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Table of Contents
SUBJECT PAGE
Safety Precautions and Instructions ............ i Glossary of Abbreviations .................... vi Reference Material
... .......................... VIII
Service Assistance ........................... ix Section 1. Introduction ...................... l-l Specifications ................................ l-l
Generator .................................. l-l
Engine .................................... l-l
Accessories ................................ l-l Service Views ............................... l-4
Section 2. Operation ........................ 2-l Prestart Checks .............................. 2-l Controller ................................... 2-l
Starting ..................................... 2-2
Preheat Feature (Optional) 13.5/l 4/l 8.5/2OCCOZ and 11/11.5/15/17.5 CCFOZ Models Only ........ 2-2
Stopping ..................................... 2-2 Circuit Protection ............................. 2-3
Engine Safety Shutdown Switches .............. 2-3 Remote Panels (Optional) ..................... 2-4
Remote Start Panel ......................... 2-4
Remote Start and Twb-Meter Panel ........... 2-5
Remote Stat-t and Four-Meter Panel ........... 2-6 Section 3. Scheduled Maintenance ........... &I General ..................................... 3-1
Service Schedule ............................ 3-2 Lubrication System ........................... 3-4
Specifications .............................. 3-4
OilCheck.. ................................ 3-4
Oil Change ................................. 3-4
Oil Filter Change ............................ 3-5 Fuel System ................................. 3-6
Specifications .............................. 3-6
Fuel Filter .................................. 3-6
Bleeding ................................... 3-6
Air Intake Silencer Cleaner .................... 3-7
Turbocharger (13.5/l 8.5/21 CCOZ and 11/15/16.5/18CCFOZ) ................... 3-8
Servicing Mixing Elbow ....................... 3-9 Governor .................................... 3-9
Valve Adjustment. ............................ 3-9
Cylinder Head Retightening ................... 3-11 Cooling System ............................. 3-11
Closed/Heat Exchanger .................... 3-l 1
Siphon Break ............................... 3-12
SUBJECT PAGE
Belt Tension ................................ 3-l 4 Sea Water Pump Belt ...................... 3-14 Battery Charging Alternator Belt ............. 3-l 4
Generator Service ........................... 3-l 5 Wattage Requirements ....................... 3-l 5 Storage Procedure .......................... 3-l 5 Section 4. General Troubleshooting .......... 4-l Section 5. Controller Troubleshooting ........ 5-l Sequence of Operation (E-239563
Circuit Board) ............................... 5-l Starting.. .................................. 5-l Running ................................... 5-l Stopping ................................... 5-2
Engine Safety Shutdown Switches. ............. 5-3 Low Oil Pressure (LOP)
Shutdown Switch .......................... 5-3 High Water Temperature (HWT) and
High Exhaust Temperature (HET) Shutdown Switch .......................... 5-3
Overspeed Safety Shutdown (SDR) ............ 5-3 Section 6. Generator/Controller Troubleshooting ............................ 6-l Controller Circuit Board ....................... 6-l Section 7. Component Testing
and Adjustment ............................ 7-l Separate Excitation ........................... 7-l Voltage Regulator Test-Powerboost” V ........ 7-3
Test Procedure ............................. 7-4 Voltage Regulator Adjustment ................ 7-5 Adjustment Procedure ....................... 7-6
Exciter Field ................................. 7-6 Exciter Armature ............................. 7-8 Rectifier Module. ............................. 7-9 Generator Main Field (Rotor) .................. 7-9
Stator .................................... 7-10 Controller Circuit Board ...................... 7-l 4 Engine/Generator Components ............... 7-l 6
Fuel Solenoid ............................. 7-l 9 Fuel Pump ................................ 7-20
Section 8. Disassembly/Reassembly ......... 8-l Section 9. Wiring Diagrams .................. 9-l Section IO. Specifications Chart ............ IO-I Generator Models ........................... 1 O-l Engine Models .............................. 1 O-5 Installation ................................. 1 O-9 Common Hardware Application
Guidelines, Specification G-585 ............. 1 O-l 1 Common Hardware Application (G-585) ....... 1 O-l 2 Common Hardware Identification ............. 1 O-l 3 General Torque Specifications ............... 1 O-l 5
TP-5630 1 O/93 Table of Contents
Safety Precautions and Instructions A generator set, like any other electro-mechanical device, can pose potential dangers to life and limb if improperly maintained or imprudently operated. The best way to prevent accidents is to be aware of the potential dangers and to always use good common sense. In the interest of safety, some general precautions relating to the operating of a generator set follow. Keep these in mind. This manual contains several types of safety precautions which are explained below.
A DANGER
Danger is used to indicate the presence of a hazard that will cause severe personal injury, death, or substantial property damage if the warning is ignored.
A WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.
A CAUTION
Caution is used to indicate the presence of a hazard that Morwcause minorpersonal injury or property damage if the warning is ignored.
NOTE Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related.
Safety decals are affixed to the generator set in prominent places to advise the operator or service technician of potentially hazardous situations. The decals are reproduced here to improve operator recognition and thereby increase decal effectiveness. For a further explanation of decal information, reference the accompanying safety precautions. Before operating or servicing the generator set, be sure you understand the message of these decals. Replace decals if missing or damaged.
EXHAUST SYSTEM
A WARNING
Carbon monoxide. Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
A
Carbon monoxide can cause severe nausea, fainting, or death. Use the following precautions when installing and operating generator set. Carbon monoxide is particularly threatening in that it is an odorless, colorless, tasteless, nonirritating gas. Be especially careful if operating the generator when moored or anchored under calm conditions as gases may accumulate. If operating the set dockside, moor your craft so that the exhaust discharges on the lee side (the side sheltered from the wind), and always be mindful of others-make sure your exhaust is directed away from other boats and occupied buildings. Do not install exhaust outlet where exhaust can be drawn through portholes, vents, or air conditioners. If generator set’s exhaust discharge hole is near to your crafts water line, DO NOT OVERLOAD CRAFT so as to close or restrict exhaust discharge hole.
Carbon monoxide can cause severe nausea, fainting, or death. Diesel fumes can rapidly destroy copper tubing in diesel exhaust systems. Do not use copper tubing in diesel exhaust systems. Exhaust sulphur will cause rapid deterioration and this could result in exhaustiater leakage. (Diesel Models on/‘)
Carbon monoxide can cause severe nausea, fainting, or death. In addition to routine inspection of the exhaust system, a carbon monoxide detector should be considered. Consult your boat builder or marina for installation of approved detectors. It is essential that all detectors be routinely inspected for proper operation.
TP-5630 1 O/93 Safety Precautions and instructions i
ACCIDENTAL STARTING
Accidental starting. Can cause severe injury or death. Disconnect battery cables before working on generator set (negative lead first and reconnect it last).
Accidental starting can cause severe injury or death. Disconnect battery cables (remove negative lead first and reconnect it last) to disable generator set before working on any equipment connected to generator. The generator set can be started by remote start/stop switch unless this precaution is followed.
MOVING PARTS
r
A WARNING
-3 b!!b Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards and electrical enclosures in place.
A WARNING
at& 0
Rotating parts. Can cause severe injury or death.
Do not operate generator set without all guards, screens, or covers in place.
Flying projectiles can cause severe injury or death. Retorque all crankshaft and rotor hardware after servicing. When making adjustments or servicing generator set, do not loosen crankshaft hardware or rotor thru-bolt. If rotating crankshaft manually, direction should be clockwise only. Turning crankshaft bolt or rotor thru-bolt counterclockwise can loosen hardware and result in serious personal injury from hardware or pulley flying off engine while unit is running.
Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, and clothing away from belts and pulleys when unit is running. Replace guards, covers, and screens before operating generator set.
Exposed moving parts can cause severe injury or death. Additional Precautions Regarding Sound Shield Equjpped Models: Some scheduled maintenance procedures require the generator set to be running while performing service. If the sound shield has been removed leaving belts and pulleys exposed, be especially careful of this area.
ENGINE BACKFIRE/FLASH FIRE
A WARNING
Fire. Can cause severe injury or death.
Do not smoke or permit flame or spark to occur near fuel or fuel system.
L
A sudden backfire can cause severe injury or death. Do not operate with air cleaner/silencer removed. (Diesel Models only.)
A sudden flash fire can cause severe injury or death. Do not smoke or permit flame or spark to occur near fuel system. Keep the compartment and generator set clean and free of debris to minimize chances of fire. Wipe up all spilled fuel and engine oil.
ii Safety Precautions and Instructions TP-5630 1 O/93
HAZARDOUS NOISE
A CAUTION
Hazardous noise. Can cause loss of hearing. Never operate generator without a muffler or with
faulty exhaust system.
HAZARDOUS VOLTAGE/ELECTRICAL
SHOCK
A WARNING
-9 Fib Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards
and electrical enclosures in place.
Hazardous voltage can cause severe injury or death. Wherever electricity is present, there is the hazard of
electrocution. Take the same precautions with electrical
appliances in your craft that you would observe in your
home. Open main circuit breaker on all power sources
before servicing equipment. Make sure unqualified
persons, especially children, cannot gain access to your
set-keep the compartment door locked or securely
latched at all times. Be sure that generator is properly
grounded. Never touch electrical leads or appliances with
wet hands, when standing in water, or on wet ground as
the chance of electrocution is especially prevalent under
such conditions.
Hazardous voltage can cause severe injury or death. The heat sink of the voltage regulator contains high
voltage. Do not touch voltage regulator heat sink when
testing or electrical shock will occur.
(PowerBoost, PowerBoost Ill, and PowerBoost V Voltage Regulator Models only)
Hazardous voltage can cause severe injury or death. Short circuits can cause bodily injury and/or equipment
damage. Do not contact electrical connections with tools
or jewelry while adjustments are made. Remove
wristwatch, rings, and jewelry that can cause short circuits.
Hazardous “backfeed” voltage can cause severe injury or death. Do not connect to any building/marina
electrical system without connecting through an approved
device and after building main switch is open. Backfeed
connections can cause serious injury or death to utility
personnel working to repair a power outage and/or
personnel in the vicinity. Unauthorized connection may be
unlawful in some states and/or localities. A ship-to-shore
transfer switch must be installed to prevent 1
interconnection of generator set power and shore power.
FUEL SYSTEM
A WARNING
Explosive fuel vapors. Can cause severe injury or death.
Use extreme care when handling, storing,
and using fuels.
Explosive fuel vapors can cause severe injury or death. All fuels are highly explosive in a vapor state. Use
extreme care when handling, storing, and using fuels.
Store fuel in a well-ventilated area away from
spark-producing equipment and out of the reach of
children. Never add fuel to the tank while the engine is
running since spilled fuel may ignite on contact with hot
parts or from ignition spark. Do not smoke or permit flame
or spark to occur near potential sources of spilled fuel or
fuel vapors. Keep fuel lines and connections tight and in
good condition-don’t replace flexible fuel lines with rigid
lines. Flexible sections are used to avoid breakage due to
vibration. Should any fuel leakage, fuel accumulation, or
electrical sparks be noted, DO NOT OPERATE
GENERATOR SET. Have systems repaired before
resuming generator operation.
Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a
container to catch fuel when draining fuel system. Wipe up
all spilled fuel after draining system.
Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Do not
modify the tank or propulsion engine fuel system. Craft
must be equipped with a tank allowing one of the two
pickup arrangements described. Tank and installation
must conform to U.S.C.G. Regulations.
TP-5630 10193 Safety Precautions and Instructions iii
BAlTERY HOT PARTS
A WARNtNG
Sulfuric acid in batteries. Can cause severe injury or death.
Use protective goggles and clothes. Can cause
permanent damage to eyes, burn skin, and eat holes
in clothing.
Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can cause permanent
damage to eyes, burn skin, and eat holes in clothing.
Always wear splash-proof safety goggles when working
around the battery. If battery electrolyte is splashed in the
eyes or on skin, immediately flush the affected area for 15
minutes with large quantities of clean water. In the case of
eye contact, seek immediate medical aid. Never add acid
to a battery once the battery has been placed in service.
Doing so may result in hazardous spattering of electrolyte.
Explosion can cause severe injury or death. Battery
gases can cause an explosion. Do not smoke or permit
flame or spark to occur near a battery at any time,
particularly when it is being charged. Avoid contacting
terminals with tools, etc. to prevent burns and to prevent
sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
battery. Never connect negative (-) battery cable to
positive (+) connection terminal of starter solenoid. Do not
test battery condition by shorting terminals together or
sparks could ignite battery gases or fuel vapors. Any
compartment containing batteries must be well ventilated
to prevent accumulation of explosive gases. To avoid
sparks, do not disturb battery charger connections while
battery is being charged and always turn charger off
before disconnecting battery connections. When
disconnecting battery, remove negative lead first and
reconnect it last.
A WARNING
Hot coolant and steam. Can cause severe injury or death.
Before removing pressure cap stop generator,
allow to cool and loosen pressure cap to relieve
pressure.
1
A WARNING 1
Hot engine and exhaust system. Can cause severe injury or death.
Do not work on generator set until unit is allowed to
cool.
Hot parts can cause severe injury or death. Do not
touch hot engine parts. An engine gets hot while running
and exhaust system components get extremely hot.
Hot coolant can cause severe injury or death. Allow
engine to cool and release pressure from cooling system
before opening pressure cap. To release pressure, cover
the pressure cap with a thick cloth then turn it slowly
counterclockwise to the first stop. After pressure has been
completely released and the engine has cooled, remove
cap. If generator set is equipped with a coolant recovery
tank, check coolant level at tank.
iv Safety Precautions and Instructions TP-5630 10193
NOTES
NOTICE This generator set has been rewired from its nameplate voltage to:
246242
NOTICE
This is a positive terminal only. Do not attach negative lead!
NOTICE Check zinc anode every 100 hours or 3 months.
NOTICE
51 Do not use as a step.
Standing on genset could impair operation of unit.
NOTE Wipe up all spilled diesel fuel after bleeding system. Wash
hands after any contact with fuel oil.
(Diesel models only).
NOTE HARDWARE DAMAGE! Engine and generator may make
use of both American Standard and metric hardware. Be
sure to use the correct size tools to prevent rounding of bolt
heads and nuts.
NOTE Special attention should be given when checking for
proper coolant level. After the coolant has been drained, it
normally requires some time before complete refill of the
engine water jacket takes place.
NOTE ENGINE DAMAGE! Failure to bleed air from cooling
system may cause overheating and subsequent damage
to engine.
NOTE When replacing hardware, do not substitute with inferior grade hardware. 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 proper identification.
NOTE High-mineral content sea water (salt water) can cause
rapid destruction of all metals. Wipe up all salt water
spillage on and around generator set and keep metal
surfaces free from accumulated salt deposits.
TP-5630 10193 Safety Precautions and Instructions v
Glossary of Abbreviations Abbreviations are used throughout this manual. Normally in the text they will appear in complete form with the abbreviation following in parentheses the first time they are used. After that they will appear in the abbreviated form. The commonly used abbreviations are shown below.
Abbreviation
AC
AHWT
ALOP
AM
amp amps
ANSI
API
approx.
A/R
A/S
ASA
assy.
ASTM
ATDC
ATS
aux.
AWG
AWM
bhp bmep
Btu
“C
cc
CCA
CEC
cfh
cfm
CID
cm
cmm
co.
cont’d.
C.S.A.
cu. in.
cyl.
dBA
DC
DCR
deg.
dept.
dia.
Description
alternating current
anticipatory high water temp.
anticipatory low oil pressure
amplitude modulation
ampere
amperes
American National Standard Institute
American Petroleum Institute
approximate, approximately
as required, as requested
as supplied, as stated, as suggested
American Standards Association
assembly
American Society for Testing Materials
after top dead center
automatic transfer switch
auxiliary
American Wire Gauge
appliance wiring material
brake horsepower
brake mean effective power
British thermal unit
Celsius degree
cubic centimeter
cold cranking Amps.
Canadian Electrical Code
cubic feet per hour
cubic feet per minute
cubic inch displacement
centimeter, centimeters
cubic meters per minute
company
continued
Canadian Standards Association
cubic inch, cubic inches
cylinder
decibels
direct current
direct current resistance
degree
department
diameter
Abbreviation
e.g.
EMI
etc.
ext.
“F
fl. oz.
FM
fs
ft.
ft. Ibs.
ga. gal., gals.
gal./hr.
gph
gpm
gr. grd.
HCHT
HET
Hg
H20
hp
hr, hrs
HWT
Hz
ID
in.
inc.
in. Ibs.
int.
int.-ext.
IS0
J
JIS
kg kg/cm2
kgm km
kPa
kph kV
kVA
Description
example given
electromagnetic interference
etcetera, (and so forth)
external
Fahrenheit degree
fluid ounce, fluid ounces
frequency modulation
full scale
foot, feet
foot pound, foot pounds
gauge gallon, gallons
gallons per hour
gallons per hour
gallons per minute
grade
ground
high cylinder head temperature
high exhaust temperature
mercury (element)
water
horsepower
hour
high water temperature
hertz (cycles per second)
inside diameter
inch(es)
incorporated
inch pounds
internal
internal-external
International Standards Organization
joule, joules
Japanese Industry Standard
kilogram, kilograms
kilograms per square centimeter
kilogram meter(s)
kilometer, kilometers
kiloPascal, kiloPascals
kilometers per hour
kilovolt
kilovolt amperes
vi Glossary of Abbreviations TP-5630 1 O/93
Abbreviation
kW
kWH
L
LxWxH
LED, LEDs
lb., Ibs.
Uhr.
Umin.
LOP
LP
LWT
m
m3
max.
MCM
mi.
mil
min.
mJ
MJ
mm
m3/min
MPa
mph MS
mW
MW
N/A
NEC
NEMA
NFPA
Nm
no., nos.
NPT
N/R
Description
kilowatt, kilowatts
kilowatt hour
liter, liters
length x width x height
light emitting diode
pound, pounds
liter per hour, liters per hour
liter(s) per minute
low oil pressure
liquefied petroleum
low water temperature
meter, meters
cubic meter, cubic meters
maximum
one thousand circular mils.
mile, miles
one one-thousandth of an inch
minimum
millijoule, millijoules
mega joule, mega joules
millimeter, millimeters
cubic meters per minute
megaPascal
miles per hour
military standard
milliwatt, milliwatts
megawatt, megawatts
not available
National Electrical Code
National Electrical
Manufacturers Association
National Fire Protection Association
Newton meter, Newton meters
number, numbers
National Standard taper pipe
thread per general use
not required
Abbreviation Description
OD outside diameter
OEM original equipment manufacturer
OS overspeed, oversize
ov overvoltage
OZ. ounce, ounces
PF power factor
pot. potentiometer
ppm parts per million
psi pounds per square inch
pt., pts. pint, pints
qt., qts. quart, quarts
qty. quantity
ref. reference
RFI radio frequency interference
rms root mean square
rpm revolutions per inch
SAE Society of Automotive Engineers
sec. second, seconds
SCR silicon controlled rectifier
spec, specs specification
sq- square
sq. cm square centimeters
sq. in. square inch, square inches
tach tachometer
TDC top dead center
temp. temperature
TIF telephone influence factor
turbo turbocharger
UNC Unified coarse thread (was NC)
UNF Unified fine thread (was NF)
UL Underwriter’s Laboratories, Inc.
us undersize
V volt, volts
VAC volts alternating current
VDC volts direct current
W watt, watts
TP-5630 1 O/93 Glossary of Abbreviations vii
Reference Material It is recommended that the following Regulations and Standards be followed when installing Marine Generator Sets.
PLEASURE CRAFT
IEEE 45 The Institute of Electrical and Electronics Engineers Inc. 345 East 47th Street New York, NY 10017 l-800-678-4333
COMMERCIAL VESSELS Designed and manufactured to meet U.S. Coast Guard Title 33.
U.S. Coast Guard Code of Federal Regulations Tile 33 Subparts l-Electrical Systems Subparts J-Fuel Systems
In order to use these generator sets for commercial applications where U.S. Coast Guard Title 46 Certificate is required, additional modifications will be necessary.
Title 46 Subchapter F-Marine Engineering
Part 58-Main and Auxiliary Machinery and Related Systems
U.S. Coast Guard Code of Federal Regulations Title 46 Subchapter F-Marine Engineering
Part 58-Main and Auxiliary Machinery and Related Systems
Order the above publications from: Superintendent of Documents U.S. Government Printing Office Washington, DC 20402 l-202-783-3238
Subchapter J-Electrical Engineering Part 11 l-Electrical Systems- General Requirements Part 112-Emergency Lighting and Power Systems
Boating Safety Circular Commandant (G-BC) Boating Statistics (G-BP-l)
Subchapter T-Small Passenger Vessels (Under 100 Gross Tons) Part 182-Machinery Installation Part 183-Electrical Installation
U.S. Coast Guard Headquarters 2100 Second Street, S.W. Washington, DC 20593-0001 Boating Safety Hotline: l-800-368-5647
Underwriters Laboratories, Inc. (UL) Publications Stock 333 Pfingsten Road Northbrook, IL 60062 Marine Department: l-91 9-549-l 400
Order the above publications from: Superintendent of Documents U.S. Government Printing Office Washington, DC 20402 l-202-783-3238
American Bureau of Shipping (ABS) 65 Broadway New York, NY 10006
NFPA 302 National Fire Protection Association Batterymarch Park Quincy, MA 02269 I-800-735-01 00
Customer Service Society of Automotive Engineers (SAE) 400 Commonwealth Drive Warrendale, PA 15096 l-41 2-776-4970
Order ABS publications from:
American Bureau of Shipping Book Order Section 45 Eisenhower Drive P.O. Box 910 Paramus, NJ 97653-0910
Lloyd’s Register of Shipping 71 Fenchurch Street London, EC3M 4BS England
American Boat and Yacht Council, Inc. (ABYC) 405 Headquarters Drive, Suite 3 Millersville, MD 21108 l-301 -923-3932 or l-301 -923-3953
Midwest Off ice: Lloyd’s Register of Shipping 100 South York Street, Room 226 Elmhurst, IL 60126 l-31 2-279-5414
. . . VIII Reference Material TP-5630 10193
Service Assistance See the Yellow Pages of your Telephone Directory under
Generator-Electric for your closest Kohler Generator
Dealer or contact your local marina.
KOHLER CO., Kohler, Wisconsin 53044
Phone 414-565-3381
Fax 414-565-3648
For Sales & Service in U.S.A. & Canada
Phone l-800-544-2444
Provide MODEL, SPECIFICATION, SERIAL, and
ENGINE numbers from the generator nameplate to
receive current parts and information for your generator
set.
TP-5630 10193 Service Assistance ix
Section I. Introduction This manual covers the operation, maintenance,
troubleshooting, and repair of the alternating current
Marine Generator Sets listed in Figure l-l.
Models Voltage Phase
13.5/l 8.5/21 CCOZ 100/200-l 20/240 1 (60 Hz)
14/20/24CCCZ 120/208-277/480 3 (60 Hz broad range)
11 /15/l 6.5/l 8CCFOZ 220-240, 1 100/200-11 o/220 (50 Hz)
11.5/l 7.5/20 CCFOZ 11 O/l 90-240/416 3 (50 Hz broad range)
Figure 1-l. Generator Model Coverage
Service requirements are minimal but are very important
to the safe and efficient operation of your generator set;
therefore, inspect associated parts often. It is
recommended that an authorized service
dealer/distributor perform required servicing to assure
your unit continues to meet USCG requirements.
Please take a few moments to read this manual, then
carefully follow all service recommendations to keep your
set in top condition. Keep this manual aboard your craft for
future reference. See Figures 1-2, l-3, and 1-4 for
identification and location of components.
All information found in this publication is based on data
available at time of printing. Kohler Co. reserves the right
to make changes to this literature and the products
represented at any time without notice and without
incurring obligation.
Specifications
Generator Accessories
Derating: Nameplate rating shown is at 25” C (77” F) and Several accessories are available to finalize the
at 500 ft. (150 m) on units without sound shields. Units will installation or to add convenience to operation and
derate at higher ambient temperatures and/or different service. All the most current information can be obtained
altitudes. Consult factory for specific derating information. by contacting your local Kohler dealer/distributor.
Available accessories at the time of print of this publication
Engine are as follows.
The 13SCCOZ/ll CCFOZ and 14CCOZ/l1.5CCFOZ are LINE CIRCUIT BREAKERS
powered by a Yanmar threecylinder, water-cooled, Line circuit breakers protect the generator from extreme
four-cycle diesel engine. The turbocharged, three-cylinder overload.
engine with heat exchanger is Model 3JH2LT-K. PREHEATER KITS
The 18.5CCOZ/15CCFOZ and 2OCCOZ/l7.5CCFOZ are
powered by a Yanmar four-cylinder, water-cooled, Air Intake Heater Kit provides improved starting in cold
four-cylinder diesel engine. The turbocharged ‘limates
four-cylinder engine with heat exchanger is Model
4JH2LT-K. REMOTE CONNECTION/EXTENSION
HARNESS The 21 CCOZ/l6.5CCFOZ, 24CCOZ/2OCCFOZ and
18CCFOZ are powered by a Yanmar four-cylinder, Provides additional wiring between all remote panels and
water-cooled, four-cycle diesel engine. The turbocharged controller connector in 15 ft. (4.6 m) or 25 ft (7.6 m)
and intercooled four-cylinder engine with heat exchanger increments-75 ft. (22.6 m) maximum. One required for
is Model 4JH2LHT-K. each Remote Meter Panel Kit (see Section 2).
Heat exchanger cooling consists of heat exchanger with REMOTE WIRING HARNESS (124NCH)
coolant recovery tank, thermostat, rubber impeller sea This one-foot (0.3 m) wiring harness has a 6-pin connector
water pump, centrifugal type engine circulating pump, on one end which is keyed to the controller box connector.
water-cooled exhaust manifold, and exhaust mixer. The other end has pigtails for connection to customer
supplied start switch, generator “ON” light, hourmeter, etc.
TP-5630 10193 Introduction l-l
SEA WATER STRAINER
Available for in-line installation between seacock and sea- water pump.
SENDER KIT
Provides sender capability which is necessary to make remote meter panel gauges functional.
SHIP-TO-SHORE SWITCH
Allows immediate switching to Kohler generator set power or shore power protecting your electrical system from the possibility of simultaneous connection of both power sources.
Required to prevent sea-water entry into the engine when generator set is installed at or below water line.
SOUND SHIELD
Provides highly effective silencing, ease of access for engine/generator service, low maintenance, excellent durability, and safety.
SILENCERS
Reduce engine exhaust noise. Super Silencer II is a tube type and Super Silencer III is a canister (lift) type.
1-2 Introduction TP-5630 1 O/93
TP-5630 1 O/93
Notes
Introduction l-3
I
J
Figure 1-2. Service Views-l3.5CCOZ/11CCFOZ, 14CCOZ/ll SCCFOZ
l-4 Introduction TP-5630 10193
Service Views
13.5CCOZ/ll CCFOZ, 14CCOZ/11.5CCFOZ
1. Controller 2. Air Intake Silencer 3. Fuel Solenoid 4. Lifting Eye 5. Lifting Eye 6. Fuel Injectors 7. Oil Fill 8. Water Temperature Sender (Optional) 9. Fuel Filter
10. Fuel Return Connector 11. Fuel Injection Pump 12. Oil Fill 13. Governor 14. Sea Water Pump (Water Inlet) 15. Oil Pressure Sender (Optional) 16. Lube Oil Filter 17. Oil Drain Valve and Hose 18. Oil Check 19. Fuel Feed Pump (Fuel Inlet) 20. Low Oil Pressure Safety Shutdown Switch 21. Coolant (Fresh Water) Drain 22. High Water Temperature Safety Shutdown Switch 23. Overflow Tube 24. Pressure Cap
Heat Exchanger Coolant (Fresh Water) Drain Sea Water Drain High Exhaust Temperature Safety Shutdown Switch AC Load Lead Connector Nameplate Remote Start Connector Mixing Elbow (Water Outlet/Exhaust Outlet) Coolant (Fresh Water Drain Battery Negative (-) 2 onnection Starter Solenoid Starter Motor Ground Lug (Equipment Ground) Battery Positive (+ Connection Sea Water (Drain b oint) Petcock Belt Guard Coolant (Fresh Water) Drain Battery Charging Alternator V-Belts Engine-Driven Water Pump
Not Shown
Air Intake Heater (optional Preheat Kit required to make air intake heater functional).
TP-563010l93 Introduction l-5
Figure 1-3. Service Views-l8.5CCOU15CCFOZ, 2OCCOZIl7SCCFOZ
l-6 Introduction TP-5630 10193
Service Views (continued) 18.5CCOZ/l XCFOZ, 2OCCOZ/17.5CCFOZ
1. Controller 2. Nameplate 3. Air Intake Silencer 4. Lifting Eye 5. Fuel Solenoid 6. Fuel lniectors 7. Oil Fill a 8. Water Temperature Sender (Optional) 9. Fuel Filter
10. Fuel Return Connector 11 . Oil Fill 12. Fuel Injection Pump 13. Governor 14. Sea Water Pump (Drain Point
1 15. Oil Pressure Sender (Optiona ) (Water Inlet)
16. Oil Drain Valve and Hose 17. Lube Oil Filter 18. Oil Check 19. Fuel Feed Pump (Fuel Inlet) 20. Low Oil Pressure Safety Shutdown Switch 21. Coolant (Fresh Water) Drain 22. Overflow Tube 23. Pressure Cap 24. Lifting Eye
25. 26.
z. 29:
:::
::* 34: 35.
:;. 38:
!Z:
::. 43:
Heat Exchanger Coolant (Fresh Water) Drain Sea Water Drain High Exhaust Temperature Safety Shutdown Switch AC Load Lead Connector Remote Start Connector Mixing Elbow (Water Outlet/ Exhaust Outlet) Coolant (Fresh Water Drain Battery Negative (-) & onnection Starter Solenoid Starter Motor Battery Positive (+) Connection Ground Lug (Equipment Ground) piersater (Drain Point) Petcock
Battery Charging Alternator Engine-Driven Water Pump Belt Guard High Water Temperature Safety Shutdown Switch
Not Shown
Air Intake Heater Coil (optional Preheater Kit required to make it fuctional).
TP-563010193 Introduction 1-7
L
Figure 1-4. Service Views--2lCCOZ/16SCCFOZ, 18CCFOZ, 24CCOU2OCCFOZ
l-8 Introduction TP-5630 1 O/93
Service Views (continued)
21 CCOZII 6.5CCFOZ, 18CCFOZ, 24CCOZI2OCCFOZ
1. Controller 2. Nameplate 3. Air Intake Silencer 4. Lifting Eye 5. Fuel Solenoid 6. Fuel Injectors 7. Oil Fill 8. Water Temperature Sender (Optional) 9. Fuel Filter
10. Fuel Return Connector 11 . Oil Fill 12. Fuel Injection Pump 13. Governor 14. Sea Water Pump (Drain Point
1 15. Oil Pressure Sender (Optiona ) (Water Inlet)
16. Oil Drain Valve and Hose 17. Lube Oil Filter 18. Oil Check 19. Fuel Feed Pump (Fuel Inlet) 20. Low Oil Pressure Safety Shutdown Switch 21. Coolant (Fresh Water) Drain 22. Overflow Tube
23. Pressure Cap 24. Lifting Eye 25. Heat Exchanger 26. Coolant (Fresh Water) Drain 27. Sea Water Drain 28. Coolant (Fresh Water) Drain 29. Sea Water Drain 30. High Exhaust Temperature Safety Shutdown Switch 31. Mixing Elbow (Water Outlet/Exhaust Outlet) 32. AC Load Lead Connector 33. Remote Start Connector 34. Battery Negative (-) Connection 35. Starter Solenoid 36. Starter Motor 37. Battery Positive (+) Connection 38. Ground Lug (Equipment Ground) 39. Sea Water (Drain Point) Petcock 40. V-Belts 41. Battery Charging Alternator 42. Belt Guard 43. Engine-Driven Water Pump 44. High Water Temperature Safety Shutdown Switch
TP-563010/93 Introduction l-9
Section 2.
Prestart Checks
To insure continued satisfactory operation, the following items should be checked before each start-up.
Air Intake Silencer: Must be clean and properly installed to prevent unfiltered air from entering engine. See Section 3, Scheduled Maintenance.
Battery: Remove caps and check the electrolyte level of each cell (batteries with filler caps only); add distilled water if necessary. Check to make sure it is connected correctly. Battery installation and connections must, meet Coast Guard Standards. Battery should be serviced by authorized personnel only. See Section 3, Scheduled Maintenance.
Compartment: Keep the engine room or compartment clean and dry. Check for fuel or oil leaks. Check the condition of fuel system, exhaust piping, hoses, and muffler; have any faulty components repaired before getting underway. Open hatch to air out compartment and use “ignition-protected” bilge blowers, if required, to clear fumes from area before each start-up. If fuel leaks, fumes, exhaust gases, or electrical sparks are noted, arrange for qualified personnel to make necessary repairs before operating generator set.
Operation
Fuel Level: Make sure the fuel tanks are full and the fuel system primed for operation. See Section 3, Scheduled Maintenance.
Oil Level: Should be at or near FULL mark. Add oil as needed to bring level up to this range. See Section 3, Scheduled Maintenance.
Cooling: The coolant level on closed-type heat exchanger systems can be checked using the coolant recovery tank. The ADD/COLD mark indicates full when cold and the FULL/HOT mark indicates full when hot. Maintain the coolant level between these marks. If cooling system has been drained and requires filling, open pressure cap on heat exchanger and add fresh coolant until level is just below overflowtube opening. See Section 3, Scheduled Maintenance.
Sea-Water Pump Priming: The sea-water pump must be primed before initial start-up or whenever cooling sea water has been drained. To prime pump, close seacock and remove the hose from water-filter outlet. Fill hose and pump with clean water. Replace hose and open seacock. Check for pump operating on start-up by observing water discharge from exhaust outlet.
Controller
For identification of controller, see Figure 2-1.
1.
2.
3.
4.
5.
Start-Stop/Preheat Switch: Used to start and stop generator set-refer to “Starting” and “Stopping” following.
Hourmeter: Records total generator set operating hours for reference in maintenance scheduling.
DC Circuit Breaker: The generator set will shut down automatically after fault. See “Circuit Protection” following.
AC Circuit Breaker (Optional): Will trip when a current overload is detected in the output circuit. Used to disconnect generator set during maintenance of craft wiring. To close circuit breaker(s), place in ON position.
Remote Start Connector: 6-pin connector on controller back panel allows connection of (optional) remote start kits. Figure 2-1. Controller
TP-563010l93 Operation 2-1
Starting
Open manual fuel shut-off valve (if equipped). Start
generator set by placing controller start switch to START
position or use remote start-stop switch.
Preheat Feature (Optional) 13.5/l 4/l 8.5/2OCCOZ and
1 l/l 1.5/l 5/l 7.5CCFOZ Models Only
During cold-weather starts (below 23°F [-5X]), place
controller start switch in STOP/PREHEAT position for
15-20 seconds before attempting to start generator set.
This provides energizing of the air heater coil. Do not
energize preheat feature for more than 30 seconds or
damage may occur.
If engine fails to start after the first attempt, close the
seacock before attempting start-up. This will help prevent
sea water from entering the engine cylinders through the
exhaust valves.
NOTE
Do not crank engine continuously for more than IO
seconds at a time. A 60-second cooldown period must be
allowed between cranking attempts if the engine does not
start. If the unit fails to start after three attempts, contact an
authorized Kohler dealer/distributor for repair. Failure to
follow these guidelines may result in damage to the starter
motor from overheating.
NOTE
If excessive cranking is encountered during starting,
failure to close seacock, may cause possible filling of
exhaust piping and silencer with sea water. This condition
may further hinder generator starting and cause sea water
entry into the engine cylinders through the exhaust valve.
To correct this situation, close seacock and drain water
from exhaust system at silencer drain plug before
attempting to start generator set. If excessive cranking is a
chronic’ problem, have the unit (including the exhaust
system) serviced by an authorized Kohler dealer/
distributor.
Once the generator set is started, the seacock must be
opened to allow passage of cooling water.
NOTE
Failure to open seacock after generator set is running will
result in serious engine damage due to overheating and
damage to the sea water pump impeller.
NOTE
Check that the marine ship-to-shore transfer switch is in
the proper position, if used.
Stopping
Run generator set at no load for five minutes to allow NOTE
engine cooldown. Place controller start switch to STOP Do not place Start-Stop/Preheat Switch in
position and wait until generator set comes to a complete STOP/PREHEAT position for more than 30 seconds or
stop; or use remote start-stop switch. damage may occur to preheat feature (if equipped).
2-2 Operation TP-5630 1 O/93
Circuit Protection
AC Circuit Breakers (Optional): Will trip when a current Voltage Regulator Fuse (8Amp): Protects unit in case of
overload is detected in the output circuit. After removing fault in the voltage regulator and/or generator circuit. After
some of the electrical load, reset AC circuit breaker(s) by fault is corrected, replace with a new fuse of the same
placing in ON position. Unit is now ready to be restarted. rating. Voltage regulator circuit is now functional.
Circuit breaker selection is based on voltage configuration
for each model. Battery Charging Fuse: A lo-amp fuse protects the
DC Circuit Breaker: A 1 O-amp circuit breaker located on battery charging alternator, battery charging regulator,
the controller protects the controller circuit board and and circuitry. After fault is corrected, replace with a new
circuitry. If unitshutsdown, checkcircuitbreaker, iftripped, fuse of the same rating. Battery
reset then restart the generator set. functional.
Engine Safety Shutdown Switches
The engine is protected by safety shutdown switches
which automatically reset after the problem is corrected or
the unit is allowed to cool (if overheating was the problem).
Engine safety shutdown switches become functional
when unit comes up to speed and AC voltage is available
and after a 5-l 0 second time delay.
High Exhaust Temperature (HET) of 215°F (102°C) 8
will cause the unit to shut down.
Low Oil Pressure (LOP) of 7.1 psi (49 kPa) or less will
shut down the unit.
TP-5630 10193
charging circuit is now
NOTE
The Low Oil Pressure switch does not act as a low oil level
switch. The only way to protect against damage from low
oil level is to check oil level regularly.
High Water Temperature (HWT) of 230°F (1lOC) *3” will
cause the unit to shut down.
Overspeed Safety Shutdown (SDR) (Optional) will
cause unit to shut down at an engine speed of 2100 rpm
(70 Hz).
Operation 2-3
Remote Panels (Optional)
Three remote panels are offered. The first uses a start/stop switch. The second has a start/stop switch and
two gauges. The third incorporates a start/stop switch and
four gauges.
Remote Start Panel
Remote start panel allows starting-stopping from a
location remote of the generator set. Generator sets are
equipped with a 6-pin connector on controller for
connection of the kit. See Figure 2-2.
If difficulty with the remote operation occurs, the switch
can be tested for proper function. Prior to testing,
disconnect the J3/P3 connector. See Figure 2-3.
NOTE
More troubleshooting information on remote start panels
is provided at the end of this section.
r \ .
0 KOHLER
GENERATOR
START
n
STOP/PREHEAT
c 0 , L J
l-656
L
P
P&
d
I
IOA. Fuse
K.2
Kl
Relay Circuit Board
C-
P2-3
T T
Gen. ON - Light
Figure 2-3. Remote Start Panel
Figure 2-2. Remote Stat-t Panel
2-4 Operation TP-5630 1 O/93
Remote Start and Two-Meter Panel NOTE More troubleshooting information on remote start panels
Allows starting-stopping from a location remote of the is provided at the end of this section.
generator set. The illuminated gauges include an engine
oil pressure gauge, and a water temperature gauge.
Generator sets come equipped with a 6-pin connector on
controller back panel for connection of the kit. See
Figure 2-4 for remote start and two-meter panel kit.
NOTE
Remote start panel will require a sender kit.
Start/Stop Switch: Rocker-type switch with ON light used
to start and stop the generator set.
Engine Oil Pressure Gauge: Measures engine oil
pressure. Normal engine operating range is 40-60 psi
(276-414 kPa) for 60 Hz models. 50 Hz models will show a
slightly lower pressure range.
NOTE
During the engine break-in period, it is normal for the
engine to produce higher oil pressure readings.
Water Temperature Gauge: Measure engine coolant
temperature. Normal engine operating range is
170-195°F (77-91 “C).
If difficulty with remote operation occurs, the switch,
gauges, and gauge senders can be tested for proper
function. Prior to testing, disconnect the J3/P3 connector.
See Figure 2-5.
l-762
Figure 2-4. Remote Start and Two-Meter Panel
Figure 2-5. Remote Start and Two-Meter Panel
Operation 2-5
Remote Start and Four-Meter Panel
Allows starting-stopping from a location remote of the
generator set. The illuminated gauges include a DC
voltmeter, engine oil pressure gauge, water temperature
gauge, and generator running time hourmeter. Generator
sets come equipped with a 6-pin connector on controller
back panel for connection of the kit. See Figure 2-6 for
remote start and four-meter panel features.
If difficulty with remote operation occurs, the switch,
gauges, and gauge senders can be tested for proper
function. Prior to testing, disconnect the J3/P3 connector.
See Figure 2-7.
NOTE
More troubleshooting information on remote start panels
is provided at the end of this section.
KOHLER MARINE OENERATCIRS
START
0 c STOP
Figure 2-6. Remote Start and Four-Meter Panel
NOTE
Remote start panel will require a sender kit.
Start/Stop Switch: Rocker-type switch with ON light used
to start and stop the generator set.
DC Voltmeter: Measures voltage of starting battery(ies).
Normal battery operating range is 12-I 4 volts.
Engine Oil Pressure Gauge: Measures engine oil
pressure. Normal engine operating range is 40-60 psi
(276-414 kPa) for 60 Hz models. 50 Hz models will show a
slightly lower pressure range.
NOTE
During the engine break-in period, it is normal for the
engine to produce higher oil pressure readings.
Water Temperature Gauge: Measures engine coolant
temperature. Normal engine operating range is 170-l 95°F
(77-91 “C).
Hourmeter: Records total generator set operating hours
for reference in maintenance scheduling.
If difficulty with remote operation occurs, the switch,
gauges, and gauge senders can be tested for proper
function. Prior to testing, disconnect the J3/P3 connector.
See Figure 2-7.
en N t I wr I -
. .
I I
Sender
AK2 I
Relay Circuit
T K1 Board
w I
P3-3 -2
T
J3-3
L. Blue
0 Oil Pressure Gauge
b DC Voltmeter
b
Hourmeter
l-940
Figure 2-7. Remote Start and Four-Meter Panel
2-6 Operation F-5630 1 O/93
TROUBLESHOOTING REMOTE
START PANELS
Generally, sender can be presumed good if it changes its
resistance value as its respective pressure/temperature
changes. Adefectivesenderwill either be open or shorted.
To test water temperature sender, connect ohmmeter to
controller socket P3-1 and P3-2. See Figure 2-8 for
resistance by varying temperature. Start generator set to
Water Temperature Sender Values
change temperature. STOP generator set when test is I I
Figure 2-8. Water Temperature Sender Resistance complete.
Oil Pressure Sender Values
To test oil pressure sender, connect ohmmeter to controller
socket P3-1 and P3-3. See Figure 2-9 for resistances by
varying pressure. Start generator set to change pressure.
STOP generator set when test is complete.
0 psi 5-l 3 ohms 15 osi 44-52 ohms 30 psi 80-88 ohms 45 psi 115-l 25 ohms
Figure 2-9. Oil Pressure Sender Resistance
Component
demote switch
Ohmmeter Connections Remarks Results
Remote switch: yellow/red Ohmmeter on R x 1 scale. Continuity-switch is wire terminal and black good. wire terminal (bottom and middle terminals). Press rocker switch to START position.
Remote switch: grey/black Ohmmeter on R x 1 scale. Continuity-switch is wire terminal and black good. wire terminal (top and middle terminals). Press rocker switch to STOP position.
Component Voltmeter Connections Remarks Results
Remote switch ON light*, Red test lead to P3-4 and If 12-volts DC is present Voltmeter setting 12 volts Jauge lights, DC voltme- black test lead to P3-1. and component does not or greater. Generator set ier, and hourmeter Place controller rocker function after J3 is does not need to be
switch to START position. connected to controller running, just cranking for STOP generator set when P3, replace component. this test. test is completed. NOTE: Hourmeter is not
illuminated. To further test components, connect to 12- volt battery. NOTE: Hourmeter is polarity sensitive.
Water temperature gauge Red test lead to P3-4 If 0.5-l 2-volts DC is Voltmeter setting 12 volts (socket side) and black present and gauge does or greater. test lead to P3-2 (socket not function after J3 is side). Start generator set connected to controller, for test. STOP unit when replace gauge. test is completed.
Oil pressure gauge Red test lead to P3-4 If 0.5-l 2-volts DC is Voltmeter setting 12 volts (socket side) and black present and gauge does or greater. test lead to P3-3 (socket not function after J3 is side). Start generator set connected to controller, for test. STOP unit when replace gauge. test is completed.
NOTE: Check continuity of gauge wiring and extension harness before replacing components.
* See Remote Start Panel.
Figure 2-10. Troubleshooting Remote Start Panels
TP-5630 1 O/93 Operation 2-7
Section 3. Scheduled
General
Schedule routine maintenance using the “Service Schedule” following and the hourmeter located on the controller (see Section 2, Operation). If the generator set will be subject to extreme operating conditions, service unit accordingly.
Service intervals are located on the top rows of the “Service Schedule” chart. They include how often maintenance tasks need to be done. Each service item is to be repeated at the specified interval. For example, an item required at 50 hours will again need to be performed at 100 hours, 150 hours, etc.
For continued satisfactory operation and longevity of the engine and generator set, proper maintenance and eventual overhaul by a competent mechanic is essential. While it is not possible to anticipate component failure, rough operation, metallic noises, and excessive oil consumption are among the indicators of potential problems. Do not ignore these conditions!
NOTE
Operate the generator set with one-third load or more applied at least once a month. Allow generator set to run about one hour to reach operating temperature. This prevents the formation of corrosion on internal engine components when exposed to the breakdown of exhaust gases and sea water for long periods of generator inactivity. If unit is to be out of service for several months, see “Storage Procedure.”
NOTE
High-mineral content sea water (salt water) can cause rapid destruction of metals. Even if protected by paint or oil coating, salt water will cause metal erosion. Wipe up all salt water spillage on and around generator set and keep metal surfaces free from accumulated salt deposits.
NOTE
HARDWARE DAMAGE! Engine and generator make use of both SAE and metric hardware. Be sure to use the correct size tools to prevent rounding of bolt heads and nuts.
NOTE
If generator set is operated with less than l/3 load and/or for short periods, service turbocharger every 25 hours.
Maintenance
Accidental starting. Can cause severe injury or death. Disconnect battery cables before working on generator set (negative lead first and reconnect it last).
Accidental starting can cause severe injury or death. Disconnect battery cables (remove negative lead first and reconnect it last) to disable generator set before working on any equipment connected to generator. The generator set can be started by remote start/stop switch unless this jrecaution is followed.
A WARNING
Rotating parts. Can cause severe injury or death.
Do not operate generator set without all guards, screens, or covers in place.
Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from belts and pulleys when unit is running. Replace guards, covers, and screens before operating generator set.
Exposed moving parts can cause severe injury or death. Additional Precautions Regarding Sound Shield Equipped Models: Some scheduled maintenance procedures require the generator set to be running while performing service. If the sound shield has been removed leaving belts and pulleys exposed, be especially careful of this area.
TP-5630 1 O/93 Scheduled Maintenance 3-1
Service Schedule
After 66 Every Every Every Every Before Hours or 100 Hrs. or 160 Hrs. or 300 Hrs. or 600 Hours
Starting One Month 3 Months 3 Months 6 Months or Yearly
FUEL SYSTEM Check the fuel oil level . . . . . . . . . . . . . . . X Fillfueltank _.._.........____....... X Remove sediment from fuel tank _ . . . . . . . . . . . . . . . . . . . . . . . . _ . _ . _ . . _ . . . . . . Check for any abnormal fuel injection sound . . . . . . X
(During Operation) Replace fuel filter element* . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . X . . . . . . . .
(Break-in Period) Check the injection timing*#& @ . . _ . . . . . . . . . . . . . . . . . . _ . _ _ _ _ . . . . . . . . . . . _
Check governor operation and adjustasnecessaty*&@ . . . . . . . .._..__............................
Check the fuel injection nozzles*#&@....................................................
. . . . . . . . . . . . . . . . . . . . . . . . X
............ X
............ X
............ X
............ X
LUBRICATION SYSTEM Check the oil level-crankcase . . . . . . . . X Replace the oil-crankcase . . . . . _ . _ _ _ . . . . . . _ . . . . X . . . . . . _ . _ _ . . . _ . . . . . _ X
(Break-in Period) (150 Hours)
Replace the lube oil filter element* . . . . . . . . . . . . . . . X . . . . . . . . . . . . . . . . . . . . . X (Break-in Period)
COOLING SYSTEM Checkcoolantlevel..................X................................... Seawater outlet . . . . . . . . _ . _ . . . . . . . . . X
(During Operation) Inspect exhaust system components
for cracks and corrosion (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and outlet flapper)*& . . . . . X
Adjust the tension of engine waterpumpbelt* .._..._............._..._. X.....................X
(Break-in Period)
Adjust the tension of sea waterpumpbelt* . . . . . .._..__.............. X.....................X
(Break-in Period)
Check function of siphon break (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Flush cooling system *& . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . _ _ . . _ . . . . . . . _ . . .
Replace the impeller of the seawaterpump*t....................................................
.................... X
.................... X
........ x ......... x (Check)
Check the thermostat function* .,. . . . . _ _ . . . . . . _ _ _ _ . . . . . . . . . . . . _ . . . . _ . . . . _ _ . . _ . . . . . . . . . . . . . _ _ _ . . . . . X
@ Should be performed by an authorized dealer/distributor. * Requires removal of sound shield (if installed). # Reference Engine Service Manual for procedure. & Read WARNING regarding “Moving Parts” found at the beginning of Section 3. t More often under silty or dirty water conditions.
3-2 Scheduled Maintenance T P-5630 1 Q/93
Service Schedule (continued)
After 60 Every Every Every Every Before Hours or 100 Hrs. or 160 Hrs. or 300 HIS. or 500 Hours
Starting One Month 3 Months 3 Months 6 Months or Yearly
AIR CLEANER, Etc. Check the exhaust gas condition . . . . . . X
(During Operation)
Inspect turbocharger compressor (135/185/2lCCOZ and 11/15/165CCFOZ)* @ . . . _ . _ . . . . . . . . . . . . . . . . . X
Check for abnormal turbocharger rotor noise during operation (13.5/l 8.5/21 CCOZ and 11/15/16.5CCFOZ)*#& @ . . . . _. . _ . . . . . . . . . . . . . _. . . . . . . . . . . _ _ . . . _ _ . . . . . . . . . . _ _. . . . . . . . . . . X
(1500 Hrs.)
Clean the intake silencer element* _ . . . . . . . . . . . _ _ _ . . . . . . . . . . . . X . . . . . . . . . . . . . . . . . . . . . X (Clean) (Replace)
Clean the exhaust/water mixing elbow* . . . . . . _ _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Check the breather pipe* . . . . . . . _ _ . _ . . . . . . . . . . . _ . . . . . . . . . _ . _ . _ . . . . . . . . . . X Check turbo rotor shaft for wear (end
play and radial tolerances) (13.5/l 8.5/21 CCOZ andll/l5/16.5CCOZ)#*@ . . . . . . . ..__.............................._.....I...... X
(6000 Hrs.)
ELECTRICAL SYSTEM Check electrolyte level in the battery . . . X
(batteries with filler caps only) Check the electrical connections* . . . . . . . . . . . . . . . . X Adjust the tension of the alternator
driving belt* _..____..___........_...._..... X................................. X (Break-in Period)
Check the battery specific gravity . . . . . . . . _ . _ . . . . . . . . . . _ _ . . . . . X (batteries with filler caps only)
CYLINDER HEAD, Etc. Check for leakage of water and oil*& . . . X . . . . . . . . X Retighten the cylinder head bolts* . . . _ . . . . . . . _ _ . _ X . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
(Break-in Period) (Two Years)
Adjust intake/exhaust valve clearance* . . . . . . . _ _ . . X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X (Break-in Period)
Check mounting bolts and vibromounts fortightness*......................................................X
Retighten all major nuts and bolts* _ _ _ . . . . . . . . _ _ . _ _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . . . . . X
REMOTE CONTROL SYSTEM, Etc. Check compartment condition
(fuel, oil, or water leaks) . _ . . . . . . . . X Test run generator set. . . . . . . . . . . _ . _ . _ . . . . . . . . . . X
(Monthly)
Check the remote control operation . . . _ . . . . . . . . . _ X _ . . . . . . . . . . . . . _ _ . . . . . . . . . . . . . . . . . X (Break-in Period)
GENERATOR Blow dust out of generator*& . . . . . . . . _ . . . . . . . . . _ . _ _ _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
@Should be performed by an authorized dealer/distributor. * Requires removal of sound shield (if installed). # Reference Engine Service Manual for procedure. & Read WARNING regarding “Moving Parts” found at the beginning of Section 3.
TP-5630 1 O/93 Scheduled Maintenance 3-3
Lubrication System
Specifications
The selection of engine oil is very important to a diesel engine. If an unsuitable oil is used or an oil change is neglected, it may result in damage and a shorter engine life. Oil must meet the API (American Petroleum Institute) classification of CD, CC/CD, or CC. Recommended SAE (Society of Automotive Engineers) viscosity designation for given temperature ranges is listed in Figure 3-l.
S.A.E. Service 3rade
"C-30-20-10 0 IO 20 30 40 "F I I I I I I
"F 0 20 40 60 80 100°F Operating Temperature
‘+:w . . . . . .,.,.,:,,,,,,:,,,,:,,,, ‘.‘. :‘“:::.:::i:::i::ii:i.iii:
““~‘~:w.~ 1. ““:‘~‘w.. .:\..:.: .,.,:,,,,:,, ,:,,, ~‘.‘....W . . . . . .,.,:,,,,: I.:.::.:.::.:.:: /: .,.,.,,,,,,,,,,,,,,,, ,,.,
. . . . . . . . . . . . . . . . . . . . . . . .
::i::::.:.:.i... ,,,:,,,, ::,, ::::i’:i:i::::~~i:i:iii:i:i :::::,,:,:,,,,,
,,_ Recommended Value
r--i I I L--J Usable Limit
Figure 3-1. Engine Oil Selection
NOTE
Failure to observe these standards may cause inadequate lubrication/oil pressure and cold starting difficulties.
Oil Check
Check the oil level in the crankcase daily, or before each start-up, to insure that the level is in the “safe range.” To check oil level, remove dipstick and wipe the end clean, reinsert as far as possible, and remove. Level should be between MIN and MAX marks on the dipstick (Figure 3-2).
1. MIN Mark 2. MAX Mark
Figure 3-2. Oil Level Check
NOTE
Do not check oil level when set is in operation. The engine must be stopped and on a level surface when checking oil. Most accurate oil reading is obtained by shutting down the generator and waiting several minutes before checking oil.
NOTE
Do not operate the set if the oil level is belowthe MIN mark or above the MAX mark.
Oil Change
Change oil for the first time after 50 hours or one month and then at the specified interval. Change oil more frequently under dirty, dusty conditions. Change oil while the engine is still warm.
1. To drain oil, remove end cap and place oil drain hose in a suitable container. See Figure 3-3 for location.
1. Oil Drain Hose 2. Oil Drain Valve Figure 3-3. Oil Drain Hose
(21CCOUi 6SCCFOZ Model Shown)
3-4 Scheduled Maintenance TP-5630 10193
2. Allow ample time for oil to drain. After draining process is complete, replace end cap on hose.
NOTE If an electric oil drain pump is used, place the pump outlet hose into a suitable container. Remove oil fill cap. See Figure 3-4. Activate pump until all oil is removed. Fill with proper amount and type of oil, see Section 10, Specifications. Replace oil fill cap(s). Disconnect pump and install end cap on hose. Go to Step 5.
1. Oil Fill at Valve Cover 2. Oil Fill at Governor
Figure 3-4. Oil Fill Locations (typical) (21 CCOUI 6.5CCFOZ Model Shown)
3. Remove oil fill cap. One is located near the top of the engine on the valve cover and one is located near the governor. See Figure 3-4.
4. If engine oil filter is to be replaced, see “Oil Filter Change” following.
5. Fill crankcase with proper amount and type of oil. See Section 10, Specifications. Replace oil fill
cap(s).
6. Start generator set and check for oil leaks.
7. STOP generator set. Remove dipstick and wipe clean, reinsert as far as possible and remove to check oil level. Add oil, as necessary, to bring level up to MAX mark.
NOTE Too high an oil level causes high oil consumption and carbonizing of the engine. Too low a level will damage the engine.
TP-5630 10193
NOTE Do NOT pollute the environment. Dispose of used engine oil and other contaminants in a safe and approved manner.
Oil Filter Change
Replace the oil filter initially after 50 hours or one month and then at the specified interval or during every other oil change. Change more frequently if operating in dirty, dusty conditions. See Figure 3-5 and refer to the following procedure.
1. Lube Oil Filter
Figure 3-5. Lube Oil Filter (21 CCOZ/16SCCFOZ Model Shown)
1.
2.
3.
4.
5.
Loosen oil filter by turning in a counterclockwise direction. Remove oil filter and use rags to clean up spilled oil. Dispose of oil filter in a safe and approved manner.
Clean contact surface on oil filter adapter.
Lightly lubricate the gasket surface of the new filter with fresh engine oil. Thread filter on adapter until gasket makes contact; hand tighten an additional one-half turn. Wash hands after any contact with engine oil. If oil change is also being perfomed, skip Steps 4-5 and go back to “Oil Change” procedure. If oil change is not being performed, continue to Step4.
Start generator set and check for oil leaks.
STOP generator set. Remove dipstick and wipe clean, reinsert as far as possible, and remove to checkoil level. Add oil, as necessary, to bring level up to MAX mark.
Scheduled Maintenance 3-5
Fuel System
Specifications
Use a clean, good quality No. 2-D diesel fuel oil with a
cetane number of 45 or greater. The fuel must meet the
requirements of the American Society of Testing and
Materials (ASTM) diesel fuel classification D975.
Cleanliness of the fuel is especially important on diesel
engines which have easily clogged, precision fuel injectors
and pumps.
Recommended fuel:
United States ASTM/D975 No. 2-D diesel oil.
United Kingdom BS2869 Class Al.
NOTE
Never store diesel fuel in galvanized containers; diesel
fuel and the galvanized coating react chemically to
produce flaking which quickly clogs filters or causes failure
of the fuel pump or injectors. Do not run the generator set
out of fuel. Airwill be drawn into the fuel lines and the entire
system will have to be bled before the unit can be
restarted.
NOTE
Avoid storing fuel over long periods of time. Take special
precautions to keep all dirt, water, and other contaminants
out of the fuel. Storage tanks containing diesel fuel
contaminants with water may cause the growth of
“microbes.” The presence of microbes will form a slime
which will clog fuel filter and lines.
Fuel Filter
The fuel filter can be cleaned with fresh fuel oil and
compressed air. The useful life will be determined largely
by the quality and condition of the fuel used. Under normal
conditions, the fuel filter element should be replaced at the
specified interval. Use the following procedure to service
fuel filter.
1.
2.
Close fuel valve.
The priming procedure requires the battery to be
connected so that engine cranking will occur. Do not allow
engine/generator to start. To prevent engine starting,
disconnect line 71 A from the starter motor solenoid (spade
terminal).
Use the following procedure to bleed fuel system.
3.
Loosen fuel filter by turning in a counterclockwise
direction. Remove fuel filter and use rags to clean up
spilled fuel oil. Dispose of fuel filter in a safe and
approved manner. See Figure 3-6.
Clean contact surface on fuel oil filter adapter. 1. Loosen vent screw A at fuel filter. See Figure 3-7.
3-6 Scheduled Maintenance TP-5630 10193
4. Lightly lubricate the gasket surface of the new fuel
filter with fresh fuel oil. Thread filter on adapter until
gasket makes contact; hand tighten an additional
one-half turn. Wash hands after any contact with fuel
oil.
5. Open fuel valve.
6. See “Bleeding” section following.
Figure 3-6. Fuel Filter Location (21 CCOU165CCFOZ Model Shown)
Bleeding
If the generator set engine runs out of fuel, if air leaks
develop in the suction side of the fuel system, or if the fuel
filter is replaced, it will be necessary to bleed the entire
system to prevent starting failures and/or erratic
operation.
NOTE
2. Toggle the start/stop switch. Place the start/stop 1
switch in the START position for a few seconds and
then place the switch in the STOP position until fuel,
free of air bubbles, flows from vent screw A. Tighten
connection.
3. Loosen vent screw B at fuel filter.
4. Toggle the start/stop switch until fuel, free of air
bubbles, flows from vent screw B. Tighten
connection.
5. Loosen vent screw C at fuel injection pump.
6. Toggle the start/stop switch until fuel, free of air
bubbles, flows from vent screw C. Tighten
connection. 1. Fuel Filter 2. Fuel Injection Pump
NOTE 3. Vent Screw A 4. Vent Screw B
Wipe up all spilled diesel fuel after bleeding system. 5. Vent Screw C
Wash hands after any contact with fuel oil. Figure 3-7. Bleeding Fuel System
Air Intake Silencer Cleaner
A round polyurethane sound-absorbing type intake
silencer is employed to silence the intake air drawn into the
cylinder head from the intake port. Besides providing a
silencing effect, the silencer also acts as an air cleaner.
Clean the air silencer at the specified interval shown in the
appropriate service schedule. Clean more frequently if
operating in dirty, dusty conditions. Should the air silencer
become damaged or severely contaminated with dirt it
should be replaced. See Figure 3-8 and refer to the
following procedure.
1.
2.
Release the two spring clips and remove intake
silencer cover.
Remove element from cover and inspect. If in
reasonable condition for cleaning, continue to Step 3
for procedure. If damaged or in poor condition,
replace element; skip Step 3 and go to Step 4.
1. Air Intake Silencer/Cleaner
2. Spring Clip
Figure 3-8. Air Intake Silencer
TP-5630 1 O/93 Scheduled Maintenance 3-7
3. Wash the element in mild detergent and water 1
solution. Rinse and allow to air dry. See Figure 3-9.
4. Wipe cover and base with a clean rag to remove any
dirt. Check base for damage, replace as necessary.
5. Reassemble element and cover assembly to intake
silencer base. Make sure sealing surfaces fit
properly and reattach spring clips. Air-intake silencer
duct should be at the 5 o’clock position as viewed
from the generator end.
6. Remove screws from crankshaft pulley and replace
belt guard or ground shield (if so equipped).
Turbot (13.5/l 8.5/21 CC02 am
The compressor (blower) should be inspected at the
specified interval for build-up of carbon residue. All other
turbocharger inspection and service as described in the
“Service Schedule” must be performed by an Authorized
Service Dealer/Distributer using Yanmar Service
Manuals. See Figure 3-10 and use the following
procedure to inspect compressor.
1.
2.
3.
4.
Remove breather hose from air-intake silencer
connector, if equipped.
Loosen hose clamp on air-intake silencer and
remove air-intake silencer.
Inspect compressor (blower) housing and impeller
(blower wheel) for build-up of carbon residue. If
cleaning is required, contact an authorized service
dealer/distributer for proper cleaning. Use a Yanmar
approved turbocharger cleaner.
Place air-intake silencer over turbocharger
compressor housing inlet and tighten clamp.
l-776
I. Element Figure 3-9. Washing Element
larger 11 /I 5/l 6.5/l 8CCFOZ)
Figure 3-10. Turbocharger Inspection (21 CCOZ/i 6SCCFOZ Model Shown)
NOTE
5.
Air intake silencer duct should be directed down and
away from engine.
Attach breather hose to air-intake silencer connector,
if equipped.
3-8 Scheduled Maintenance TP-5630 1 O/93
Servicing Mixing Elbow Check mixing elbow for carbon build-up and corrosion conducive to rapid deterioration and failure if not properly
inside the pipe. Clean residual carbon build-up with a wire maintained. If any damage is detected with mixing elbow
brush. Inspect exhaust manifold mounting threads for or other exhaust components, replacement should be
cracking and corrosion. The mixing elbow combines high made to prevent engine exhaust (carbon monoxide)
temperature exhaust and cooling sea water. The mixture leakage.
when exposed to engine vibration makes conditions
Governor The centrifugal, mechanical governor serves to keep 1
engine speed constant by automatically adjusting the
amount of fuel supplied to the engine according to
changes in the load. No regular service is required on the
unit. The governor is adjusted during run-in at the factory,
and further adjustment should not be needed unless
greatly varying load conditions are encountl
ered or if poor governor control develops after extended
usage.
60 Hz generator sets are designed to operate in the range
of 57-63 Hz (1800 rpm under full load and 1890 rpm under
no load).
50 Hz generator sets are designed to operate in the range
of 47-53 Hz (1500 rpm under full load and 1590 rpm under
no load).
To check speed, use frequency meter connected to load ’
leads or use hand tachometer. Loosen locking nut on 1. Locking Nut
speed adjusting screw; turn screw in clockwise direction to 2. Speed Adjusting Screw
increase speed (and frequency). To decrease speed, turn Figure 3-11. Governor
screw counterclockwise. lighten locking nut at new (21 CCOU16.5CCFOZ Model Shown)
setting. See Figure 3-11.
Valve Adjustment With poppet-type valve mechanism, each valve is spring
held in the closed position until forced open by the action of
the rocker arm in contact with the push rod which is moved
by the tappet which rides on a lobe of the camshaft. Rocker
arms have adjusting screws with locknuts for adjusting the
valve stem-to-rocker-arm clearance. Check the
intake/exhaust valve clearance at the specified interval
shown in the appropriate service schedule. Valve
clearance of both intake and exhaust valves is 0.0079 in.
(0.2 mm) with the engine cold.
NOTE The engine firing order is based on the No.1 piston being
next to the flywheel, not the crankshaft pulley.
1. Remove rocker arm cover nuts and breather hose at
rocker arm cover connection. Carefully pry rocker
arm cover from cylinder head. Wipe excess oil from
components using a clean rag.
NOTE Be careful not to damage gasket or mating surface.
TP-5630 1 O/93 Scheduled Maintenance 3-9
2. Locate intake valve of No. 1 cylinder (the second
valve from the flywheel). See Figure 3-12 or 3-13.
Remove the belt guard. Rotate crankshaft clockwise
(facing pulley), using a wrench on one of the
crankshaft pulley bolts, until intake valve of No. 1
cylinder begins to open. Continue rotation until timing
mark numbered 1 on flywheel aligns with mark
engraved on stator housing shown in Figure 3-14.
I-94c
Figure 3-12.3~Cylinder Valve Adjustment
I-94c
Figure 3-13.4~Cylinder Valve Adjustment
3.
3-10
Figure 3-14. Timing Mark
Valves 1,2,4, and 5 can now be adjusted. See Figure
3-l 2 or 3-l 3. Use a feeler gauge to check clearance
between rocker arm and valve stem. If necessary,
loosen lock nut and move adjusting screw until very
slight drag is felt on the feeler gauge as it is
withdrawn. Tighten lock nut. See Figure 3-15.
3-Cylinder Engine:
Rotate crankshaft clockwise until intake valve of
No. 2 cylinder begins to open. Continue rotation
until timing mark numbered 2 on flywheel aligns
with mark on stator housing shown in Figure
3-14. Adjust valves 3 and 6. See Figure 3-l 2.
4-Cylinder Engine:
Rotate crankshaft clockwise until intake valve of
No. 4 cylinder begins to open. Continue rotation
until timing mark numbered 4 on flywheel aligns
with mark on stator housing shown in Figure
3-14. Adjust valves 3, 6, 7, and 8. See Figure
3-l 3.
4. With mating surfaces clean and gasket properly
aligned, install rocker arm and cover and nuts. Be
certain that O-ring is properly seated in groove.
5. Install the belt guard.
I I l-777
1. Locknut 4. Rock Arm 2. Adjusting Screw 5. Push Rod 3. Feeler Gauge 6. Clearance (Lash)
Figure 3-15. Valve Adjustment
Scheduled Maintenance TP-5630 10193
A WARNING
0 I i&s
0
Rotating parts.
Can cause severe injury or death.
Do not operate generator set without all guards,
screens, or covers in place. L J
Cylinder Head Retightening
Loosen and retighten cylinder-head bolts at the specified
interval. lighten to specifications given in Section 10,
Specifications and use the sequence shown in Figure 3-l 6
or 3-17.
1. Flywheel Side of Cylinder Head
Figure 3-16. Cylinder Head Tightening Sequence- Three Cylinder
Cooling
Closed/Heat Exchanger
In a closed cooling system, the sea water does not Before filling the cooling system, verify that all petcocks
circulate through the engine but circulates through the are closed and all hose clamps are tight. If cooling system
separate chambers within the heat exchanger to cool the has been drained and requires filling, open pressure cap
engine water. It is then mixed with engine exhaust and on heat exchanger and add fresh coolant until level is just
ejected out the ,exhaust outlet. See Section 10, below overflow tube opening. Add additional coolant, as
Specifications for coolant capacity (including coolant necessary, to coolant recovery tank. Fill to just below the
recovery tank), thermostat rating, and pressure cap rating. HOT (full) mark. Maintain proper coolant level in coolant
A solution of 50% ethylene glycol and 50% clean, softened recovery tank. The COLD (add) mark indicates full when
water is recommended to inhibit rust/corrosion and cold and the HOT (full) mark indicates full when hot.
provide freezing protection. Coolant level should always be between these marks.
Flying projectiles can cause severe injury or death.
Retorque all crankshaft and rotor hardware after servicing.
When making adjustments or servicing generator set, do
not loosen crankshaft hardware or rotor thru-bolt. If
rotating crankshaft manually, direction should be
clockwise only. Turning crankshaft bolt or rotor thru-bolt
counterclockwise can loosen hardware and result in
serious personal injury from hardware or pulley flying off
engine while unit is running.
It may be necessary to remove the rocker arm assembly to
access some of the cylinder-head bolts. See the engine
service manual for complete information.
1. Flywheel Side of Cylinder Head
Figure 3-17. Cylinder Head Tightening Sequence- Four Cylinder
System FliLlNG AND CHECKING
TP-5630 1 O/93 Scheduled Maintenance 3-11
A WARNING
Can cause severe injury or death. I
Before removing pressure cap stop generator,
allow to cool and loosen pressure cap to relieve
Hot coolant can cause severe injury or death. Allow engine to cool and release pressure from cooling system
before opening pressure cap. To release pressure, cover
the pressure cap with a thick cloth then turn it slowly
counterclockwise to the first stop. After pressure has been
completely released and the engine has cooled, remove
cap. If generator set is equipped with a coolant recovery
tank, check coolant level at tank.
NOTE
Special attention should be given when checking for
proper coolant level. After the coolant has been drained, it
normally requires some time before complete refill of the
engine water jacket takes place.
NOTE
High-mineral content sea water (salt water) can cause
rapid destruction of all metals. Wipe up all salt water
spillage on and around generator set and keep metal
surfaces free from accumulated salt deposits.
FLUSHING AND CLEANING
For optimum protection, the cooling system should be
periodically drained, flushed, and refilled, see “Service
Schedule.” Open petcocks located at heat exchanger,
engine block, and cooling system and let the system
completely drain. Some models may have petcocks
located behind belt guard. Removal of the pressure cap
will make draining easier. Drain, clean, and flush coolant
recovery tank. Chemical cleaners are available for badly
rusted or corroded cooling system; follow manufacturer’s
instructions. Flush system with clean water before filling
with recommended coolant.
PRESSURE CAP
Closed/heat exchanger systems incorporate a
pressurized cap to raise the boiling point of the coolant and
make use of higher operating temperatures. If leakage or
malfunction occurs, replace with same rating type of cap.
The pressure cap rating is found in Section 10,
Specifications.
Siphon Break
A siphon break provision is used to prevent sea water to function properly. Check the siphon break at the
entry into the engine when the engine exhaust manifold recommended interval for proper function. Generator set
outlet is located less than 9 in. (23 cm) above the water line must not be running during servicing.
when the craft is loaded to maximum capacity and is shut NOTE
down. When used in contaminated waters or salt water, Ambient water temperature and/or water salinity may
the formation of corrosion may not allow the siphon break require more frequent servicing.
3-12 Scheduled Maintenance TP-5630 1 O/93
NOTE Numt 3ers in illustration refer to
items below and not to dimensions.
l-94(
1. Mounting Base 15. Pitch of Exhaust Hose 0.5 in. per ft. 2. Retaining Cap (1.3 cm per 30.5 cm) min. 3. Reed Valve Assembly 16. Distance of Siphon Break above Waterline 1 ft. -.. - I___ . . 4. Siphon Break 5. Intake Strainer 6. Seacock 7. Sea Water Strainer 8. Engine-Driven Sea Water Pump 9. Coolant Recovery Tank
10. Heat Exchanger (Locations Vary by Model) 11. Exhaust Mixer Elbow 12. Water Lock (Optional) 13. Silencer 14. Locate Coolant Recovery Tank at Same Height
as Overflow on Exhaust Manifold Filler Neck
(30.5 cm) min. 17. Distance of Silencer from Exhaust Mixer Elbow 10 ft.
(3 m) max. 18. Vertical Lift of Silencer 4 ft. (1.2 m) max. 19. Pitch of Exhaust Hose 0.5 in. per ft.
(1.3 cm per 30.5 cm) min. 20. Distance of Exhaust Outlet above Waterline 4 in.
(10 cm) min. 21. Distance of Exhaust Mixer Elbow above Waterline. If
less than 9 in. (23cm), siphon break is required.
Figure 3-18. Siphon Break (Threaded Brass Type)
SIPHON BREAK
(THREADED BRASS TYPE)
NOTE
Use two hose clamps on each end of all flexible exhaust
hose connections. Remove the valve from the assembly and examine the
rubber seal for wear and proper seating; replace as
necessary. See Figure 3-l 8. To install, coat threads with NOTE
pipe sealant and tighten. Data given also applies to side exhaust installations.
TP-5630 1 O/93 Scheduled Maintenance 3-13
Belt Tension
The belt tension should be checked initially at 50 hours or
one month and then at the specified interval found in the
‘Service Schedule.” If the tension is not within
specifications, adjust belt(s) as described below.
A WARNING
a+ 0 - #
Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads
away from belts and pulleys when unit is running. Replace
guards, covers, and screens before operating generator
set.
Sea Water Pump Belt
1. Engine-Driven Water Pump Pulley 2. Battery Charging Alternator Pulley 3. Crankshaft Pulley 4. Sea Water Pump Pulley 5. Check Sea Water Pump Belt Tension Here 6. Adjusting (Pivot) Screw 7. Adjusting Screw 8. Check Alternator Belt Tension Here 9. Adjusting Screw
10. Adjusting Arm (Pivot) Screw il. Alternator (Pivot) Screw
Figure 3-19. Belt Tension (Typical)
3-l 4 Scheduled Maintenance TP-5630 10193
1.
2.
Remove belt guard.
Check belt tension at the midpoint of the longest span
of the belt. At this point, a used belt should deflect
about 0.4-0.6 in. (IO-15 mm) with about 50-60 Ibs.
(222-266 N) of force. See Figure 3-19. A new belt
should be checked after 10 minutes of operation.
3.
4.
If belt is not within specifications, go to Step 3.
If belt is within specifications, go to Step 6.
Loosen adjusting screws.
While prying sea water pump outward, tighten
adjusting screws.
5. Recheck and adjust as necessary.
6. Replace the belt guard.
3attery Charging Alternator Belt
1
2.
Remove belt guard.
Check belt tension at the midpoint of the longest span
of the belt. At this point, the belt should deflect about
0.4-0.6 in. (lo-15 mm) with about 22 Ibs. (10 kg) of
force, see Figure 3-18.
If belt is not within specifications, go to Step 3.
If belt is within specifications, go to Step 7.
3. Loosen adjusting arm pivot screw, alternator pivot
screw, and alternator adjusting screw.
4. While prying alternator outward, tighten alternator
adjusting screw.
5. Tighten adjusting arm pivot screw and alternator
pivot screw.
6. Recheck and adjust as necessary.
7. Reinstall the belt guard.
NOTE If the battery is used while the craft is docked and the
generator set is not running (i.e. auxiliary lights,
two-way radio, etc.,) the battery will be drained and
may not have enough powerto start the generator set
later. Therefore, it may be necessary to connect a
battery charger while the craft is docked and running
on shore power.
Generator Service Under normal conditions generator service will not be operation. Service more frequently if bearing inspection
required on a regular basis. If operating under extremely indicates excessive rotor end play or bearing damage
dusty and dirty conditions, use DRY compressed air to from corrosion or heat buildup. The rotor bearing is sealed
blow out of the generator at frequent intervals. Do this with and requires no additional lubrication. All generator
the generator set operating and direct the stream of air in service must be performed by an authorized service
through the cooling slots at the end of the generator. The dealer/distributor.
rotor bearing should be replaced every 10,000 hours of
Wattage Requirements
If the rated amperage capacity of the generator set is breaker, turn off some of the appliances and lights inside
exceeded, the circuit breaker located on the controller will the craft to bring the load down within the rated amperage
trip to protect the generator against damage. This could limits of the set. If this is done and the circuit breaker trips
be caused by a short in the AC circuit in the craft or simply again after being reset, a short circuit is indicated. In this
by having too many appliances on at the same time event, turn off the set and have a qualified electrician
resulting in an overload condition. If the circuit breaker locate and correct the cause of the short circuit. For more
trips, the set may continue running but there will be no AC information regarding generator set capacity, see Section
output to the protected circuit. Before resetting the circuit 10, Specifications.
Storage Procedure
It is recommended that the craft be afloat at the time of
generator set storage since unit must be started.
1.
2.
3.
4.
5.
6.
Start generator set and run until operating
temperature is reached or about 15 minutes. STOP
generator set. Drain oil from crankcase while engine
is still warm. Refill crankcase with specified weight oil.
NOTE
Follow Steps 2-5 or 6-9.
Close seacock and remove hose at seacock. Place
hose in a container of coolant/antifreeze. Container
should have approx. l-2 U.S. gallons (3.7-7.5 L) of
antifreeze. A mixture of 50% ethylene glycol and 50%
clean, softened water is sufficient.
With a suitable container at exhaust outlet, run
generator set until coolant is observed being
discharged at exhaust outlet or until coolant mixture
is used up. Do not allow coolant mixture to flow into
waterways. STOP generator set.
Connect hose to seacock. Leave seacock closed.
Check coolant level of heat exchanger and add if
necessary.
Close seacock and drain all sea water out of cooling
system.
7.
8.
9.
IO.
11.
12.
13.
14.
Drain sea water from strainer and sea-water pump.
Open petcock on heat exchanger to only drain sea
water. Use an air hose to blow out any remaining
water, if necessary. Check coolant level of heat
exchanger and add if necessary.
Drain sea water from exhaust water line.
NOTE
If freezing temperatures will be encountered during
storage, be sure antifreeze is capable of withstanding
the lowest possible temperatures. Generally, a
mixture of 50% ethylene glycol and 50% clean,
softened water is sufficient.
Diesel fuel can be stored in fuel tank for several
months.
Clean exterior of generator set and spread a light film
of oil or silicon spray over any exposed surfaces
which may be subject to rust or corrosion.
Tape to seal air inlet, exhaust pipe, and fuel tank cap.
Disconnect and remove battery. Battery should be
placed in a warm, dry location for period of storage.
Recharge once a month to maintain full charge.
Cover entire unit with a dust cover.
TP-5630 1 O/93 Scheduled Maintenance 3-15
Section 4. General Troubleshooting Use the following tables as a quick reference in
troubleshooting individual problems. Generator set faults
are listed by specific groups and include likely causes and
remedies. The source of more detailed information
needed to correct a problem is indicated. These sources
include various sections of this manual, the Operation and
Installation Manual, and the Engine Service Manual.
Corrective action and testing in many cases requires
knowledge of electrical and electronic circuits. It is
recommended that service only be done by authorized
service dealers/distributors. Improper repair by
unqualified personnel can lead to additional failures.
NOTE
When Kl , K2, K3, K4 or K5 relays are receiving power, the
corresponding LED will light. The LED does not indicate
whether the relay coil is energized. This conclusion can
only be reached through deductive analysis of generator
faults and by performing a continuity test on the relay coil
(see Section 7, Controller Circuit Board).
TP-5630 10193 General Troubleshooting 4-l
Problem
ENGINE
Will not crank (dead)
Possible Cause
Controller voltage- supply circuit
breaker tripped
Battery disconnected or improperly connected
Dead battery
Corroded or loose battery connections
Defective starter
Defective starter solenoid
Defective start/stop switch
Open wiring, terminal, pin, foil, etc.
Remote start/stop switch not operating
properly
Corrective Action
Reset circuit breaker or replace fuse.
Troubleshoot DC circuit and wiring. If circuit breaker
failure continues, replace circuit breaker
Check connections
Check electrolyte level and specific gravity (batteries with filler
caps only). Perform load test
Clean or replace
Replace
Check continuity of circuit. Bypass relay using
jumper wire. If starter cranks, replace solenoid
Check continuity
Check continuity
Check wiring and connection to
controller. If start/stop switch on controller functions, replace/
repair remote switch and/or wiring
Reference
Section 7, Engine/ Generator Components
Section 9, Wiring Diagrams
Section 9, Wiring Diagrams
Operation Manual
Operation Manual
Engine Service Manual
Section 7, Engine/ Generator Components
Section 9, Wiring Diagrams Engine Service Manual
Section 7, Component Testing
Section 9, Wiring Diagrams
Section 7, Component Testing
Section 9, Wiring Diagrams
Section 9, Wiring Diagrams Section 7, Component
Testing
4-2 General Troubleshooting TP-5630 1 O/93
Problem Possible Cause Corrective Action Reference
Will not start (cranks
okay)
No fuel in tank Replenish and bleed fuel system
Section 3, Fuel System
Defective fuel solenoid
Defective fuel-feed
pump
Air intake restriction
Check continuity and ground connection
Replace fuel-feed
pump
Check air intake
Section 7, Fuel Solenoid
Section 7, Fuel Pump
Section 3, Air Intake Silencer/Cleaner
Engine malfunction
Clogged fuel filter
K2 relay coil defective (If LED2 is lit, relay is receiving power but
may not be energized)
Open wiring, terminal, or pin (P2 connector)
Troubleshoot engine
Replace filter
Check continuity
Engine Service Manual
Section 3, Fuel Filter
Section 7, Controller Circuit Board
Section 9, Wiring Diagrams
Check continuity Section 9, Wiring Diagrams
K4 relay defective (K2 relay) must be energized
Air in fuel system
Water, dirt in fuel system
Dirty or faulty injectors
Improper compression
Improper type of fuel
Section 7, Controller Circuit Board
Section 9, Wiring Diagrams
Section 3, Fuel System
Engine Service Manual
Engine Service Manual
Section 3, Fuel System
Improper type of crankcase lube oil
Defective K4 relay contacts
Check relay coil continuity
Bleed air
Drain, flush fuel system
Check injectors
Check compression
Use proper type of fuel; consult fuel supplier
Use proper lube oil
Test circuit board
Section 3, Lubrication System
Section 7. Controller Circuit Board
Weak or dead battery Check electrolyte level and specific gravity (batteries with filler
caps only). Perform load test
Operation Manual
TP-5630 1 O/93 General Troubleshooting 4-3
Problem
Engine starts, but stops after start switch is released
Hard starting
Possible Cause
No generator output voltage
Open wiring (Pi or P2 connector)
Kl relay coil defective
If LED1 is not lit, Kl relay may not be
receiving power from stator Bl/B2 winding
No/low oil pressure (time delay of 5-10 seconds)
Defective low oil pressure (LOP)
shutdown
Stale or bad fuel
Air intake restriction
Worn piston rings, valves, etc.
Improper cooling (hot engine only)
Air in fuel system
Water, dirt in fuel system
Dirty or faulty injectors
Improper type of fuel
Corrective Action
Check AC voltage. Separately excite unit.
Check stator and main field (rotor) continuity
Check continuity
Check continuity
Check for power at relay
Check oil pressure, oil pump, and low oil
pressure shutdown switch
Reference
Section 9, Wiring Diagrams Section 7, Component
Testing-Separate Excitation Section 9, Wiring Diagrams
Section 9, Wiring Diagrams
Section 7, Controller Circuit Board
Section 9, Wiring Diagrams
Section 7, Stator Section 7, Component
Testing-Engine/ Generator Components
Engine Service Manual
Disconnect lead from LOP switch and isolate terminal. If engine continues to run, replace LOP switch. LOP switch contacts close at approx. 6.8 psi (47 kPa). NOTE: Verify proper engine oil pressure, before replacing LOP shutdown switch.
Replace
Check air intake Intake Silencer/Cleaner
Check compression
Inspect cooling system
Bleed air
Drain, flush fuel system
Check injectors
Use proper type of fuel; consult fuel supplier
Section 3, Air
Engine Service Manual
Section 3, Cooling System
Section 3, Fuel System
Engine Service Manual
Section 3, Fuel System
4-4 General Troubleshooting TP-5630 1 O/93
Problem Possible Cause
Generator set shuts down by itself
No fuel in tank
Fuel line restriction
Clogged fuel filter
Defective fuel feed
pump
Engine overloaded (hot engine only)
Engine overheated (hot engine only)
Loss of generator output voltage to Kl relay (LED1 not lit)
Air intake clogged
No/low oil pressure
Controller circuit breaker tripped
Air in fuel system
Defective low oil pressure (LOP)
shutdown
Defective high water temperature (HWT)
safety shutdown switch
Defective high exhaust
temperature safety shutdown switches
Corrective Action
Replenish
Inspect fuel lines and tank
Replace filter
Check fuel feed pump
Reduce electrical load
Check air intake, carburetor adjustment,
oil level, etc.
Check AC voltage at rectifier (BRl)
Check continuity of Bi/B2 stator leads
Clean air intake
Reference
Section 3, Fuel System
Engine Service Manual
Section 3, Wattage Requirements
Section 3, Service Schedule
Engine Service Manual
Section 9, Wiring Diagrams
Section 7, Stator
Section 3, Air Intake Silencer/Cleaner
Check oil pressure, oil pump, and low oil
pressure shutdown switch
Engine Service Manual
Reset circuit breaker. If Section 7, Engine/ breaker trips repeatedly, Generator Components replace circuit breaker Section 8, Wiring Diagrams
Bleed air Section 3, Fuel System
Disconnect lead from LOP switch and isolate terminal. If engine continues to run, replace LOP switch. LOP switch contacts close at approx. 6.8 psi (47 kPa). NOTE: Verify proper engine oil pressure, before replacing LOP shutdown switch.
Disconnect lead from HWT switch and isolate terminal of lead. NOTE: Verify proper engine operating temperature before replacing HWT switch. If engine continues to run, replace HWT switch. HWT switch contacts close at approx. 203” F (95” C).
Disconnect lead(s) from HET switch and isolate terminal of lead. NOTE: Verify proper operating temperature before replacing HET shutdown switches. If engine continues to run, replace defective switch. Shutdown switch contact closes at approx. 215” F (102°C).
TP-5630 1 O/93 General Troubleshooting 4-5
Problem
Will not carry load or runs rough
Possible Cause
Excessive load connected to
generator
Improper cooling (hot engine only)
Governor not properly adjusted or defective (Engine not operating
at rated rpm)
Fuel line restriction
Dirty fuel filter
Defective fuel- feed pump
Excessive carbon build-up
Valves not seating
Air intake restriction
Improper type of fuel
Incorrect fuel injection timing
Vent in fuel tank cap obstructed
Water, dirt, or air in fuel system
Dirty or faulty injectors
Improper cylinder top clearance
Defective piston or piston ring
Defective crankshaft bearing or piston pin bearing
Improper valve clearance
Improper compression
Defective valve spring
Corrective Action
Reduce electrical load
Inspect cooling system
Check speed using tachometer or
frequency meter. NOTE: Hz x 120/No. of rotor poles = rpm
(Example: 60 x 120/4 = 1800)
Inspect fuel lines and tank
Replace fuel filter
Check fuel-feed pump
Clean cylinder head
Inspect valves and valve seats
Check air intake
Use proper type of fuel; consult fuel supplier
Check injection timing
Clean cap in solvent, blow dry
Drain, flush, fill, and bleed air in the system
Check injectors
Check clearance
Check components
Check components
Adjust proper valve clearance
Check compression
Replace valve spring
Reference
Section 3, Wattage Requirements
Section 3, Cooling System
Section 3, Governor
Section 3, Fuel System
Engine Service Manual
Engine Service Manual
Engine Service Manual
Section 3, Air Intake Silencer/Cleaner
Section 3, Fuel System
Engine Service Manual
Section 3, Fuel System
Engine Service Manual
Engine Service Manual
Engine Service Manual
Engine Service Manual
Section 3, Valve Adjustment
Engine Service Manual
Engine Service Manual
4-6 General Troubleshooting TP-5630 10193
Problem
Will not carry load or runs rough (cont’d)
Lacks power
Overheats
Possible Cause I
Corrective Action
Defective injection
pump
Defective turbocharger
Improper lube oil
Governor not properly adjusted or defective (Engine not operating
at rated rpm)
Air intake restriction
I
Carbon build-up
Improper cooling
Engine overloaded
Stale or bad fuel
Fuel line restriction
Dirty fuel filter
Defective turbocharger
Improper cooling (Check hoses for
blockage and components for function.)
Air intake restriction
Air heater (optional) malfunction
Engine malfunction
Defective fuel-feed pump
Check injection pump
Check turbocharger
Use proper viscosity oil
Check engine speed using frequency meter
or tachometer. NOTE: Hz x 120/No. of rotor poles = rpm
(Example: 60 x 120/4 = 1800)
Check air intake
Clean carbon from cylinder heads
Inspect cooling system
Reduce electrical load
Replace
Check fuel lines and tank
Replace fuel filter
Check turbocharger
Check cooling system
Check air intake
Check heater and relay
Troubleshoot engine
Check fuel-feed pump
Reference
Engine Service Manual
Engine Service Manual
Section 3, Lubrication System
Section 3, Governor
Section 3, Servicing Air Intake Silencer/Cleaner
Engine Service Manual
Section 3, Cooling System
Section 3, Wattage Requirements
Section 3, Fuel System
Engine Service Manual
Section 3, Cooling System
Section 3, Servicing Air Cleaner
Engine Service Manual Section 9, Wiring Diagrams
Engine Service Manual
Engine Service Manual
TP-5630 1 O/93 General Troubleshooting 4-7
Problem
Operates erratically
Unit is noisy
Possible Cause
Air intake restriction
Stale or bad fuel
Governor not properly adjusted or defective (Engine not operating
at rated rpm)
Fuel line restriction
Exhaust system leak
Broken or damaged vibro mounts
Loose or vibrating sheet metal/housing
Inadequate compartment
clearances
Exhaust piping or air inlets/outlets not
securely installed
No compartment sound insulation
Excessive vibration- engine/generator
Corrective Action
Check air intake
Replace
Check engine speed using frequency-meter
or tachometer. NOTE: Hz x 120/No. of rotor poles = rpm
(Example: 60 x 12014 = 1800)
Inspect fuel lines and tank.
Check and replace as necessary
Check and replace as necessary
Retighten screws
Check clearances
Inspect for loose parts
Install sound shield
Install fireproof insulation
Check main field (rotor), crankshaft, bearing, etc. (Disassembly of engine and/or generator may
be required)
Reference
Section 3, Servicing Air Intake Silencer/Cleaner
Section 3, Governor
Operation and Installation Manual-Exhaust Systems
Section 8, Disassembly/ Reassembly
Section 10, Specifications Chart-Generator
Operation and Installation Manual-Compartment
Size
Operation and Installation Manual-Exhaust Systems
Section 1. Accessories Instructions with Kit
Operation and Installation Manual-Compartment
Size
Section 8, Disassembly/ Reassembly
Engine Service Manual
4-8 General Troubleshooting TP-5630 1 O/93
Problem
ELECTRICAL SYSTEM
Battery will not charge
Starter does not work properly
Possible Cause
Loose or corroded connections
Sulfated or worn-out battery
Defective alternator
Loose or defective alternator belt
Defective alternator voltage regulator
Loose or corroded connections
Low battery output
Defective starter solenoid
Defective start/stop switch
Defective wiring
Defective starter
Battery cables undersize
Corrective Action
Clean and tighten connections
Check electrolyte level and specific gravity (batteries with filler
caps only)
Test and replace, if necessary
Adjust belt tension or replace belt
Test and replace, if necessary
Clean and tighten loose connections
Check electrolyte level and specific gravity (batteries with filler
caps only)
Check starter solenoid Replace starter
solenoid, as necessary
Replace switch
Check wiring
Replace starter
Select proper size cable
Reference
Section 3, Battery
Operation and Installation Manual
Engine Service Manual
Section 3, Belt Tension
Section 7, Component Testing
Operation and Installation Manual
Section 7, Component Testing
Engine Service Manual
Section 7, Component Testing
Section 9, Wiring Diagrams
Engine Service Manual
Section 10, Specifications Chart-Installation
Operation and Installation Manual-Electrical System
TP-5630 1 O/93 General Troubleshooting 4-9
Problem
Starter cranks slowly
L
Possible Cause
Low battery output
Too heavy viscosity lube oil
Loose or corroded wiring
High starter current draw
Battery cable undersize
Corrective Action
Check electrolyte level and specific gravity (batteries with filler
caps only)
Use proper viscosity oil
Clean and tighten loose connections
Repair/Replace starter
Select proper size cable
Reference
Operation and Installation Manual
Section 3, Lubrication System
Section 10, Specifications Chart-Installation
Operation and Installation Manual-Electrical Systems
4-10 General Troubleshooting TP-5630 1 O/93
Problem
GENERATOR
No generator output voltage
Possible Cause
AC output circuit breaker open or
defective
AC circuit breaker tripping due to
overload on unit
Transfer switch in OFF or other
power source position
No battery voltage to terminal (10) and (12) of voltage regulator during
cranking
Short circuit in vessel installation wiring causing
circuit breaker to trip
Open wiring, terminals or pin in exciter
field (field flashing)
Defective main field (rotor) (open, grounded, or shorted windings)
Defective stator (open, grounded, or shorted
windings)
Open D5 or D8 diode
Kl relay (normally closed) contacts open
Defective voltage regulator
Misadjusted voltage regulator
Corrective Action
Check position of circuit breaker
Check AC voltage on generator side of circuit
breakers
Reduce load Reset and attempt
start-up
Turn handle to proper position
Check for 12 VDC at voltage regulator
(10) and (12)
Reset circuit breaker. If breaker trips again, check vessel wiring.
Check continuity
Test and/or replace
Test and/or replace
Check for open or shorted diode
(a good diode has high resistance one way and low resistance the other way, when tested with
ohmmeter)
Check continuity
~
Excite (main field) separately
Reference
Section 2, Circuit Protection
Section 9, Wiring Diagrams
Section 3, Wattage Requirement
Section 9, Wiring Diagrams Operation and Installation
Manual - Electrical Connections
Section 9, Wiring Diagrams
Section 9, Wiring Diagrams Vessel Wiring Diagram
Section 9, Wiring Diagrams
Section 7, Main Field (Rotor)
Section 7, Stator
Section 9 Wiring Diagrams Section 7, Circuit Board
Section 9, Wiring Diagrams Section 7, Circuit Board
Section 7, Separate Excitation
Section 7, Voltage Regulator Test
TP-5630 1 O/93 General Troubleshooting 4-11
Problem
Low generator output voltage
High generator output voltage
Possible Cause
Low engine rpm
Set overloaded
Defective main field (rotor)
Defective stator
Defective voltage regulator
Improperly adjusted voltage regulator
Defective voltage regulator
Voltage regulator misadjusted
Open or poor splice connection at
terminals Vl-1 or V4-4 on 1 -phase stator
(regulator sensing); or poor pin
connection at voltage regulator
Corrective Action
Check engine speed using frequency meter
or tachometer. NOTE: Hz x 120/No. of rotor poles = rpm.
(Example: 60 x 120/4 = 1800)
Make sure capacity is not being exceeded
Test and/or replace
Test and/or replace
Test and/or replace
Readjust
Test and/or replace
Readjust
Check continuity
Reference
Section 3, Governor Adjustments
Section 3, Wattage Requirements
Section 7, Main Field (Rotor)
Section 7, Stator
Section 7, Voltage Regulator
Section 7, Voltage Regulator
Section 7, Voltage Regulator
Section 7, Voltage Regulator
Section 7, Stator
4-l 2 General Troubleshooting TP-5630 1 O/93
Section 5. Controller Troubleshooting Sequence of Operation (E-239563 Circuit Board)
The following test is the controller sequence of operation
when starting, running, stopping, or during fault shutdown
of the set. Use this section as a starting point for controller
fault identification. Refer to Figure 5-1 for the
accompanying wiring schematic. Figure 5-1 illustrates a
1 -phase 4-lead stator. The 3-phase generator is identical
but uses a 12-lead stator. See Legend for symbol
descriptions.
Starting
Close start/stop switch between N and 47 (local or
remote starting).
K2 relay is energized (LED2 lights).
Normally open K2 contacts close to energize K3
relay (LED3 lights), K25 (fuel solenoid) relay,
controller hourmeter, and generator armature
exciter field.
K3 relay normally open contacts close to energize
K20 (starter) relay. K20 relay normally open
contacts close to energize S relay (starter solenoid).
S relay normally open contacts close to energize
starter motor.
K25 normally open contacts close to energize fuel
solenoid.
Normally closed LOP contacts open.
Running
When proper output is obtained from stator main
field windings Bl/B2, Kl relay is energized (LED1
lights). After a 5-10 second time delay, K5 relay is
energized (LED5 lights).
NOTE
Voltage to the Kl relay and K5 relay are rectified and
regulated at 12 volts DC by bridge rectifier BRl and
voltage regulator VR1 .
LED5 .r*
T&50 ’ ARMATURE TB-6 0 1
Figure 5-1. Sequence of Operation, l-Phase
TP-5630 1 O/93 Controller Troubleshooting
Stator winding Vl-V4 provides voltage sensing
source to the voltage regulator VR2 (PBV).
Normally open Kl (A) contacts close to maintain
voltage to K2 relay (LED2 remains lit).
Normally open K2 contacts remain closed to
maintain voltage to fuel solenoid and controller
hourmeter.
Normally open Kl (B) contacts close to energize the
(optional) oil pressure, coolant temperature, battery
voltmeter, and hourmeter gauges and generator
“ON” light.
Normally open K5 contacts close to permit high
water temperature (HWT), high exhaust
temperature (HET), and low oil pressure (LOP)
switches to function.
NOTE
Low oil pressure (LOP) switch contacts open when
engine develops proper oil pressure.
One set of normally closed Ki (C) contacts open to
disconnect circuit to (+) connection of exciter fields
(field flashing).
A set of normally closed Ki (E) contacts open to
disconnect circuit to (-) connection of exciter field
(field flashing). Normally closed Ki (D) contacts
open to deenergize K3 relay (LED3 goes out) and
prevents accidental reenergizing of starter motor.
K3 contacts open to deenergize K20 relay. K20
contacts open to deenergize S relay. S contacts
open to deenergize starter motor.
When the unit is running, start switch contacts N and
47 are opened by releasing start/stop rocker switch.
Stopping
Close start/stop switch between N and 43 (local or
remote).
K4 relay is energized (LED4 lights).
Normally closed K4 contacts open to deenergize
K25 relay. K25 normally open contacts open to
deenergize fuel solenoid.
Normally open K4 contacts close to maintain ground
to K4 relay.
As unit is shutting down, Ki relay is deenergized
(LED1 goes out). Normally open Kl (A) contacts
open to deenergize K2 relay (LED2 goes out).
Normally closed K2 contacts close to ground circuit
to K4 relay until unit comes to a complete stop.
Controller Troubleshooting
rL K2
1 K4 i
L-
TB-50 ’
TE60 j
ARMATURE
l-940
Figure 5-l. Sequence of Operation, l-Phase
(Continued)
TP-5630 1 O/S3
A
ALT
BRl
BV
D
FS
GRD
HET
HWT
HR
HXT
Kl
K2
K3
Ampere Rating
Battery Charging Alternator
Bridge Rectifier (Supply Voltage)
Battery Voltmeter
Diode
Fuel Solenoid
Ground
High Exhaust Temperature Switch
High Water Temperature Switch
Hourmeter
High Exhaust Temperature Switch
AC Crank Disconnect Relay (Circuit Board)
Engine Run Relay (Circuit Board)
Engine Crank Control Relay (Circuit Board)
Legend
K4
K5
K20
K25
LED
LOP
M
OP
Qi
Q2
S
SDR
VRl
VR2
WT
Fault Shutdown Relay (Circuit Board)
Fault Shutdown Time Delay Relay
(Circuit Board)
Starter Relay/Solenoid
Fuel Solenoid Relay
Light Emitting Diode
Low Oil Pressure Switch
Starter Motor
Oil Pressure Gauge
Thyristor
SCR (Silicone Controlled Rectifier)
Starter Relay
Overspeed Shutdown Relay
Voltage Regulator
Voltage Regulator PBV
Water Temperature Gauge
Engine Safety Shutdown Switches
Low Oil Pressure (LOP) Shutdown Switch
l When low oil pressure is encountered, LOP
shutdown switch contacts close and energize K4
relay (LED4 lights).
NOTE
During cranking low oil pressure shutdown switch is
deactivated until K5 relay is energized. This allows
the engine to reach normal operating oil pressure.
Normally closed LOP contacts open when unit
develops adequate oil pressure.
l Normally closed K4 contacts open to deenergize
K25 relay. K25 normally open contacts open to
deenergize fuel solenoid.
l Normally open K4 contacts close to maintain ground
to K4 relay.
l As unit is shutting down, Ki relay is deenergized
(LED1 goes out). Normally open Kl (A) contacts
open to deenergize K2 relay (LED2 goes out).
Normally closed K2 contacts close to ground circuit
to K4 relay until unit comes to a complete stop.
High Water Temperature (HWT) and High Exhaust Temperature (HET)
Shutdown Switch
l When high temperature is encountered at one (or
both) of these sources, the shutdown switch
contacts close and energize K4 relay (LED4 lights).
TP-5630 1 O/93
Normally closed K4 contacts open to deenergize
K25 relay. K25 normally open contacts open to
deenergize fuel solenoid.
Normally open K4 contacts close to maintain ground
to K4 relay.
As unit is shutting down, Kl relay is deenergized
(LED1 goes out). Normally open Kl (A) contacts
open to deenergize K2 relay (LED2 goes out).
Normally closed K2 contacts close to ground circuit
to K4 relay until unit comes to a complete stop.
Overspeed Safety Shutdown (SDR)
When engine speed exceeds 70 Hz (2100 rpm),
shutdown relay (SDR) on overspeed protection
circuit board is energized. Normally open SDR
contacts close to complete circuit and energize K4
relay (LED4 lights).
Normally closed K4 contacts open to deenergize
K25 relay. K25 normally open contacts open to
deenergize fuel solenoid.
Normally open K4 contacts close to maintain ground
to K4 relay.
As unit is shutting down, Ki relay is deenergized
(LED1 goes out). Normally open Kl (A) contacts
open to deenergize K2 relay (LED2 goes out).
Normally closed K2 contacts close to ground circuit
to K4 relay until unit comes to a complete stop.
Controller Troubleshooting 5-3
Section 6. Generator/Controller Troubleshooting
The flow chart is a guide to troubleshoot the generator set the beginning of this manual. Additional safety
including the controller circuit board. Before beginning the precautions are included with the tests; DO NOT
troubleshooting procedures, read all safety precautions at NEGLECTTHESE PRECAUTIONS.
Controller Circuit Board
The controller circuit board is equipped with LEDs (light
emitting diodes) to indicate the presence of relay coil
power and to aid in circuit board and generator fault
detection. See Figure 6-I.
When Kl , K2, K3, K4, or K5 relays are receiving power, the
corresponding LED will light. The LED does not indicate
whether the relay coil is energized. This conclusion can
only be reached through deductive analysis of generator
faults and by performing a continuity test on the relay coil (see Section 7, Controller Circuit Board).
Use the following flow chart as an aid in troubleshooting the generator set. If the prescribed remedy does not correct the problem, the circuit board may have to be replaced.
Where a check or test is referenced, go to that appropriate part of Section 7, Component Testing and Adjustment for detailed instructions.
TP-5630 1 O/93 GeneratorKontoller Troubleshooting 6-1
0
LED3
30
E-239563
Dll
R Pl-9
PI -1
P2-1
PI -a K4C
4x1 5 h
,r DIO
P2-3 KlB
31, 2 &KID I I ,-
Pl -5 D7
4$C 2 DE
R Ih R
D4 PI-12 u
n
PI-3
7q’A 6
+i
PI-15
I
P2-2
,LD2 3 -- K5B
1 Pl-13
,L Dl
K4B 21, 3
D4 u Pi-7
I I
D6 Pl-10
R K2E
7y, 5 P2-8 Ih
P2-5
PI-2
P2-6
P2-9
KiE 5yl7
n
P2-4
P2-7
P1-6
VI v GRD
,L D3 Ri
5
cz K5A 2
,L LED5 b
1 KIA
7: Cl R2 Fi3
Ql 8 yQ2
R4 \r -4 c2 R5
R6
LED1
Figure 6-1. Controller Circuit Board E-239563
6-2 Generator/Controller Troubleshooting TP-5630 10193
GENERATOR/CONTROLLER TROUBLESHOOTING
Press start switch (Local or remote)
b Yes GotoA l (next page)
No
Lrl No
T - Is K2 relay LED lit? b Yes
I
I I
I
r
Is K2 relay functioning properly?
I - Check condition/
connections of start/stop switch (N, 43, and 47).
- Check battery condition and connections.
- Check connections at PI-14.
- Do all check okay?
0
K3 relay or Kl relay faulty. Replace circuit board
Is voltage present at K20 relay coil?
I No I Yes
Is K3 relay functioning properly?
Q No
e
&-’ 1 0 Yes
Replace circuit board
Jr
Is voltage present at No c functioning S relay contact
(starter motor side)?
Replace K20 relay
Replace S relay Replace starter motor
TP-5630 1 O/93 Generator/Contoller Troubleshooting 6-3
GENERATOR/CONTROLLER TROUBLESHOOTING (Cont’d.)
Does engine start?
No
Lrl No l
11
Is 12 Volts DC . present at
fuel solenoid? (check wiring)
, Yes
Is 10 Amp. fuse okay?
- Check Pl-8 connection - Check P4-14 connection - Replace circuit board
(K2 relay defective)
6-4 Generator/Controller Troubleshooting TP-5630 10193
GENERATOR/CONTROLLER TROUBLESHOOTING (Cont’d.)
B+ Does engine continue to run after start Yes
Can engine be stopped Yes
switch is released? - by using stop switch?
+i
1 1
No GENERATOR SET
No CHECKS OUT OKAY I
I I
4 Yes Does Ki relay LED liaht?
I
?l Yes
Does K5 relay LED light after 5-10 seconds of ----+ No running time?
I I
Is K25 relay functioning properly?
ti
Yes
No
I
Yes 9 Replace circuit board (K4 relay defective)
No
Do local and remote start/stop switches function properly? No -P
ti Yes
1
I
Yes 0 1 .
Does engine have proper oil pressure? Use a mechanical gauge to verify oressure.
Replace defective No - SDR Circuit Board
Replace defective temperature switch(es> GotoC
; (next page)
TP-5630 1 O/93 GeneratorKontoller Troubleshooting 6-5
GENERATOR TROUBLESHOOTING
Is there AC output when start button Is AC output at Test
C is HELD and unit is Yes proper voltage? voltage
running? (e.g. 120 volts AC) No
regulator
J
No
I
Go to B at the beginning of preceding page
I f r--- ----i
I (OPTIONAL) 1
clr
Is there 12VAC output at Bl/B2 stator winding? No
Test stator, main field (rotor) and exciter/armature
b Yes
L --- ----
7 J
1 Separately excite generator set to determine if other components are defective.
1
Is AC output voltage at spec.? (See Section 7, Separate Excitation)
No
Test stator, main field (rotor), and exciter/armature
4 Yes
Test -l voltage regulator
J
6-6 Generator/Controller Troubleshooting TP-5630 10193
Section 7. Component Testing and Adjustment
This section is a guide for checking generator, controller, manual during all test procedures. Additional safety
and some engine components for improper operation. precautions are included with the tests; OBSERVE
Follow the safety precautions at the beginning of this THESE PRECAUTIONS!
Separate To isolate the cause of no- or low-AC stator output to either
the voltage regulator circuit or the generator components,
separately excite the generator. See Figure 7-l.
The exciter field may be magnetized using an outsider DC
power source (12-volt automotive battery). The separate
excitation test duplicates the role of the voltage regulator in
providing excitation current to the exciter field.
A WARNING
Hazardous voltage. 1 Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards
and electrical enclosures in place.
Excitation Hazardous voltage can cause severe injury or death. Wherever electricity is present, there is the hazard of
electrocution. Take the same precautions with electrical
appliances in your craft that you would observe in your
home. Open main circuit breaker on all power sources
before servicing equipment. Make sure unqualified
persons, especially children, cannot gain access to your
set-keep the compartment door locked or securely
latched at all times. Be sure that generator is properly
grounded. Never touch electrical leads or appliances with
wet hands, when standing in water, or on wet ground as
the chance of electrocution is especially prevalent under
such conditions.
While separately exciting the generator to determine the
presence of a faulty voltage regulator, it is possible to
determine if a running fault exists in the generator
components (exciter, armature, rotor, stator, and rectifier
module).
A generator component that appears good while static
(stationary) may exhibit a running open or short while
dynamic (moving). This fault can be caused by centrifugal
forces acting on the windings while rotating or by insulation
breakdown as temperatures increase.
VOLTAGE D OUTPUT - REGULATOR &
WIRING
NOOUTPUT - SEPARATE - EXCITER CIRCUIT
NOOUTPUT - EXCITATION
& RECTIFIER MODULE
I
ml 111 STATOR
l-940
Figure 7-1. Generator Troubleshooting
TP-5630 1 O/93 Component Testing and Adjustment 7-1
A WARNING
Sulfuric acid in batteries. Can cause severe injury or death.
Use protective goggles and clothes. Can cause
permanent damage to eyes, burn skin, and eat holes
in clothing.
Sulfuric acid in batteries can cause severe injury or
death. Sulfuric acid in battery can cause permanent
damage to eyes, burn skin, and eat holes in clothing.
Always wear splash-proof safety goggles when working
around the battery. If battery electrolyte is splashed in the
eyes or on skin, immediately flush the affected area for 15
minutes with large quantities of clean water. In the case of
eye contact, seek immediate medical aid. Never add acid
to a battery once the battery has been placed in service.
Doing so may result in hazardous spattering of electrolyte.
Explosion can cause severe injury or death. Battery
gases can cause an explosion. Do not smoke or permit
flame or spark to occur near a battery at any time,
particularly when it is being charged. Avoid contacting
terminals with tools, etc. to prevent burns and to prevent
sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
battery. Never connect negative (-) battery cable to
positive (+) connection terminal of starter solenoid. Do not
test battery condition by shorting terminals together or
sparks could ignite battery gases or fuel vapors. Any
compartment containing batteries must be well ventilated
to prevent accumulation of explosive gases. To avoid
sparks, do not disturb battery charger connections while
battery is being charged and always turn charger off
before disconnecting battery connections. When
disconnecting battery, remove negative lead first and
reconnect it last.
1. Disconnect all leads from the voltage regulator. See
Figure 7-2.
V/HZ VOLT
P5-1
000:
I
0000
0000
3 12
70 8
1. LED 1 (1 wut) 2. LED 2 (Output) 3. LED 3 (Sensing)
Figure 7-2. PowerBoostTM V Voltage Regulator
2.
3.
4.
5.
6.
Disconnect P6 (Fl , F2) connector.
Connect separate excitation circuit as shown in
Figure 7-3. (Connect an ammeter and a 10 ampere
fuse in series with Fl .) Note and record the ammeter
reading.
The approximate ammeter reading should be battery
voltage divided by the specified exciter resistance
(cold).
Volts (Battery Voltage)
Ohms (Exciter Resistance)
Amps = (Exciter Current)
Specified values are found in Section IO,
Specifications.
Start engine and check that ammeter remains stable.
An increasing meter reading indicates a shorted
exciter field. A decreasing meter reading to zero, or
unstable reading, suggests a running open in exciter.
If ammeter is stable, proceed to step 6.
Check for AC output across stator leads and compare
to values in Section 10, Specifications. If output
varies considerably from those listed, a faulty stator,
rotor, rectifier module, or armature is likely. Refer to
this section for further information.
7-2 Component Testing and Adjustment TP-5630 10193
7. If AC output is within specifications, the voltage
regulator is probably defective. If there is no generator output during normal operation but output
is available when the set is separately excited, the
voltage regulator is probably defective.
NOTE
Stator Output Voltages (with Separately Excited
Generator) found in Section 10, Specifications-
Generator are based on a battery voltage of 12 volts.
Should actual battery voltage vary (11-14 volts),
resulting values will also vary.
PowerBoost” V Voltage Regulator
Disconnect P6 Connector : : (Fl/F2 leads) before L ; 7 ’ separate excitation.
10 Amp Fuse
Generator Frame
l-940
Figure 7-3. separate txcitatlon r;onnections
Voltage Regulator Test- Powerboost M V
The PowerBoost” V voltage regulator monitors output
voltage magnitude to control current to the generator
exciter field. The voltage regulator has an under-frequency
unloading feature which is referred to as Volts-per-Hz
(V/Hz). To determine if the voltage regulator is functioning
properly, reduce engine speed (Hz) and watch for a
corresponding drop in AC voltage. AC voltage should
remain constant until engine speed drops below 57.5 Hz
(on 60 Hz models) or 47.5 Hz (on 50 Hz models). When
frequency drops below 57.5/47.5 Hz, AC voltage should
decline. To further check the voltage regulator for proper
function, perform the following test to check regulator
output. To test the voltage regulator the following
components will be needed:
l
0
Step-up Transformer, 1:2, 120 to 240 Volts
(1 .O Amp minimum)
Variable Transformer, O-140 Volts
(1 .O Amp minimum)
250 Volt, 100 Watt Lamp
AC Voltmeter 250 Volt (minimum)
1 Amp Fuse
1 SPST Switch, 1 Amp (minimum)
120 Volt AC Plug (200-240 Volt AC Plug optional)
#I 4 AWG Copper Wire (minimum)
TP-5630 1 O/93 Component Testing and Adjustment 7-3
Test Procedure
1. Connect components as shown in Figure 7-4. If a
200-240 volt power source is available, the step-up
transformer is not required.
2. Turn Volts potentiometer (pot.) fully counter-
clockwise.
3. Plug power cord into outlet. Turn power supply on. AC
voltmeter should indicate power supply voltage of
200-240 volts. Lamp should be off. Slowly turn Volts
adjustment pot. clockwise. The lamp should go on. If
the light does not go on, the voltage regulator is
defective and should be replaced.
4. Turn power supply off and disconnect power cord.
1. Voltage Regulator PBV 8. Black Wire 2. 250 Volt, 100 Watt Lamp 9. White Wire 3. AC Voltmeter 250 Volt (Minimum) 10. 100-l 20 VAC 4. Volts Potentiometer 11. 200-240 VAC (Optional) 5. 1:2 Step-Up Transformer 12. LED 3 (Sensing) 6. Single-Pole Single-Throw Switch 13. LED 1 (Input) 7. I-Amp Fuse 14. LED 2 (Output)
Figure 7-4. PowerBoost” V Voltage Regulator Test
7-4 Component Testing and Adjustment TP-5630 10193
Voltage Regulator Adjustment
The PowerBoost N V voltage regulator monitors generator
output to control current flow to the generator field.
PowerBoost” V maintains generator ouput under load
until the generator engine speed drops to a preset level
(factory setting 57.5 Hz on 60 Hz models and 47.5 Hz on
50 Hz models). At this point (under factory settings) the
regulator allows generator voltage and current to drop to a
level sufficient to handle load. When the generator speed
returns to normal (60 Hz or 50 Hz) as load is accepted,
generator output also returns to normal. The voltage
under a variety of load conditions. Under normal
circumstances, no further adjustment is necessary.
However, if the regulator is replaced, has been tampered
with, or voltage/frequency reconnection has been done,
readjust according to the following procedure. Voltage
regulator components are identified in Figures 7-5 and 7-6
and described in the following paragraphs.
NOTE
Figure 7-5 illustrates a 3-phase connection. l-phase
connection is to stator windings 1 (replaces 7) and 4
(replaces 8). See 1 -phase schematic in Section 9, Wiring
regulator is factory set for proper generator operation Diagrams. Remaining connections are identical.
PowerBoost V Voltage Regulator 1
V/HZ VOLTS
LED3 0
Sensing Leads (208-240 Volts nominal)
Main Field (Rotor)
i-l Armature
Bl B21 42 53 6
Stator Windings l-940
Figure 7-5. PowerBoost” V Voltage Regulator-3-Phase Connection
TP-5630 1 O/93 Component Testing and Adjustment 7-5
V/HZ VOLT
$ El 1 I
TB
1. Stability Potentiometer 4. LED 1 2. Volts/Hertz Potentiometer 5. LED 2 3. Voltage Potentiometer 6. LED3
Figure 7-6. PowerBoost” V Adjustments
NOTE The voltage regulator is located in the generator junction
box and is serviceable by removing six screws.
Voltage Adjustment Pot.-Adjusts generator output
within range of 190-270 volts (line-to-line).
Stability Pot.-“ Fine-tunes” regulator to reduce light
flicker.
Volts/Hz-Adjustment determines engine speed (Hz) at
which generator output voltage will begin to drop.
Exciter Field
The exciter field is magnetized by DC voltage from the
battery. When the exciter armature is rotated within the
magnetized exciter field windings, an electrical current
develops within the exciter armature. Test the exciter field
according to the following procedure.
1. Disconnect generator starting battery (negative lead
first). Disconnect exciter leads Fi and F2 at P6
connector.
7-7. The resistance reading for a cold exciter field is
found in Section IO, Specifications. A low reading
indicates an internal short and a high reading
indicates an open winding. Repair or replace exciter
field if ohmmeter readings indicate exciter field is
defective. If resistance test proves inconclusive,
perform a megohmmeter test on field as described in
the next step.
7-6 Component Testing and Adjustment TP-5630 10193
1. With generator set off, turn remote rheostat (if
equipped) to midpoint. Turn Voltage, Volts/Hz, and Stability pots. fully counterclockwise. Connect
voltmeter to AC circuit or an electrical outlet.
2. Start generator set. Rotate voltage adjustment pot. clockwise (increase voltage) or counterclockwise
(decrease voltage) until desired output voltage is
achieved.
3. Rotate stability pot. clockwise until minimum light
flicker is obtained.
4.
5.
Readjust voltage adjustment pot. (if necessary).
Mechanical Governor: Adjust engine speed to desired cut-in frequency
(factory setting 57.558 Hz for 60 Hz models or
47.5-48 Hz for 50 Hz. models) as measured on
frequency meter. See Section 3, Governor.
6. Rotate volts/Hz adjustment pot. clockwise until
voltage level begins to drop (as measured on
voltmeter). When set to these specifications, the
generator will attempt to maintain normal output until
engine speed drops below the frequency set in Step5
(as load is applied).
7. Mechanical Governor: Readjust engine speed to normal (63 Hz/1890 rpm
for 60 Hz or 52.5 Hz/l 575 rpm for 50 Hz). See Section
3, Governor.
8.
9.
10.
Readjust voltage adjustment pot. (if necessary).
Readjust stability pot. (if necessary).
Use remote rheostat (if equipped) to make final
voltage adjustments. STOP GENERATOR SET
Adjustment Procedure
2. Check exciter field resistance by connecting an
ohmmeter across exciter field Fi and F2. See Figure
A WARNING
Hazardous voltage. I Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards
and electrical enclosures in olace.
Hazardous voltage can cause severe injury or death. Wherever electricity is present, there is the hazard of
electrocution. Take the same precautions with electrical
appliances in your craft that you would observe in your
home. Open main circuit breaker on all power sources
before servicing equipment. Make sure unqualified
persons, especially children, cannot gain access to your
set-keep the compartment door locked or securely
latched at all times. Be sure that generator is properly
grounded. Never touch electrical leads or appliances with
wet hands, when standing in water, or on wet ground as
the chance of electrocution is especially prevalent under
such conditions.
PowerBoost N V Voltage Regulator I I
I- Ohmmeter 8 t I I I 8 I El I I I I P O
Disconnect :A,1 P6 Connector I
(Fi /F2 Leads)
3. Check exciter field for a grounded condition. Using a
megohmmeter, apply 500~volts DC to Fl or F2 lead
and exciter field frame. See Figure 7-8. (Follow the
instructions ofthe megohmmeter manufacturerwhen
performing this test.) A reading of approximately
500K ohms (l/2 megohm) and higher indicates the
field winding is good. A reading of less than 500K
ohms (approximately) indicates deterioration of
winding insulation and possible current flow to
ground. Repair or replacement of the exciter field is
necessary.
PowerBoost TH V Voltage Regulator
Disconnect P6 Connector (Fi/F2 Leads
before Testing.
-E l-940
Figure 7-8. Megohmmeter Connections on Exciter Field
Figure 7-7. Checking Exciter Field Resistance
TP-5630 1 O/93 Component Testing and Adjustment 7-7
Exciter Armature
The exciter armature supplies excitation current to the generator main field (through the rectifier module). Test the exciter armature as described in the following steps. The generator must be disassembled prior to performing this test.
1.
2.
With generator disassembled, disconnect armature leads from rectifier module AC terminals.
With an ohmmeter on the R x 1000 scale, check resistance across all three exciter armature leads. See Figure 7-9. The armature resistance is found in Section 10, Specifications. No continuity indicates an open armature winding. If the resistance test proves inconclusive, perform a megohmmeter test on the armature as described in the next step.
NOTE Most ohmmeters will not provide accurate readings when measuring less than one ohm. The exciter armature can be considered good if a low resistance reading is obtained (continuity) and there is no evidence of shorted windings (heat discoloration).
A WARNING
Hazardous voltage. 1 Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards and electrical enclosures in olace.
Hazardous voltage can cause severe injury or death. Wherever electricity is present, there is the hazard of electrocution. Take the same precautions with electrical appliances in your craft that you would observe in your home. Open main circuit breaker on all power sources before servicing equipment. Make sure unqualified persons, especially children, cannot gain access to your set-keep the compartment door locked or securely latched at all times. Be sure that generator is properly grounded. Never touch electrical leads or appliances with wet hands, when standing in water, or on wet ground as the chance of electrocution is especially prevalent under such conditions.
3.
7-8
Check exciter armature for a grounded condition. Using a megohmmeter, apply 500-volts DC to either armature lead and the armature frame. (Follow the
l-940
Figure 7-10. Megohmmeter Connections on Exciter Armature
Component Testing and Adjustment TP-5630 10193
instructions of the megohmmeter manufacturerwhen performing this test.) See Figure 7-10. A reading of approximately 500K ohms (l/2 megohm) and higher indicates the exciter armature is good. A reading of less than 500K ohms (approximately) indicates deterioration of winding insulation and possible current flow to ground. Repair or replacement of the exciter armature is necessary.
Ohmmeter
Windings
Figure 7-9. Exciter Armature Ohmmeter Test
Windings
\ I Shaft
Connection Ohmmeter
-EL
Rectifier Module
The rectifier module (located electrically between exciter
armature and main field) converts the AC from the exciter
armature to DC which magnetizes the generator main
field. Test the rectifier as described in the following steps.
1. Disconnect exciter armature and main field leads
from rectifier module.
2. Using an ohmmeter on the R x 100 scale, check the
resistance of rectifier diodes as shown in Figure 7-11.
To test diode, carefully scrape insulation coating from
diode terminals 1 and 2 and place ohmmeter leads on
terminals 1 and 2. The ohmmeter should show a low
resistance in one direction and, upon reversing the
ohmmeter leads, a higher resistance in the other
direction. Replace the rectifier module if any of the
diodes tests differently than described.
I-940 _ .- .-..- . . 1. urocie lerminal 2. Diode Terminal
Figure 7-11. Testing Rectifier Module
Generator Main Field (Rotor)
The generator main field (magnetized by DC from the Hazardous voltage can cause severe injury or death. rectifier module) rotating within the stator windings Follow instructions of test equipment manufacturer when
induces AC in the stator windings. Test generator main performing high voltage test on rotor or stator. Improper
field as described in the following steps. The generator test procedure can damage equipment or lead to future
must be disassembled prior to performing this test.
A WARNING
-P B!b Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards
and electrical enclosures in place.
generator failures.
1.
2.
With the generator disassembled, disconnect
generator main field (rotor) windings from the rectifier
module terminals F+ and F-.
Check the main field resistance by connecting an
ohmmeter across main field F+ and F- leads. See
Figure 7-12. The resistance reading for a cold main
field is found in Section IO, Specifications. A low
reading indicates an internal short and a high reading
indicates an open winding. Repair or replace main
field if ohmmeter readings indicate main field is
defective. If the resistance test proves inconclusive,
perform a megohmmeter test on the armature as
described in the next step.
TP-5630 1 O/93 Component Testing and Adjustment 7-9
3. Check the main field for a grounded condition. Using
a megohmmeter, apply 500-volts DC to either main
field lead and the main field frame. (Follow the
instructions of the megohmmeter manufacturerwhen
performing this test.) See Figure 7-13. A reading of
approximately 500K ohms (i/2 megohm) and higher
indicates the mainfield is good. A reading of less than
500Kohms (approximately) indicates deterioration of
winding insulation and possible current flow to
ground. Repair or replacement of the main field is
necessary.
Stator
The stator consists of a series of coils of wire laid in a
laminated steel frame. The stator leads supply voltage to
the AC load and the exciter regulator.
Prior to testing, inspect the stator for heat discoloration
and visible damage to housing lead wires, exposed coil
windings, and exposed and varnished areas of frame
laminations. Check that the stator is securely fastened in
the stator housing.
Ohmmeter
__!E!- Figure 7-12. Ohmmeter Connections on Main Field
Megohmmeter
l-940
Figure 7-13. Megohmmeter Connections on Main Field
1.
2.
3.
4.
CHECKING STATOR CONTINUITY AND RESISTANCE
Disconnect generator starting battery (negative
leads first).
Disconnect all stator leads.
Adjust ohmmeter to zero ohms on R x 1 scale. Check
stator continuity by connecting meter leads to stator
leads as shown in Figure 7-14 or 7-15.
There must be continutiy between leads of an
individual winding.
There must be NO continuity between leads of
separate windings.
There must be NO continuity between any
winding lead and ground on the stator housing or
frame laminations.
Contact ohmmeter leads and readjust ohmmeter to
zero ohms. Check cold resistance of stator windings
by connecting meter leads to stator leads of an
individual winding (Bl-B2, Vl-1, l-2, etc.: l-phase;
Bl-82, l-4,2-5, etc.: 3-phase). Typical statorwinding
resistances are shown in Section 10, Specifications.
If the stator resistance test proves inconclusive,
perform a megohmmeter test on stator as described
in the next step.
NOTE Most ohmmeters will not provide accurate readings
when measuring less than one ohm. The stator can
be considered good if a low resistance reading
(continuity) is obtained and there is no evidence of
shorted windings (heat discoloration).
NOTE Since ohmmeters do vary in their accuracy, use data
from Section IO, Specifications-Generator as a
reference for approximate readings. Ohmmeter
readings must be taken at room temperature or about
70” F (21 ‘C).
7-10 Component Testing and Adjustment TP-5630 10193
NOTE Stator resistance will vary directly with increased
temperature.
Should any of the stator readings vary considerably
during the previous checks, the stator must be
repaired or replaced.
A WARNING
-2 vb Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards
and electrical enclosures in place.
7-17. (Follow the instructions of the meghommeter
manufacturerwhen performing this test.) Repeat test
on other leads until all stator windings have been
tested. A reading of approximately 500K ohms (l/2
megohm) and higher indicates the stator is good. A
reading of less than 500K ohms (approximately)
indicates deterioration of winding insulation and
possible current flow to ground. Repair or
replacement of the stator is necessary.
m$-J Vl
W A
6-i 3 4
f
a r-3 55 66
v4
t- B’
_?_
Hazardous voltage can cause severe injury or death. -
Follow instructions of test equipment manufacturer when
performing high voltage test on rotor or stator. Improper
test procedure can damage equipment or lead to future
generator failures. A. Continuity/Resistance Between Points B. No Continuity Between Points C. No Continuity Between Points
l-940
5. Check stator for a grounded condition. Using a NOTE: Perform tests on all statorwindings.
megohmmeter, apply 500-volts DC to any stator lead
from winding and stator frame. See Figure 7-16 or Figure 7-14. Stator Windings, l-Phase
l-940
A. Continuity/Resistance Between Points B. No Continuity Between Points C. No Continuity Between Points
NOTE: Perform tests on all stator windings.
Figure 7-15. Stator Windings, 3-Phase
TP-5630 1 O/93 Component Testing and Adjustment 7-11
PowerBoost V Voltage Regulator
LED1 0 LED2 0
lol a
V/HZ VOLTS
LED3 0
Voltage Regulator Power
Main Field (Rotor)
Armature
Sensing Leads (208-240 Vqlts nominal)
Rectifier U I Module
’ 1 Stator Windings
Figure 7-16. Megohmmeter Connections on Stator, l-Phase
7-l 2 Component Testing and Adjustment TP-5630 1 O/93
F2
LED3 0
Exciter Field
PowerBoost V Voltage Regulator
V/HZ VOLTS
Sensing Leads (208-240 Vtts nominal)
Voltage Regulator Power
Supply Leads
Stator Windings
Main Field (Rotor)
MoaU’e LF%zFFr Armature Bl B21 4 2 53
Stator Windings
Megohmmeter
12;11 Connection
P 9 U
6
l-940
Figure 7-17. Megohmmeter Connections on Stator, 3-Phase
TP-5630 1 O/93 Component Testing and Adjustment 7-l 3
Controller Circuit Board
It is possible to check some controller circuit board the manufacturer’s instructions. To obtain accurate
components (relays) without removing the component readings when testing, remove all circuit board connectors
from the board. These checks should be made prior to and conformal coating (transparent insulation) from
installing a new board and attempting start-up. Most of the component terminals. Use the following chart and see the
tests are referenced in Section 4, General controller circuit board schematic on the following pages.
Troubleshooting. Use a high quality multimeter and follow
E-239563 Circuit Board
Component
Kl Relay Coil
Ohmmeter Connections
Kl coil terminals (See relay schematic)
Remarks
Ohmmeter on RxlOscale
Results
If good-approx. 160 ohms. Low resistance (continuity)- shorted coil. High resistance-open coil.
K2 Relay Coil K2 coil terminals Ohmmeter on (See relay schematic) RxlOscale
If good-approx. 160 ohms. Low resistance (continuity)- shorted coil. High resistance-open coil.
K3 Relay Coil K3 coil terminals (See relay schematic)
Ohmmeter on Rx loscale
If good-approx. 400 ohms. Low resistance (continuity)- shorted coil. High resistance-open coil.
K4 Relay Coil K4 coil terminals (See relay schematic)
Ohmmeter on RxiOscale
If good-approx. 125 ohms. Low resistance (continuity)- shorted coil. High resistance-open coil.
K5 Relay Coil K5 coil terminals (See relay schematic)
Ohmmeter on RxiOscale
If good-approx. 510 ohms. Low resistance (continuity)- shorted coil. High resistance-open coil.
7-14 Component Testing and Adjustment TP-5630 10193
P2
l5.l
PCB ASSY 0 0 E-23%63
000 OQQ
r
E-239563
Dll
R Pl-9
Pl-6 K4C
4Ul 5 h
KlB P2-3
311-2----
D4 Pl-12 u
DlO
KlD
Pl-15
xD* 3__ K5B
1 Pl -13
,L Di
K4B 211 3
D4 u Pl-7
I 1
D6 Pl-10
R K2E
7x1 5 P2-6 Ih
P2-5
Pi-2
P2-6
P2-9
P2-4
KlE 5yl7 P2-7
Pl-3
VRl
VI v GRD
,L D3 Rl
5
Pi-6 CI K5A
2 ,L LED5
:) R6
:: 1 KlA
-4 Cl R2 R3
Ql ;rcctz 6 ,L LED1
h t
R4 7: C2 R5
Y-51 79
TP-5630 1 O/93 Component Testing and Adjustment 7-15
Figure 7-18. Controller Circuit Board Testing
Engine/Generator Components
With the generator set battery connected, the wiring each component using a DC voltmeter. This will verify that
harness and some engine/generator components can be the switches function and 12 volts DC is present at each
checked. Place the controller or remote start/stop switch component.
in the prescribed position and check for 12 volts DC at
Component Voltmeter Connections Remarks Results
Hourmeter and wiring
Red test clip to (+) Voltmeter setting 12-volts If good-12-volts DC terminal. Black test clip DC reading indicates or greater. To determine if to (-) terminal. Place wiring harness is okay. hourmeter is good, proceed controller or remote switch to next step. in START position.
None (see Remarks) Disconnect hourmeter leads and apply 12-volts DC to hourmeter.
If good-hourmeter will operate.
NOTE: Hourmeter is polarity sensitive.
Bl and B2 stator auxiliary winding
Disconnect Bl/B2 leads. Voltmeter setting 20- Reading of 12-l 5 volts Connect AC voltmeter volts AC or greater. indicates Bl/B2 winding to leads. Start generator set is good. NOTE: Voltage can only and allow to reach be measured momentarily proper speed. since unit will not continue to run after start switch is released. STOP generator.
Fuel solenoid Red test clip to red lead of solenoid and black test clip to engine block (ground). Place controller switch to START position. STOP generator set.
Voltmeter setting 12 volts If good-12-volts DC or greater. If lead can not reading indicates wiring is be disconnected, cut leads okay. and crimp on fully insulated push-on terminals. To determine if fuel solenoid is good, proceed to next step.
None (see Remarks) Disconnect red and white leads at push-on terminals. Apply 12-volts DC to red lead and momentarily apply 12- volts DC to white lead. NOTE: Apply voltage only momentarily to
If good-fuel solenoid plunger will energize when voltage is applied to white lead and remain held in after white lead is disconnected as long as red lead has voltage applied to it.
white lead to prevent fuel solenoid damage. This coil draws 50 amps and is intended only to pull in solenoid.
7-16 Component Testing and Adjustment TP-5630 1 O/93
K20
FS
SiRD
HET
HR
HWT
K25
LOP
M s
Legend
Starter Relay/ Solenoid Fuel Solenoid
Ground
High Exhaust Temp.
Shutdown Switch
Hourmeter
High Water Temp.
Shutdown Switch
Fuel Solenoid Relay Low Oil Pressure Shutdown Switch Starter Motor Starter Relay
K25 I I
7nA I
71A
I K20 FP
Electrical Contacts
Actuator
HET
- LOP
Start
B2_ - I
Rocker Switch Electrical Contacts and Actuator Positions
NOTE Rocker switch closed electrical contacts are opposite from rocker switch actuated position.
LJ Exciter
Figure 7-19. Wiring Harness Connections with E-239563 Circuit Board
TP-5630 1 O/93 Component Testing and Adjustment 7-l 7
Component
Controller switch
K20 relay coil and wiring
K25 relay coil and wiring
Starter solenoid (S relay)
Controller 1 O- amp circuit breaker and wiring
Exciter field windings
Exciter armature windings
Main field (rotor)
Ohmmeter Connections
P2-6 and P2-4
P2-6 and P2-5
Pl-4 and Pl-9
Pl-8 and Pi-9
P4-22 and battery (+) cable. NOTE: J4 and P4 must be disconnected to perform this test.
Battery positive (+) cable and PI-14 NOTE: J4 and P4 must be connected to perform this test.
P7 (FP/FN) NOTE: Disconnect P7 connector for this test.
Disconnect armature leads from rectifier. Connect ohmmeter to two armature leads. Repeat test on third lead.
Disconnect rotor F+ and F- leads from rectifier. Connect ohmmeter to F+ and F- leads.
7-18 Component Testing and Adjustment
Remarks
Ohmmeter on R x 1000 scale. Place rocker switch in START position.
Ohmmeter on R x 1000 scale. Place rocker switch in STOP position.
Ohmmeter on R x 1 scale
Ohmmeter on R x 1 scale
Ohmmeter on R x 1 scale
Ohmmeter on R x 1000 scale
Ohmmeter on R x 1 scale. Disconnect exciter field leads to voltage regulator at P6.
Ohmmeter on R x 1 scale
Ohmmeter on R x 1 scale
Results
If good-zero ohms (continuity). Any resistance other than zero or very low ohms- replace switch.
If good-zero ohms (continuity). Any resistance other than zero or very low ohms- replace switch.
If good-85 ohms. Low resistance-shorted C relay coil and/or wiring. High resistance-open C relay and/or wiring.
If good-400 ohms. Low resistance-shorted K25 relay coil and/or wiring. High resistance-open K25 relay and/or wiring.
If good-approx. 0.5-0.6 ohms at 805°F (275°C).
If good-zero or very low ohms. No reading (infinity)-open circuit or circuit breaker tripped.
If good-see Section 10, Specifications. Low resistance- excitershorted. High resistance-exciteropen.
If good-see Section 10, Specifications. Low resistance-armature windings shorted. High resistance-armature windings open.
If good-See Section IO, Specifications. Low resistance-rotor windings shorted. High resistance-rotor windings open.
TP-5630 1 O/93
Component
Bl /B2 stator windings
Ohmmeter Connections
P8-4 and P8-5 NOTE: P8 and J8 must be disconnected to perform this test.
Remarks Results
Ohmmeter on R x 1 scale If good-see Section 10, Specifications. Low resistance-Bl/B2 windings shorted. High resistance-Bl/B2 windings open.
Pl ground connection
,Pl-9 and ground Ohmmeter on R x 1 scale If good-zero ohms (continuity). Any other reading indicates a poor ground connection.
Low oil pressure (LOP) safety shutdown switch
High exhaust temperature (HET), high water temperature (HWT) safety shutdown switches
Pl -15 and engine Ohmmeter on R x If good-zero ohms block (ground) 1000 scale. (continuity). Then, NOTE: J4 and P4 must This test is not disconnect LOP switch lead be connected to conclusive until the and isolate terminal. Meter perform this test. temperature shutdown reading should show
switches are checked. an open circuit.
Pi -15 and engine Ohmmeter on R x 1000 If good-open circuit. block (ground) scale Any continuity suggests NOTE: LOP switch that temperature switch(es) lead should be removed are defective. Disconnect and isolated. individual leads to determine NOTE: J4 and P4 must which switch is defective. be connected to perform this test.
Fuel Solenoid Current (amps) and resistance readings are shown in
Figure 7-20. Resistance readings can be taken to
The fuel solenoid serves to pull the injector pump lever to determine if the solenoid windings are open or shorted.
the “fuel on”position when energized. The fuel solenoid is These tests must be made with fuel solenoid disconnected
spring loaded to return the injector-pump lever to the “fuel from engine wiring harness.
off” position when de-energized.
The generators use a three-lead fuel solenoid. This
solenoid has a white lead (P) which energizes the “pull-in”
coil only during cranking. During operation the red lead
energizes the “hold”coil and the black lead is the common
ground. Figure 7-20. Fuel Solenoid Readings
TP-5630 1 O/93 Component Testing and Adjustment 7-19
In addition to the ohmmeter test, check for smooth,
non-binding movement of plunger. It is important that the Fuel Pump
linkage between the fuel solenoid and the fuel injection
pump lever be properly adjusted to allow the solenoid The fuel pump transfers fuel from a source to the injection
plunger to fully compress. Improper adjustment may
pump
’
cause burn-out of the “pull-in” coil. lf the fuel solenoid is The fuel pump can be tested using the following
removed or the setting is suspected to be incorrect, use procedure. the following procedure and see Figure 7-21.
1. Remove linkage to allow fuel solenoid plunger to be
manually compressed.
2. With fuel solenoid fully compressed, align linkage
and check injection pump lever for travel. Fuel
solenoid should fully compress and injection pump
lever should be 0.05 in. (1.6 mm) before lever
contacts (internal full open) stop.
NOTE
Fuel solenoid must compress (bottom) fully or
burn-out of fuel solenoid “pull-in” coil will occur.
3. If alignment is not correct, check linkage and
mounting brackets. Loosen locknuts and adjust ball
joint length in or out to attain proper alignment.
Tighten locknut.
1. Fuel Solenoid 2. Ball Joints 3. Locknuts
Figure 7-21. Fuel Solenoid Linkage
1. Remove the two leads at the bottom of the fuel pump.
The pump terminals are labeled (-) and (+). See
Figure 7-22.
2. Connect inlet side of pump to a fuel source.
Disconnect outlet hose from fuel filter and place hose
end in a container to catch fuel.
3. Connect positive (+) terminal of 12 V battery to
positive terminal of fuel pump. Connect negative
terminal of fuel pump to negative (-) terminal of
battery. You should hear pump operate and see fuel
discharged from pump outlet. If pump does not
operate, replace pump.
1. Negative terminal 2. Positive Terminal 3. Fuel Inlet 4. Fuel Outlet
Figure 7-22. Fuel Pump
7-20 Component Testing and Adjustment TP-5630 1 O/93
Section 8. Disassembly/Reassembly Disconnect all external connections-battery cables at
battery (negative lead first), AC-output leads in controller,
remote start panel at controller P3 connector, water line at
sea-water pump, fuel line at fuel pump filter inlet, and
exhaust line at mixing elbow. Observe all safety
precautions listed during the disassembly/reassembly
procedures.
NOTE
Several models are covered in this manual, and the
procedure for disassembly may vary due to product
updates and assembly variations.
NOTE
The voltage regulator is located in the controller box.
Remove controller cover to service voltage regulator.
Adjustments are possible without removing the voltage
regulator from the controller.
NOTE
HARDWARE DAMAGE! Engine and generator make use
of both SAE and metric hardware. Be sure to use correct
size tools to prevent rounding of bolt heads and nuts.
A WARNING
Hazardous voltage. 1 Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards
and electrical enclosures in place.
Hazardous voltage can cause severe injury or death.
The heat sink of the voltage regulator contains high
voltage. Do not touch voltage regulator heat sink when
testing or electrical shock will occur.
(PowerBoost, PowerBoost Ill, and PowerBoost V Voltage
Regulator Models only.)
Disassembly 1. Remove end panel from generator end of unit.
Loosen four screws and lift off cover. See Figure 8-l
2. Disconnect P4 (22-pin) connector from J4. Remove
bolt to disconnect ground strap. Disconnect P8, P7,
and P6 connectors. See Figure 8-2.
1. Generator End Panel 2. Controller Cover
Figure 8-1. Covers
TP-5630 1 O/93
1, P4 (22-Pin) Connector 2. Ground Strap 3. P7 (2-Pin) Connector 4. P6 (2-Pin) Connector 5. P8 (6-Pin) Connector
Figure 8-2. Connectors
Disassembly/Reassembly 8-l
NOTE
Output leads can be connected in various positions
for different volt configurations. Mark leads for proper
reconnection.
3. Disconnect the generator output leads from circuit
breaker and neutral stud (LO). Remove four controller
mount locknuts. See Figure 8-3. Lift controller from
rubber mounts while guiding leads through bottom
hole of controller box.
1. Controller Mount Locknut 2. Neutral Stud (LO)
Figure 8-3. Removing Controller
4. Remove tie wraps from wire harness as necessary.
Remove four bolts to remove exciter field. See Figure
8-4.
Figure 8-4. Removing Exciter Field
5. Remove three bolts and spacers from rectifier board.
Disconnect main field (rotor) leads from rectifier
board positive/negative terminals. Remove bolt and
washer. Remove armature from shaft, guiding main
field (rotor) leads through armature bores. See
Figure 8-5.
1. Armature Retaining Bolt 2. Armature 3. Rectifier Board 4. Rotor Leads
Figure 8-5. Removing Armature
6. Remove two vibromount bolts. Raise generator end
and place wood block under locator plate. Lower
generator until locator plate is supported by wood
block. Remove four overbolts from end bracket. See
Figure 8-6.
NOTE Hoist capcity should be rated one-half ton or greater.
1. Locator Plate 2. Wood Block 3. Vibromount Bolts 4. Overbolts
Figure 8-6. Supporting Generator
8-2 Disassembly/Reassembly TP-5630 1 O/93
7. Remove two bolts and starter cover.
Figure 8-7. Removing Stator Cover
8. Install sling centered on stator housing. Use two-jaw
puller to pull end bracket/stator assembly from
bearing on main field (rotor) shaft. See Figure 8-7.
(End bracket can separate from stator during
removal.) Remove stator assembly from main field.
Figure 8-8. Removing Stator Assembly
TP-5630 10193
9. Remove eight metric bolts to remove drive disc/rotor
assembly from flywheel. See Figure 8-9.
1. Drive Discs (Two Used) 2. Main Field (Rotor)
Figure 8-9. Removing Main Field (Rotor)
10. Clamp rotor in a soft-jaw vise. Remove eight bolts
and remove drive discs from rotor. See Figure 8-10.
Figure 8-10. Removing Drive Discs
Disassembly/Reassembly 8-3
11. Remove eight slot-head bolts. Remove the fan and
four bolt spacers.
1.
2.
3.
Figure 8-11. Removing Fan
Reassembly
Apply Loctite 271 to threads of eight slot-head bolts
and install fan and four bolt spacers.
Clamp main field (rotor) in a soft-jaw vise. Install two
drive discs and tighten eight bolts to 30 ft. tbs. (40
Nm).
Install rotor/drive disc assembly on flywheel using
eight bolts and washers. Tighten bolts to 20 ft. Ibs. (27
Nm). Use a strap wrench to prevent rotor from
Figure 8-12. Installing Main Field (Rotor) 5. Install starter cover on stator housing using two bolts.
6-4 Disassembly/Reassembly TP-5630 1 O/93
4. Inspect O-ring in end bracket bearing bore and
replace O-ring if damaged. Use a sling to support
stator assembly while installing over rotor. Be careful
not to damage rotor. Check that alignment marks on
end frame and stator as well as stator and locator
plate are aligned. See Figure 8-13. Install four
overbolts and tighten to 30 ft. Ibs. (40 Nm).
1. End Frame/Stator Alignment Marks 2. Stator/Locator Plate Alignment Marks
Figure 8-13. Installing Stator
6. Use hoist to raise generator end. Remove wood block under locator plate. Lower generator and install bolt, large washer, three small washers (one at locknut), and locknut in each vibromount. Tighten mount bolts to 20 ft. Ibs. (28 N.m).
7. Apply anti-seize compound to keyed end of rotor shaft. Bring rotor leads through bores in armature while installing armature on shaft. Check keyway of shaft and key of armature for damage. Install armature retaining bolt and washer.
8. Install rotor leads to rectifier board at positive and negative terminals using screws and lockwashers.
NOTE Position lockwashers against rectifier board.
9. Install three spacers and bolts to mount rectifier board to armature.
10. Install exciter field using four bolts and washers. Field leads are at top.
11. Install tie wraps to secure wires as necessary.
12. Bring output leads through bottom of controller box. Check that grommet is intact and there are no sharp
edges exposed that could damage wiring. Install box on rubber mounts and install four locknuts. Connect leads to circuit breaker and neutral stud (LO) as marked during disassembly.
NOTE Generator set nameplate can be checked to verify original voltage configuration. See Section 9, Wiring Diagrams for more information regarding voltage reconnection.
13. Connect P4 (22-pin), P6, P7, and P8 connectors. Connect ground strap using bolt, washer, and lockwasher (install lockwasher against ground strap).
14. Install controller cover.
15. Install end panel with louvered openings down.
16. Reconnect all external connections-exhaust line to mixing elbow, fuel line to fuel pump filter inlet, water line to sea-water pump, remote start panel to controller P3 connector, AC output leads in controller, and battery cables to battery (negative lead last).
17. Open seacock and fuel valve.
TP-5630 10193 Disassembly/Reassembly 8-5
Section 9. Wiring Diagrams
2-Wire Generator Sets
Electra Switch
3-Wire Generator Sets
To Load
Ll
To Generator 6
To Load
Kraus NaimletYAmerican Solenoid (Early Rectangular Design)
P-Wire Generator Sets 3-Wire Generator Sets
To Load
To Load
Kraus NaimetYAmerican Solenoid (Newer Round Design)
2-Wire Generator Sets 3-Wire Generator Sets
To Generator
To Load
To Load TP-5399-5
Figure 9-l. Marine Manual (Ship-to-Shore) Transfer Switch
TP-5630 1 O/93 Wiring Diagrams 9-l
9-2 Wiring Diagrams
This Page Intentionally Left Blank.
TP-5630 10193
Kraus NaimetVAmerican Solenoid
4-Wire, three phase Generator Sets
To Generator Set
Ll L2 L3 LO
To Load
t-940
Figure 9-2. Manual (Ship-to-Shore) Transfer Switch
TP-5630 10193 Wiring Diagrams 9-3
12 YOCT SCHEMATIC
LEGEND
229073-D
Figure 9-3. Wiring Diagram-Schematic (13.5/l 8.!$21 CCOZ and 11/l 5/l 6.5CCFOZ) (Equipped with A-258296 Voltage Regulator)
9-4 Wiring Diagrams TP-5630 1 O/93
NOTE : CONNECTOR SHOWN FROM
PIN INSERTION END.
REMOTE PANEL
SACK VIEW OF PANEL (2 AND 4 GAUGE REMOTE PANEL)
GENERATOR CONNECTIONS
FOR VOLT - RECONNECTABLE CONFIGURATIONS-SEE ADV-5857
229073-D
Figure 9-4. Wiring Diagram-Point-to-Point Wiring (13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ) (Equipped with A-258296 Voltage Regulator)
TP-5630 1 O/93 Wiring Diagrams 9-5
lP”OLT SCHEMATIC
LEGEND
AH -AIR HEATER RELAY BV - BA-ITERY VOLT METER FP - FUEL PUMP FS - FUEL SOLENOID HR - HOUR METER Kl -AC CRANK DISCONNECT RELAY K2- ENGINE RUN RELAY K3 - ENGINE CRANK RELAY K4 - FAULT SHUTDOWN RELAY K5 - FAULT SHUTDOWN TIME DELAY RELAY K20 - STARTER RELAY/SOLENOID K25 - FUEL SOLENOID RELAY M - STARTER MOTOR OP - OIL PRESSURE GAUGE OPS - OIL PRESSURE SENDER S - STARTER RELAY SDR - OVERSPEED SHUTDOWN RELAY TDR - TIME DELAY RELAY VRl -VOLTAGE REGULATOR WT- WATER TEMPERATURE GAUGE WTS - WATER TEMPERATURE SENDER -OPTIONAL
229937-D
Figure 9-5. Wiring Diagram-Schematic (13.5/18.5/21 CC02 and II/l 5/l 6.5/l BCCFOZ) (Equipped with B-258296 Voltage Regulator)
Q-6 Wiring Diagrams TP-5630 1 O/93
VOLTAGE REGULATOR (POWER BOOST 5)
REMOTE PANEL
BACK VIEW OF PANEL
NOTE : CONNECTOR SHOWN FROM PIN INSERTION END.
CONTROLLER
P7
IIT Y LYY
2 P
SEE GENERATOR CONNECTIONS
FOR VOLT- RECONNECTABLE
CONFIGURATIONS - SEEADV-5857
229937-D
Figure 9-6. Wiring Diagram-Point-to-Point Wiring (13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ) (Equipped with B-258296 Voltage Regulator)
TP-5630 1 O/93 Wiring Diagrams 9-7
12 “OLi SCHEMATIC
I - “4 1 vo+-J P4 -6 L
Figure 9-7. Wiring Diagram-Schematic (14/20/24CCOZ and 11.5/17.5/2OCCFOZ) (Equipped with A-258296 Voltage Regulator)
9-8 Wiring Diagrams TP-5630 1 O/93
J3
-_-
I I M I I I”
225652-D
Figure 9-8. Wiring Diagram-Point-to-Point Wiring (14/20/24CCOZ and 11.5/17.5/2OCCFOZ) (Equipped with A-258296 Voltage Regulator)
TP-5630 1 O/93 Wiring Diagrams 9-9
12 “OLT SCHEMATIC
I s *Ill/ _ I r
229938-D
Figure 9-9. Wiring Diagram-Schematic (14/20/24CCOZ and 11.5/17.5/2OCCFOZ) (Equipped with B-258296 Voltage Regulator)
9-10 Wiring Diagrams TP-5630 1 O/93
NOTE : CONNECTOR SHOWN FROM PIN INSERTION END.
REMOTE PANEL
BACK VIEW OF PANEL (2AND 4 GAUGE REMOTE PANEL)
VOLTAGE REGULATOR
( POWER BOOST 5)
I
GENERATOR CONNECTIONS
229938-D
Figure 9-10. Wiring Diagram-Point-to-Point Wiring (14/20/24CCOZ an! 11.5/17.5/2OCCFOZ) (Equipped with B-258296 Voltage Regulator)
TP-5630 10193 Wiring Diagrams 9-11
TP-5592/TP-5630
12 VOLT SCHEMATIC
I +! I I !
13.5CCOZ,18.5CCOZ, and 21 CCOZ Wiring Diagram-Schematic (Specs: PA-1 26136, PA-1 26137, and PA-1 26138)
11194
TP-5592/TP-5630
CUSTOMER SUPPLIED WIRING CONTROu.ER
13.5CCOZ,18.5CCOZ, and 21 CC02 Wiring Diagram-Point-to-Point (Specs: PA-1 26136, PA-1 26137, and PA-1 26138)
11194
7 LED3
50
n E-239563
PI-9
PI-1
P2-1
__I_/ P2-3
KIB 31, 2
, I
PI-5 D7
4vyc 2 D8
R Ih R
D4 PI-12 u I
PI-3
A’* 6
+-I PI-15
I
P2-2
,L D2 3 -- KSB
1 PI-13
,L Dl
K4B 21, 3 D4 u PI -7
I, R
D6 PI-IO
R K2E
7u, 5 P2-8 I?,
P2-5
PI -2
P2-6
P2-9
P24
KIE 5yl7 P2-7
PI-6
zt Cl R2
01 ,L LED1
;: R4 jr 7: c2 RS
Figure 9-11. Controller Circuit Board E-239563
S-l 2 Wiring Diagrams TP-5630 1 O/S3
Four-Lead Reconnectable (Single-Phase) Generator Sets Where Generator Output Can Be Reconnected for 100-120 Volt or IOO-120/200-240 Volt, 60 Hz;
or 100-l 20 Volt,lOO-120/200-240 Volt, or 200-220-240 Volt, 50 Hz
To illustrate the proper reconnection of 4-lead generator sets, the following information is provided. In all cases, the National Electrical Code (NEC) should be followed.
NOTE When a generator set is reconnected to a voltage different than nameplate voltage, notice should be placed on the unit indicating this change. A decal (part no. 246242) is available for this purpose from authorized Kohler dealers/distributors.
Jumper lead not used. Circuit breaker MUST be a circuit breaker manufacturer two-pole circuit breaker. Two single-pole circuit breakers do not conform to NEC requirements when supplying a 200-240 volt load. This is true even if they are mechanically attached together. Leads Ll and L2 are different phases and must never be connected together.
L”_” Side 6
Single-Pole H Circuit
Breaker
100-l 20 Volt. 2 Wire 4 3 2 1
Stator Leads
60 Hz 50 Hz LO-L1 100-l 20 Volt 100-l 20 Volt LO-L2 100-l 20 Volt 100-l 20 Volt
ILoad FE 1: Side i> c>
Y x_ j Line -O
Side
Factory H Two-Pole
Circuit Breaker
4 3 2 1 100-l 20/200-240 Volt, Stator Leads 3 Wire
Figure 9-13. IOO-120/200-240 Volt Configuration
r T
I
60 Hz 50 Hz LO-L1 100-l 20 Volt 100-l 20 Volt LO-L2 100-l 20 Volt 100-l 20 Volt LO-L2 200-240 Volt 200-240 Volt
LO (Neutral) > LO
@Ground B GRD.
B Ll
Load Side Single-Pole
H Circuit
Line Side
Breaker
\ Tape to insulate from ground
4 3 2 1 200-220-240 Volt, 2 Wire Stator Leads
60 Hz 50 Hz LO-L1 not used 200-220-240 Volt
Figure 9-14.200-220-240 Volt Configuration*
* Only available on generator sets equipped with B-258296 voltage regulator.
Wiring Diagrams 9-13
Figure 9-12.100-120 Volt Configuration*
TP-5630 10193
12 LEAD STATOR 60 Hz - 120/208V. OR 139/24OV. 3 PH. 4 WIRE LOW WYE 50 Hz - 120/208V. OR 11 O/l 90 V. 3 PH. 4 WIRE LOW WYE
Li
60 HZ - 100-120/200-240X - 1 PH. 3 WIRE 50 HZ - IOO-120/200-240V. - 1 PH. 3 WIRE
12 LEAD STATOR 60 Hz - 120/24OV. 3 kH. 4 WIRE DELTA 50 Hz - 110/22OV. 3 PH. 4 WIRE DELTA
6 3 12 9
12 LEAD STATOR 60 Hz - 277/48OV. 3 PH. 4 WIRE HIGH WYE 50 Hz - 220/38OV. 3 PH. 4 WIRE HIGH WYE
Figure 9-15. Voltage Reconnections with 12-Lead Stator
9-14 Wiring Diagrams TP-5630 1 O/93
Section IO. Specifications Chart
Generator Models 21ccoz
13.5ccoz 18.5CCOZ 16.5CCFOZ 11CCFOZ 1 SCCFOZ 18CCFOZ
Dimensions in. (mm)
- (L) 36.6 (930) 41.3 (1049) 41.3 (1049) - (W 22.2 (564) 22.2 (564) 22.2 (564) - 0-U 26 (660) 26.4 (671) 26.4 (671) - (L) w/sound shield 41.3 (1049) 44.8 (1138) 44.8 (1138)
- (W) w/sound shield 25.8 (655) 25.8 (655) 25.8 (655) - (H) w/sound shield 27.5 (699) 28.0 (711) 28.0 (71) Weight (wet) Ibs. (kg) 680 (308) 765 (347) 790 (358)
w/ sound shield (wet) Ibs. (kg) N/A 870 (395) 895 (405)
Air Requirements-CFM (Vmin.)
- Combustion 60 Hz/50 Hz 86.78172.32 115.91/96.59 115.91/96.59
(1422/l 185) (1899/l 582) (1899/l 582)
- Cooling 60 Hz/50 Hz 21 O/l 75 21 O/l 75 21 O/l 75
(5946/4955) (5946/4955) (5946/4955)
Angular Operation (max.) 25” continuous,
(in all directions) 30” intermittent (three minutes or less)
Minimum Clearances for vibration and 1.5 in.
cooling (top, front, rear, and sides) (38 mm)
(without sound shield)
Fuel Consumption 60 Hz U.S. gal./hr. (Uhr.)
(fuel consumption based on CCOZ63 voltage configuration)
LOAD - 25% 0.48 (1.8) 0.63 (2.4) 0.67 (2.5)
- 50% 0.71 (2.7) 0.90 (3.4) 0.98 (3.7)
- 75% 0.93 (3.5) 1.24 (4.7) 1.37 (5.2)
- 100% 1.19 (4.5) 1.63 (6.2) 1.77 (6.7)
Fuel Consumption 50 Hz U.S. gal./hr. (Uhr.)
(fuel consumption based on CCFOZ63 voltage configuration)
LOAD - 25% 0.38 (1.8) 0.50 (1.9) 0.53 (2.0)
- 50% 0.54 (1.9) 0:72 (2.7) 0.77 (2.9)
- 75% 0.72 (2.7) 1 .OO (3.8) 1.05 (4.0)
- 100% 0.93 (3.5) 1.38 (5.2) 1.40 (5.3)
Generator Type four pole, rotating field
Coupling Type flexible disc
Excitation Type brushless exciter
Shaft RPM (60/50 Hz) 1800/l 500
Number of Output Leads 4
Voltage Regulator PowerBoost’” V
Voltage Regulation +2%
Frequency Regulation *5%
TP-5630 1 O/93 Specifications Chart 1 O-l
Generator Models (continued)
21 cc02
13.5ccoz 18.5CCOZ 16.5CCFOZ
11CCFOZ 15CCFOZ 1 BCCFOZ
Exciter Field Voltage/Current
Readings at Rated Voltage (Hot)
- No Load (63 Hz)
- Full Load (60 Hz)
Exciter Field Resistance (Cold)
Exciter Armature Resistance (Cold)
Main Field (Rotor) Resistance (Cold)
Stator Output Voltages with
Separately Excited Generator, Using
12-Volt Battery (60 Hz only) *
- l-2, 3-4 (Vl -V4)
- 55-66
- Bl -B2
Stator Resistance (Cold)
- l-2, 3-4 (Vl -V4)
- 55-66
- Bl -B2
410.7 6/l .O 6/l .O
12/l .8 11/l .8 1512.3
5.8 5.8 5.8
0.5 0.5 0.5
4.3 3.0 3.0 (21 CCOZ/l6.5CCFOZ)
4.0 (18CCFOZ)
135 95 95
180 125 125
17 12 12
0.12 0.07 0.07
1.50 1.30 1.30
0.07 0.06 0.06
* To limit battery current and prevent damage to the generator, use a 1 O-ohm, 1 O-watt resistor in series with the 12-volt
battery to obtain the following values.
NOTE: Straight 100-200 volt configurations are available only with models equipped with B-25896
voltage regulator Power Boost TM V.
1 O-2 Specifications Chart TP-5630 1 O/93
Generator Models (continued)
14ccoz 2occoz 24CCOZ
11.5CCFOZ 17.5CCFOZ POCCFOZ
Dimensions in. (mm)
- (L)
-((w>
- (H) - (L) w/sound shield
- (W) w/sound shield
- (H) w/sound shield
Weight (wet) Ibs. (kg)
w/ sound shield (wet) Ibs. (kg)
Air Requirements-CFM (Vmin.)
- Combustion 60 Hz/50 Hz
36.6 (930) 41.3 (1049) 41.3 (1049)
22.3 (567) 22.3 (567) 22.3 (567)
26 (660) 26.4 (671) 26.4 (671)
43 (104993) 46.5 (1181) 46.5 (1181)
25.8 (655) 25.8 (655) 25.8 (655)
28.3 (718) 28.8 (730) 28.8 (730)
690 (313) 775 (352) 800 (363)
785(356) 880 (399) 905 (411)
- Cooling 60 Hz/50 Hz
Angular Operation (max.)
(in all directions)
Minimum Clearances for vibration and
cooling (top, front, rear, and sides)
(without sound shield)
86.78/72.32 115.91/96.59 115.91/96.59
(1422/l 185) (1899/l 582) (1899/l 582)
210/175 21 O/l 75 21 O/l 75
(5946/4955) (5946/4955) (5946/4955)
25” continuous,
30” intermittent (three minutes or less)
1.5 in.
(38 mm)
Fuel Consumption 60 Hz U.S. gal./hr. (Uhr.)
(fuel consumption based on CCOZ63 voltage configuration)
LOAD - 25% 0.48 (1.8) 0.63 (2.4)
- 50% 0.71 (2.7) 0.90 (3.4)
- 75% 0.93 (3.5) 1.24 (4.7)
- 100% 1 .I9 (4.5) 1.63 (6.2)
Fuel Consumption 50 Hz U.S. gal./hr. (Uhr.)
(fuel consumption based on CCFOZ63 voltage configuration)
LOAD - 25% 0.38 (1.8) 0.50 (1.9)
- 50% 0.54 (1.9) 0.72 (2.7)
- 75% 0.72 (2.7) 1 .OO (3.8)
- 100% 0.93 (3.5) 1.38 (5.2)
Generator Type four pole, rotating field
Coupling Type flexible disc
Excitation Type brushless exciter
Shaft RPM (60/50 Hz.) 1800/l 500
Number of’output Leads 12
Voltage Regulator PowerBoost’” V
Voltage Regulation *2%
Frequency Regulation *5%
0.67 (2.5)
0.98 (3.7)
1.37 (5.2)
1.77 (6.7)
0.53 (2.0)
0.77 (2.9)
1.05 (4.0)
1.40 (5.3)
TP-5630 1 O/93 Specifications Chart 1 O-3
Generator Models (continued)
14ccoz 2occoz 24CCOZ
11 .SCCFOZ 17.5CCFOZ POCCFOZ
Exciter Field Voltage/Current
Readings at Rated Voltage (Hot)
- No Load (63 Hz) 6/0.9
- Full Load (60 Hz) 17/2.6
Exciter Field Resistance (Cold) 5.8
Exciter Armature Resistance (Cold) 0.5
Main Field (Rotor) Resistance (Cold) 4.3
Stator Output Voltages with
Separately Excited Generator, Using
12-Volt Battery (60 Hz only) *
- l-4, 2-5, 3-6, 7-l 0, 8-11, 9-l 2, 7-8 o/l -V4) 110
- 55-66 125
- Bl -B2 12
Stator Resistance (Cold)
- l-4, 2-5, 3-6, 7-10, 8-11, 9-12, 7-8 (vl-V4) 0.06
- 55-66 1.5
- Bl -B2 0.06
8/l .4 8/l .4
1312.0 1612.4
5.8 5.8
0.5 0.5
3.0 3.0
70
90
9
0.04
1.3
0.05
70
90
9
0.04
1.3
0.05
* To limit battery current and prevent damage to the generator, use a 1 O-ohm, 1 O-watt resistor in series with the 12-volt
battery to obtain the following values.
NOTE: Straight 100-200 volt configurations are available only with models equipped with B-25896
voltage regulator Power Boost TM V.
1 O-4 Specifications Chart TP-5630 1 O/93
Engine Mddels
21 cc02
13.5ccoz 18.5CCOZ 16.5CCkOZ
11CCFOZ 1 SCCFOZ 18CCFOZ
Engine Manufacturer Yanmar
Engine Model 3JH2LT-K
Number of Cylinders 3
Cylinder Block Material
Cylinder Head Material
Piston Rings
Crankshaft
Connecting Rod
Governor
Bore x Stroke in. (mm)
Displacement CID (L) 87.26 (1.43)
Compression Ratio 17.79:1
Horsepower 60/50 Hz 20/l 6.5
RPM 60/50 Hz
Direction of Rotation
(as viewed from generator end)
Lubrication System
Lube Oil Capacity (w/filter) 5.0 (4.7)
Oil Recommendation (API)
Engine Firing Order l-3-2
(#l cylinder nearest to flywheel)
Fuel Injection Timing (BTDC) 17”
Fuel Injection Pressure psi (kg/cm sq.) 2844 +71 (200 25)
Combustion System
Battery Voltage
Battery Recommendation (min.)
Battery Charging (alternator)
Fuel Recommendation
Fuel System
Fuel Pump Prime Pump
Fuel Pump Lift (recommended) ft. (m)
Coolant Capacity U.S. qts. (L)
Coolant Recovery Tank qts. (L)
Recommended Coolant
Thermostat
Pressure Cap Rating
Starter Motor
Intake/Exhaust Valve Clearance (cold)
in. (mm)
Yanmar
3JH2LT-K
4
cast iron
cast iron
2 compression/l oil
stamped forging
forged steel
centrifugal, mechanical
3.31 (84) x 3.39 (86)
116.6 (1.91)
16.99:l
27.5/22.5
1800/l 500
Counterclockwise
pressure
6.1 (5.8)
CD
1-3-4-2
17” 21
2844 271 (200 25)
direct injection
12 Volt, negative ground
500 CCA, 100 Amp Hr.
50 Amps @ 12 Volts
Yanmar
3JH2LT-K
4
116.6 (1.91)
16.99:l
37127.5
6.1 (5.8)
1-3-4-2
17” rl
2844 271 (200 25)
Diesel, ASTM/D975-66T, No. 1 -D or No. 2-D
electric solenoid fuel shutoff
electric
4.0 (1.2)
2.36 (2.23) 3.15 (3.0) 3.15 (3.0)
.85 (.8)
50% ethylene glycol;
50% clean, softened water
195°F (90X)
12.8 psi (88.3 kPa)
1.8 kW, gear-reduction automotive type
0.0079 (0.2) 0.0079 (0.2) 0.0079 (0.2)
TP-5630 10193 Specifications Chart 1 O-5
Engine Models (continued)
21 cc02
13.5ccoz 18SCCOZ 16.5CCFOZ
11CCFOZ 1 SCCFOZ 18CCFOZ
Belt Tension (force) 0.38 in. (10 mm) @ 22 Ibs. (10 kg)
Cylinder Head Torque
- Initial ft. Ibs. (Nm) 29 (39) 29 (39) 29 (39)
- Final ft. Ibs. (Nm) (2-step intervals) 58 (79) 58 (79) 58 (79) Flex Plate to Rotor Bolt Torque ft. Ibs. (Nm) 30 (41) 30, (41) 30 (41)
Flex Plate to Flywheel Bolt Torque 20 (27) 20 (27) 20 (27)
ft. Ibs. (Nm)
Generator Adapter Plate to Flywheel Housing
Bolt Torque ft. Ibs. 30 (41) 30 (41) 30 (41)
Over Bolt Torque ft. Ibs. 30 (41) 30 (41) 30 (41)
Inlet Water Line Hose ID in. (mm)
(sea-water pump inlet) (‘;53 (z) & Outlet Water Line Hose ID in. (mm)
(mixing elbow outlet) (736) (736) (&)
Fuel Inlet (Fuel Pump Inlet) 3/8 ID/l/4 NPT 3/8 ID/l/4 NPT 3/8 ID/l/4 NPT
Fuel Return Size/Type 3/8 ID/l/4 NPT 3/8 ID/l /4 NPT 3/8 ID/l/4 NPT
1 O-6 Specifications Chart TP-5630 1 O/93
Engine Models (continued)
14ccoz
11 .SCCFOZ
2occoz 24CCOZ
17.5CCFOZ POCCFOZ
Engine Manufacturer Yanmar
Engine Model 3JH2LT-K
Number of cylinders 3
Cylinder Block Material
Cylinder Head Material
Piston Rings
Crankshaft
Connecting Rod
Governor
Bore x Stroke in. (mm)
Displacement CID (L) 87.26 (1.43)
Compression Ratio 17.79:1
Horsepower 60/50 Hz 20/l 6.5
RPM 60/50 Hz
Direction of Rotation
(as viewed from generator end)
Lubrication System
Lube Oil Capacity (w/filter) 5.0 (4.7)
Oil Recommendation (API)
Engine Firing Order l-3-2
(#l cylinder nearest to flywheel)
Fuel Injection Timing (BTDC) 17”
Fuel Injection Pressure psi (kg/cm sq.) 2844 *71 (200 25)
Combustion System
Battery Voltage
Battery Recommendation (min.)
Battery Charging (alternator)
Fuel Recommendation
Fuel System
Fuel Pump Prime Pump
Fuel Pump Lift (recommended) ft. (m)
Coolant Capacity U.S. qts. (L)
Coolant Recovery Tank qts. (L)
Recommended Coolant
Thermostat
Pressure Cap Rating
Starter Motor
Intake/Exhaust Valve Clearance (cold)
in. (mm)
Yanmar
3JH2LT-K
4
cast iron
cast iron
2 compression/l oil
stamped forging
forged steel
centrifugal, mechanical
3.31 (84) x 3.39 (86)
116.6 (1.91)
16.99:1
275122.5
1800/l 500
Counterclockwise
pressure
6.1 (5.8)
CD
l-3-4-2
17” 21
2844 k71 (200 35)
direct injection
12 Volt, negative ground
500 CCA, 100 Amp Hr.
50 Amps @ 12 Volts
Yanmar
3JH2LT-K
4
116.6 (1.91)
16.99:1
37127.5
6.1 (5.8)
l-3-4-2
17” 21
2844 k71 (200 25)
Diesel, ASTM/D975-66T, No. 1 -D or No. 2-D
electric solenoid fuel shutoff
electric
4.0 (1.2)
2.36 (2.23) 3.15 (3.0) 3.15 (3.0)
0.85 (.8)
50% ethylene glycol;
50% clean, softened water
195°F (90X)
12.8 psi (88.3 kPa)
1.8 kW, gear-reduction automotive type
0.0079 (0.2) 0.0079 (0.2) 0.0079 (0.2)
TP-5630 10193 Specifications Chart 1 O-7
Engine Models (continued)
14ccoz 2occoz 24CCOZ
11 .SCCFOZ 17.5CCFOZ 16.5CCFOZ
Belt Tension (force)
Cylinder Head Torque
- Initial ft. Ibs. (Nm)
- Final ft. Ibs. (Nm) (2-step intervals)
Flex Plate to Rotor Bolt Torque
ft. Ibs. (Nm)
29 (39)
58 (79)
30 (41)
0.38 in. (10 mm) @ 22 Ibs. (10 kg)
29, (39) 58 (79)
30 (41)
Flex Plate to Flywheel Bolt Torque
ft. Ibs. (Nm)
20 (27) 20 (27)
Generator Adapter Plate to Flywheel Housing
Bolt Torque ft. Ibs. 30 (41)
Over Bolt Torque ft. Ibs. 30 (41)
Inlet Water Line Hose ID in. (mm)
(sea water pump inlet) (Z)
Outlet Water Line Hose ID in. (mm)
(mixing elbow outlet) (736) Fuel Pump Inlet Thread Size l/4 NPT
Fuel Return Thread Size l/4 NPT
30 (41)
30 (41)
(‘;59
(736) l/4 NPT
l/4 NPT
29 (39)
58 (79)
30 (41)
20 (27)
30 (41)
30 (41)
(‘;59
&). l/4 NPT
l/4 NPT
1 O-8 Specifications Chart TP-5630 1 O/93
Installation Motor Starting Requirements Cooling Water Hose ID
Motor Requirements
l/4 HP
l/3 HP
l/2 HP
314 HP
1 HP
2 HP
3 HP
Starting Running (In-Rush) Watts Watts
750 330
1000 400
1500 600
2000 750
3300 1100
4000 2000
5000 3000
Fuel Pump Lift and inlet/Return Size ID
Model
Fuel Pump Fuel Inlet/ Recommended Lift Return Size
ft. (m) in.
All Models 4 (1.2) l/4 NPT
Model Wattage
Water Pump Inlet ID
in. (mm)
Mixing Elbow Hose ID in. (mm)
All Models 1 (25) 3 (76)
Battery Cable Size
Distance Between Generator Set At 0°F and Battery (-18°C)
Cable Size (AWG)
At 32°F At 75°F
(8C) (24°C)
40 Feet (12.2 m) 0 0
30 Feet (9.1 m) 0 1
25 Feet (7.6 m) 1 2
20 Feet (6.1 m) 2 2
15 Feet (4.6 m) 2 4
10 Feet (3.0 m) 4 6
5 Feet (1.5 m) 6 6
2.5 Feet (0.8 m) 8 8
Will Operate Air Conditioner of Size Indicated
Power to Spare for Lighting
Appliances, Tools
13.5CCOZ (1 -PH) 13,500
18.5ccoz (1 -PH) I 8,500
21 CCOZ (1 -PH) 21,500
14CCOZ (3-PH) 14,000
20CCOZ (3-PH) 20,000
24CCOZ (3-PH) 24,000
11 CCFOZ (1 -PH) 11,000
15CCFOZ (1 -PH) 15,000
16.5CCFOZ (1 -PH) 16,500
1aCCFOZ (1 -PH) I 8,000
11.5CCFOZ (3-PH) 11,500
17.5CCFOZ (3-PH) 17,500
20CCFOZ (3-PH) 20,000
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
Three 13,500 BTU
7,800
I 2,800
15,300
8,300
14,300
16,400
5,300
9,300
i 0,800
12,300
5,800
11,800
14,300
TP-5630 10193 Specifications Chart 1 O-9
Installation (continued)
Appliance Average Wattage Ratings (60 Hz)
Electrical Appliance
Motor Starting Watts
Running Watts
Automatic Pilot
Blanket, Electric
Blender
Broiler
Depthometer
Drill, 3/8”
Dryer, Hair
Fan, Air Circulating
Food, Mixer
Heater, Space
Heater, Water
Iron
Light Bulbs
Pan, Frying
Percolator, Coffee
Radar
Radio
Radiophone
Range, Electric
(per element)
Soldering Gun
Television
Toaster
Water System
800
600
50-200
400
-
500-l 500
150-250
50-250
600
1350
25-l 000
350
850-I 200
25-l 00
235
750-l 500
1500
900-l 200
(as indicated)
1200
650
750-l 500
50-l 00
100-200
1000-l 500
250
300-750
750-l 200
300-l 250
1 O-l 0 Specifications Chart TP-5630 1 O/93
Common Hardware Application Guidelines, Specification G-585
Starting late 1991, many Parts Catalogs and Service
Manuals will contain common hardware entries and
hardware references (see “Hardware References”)
instead of part numbers for common hardware.
Kohler Specification G-585 gives common hardware
application guidelines. Use the information below and on
the following pages to identify proper fastening techniques
when no specific reference for reassembly is made.
l Bolt/Screw Length: When bolt/screw length is not given,
use Figure 1 O-l as a guide. As a general rule, a minimum
of 112 the bolt/screw diameter beyond the nut is the
preferred method.
l Spiit Lock Washers: Split lock washers will no longer be
used as a locking device. For hardware up to l/2” in
diameter a whiz nut (serrated flange) will be used. The
locking method used for hardware above l/2” in diameter
will be SAE flat washers with preloading (torque) of the
bolt/screw. See “General Torque Specifications” and
other torque specifications in the service literature.
l Common Hardware Entries: When hardware size
(diameter and threads per inch) is given but no indication
of type of additional hardware is shown, use the illustration
length of one thread beyond the nut and a maximum length in Figure 1 O-2 as a guide.
Preferred Nut/Bolt Clearance
Min. 1 Full Thread
l/2 Bolt Diameter Beyond Top of Nu
Unacceptable Nut/Bolt Clearance
Below Top of Nut
TP-5630 1 O/93
Figure 10-I. Acceptable Bolt Lengths
Specifications Chat-l 1 O-11
Common Hardware Application (G-585)
Steps for common hardware application:
1. Determine entry hole type: round, or slotted.
2. Determine exit hole type: fixed female thread (weld nut), round, or slotted.
For round .and slotted exit holes, determine if hardware is greater than l/2 inch in
diameter, or l/2 inch in diameter or less. Hardware that is greater than 7/2 inch in di-
ameter takes a standard nut and SAE washer. Hardware 7/2 inch or less in diameter
can take a properly torqued whiz nut. See the diagram below.
3. Follow these SAE washer rules after determining exit hole type:
a. Always use a washer between hardware and a slot.
b. Always use a washer under a nut (see 2. above for exception).
c. Use a washer under a bolt when the female thread is fixed (weld nut).
4. Refer to the diagram below, which depicts the preceding hardware configuration possibilities.
Entry Hole Types
I
Cap Screw
Standard Nut And SAE washer: Greater
Than l/2” Dia. Hardware
/ Exit Hole Types
Whiz Nut: Up To And Including l/2”
Dia. Hardware
Figure 1 O-2. Acceptable Hardware Combinations
1 O-1 2 Specifications Chart TP-5630 10193
Common Hardware Identification Common hardware has many different head, drive, and page. This is a guide for identification purposes. Not all
grade (hardness) styles. Some ofthe more common types generator hardware used is shown.
are shown in Figure 1 O-3, below, and in Figure 1 O-4, next
Screws/Bolts/Studs HEAD STYLES
Hex. Head or Hex. Head or
Machine Head Machine Head
Hex. Head or
Machine Head
with Washer
Flat Head Round
Head
Pan
Head
Hex.
Socket
Head Cap
or Allen
Head Cap
Socket Head or
Allen Head
Shoulder Bolt
Sheet Metal
Screw
Stud
DRIVE STYLES
Hex. and
Slotted
Phillips Slotted Hex. Socket
GRADE (HARDNESS)
American Standard Metric
(>a@@ o(c)00
Grade 2 Grade 5 Grade 8 Grade 8/9 6.8 8.8 10.9 12.9
SAMPLE DIMENSIONS
American Standard
Major Thread Diameter In Fractional -..---- U-y ’ lLLength In Inches
Inches Or Screw Number Size Threads Per Inch
Metric
M8-1 25 x 20 Major Thread Diameter In Millimeters/ 7 --Length In Millimeters
Distance Between Threads In Millimeters
TP-5630 1 O/93
Figure 10-3. Screws/Bolts/Studs
Specifications Chart 1 O-l 3
Nuts STYLES
Hex. Head Lock Nut or
Nylock Nut
Square Nut Cap Nut or
Acorn Nut
Wing Nut
GRADE (HARDNESS)
American Standard Metric
Grade 2 Grade 5
@@@@
6.8 8.8 10.9 12.9
SAMPLE DIMENSIONS
American Standard l/4-20
Major Thread Diameter In Fractional I -Threads Per Inch
Inches Or Screw Number Size
Metric
M8-1 25 Major Thread Diameter In Millimeters~ I Distance Between Threads In Millimeters
Washers STYLES
Plain Split Lock Spring Washer External Internal Internal-External
Washer Washer or or Wave Washer Tooth Lock Tooth Lock Tooth Lock Washer
Spring Washer Washer Washer
GRADE (HARDNESS) 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
Internal Dimension I 9&2X5+X&6
I Thickness
External Dimension
Lock Washers 58 t
Internal Dimension
Figure 10-4. Nuts and Washers
1 O-l 4 Specifications Chart TP-5630 1 O/93
General Torque Specifications
The values given are for clean, dry threads.
Assembled in Cast Iron or Steel Assembled in Aluminum
OQ@ <:(-J
Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5
8-32
1 O-24
1 O-32
l/4-20
I/4-28
5/l 6-l 8
5/i 6-24
318-l 6
318-24
7/l 6-l 4
7/l 6-20
1.12-l 3
l/2-20
9116-12
9/l 6-l 8
518-l 1
518-l 8
314-l 0
314-l 6
in. Ibs. (Nm)
in. Ibs. (Nm)
in. Ibs. (Nm)
in. Ibs. (Nm)
in. Ibs. (Nm)
in. Ibs. (Nm)
in. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
ft. Ibs. (Nm)
20 (2.3)
32 (3.6)
32 (3.6)
70 (7.9)
85 (9.6)
150 (17)
165 (18.6)
22 (30)
25 (35)
35 (45)
45 (54)
50 (65)
70 (95)
75 (105)
100 (136)
110 (149)
140 (190)
150 (203)
200 (271)
25 (2.8)
40 (4.5)
40 (4.5)
115 (13)
140 (15.8)
250 (28.2)
270 (30.5)
35 (45)
40 (54)
55 (75)
75 (105)
80 (110)
105 (140)
125 (165)
165 (224)
180 (244)
230 (312)
245 (322)
325 (440)
20 (2.3)
32 (3.6)
165 (18.6) 70 (7.9)
200 (22.6)
350 (40) 150 (17)
360 (41)
50 (65)
60 (80)
80 (108)
105 (142)
115 (155)
165 (224)
175 (237)
230 (312)
260 (353)
330 (447)
350 (475)
470 (637)
SAMPLE DIMENSIONS
American Standard X 1 l/4-20
Major Thread Diameter In Fractional I I -..._- Length in Inches
Inches Or Screw Number Size Threads Per Inch
TP-5630 1 O/93 Specifications Chart 1 O-1 5
