circuit equipped). connections. board. D Check starter motor. D Check battery(ies). Load test battery(ies). TP-5353 8/94 Generator/Controller Troubleshooting 6-15...
  • Page 83 D Fuel pump (gasoline) circuit board D Check/test electronic gov- D Fuel valve ( gas) (defective K4 ernor and/or voltage regu- relay). lator. D Fuel solenoid (diesel 20-180 kW) D Governor controller (diesel 200-300 kW) 6-16 Generator/Controller Troubleshooting TP-5353 8/94...
  • Page 84 Does start/stop Replace Did K4 Repair/replace switch function defective relay LED wiring harness. correctly and wiring start/stop light? checkout okay? switch. Replace circuit board (defective K4 relay). Replace circuit board (defective K4 relay). TP-5353 8/94 Generator/Controller Troubleshooting 6-17...
  • Page 85 (if so equipped)? defective engine D Ignition module (gas/gasoline) components. D Fuel pump (gasoline) D Fuel valve (gas) Replace circuit D Fuel solenoid (diesel 20-180 kW) board (K4 relay D Governor controller (diesel 200-300 kW) defective). 6-18 Generator/Controller Troubleshooting TP-5353 8/94...

  • Page 86: Section 7. Component Testing And Adjustment

    The generator set can be started by automatic transfer switch or remote start/stop switch unless these precautions are followed. TP-5353 8/94 Generator Troubleshooting 7-1...

  • Page 87: Troubleshooting Generator-No Output Voltage

    Replace rotor. Replace SCR between voltage regu- place circuit assembly. lator and LED circuit board. (LED or flyback board. Does wiring diode is shorted and/ check out okay? or grounded .) Repair/replace Replace voltage wiring. regulator. 7-2 Generator Troubleshooting TP-5353 8/94...

  • Page 88: Troubleshooting Generator-High Output Voltage

    If sensing voltage If sensing voltage is is high, replace low, check voltage Replace voltage regulator. on all phases. Is voltage voltage balanced regulator. on all windings? Test stator windings. TP-5353 8/94 Generator Troubleshooting 7-3...

  • Page 89: Generator Testing

    If high voltage is transferred to load the photo transistor board as described later in this during test, personal injury and equipment damage may section. result. Do not use the safeguard circuit breaker in place of the line circuit breaker. 7-4 Generator Troubleshooting TP-5353 8/94...
  • Page 90 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 MAGNETS LED BOARD BOARD TP-5353-7 Figure 7-2. AC Voltage Control (Typical) TP-5353 8/94 Generator Troubleshooting 7-5...

  • Page 91: Overvoltage

    Regulator) Operation and Adjustment later in this is functioning properly. If overvoltage continues, section. replace the SCR assembly. NOTE When replacing SCR assembly, do not exceed torque value of 8 in. lbs. (0.9 Nm) when tightening SCR mounting bolts. 7-6 Generator Troubleshooting TP-5353 8/94...

  • Page 92: Led Circuit Board Test

    If high voltage is transferred to load during test, personal injury and equipment damage may result. Do not use the safeguard circuit breaker in place of the line circuit breaker. 3-100 R12758-5 Figure 7-4. LED Flashlight Test TP-5353 8/94 Generator Troubleshooting 7-7...
  • Page 93 LED board. See Figure 7-5. Shine flashlight on photo transistor. DC voltage reading should drop, showing the AVR is functioning properly. If voltages are not observed, refer to the AVR test. Stop generator set. 3-094 R8936-10 Figure 7-5. Checking LED Board 7-8 Generator Troubleshooting TP-5353 8/94...

  • Page 94: Scr Assembly And Photo Transistor Board

    D Fuse, 1 amp (in holder) assume that the component of unknown quality is defective. Test either component in this manner. D 120 volt AC plug with cord D One “good” SCR assembly and photo transistor board TP-5353 8/94 Generator Troubleshooting 7-9...
  • Page 95 8 in. lbs. (0.9 Nm) when tightening with the SCR foil pattern. Secure all SCR SCR mounting bolts. connections with terminal nuts to ensure good contact with foil pattern during testing. The SCR 7-10 Generator Troubleshooting TP-5353 8/94...
  • Page 96 3. White Wire 9. 120 Volt/100 Watt Lamp 4. Red Wire 10. Fuse (1 Amp) 5. Green Wire 11. Switch (DPST) S1 6. Black Wire 12. 120 Volts AC Figure 7-7. SCR Assembly and Photo Transistor Board TP-5353 8/94 Generator Troubleshooting 7-11...

  • Page 97: Automatic Voltage Regulator (Avr) Operation And Adjustment

    2. Set stability pot to far counterclockwise position. determine cause of malfunction. 3. Connect a 100-watt light bulb across terminals V0 and V7 on controller terminal strip or across terminals on controller frequency meter. 7-12 Generator Troubleshooting TP-5353 8/94...

  • Page 98: To Test Avr

    1. AVR Board in Junction Box 2. Controller Terminal Strip voltage regulator wiring tests good, replace the Figure 7-9. AVR and Connections voltage regulator. Low voltage at the LED circuit board may cause a low output voltage fault. TP-5353 8/94 Generator Troubleshooting 7-13...

  • Page 99: Stator

    (continuity). High resistance across A or low Figure 7-10. Stator resistance (continuity) across B and ground indicates a faulty stator; replace stator. See Figure 7-11. 11 9 A. CONTINUITY/RESISTANCE B. NO CONTINUITY C. NO CONTINUITY TP-5353-7 Figure 7-11. Stator Winding Test 7-14 Generator Troubleshooting TP-5353 8/94...

  • Page 100: Generator Field

    1. Megohmmeter connections across F+ and F-- leads and rotor shaft indicates deterioration of winding insulation and Figure 7-13. High Voltage Test possible current flow to ground. Repair or replacement of the rotor assembly is necessary. TP-5353 8/94 Generator Troubleshooting 7-15...

  • Page 101: Exciter Armature

    9 9 9 9 3-100 R12758-8 TP-5353-7 3-100 1. Ohmmeter connections across AC leads R12758-8 TP-5353-7 Figure 7-14. Exciter Armature Continuity Check 1. Megohmmeter connections across either AC lead and rotor shaft Figure 7-15. High Voltage Test 7-16 Generator Troubleshooting TP-5353 8/94...

  • Page 102: End Bracket Removal And Replacement

    5. Use a puller tool to remove end bracket. See Figure 7-16. NOTE To avoid loosening exciter field magnets, do not 3-096 attempt to remove end bracket by pounding with a R8936-2 hammer. Figure 7-16. Removing End Bracket TP-5353 8/94 Generator Troubleshooting 7-17...

  • Page 103: Speed Sensor Test

    1. DC Voltmeter 2. 12-Volt Battery or DC Power Supply If the speed sensor is not emitting a signal, test the 3. Sensing Surface speed sensor through the following procedure: Figure 7-17. Speed Sensor Test 7-18 Generator Troubleshooting TP-5353 8/94...

  • Page 104: Air Damper Switch Adjustment

    Figure 7-18. Air Damper Lever (Detroit Diesel 8. Reconnect the generator set battery. The air Powered) damper LED on microprocessor controllers must not be on. If the LED is on, readjust the switch as described in step 2. TP-5353 8/94 Generator Troubleshooting 7-19...

  • Page 105: Overspeed/Time Delay Circuit Board

    13 and 13A. Stator Lead V0 4. If the circuit board fails steps 2 and/or 3 it is Stator Lead V7 defective. P1--15 (K4 Relay) Engine Shutdown Switches TP-5414-7 Figure 7-19. Overspeed/Time Delay Circuit Board 7-20 Generator Troubleshooting TP-5353 8/94...

  • Page 106: Overvoltage Circuit Board

    If generator set shuts down, go to step 3. NOTE G-291739 If generator set does not shut down, stop generator Figure 7-20. Overvoltage Circuit Board set using generator master switch. Recheck TP-5353 8/94 Generator Troubleshooting 7-21...

  • Page 107: Governor Adjustment

    8. Governor Mounting eyebolt away from the pivot point. After sensitivity is Figure 7-21. Governor Components and correct, tighten the nut that was previously loosened to Adjustments 7-22 Generator Troubleshooting TP-5353 8/94...

  • Page 108: Mechanical Governor-Stanadyne

    Hz). To increase engine speed, rotate fast idle 2. Fast Idle Adjusting Screw adjusting screw counterclockwise; rotate fast idle Figure 7-22. Governor Adjustments—Typical adjusting screw clockwise to decrease engine speed. Reconnect speed control to fuel injection pump lever. Stop generator set. TP-5353 8/94 Generator Troubleshooting 7-23...

  • Page 109: Mechanical Governor-Nippondenso

    Tighten lock nut TP-5353-7 securely. Stop generator set. 1. Injection Pump Lever 2. Fast Idle Adjusting Screw Figure 7-23. Governor Adjustments 7-24 Generator Troubleshooting TP-5353 8/94...

  • Page 110: Mechanical Governor-Bosch P 125-180 Kw Detroit Diesel-Powered Models

    Tighten lock nut securely. Stop generator set. NOTE If the fast idle is 50 rpm above or below the minimum/maximum settings, have an authorized service dealer remove and adjust the pump on a test stand. TP-5353 8/94 Generator Troubleshooting 7-25...

  • Page 111: Electronic Governor-Barber-Colman Dyna 2500 20-100 Kw Ford-Powered Models

    Upset the linkage by hand. If the linkage oscillates 3-5 times then stops, the setting is correct. Stop the TP-5353-7 generator set. 1. Actuator 2. Linkage Figure 7-26. Throttle Actuator (Typical) 7-26 Generator Troubleshooting TP-5353 8/94...

  • Page 112: Electronic Governor-Barber-Colman Dyna 8000

    Figure 7-28. Throttle Actuator (Typical) TP-5353-7 1. Control Unit: Terminal #1—Positive, Terminal #2—Negative 2. Magnetic Pickup 3. Optional Remote Speed Pot 4. Actuator 5. Relay 6. White Lead 7. Black Lead Figure 7-27. Governor Control Unit TP-5353 8/94 Generator Troubleshooting 7-27...
  • Page 113 8. Jog the actuator lever by hand. It should waver Hz on the frequency meter). from three to five times before stabilizing. The governor is now calibrated. Stop the generator set. 3. If governing is unstable, turn “I” and gain potentiometers slightly counterclockwise. 7-28 Generator Troubleshooting TP-5353 8/94...

  • Page 114: Electronic Governor-Barber-Colman Dyna 2500 125-180 Kw John Deere-Powered Models

    3. Optional Remote Speed Pot 4. Actuator 5. Connect to Ground Stud in Controller 6. Connect to Cranking Solenoid Battery (+) 7. Relay 8. Connect to 70 of Safeguard Breaker Terminal Block Figure 7-29. Governor Control Unit TP-5353 8/94 Generator Troubleshooting 7-29...
  • Page 115 (50 or 60 3-5 times before stabilizing. The governor is now Hz on the frequency meter). calibrated. Stop the generator set. 3. If governing is unstable, turn “I” and gain potentiometers slightly counterclockwise. 7-30 Generator Troubleshooting TP-5353 8/94...

  • Page 116: 20-100 Kw John Deere-Powered And

    8. Magnetic Pickup 11. Magnetic Pickup 12. Twist Magnetic Pickup Leads Before Connecting to Controller. 1 Figure 7-31. Governor Control Unit turn per inch (25 mm) (Nonparalleling Generator Set) Figure 7-32. Governor Control Unit (Paralleling Generator Set) TP-5353 8/94 Generator Troubleshooting 7-31...
  • Page 117 Stop the position. Back out the low idle adjustment screw a generator set. maximum of three turns. Excessive backing out of the low idle screw results in the disengagement of the pump’s internal components. 7-32 Generator Troubleshooting TP-5353 8/94...
  • Page 118 After the engine becomes unstable, slowly turn the gain pot counterclockwise (CCW) until stable. Interrupt the governor by momentarily removing power from the governor. The engine should recover in 3-5 diminishing oscillation. Stop the generator set. TP-5353 8/94 Generator Troubleshooting 7-33...

  • Page 120: Section 8. Generator Disassembly/Reassembly

    The generator set can be started by automatic transfer switch or remote start/stop switch unless these precautions are followed. TP-5353 8/94 Generator Disassembly/Reassembly 8-1...
  • Page 121 Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE. Propane (LP)—Adequate ventilation is mandatory. Propane is heavier than air; install gas detectors low in room. Inspect detectors often. 8-2 Generator Disassembly/Reassembly TP-5353 8/94...
  • Page 122 3. Voltage Regulator Wiring Harness 10. Drive Discs 4. Junction Box 11. Engine Side of Flywheel 5. Generator Guard 12. Flywheel 6. Junction Box Rear Cover 13. Stud 7. Skid 14. Spacer Figure 8-1. Generator Components (Typical) TP-5353 8/94 Generator Disassembly/Reassembly 8-3...
  • Page 123 11. Generator Fan 4. Insulating Washer 12. Drive Discs 5. Insulator 13. Stator Assembly 6. Magnetic Actuator 14. Generator Adapter 7. End Bracket 15. Generator Fan Guard 8. Exciter Field Assembly Figure 8-2. Generator Components (Typical) 8-4 Generator Disassembly/Reassembly TP-5353 8/94...

  • Page 124: Disassembly

    The stator attaches to the generator board. adapter/flywheel housing. Do not remove generator adapter/flywheel housing from stator assembly unless replacing the stator assembly. TP-5353 8/94 Generator Disassembly/Reassembly 8-5...
  • Page 125 13. Slowly lower rotor to horizontal position. Set the rotor on a wooden surface. Take care not to damage windings, laminations, or bearing. See Figure 8-7. 3-088 R8348-15 1. Rotor Assembly Figure 8-7. Lowering Rotor 8-6 Generator Disassembly/Reassembly TP-5353 8/94...
  • Page 126 Figure 8-9. End Bracket View Figure 8-8. Removing Generator Adapter 15. Remove generator adapter mounting bolts. Fasten hoist hooks to end bracket and raise assembly slightly. Bump generator adapter loose by using a rubber mallet. TP-5353 8/94 Generator Disassembly/Reassembly 8-7...

  • Page 127: Reassembly

    NOTE NOTE Position end bracket housing eye opposite the stator mounting bracket during reassembly. Position adapter hoisting eye so that it is opposite of the stator mounting bracket and directly below end bracket hoisting eye. 8-8 Generator Disassembly/Reassembly TP-5353 8/94...
  • Page 128 (available as service part no. 257850). laminations, or bearing. WARNING Hazardous voltage. Moving rotor. Can cause severe injury or death. Do not operate generator set without all guards and electrical enclosures in place. TP-5353 8/94 Generator Disassembly/Reassembly 8-9...
  • Page 129 Secure leads with stop nuts. Torque connections to 8 in. lbs. (0.9 Nm) maximum. 3-089 3-089 R12758-29 R12758-29 1. Magnetic Actuator 2. Photo Transistor Board Figure 8-15. Mounting Photo Transistor Board and Figure 8-14. Installing Photo Transistor Board Magnetic Actuator 8-10 Generator Disassembly/Reassembly TP-5353 8/94...
  • Page 130 Some models mount drive discs to flywheel using the outer circumference and was not a flat surface bolts. Some applications use hardened washers. drive disc. Later models use a flat surface drive disc. Loctite is a registered trademark of Loctite Corporation. TP-5353 8/94 Generator Disassembly/Reassembly 8-11...
  • Page 131 Section 1—Specifications, Generator. 21. Remove chains or slings used for suspending generator. Final tighten drive discs to flywheel. Torque hardware to values given in Section 1—Specifications, Generator. 22. Install fan guard. 8-12 Generator Disassembly/Reassembly TP-5353 8/94...
  • Page 132 (0.36-0.71 mm) etc. TP-5353-8 1. Speed Sensor 2. Wire 16: White/Clear 3. Wire 24: Red 4. Wire 2: Black 5. Air Gap: 0.014-0.028 in. (0.36-0.71 mm) 6. Actuator Cup Figure 8-20. Speed Sensor Air Gap TP-5353 8/94 Generator Disassembly/Reassembly 8-13...

  • Page 134: Section 9. Generator Reconnection

    HI side toward generator set. switch or remote start/stop switch unless these NOTE precautions are followed. Current transformers (CTs) are only used on generator sets equipped with controllers with meters and/or safeguard circuit breakers. TP-5353 8/94 Generator Reconnection 9-1...
  • Page 135 NOTE 12-lead generator sets reconnectable. The 6-lead, 600-volt generator set is not reconnectable. Some special wound stators are made for a specific voltage configuration and are also not reconnectable. TP-5750-5 Figure 9-1. Generator Reconnections 9-2 Generator Reconnection TP-5353 8/94...
  • Page 136 Adjust voltage if necessary with the voltage adjustment potentiometer on the generator controller front panel switchgear. Figure 9-3. STOP generator set when adjustment is complete. ADV-5849 P1 1. Voltage Adjustment Figure 9-3. Voltage Adjustment TP-5353 8/94 Generator Reconnection 9-3...

  • Page 137: Generator Frequency Change And Adjustment

    7—Component Testing and Adjustment, Governors. C-255670-B 1. T1 Terminal 2. T2 Terminal 3. T3 Terminal Figure 9-4. Jumper Location for 50 or 60 Hz Operation TP-5353-6 1. Frequency Meter Connection Points Figure 9-5. Frequency Meter Connections 9-4 Generator Reconnection TP-5353 8/94...

  • Page 138: Appendix A. Glossary Of Abbreviations

    Institute of Electrical and cont’d. continued Electronic Engineers CPVC chloropoly vinyl chloride inch, inches cathode ray tube inc. incorporated Canadian Standards Association in. lbs. inch pounds current transformer int. internal cu. in. cubic inch (es) int.-ext. internal--external TP-5353 8/94 Appendices A-1...
  • Page 139 National Electrical Code U.S.A. United States of America NEMA National Electrical Manufacturers volt, volts Association volts alternating current NFPA National Fire Protection Association volts direct current Newton meter(s) very high frequency N.O. normally open watt, watts A-2 Appendices TP-5353 8/94...

  • Page 140: Appendix B. Common Hardware

    5. Weld nuts 6. Exit hole types Figure B-2. Acceptable Hardware Combinations 1. 1/2 in. bolt diameter 2. Min. 1 full thread beyond top of nut 3. Below top of nut Figure B-1. Acceptable Bolt Lengths TP-5353 8/94 Appendices B-1...

  • Page 142: Appendix C. Common Hardware

    M8-1.25 x 20 Major Thread Diameter In Millimeters Length In Millimeters Distance Between Threads In Millimeters Allenä is a trademark of Holo-Krome Co. PhillipsR is a registered trademark of the Phillips Screw Company. Figure C-1. Screws/Bolts/Studs TP-5353 8/94 Appendices C-1...
  • Page 143 There is no marking to identify hardness. Usually hardened washers have a black oxide or black phosphate finish rather than a zinc (silver-colored) finish. SAMPLE DIMENSIONS Plain Washers 9/32 x 5/8 x 1/16 Internal Dimension Thickness External Dimension Lock Washers Internal Dimension Figure C-2. Nuts/Washers C-2 Appendices TP-5353 8/94...

  • Page 144: Appendix D. General Torque Specifications

    16 x 2.00 ft. lbs. (Nm) (133) (141) (204) 16 x 1.50 ft. lbs. (Nm) (141) (157) (228) 18 x 2.50 ft. lbs. (Nm) (181) (196) (283) 18 x 1.50 ft. lbs. (Nm) (196) (212) (306) TP-5353 8/94 Appendices D-1...
  • Page 147 For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Kohler Power Systems Asia Pacific Headquarters TP-5353 8/94c 7 Jurong Pier Road Singapore 619159 E 1993, 1994, 2000 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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