Kohler 4EFCD-Low CO Service Manual Download Page 85

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TP-6391 9/08

Appendix 85

Metric

Hex head bolts are hardness grade 8.8 unless noted.

Part No.

Dimensions

Hex Head Bolts (Partial Thread)

M931-05055-60

M5-0.80 x 55

M931-06040-60

M6-1.00 x 40

M931-06055-60

M6-1.00 x 55

M931-06060-60

M6-1.00 x 60

M931-06060-SS

M6-1.00 x 60

M931-06070-60

M6-1.00 x 70

M931-06070-SS

M6-1.00 x 70

M931-06075-60

M6-1.00 x 75

M931-06090-60

M6-1.00 x 90

M931-06145-60

M6-1.00 x 145

M931-06150-60

M6-1.00 x 150

M931-08035-60

M8-1.25 x 35

M931-08040-60

M8-1.25 x 40

M931-08045-60

M8-1.25 x 45

M931-08050-60

M8-1.25 x 50

M931-08055-60

M8-1.25 x 55

M931-08055-82

M8-1.25 x 55*

M931-08060-60

M8-1.25 x 60

M931-08070-60

M8-1.25 x 70

M931-08070-82

M8-1.25 x 70*

M931-08075-60

M8-1.25 x 75

M931-08080-60

M8-1.25 x 80

M931-08090-60

M8-1.25 x 90

M931-08095-60

M8-1.25 x 95

M931-08100-60

M8-1.25 x 100

M931-08110-60

M8-1.25 x 110

M931-08120-60

M8-1.25 x 120

M931-08130-60

M8-1.25 x 130

M931-08140-60

M8-1.25 x 140

M931-08150-60

M8-1.25 x 150

M931-08200-60

M8-1.25 x 200

M931-10040-82

M10-1.25 x 40*

M931-10040-60

M10-1.50 x 40

M931-10045-60

M10-1.50 x 45

M931-10050-60

M10-1.50 x 50

M931-10050-82

M10-1.25 x 50*

M931-10055-60

M10-1.50 x 55

M931-10060-60

M10-1.50 x 60

M931-10065-60

M10-1.50 x 65

M931-10070-60

M10-1.50 x 70

M931-10080-60

M10-1.50 x 80

M931-10080-82

M10-1.25 x 80*

M931-10090-60

M10-1.50 x 90

M931-10090-82

M10-1.50 x 90*

M931-10100-60

M10-1.50 x 100

M931-10110-60

M10-1.50 x 110

M931-10120-60

M10-1.50 x 120

M931-10130-60

M10-1.50 x 130

M931-10140-60

M10-1.50 x 140

M931-10180-60

M10-1.50 x 180

M931-10235-60

M10-1.50 x 235

M931-10260-60

M10-1.50 x 260

M960-10330-60

M10-1.25 x 330

M931-12045-60

M12-1.75 x 45

M960-12050-60

M12-1.25 x 50

M960-12050-82

M12-1.25 x 50*

M931-12050-60

M12-1.75 x 50

M931-12050-82

M12-1.75 x 50*

M931-12055-60

M12-1.75 x 55

M931-12060-60

M12-1.75 x 60

M931-12060-82

M12-1.75 x 60*

M931-12065-60

M12-1.75 x 65

M931-12075-60

M12-1.75 x 75

M931-12080-60

M12-1.75 x 80

M931-12090-60

M12-1.75 x 90

M931-12100-60

M12-1.75 x 100

M931-12110-60

M12-1.75 x 110

Part No.

Dimensions

Hex Head Bolts (Partial Thread),
continued

M960-16090-60

M16-1.50 x 90

M931-16090-60

M16-2.00 x 90

M931-16100-60

M16-2.00 x 100

M931-16100-82

M16-2.00 x 100*

M931-16120-60

M16-2.00 x 120

M931-16150-60

M16-2.00 x 150

M931-20065-60

M20-2.50 x 65

M931-20090-60

M20-2.50 x 90

M931-20100-60

M20-2.50 x 100

M931-20120-60

M20-2.50 x 120

M931-20140-60

M20-2.50 x 140

M931-20160-60

M20-2.50 x 160

M931-22090-60

M22-2.50 x 90

M931-22120-60

M22-2.50 x 120

M931-22160-60

M22-2.50 x 160

M931-24090-60

M24-3.00 x 90

M931-24120-60

M24-3.00 x 120

M931-24160-60

M24-3.00 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

M933-06050-60

M6-1.00 x 50

M933-07025-60

M7-1.00 x 25

M933-08010-60

M8-1.25 x 10

M933-08012-60

M8-1.25 x 12

M933-08016-60

M8-1.25 x 16

M933-08020-60

M8-1.25 x 20

M933-08025-60

M8-1.25 x 25

M933-08030-60

M8-1.25 x 30

M933-08030-82

M8-1.25 x 30*

M933-10012-60

M10-1.50 x 12

M961-10020-60

M10-1.25 x 20

M933-10020-60

M10-1.50 x 20

M933-10025-60

M10-1.50 x 25

M961-10025-60

M10-1.25 x 25

M933-10025-82

M10-1.50 x 25*

M961-10030-60

M10-1.25 x 30

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

M933-10035-82

M10-1.50 x 35*

M961-10040-60

M10-1.25 x 40

Part No.

Dimensions

Hex Head Bolts (Full Thread),
continued

M933-12016-60

M12-1.75 x 16

M933-12020-60

M12-1.75 x 20

M961-12020-60F

M12-1.50 x 20

M933-12025-60

M12-1.75 x 25

M933-12025-82

M12-1.75 x 25*

M961-12030-60

M12-1.25 x 30

M933-12030-82

M12-1.75 x 30*

M961-12030-82F

M12-1.50 x 30*

M933-12030-60

M12-1.75 x 30

M933-12035-60

M12-1.75 x 35

M961-12040-82

M12-1.25 x 40*

M933-12040-60

M12-1.75 x 40

M933-12040-82

M12-1.75 x 40*

M961-14025-60

M14-1.50 x 25

M933-14025-60

M14-2.00 x 25

M961-14050-82

M14-1.50 x 50*

M961-16025-60

M16-1.50 x 25

M933-16025-60

M16-2.00 x 25

M961-16030-82

M16-1.50 x 30*

M933-16030-82

M16-2.00 x 30*

M933-16035-60

M16-2.00 x 35

M961-16040-60

M16-1.50 x 40

M933-16040-60

M16-2.00 x 40

M961-16045-82

M16-1.50 x 45*

M933-16045-82

M16-2.00 x 45*

M933-16050-60

M16-2.00 x 50

M933-16050-82

M16-2.00 x 50*

M933-16060-60

M16-2.00 x 60

M933-16070-60

M16-2.00 x 70

M933-18035-60

M18-2.50 x 35

M933-18050-60

M18-2.50 x 50

M933-18060-60

M18-2.50 x 60

M933-20050-60

M20-2.50 x 50

M933-20055-60

M20-2.50 x 55

M933-24060-60

M24-3.00 x 60

M933-24065-60

M24-3.00 x 65

M933-24070-60

M24-3.00 x 70

Pan Head Machine Screws

M7985A-03010-20 M3-0.50 x 10
M7985A-03012-20 M3-0.50 x 12

M7985A-04010-20 M4-0.70 x 10
M7985A-04016-20 M4-0.70 x 16
M7985A-04020-20 M4-0.70 x 20
M7985A-04050-20 M4-0.70 x 50
M7985A-04100-20 M4-0.70 x 100

M7985A-05010-20 M5-0.80 x 10
M7985A-05012-20 M5-0.80 x 12
M7985A-05016-20 M5-0.80 x 16
M7985A-05020-20 M5-0.80 x 20
M7985A-05025-20 M5-0.80 x 25
M7985A-05030-20 M5-0.80 x 30
M7985A-05080-20 M5-0.80 x 80
M7985A-05100-20 M5-0.80 x 100

M7985A-06100-20 M6-1.00 x 100

Flat Head Machine Screws

M965A-04012-SS

M4-0.70 x 12

M965A-05012-SS

M5-0.80 x 12

M965A-05016-20

M5-0.80 x 16

M965A-06012-20

M6-1.00 x 12

* This metric hex bolt’s hardness is grade 10.9.

Summary of Contents for 4EFCD-Low CO

Page 1: ...Marine Generator Sets Models 5ECD 4EFCD 7 3ECD 6EFCD 5ECD 4EFCD Low CO 7 3ECD 6EFCD Low CO Controller Advanced Digital Control TP 6391 9 08a Service ...

Page 2: ...TP 6391 9 08 2 ...

Page 3: ...isplay and Keypad 24 4 3 Master Switch 24 4 4 Sequence of Operation 25 4 4 1 Starting the Generator Set 25 4 4 2 Running Sequence 25 4 4 3 Stopping the Generator Set 25 4 5 Faults 25 4 5 1 Shutdowns 25 4 5 2 Warnings 25 4 5 3 SECM Fault Codes and Diagnostics 29 4 6 Relay Interface Board RIB 35 4 7 CO Sensor Module 35 4 8 K5 Main Power Relay 35 4 9 Silicon Controlled Rectifier SCR Module 36 4 10 Co...

Page 4: ...ctronic Throttle Assembly 57 5 12 Fuses 57 5 13 Continuity Checks 58 Section 6 Generator Disassembly Reassembly 59 6 1 Disassembly 59 6 2 Collector Ring and Bearing Replacement 62 6 3 Reassembly 63 Section 7 Wiring Diagrams 65 Appendix A Abbreviations 79 Appendix B Common Hardware Application Guidelines 81 Appendix C General Torque Specifications 82 Appendix D Common Hardware Identification 83 App...

Page 5: ...ore working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables 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 ...

Page 6: ...pors WARNING The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels 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 because spilled fuel may ignite on contact with hot parts or from sp...

Page 7: ...ct the generator set to the building marina electrical system only through an approved device and after the building marina main switch is turned off 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 shore...

Page 8: ...TP 6391 9 08 8 Safety Precautions and Instructions Notes ...

Page 9: ...e manuals contain operation installation and parts information not provided in this manual Separate engine Operation and Service manuals are also available The following table lists the available manual part numbers Literature Type Part Number Installation Manual TP 5982 Operation Manual Generator TP 6390 Operation Manual Engine TP 6001 Parts Catalog TP 5987 Service Manual Generator TP 6391 Servic...

Page 10: ...Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Re...

Page 11: ...4 4 4EFCD 2F2 220 1 60 18 18 4 4 7 3ECD 2F2 120 1 60 60 83 7 3 7 3 7 3ECD 2F2 120 240 1 60 30 42 7 3 7 3 110 54 55 6 6 6EFCD 2F2 110 220 1 50 27 27 6 6 6EFCD 2F2 220 1 50 27 27 6 6 RATINGS Marine continuous ratings per ISO 3046 ISO 8528 1 and Kohler ISO rating guideline 2 14 Obtain technical information bulletin TIB 101 on ratings guidelines for complete ratings definitions Figure 1 1 Generator Se...

Page 12: ...noted below or provided in the Engine Service Manual Torque Specifications 5 7 3ECD 4 6EFCD Rotor bolt 23 Nm 204 in lbs Generator overbolts 13 Nm 120 in lbs Lifting eye bolt 19 Nm 14 ft lbs Generator adapter to engine bolts 15 Nm 132 in lbs Engine oil drain boss inside generator adapter 47 Nm 35 ft lbs Generator adapter to exhaust manifold 13 6 Nm 120 in lbs Spark plugs 12 17 Nm 9 12 ft lbs Intake...

Page 13: ...mpression 1 oil Piston material Aluminum Crankshaft material Aluminum Crankshaft bearings type Inserts Governor type Electronic Lubrication system Full pressure Oil capacity w filter L qt 1 36 1 44 Oil pressure kPa psi 276 40 Oil recommendation API SC SD SE SF SG SH or SJ Fuel system type Throttle body fuel injected Battery charging 15 amps Battery voltage 12 VDC Battery ground Negative Battery re...

Page 14: ...ocated on the catalyst on the nonservice side Available on units with serial numbers 2199434 and later Appears as LOC fault on ADC 17 CO sensor module available on units with serial number 2085259 and later 18 Generator set master switch 19 Catalyst assembly water outlet exhaust outlet nonservice side 20 Seawater drain remove plate for service 21 Seawater pump water inlet 22 Cooling air inlet 23 F...

Page 15: ...ator set engine service at the intervals specified by the engine service literature Contact an authorized Kohlerr service distributor dealer to obtain engine service literature Generator Set Service See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized Kohlerr service distributor dealer perfor...

Page 16: ...XHAUST SYSTEM Inspect exhaust system components X Check the exhaust gas condition X during operation Service backfire flame arrestor X Check and or replace the catalyst assembly X Clean the water passage slots holes in the exhaust manifold catalyst X 200 hrs Replace the CO sensor module if equipped X 2 years Check the crankcase breather pipe for obstructions X Inspect the complete exhaust system X...

Page 17: ...he ADC 2100 display Section 4 5 describes the warning and shutdown fault codes D Blown fuses See Figure 3 1 for fuse identification Always check and replace the fuses before replacing other components See Figure 2 for fuse part numbers Label Amp Fuse F1 10 Auxiliary winding F2 10 Controller F3 10 Customer connection F4 15 Coils injectors F5 15 ECM O2 sensor fuel pumps and temp sender F6 15 Voltage...

Page 18: ... connector Replace any bad leads Use a pin pusher part 241918 large or 241919 small to remove leads from the connector if necessary If replacing the leads does not solve the problem replace the RIB Section 7 Section 4 6 Crank relay on relay interface board RIB Check connections to the RIB Check for 12VDC to the RIB on lead 71N Section 4 6 Section 7 Check for a good ground connection lead N Section...

Page 19: ... fuse Check ECM ground connection pin 14 Section 7 Blown F6 fuse Check voltage regulator wiring Section 7 Starts but shuts down Fault shutdown Check for a fault shutdown code on the controller s LED display Correct the fault and then move the generator set master switch to OFF RESET to reset the controller Section 4 5 Section 5 10 Stops suddenly Fault shutdown Check for a fault shutdown code on th...

Page 20: ... and or replace Engine S M Blown F5 fuse Check ECM ground connection pin 14 Section 7 Overheats Inadequate cooling Inspect cooling system for air intake obstructions Backfire flame arrestor clogged Clean or replace O M Low output Generator overloaded Reduce load p or excessive drop in Incorrect controller configuration Check and adjust the controller configuration parameters Section 4 11 2 drop in...

Page 21: ... breaker Alternator or control system Perform separate excitation procedure to isolate the problem to the alternator or the control system Then troubleshoot the alternator or control system components as follows Section 5 2 Aux winding F1 fuse blown Replace blown fuse If fuse blows again check stator Section 5 3 SCR module Check auxiliary winding fuse F1 lead 55 Replace SCR module and test voltage...

Page 22: ... See Generator set operates erratically this table Broken or damaged vibromount s Check and replace as necessary Loose or vibrating sheet metal housing Retighten screws replace rivets Exhaust piping or air inlets outlets not securely installed Inspect for loose parts and secure if necessary Excessive engine generator vibration Check rotor crankshaft bearing etc disassembly of engine and or alterna...

Page 23: ...sed with the ADC controller Section 4 6 describes the relay interface board A silicon controlled rectifier SCR module works with the controller to regulate the output voltage See Section 4 9 GM39685D J 1 LO stud 2 Ground stud 3 Relay interface board RIB 4 SCR module 5 K5 main power relay 6 Line circuit breaker panel load connection 7 Fuse location See Section 5 12 8 ADC 2100 controller 9 CO sensor...

Page 24: ...areful not to reverse the RUN and AUTO leads 1 2 4 3 1 LED display 2 Select button use for setup and adjustment only 3 Upanddownarrowbuttons useforsetupandadjustmentonly 4 Generator set master switch GM28707A C Figure 4 2 ADC Controller Controller Display Item Description Crank indication Displays CC_1 CC_2 or CC_3 to indicate the first second or third attempt to start the engine The last digit fl...

Page 25: ...ection 4 4 1 above 4 4 2 Running Sequence When the engine speed reaches 750 rpm the crank relay deenergizes and the crank LED 3 turns off When the output voltage on leads 11 and 44 reaches about 30 VAC the flash relay deenergizes and the flash LED 2 turns off 4 4 3 Stopping the Generator Set The following procedures describe the actions required to stop the generator set Local Stopping 1 Run the g...

Page 26: ...urs if communication is lost between the CO sensor and the ADC Check the connections to the CO sensor If connections are okay replace the CO sensor Contact an authorized distributor dealer for service HE High engine temperature Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This protective becomes active after the engine reaches the crank ...

Page 27: ...system controlled by the engine ECM Engine S M OU Overvoltage Shutdown occurs if the voltage exceeds 120 of the system nominal voltage for more than 2 seconds Check AC voltage Check wiring and connections 5 7 7 UF Underfrequency Shutdown occurs when the governed frequency falls blow 90 of the nominal system frequency for more than 5 seconds or below 59 Hz for more than 60 seconds This protective b...

Page 28: ...rized distributor dealer for service if problem continues CO 6 Carbon monoxide sensor warning Fault code is displayed if the CO sensor is inoperative Replace the CO sensor Contact an authorized distributor dealer for service if problem continues HB High battery voltage warning Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for ...

Page 29: ...tructions inside the throttle body a loose throttle plate or the throttle plate shaft for bearing wear Check the ETC driver wiring for an open circuit ETC Pin 1 to SECM Pin 22 ETC Pin 4 to SECM Pin 24 Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS Pin 1 DRIVER to Pin 4 Driver approx 3 0 Ohms 30 NOTE Do not ser...

Page 30: ...ed or the circuit is opened to the SECM EC50 and EC56 are expected faults when the TMAP connector is unplugged Check the TMAP connector and MAP signal wiring for an open circuit TMAP Pin 4 to SECM Pin 5 SIGNAL TMAP Pin 1 to SECM Pin 1 GND TMAP Pin 3 to SECM Pin 18 XDCR 5VDC Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP Pin 1 GND to Pin 4 PRESSURE SIGNAL ...

Page 31: ...emperature ECT Sensor Input Low Fault appears if the coolant sensor wire is shorted to ground or the sensor has failed Check the sensor connector and wiring for a short to GND SECM SIGNAL Pin 16 to ECT Pin A SECM GND Pin 1 to ECT Pin B EC60 Oxygen Sensor Input High Fault appears if the O2 sensor SECM driver signal is shorted to power Check if the O2 sensor is shorted to 5VDC or battery O2 SIGNAL P...

Page 32: ...n the non service side of the generator set behind the ADC 2100 control NOTE Older harness designs have a small black relay that is mounted to the generator end bell with spade connectors at the bottom Newer harness designs after serial number 2175814 have the relay attached directly to the harness P30 connector at the same location Verify power at 12P wire at the K5 relay Reference negative to P1...

Page 33: ...re the resistance at the P1 ADC connector pins 11 and 10 YEL and GRN labeled wires The meter should indicate 60 ohms If the meter reads 0 ohms there s an open circuit between the pins to the R1 resistor If the meter reads 120 ohms the two resistors in the harness are no longer in parallel Check the connections between the resistors Verify a resistance of 60 ohms at the P4 customer interconnect con...

Page 34: ... parallel Check the connections between the resistors Verify resistance of 60 ohms at the P10 ECM connector wires BLK and RED pins 6 and 19 If the meter reads 0 ohms there s an open circuit between these pins wires and or the harness resistors If the meter reads 120 ohms the two resistors in the harness are no longer in parallel Check the connections between the resistors Figure 4 8 Troubleshootin...

Page 35: ... the new board onto the stand offs and reconnect P14 and the brush leads 4 GM29671 A 1 K1 common fault relay optional 2 K2 crank relay standard 3 K3 flash relay standard 4 K4 auxiliary run relay optional 5 K5 run relay standard 6 P14 engine harness connection standard 7 P13 connection to optional relay harness optional FLASH K3 VBAT D3 D1 D2 K1 FLASH LED2 CRANK LED3 D4 D5 T2 FP 9 FN T1 7 RUN R R R...

Page 36: ... D Jumper 1 Set the ohmmeter to the R x 1 scale 2 Connect the ohmmeter from to on the SCR module You should read high resistance in one direction and low resistance in the other reverse the leads GM28483 G1 G2 AC2 AC1 Figure 4 12 Silicon Controlled Rectifier SCR Module 3 Connect the ohmmeter from AC1 to on the SCR module You should read high resistance in both directions 4 Connect the ohmmeter fro...

Page 37: ... Adjustment Procedure in Section 5 7 2 and the controller voltage adjustment instructions in Section 4 11 ADC 2100 Controller Replacement Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger if equipped 3 Disconnect the generator set engine starting battery negative lead first 4 Remove four mounting screws from the front of the controller ...

Page 38: ...ital voltmeter is required for these adjustments Use a voltmeter to check the output voltage If the output voltage is not within specifications use the ADC controller to adjust the output voltage while the generator set is running The flowcharts in Figure 4 16 and Figure 4 17 outline the adjustment procedures Note Be sure to save your settings before exiting the configuration mode Voltage changes ...

Page 39: ...de or To raise or lower the voltage stability gain in smaller increments To enter volts Hz adjustment mode To raise or lower the volts Hz 00 low 09 high or Hold Wait about 5 seconds until the display changes from runtime hours to the program version number Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password x x x x x x 1 P 1 P 2 P...

Page 40: ... switch is moved to the OFF RESET position To save changes To discard changes without saving or S A V E Y E S Now move the master switch to OFF RESET n o There are 3 options when the display says SAVE Press or To return to the first parameter coarse voltage adjustment to check or change settings before saving See Figure 4 16 Yes or no flashes when the up or down arrow is pressed and then the contr...

Page 41: ...e This parameter sets the nominal system voltage and frequency To adjust the output measured voltage see Section 4 11 Unit configuration Uc This parameter sets the generator set type marine standby or mobile The setting for the 5 7 3ECD and 4 6EFCD is Uc00 marine Engine configuration Ec The engine configuration must match the generator set engine type The engine configuration setting for the 5 7 3...

Page 42: ...der Kits Gauge Kit Gauge Description Cn Setting Power Down Time when master switch in AUTO position Description None Cn00 48 hours No CAN communication not for use with these models GM32337 KP1 Remote Digital Gauge for Marine Cn01 Never None 3 inch J1939 gauge with no sleep mode CAN communication not for use with these models GM46035 KP1 Three Inch Digital Gauge Cn02 48 hours Smartcraftt 3 inch ga...

Page 43: ... the engine type to Ec04 if necessary U u 0 x U c 0 0 U u 0 x 1 0 4 0 A d n c Press Now release the Select button or To enter advanced configuration mode Go to Figure 4 22 or To proceed to the save mode without entering the advanced configuration mode Go to Figure 4 23 Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs battery voltage and communica...

Page 44: ... reverts to the last saved settings when the master switch is moved to the OFF RESET position Figure 4 22 Advanced Configuration Mode engine data input types battery voltage and engine communications To save changes To discard changes without saving or x in the runtime hours display above denotes any number from 0 to 9 S A V E Y E S Now move the master switch to OFF RESET n o There are 3 options w...

Page 45: ...eck the condition of the alternator fuse before performing the separate excitation procedure See Figure 5 1 The fuse is located on the fuse panel See Figure 4 1 for the fuse panel location If the fuse is not blown use the following procedure to separately excite the generator using an external voltage source a 12 volt automotive battery Separately exciting the generator can identify faulty voltage...

Page 46: ... FN brush leads as shown in Figure 5 3 Note and record the ammeter reading Note The approximate ammeter reading should be the battery voltage divided by the specified rotor resistance See Section 1 Specifications for specified rotor resistance values Example 12 volts battery voltage 3 4 ohms rotor resistance 3 5 amps rotor current 3 Start the engine and check that the ammeter reading remains stabl...

Page 47: ...ect the generator set engine starting battery negative lead first 4 Disconnect all stator leads before performing all stator tests 5 To check for stator continuity set the ohmmeter on R x 1 scale First set the ohmmeter zero by holding the red and black meter leads together and setting the ohmmeter reading to zero Then check the stator continuity by connecting the meter leads to the stator leads as...

Page 48: ...mage to pole shoes insulation exposed coil windings and slip ring surfaces Rotate the bearing to check for wear heat discoloration or noise 5 4 1 Rotor Continuity and Resistance Tests Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Moving parts WARNING High voltage test Hazardous voltage can cause severe injur...

Page 49: ... to determine whether the rotor is shorted to ground a Raise and secure the brushes away from the slip rings by inserting a retaining wire in the brush holder hole b Using a megohmmeter apply 500 volts DC to one rotor slip ring and the rotor poles or shaft Follow the instructions of the megohmmeter manufacturer when performing this test Note A reading of approximately 500 kOhms 1 2 megohm or highe...

Page 50: ... controller Weak springs damaged slip rings sticking brushes a loose brush holder or poor brush contact causes arcing The brushes must be free to move within the holder and be held in contact with the slip rings by the springs When correctly positioned spring pressure on the brush surface causes the brush to wear evenly The entire brush must ride on the ring or arcing occurs and causes burned ring...

Page 51: ...e voltage current drop enables the engine to pick up the load When the generator speed returns to normal 60 Hz or 50 Hz as load is accepted the generator output also returns to normal Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Moving parts WARNING Short circuits Hazardous voltage current can cause severe ...

Page 52: ...tdown Tests Verify the operation of the generator set overspeed overcrank and low oil pressure shutdowns by performing the following tests If these tests are inconclusive test individual shutdown circuit components wiring harness switch etc as described elsewhere in this section Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosu...

Page 53: ... it Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Moving parts WARNING Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens a...

Page 54: ... Disconnect the TMAP sensor and use an ohmmeter to measure the resistance across the sensor The sensor resistance varies with temperature and should be within the values shown in Figure 5 15 If the resistance is very low indicating a short circuit or very high indicating an open circuit replace the TMAP sensor 1 GM39685D J 1 TMAP Sensor 2 Manifold elbow 3 Intake manifold assembly 2 3 Figure 5 13 T...

Page 55: ...he OFF position and allow the generator set to cool Disconnect the crankshaft position sensor and use an ohmmeter to measure the resistance across the sensor pins See Figure 5 18 Ignition Coil This system uses a single coil incorporating the ignition driver circuitry inside the coil See Figure 5 19 The ECM signals the coil to begin its cycle Then the coil waits for the trigger signal from the ECM ...

Page 56: ...V the ECM interprets the air fuel mixture as lean so the ECM decreases the duty cycle If the ECM receives a voltage signal above 500mV the air fuel mixture would be interpreted as too rich and the ECM would increase the duty cycle Set the generator set master switch to the OFF position and allow the generator set to cool Disconnect the heated oxygen sensor and use an ohmmeter to measure the resist...

Page 57: ...llow the generator set to cool Disconnect the TPS sensor and use an ohmmeter to measure the resistance across the sensor pins See Figure 5 25 TPS Electronic Throttle Sensor Pin Resistance Check approx Pin 2 GND to Pin 6 TPS1 SIGNAL 1 25 kOhms 30 Pin 3 PWR to Pin 6 TPS1 SIGNAL 1 25 kOhms 30 Pin 1 DRIVER to Pin 4 DRIVER 3 0 Ohms 30 Figure 5 25 TPS Electronic Throttle Sensor Resistance 5 12 Fuses See...

Page 58: ...hecks to prevent damage to the ohmmeter To further check generator set components disconnect the battery and remove wiring harness plugs from the controller circuit board Refer to the wiring diagrams in Section 7 and use an ohmmeter to check for continuity and good ground connections A zero reading on the ohmmeter indicates continuity No ohmmeter reading indicates very high resistance or an open c...

Page 59: ...connect power to the battery charger if equipped 3 Disconnect the generator set engine starting battery negative lead first Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery WARNING 4 Disconnect wiring harn...

Page 60: ...plate 2 Vibromount hardware 3 Seawater pump 3 Figure 6 3 Alternator End Cover 19 Attach a hoist hook to the generator lifting eye Note The hoist capacity rating should be one half ton or greater 20 Tilt the generator set up and brace it with a block of wood See Figure 6 4 1 1 Block of wood 598691 Figure 6 4 Raising the Generator 21 Remove the overbolts See Figure 6 6 Use a rubber mallet to separat...

Page 61: ...h holder shim 7 Rotor bolt 8 Hardened washer 9 Generator overbolt quantity 4 10 Retainer wire 11 Brush assembly mounting screws quantity 2 12 Bracket brush holder 13 Fan guard bolts quantity 2 14 Fan guard 15 End bracket 16 Pipe plug 17 End drive fitting 18 End bracket bearing 19 O ring 20 Stator assembly 21 Rotor assembly 15 16 9 9 9 1 2 3 4 5 6 7 17 18 19 20 21 Figure 6 6 Alternator Assembly Com...

Page 62: ...otor shaft Note The new collector rings must be turned down to a finish of 32 micro inches using a lathe and commutator stones Turn down the collector rings on the rotor shaft 7 Solder the leads onto the collector ring terminals The connection is not to exceed 9 65 mm 0 38 in beyond the collector rings See Figure 6 8 8 Test to ensure continuity at the collector rings Min diameter mm in 57 15 2 250...

Page 63: ...hers and a locknut on each vibromount Tighten the mounting bolts 10 Install the SCR module and relay board 11 Reinstall the support bracket to mount the junction box See Figure 4 1 12 Install tie wraps to secure the wires as necessary 13 Reconnect the leads to the circuit breaker QCON1 to the F1 fuse FP and FN leads neutral stud LO and ground stud GRD as marked during disassembly Refer to the wiri...

Page 64: ...TP 6391 9 08 64 Section 6 Generator Disassembly Reassembly Notes ...

Page 65: ...Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Nevercontact electricalleadsor applianceswhen standingin wateror onwet ground because these condi...

Page 66: ...TP 6391 9 08 66 Section 7 Wiring Diagrams GM39836A F Figure 7 1 Point to Point Wiring Diagram Sheet 1 of 2 For Units With Serial Numbers before 2085259 ...

Page 67: ...TP 6391 9 08 67 Section 7 Wiring Diagrams GM39836B F Figure 7 2 Point to Point Wiring Diagram Sheet 2 of 2 For Units With Serial Numbers before 2085259 ...

Page 68: ...TP 6391 9 08 68 Section 7 Wiring Diagrams ADV7029A F Figure 7 3 Schematic Wiring Diagram Sheet 1 of 2 For Units With Serial Numbers before 2085259 ...

Page 69: ...TP 6391 9 08 69 Section 7 Wiring Diagrams ADV7029B F Figure 7 4 Schematic Wiring Diagram Sheet 2 of 2 For Units With Serial Numbers before 2085259 ...

Page 70: ...TP 6391 9 08 70 Section 7 Wiring Diagrams GM39836A H Figure 7 5 Point to Point Wiring Diagram Sheet 1 of 2 For Units With Serial Number 2085259 to 2199434 ...

Page 71: ...TP 6391 9 08 71 Section 7 Wiring Diagrams GM39836B H Figure 7 6 Point to Point Wiring Diagram Sheet 2 of 2 For Units With Serial Number 2085259 to 2199434 ...

Page 72: ...TP 6391 9 08 72 Section 7 Wiring Diagrams ADV7029A G Figure 7 7 Schematic Wiring Diagram Sheet 1 of 2 For Units With Serial Number 2085259 to 2199434 ...

Page 73: ...TP 6391 9 08 73 Section 7 Wiring Diagrams ADV7029B G Figure 7 8 Schematic Wiring Diagram Sheet 2 of 2 For Units With Serial Number 2085259 to 2199434 ...

Page 74: ...TP 6391 9 08 74 Section 7 Wiring Diagrams GM50546A B Figure 7 9 Point to Point Wiring Diagram Sheet 1 of 2 ...

Page 75: ...TP 6391 9 08 75 Section 7 Wiring Diagrams GM50546B B Figure 7 10 Point to Point Wiring Diagram Sheet 2 of 2 ...

Page 76: ...TP 6391 9 08 76 Section 7 Wiring Diagrams ADV7285A B Figure 7 11 Schematic Wiring Diagram Sheet 1 of 2 ...

Page 77: ...TP 6391 9 08 77 Section 7 Wiring Diagrams ADV7285B B Figure 7 12 Schematic Wiring Diagram Sheet 2 of 2 ...

Page 78: ...TP 6391 9 08 78 Section 7 Wiring Diagrams Notes ...

Page 79: ...rmer 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 p...

Page 80: ...on 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 p...

Page 81: ...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 82: ...m ft lb 259 0 191 721 0 532 1109 0 818 1 12 Nm ft lb 283 0 209 789 0 582 1214 0 895 Metric Fasteners Torque Specifications Measured in Nm ft lb Assembled into Cast Iron or Steel Assembled into Aluminum Size mm Grade 5 8 Grade 8 8 Grade 10 9 Aluminum Grade 5 8 or 8 8 M6 x 1 00 6 2 4 6 9 5 7 13 6 10 M8 x 1 25 15 0 11 23 0 17 33 0 24 M8 x 1 00 16 0 11 24 0 18 34 0 25 M10 x 1 50 30 0 22 45 0 34 65 0 4...

Page 83: ...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 84: ...4 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 29...

Page 85: ... 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 86: ...12 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 B...

Page 87: ...TP 6391 9 08 87 ...

Page 88: ... Kohler 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 KohlerPower 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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