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Kohler 125EOZ/100EFOZ Service Manual Download Page 148

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Kohler Co., 1997, 2001. All rights reserved.

TP-5737 5/01b

KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Web site www.kohlergenerators.com
Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International)
For the nearest sales and service outlet in U.S.A. and Canada
Phone 1-800-544-2444

Kohler

r

Power Systems

Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65)264-6422, Fax (65)264-6455

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Summary of Contents for 125EOZ/100EFOZ

Page 1: ...33CFOZ 40EOZ 33EFOZ 50COZ 40CFOZ 50EOZ 40EFOZ 65COZ 50CFOZ 65EOZ 55EFOZ 80EOZ 70EFOZ 99EOZ 80EFOZ 125EOZ 100EFOZ 150EOZ 125EFOZ Controllers Decision Makert 3 Decision Makert 1 Standard Decision Maker...

Page 2: ...ble 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...

Page 3: ...10 2 7 4 Starting the Generator Set 10 2 7 5 Stopping the Generator Set 10 2 7 6 Prime Power Mode Operation 11 2 7 7 Fault Shutdowns 11 2 7 8 Controller Resetting Procedure Following Fault Shutdown 1...

Page 4: ...al TB1 Terminal Strip 42 Section 6 Decision Makert 1 Controller Troubleshooting 45 6 1 Decision Makert 1 and Decision Makert 1 Expanded Relay Controller 45 6 2 Relay Controller 52 Section 7 Component...

Page 5: ...Reassembly 83 8 1 Disassembly 87 8 2 Reassembly 89 Section 9 Wiring Diagrams 95 9 1 Voltage Reconnection 116 9 1 1 Introduction 116 9 1 2 Voltage Reconnection Procedure 116 9 2 Overvoltage Shutdown A...

Page 6: ......

Page 7: ...generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master swit...

Page 8: ...ath Do not smoke or permit flames or sparks near the fuel system Keep the compartment and the generator set clean and free of debris to minimize the risk of fire Wipe up spilled fuels and engine oil C...

Page 9: ...on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition D...

Page 10: ...ackfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building marina electrical system only through an approved device and after the buil...

Page 11: ...oval 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 b...

Page 12: ...TP 5737 5 01 VI Safety Precautions and Instructions Notes...

Page 13: ...ervals Obtain service from an authorized service distributor dealer to keep equipment in top condition x in 001 002 a Service Assistance Please contact a local authorized distributor dealer for sales...

Page 14: ...TP 5737 5 01 ii Service Assistance Notes...

Page 15: ...ion in ohms COZ CFOZ Models Specification in ohms EOZ EFOZ Models Oil Pressure Sender 0 kPa 0 psi 120 9 8 240 17 15 172 kPa 25 psi 76 5 6 7 5 153 12 15 690 kPa 100 psi 16 8 33 5 Water Temperature Send...

Page 16: ...See Figure 1 1 The flush mounted annunciator panel extends all of the fault and prealarm lights audio of the Decision Maker 3 controller The remote annunciator includes an alarm horn an alarm silence...

Page 17: ...ircuit Breaker The line circuit breaker interrupts generator output in the event of an overload or short circuit Use the kit to manually disconnect the generator set from the load when servicing the g...

Page 18: ...the FASTCHECK are listed below refer to Figure 1 5 to identify LEDs and switches LEDs on the FASTCHECK indicate the energizing of the following circuits D Fuel solenoid diesel D Engine crank D AC vol...

Page 19: ...achine because it is not dependent upon the generator set output voltage for excitation power Possibly the greatest advantage of this type of machine is its inherent ability to support short circuit c...

Page 20: ...ide detector is 1 in the craft 2 functional and 3 energized whenever the generator set operates Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Mainta...

Page 21: ...nside controller 2 Frequency meter 3 AC voltmeter 4 Controller TB1 and TB2 terminal strips on circuit board 5 AC ammeter 6 Scale lamps upper lower 7 Selector switch 8 Annunciator panel lamps 9 Alarm s...

Page 22: ...the engine reaches temperature shutdown range Hourmeter The hourmeter records the generator set total operating hours for reference in maintenance scheduling Lamp test switch The switch tests the con...

Page 23: ...set in emergency situations Use the emergency stop switch for emergency shutdowns only Use the generator set master switch for normal shutdowns 2 7 2 Fuses and Terminal Strips The following table des...

Page 24: ...lights and the engine shuts down immediately when any customer supplied sensing devices connected to auxiliary immediate shutdown ports P1 17 and P1 18 activate them x op 005 004 2 7 4 Starting the G...

Page 25: ...er switch to the AUTO position to return controller functions to normal Prime Power Stopping Move the generator set master switch to the OFF RESET position to stop the generator set and power down the...

Page 26: ...use of the shutdown has been corrected 6 Reconnect the generator set to the load via the line circuit breaker or automatic transfer switch 7 Place the generator set master switch in the AUTO position...

Page 27: ...gine shuts down because of one of the following faults high engine temperature low water level low oil pressure overcrank or overspeed See Section 2 8 4 Fault Shutdowns for additional shutdown informa...

Page 28: ...fety Precautions at the beginning of this section before proceeding 2 Correct the cause of the fault shutdown See the Safety Precautions at the beginning of this section before proceeding 3 Start the...

Page 29: ...total operating hours for reference in maintenance scheduling Voltage adjust potentiometer Potentiometer fine tunes 5 generator output voltage 10 amp controller fuse Fuse protects the controller circ...

Page 30: ...artup NOTE The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Overcrank Shutdown occurs after 30 seconds of continuous cranking Shutdown occurs afte...

Page 31: ...or death Operate the generator set only when all guards screens and covers are in place WARNING Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death K...

Page 32: ...on using a coolant tester 2 Add or replace coolant as necessary to ensure adequate freezing protection Use the guidelines included in the engine operation manual 3 Run the generator set for 30 minutes...

Page 33: ...rrective action and testing often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service distributor dealer perform...

Page 34: ...roller Section 5 or 6 x x Controller circuit board s inoperative Replace the controller circuit board Section 5 or 6 Cooling System x x Air openings clogged Clean the air openings x Impeller inoperati...

Page 35: ...he inoperative switch Gen S M or W D x x Starter starter solenoid inoperative Replace the starter or starter solenoid Eng S M x High water temperature switch inoperative Replace the inoperative switch...

Page 36: ...r and check for AC voltage at the generator side of the circuit breaker x Transfer switch test switch in the OFF position Move the transfer switch test switch to the AUTO position ATS O M x Wiring ter...

Page 37: ...showing input output circuits for reference in troubleshooting This information deals directly with the 16 light microprocessor 1 10 9 6 2 5 11 7 3 12 4 8 A 328917 X 1 Selector switch 2 Lamp circuit b...

Page 38: ...processor chip 6 TB1 terminal strip 7 TB2 terminal strip 8 P3 connector control panel harness to P4 LED indicator panel assembly 9 LED4 K4 relay 10 P1 connector DC harness 11 LED3 K3 relay 12 P2 conne...

Page 39: ...peration requires optional kit 5 9 Crank mode open cyclic ground continuous 6 9A Crank mode ground 7 4 Remote start active low 8 3 Remote start ground Check the operation of active low circuits by pla...

Page 40: ...h run position wire 47 Figure 5 7 P3 Connector Pins Pin Description 1 Ground front panel wire 2 2 Not used 3 Not used 4 Output from generator set master switch auto position wire 46 5 Not used 6 Volta...

Page 41: ...WT AOP Low Fuel Battery Charger Fault Low Battery Common Fault Indicator Activated By HWT AWT LOP AOP LWT OC OS LF AUX Connect AV Alarm or Common Fault Relay Kit Running Mode Cool Down Mode Common Fau...

Page 42: ...enoid HWT High Water Temperature HXT High Exhaust Temperature LBV Low Battery Volts LF Low Fuel LOP Low Oil Pressure LWT Low Water Temperature NIA Not In Auto OC Overcrank OS Overspeed SG Safeguard Ci...

Page 43: ...Auxiliary Prealarm AHET Anticipatory High Engine Temperature AWT Anticipatory High Water Temperature BC Battery Charger Fault EAD Engine Air Damper ES Emergency Stop FS Fuel Solenoid HET High Engine...

Page 44: ...TP 5737 5 01 30 Section 5 Decision Makert 3 Troubleshooting ADV 6122 B Figure 5 12 Logic Schematic Decision Maker 3...

Page 45: ...ercrank lamp flashes Speed sensor signal is absent longer than one second No AC output is present Auxiliary lamp flashes Battery power was reconnected or was low and then came back up again while gene...

Page 46: ...cy stop LED4 is lit at all times except during emergency stop The K4 relay is located on the controller circuit board If the emergency stop kit is connected local or remote remove the jumper from circ...

Page 47: ...nd correlated with possible causes and corrective action Before beginning any troubleshooting procedure read all safety precautions at the beginning of this manual and those included in the text Do no...

Page 48: ...onent s Inoperative audio visual alarm Blown F1 fuse remote annunciator 3 amp Blown F2 fuse controller 3 amp Battery connections reversed Shorted DC supply to indicator panel Shorted controller circui...

Page 49: ...s the controller LED4 lit Yes Is the emergency stop switch controller or remote activated See emergency stopping in Section 2 Operation Do the controller s LED2 and LED3 light with the generator set m...

Page 50: ...ck the P1 harness and connector pins Is the harness inoperative Yes Repair or replace the harness No Replace the circuit board Check the bulbs Are the bulbs burned out Yes Replace the bulbs No Check t...

Page 51: ...re 5 22 Controller Instrumentation Press the lamp test button Do the lamps light Lamp circuit board not functioning or not functioning properly i e fault lamps and alarm horn only Improper input signa...

Page 52: ...sensor positive terminal and negative terminal Check wire 16 for 3 6 volts DC and wire 24 for 8 10 volts DC Does this test check out okay Is the speed sensor air gap greater than that specified in Sec...

Page 53: ...UN engine running Indicator Lamps D IGN ignition lamp D Shows battery voltage supplied to fuel solenoid D Lights during cranking and running D CRK crank lamp D Shows battery voltage switched to starte...

Page 54: ...nector P1 and to the top of the FASTCHECK 3 Move the generator set master switch to the OFF RESET position 4 Move the FASTCHECK engine switch to the OFF position 5 Clip the red and black harness leads...

Page 55: ...on FASTCHECK should light for approximately 5 seconds and then go out Five seconds later the IGN CRK and REG lamps should relight for 5 seconds before going out again 15 seconds total elapsed time The...

Page 56: ...ts etc do not function Test point connections are shown in Figure 5 29 and Figure 5 30 Note When checking controller test point voltage place the negative lead of the voltmeter on the terminal designa...

Page 57: ...and TB1 40 Anticipatory Low Engine Oil Pressure AOP Master switch in RUN position engine switch in RUN hold toggle switch to AOP TB1 42A and TB1 41 Low Water Temperature LWT if equipped Master switch...

Page 58: ...TP 5737 5 01 44 Section 5 Decision Makert 3 Troubleshooting Notes...

Page 59: ...lay 6 Ground strap 7 Hourmeter front panel 8 Fault lamp front panel 9 Voltage adjust potentiometer front panel 10 10 amp fuse front panel 11 Generator set master switch front panel Figure 6 1 Decision...

Page 60: ...uit between N and 47 K2 Open Open Deenergizes engine components generator set shuts down Fault shutdowns Low oil pressure LOP high engine temperature HET after the engine operating temperature reaches...

Page 61: ...D Overcrank Overspeed LWL HET and LOP drive the fault shutdown circuit D Fault latch provided by K1 normally open contacts D Overcrank shutdown is only driven by AC D Crank disconnect driven by AC an...

Page 62: ...TP 5737 5 01 48 Section 6 Decision Makert 1 Controller Troubleshooting ADV 6120 A Figure 6 5 Decision Maker 1 Relay Controller with E 254717 Circuit Board...

Page 63: ...TP 5737 5 01 49 Section 6 Decision Makert 1 Controller Troubleshooting ADV 6120 D Figure 6 6 Decision Maker 1 Relay Controller with F 254717 Circuit Board...

Page 64: ...TP 5737 5 01 50 Section 6 Decision Makert 1 Controller Troubleshooting ADV 6121 Figure 6 7 Decision Maker 1 Expanded Relay Controller with E 254717 Circuit Board...

Page 65: ...TP 5737 5 01 51 Section 6 Decision Makert 1 Controller Troubleshooting ADV 6121 C Figure 6 8 Decision Maker 1 Expanded Relay Controller with F 254717 Circuit Board...

Page 66: ...remote computer Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Moving rotor WARNING Grounding electrical equi...

Page 67: ...f the start stop switch N 4 and 47 See Wiring Diagrams D Check the battery condition and connections Do the above items check out okay Yes Is the 10 amp fuse functioning Is the K4 relay LED4 lit The K...

Page 68: ...okay No Yes Replace the circuit board Repair replace the wiring harness No Unit starts but then shuts down Is the K2 relay energized Yes Is the K10 with F 254717 or K5 with E 254717 relay energized N...

Page 69: ...es Is the K3 relay LED3 lit No Check for 120 volts AC output from the stator 10 7 winding at V0 and V7 See Section 7 Stator Testing Run the generator set while performing this test Test the speed sens...

Page 70: ...TP 5737 5 01 56 Section 6 Decision Makert 1 Controller Troubleshooting Notes...

Page 71: ...y an automatic transfer switch remote start stop switch or engine start command from a remote computer Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards...

Page 72: ...place the photo transistor board If no voltage is detected test the rotor Do the exciter armature and main field windings check out okay If no DC voltage is present unplug the connector at the LED cir...

Page 73: ...eplace the voltage regulator Yes No Yes No No Yes Yes No Figure 7 2 Troubleshooting Generator High Output Voltage Accidental starting Can cause severe injury or death Disconnect the battery cables bef...

Page 74: ...meter for AC output voltage 2 If AC output is not present then a Check wire 1B from the safeguard breaker and wire 7N ground to the voltage regulator b Check for voltage to the safeguard breaker if eq...

Page 75: ...Hz 60 Hz C A LED BOARD PHOTO TRANSISTOR BOARD MAGNETS MAGNETS EXCITER ARMATURE SCR ASSEMBLY GENERATOR FIELD 12 LEAD STATOR BATTERY STARTER P S P HC 15 AMP CONTROL RELAY CONTACTS SELECTOR SWITCH T3 T1...

Page 76: ...y 3 Check the stator for shorted or open windings See Section 7 6 Stator 4 Verify the AVR adjustment See Section 7 5 Automatic Voltage Regulator Operation and Adjustment 7 3 LED Circuit Board Test The...

Page 77: ...be high Switch the flashlight off or turn it away from the rotating photo transistor board The AC output voltage should be low If these conditions exist high voltage while the photo transistor board i...

Page 78: ...oving the entire SCR assembly for testing See Section 7 9 End Bracket Removal and Replacement and Section 8 Disassembly Reassembly for end bracket removal Testing the SCR assembly and photo transistor...

Page 79: ...orking Note When testing the SCR assembly secure all connections with nuts to ensure good contact between the wire terminals and the foil pattern The threaded studs are insulated from the foil pattern...

Page 80: ...er until minimum flicker is obtained 6 Use the controller voltage adjustment potentiometer or remote voltage adjustment potentiometer to make adjustments to the generator while running under normal lo...

Page 81: ...oller If this circuit is open repair or replace the inoperative components and or wiring 6 Check for battery voltage at the voltage regulator harness plug pins 2 and 11 with the generator set running...

Page 82: ...ot windings exist See Figure 7 12 Note Disconnect V7 V8 V9 and V0 leads at the controller AC fuse terminal blocks before performing the open winding test b Open windings With an ohmmeter check each pa...

Page 83: ...t Removal and Replacement and Section 8 Disassembly Reassembly 3 Disconnect F and F from the SCR assembly 4 With an ohmmeter check for continuity across the F and F leads see Figure 7 14 Resistance re...

Page 84: ...ere injury or death Avoid touching the generator set field or exciter armature When shorted the generator set field and exciter armature become hot enough to cause severe burns Exciter Armature Test 1...

Page 85: ...icates the field winding is functional A reading of less than 5 7 kOhms approximately indicates deterioration of the winding insulation and possible current flow to ground 8 Repair or replace the roto...

Page 86: ...ch inside the stator shell and disconnect the photo transistor board leads from the SCR assembly to allow for slack when removing the end bracket 5 Remove the four bolts holding the end bracket to the...

Page 87: ...speed sensor voltmeter and DC voltage source as shown in Figure 7 19 o 1 2 3 TP 5353 7 1 DC voltmeter 2 12 volt battery or DC power supply 3 Speed sensor Figure 7 19 Speed Sensor Test 2 Touch the sens...

Page 88: ...ts can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment 7 1...

Page 89: ...r master switch in the RUN position 5 Use the controller or remote voltage adjusting potentiometer on each generator set to fine adjust voltage as necessary 6 Apply resistive load 1 0 power factor unt...

Page 90: ...n information Use the engine service manual for troubleshooting ECM senders switches 7 13 1 Oil Pressure Sender Testing Disconnect the oil pressure sender lead 7C See Figure 7 21 Check the sender resi...

Page 91: ...d control to the fuel injection pump lever 5 Stop the generator set TP 5353 7 1 2 1 Injection pump lever 2 Fast idle adjusting screw Figure 7 23 Governor Adjustments Typical 7 14 2 Electronic Governor...

Page 92: ...he power is off The magnetic pickup air gap is 0 36 0 71 mm 0 014 0 028 in TP 5353 7 1 2 1 Actuator 2 Linkage Figure 7 26 Throttle Actuator Barber Colman Dyna 2500 John Deere 6076 Shown The Barber Col...

Page 93: ...3 If governing is unstable turn the I and gain potentiometers slightly CCW Note Except for the speed potentiometer control unit potentiometers have internal stops at 0 and 100 4 With the engine runnin...

Page 94: ...guard breaker terminal strip 5 Connect to cranking solenoid battery 6 Connect to 70 on safeguard breaker terminal strip 7 Actuator 8 Magnetic pickup Figure 7 28 Governor Control Unit Nonparalleling Ge...

Page 95: ...pump s internal components Note Follow this procedure carefully to prevent engine overspeed and damage to the generator or other load 3 Turn the droop adjusting screw counterclockwise until it stops...

Page 96: ...ockwise until the engine becomes unstable After the engine becomes unstable slowly turn the gain potentiometer counterclockwise until stable Interrupt the governor by momentarily removing power from t...

Page 97: ...tions exist which may require taking notes The reassembly procedure includes important alignment steps and provides critical torque specs Accidental starting Can cause severe injury or death Disconnec...

Page 98: ...ondition Donotreplaceflexiblefuellineswithrigidlines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulat...

Page 99: ...ltage regulator panel 3 Voltage regulator 4 Voltage regulator wiring harness 5 Junction box cover 6 Junction box panel 7 Junction box 8 Alternator assembly 9 End bracket cover 10 Skid 11 Generator fan...

Page 100: ...circuit board cover 2 LED circuit board 3 Photo transistor board 4 Insulating washer 5 Insulator 6 Magnetic actuator 7 End bracket 8 Exciter field assembly 9 Rotor assembly 10 SCR assembly 11 Generat...

Page 101: ...ywheel housing 6 Remove the nuts and spacers holding the drive discs to the flywheel 7 Work the drive discs over the studs if equipped to separate the generator set from the engine See Figure 8 4 8 Se...

Page 102: ...wly lower the rotor to a horizontal position Set the rotor on a wooden surface Take care not to damage the windings laminations or bearing See Figure 8 7 14 Place the generator set assembly on the gen...

Page 103: ...ring inside the end bracket bore Install a new tolerance ring when reinstalling the end bracket 2 Place the stator in a vertical position with the end bracket side up Note The end bracket side of the...

Page 104: ...sembly on the end bracket end when installing the rotor Fasten the hoisting hook to the end bracket eye and lower the generator set assembly to a horizontal position 8 Attach the hoisting hooks to the...

Page 105: ...Figure 8 14 Push the lead through the hole in the rotor shaft and then through the exciter laminations ending near the SCR assembly 11 Attach the photo transistor board and magnetic actuator to the e...

Page 106: ...ssembly in a horizontal position Take care not to damage the rotor or stator Position the generator set so that the hoisting eyes are to the top 16 Apply LoctiteR No 271 red to the stud threads if so...

Page 107: ...ywheel Torque the hardware to the values given in Section 1 Specifications Generator 22 Install the fan guard 23 Install the speed sensor and set the speed sensor air gap at 0 36 0 71 mm 0 01 0 03 in...

Page 108: ...TP 5737 5 01 94 Section 8 Disassembly Reassembly Notes...

Page 109: ...ch or engine start command from a remote computer Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Moving rotor...

Page 110: ...TP 5737 5 01 96 Section 9 Wiring Diagrams Notes...

Page 111: ...TP 5737 5 01 97 Section 9 Wiring Diagrams 344496A E Figure 9 1 Wiring Diagram Decision Makert 1 Standard Controller Sheet 1 of 3...

Page 112: ...TP 5737 5 01 Section 9 Wiring Diagrams 98 344496B E Figure 9 2 Wiring Diagram Decision Makert 1 Standard Controller Remote Panel Options Sheet 2 of 3...

Page 113: ...TP 5737 5 01 99 Section 9 Wiring Diagrams 344496C E Figure 9 3 Wiring Diagram Decision Makert 1 Standard Controller Remote Panel Options Sheet 3 of 3...

Page 114: ...TP 5737 5 01 Section 9 Wiring Diagrams 100 344497A D Figure 9 4 Wiring Diagram Decision Makert 1 Expanded Controller Sheet 1 of 4...

Page 115: ...TP 5737 5 01 101 Section 9 Wiring Diagrams 344497B D Figure 9 5 Wiring Diagram Decision Maker t1 Expanded Controller Remote Panel Options Sheet 2 of 4...

Page 116: ...TP 5737 5 01 Section 9 Wiring Diagrams 102 344497C D Figure 9 6 Wiring Diagram Decision Maker t1 Expanded Controller Remote Panel Options Sheet 3 of 4...

Page 117: ...TP 5737 5 01 103 Section 9 Wiring Diagrams 344497D D Figure 9 7 Wiring Diagram Decision Makert 1 Expanded Controller Remote Panel Options Sheet 4 of 4...

Page 118: ...TP 5737 5 01 Section 9 Wiring Diagrams 104 344498A C Figure 9 8 Wiring Diagram Decision Makert 3 Controller Sheet 1 of 5...

Page 119: ...TP 5737 5 01 105 Section 9 Wiring Diagrams 344498B C Figure 9 9 Wiring Diagram Decision Makert 3 Controller Remote Panel Options Sheet 2 of 5...

Page 120: ...TP 5737 5 01 Section 9 Wiring Diagrams 106 344498C C Figure 9 10 Wiring Diagram Decision Makert 3 Controller Remote Panel Options Sheet 3 of 5...

Page 121: ...TP 5737 5 01 107 Section 9 Wiring Diagrams 344498D C Figure 9 11 Wiring Diagram Decision Makert 3 Controller Remote Panel Options Sheet 4 of 5...

Page 122: ...TP 5737 5 01 Section 9 Wiring Diagrams 108 344498E C Figure 9 12 Wiring Diagram Decision Makert 3 Controller Remote Panel Options Sheet 5 of 5...

Page 123: ...TP 5737 5 01 109 Section 9 Wiring Diagrams ADV 6120 A Figure 9 13 Decision Maker 1 Relay Controller with E 254717 Circuit Board...

Page 124: ...TP 5737 5 01 Section 9 Wiring Diagrams 110 ADV 6120 D Figure 9 14 Wiring Diagram Decision Makert 1 Standard Controller with F 254717 Circuit Board...

Page 125: ...TP 5737 5 01 111 Section 9 Wiring Diagrams ADV 6121 Figure 9 15 Decision Maker 1 Expanded Relay Controller with E 254717 Circuit Board...

Page 126: ...TP 5737 5 01 Section 9 Wiring Diagrams 112 ADV 6121 C Figure 9 16 Wiring Diagram Decision Makert 1 Expanded Controller with F 254717 Circuit Board...

Page 127: ...TP 5737 5 01 113 Section 9 Wiring Diagrams ADV 6122 B Figure 9 17 Wiring Diagram Decision Makert 3 Controller...

Page 128: ...TP 5737 5 01 Section 9 Wiring Diagrams 114 Notes...

Page 129: ...fault lamp active low if used 63 Low fuel LF fault connect fuel level sensor to TB1 63 to activate fault lamp active low if used 70C Generator in cool down mode signal 70R Generator in running mode s...

Page 130: ...negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop...

Page 131: ...sets are reconnectable The 6 lead 600 volt generator set is not reconnectable Some specially wound stators made for a single voltage are also not reconnectable Note 600 volt models only Use 1 turn of...

Page 132: ...wardthegeneratorset Somegeneratorsetshave no current transformers Note Phase Rotation A L1 B L2 and C L3 Note All 12 lead generator sets are reconnectable The 6 lead 600 volt generator set is not reco...

Page 133: ...or 3 phase configuration depending on generator set connection Connect a voltmeter across leads L1 and L2 if the controller has no meters Note Equipment damage Verify that the voltage ratings of the...

Page 134: ...ge to 115 of the nominal output voltage using the voltage adjustment potentiometer If the voltage configuration is 139 240 volts low wye or 277 480 volts high wye 3 phase 4 wire 60 Hz adjust the outpu...

Page 135: ...rminal 2 T1 terminal 3 T3 terminal Figure 9 25 Jumper Location for 50 or 60 Hz Operation 9 3 2 Frequency Adjustment Check the frequency meter for a no load reading of 63 Hz for 60 Hz operation and 53...

Page 136: ...TP 5737 5 01 122 Section 9 Wiring Diagrams Notes...

Page 137: ...e 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...

Page 138: ...onal Safety and Health Administration O V overvoltage oz ounce p pp page pages PA packed accessory PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase PHC Phillips hea...

Page 139: ...p 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...

Page 140: ...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...

Page 141: ...al 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 Krom...

Page 142: ...6024 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...

Page 143: ...25 x 20 M933 10020 60 M10 1 50 x 20 M933 10025 60 M10 1 50 x 25 M933 10030 60 M10 1 50 x 30 M933 10030 82 M10 1 50 x 30 M961 10035 60 M10 1 25 x 35 M933 10035 60 M10 1 50 x 35 M933 12016 60 M12 1 75...

Page 144: ...Log Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were performed Enter hours to the nearest quarter hour OPERATING HOURS SERVIC...

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Page 148: ...5 3381 Web site www kohlergenerators com Fax 920 459 1646 U S A Sales Fax 920 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444 Kohlerr Power Sys...

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