Kohler 10EOZ Manual Download Page 3

Page: 3 / 80

TP-6053 7/04

Table of Contents

Safety Precautions and Instructions

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Introduction

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Service Assistance

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Section 1 Specifications

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1.1

General

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1.2

Service Views

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1.3

Engine

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1.4

Generator

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Section 2 Scheduled Maintenance

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2.1

General

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2.2

Lubrication System

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2.3

Battery

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2.4

Generator Storage

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Section 3 Intake and Exhaust System

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3.1

Air Intake Silencer/Filter

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3.2

Exhaust System

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3.3

Mixing Elbow

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Section 4 Fuel System

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4.1

General

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4.2

Fuel Specifications

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4.3

Fuel Filter

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4.4

Bleed the Fuel System

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4.5

Fuel Solenoid

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4.6

Fuel Pump

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4.7

Governor

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Section 5 Cooling System

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5.1

General

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5.2

Water-Cooled Exhaust Manifold

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5.3

Closed Heat Exchanger

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5.4

Fill Check and Coolant

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5.5

Flush and Clean Cooling System

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5.6

Pressure Cap

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5.7

Impeller Inspection and Replacement

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5.8

Belt Tension

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5.9

Siphon Break

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5.10 Anticorrosion Zinc Anode

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Section 6 Controller Troubleshooting

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6.1

General

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6.2

Controller Sequence of Operation

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6.2.1

Start

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6.2.2

Run

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6.2.3

Stop

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6.3

Engine Safety Shutdown Switches

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6.3.1

Low Oil Pressure (LOP) Shutdown

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6.3.2

High Water Temperature and
High Exhaust Temperature
Shutdown Switch

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6.4

Controller Circuit Board

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6.5

Troubleshooting

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Section 7 Generator Troubleshooting

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7.1

General

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7.2

General Troubleshooting

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7.3

Separate Excitation

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7.4

PowerBoost IIIE Voltage Regulators

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7.4.1

Voltage Regulator Test

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7.4.2

Voltage Regulator Adjustment

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7.5

Exciter Field

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7.6

Exciter Armature

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7.7

Rectifier Module

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7.8

Rotor

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7.9

Stator

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Section 8 Component Troubleshooting

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8.1

General

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8.2

Remote Panels (Optional)

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Section 9 Generator Disassembly/
Reassembly

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9.1

Disassembly

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9.2

Reassembly

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Section 10 Voltage Reconnection and
Wiring Diagrams

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10.1 Voltage Reconnection

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10.1.1

100--120-Volt Configurations

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10.1.2

100--120/200--240-Volt
Configurations

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10.1.3

200--240-Volt Configurations

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10.2 Marine Manual (Ship-to-Shore)

Transfer Switch

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10.3 Wiring Diagram, Schematic

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10.4 Wiring Diagram, Point-to-Point

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10.5 Remote Start Panel

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10.6 Remote Start and 2-Meter Panel

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10.7 Remote Start and 4-Meter Panel

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Appendix A Abbreviations

A-1

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Appendix B Common Hardware Application
Guidelines

A-3

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Appendix C General Torque
Specifications

A-4

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Appendix D Common Hardware
Identification

A-5

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Appendix E Common Hardware List

A-6

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Summary of Contents for 10EOZ

Page 1: ...Marine Generator Sets Models 5EOZ 8EOZ 9EOZ 10EOZ 4EFOZ 6 5EFOZ 8EFOZ 9EFOZ TP 6053 7 04a Service ...

Page 2: ......

Page 3: ... 3 1 Low Oil Pressure LOP Shutdown 26 6 3 2 High Water Temperature and High Exhaust Temperature Shutdown Switch 26 6 4 Controller Circuit Board 27 6 5 Troubleshooting 28 Section 7 Generator Troubleshooting 33 7 1 General 33 7 2 General Troubleshooting 33 7 3 Separate Excitation 34 7 4 PowerBoost IIIE Voltage Regulators 34 7 4 1 Voltage Regulator Test 35 7 4 2 Voltage Regulator Adjustment 35 7 5 Ex...

Page 4: ...TP 6053 7 04 Table of Contents Notes ...

Page 5: ...reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin WARNING Battery electrolyte is a diluted sulfuric acid Batteryacid cancause severe injury or death Battery acid can cause...

Page 6: ...ight headedness dizziness D Physical fatigue weakness in joints and muscles D Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision D Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxid...

Page 7: ...olvents salt deposits and water Ignition protected equipment Explosive fuel vapors can cause severe injury or death Gasoline vapors can cause an explosion USCG Regulation 33CFR183 requires thatallelectricaldevices ship to shore transfer switch remote start panel etc must be ignition protected when used in a gasoline and gaseous fueled environment The electrical devices listed above are not ignitio...

Page 8: ...ctrical system only through an approved device and after the building marina main switch is opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a ship to shoretransferswitch toprevent interconnection of the gen...

Page 9: ...moval Exposed moving parts can cause severe injury or death The generator set must be operating in order to perform some scheduled maintenance procedures Be especially careful if the sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only Notice NOTICE This generator set has been rewired from its nameplate voltage to 246242 NOTICE Voltage reconnection ...

Page 10: ...TP 6053 7 04 VI Safety Precautions and Instructions Notes ...

Page 11: ...nd service x in 001 003 Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer D Consult the Yellow Pages under the heading Generators Electric D Visit the Kohler Power Systems website at KohlerPowerSystems com D Look at the labels and stickers on your Kohler product or review the appropriate lit...

Page 12: ...eadily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Number Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufa...

Page 13: ...nger is model 3TNE68 The 8EOZ 6 5EFOZ models are powered by a Yanmar three cylinder water cooled four cycle diesel engine The three cylinder engine with heat exchanger is model 3TNE74 The 9EOZ 8EFOZ models are powered by a Yanmar three cylinder water cooled four cycle diesel engine The three cylinder engine with heat exchanger is model 3TNE78A The 10EOZ 9EFOZ models are powered by a Yanmar three c...

Page 14: ...lts 14 Seawater pump water inlet 15 Coolant fresh water drain 16 Heat exchanger 17 Coolant drain fresh water 18 Anticorrosion zinc anode 19 Fuel filter 20 Oil filter 21 Oil drain valve and hose 22 Fuel feed pump 23 Oil check 24 Fuel inlet connection 25 Low oil pressure safety shutdown switch 26 Wet exhaust manifold 27 Thermostat 28 AC load lead connector 29 Remote start connector 30 High exhaust t...

Page 15: ...il fill 13 Seawater pump water inlet 14 V belts 15 Heat exchanger 16 Coolant drain fresh water 17 Anticorrosion zinc anode 18 Fuel filter 19 Oil filter 20 Oil drain valve and hose 21 Fuel feed pump 22 Oil check 23 Fuel inlet connection 24 Low oil pressure safety shutdown switch 25 Wet exhaust manifold 26 Thermostat 27 AC load lead connector 28 Remote start connector 29 High exhaust temperature saf...

Page 16: ...ty shutdown switch 13 V belts 14 Seawater pump water inlet 15 Fuel filter 16 Oil drain valve and hose 17 Oil filter 18 Fuel feed pump 19 Fuel inlet connection 20 Oil check 21 Coolant drain fresh water 22 Fuel return 23 Wet exhaust manifold 24 Thermostat 25 AC load lead connector 26 Remote start connector 27 High exhaust temperature safety shutdown switch 28 Mixing elbow 29 Anticorrosion zinc anode...

Page 17: ... capacity w filter L qts 3 3 2 2 4 2 3 5 2 5 5 3 4 3 6 Oil recommendation API CD CD CC or CC Engine firing order 1 cylinder nearest to flywheel 1 3 2 Fuel injection timing BTDC 14 1 16 1 10 1 Fuel injection pressure kg cm sq psi 120 1706 200 2844 Combustion system Indirect injection swirl precombustion chamber Direct injection Battery voltage 12 volt negative ground Battery recommendation min 500 ...

Page 18: ...let mm in 51 2 Fuel inlet fuel pump inlet 1 4 NPT Fuel return size type 1 4 NPT 1 4 Generator Generator Model 5 8EOZ and 4 6 5EFOZ 9 10EOZ and 8 9EFOZ Hot exciter field voltage current readings at rated voltage No load 63 Hz volts amps 19 0 9 12 0 8 Full load 60 Hz volts amps 32 1 5 33 2 2 Resistor F1 lead to exciter field ohms 15 2 10 2 Cold exciter field resistance ohms 4 8 Cold exciter armature...

Page 19: ... pulleys when the generator set is running Replace guards screens and covers before operating the generator set Sound shield removal Exposed moving parts can cause severe injury or death The generator set must be operating in order to perform some scheduled maintenanceprocedures Be especially careful if the sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped m...

Page 20: ... skin WARNING Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 min...

Page 21: ...nmentally safe marine antifreeze with corrosion inhibitors 6 With a container at the exhaust outlet run the generator set until coolant discharges at the exhaust outlet or until depleting the coolant mixture Do not allow the coolant mixture to flow into waterways 7 Stop the generator set 8 Connect the hose to the seacock Leave the seacock closed 9 Check the coolant level in the heat exchanger and ...

Page 22: ...TP 6053 7 04 10 Section 2 Scheduled Maintenance Notes ...

Page 23: ... before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold mixing elbow exhaust li...

Page 24: ...TP 6053 7 04 12 Section 3 Intake and Exhaust System Notes ...

Page 25: ...n of the fuel largely determine the filter s useful life Replace the fuel filter element according to the service schedule Section 1 2 shows the location of the fuel filter There are two types of fuel filtering systems the spin on fuel filter and the fuel filter element Use the applicable procedure below to replace the fuel filter See Figure 4 2 or Figure 4 3 Spin On Fuel Filter Replacement Proced...

Page 26: ... the fuel system 1 The generator set operates until the fuel supply is emptied 2 The air leaks in the suction side of the fuel system 3 Replacing the fuel filter 4 Vapor lock Note Connect the battery during the priming procedure to allow engine cranking Do not allow the engine generator to start To prevent starting toggle the start stop switch by momentarily placing the start stop switch in the ST...

Page 27: ... pump lever to the fuel off position when deenergized The generators in this manual use a 3 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 Current amps and resistance readings are shown in Figure 4 5 Resistance readings determine if the solenoid w...

Page 28: ... 3 If the alignment is not correct check the linkage and mounting brackets Loosen locknuts and adjust the ball joint s length in or out to attain proper alignment Tighten the locknut 1 Fuel solenoid 2 Locknuts 3 Ball joints Stop Run Adjust 1 16 inch for max 2 1 3 Stop Lever Figure 4 6 Fuel Solenoid Linkage 4 6 Fuel Pump The fuel pump transfers fuel from a source to the fuel injection pump Fuel Pum...

Page 29: ...perate at 57 63 Hz 1800 rpm under full load and 1890 rpm under no load 50 Hz generator sets are designed to operate at 47 53 Hz 1500 rpm under full load and 1590 rpm under no load Check the engine speed using a frequency meter connected to the load leads Loosen the locking nut on the speed adjusting screw Turn the screw clockwise to increase the speed and frequency Turn the screw counterclockwise ...

Page 30: ...TP 6053 7 04 18 Section 4 Fuel System Notes ...

Page 31: ...ool Release pressure from the cooling system before removing the pressure cap To releasepressure coverthepressure capwith athick clothand then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank NOTICE Saltwater damage Saltwate...

Page 32: ...oolant recovery tank Periodically check the coolant level on closed systems by removing the pressure cap Do not rely solely on the level in the coolant recovery tank Add fresh coolant mixture until the level is just below the overflow tube opening Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has coole...

Page 33: ...Inspect the impeller for damage including visible cracked broken worn or missing fins The impeller vanes should be straight and flexible See Figure 5 5 5 Lubricate the impeller with soapy water before re installation 6 While installing the impeller always rotate the drive shaft and the impeller together in the same direction as the engine rotation 7 Inspect the coverplate and gasket for corrosion ...

Page 34: ...est span of the belt by pressing the belt with your finger and measuring the resulting deflection See Figure 5 6 and Figure 5 7 If the belt is not within specifications go to step 5 If the belt is within specifications go to step 9 5 Loosen the adjusting arm pivot screw alternator pivot screw and alternator adjusting screw 6 While prying the alternator outward tighten the alternator screw 7 Tighte...

Page 35: ...rtighten Note Consult the installation manual for a complete explanation of the dimensions and other installation considerations Waterline 1 2 3 7 8 9 18 10 11 12 13 14 15 16 17 20 19 6 5 4 TP 5586 3 21 1 Mounting holes 2 Retaining cap 3 Reed valve assembly 4 Silencer vertical lift 1 2 m 4 ft max 5 Exhaust mixer elbow distance above waterline If less than 23 cm 9 in a siphon break is required 6 Si...

Page 36: ... heat exchanger and drain the coolant into a container 2 Remove the corrosion on the zinc anode Replace the anode when the percent of the zinc remaining is less than 50 of the length and diameter shown in Figure 5 10 3 Clean the threaded opening of the heat exchanger and coat the threads of the zinc anode with pipe sealant 4 Install the zinc anode into the heat exchanger 5 Open the seacock 6 Refil...

Page 37: ...nnection and Wiring Diagrams to assist in the troubleshooting procedure 6 2 1 Start Close the start stop switch between N ground and 47 local or remote starting The K2 relay energizes The normally open K2 contacts close to energize the K3 relay LED3 lights the K25 fuel solenoid relay the controller hourmeter and the generator armature exciter field The K25 relay normally open contacts close to ene...

Page 38: ...elay LED 2 goes out The normally closed K2 contacts close to ground the circuit to the K4 relay until the generator set comes to a complete stop 6 3 Engine Safety Shutdown Switches 6 3 1 Low Oil Pressure LOP Shutdown When low oil pressure occurs the LOP shutdown switch contacts close and energize the K4 relay LED4 lights Note During cranking the low oil pressure shutdown switch is deactivated unti...

Page 39: ...r Circuit Board Some controller circuit board components can be tested without removing the component from the circuit board Perform these checks prior to installing a new circuit board and attempting startup Use a high quality multimeter and follow the manufacturer s instructions To obtain accurate readings when testing remove all the circuit board connectors and conformal coating transparent ins...

Page 40: ...and 47 S Check the battery condition and connections S Check the connections at P1 14 S Do all check okay Is the K2 relay functioning correctly No Yes Replace the circuit board The K3 relay or K1 relay is faulty Replace the circuit board Is voltage present at the S relay coil Yes Is the K20 relay functioning correctly Is voltage present at the S relay contact starter motor side No Yes Replace the ...

Page 41: ...No Engine fault check the fuel supply fuel feed pump fuel injection pump etc Yes Replace the circuit board inoperative K4 relay No Replace the inoperative start stop switch A No Replace the fuse Yes Is the K25 relay functioning correctly No Replace the K25 relay Yes S Check the P1 8 connection S Check the P4 14 connection S Replace the circuit board the K2 relay is inoperative Go to B next page Fi...

Page 42: ... solenoid No No Replace the circuit board the K5 relay is inoperative Does the low oil pressure LOP safety shutdown switch check out okay No Replace the LOP safety shutdown switch Yes No Did the K4 relay LED light Replace the circuit board inoperative K4 relay No Do the local and remote start stop switches function correctly Replace the circuit board inoperative K1 or K2 relay Yes Replace the inop...

Page 43: ...r armature Yes Is there 12VDC at the exciter field Yes Test the stator and the main field No No Separately excite the generator set to determine if other components are inoperative Replace the controller circuit board Yes No Test the voltage regulator Is AC output voltage at spec See Section 7 3 Separate Excitation Test the stator main field rotor and exciter armature Is the voltage regulator fuse...

Page 44: ...TP 6053 7 04 32 Section 6 Controller Troubleshooting Notes ...

Page 45: ...andards Never contact electrical leads or appliances when standing in water oronwetgroundbecause theseconditions increasethe riskof electrocution High voltage test Hazardous voltage can cause severe injury or death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator...

Page 46: ...iter field 8 10 or 15 ohm resistor 9 P6 connector disconnect P6 connector before separate excitation 605372 Figure 7 2 Separate Excitation Connections 5 Start the engine and check that the ammeter remains stable An increasing meter reading indicates a shorted rotor A decreasing meter reading to zero or unstable reading suggests a running open in the rotor If the ammeter is stable continue with ste...

Page 47: ...voltage regulator causes a generator high voltage output condition 5 Turn the variable transformer to zero and unplug the AC cord Note For applications requiring fine voltage adjustment connect a remote rheostat to voltage regulator terminal 66 GY R Y O WBK 66 4433 55 1 2 3 4 5 6 7 TP 598654 1 120 volts AC 2 Variable transformer 3 AC voltmeter 4 Voltage regulator PowerBoosttIIIE 5 Stator rotor con...

Page 48: ...nal 605375 Figure 7 5 PowerBoosttIIIE Voltage Regulator Adjustment 8 Use the remote rheostat if equipped to make final voltage adjustments 9 Stop the generator set 7 5 Exciter Field DC current from the battery magnetizes the exciter field When the exciter armature rotates within the magnetized exciter field windings an electrical current develops within the exciter armature There will be low or no...

Page 49: ... 3 With an ohmmeter on the R x 1 scale check the resistance across the exciter armature leads See Figure 7 8 The armature resistance should be 0 6 0 8 ohms continuity No continuity indicates an open armature winding Replace the armature 4 Perform a megohmmeter test on the exciter armature as described in the next step Consider the exciter armature good if the resistance reading continuity is low a...

Page 50: ...10 Testing Rectifier Module 7 8 Rotor The generator rotor magnetized by DC current from the rectifier module rotating within the stator windings induces AC voltage in the stator windings Test the generator rotor main field as described in the following steps Rotor Test Procedure 1 Disassemble the generator 2 Disconnect the generator main field windings from rectifier module terminals F and F 3 Che...

Page 51: ...sing The stator produces electrical output AC as the magnetized main field rotates within the stator windings Test the condition of the stator according to the following procedure Refer to the schematic in Figure 7 13 when performing the following tests Stator Test Procedure 1 Check the generator output lead connections See Section 10 Voltage Reconnection and Wiring Diagrams 2 Disconnect all the s...

Page 52: ...inding and the stator frame Follow the instructions of the megohmmeter manufacturer when performing this test Repeat the test on the other leads until all the stator windings have been tested A reading of approximately 500 kOhms 1 2 megohm and higher indicates the stator is good A reading of less than approximately 500 kOhms indicates deterioration of the winding insulation and possible current fl...

Page 53: ... jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Component Voltmeter Connections Procedure Results Hourmeter and wiring Connect the red test lead to the hourmeter positive terminal Connect the black test lead to the hourmeter negative terminal Set the voltmeter to 12 volts DC or greater Start the generator set A 12 volt DC reading indicates the wiring ...

Page 54: ...e the rocker switch in the STOP position If the switch is functional zero ohms continuity Any resistance other than zero or very low ohms replace the switch K20 relay coil and wiring Connect the ohmmeter to the P1 4 and P1 9 leads Place the ohmmeter on the R x 1 scale If functional 85 ohms Low resistance shorted C relay coil and or wiring High resistance open C relay and or wiring Replace the cont...

Page 55: ... shutdown switch Connect the ohmmeter to the P13 1 and engine block ground Place the ohmmeter on the R x 1000 scale This test is not conclusive until the temperature shutdown switches are checked If functional zero ohms continuity Then disconnect the LOP switch lead and isolate the terminal Meter reading should show an open circuit Figure 8 3 Engine Generator Component Testing Relay Controller 8 2...

Page 56: ...is complete Generator set does not need to be running just cranking for this test Note If the hourmeter is not illuminated test it by connecting it to a 12 volt battery Note The hourmeter is polarity sensitive If 12 volts DC is present and the component does not function after the J3 is connected to the controller P3 replace the component s Water temperature gauge Connect the red test lead to P3 4...

Page 57: ...oving the voltage regulator from the controller 1 Remove the end panel from the alternator end of the generator set See Figure 9 1 2 Loosen the four screws and lift off the controller cover 3 Disconnect the P4 22 pin connector from J4 4 Remove the bolt and disconnect the ground strap Note It is possible to connect the output leads in various positions for different volt configurations Mark leads 1...

Page 58: ...positive negative terminals Remove the bolt and washer 13 Remove the armature from the shaft guiding rotor leads through the armature bores See Figure 9 4 14 Remove the tie wraps and disconnect the P5 33 44 55 B1 and B2 wire connector 15 Attach the hoist hook to the generator hoisting eye Note The hoist capacity rating should be one half ton or greater 16 Remove the two vibromount bolts See Figure...

Page 59: ...mbly from the rotor See Figure 9 8 9 2 Reassembly 1 Clamp the rotor in a soft jaw vise Install the drive disc on the rotor with disc studs facing the rotor Tighten the eight bolts to 40 Nm 30 ft lbs See Figure 9 8 2 Install the rotor drive disc assembly on the engine flywheel using six washers and bolts Tighten the bolts to 27 Nm 20 ft lbs 3 Install the fan to the drive disc using four spacers was...

Page 60: ... install a bolt a large washer two small washers and a locknut in each vibromount Tighten the mounting bolts to 28 Nm 20 ft lbs 7 Apply antiseize compound to the keyed end of the rotor shaft Bring the rotor leads through the bores in the armature while installing the armature on the shaft Check the keyway of the shaft and key of the armature for damage Install the armature retaining bolt and washe...

Page 61: ...l voltage configuration See Section 10 Voltage Reconnection and Wiring Diagrams for more information regarding voltage reconnection 13 Connect the P4 22 pin connector Connect the ground strap using a bolt washer and lock washer install the lock washer against the ground strap 14 Install the controller cover 15 Install the end panel with the louvered openings down 16 Reconnect all the external conn...

Page 62: ...TP 6053 7 04 50 Section 9 Generator Disassembly Reassembly Notes ...

Page 63: ...Factory 2 Pole or 2 1 Pole Circuit Breakers Jumper Lead L1 L2 100 120 Volt 3 Wire 60 Hz 50 Hz L0 L1 100 120 Volt 100 120 Volt L0 L2 100 120 Volt 100 120 Volt Figure 10 1 100 120 Volt 3 Wire Do not connect the load side terminals of the circuit breaker together when using a factory 2 pole circuit breaker See Figure 10 1 If the installation requires a 100 120 volt 2 wire system use a 1 pole circuit ...

Page 64: ...rent phases never connect them together 60 Hz 50 Hz L0 L1 100 120 Volt 100 120 Volt L0 L2 100 120 Volt 100 120 Volt L1 L2 200 240 Volt 200 240 Volt 4 3 2 1 Stator Leads LO Neutral Line Side Factory 2 Pole Circuit Breaker Ground Load Side 100 120 200 240 Volt 3 Wire LO GRD L2 L1 Figure 10 3 100 120 200 240 Volt 3 Wire 10 1 3 200 240 Volt Configurations This configuration does not use a jumper lead ...

Page 65: ...aimler American Solenoid Early Rectangular Design Kraus Naimler American Solenoid Newer Round Design 2 1 3 4 6 5 7 8 1 2 6 5 3 4 8 7 L1 L2 To Generator Set To Shore Power To Load 3 2 4 1 7 6 8 5 L1 L2 To Generator Set To Shore Power To Load 3 Wire Generator Sets 2 1 3 4 6 5 7 8 L0 10 9 11 12 1 2 6 5 3 4 8 7 9 10 14 13 L1 L2 To Generator Set To Shore Power To Load 3 Wire Generator Sets L0 3 2 4 1 7...

Page 66: ...TP 6053 7 04 54 Section 10 Voltage Reconnection and Wiring Diagrams 10 3 Wiring Diagram Schematic 229294 N ...

Page 67: ...TP 6053 7 04 55 Section 10 Voltage Reconnection and Wiring Diagrams 10 4 Wiring Diagram Point to Point 229294 N ...

Page 68: ...ed Grey Black Start Stop Stop 10 amp fuse P3 4 J3 4 J3 5 J3 1 J3 6 TP 5588 7 10 6 Remote Start and 2 Meter Panel P3 2 J3 2 Start P P 7C K1 70 47 43 N Oil pressure gauge Water temp gauge Gen ON light Remote switch 5 P3 5 P3 6 P3 1 P3 3 P2 3 P2 7 P2 8 P2 9 P4 2 P4 3 K2 P1 14 47 P2 4 43 P2 5 P2 6 N P1 9 N Relay circuit board Local switch Violet Tan Black Yellow Red Grey Black L Blue Start Stop Stop 1...

Page 69: ...C voltmeter Oil pressure gauge Water temp gauge Gen ON light Remote switch 5 P3 5 P3 6 P3 1 P3 2 P3 3 P2 3 P2 7 P2 8 P2 9 P4 2 P4 3 K2 P1 14 47 P2 4 43 P2 5 P2 6 N P1 9 N Relay circuit board Local switch Violet Tan Black Yellow Red Grey Black L Blue Start Stop Stop P3 4 W T sender J3 4 J3 5 J3 6 J3 1 J3 2 J3 3 O P sender 10 amp fuse TP 5588 7 ...

Page 70: ...TP 6053 7 04 58 Section 10 Voltage Reconnection and Wiring Diagrams Notes ...

Page 71: ...ormer Cu copper cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO dual inlet end outlet DIN Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss DIP dual inline package DPDT double ...

Page 72: ...ion optional OS oversize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase PHC Phillips head crimptite screw PHH Phillips hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts ...

Page 73: ...op of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths 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 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a...

Page 74: ... 0 32 68 0 50 95 0 70 1 2 13 Nm ft lb 60 0 44 92 0 68 130 0 96 1 2 20 Nm ft lb 66 0 49 103 0 76 146 0 108 9 16 12 Nm ft lb 81 0 60 133 0 98 187 0 138 9 16 18 Nm ft lb 91 0 67 148 0 109 209 0 154 5 8 11 Nm ft lb 113 0 83 183 0 135 259 0 191 5 8 18 Nm ft lb 128 0 94 208 0 153 293 0 216 3 4 10 Nm ft lb 199 0 147 325 0 240 458 0 338 3 4 16 Nm ft lb 222 0 164 363 0 268 513 0 378 1 8 Nm ft lb 259 0 191 ...

Page 75: ...nal External Tooth Lock Hardness Grades American Standard Grade 2 Grade 5 Grade 8 Grade 8 9 Hex Socket Head Metric Number stamped on hardware 5 8 shown 5 8 Allent head screw is a trademark of Holo Krome Co Phillipsr screw is a registered trademark of Phillips Screw Company Sample Dimensions 1 4 20 x 1 Major Thread Diameter In Fractional Inches Or Screw Number Size Length In Inches Screws and Bolts...

Page 76: ...24 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2 13 x 1 25 X 129 19 1 2 13 x 1 50 X 129 20 1 2 13 x 1 75 X 129 21 1 2 13 x 2 00 X 129 22 1 2 13 x 2 25 X 129 23 1 2 13 x 2 50 X 129 24 1 2 13 x 2 75 X 129 25 1 2 13 x 3 00 X 129 27 1 2 13 x 3 50 X 129 2...

Page 77: ...3 00 x 160 M931 24200 60 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M4 0 70 x 6 M933 05030 60 M5 0 80 x 30 M933 05035 60 M5 0 80 x 35 M933 05050 60 M5 0 80 x 50 M933 06010 60 M6 1 00 x 10 M933 06012 60 M6 1 00 x 12 M933 06014 60 M6 1 00 x 14 M933 06016 60 M6 1 00 x 16 M933 06020 60 M6 1 00 x 20 M933 06025 60 M6 1 00 x 25 M933 06030 60 M6 1 00 x 30 M933 06040 60 M6 1 00 x 40 M933 06050...

Page 78: ...M12 1 75 Spiralock M982 12 80 M12 1 75 Elastic Stop M982 14 60 M14 2 00 Elastic Stop M6923 16 80 M16 2 00 Spiralock M982 16 80 M16 2 00 Elastic Stop M934 18 80 M18 2 5 Standard M982 18 60 M18 2 50 Elastic Stop M934 20 80 M20 2 50 Standard M982 20 80 M20 2 50 Elastic Stop M934 22 60 M22 2 50 Standard M934 24 80 M24 3 00 Standard M982 24 60 M24 3 00 Elastic Stop M934 30 80 M30 3 50 Standard Washers ...

Page 79: ......

Page 80: ...hler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 ...

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