Service
Residential/Commercial Generator Sets
Models:
15/30RYG
15/30RES
Controller:
Advanced Digital Control
TP-6198 10/04a
Table of Contents
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Generator Set Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Service View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
14
14
15
15
16
Section 2 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1
Cleaning Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
17
19
19
20
Section 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
21
21
Section 4 Controller
4.1
4.2
4.3
4.4
27
27
28
28
29
29
29
29
29
29
30
30
30
30
33
34
35
35
38
42
.......................................................................
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1
Starting Sequence, Master Switch Moved to RUN . . . . . . . . . . . . . . . . .
4.4.2
Starting Sequence, Remote Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3
Running Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4
Stopping Sequence, Master Switch Moved to OFF/RESET . . . . . . . . . .
4.4.5
Stopping Sequence, Remote Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2
Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Relay Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Silicon Controlled Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Controller Configuration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.1
Voltage Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.2
Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Continuous Power Mode Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TP-6198 10/04
Table of Contents
Table of Contents, continued
Section 5 Component Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Main Field (Rotor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.1
Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.2
Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 Voltage Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9 Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10 Fault Shutdown Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.1 Controller Fault Shutdown Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.2 Fault Shutdown Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11 Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.1 Fuel Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.2 Fuel Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.3 Fuel Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.12 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.13 Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
43
43
44
46
47
48
49
49
49
50
50
51
51
51
52
53
53
53
53
54
Section 6 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1 Specification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2 Wiring Diagram Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
Appendix E Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
Table of Contents
TP-6198 10/04
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical
equipment,
including generator sets, transfer
switches,
switchgear,
and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of
safety precautions and instructions:
Danger, Warning, Caution, and Notice.
Accidental Starting
WARNING
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.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal
injury,
death,
or
substantial property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal
injury,
death,
or
substantial property damage.
Disabling
the
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 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 switch, remote start/stop
switch, or engine start command from a
remote computer.
CAUTION
Battery
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
WARNING
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition.
Replace missing or
damaged decals.
TP-6198 10/04
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.
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 minutes
with large quantities of clean water.
Seek immediate medical aid in the
case of eye contact. Never add acid to
a battery after placing the battery in
service, as this may result in
hazardous spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
Safety Precautions and Instructions
5
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparks to occur
near a battery at any time, particularly
when it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing
the equipment.
Discharge static
electricity from your body before
touching batteries by first touching a
grounded metal surface away from the
battery. To avoid sparks, do not disturb
the battery charger connections while
the battery is charging. Always turn the
battery
charger
off
before
disconnecting the battery connections.
Ventilate the compartments containing
batteries to prevent accumulation of
explosive gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or
equipment
damage.
Disconnect
the
battery
before
generator
set
installation
or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery.
Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
Servicing the fuel system. A flash
fire can cause severe injury or
death. Do not smoke or permit flames
or sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency.
Train all
personnel
on
fire extinguisher
operation
and
fire
prevention
procedures.
Engine Fluids and
Chemical Products
WARNING
Handling caustic engine fluids and
chemical products.
Can cause severe chemical burns,
nausea, fainting, or death.
Most chemicals such as used engine
oil, antifreeze/coolant, rustproofing
agent, inhibiting oil, degreasing
agent, spray paint, and adhesives
are hazardous to health. Read and
follow the user information found on
the packaging. Avoid inhalation and
skin contact.
Use only in
well-ventilated areas and use a protective mask when spraying. Store
engine fluids and chemical products
in a locked cabinet. Contact your local recycling center for disposal information and locations.
WARNING
Flammable engine solvents and
cleaners.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near flammable engine
solvents and cleaners. Read and
follow the user information found on
the packaging. Use only in wellventilated areas. Never use gasoline
or low flash-point solvents as
cleaning agents.
Leaking or accumulated engine
fluids. A fire can cause severe injury
or death. Clean up engine fluids
including fuel, oil, grease, and coolant.
Determine the source of engine leaks
and correct before starting the
generator set. Keep the generator set
area clean and remove combustible
materials.
6
Safety Precautions and Instructions
TP-6198 10/04
Used engine oil. Contact with used
engine oil may cause severe skin
irritation. Repeated and prolonged
skin exposure may have other
health risks. Used engine oil is a
suspected carcinogen. Avoid contact
with skin. Thoroughly wash your
hands and nails with soap and water
shortly after handling used engine oil.
Wash or dispose of clothing or rags
containing used engine oil. Dispose of
used engine oil in a responsible
manner. Contact your local recycling
center for disposal information and
locations.
Fire-damaged or burned O-rings
may cause the formation of
hydrofluoric acid.
Contact with
hydrofluoric acid may cause severe
skin irritation and chemical burns.
O-rings and other fluoroelastomer
seals exposed to fire or temperatures
above 316_C (600_F) (i.e., during
welding) may decompose forming
hydrofluoric acid. Avoid inhalation or
skin contact.
Do not incinerate
O-rings. Dispose of O-ring waste
material in a responsible manner.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe
fainting, or death.
nausea,
The exhaust system must be
leakproof and routinely inspected.
Carbon
monoxide
detectors.
Carbon monoxide can cause severe
nausea, fainting, or death. Install
carbon monoxide detectors on each
level of the building. Locate the
detectors to adequately warn the
building’s occupants of the presence of
carbon monoxide. Keep the detectors
operational at all times. Periodically
test and replace the carbon monoxide
detectors
according
to
the
manufacturer’s instructions.
TP-6198 10/04
Carbon
monoxide
symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present
in exhaust gases. Carbon monoxide is
an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Carbon
monoxide
poisoning
symptoms
include but are not limited to the
following:
D Light-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 monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
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 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. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate
the generator set in the presence of
fuel leaks, fuel accumulation, or
sparks. Repair fuel systems before
resuming generator set operation.
Carbon
monoxide
detectors.
Carbon monoxide can cause severe
nausea, fainting, or death. Install
carbon monoxide detectors on each
level of the building. Locate the
detectors to adequately warn the
building’s occupants of the presence of
carbon monoxide. Keep the detectors
operational at all times. Periodically
test and replace the carbon monoxide
detectors
according
to
the
manufacturer’s instructions.
Propane (LP)—Adequate ventilation
is mandatory. Because propane is
heavier than air, install propane gas
detectors low in a room. Inspect the
detectors per the manufacturer’s
instructions.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Explosive fuel vapors can cause
severe injury or death.
Take
additional precautions when using the
following fuels:
Natural Gas—Adequate ventilation is
mandatory. Because natural gas rises,
install natural gas detectors high in a
room. Inspect the detectors per the
manufacturer’s instructions.
Gas fuel leaks.
Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check the LP vapor gas or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to
6--8 ounces
per
square
inch
(10--14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble formation.
A
successful test depends on the ability
of the solution to bubble.
Use extreme care when handling,
storing, and using fuels.
Safety Precautions and Instructions
7
LP liquid withdrawal fuel leaks.
Explosive fuel vapors can cause
severe injury or death. Fuel leakage
can cause an explosion. Check the LP
liquid withdrawal gas fuel system for
leakage by using a soap and water
solution with the fuel system test
pressurized to at least 90 psi
(621 kPa). Do not use a soap solution
containing either ammonia or chlorine
because
both
prevent
bubble
formation. A successful test depends
on the ability of the solution to bubble.
Hazardous Noise
WARNING
Hazardous voltage. Moving parts.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
WARNING
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA.
Prolonged exposure to
noise levels greater than 85 dBA can
cause permanent hearing loss. Wear
hearing protection when near an
operating generator set.
Hazardous Voltage/
Moving Parts
DANGER
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.
CAUTION
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator
set
without
first
disconnecting the battery, controller
wiring
harness,
and
engine
electronic control module (ECM).
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. 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. Never contact electrical
leads or appliances when standing in
water or on wet ground because these
conditions increase the risk of
electrocution.
Disconnecting the electrical load.
Hazardous voltage can cause
severe injury or death. Disconnect
the generator set from the load by
turning off the line circuit breaker or by
disconnecting the generator set output
leads from the transfer switch and
heavily taping the ends of the leads.
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
8
Safety Precautions and Instructions
TP-6198 10/04
Welding on the generator set. Can
cause severe electrical equipment
damage.
Before welding on the
generator set perform the following
steps: (1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine batterycharging
alternator
connections.
(5) Attach the weld ground connection
close to the weld location.
Installing the battery charger.
Hazardous voltage can cause
severe injury or death.
An
ungrounded battery charger may
cause electrical shock. Connect the
battery charger enclosure to the
ground of a permanent wiring system.
As an alternative, install an equipment
grounding conductor with circuit
conductors and connect it to the
equipment grounding terminal or the
lead on the battery charger. Install the
battery charger as prescribed in the
equipment manual. Install the battery
charger in compliance with local codes
and ordinances.
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 set failure.
Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies).
Have a qualified
electrician install the battery(ies).
Short
circuits.
Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing
the equipment.
TP-6198 10/04
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install
a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.
WARNING
Heavy Equipment
WARNING
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.
Hot Parts
WARNING
Airborne particles.
Can cause severe injury or blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
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,
and covers before operating the
generator set.
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
Servicing the alternator. Hot parts
can cause severe injury or death.
Avoid touching the alternator field or
exciter armature. When shorted, the
alternator field and exciter armature
become hot enough to cause severe
burns.
Safety Precautions and Instructions
9
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.
Servicing the engine heater. Hot
parts can cause minor personal
injury or property damage. Install the
heater before connecting it to power.
Operating
the
heater
before
installation can cause burns and
component damage.
Disconnect
power to the heater and allow it to cool
before servicing the heater or nearby
parts.
10
Safety Precautions and Instructions
NOTICE
Notice
NOTICE
Canadian installations only. For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
Electrostatic discharge damage.
Electrostatic
discharge
(ESD)
damages electronic circuit boards.
Prevent
electrostatic
discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short, to
ground.
TP-6198 10/04
Introduction
This manual provides troubleshooting and repair
instructions for the generator set models listed on the
front cover.
For engine service procedures not covered in this
manual, refer to the Engine Service Manual listed below.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately
skilled and suitably trained maintenance personnel
familiar with generator set operation and service.
Routine Service Parts
Figure 2 and Figure 3 contain part numbers for
recommended spare parts. Contact your Kohler
generator distributor/dealer for a complete list of service
parts for your generator set or for models or spec
numbers not listed here.
Part Description
Maintenance kit (includes air cleaner
element, belt, and oil filter):
15RYG/RES
30RYG/RES
Part Number
GM35030-KP1
GM35030-KP2
Air cleaner element
GM16944
Belt
15RYG/RES
30RYG/RES
GM28353
GM28352
Oil filter
GM28351
Spark plug
GM35826
Auxiliary winding fuse, 10 amp (F1)
358337
Relay interface board fuse, 10 amp (F2)
223316
Controller fuse, 10 amp (F3)
223316
Figure 2
Recommended Spare Parts
List of Related Materials
Model
Circuit Breaker Part Number
Separate manuals contain operation, installation, and
parts information not provided in this manual. A
separate engine service manual is also available.
Figure 1 lists the available manual part numbers.
15RES
GM28743
(70 amp, 2 pole, 240 volt)
30RES
GM28792
(125 amp, 2 pole, 240 volt)
Document Description
Part Number
Operation Manual, 15/30RYG
TP-6197
Installation Manual, 15/30RYG
TP-6329
Operation Manual, 15/30RES
TP-6344
Installation Manual, 15/30RES
TP-6341
Parts Catalog, 15/30RYG/RES *
TP-6319
Wiring Diagram Manual, 15/30RYG/RES
TP-6437
Engine Service Manual
TP-6362
Figure 3
Circuit Breakers
(Standard on RES Models)
* One parts catalog combines generator and engine information.
Figure 1
Related Literature
TP-6198 10/04
Introduction
11
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
KohlerPower.com.
D Look at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product.
D Call toll free in the US and Canada 1-800-544-2444.
D Outside the US and Canada, call the nearest regional
office.
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
12
Service Assistance
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 Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131
TP-6198 10/04
Section 1 Specifications
1.1 Introduction
1.2 Generator Set Ratings
The spec sheets for each generator set provide specific
generator and engine information.
Refer to the
generator set spec sheet for data not supplied in this
manual. Consult the generator set installation manual,
engine operation manual, and engine service manual
for additional specifications.
See the generator set ratings table in Figure 1-1.
Consult generator set nameplate for specific generator
set ratings.
Natural Gas Rating
Model
Series
Alternator
4H7
15RYG
4J7
15RES
Hz
60
kW/kVA
Amps
kW/kVA
Amps
13.0/13.0
54
15.0/15.0
63
120/208
3
60
13.0/16.2
45
15.0/18.8
52
120/240
3
60
13.0/16.2
39
15.0/18.8
45
127/220
3
60
13.0/16.2
43
15.0/18.8
49
139/240
3
60
13.0/16.2
39
15.0/18.8
45
277/480
3
60
13.0/16.2
20
15.0/18.8
22
120/240
1
60
13.0/13.0
54
15.0/15.0
63
2F5
120/240
1
60
24.0/24.0
100
24.0/24.0
100
120/208
3
60
19.0/23.7
66
19.0/23.7
66
120/240
3
60
19.0/23.7
57
19.0/23.7
57
127/220
3
60
19.0/23.7
62
19.0/23.7
62
139/240
3
60
20.0/24.9
60
20.0/24.9
60
277/480
3
60
20.0/24.9
30
20.0/24.9
30
120/240
1
60
27.0/27.0
112
30.0/30.0
125
120/208
3
60
26.0/32.4
90
26.0/32.4
90
120/240
3
60
26.0/32.4
78
26.0/32.4
78
127/220
3
60
26.0/32.4
85
26.0/32.4
85
139/240
3
60
27.0/33.6
81
27.0/33.6
81
277/480
3
60
27.0/33.6
41
27.0/33.6
41
120/240
1
60
27.0/27.0
112
30.0/30.0
125
2F7
2G7
30RES
Ph
1
4H7
2G5
30RYG
LP Rating
Voltage
120/240
2F7
RATINGS: All three-phase units are rated at 0.8 power factor. Standby Ratings: Standby ratings apply to installations served by a reliable
utility source. The standby rating is applicable to varying loads for the duration of a power outage. There is no overload capability for this
rating. Ratings are in accordance with ISO-3046/1, BS 5514, AS 2789, and DIN 6271. Prime Power Ratings: Prime power ratings apply to
installations where utility power is unavailable or unreliable. At varying load, the number of generator set operating hours is unlimited. A
10% overload capacity is available for one hour in twelve. Ratings are in accordance with ISO-8528/1, overload power in accordance with
ISO-3046/1, BS 5514, AS 2789, and DIN 6271. For limited running time and base load ratings, consult the factory. Obtain the technical
information bulletin (TIB-101) on ratings guidelines for the complete ratings definitions. The generator set manufacturer reserves the right to
change the design or specifications without notice and without any obligation or liability. GENERAL GUIDELINES FOR DERATION:
Altitude: Derate 1.5% per 305 m (1000 ft.) elevation above 1006 m (3300 ft.). Temperature: Derate 2.0% per 5.5_C (10_F) temperature
above 21_C (70_F).
Figure 1-1
Generator Set Ratings
TP-6198 10/04
Section 1 Specifications
13
1.3 Controller Specifications
The generator set is equipped with the ADC 2100. For a
specific description of the controller, see Section 2,
Operation, in the operation manual.
1.4 Engine Specifications
Engine Specification
Manufacturer
30RYG/RES
(60 Hz)
GM
Model
1.6L OHC
Cycle
4
Operating temperature
--20_ to 70_C
(--4_ to 158_F)
Number of cylinders
4
Storage temperature
--60_ to 70_C
(--76_ to 158_F)
Displacement, L (cu. in.)
Environmental Specification
Humidity
15/30RYG/RES
0%--95% condensing
Power requirements:
Compression ratio
Rated power, propane fuel,
kWm (BHP)
Rpm
Voltage
12 VDC
Current
250 mA @ 12 VDC
Bore x stroke, mm (in.)
Valve (exhaust) material
Cylinder head material
19.0 (25.5)
37.2 (50)
1800
3600
79 x 81.5 (3.11 x 3.21)
High alloy steel
Aluminum
2 compression/1 oil control
Piston material
High silicon content aluminum
Main bearings: quantity,
type
Governor
Lubrication system
Oil capacity (w/filter), L (qt.)
Oil pressure, kPa (psi)
Fuel system
LP/natural gas minimum
supply pressure,
oz./in.2 (in. H2O)
Cast iron
5, replaceable inserts
Electronic
Full pressure
3.5 (3.7)
150 (22)
LP gas or natural gas
4--6 (7.11)
Battery voltage
12 VDC
Battery ground
Negative
Spark plug gap, mm (in.)
Section 1 Specifications
9.4:1
1.6 (98)
Piston rings
Crankshaft material
14
15RYG/RES
(60 Hz)
0.8--0.9 (0.031--0.035)
Ignition system
Distributorless electronic
Starter motor
Solenoid-actuated pinion
Cooling system
Water-cooled
Valve material
Intake
Exhaust
Chrome/silicone steel
Stellite F
TP-6198 10/04
1.5 Torque Specifications
1.6 Alternator Specifications
Follow the general torque specification found in
Appendix C of this manual unless noted below or listed
in the engine service manual.
Torque Specifications
Alternator overbolts
Drive disk to flywheel
Cylinder head nuts
60 Hz
Excitation method
Voltage regulator type
34 Nm (25 ft. lb.)
Coupling type
16.5 Nm (12 ft. lb.)
25 Nm (18 ft. lb.)
38 Nm (28 ft. lb)
Muffler flange bolts
50 Nm (35 ft. lb.)
Spark plug
25 Nm (18 ft. lb.)
15/30RYG/RES
Frequency Hz
15/30RYG/RES
Drive disk to rotor
Radiator fan fasteners
Alternator Specification
Brush type
Digital
Flexible disc
Winding material
Class H
Bearing, quantity and type
1 sealed
Circuit protection
22.5 Nm (17 ft. lb.)
Controller (F3)
10-amp fuse
Aux. winding (F1)
10-amp fuse
Relay Interface Board (F2)
10-amp fuse
Brush length, new
15RES
and
15RYG
15RYG
30RYG
Alternator model
4H7
4J7
Stator leads, qty.
4
12
Phase
1
3.0
Alternator Specification
Rotor resistance, ohms, cold
1.9 cm (0.75 in.)
30RYG
30RES
and
30RYG
30RYG
2F5
2G5
2F7
2G7
4
12
4
12
3
1
3
1
3
3.0
4.2
4.2
5.6
5.6
0.07
—
0.03
—
0.02
—
—
0.04
—
0.09
—
0.06
1.26
1.3
0.53
0.19
0.44
0.18
105
—
88
—
Stator resistance, ohms,* cold
Main winding: 1-2, 3-4
Main winding: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12
Aux. winding: 55-66
Stator output AC voltage with separately excited rotor using 12-volt battery, minimum
Main winding: 1-2, 3-4
Main winding: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12
Aux. winding: 55-66
105
—
—
120
—
140
—
112
130
150
140
190
117
150
Rotor field DC voltage/current readings at rated output voltage, hot
No load
16V/4.5A
16V/4.5A
16V/3.9A
12V/2.5A
19V/3.9A
15V/2.2A
Full load
36V/8.6A
40V/9.5A
46V/7.6A
63V/9.8A
53V/7.4A
69V/9.6A
* Most ohmmeters do not give accurate readings when measuring less than 1 ohm. The stator can be considered good if a low resistance
reading (continuity) is obtained and there is no evidence of shorted windings (discoloration). Do not confuse a low resistance reading with
a reading indicating a shorted winding.
TP-6198 10/04
Section 1 Specifications
15
1.7 Service View
9
7
6
10
11
Service-Side View
8
5
4
12
3
13
2
14
1
15
24
23
22
21
20
19
18
17
16
Non Service-Side View
26
25
27
28
32
31
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Fuses (F1, F2, and F3)
Generator set master switch (RUN\OFF/RESET\AUTO)
Advanced Digital Control (ADC 2100)
Runtime hour display
Nameplate
Air cleaner
Oil check
Oil fill (on valve cover)
Coolant temperature sender
Fuel/air mixer
Pressure cap (engine water fill)
Coolant overflow tube
Radiator
Belt guard
Battery charging alternator
Low oil pressure switch
Figure 1-2
16
30
GM32850D-J
29
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Coolant overflow bottle (daily coolant check/fill location)
Secondary fuel regulator
Fuel solenoid valve
Oil drain valve
Positive (+) battery connection point
Fuel inlet
Engine control module (ECM)
AC line circuit breaker panel
Exhaust connection
Spark plugs
Remote customer interface connector
Customer load lead access
Oil filter
Negative (--) battery connection point
Coolant drain
Cooling air inlet
Generator Set Service View
Section 1 Specifications
TP-6198 10/04
Section 2 Scheduled Maintenance
WARNING
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.
Disabling the 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 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 switch, remote
start/stop switch, or engine start command from a remote
computer.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The
engine and exhaust system components become extremely
hot during operation.
WARNING
Hazardous voltage. Moving parts.
Can cause severe injury or death.
Alternator Service. Under normal operating conditions
the generator set alternator does not require scheduled
service. Refer to the service schedule for items that
require maintenance.
Engine Service. Perform generator set engine service
at the intervals specified by the engine service literature.
Contact an authorized Kohlerr distributor/dealer to
obtain engine service literature.
All generator sets have emission-certified engines. The
carburetors on emission-certified engines are not
adjustable.
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 distributor/dealer
perform all generator service.
Routine Maintenance. Refer to the following generator
set service schedule, the engine service schedule, and
the runtime hours displayed on the ADC 2100 to
determine when to schedule routine maintenance.
Service the generator set more frequently if it is subject
to extreme weather, long operating hours, or dusty or
dirty conditions.
Service Schedule. Perform maintenance on each item
in the service schedule at the designated interval for the
life of the generator set.
Tools. Tools and instruments used to perform some
maintenance items are not generally available to the
generator set owner.
Therefore, have service
performed by an authorized distributor/dealer.
2.1 Service Schedule
Perform the items listed in the service schedule at the
designated intervals for the life of the generator set. For
example, an item serviced every 100 hours or 3 months
must also be serviced after 200 hours or 6 months,
300 hours or 9 months, etc.
Note: See the generator set operation manual and the
engine service manual for service procedures not
included in this manual.
Operate the generator set only when
all guards and electrical enclosures
are in place.
TP-6198 10/04
Section 2 Scheduled Maintenance
17
Perform Service at Intervals Indicated (X)
Fuel System
Check the fuel level and fill as necessary (LP)
Before
Starting
Weekly
100 Hr.
(3 Mo.)
300 Hr.
(6 Mo.)
400 Hr.
(Yearly)
X
Check the solenoid valve operation *
X
Check the fuel lines and replace as necessary *
X
Lubrication System
Check the crankcase oil level and add oil as necessary
X
24 hr.
Replace the oil in the crankcase
X
200 hr.
Replace the lube oil filter element
X
200 hr.
Cooling System
Check the coolant level and fill as necessary
X
Inspect the radiator and hoses
X
Check the belt tension and condition *
X
Check the coolant protection and tighten the hose clamps *
X
Flush the cooling system *
X
800 hr.
Ignition System
Clean and regap the spark plugs
X
Replace the spark plugs
X
800 hr.
Intake/Exhaust System
Inspect the exhaust system components *
X
Check the installation and operation of CO detectors
X
Check the exhaust gas condition during operation
X
Inspect and clean the air cleaner element
X
Replace the air cleaner element
X
Inspect the complete exhaust system ]
X
Electrical System
Keep the battery charged and in good condition w
X
Check and tighten electrical connections
Clean the battery cables as required *
X
X
Engine and Mounting
Check for fuel, coolant, and oil leakage *[
X
Retighten all nuts and bolts as required
X
Check tightness of mounting bolts/vibromounts
X
Remote Control System
Check the remote control operation
X
X
Generator Set
Test run the generator set
Blow dust out of the generator *
Clean collector ring and inspect brushes *
X
X
X
1000 hr.
* Consult your local distributor/dealer for service.
[ Read WARNING found at the beginning of manual regarding moving parts.
] Should be performed by your local distributor/dealer.
w Consult battery manufacturer’s instructions.
Note: Hr. refers to hours of generator set operation.
Figure 2-1
18
Service Schedule
Section 2 Scheduled Maintenance
TP-6198 10/04
2.2 Battery
WARNING
Use a 12-volt battery with a minimum rating of 525 cold
cranking amps at --18_C (0_F) The generator set uses a
negative ground with a 12-volt engine electrical system.
Make sure that the battery is correctly connected and
the terminals are tight. See Figure 2-2.
Note: The generator set will not start and circuit board
damage may result if the battery is connected in
reverse.
Sulfuric acid in batteries.
Can cause severe injury or death.
1
2
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
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 minutes with large quantities of
clean water. Seek immediate medical aid in the case of eye
contact. Never add acid to a battery after placing the battery in
service, as this may result in hazardous spattering of battery
acid.
Battery acid cleanup. Battery acid can cause severe
injury or death. Battery acid is electrically conductive and
corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
soda) to a container with 4 L (1 gal.) of water and mix the
neutralizing solution. Pour the neutralizing solution on the
spilled battery acid and continue to add the neutralizing
solution to the spilled battery acid until all evidence of a
chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.
Battery gases. Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke
or permit flames or sparks to occur near a battery at any time,
particularly when it is charging. Do not dispose of a battery in
a fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or
other metal objects. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface
away from the battery. To avoid sparks, do not disturb the
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury
or death. Short circuits can cause bodily injury and/or
equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the
battery.
Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--)
battery cable to the positive (+) connection terminal of the
starter solenoid. Do not test the battery condition by shorting
the terminals together.
TP-6198 10/04
EZ-273000-J
1. To positive (+) terminal on starter solenoid.
2. To ground (--) terminal on or near starter motor.
Figure 2-2
12-Volt Engine Electrical System Single
Starter Motor, Typical Battery Connection
Clean the battery and cables and tighten battery
terminals using the service schedule recommendations.
Clean the battery by wiping it with a damp cloth. Keep
the electrical connections dry and tight.
Consult the battery manufacturer’s instructions for
battery care and maintenance.
2.2.1
Cleaning Battery
To prevent dirt and grime buildup, occasionally wipe the
battery with a damp cloth.
To prevent corrosion, maintain tight, dry electrical
connections at the battery terminals. To remove
corrosion from battery terminals, disconnect the cables
from the battery and scrub the terminals with a wire
brush. Clean the battery and cables with a solution of
baking soda and water. Do not allow the cleaning
solution to enter the battery’s cells. After cleaning, flush
the battery and cables with clean water and wipe them
with a dry, lint-free cloth.
After reconnecting the battery cables, coat the battery
terminals with petroleum jelly, silicone grease, or other
nonconductive grease.
Section 2 Scheduled Maintenance
19
2.2.2
Battery Charger
Generator sets may be equipped with a factory-installed
battery charger to keep the starting battery fully
charged. Observe the battery polarity when connecting
the battery charger. Check the battery charger fuse and
power supply.
See the instruction sheet supplied with the battery
charger for information about battery charger operation
and troubleshooting.
20
Section 2 Scheduled Maintenance
TP-6198 10/04
Section 3 Troubleshooting
3.1 Introduction
D Fault shutdown.
Corrective action and testing in many cases requires
knowledge of electrical systems and electronic circuits.
Have an authorized distributor/dealer or trained service
technician perform testing and service.
D Blown fuses.
Refer to the engine service manual for engine service
information.
D Incorrect controller settings.
The first step in troubleshooting the generator set
controls is to verify that the controller is correctly
configured for the generator set. The generator set
installation manual explains how to check and change
the controller configuration.
If the troubleshooting procedures in this section identify
a bad part, refer to the parts catalog for replacement part
numbers. See the List of Related Materials in the
Introduction for the literature part numbers.
Check for a fault code on the
ADC 2100 display.
Section 4.5 describes the
warning and shutdown fault codes.
Fuses protect the controller, SCR
module, and relay interface board. Always check and
replace the fuses before replacing other components.
Always check the
controller configuration settings before replacing the
controller. Section 4.9 explains how to check and
change the controller settings.
D Inadequate fuel supply.
Check for damaged
primary or secondary fuel regulators, loose
connections to the fuel solenoid valve, a damaged or
closed fuel shutoff valve, an empty LP fuel tank, or
other problems with the fuel supply. Check the fuel
supply pressure to the generator set.
See
Section 5.11, Fuel Systems.
3.2 Initial Checks
3.3 Troubleshooting Chart
When troubleshooting, always check for simple
problems first. Check for the following common
problems before replacing parts:
Use the following table as a reference in troubleshooting
individual problems. Generator set faults are listed in
groups and include likely causes and remedies. The
simplest and most likely causes of the problem are listed
first; follow the recommendations in the order shown.
The reference column provides additional sources of
information in this and related manuals regarding the
problem and solution.
D Loose connections or damaged wiring.
D Dead battery.
Troubleshooting Chart
Problem
Possible Cause
Generator
Weak or dead battery
set does not
crank
Corrective Action
Reference
Recharge or replace battery.
If battery is weak or dead, check battery charger fuse, power
supply, and operation.
O/M
Battery connections
Open circuit in engine/
controller connections
Check for reversed or poor battery connections.
Check for loose connections.
Check the wire harness continuity.
—
Section 6
Blown fuse F3, controller
Replace fuse; if fuse blows again, check circuit and
components.
Section 5.12
Section 6
Blown fuse F2, relay
interface board (RIB)
Replace fuse.
If fuse blows again, disconnect the board leads one at a time to
identify the cause of the blown fuse:
Lead 70A at the fuel valve
Lead 71A at P30
Leads FP and FN at the rotor
Repair or replace the component causing the blown fuse.
Section 5.12
Section 6
Engine S/M: Engine Service Manual
TP-6198 10/04
I/M: Generator Set Installation Manual
O/M: Generator Set Operation Manual
Section 3 Troubleshooting
21
Troubleshooting Chart
Problem
Generator
set does not
crank,
continued
Possible Cause
Corrective Action
Reference
Blown fuse F2, relay
interface board (RIB),
continued
If fuse continues to blow and the previous step did not identify
the cause, check the continuity of leads FP and FN and the
leads from the P14 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.
Check connections to the RIB. Check for 12VDC to the RIB on
lead 71N.
Section 6
Section 4.6
Check for a good ground connection (lead N)
Check crank relay K2 operation (LED3). Replace the RIB if
relay does not operate.
Section 6
Section 4.6
Check connections to the master switch on the ADC 2100.
Section 4.3
Section 5.13
Test function of switch.
Clean and retighten.
Section 5.13
—
Check starter connections.
Rebuild or replace starter.
Check controller connections and operation. Check for power
to the controller. Move generator set master switch to OFF/
RESET and then to RUN.
Section 6
Engine S/M
Section 4
Section 6
Open (turn on) manual fuel valve. Check fuel supply tank (LP).
Check fuel pressure to the generator set. Verify adequate fuel
pressure and pipe size for the generator set plus all other gas
appliances.
—
I/M
Crank relay on relay
interface board (RIB)
Generator set master
switch
Poor ground (--)
connection
Starter
Controller
Cranks but
does not
start
Starts hard
No fuel
Insufficient fuel pressure
Fuel regulator/valve
Check regulator/valve operation.
Spark plugs or spark plug Check spark plug wires and connections. Replace or clean
connections
and regap spark plugs.
I/M
O/M
Loose connection or open Check for loose or open connections at the fuel valve (lead
circuit
70A) and at the engine control module. Check
controller/engine wiring continuity.
Section 6
Air cleaner clogged
Incorrect controller
configuration
Clean or replace.
Check for correct controller configuration parameters: unit
configuration (UC) and engine configuration (EC).
O/M
Section 4.9
Ignition system spark
control or ignition coil
Test and/or replace components.
Engine S/M
Fuel select leads 65 and
70A leads incorrectly
connected or
disconnected
Connect for natural gas. Disconnect for LP.
I/M
No engine rotation
Check for locked rotor.
sensed (check for an
overcrank fault shutdown)
Section 5.4
Low battery voltage
Check battery voltage and battery charger connections, power
supply, and operation.
O/M
Air cleaner clogged
Fuel mixture adjustment
incorrect
Replace element.
Adjust fuel valve.
O/M
O/M
Fuel select leads 65 and
70A leads incorrectly
connected or
disconnected
Connect for natural gas. Disconnect for LP.
I/M
Replace or regap spark plug(s).
O/M
Spark plug(s)
Engine S/M: Engine Service Manual
22
Section 4.6
Section 6
Section 3 Troubleshooting
I/M: Generator Set Installation Manual
O/M: Generator Set Operation Manual
TP-6198 10/04
Troubleshooting Chart
Problem
Starts hard,
continued
Starts but
shuts down
Stops
suddenly
Possible Cause
Corrective Action
Reference
Spark plug wire(s)
Check spark plug wires and connections. Replace spark plug
wires.
Engine S/M
Ignition components
(spark control or ignition
module)
Test/replace ignition components.
Engine S/M
Insufficient fuel pressure
Worn piston rings, valves
Fault shutdown
Check fuel pressure
Check compression.
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.
I/M
Engine S/M
Section 4.5
Section 5.10
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
No fuel
Fuel line restriction
Fuel lines too long
Air cleaner clogged
Blown controller fuse (F3)
Blown auxiliary winding
fuse (F1)
Turn on fuel supply.
Inspect fuel lines.
Check fuel line length.
Replace element.
Replace fuse.
Replace fuse. If fuse blows again, test generator components.
—
—
I/M
O/M
Section 5.12
Section 5.12
Blown relay interface
board (RIB) fuse (F2)
Replace fuse.
Section 5.12
Spark plug(s)
Engine overheated (hot
engine only)
Replace and regap plug(s).
Check air intake, fuel adjustment, oil level, air inlet/outlet.
Engine S/M
O/M and I/M
Low oil pressure (LOP)
switch
Attempt startup. If unit shuts down, remove lead from LOP
switch and reset controller. A successful restart attempt
indicates a faulty LOP shutdown switch.
Note: Check engine oil pressure before performing test and/or
replacing LOP shutdown switch.
Engine S/M
Fuel valve/fuel regulator
Engine overloaded
Loss of generator output
voltage to controller
Check regulator/valve operation.
Reduce electrical load.
Check connections at P15 plug.
Check continuity of AC sensing leads 11 and 44 (1-phase
models) or V7, V8, and V9 (3-phase models).
O/M and I/M
I/M
Section 6
Ignition module
K3 (flash) relay
Test and/or replace.
Check for Flash LED illumination. Check RIB fuse. Replace
relay board.
Engine S/M
Section 4.6
Engine S/M: Engine Service Manual
TP-6198 10/04
I/M: Generator Set Installation Manual
O/M: Generator Set Operation Manual
Section 3 Troubleshooting
23
Troubleshooting Chart
Problem
Operates
erratically
Lacks
power
Overheats
Possible Cause
Corrective Action
Reference
Air cleaner clogged
Spark plug(s)
Spark plug wire(s)
Fuel select leads 65 and
70A leads incorrectly
connected or
disconnected
Replace element.
Replace and regap plugs.
Replace spark plug wires.
Connect for natural gas. Disconnect for LP.
O/M
O/M
Engine S/M
I/M
Fuel line restriction
Fuel mixture adjustment
incorrect
Check fuel lines.
Check and/or adjust.
—
Ignition system
Inadequate cooling
(hot engine only)
Test and/or replace components.
Inspect air inlet and outlet.
Engine S/M
—
Carbon buildup in engine Clean cylinder head.
Engine valves not seating Check cylinder pressures with leakdown test. Inspect valves
correctly
and valve seats.
Engine S/M
Engine S/M
Air intake restriction,
inadequate cooling
Inspect air intakes and exhaust for obstructions.
Check air cleaner.
—
Generator overloaded
Spark plug(s)
Spark plug wire(s)
Fuel select leads 65 and
70A incorrectly connected
or disconnected
Reduce load.
Replace and regap plug(s).
Replace spark plug wires.
Connect for natural gas. Disconnect for LP.
—
O/M
Engine S/M
I/M
Insufficient fuel pressure
Fuel line restriction
Fuel regulator
Engine not running at
rated rpm
Check fuel pressure at carburetor outlet.
Check fuel pipe size.
Check function of fuel regulator.
Check controller settings for unit configuration (UC) and engine
type (EC).
I/M
I/M
I/M
Section 4.9.2
Engine power loss
Refer to the engine service manual for troubleshooting and
repair instructions.
Engine S/M
Ignition system
Inadequate cooling
Fuel mixture adjustment
incorrect
Test and/or replace.
Inspect cooling system for air intake obstructions.
Readjust fuel mixture.
Engine S/M
—
I/M
Engine S/M: Engine Service Manual
24
Section 3 Troubleshooting
I/M: Generator Set Installation Manual
I/M
O/M: Generator Set Operation Manual
TP-6198 10/04
Troubleshooting Chart
Problem
Low output
or
excessive
drop in
voltage
Possible Cause
Corrective Action
Reference
Generator overloaded
Reduce load.
—
Incorrect controller
configuration
Check and adjust the controller configuration parameters.
Section 4.9.2
Incorrect controller
voltage settings
Check and adjust the controller voltage settings.
Section 4.9.2
Alternator or control
system
Perform separate excitation procedure to isolate problem to the
alternator or the control system.
Section 5.2
SCR module
Check wiring and connections to the SCR module.
Check auxiliary winding fuse F1 (lead 55).
Replace SCR module and test voltage.
Section 5.12
Section 4.7
Controller
Check controller settings. Check controller fuse, wiring and
connections.
Before replacing controller, replace SCR module and test
voltage.
Section 4.9.2
Section 4.8
Rotor (open, grounded, or Test and/or replace.
shorted windings)
Section 5.4
Stator (open, grounded,
or shorted windings)
Test and/or replace.
Section 5.3
Brush connection
Check for loose brush connections.
Check the resistance through the brushes. Resistance through
the brushes should be low, 0.1--0.2 ohms without meter lead
resistance.
Section 5.6
Low engine speed
causing voltage roll-off
Check system voltage/frequency (Uu) and engine type (Ec)
parameters
Troubleshoot engine
Section 4.9.2
Light flicker
Voltage stability (gain)
setting
Check and adjust the voltage stability (gain) setting using the
ADC 2100.
Section 5.7
High output
voltage
Incorrect controller
configuration
Check and adjust the controller configuration parameters.
Section 4.9.2
Incorrect controller
voltage settings
Check and adjust the controller voltage settings.
Section 5.7
Loose voltage sensing
connections
Check connections: stator leads 11 and 44 (1-phase models)
or V7, V8, and V9 (3-phase models) and P15 controller
connection.
Section 6
SCR module
Check wiring and connections to the SCR module.
Check auxiliary winding fuse F1 (lead 55).
Replace SCR module and recheck voltage.
Section 4.7
Section 5.12
Section 4.7
Controller
Check fuses, wiring and connections. Before replacing
controller, replace SCR module and test voltage.
Section 4.8
High output
voltage,
continued
Engine S/M: Engine Service Manual
TP-6198 10/04
I/M: Generator Set Installation Manual
Engine S/M
O/M: Generator Set Operation Manual
Section 3 Troubleshooting
25
Troubleshooting Chart
Problem
No output
voltage
Noisy
operation
Possible Cause
Corrective Action
Reference
AC output circuit breaker
open
Check for AC voltage on the generator side of circuit breaker.
If there is AC voltage on the generator side of the breaker, then
a problem in the load circuits is causing the line circuit breaker
to trip. Check for and correct short circuits or overloading on
the load side before resetting the circuit 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 fuse blown
(lead 55)
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.
Section 5.12
Section 4.7
Controller
Check controller settings. Check wiring and connections.
Before replacing controller, replace SCR module and check
voltage.
Section 4.9.2
Section 4.8
Open wiring, terminal, or
pin in buildup circuit or
SCR module circuit
Check continuity.
Section 5.13
Section 6
Brushes
Inspect brushes and replace if worn
Section 5.6
Check for brushes sticking in brush holder or broken brush
spring
Section 5.6
Rotor connections
Check for open circuit in rotor connection circuit (leads FN and
FP to SCR and RIB)
Section 6
Rotor slip rings dirty or
corroded
Check slip ring condition.
Section 5.4
Rotor (open, grounded, or Check voltage and continuity.
shorted windings)
Section 5.4
Stator (open, grounded,
or shorted windings)
Check voltage and continuity.
Section 5.3
Flash relay (K3) on relay
interface board (RIB)
Check flash LED on RIB.
Check fuse F2 and troubleshoot RIB.
Section 4.6
Exhaust system leaks
Engine not running
smoothly
Check and replace as necessary.
See “Generator set operates erratically,” this table
O/M
—
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 alternator may be required).
Engine S/M
Engine S/M: Engine Service Manual
26
Section 3 Troubleshooting
I/M: Generator Set Installation Manual
—
O/M: Generator Set Operation Manual
TP-6198 10/04
Section 4 Controller
4.1 Introduction
A relay interface board (RIB) is used with the controller.
Section 4.6 describes the standard and optional RIBs.
This section describes the operation and replacement of
the ADC 2100 controller. Controller configuration and
adjustment are explained Section 4.9. See Section 3 for
troubleshooting procedures.
A silicon controlled rectifier (SCR) module works with
the controller to regulate the output voltage. See
Section 4.7.
See Figure 4-1 for the locations of the ADC 2100
controller and related components.
Service-Side View
1
4
7
Alternator-End View
8
6
5
2
GM32850B-
3
1.
2.
3.
4.
5.
6.
7.
8.
ADC 2100 controller
Fuse location (F1, F2, and F3) Note: Some earlier models had inline fuses located in the engine harness. See Section 5.12.
Line circuit breaker panel (load connection)
Generator set master switch
L0 stud
Ground stud
Relay interface board (RIB)
SCR module
Figure 4-1
Advanced Digital Control (ADC 2100)
TP-6198 10/04
Section 4 Controller
27
4.2 Controller Display and Keypad
The controller has an LED display and a three-button
keypad. See Figure 4-2. The LED display shows
runtime hours, fault codes, application program version
number, or controller parameters during configuration
and adjustment. See Figure 4-3. The keypad is used to
enter the controller’s configuration and adjustment
menus, and to change the controller settings.
1
3
2
A password key sequence is required to enter the
configuration and adjustment menus. Section 4.9
contains the instructions to enter the configuration and
adjustment menus and change the settings using the
controller keypad.
4.3 Master Switch
The generator set master switch is a three-position
(RUN\OFF/RESET\AUTO) rocker switch. The leads
connecting to the master switch are labeled RUN, VBAT,
and AUTO. Check that the three pink connectors are
connected to the terminals on the back of the switch as
shown in Figure 4-4. Be careful not to reverse the RUN
and AUTO leads.
2
1
4
GM28707A-C
LED display
Select button (for setup and adjustment only)
Up and down arrow buttons (for setup and adjustment only)
Generator set master switch
Figure 4-2
ADC Controller
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 flashes during the crank cycle rest
periods.
Runtime hours
Displays total generator set runtime
hours when no other code is displayed.
Fault codes
Flashes a 2- or 3-letter fault code to
indicate various fault conditions. See
Section 4.5.
System
parameters
Displays 2-letter codes or 4-digit
alphanumeric codes during system
configuration or adjustment. See
Section 4.9.2.
tp6196
RUN
VBAT
AUTO
1.
2.
3.
4.
1.
2.
3.
4.
5.
5
4
3
Engine wiring harness connector plug (P1)
Continuous power mode jumper location (P7)
J15 connector
J16 connector
Generator set master switch
Figure 4-4
Controller Connections
Application
Displays the version number of the
program
controller’s application program before
version number entering the configuration or adjustment
mode. See Section 4.9.2.
Figure 4-3
28
ADC Controller LED Display
Section 4 Controller
TP-6198 10/04
4.4 Sequence of Operation
4.4.2
The following sections describe the controller sequence
of operation during generator start, run, stop, and fault
shutdown modes. Use this as a starting point for
controller and relay board fault identification. Refer to
the wiring diagrams in Section 6 to assist in the
troubleshooting procedure.
When the master switch is set to the AUTO position, the
generator set starts when the remote start switch or
transfer switch engine start contacts close.
4.4.1
Starting Sequence, Master Switch
Moved to RUN
When the master switch is moved to the RUN position,
there is a delay of about 2 sec. before the controller
attempts to start the engine. The run relay energizes
and the run LED (1) turns on. The crank and flash relays
energize and the corresponding LEDs (2 and 3) turn on
0.5 sec. later. The controller display indicates the crank
cycle 1 code, CC 1.
The start sequence proceeds as described in
Section 4.4.1, Starting Sequence, Master Switch
Moved to RUN.
4.4.3
When the engine comes up to speed, the low oil
pressure switch contacts open.
Note: The controller circuit board prevents fault
shutdowns during startup until the crank
disconnect relay energizes.
The cyclic cranking cycle is programmed into controller’s
application code and is not adjustable in the field.
The factory sets the cranking cycle for three cycles of
15 sec. on time and 15 sec. off time. If the cranking
cycle seems shorter than the factory setting, check the
engine starting battery.
TP-6198 10/04
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 (1-phase
models) or V7, V8, and V9 (3-phase models) reaches
about 30 VAC, the flash relay deenergizes and the flash
LED (2) turns off.
4.4.4
The controller attempts to start the generator set three
times (three crank cycles, 15 sec. crank and 15 sec. off).
If the generator set does not start in three attempts, the
system shuts down on an overcrank fault.
Starting Sequence, Remote Start
Stopping Sequence, Master
Switch Moved to OFF/RESET
Place the generator master switch in the OFF/RESET
position. The run relay deenergizes and the run LED (1)
turns off. The generator set stops.
4.4.5
Stopping Sequence, Remote Stop
When the remote start contacts open, the run relay
deenergizes and the run LED (1) turns off, but the
controller does not power down. The controller remains
powered and displays the engine runtime hours.
Note: Disconnecting the P7 jumper inside the controller
will allow the controller to power down 48 hours
after generator set shutdown. See Section 4.10
for instructions.
Section 4 Controller
29
4.5 Faults
4.5.1
Warnings
The fault conditions listed in Figure 4-5 will cause the
controller to display a fault code but will not shut down
the generator set.
Code Fault
Description
Check
HB
Fault code is displayed if the engine starting battery voltage rises
above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC
system for more than 10 sec. when the engine is not running. This
fault condition does not inhibit engine starting.
Check the battery rating and
condition. Replace the battery as
needed.
High
battery
voltage
warning
The fault condition clears when the battery voltage returns to a
voltage within the limits for more than 10 sec.
LB
Low
battery
voltage
warning
Fault code is displayed if the engine starting battery voltage falls
below 9.5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC
system for more than 10 sec. when the engine is not running. This
fault condition does not inhibit engine starting.
Check the battery rating and
condition.
Charge or replace the battery.
The fault condition clears when the battery voltage returns to a
voltage within the limits for more than 10 sec.
Figure 4-5
4.5.2
Fault Warning Codes
Shutdowns
7
Under the fault conditions listed in Figure 4-8, the
controller displays a fault code and the generator set
shuts down.
1
3
D1
2
6
5
D2
3
1
9
7
D7
K5
RUN
D3
D5
D4
FLASH
FP
T2
LED3
CRANK
LED1
RUN
R
R3
LED2
FLASH
R2
R1
T1
FN
VBAT
R
R
GM29671-A
1.
2.
3.
4.
5.
6.
7.
6
K1 common fault relay (optional)
K2 crank relay (standard)
K3 flash relay (standard)
K4 auxiliary run relay (optional)
K5 run relay (standard)
P14, engine harness connection (standard)
P13, connection to optional relay harness (optional)
Figure 4-6
Section 4 Controller
4
3
K3
30
P13
K2
CRANK P14
Move the generator set master switch to the OFF/
RESET position to reset the controller after a fault
shutdown. Then move the switch to the AUTO or RUN
position.
The standard Relay Interface Board (RIB) contains the
K2 crank, K3 flash, and K5 run relays. Three LEDs
indicate relay operation. See Figure 4-6.
AUX
K4 RUN
D6
Always identify and correct the cause of a fault
shutdown before restarting the generator set. Refer to
Section 3, Troubleshooting, for instructions to identify
and correct the cause of the fault.
4.6 Relay Interface Board
4
1
COMMON
K1 FAULT
Relay Board
TP-6198 10/04
Refer to the schematic diagram in Section 6 for the
standard relay board connections.
The RIB is protected by a 10 amp fuse (F2). If the fuse
blows repeatedly, disconnect the board loads one at a
time to identify the cause of the blown fuse:
D Lead 70A at the fuel select QCON2 connector
D Lead 71A starter lead at the engine ECM connector
D Leads FP and FN at the rotor
If fuse continues to blow and disconnecting components
did not identify the cause, remove the leads from the
P14 connector using a pin pusher, part #241918 (large)
or #241919 (small). If replacing the leads does not solve
the problem, replace the RIB.
The generator set may be equipped with an optional
RIB, which contains the K4 auxiliary run relay and K1
common fault relay in addition to the standard relays.
The optional relay board kit includes a wiring harness for
connection of customer equipment to the K1 and K4
relays. See Figure 4-7 for optional relay connections.
Harness
Lead
Number
Connector
Pin Number
88
89
90
91
92
93
6
2
3
4
1
5
Connection
Common fault normally open
Common fault common
Common fault normally closed
Run relay normally open
Run relay common
Run relay normally closed
The individual relays are not replaceable. If one or more
relays are faulty, replace the entire RIB.
To replace the RIB:
1. Disconnect P14 and the brush leads FP and FN.
2. Pull the board straight off the mounting stand-offs.
Figure 4-7
Optional Common Fault and Run Relay
Board Harness Connections
3. Snap the new board onto the stand-offs and
reconnect P14 and the brush leads.
TP-6198 10/04
Section 4 Controller
31
Code
Fault
Description
Check
Reference
AF
Auxiliary fault
Input from a user-supplied switch that closes
when the fault is active. The generator set
shuts down 0.3 sec. after the fault is detected
and will not start when the fault is active (input is
grounded). This protection becomes active
3 sec. after crank disconnect.
Check the condition and operation of the
customer-supplied equipment connected to
the auxiliary fault input P21-6.
—
HE
High engine
temperature
Shutdown occurs if the engine coolant
Check for blocked air inlets and exhaust
temperature exceeds the maximum temperature outlets.
for more than 5 sec. This protective becomes
active after engine reaches the crank disconnect
speed.
LCL
Low coolant level Not used.
—
—
LOC
Loss of coolant
Not used.
—
—
LOP
Low oil pressure
Shutdown occurs if a low oil pressure condition
exists for more than 5 sec. This protective
becomes active 30 sec. after the engine has
reached crank disconnect speed (30-sec.
inhibit).
Check for leaks in the lubrication system.
O/M
Check the oil level and add oil if the level is
low.
O/M
Check low oil pressure switch connections
and operation.
Section 5.10
Note: The low oil pressure shutdown does not
protect against low oil level. Check the oil level
at the engine.
OC
Overcrank
OF
Overfrequency
Section 1.7
Check the oil pump and lubrication system.
Engine S/M
Shutdown occurs after 3 unsuccessful starting
attempts. The crank cycle is set for three
starting attempts of 15 sec. cranking and
15 sec. rest.
Check the fuel supply valves and pressure.
I/M
The generator set shuts down on an overcrank
fault if no engine rotation is sensed. Shuts
down after 3 sec. of cranking or 1 sec. after the
fault is detected.
Check for a locked rotor.
Section 5.4
Shutdown occurs when the governed frequency
exceeds 110% of the system’s frequency
setpoint for more than 5 sec. This protective
becomes active 10 sec. after engine start
(10-sec. inhibit).
Check system frequency setting (parameter
UU) on controller.
Section 4.9
Check engine governing system, controlled
by the engine ECM.
Engine S/M
Check spark plug and battery.
See Troubleshooting Chart, generator set
cranks but does not start.
O/M
Section 3.3
OS
Overspeed
Shutdown occurs if the engine speed exceeds
115% of the normal running speed for more than
0.3 sec.
Check engine governing 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 sec.
Check AC voltage.
Section 5.7
Check wiring and connections.
Section 6
UF
Underfrequency
Shutdown occurs when the governed frequency
falls blow 90% of the nominal system frequency
for more than 5 sec. or below 59 Hz for more
than 60 sec. This protective becomes active
10 sec. after engine start. (10-sec. inhibit).
Reduce the load and restart the generator
set.
—
UU
Undervoltage
Shutdown occurs if the voltage falls below 80%
of the nominal system voltage for more than
10 sec.
Reduce the load and restart the generator
set.
—
Check wiring and connections.
Section 6
Check controller configuration, system
voltage and frequency (parameter UU).
Section 4.9
Check AC voltage and adjust, if necessary.
Section 5.7
Replace the SCR module and test voltage
again.
Section 4.7
Separately excite unit.
Section 5.2
Check stator continuity.
Section 5.3
Replace the controller.
Section 4.8
SCF0
Software
Communication
Fault 0
Indicates a software or communication problem
within the ADC 2100.
Note: O/M = Generator Set Operation Manual; I/M = Generator Set Installation Manual
Figure 4-8
32
Fault Shutdown Codes
Section 4 Controller
TP-6198 10/04
4.7 Silicon Controlled Rectifier
Module
The silicon controlled rectifier (SCR) module works with
the ADC 2100 to regulate the output voltage. The ADC
2100 monitors generator output voltage and adjusts the
excitation current to the rotor through the SCR module.
The SCR module location is shown in Figure 4-1.
The SCR module is powered through stator leads 55
and 66 connected to SCR terminals AC1 and AC2.
Leads G connected to terminals G1 and G2 provide the
controller signal. Leads FP and FN connected to the
positive (+) and negative (--) SCR terminals provide
excitation current to the rotor. See Figure 4-9 and the
wiring diagrams in Section 6.
3. Connect the ohmmeter from AC1 to (+) on the SCR
module. You should read high resistance in both
directions.
4. Connect the ohmmeter from AC1 to (--) on the SCR
module. You should read high resistance in one
direction and low resistance in the other.
5. Repeat steps 3 and 4 for AC2.
6. Connect the ohmmeter from G1 to (+) on the SCR
module. You should read low resistance in both
directions.
7. Repeat step 6 for G2. You should read low
resistance in both directions.
8. See Figure 4-10. Connect the negative (--) lead
from the DC power source to the positive (+)
terminal on the SCR module.
AC1
AC2
G1
--
G2
+
Note: The SCR module may be damaged if the
power supply is connected incorrectly. Be
sure to connect the negative lead from the
battery to the positive terminal on the SCR
module.
GM28483
Figure 4-9
Silicon Controlled Rectifier (SCR)
Module
The SCR module is protected by a 10-amp fuse (F1) in
lead 55 in the wiring harness. Check the fuse and
replace it, if blown.
2
(+)
(--)
1
4
In the case of output voltage problems, check the
controller configuration and settings. Then test the SCR
module using the following procedure.
5
3
G1
SCR Module Test Procedure
Required equipment:
AC1
D Ohmmeter
D 12-volt test lamp (or voltmeter)
AC2
(+)
D 12-volt DC power source
D 100--500 ohm resistor
G2
(--)
tp6198
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).
TP-6198 10/04
1.
2.
3.
4.
5.
12VDC power source
12 VDC test lamp
SCR module
Jumper
100--500 ohm resister
Figure 4-10 SCR Test
Section 4 Controller
33
9. Connect the positive (+) lead from the DC power
source, with the lamp in series, to terminal AC1 on
the SCR module. The lamp should not glow.
10. Connect the jumper, with the resistor in series, from
the positive lead of the DC power source to terminal
G1 on the SCR module. The lamp should glow.
11. Repeat steps 9 and 10, with the positive (+) lead
and lamp connected to terminal AC2 on the SCR
module, and connecting the jumper with resister to
terminal G2.
12. If any of the above checks indicates a bad SCR
module, replace the module.
6. Disconnect plugs P1, P15, and P16 from the ADC
controller. See Figure 4-11.
7. Attach plugs P1, P15, and P16 to the new
controller.
8. Place the new controller into position and install the
four mounting screws.
9. Verify that the generator set master switch is in the
OFF position.
1
4.8 Controller Replacement
If the troubleshooting procedures in Section 3 identify a
bad controller, use the procedure in this section for
controller replacement. Always check the controller
configuration, fuse, wiring, and connections before
replacing the controller. For output voltage problems,
replace the SCR module and check the operation again
before replacing the controller.
After replacing the controller, verify that the new
controller’s configuration settings match the generator
set system voltage and frequency, unit configuration,
engine type, engine data input types, battery voltage,
and communications settings. Refer to Section 4.9 for
instructions to check the controller configuration and to
change the settings, if necessary.
After the controller configuration has been checked and
set to match the generator set, use a voltmeter to check
the generator set output voltage. If the output voltage
needs adjustment, use the Voltage Adjustment
Procedure in Section 5.7.2 and the controller voltage
adjustment instructions in Section 4.9.
ADC 2100 Controller Replacement Procedure
tp6196
3
2
1. Engine wiring harness connector plug (P1)
2. J15 connector
3. J16 connector
Figure 4-11 Controller Connections
1. Place the generator set master switch in the OFF
position.
10. Reconnect the engine starting battery, negative (--)
lead last.
2. Disconnect power to the battery charger.
11. Reconnect 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.
5. Carefully pull the controller forward, angling it so
that the P1 connector on the right side clears the
opening in the mounting plate.
34
Section 4 Controller
12. Follow the instructions in Section 4.9 to change the
new controller’s configuration settings to match the
generator set system voltage and frequency, unit
configuration, engine type, engine data input
types, battery voltage, and communications
settings.
TP-6198 10/04
13. Use a voltmeter to check the output voltage. Follow
instructions in Section 5.7.2, Voltage Adjustment,
to adjust the output voltage and stability.
14. Place the generator set master switch in the AUTO
position if an ATS or remote start/stop switch is
used.
Note: A digital 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 4-13
and Figure 4-14 outline the adjustment procedures.
4.9 Controller Configuration and
Adjustment
Note: Be sure to save your settings before exiting the
configuration mode.
This section contains instructions for using the
controller’s password-protected menus to check and
adjust the generator output and controller configuration.
The controller configuration and generator set output
are factory-set and should not require field adjustment
under normal circumstances. Check and adjust the
configuration and/or output in the following cases:
Voltage changes are lost if they are not saved before the
generator set shuts down. The generator set continues
to run with the new settings until it shuts down but then
reverts to the previous settings at the next startup if the
changes have not been saved.
Pressing the Select button when SAVE is displayed
returns to the first parameter, voltage adjust (1P).
D Check and adjust the controller configuration and
generator output after generator set reconnection to a
different voltage.
D Check controller configuration when troubleshooting
generator set problems.
D Check and adjust the generator set output after
installation if the voltage requires adjustment for a
particular application.
4.9.1
Voltage Adjustments
Note: Refer to the flowcharts in Figure 4-13 and
Figure 4-14 during the voltage adjustment
procedure.
Voltage Adjustment Procedure
1. With the generator set off, connect a digital
multimeter to the output leads or an electrical outlet
on the load side of the generator set. Set the meter
to measure AC voltage.
2. Start the generator set by moving the generator set
master switch to the RUN position.
WARNING
Hazardous voltage. Moving parts.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
The controller’s adjustment mode allows adjustment of
the output voltage, if necessary. Have adjustments
performed by an authorized distributor/dealer or service
technician.
TP-6198 10/04
3. Use the ADC controller to adjust the voltage
(parameter 1P) until the output voltage reaches the
desired value.
See Figure 4-12 for the
approximate change in voltage per step in
parameter 1P.
Voltage Change per Step, VAC
Measured
Voltage, VAC
Coarse Adjust
Fine Adjust
85--132
5
0.5
180--251
7
0.7
Figure 4-12 Voltage Adjustment (approximate)
4. Adjust the voltage stability (gain, parameter 2P) to
minimize light flicker.
5. Readjust the voltage, if necessary.
6. Stop the generator set.
Section 4 Controller
35
Output Voltage Adjustment Mode:
Display :*
Move the generator set master switch to the RUN position. The generator set
engine starts and the controller display shows the engine runtime hours.
x x x x
Hold:
Wait about 5 sec. until the display changes from runtime hours to
the program version number.
x. x x
Press the down arrow key and then the up arrow key 3 times to
enter the adjustment mode. (This is the controller “password.”)
1 P x x
The controller is now in the voltage coarse adjustment mode.
Press:
or
To raise or lower the voltage in large increments
(approximately 5--7 volts per step).
To enter fine voltage adjustment mode.
or
1 P x x
1 P x x
To raise or lower the voltage in smaller increments
(approximately 0.5--0.7 volts per step).
To enter coarse voltage stability (gain) adjustment mode.
2 P x x
or
To raise or lower the voltage stability (gain) in large
increments.
To enter fine voltage stability (gain) adjustment mode.
or
To raise or lower the voltage stability (gain) in smaller
increments.
To enter volts/Hz adjustment mode.
or
2 P x x
3 P 0 x
To raise or lower the volts/Hz:
0.5% per step 00=0; 09 = 4.5%
Continued on Figure 4-14.
* Shaded boxes show which character in the controller display changes for each adjustment. X in the
examples above denotes any number from 0 to 9. The actual values may vary from model-to-model.
TP6196
Figure 4-13 Output Voltage Adjustments
36
Section 4 Controller
TP-6198 10/04
Continued from Figure 4-13:
To enter SAVE mode.
Display : *
S AV E
Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to
the last saved settings when the master switch is moved to the OFF/RESET position.
There are 3 options when the display says SAVE:
Press:
S AV E
To return to the first parameter, coarse voltage adjustment, to check
or change settings before saving. See Figure 4-13.
1 P x x
To save changes.
Y E S
To discard changes without saving.
n o
or
or
“Yes”or “no” flashes when the up or down arrow is pressed and then the
controller exits the configuration mode. The display returns to the
runtime hours.
x x x x
Now move the master switch to OFF/RESET.
* X in the examples above denotes any number from 0 to 9. The actual values
may vary from model-to-model.
Figure 4-14 Output Voltage Adjustments, Continued
TP-6198 10/04
Section 4 Controller
37
4.9.2
Controller Configuration
The controller configuration for each generator model is
set at the factory and should not normally require
changes. The controller’s configuration mode allows
adjustment of the system parameters listed in this
section. Use the instructions in this section to check the
configuration after installation and change them to
match the settings shown in Figure 4-15, if necessary.
Parameter
Setting
Definition
Uu01
Single phase, 60 Hz, 120/240 VAC
Uu04
Three phase, 60 Hz, 138/277 or 240/480 VAC
Unit configuration
Uc01 *
Standby
Engine type
Ec03 *
15RYG/RES
Ec06 *
30RYG/RES
Engine data input types
See Figure 4-16.
Ed01 *
15/30RYG/RES
Ed02
15/30RYG/RES with Remote Digital Gauge
Battery voltage
Bt12 *
Battery voltage 12 VDC
Bt24
Battery voltage 24 VDC
Cn00 *
No CAN communications
Cn01
J1939 (use for Remote Digital Gauge)
Unit’s system voltage and frequency
Communications
* Factory settings.
Figure 4-15 Configuration Parameters
Parameter
Low Coolant Level Sensor
Pressure Sensor
Temperature Sensor
Magnetic Pickup
Ed00
Digital Switch
Digital Switch
Digital Switch
No
Ed01
Digital Switch
Digital Switch
Analog Sender
No
Ed02
Digital Switch
Analog Sender
Digital Switch
No
Ed03
Digital Switch
Analog Sender
Analog Sender
No
Ed04
Digital Switch
Digital Switch
Digital Switch
Yes
Ed05 *
Digital Switch
Digital Switch
Analog Sender
Yes
Ed06
Digital Switch
Analog Sender
Digital Switch
Yes
Ed07
Digital Switch
Analog Sender
Analog Sender
Yes
Ed08
Analog Sender
Digital Switch
Digital Switch
No
Ed09
Analog Sender
Digital Switch
Analog Sender
No
Ed10
Analog Sender
Analog Sender
Digital Switch
No
Ed11
Analog Sender
Analog Sender
Analog Sender
No
Ed12
Analog Sender
Digital Switch
Digital Switch
Yes
Ed13
Analog Sender
Digital Switch
Analog Sender
Yes
Ed14
Analog Sender
Analog Sender
Digital Switch
Yes
Ed15
Analog Sender
Analog Sender
Analog Sender
Yes
* Factory setting for replacement controllers. See Figure 4-15 for the default settings for certain models. The installation of optional sender
kits (available for some models) may require a different Ed setting.
Figure 4-16 Engine Data Input Types, Parameter Ed
38
Section 4 Controller
TP-6198 10/04
The controller will automatically exit the configuration
mode without saving any changes after about 1 minute
if no buttons are pressed. Start the configuration
procedure over again from the beginning if the controller
exits the configuration mode before the settings have
been saved.
Follow the instructions in Figure 4-17 to enter the
configuration mode while the engine is not running and
then step through the following parameters. Use the up
(∧) and down (∨) arrow buttons to select the appropriate
setting for the application.
Voltage/frequency setting (Uu). Select the system
voltage and frequency from the table in Figure 4-15. For
system voltages not listed in the table, select the setting
closest to the system voltage and then adjust the output
voltage to the desired level using the instructions in
Section 4.9.1.
Note: This parameter sets the nominal system voltage
and frequency. To adjust the output (measured)
voltage, see Section 4.9.
Unit configuration (Uc). This parameter sets the
generator set type: marine, standby, or mobile.
Advanced configuration mode (Adnc). The data
input types, battery voltage, and communications
setting can be changed in the advanced configuration
mode. Press the up arrow button when Adnc is
displayed to enter the advanced configuration mode.
Engine data input types (Ed). This setting defines the
type of senders used on the generator set engine. Use
Ed01 for the 15/30RYG/RES.
The remote digital gauge requires the optional analog oil
pressure sender. Install the optional sender and change
the Ed parameter to Ed02.
Battery voltage (Bt). This setting toggles between 12
and 24 VDC for the engine starting battery voltage.
Communications setting (Cn). This setting allows the
user to set the controller for communication with
optional meters. The 15/30RYG/RES is factory-set for
no CAN communications, Cn00. Change this setting to
Cn01 if the optional Remote Digital Gauge is used.
Note: Be sure to save your settings before exiting the
configuration mode. The controller reverts to the
last saved settings when the master switch is
moved to the OFF/RESET position.
Engine configuration (Ec). The engine configuration
must match the generator set engine type.
TP-6198 10/04
Section 4 Controller
39
Controller Configuration Mode:
Display:
Hold the Select button:
Move the generator set master switch to the
RUN position. (The generator set engine will
not start.)
Wait about 5 sec. until the display shows the
program version number. (The number may be
different than the one shown here.)
Press the down arrow key and then the up arrow
key 3 times to enter the configuration mode.
(This is the controller “password.”)
.
0
1 0 4
Uu 0 1
Now release the Select button.
Press:
or
To set the voltage/frequency setting. See
Figure 4-15.
Uu 0 1
To step to the next parameter, unit configuration
Uc.
or
To set the unit configuration setting to Uc01, if
necessary.
Uc 0 1
To step to the next parameter, engine type Ec.
or
To set the engine type, if necessary.
See Figure 4-15.
E c 0 6
To step to the next parameter, advanced
configuration mode or save mode selection.
Ad n c
Now either save your settings or enter the Advanced Configuration Mode to
set the engine data inputs, battery voltage, and communications.
Press:
To enter advanced configuration mode.
Go to Figure 4-18.
E d 0 1
To proceed to the save mode without
entering the advanced configuration mode.
Go to Figure 4-19.
S AV E
or
or
Note: Shaded boxes show which number in the controller display changes when the up or down arrow
key is pressed.
Figure 4-17 Configuration Mode (system voltage/frequency, unit configuration, and engine type parameters)
40
Section 4 Controller
TP-6198 10/04
Pressing the up arrow key at the Adnc display (See Figure 4-17) puts you
into the Advanced Configuration Mode.
Press:
or
To set the engine data input type to Ed01.
See Figure 4-15.
E d 0 1
To enter battery voltage selection mode.
or
To toggle between 12 and 24 VDC. Set this
parameter to 12 VDC.
B t 1 2
To enter communications selection mode.
or
To set the communications parameter to
Cn00 or Cn01. See Figure 4-15.
C n 0 0
To enter SAVE mode. Go to Figure 4-19.
S AV E
Note: Be sure to save your settings before exiting the configuration mode. The controller reverts
to the last saved settings when the master switch is moved to the OFF/RESET position.
Figure 4-18 Advanced Configuration Mode (engine data input types, battery voltage, and engine
communications)
There are 3 options when the display says SAVE:
Press:
To return to the first parameter, system voltage/frequency
Uu, to check or change settings before saving. See
Figure 4-17.
S AV E
Uu 0 1
or
To save changes.
Y E S
To discard changes without saving.
n o
or
“Yes”or “no” flashes when the up or down arrow is pressed and then
the controller exits the configuration mode. The display returns to
the runtime hours.
x x x x
Now move the master switch to OFF/RESET.
* X in the runtime hours display above denotes any number from 0 to 9.
Figure 4-19 Save Mode (after configuring generator set parameters)
TP-6198 10/04
Section 4 Controller
41
4.10 Continuous Power Mode
Jumper
A jumper across controller pins P7-1 and P7-2 maintains
power to the controller at all times. See Figure 4-20.
Controllers are shipped with the jumper connected for
continuous power.
The P7 connector has either 2 or 3 pins. Disconnecting
the jumper or moving the jumper to pins P7-2 and P7-3
allows the controller to power down automatically
48 hours after the generator set shuts down if the
generator set master switch is in the AUTO position. A
remote start signal (from a transfer switch or a remote
start/stop switch connected to controller leads 3 and 4)
or moving the generator set master switch to the RUN
position turns the controller back on.
Note: The jumper must be connected for continuous
power if the optional Remote Digital Gauge is
used.
Use the following procedure to disconnect the jumper, if
desired.
Procedure to disconnect the continuous power
mode jumper (optional).
4. Locate the P7 connector near the top of the
controller. See Figure 4-20. Remove the jumper
from pins 1 and 2 of the P7 connector. If the P7
connector has three pins, connect the jumper
across pins 2 and 3 for storage.
5. Replace the controller’s back cover and secure the
cover screws.
6. Reconnect the three pink connectors to the
generator set master switch.
7. Reconnect the P1, J15, and J16 connectors.
8. Reinstall the controller in the generator set.
9. Reconnect the generator set engine starting
battery, negative (--) lead last.
10. Reconnect power to the battery charger, if
equipped.
11. Place the generator set master switch in the AUTO
position.
2
1
1. Prevent the generator set from starting.
a. Move the generator set master switch to the
OFF/RESET position.
b. Disconnect power to the battery charger, if
equipped.
c. Disconnect the generator set engine starting
battery, negative (--) lead first.
2. Remove the controller from the generator set
housing.
a. Disconnect the engine wiring harness
connector P1 plug (35-pin) from the controller.
Disconnect the J15 and J16 connectors. See
Figure 4-20.
b. Remove controller from generator set housing
in order to access the back of the controller.
tp6195
5
3. Remove controller’s back cover to access jumper.
a. Note the labels on the three leads connected to
the generator set master switch for
reconnection later. Disconnect the leads at the
pink connectors. See Figure 4-20.
b. Remove the cover screws and remove the
controller’s back cover. See Figure 4-20.
42
Section 4 Controller
1.
2.
3.
4.
5.
4
3
Engine wiring harness connector plug (P1)
Continuous power mode jumper location (P7)
J15 connector
J16 connector
Generator set master switch connectors
Figure 4-20 Advanced Digital Control Connections
TP-6198 10/04
Section 5 Component Testing and Adjustment
5.1 Theory of Operation
5.2 Separate Excitation
Model 15/30RYG/RES generator sets utilize a
rotating-field alternator to produce AC voltage. Upon
activation of the generator master switch, DC current
from the battery magnetizes the rotor (field). When the
magnetized rotor rotates within the stator windings, an
electrical voltage develops within the stator. As engine
speed and generator output increase, the SCR module
feeds rectified stator output current to the rotor through
the brushes/slip rings to increase the strength of the
rotor field. As the rotor field increases in strength,
generator output also increases. The ADC 2100
controller monitors the generator output voltage through
leads 11 and 44 (single-phase) or leads V7, V8, and V9
(three-phase) and adjusts the DC current from the SCR
module to the rotor to meet load requirements. See
Figure 5-1.
To determine the cause of no or low AC output, refer to
the troubleshooting flow chart in Figure 5-2. Before
beginning the test procedures, read all safety
precautions at the beginning of this manual. Many of the
test procedures include additional safety precautions.
No Generator Output
Separate Excitation
Output within Specifications
Erratic or No Output
Check Wiring, Fuses,
SCR Module and
Controller
Check Rotor
Check Stator
1
55
66
ADC 2100
TP563273
55
66
AC1
AC2
G1
G2
(+)
G
F+
2
SCR
Figure 5-2
(--)
FP
Check the condition of the alternator fuse before
performing the separate excitation procedure. See
Figure 5-1. The inline fuse is located in lead 55 of the
wiring harness (for earlier models) or on the fuse panel
(for later models). 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).
3
FN
FP
11
FN
4
44
3
2
1 11
55 66
44
8
7
4
5
6
TP6198
1.
2.
3.
4.
Fuse
Power lead (55)
Excitation to rotor
Brushes
Figure 5-1
5.
6.
7.
8.
Slip rings
Main field (rotor)
Stator windings
Sensing leads (11--44)
Single-Phase Generator Schematic
TP-6198 10/04
Generator Troubleshooting
Separately exciting the generator can identify faulty
voltage regulation by the ADC controller or reveal a
running fault in the rotor and/or stator. An external
power source duplicates the role of the voltage regulator
and excites the generator field (rotor). A generator
component that appears to be in good condition while
stationary may exhibit a running open or short circuit
while moving. Centrifugal forces acting on the windings
during rotation cause a broken circuit to open, or
increasing temperatures cause the insulation to break
down, resulting in a running fault. If this test shows that
the rotor and stator are in good condition, test the
voltage regulation using the tests in Section 5.12.
Section 5 Component Testing and Adjustment
43
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. 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. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk
of electrocution.
2 3
1
FN
9
5
FP
7
- +
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
4
-
+
8
6
TP563274
Separate Excitation Procedure
Perform the following procedure to use an external
voltage source to excite the main field (rotor).
1. Disconnect the black FN and FP leads from the
alternator at the SCR module (+) and (--) terminals.
2. Connect a DC ammeter, 10-amp fuse, and a
12-volt automotive battery to the positive (FP) and
negative (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)
=
3.0 ohms (rotor resistance)
4.0 amps
(rotor
current)
3. Start the engine and check that the ammeter
reading remains stable. An increasing meter
reading indicates a shorted rotor. A meter reading
decreasing to zero or an unstable reading
suggests a running open. Refer to Section 5.4,
Main Field (Rotor), to test the rotor. If the ammeter
reading is stable, proceed to step 4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
SCR module
FN lead disconnected from SCR
FP lead disconnected from SCR
10-amp fuse
DC ammeter
12V battery
Brushes
Slip rings
Main field (rotor)
Figure 5-3
Separate Excitation Connections
5.3 Stator
The stator contains a series of coils of wire laid in a
laminated steel frame. The stator leads supply AC
voltage to the load and voltage regulator. Before testing
the stator, inspect it for heat discoloration and visible
damage to housing lead wires, exposed coil windings,
and exposed areas of frame laminations. Be sure the
stator is securely fastened to the stator housing.
Note: Disconnect all stator leads before performing all
stator tests.
WARNING
4. Check for AC output across the stator leads; see
Section 5.3, Stator. Compare the readings to the
AC output values shown in Section 1,
Specifications. If the readings vary considerably, a
faulty stator is likely. Refer to Section 5.3, Stator,
for further information.
Hazardous voltage. Moving parts.
Can cause severe injury or death.
5. If this test shows that the rotor and stator are in
good condition, check the wiring and fuses. Check
the SCR module. See Section 4.7, Silicon
Controlled Rectifier (SCR) Module. Check the
controller settings and connections.
See
Section 4, Controller.
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 set failure.
44
Section 5 Component Testing and Adjustment
Operate the generator set only when
all guards and electrical enclosures
are in place.
TP-6198 10/04
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
4
44
3
66
Stator Continuity and Resistance Tests
55
1. Place the generator set master switch in the OFF
position.
2
2. Disconnect power to the battery charger.
1
3. Disconnect 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 shown in Figure 5-4.
Figure 5-5
11
Single-Phase Alternator Stator Leads
Note: For three-phase models, leads 1--12 are the
generator output leads. Leads V7, V8, V9, 55,
and 66 are the controller and SCR module
sensing and supply leads. Refer to the schematic
in Figure 5-6 when performing the following
steps.
tp6198
R14807-14
Figure 5-4
6198
Testing Stator Windings
Figure 5-6
Note: For single-phase models, leads 1--4 are the
generator output leads. Leads 11, 44, 55, and 66
are the controller and SCR module sensing and
supply leads.
Refer to the schematic in
Figure 5-5 when performing the following steps.
Note: When taking an ohmmeter reading using lead 55,
make the connection before the inline fuse.
TP-6198 10/04
Three-Phase Alternator Stator Leads
6. Contact the ohmmeter leads and readjust the
ohmmeter to read zero ohms.
7. Check the cold resistance of the stator windings by
connecting the meter leads to the stator leads. See
Section 1.6, Alternator Specifications, for stator
winding resistances.
Section 5 Component Testing and Adjustment
45
Note: Most ohmmeters do not provide accurate
readings below 1 ohm. Low resistance
readings (continuity) and no evidence of
shorted windings (heat discoloration)
indicate a stator in good condition. See
Figure 5-7 or Figure 5-8.
Leads
1 and 2
1 and 11
2 and 11
3 and 4
3 and 44
4 and 44
55 and 66
1 and 3, 4, 44, 55, or 66
2 and 3, 4, 44, 55, or 66
3 and 1, 2, 11, 55, or 66
4 and 1, 2, 11, 55, or 66
Any stator lead and ground on stator
housing or frame laminations
Figure 5-7
Yes
No
Continuity
Note: A reading of approximately 500 kOhms
(1/2 megohm) and higher indicates a
good stator.
c. Repair or replace the stator if any reading is
less than approximately 500 kOhms. A reading
of less than 500 kOhms indicates deterioration
of the winding insulation and possible current
flow to ground.
The two-pole rotor creates the magnetic field needed to
produce alternating current in the stator windings.
Before testing, inspect the rotor for visible damage to
pole shoes, insulation, exposed coil windings, and slip
ring surfaces. Rotate the bearing to check for wear, heat
discoloration, or noise.
Rotor Continuity and Resistance Tests
WARNING
No
Continuity Test Results on a Good Stator
(Three-Phase)
Note: Because ohmmeter accuracy varies,
resistance readings are approximate
readings. Take readings of the rotor and
stator at room temperature.
Note: Make sure that all stator leads are
disconnected
before
running
the
megohmmeter test.
Section 5 Component Testing and Adjustment
b. Repeat the test on the other stator leads until
each coil is tested.
Yes
8. If the resistance test proves inconclusive, use a
megohmmeter to test the stator as described in the
next step.
46
a. Apply 500 volts DC to any stator lead and the
stator frame. Perform the megohmmeter test
following the instructions of the megohmmeter
manufacturer.
5.4 Main Field (Rotor)
Continuity Test Results on a Good Stator
(Single-Phase)
Leads
1 and 4
2 and 5
3 and 6
7 and 10
8 and 11
9 and 12
55 and 66
1 and 2, 3, 7, 8, or 9
1 and 55
Any stator lead and ground
Figure 5-8
Continuity
9. Use a megohmmeter to determine whether the
stator is shorted to ground.
Hazardous voltage. Moving parts.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
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 set failure.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. 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. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk
of electrocution.
TP-6198 10/04
Rotor Test Procedure
1. Place the generator set master switch in the OFF
position.
2. Disconnect power to the battery charger.
3. Disconnect the generator set engine starting
battery, negative (--) lead first.
4. Remove the brush cover from the alternator end
bracket.
5. Check the rotor for continuity and resistance.
Raise the brushes from the slip rings while
performing ohmmeter tests. Measure the rotor
resistance (ohms) between the two slip rings; see
Figure 5-9.
See Section 1.6, Alternator
Specifications, for rotor resistance readings. If the
resistance readings are low, perform a
megohmmeter test on rotor as described in the
next step.
Note: Because ohmmeter accuracy varies,
resistance readings are approximate. Take
readings at room temperature.
6. Perform a megohmmeter test 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 higher indicates a
good rotor.
c. Repair or replace the rotor if the reading is less
than approximately 500 kOhms. A reading of
less than 500 kOhms indicates deterioration of
the winding insulation and possible current flow
to ground.
d. Following the test, remove the retainer wire
from the brush holder and check the brush
positions on the slip rings. See Section 5.6,
Brushes.
e. Reinstall the brush cover on the end bracket.
5.5 Slip Rings
2-221
R13929-7
Figure 5-9
Rotor Resistance Check
TP-6198 10/04
Slip rings acquire a glossy brown finish in normal
operation. Do not attempt to maintain a bright,
newly-machined appearance on the slip rings. Cleaning
with a dry, lint-free cloth is usually sufficient. Use very
fine sandpaper (#00) and apply light pressure to remove
roughness. Do not use emery or carborundum paper or
cloth. Clean all carbon dust from the generator after
sanding the slip rings. If the rings are black or pitted,
remove the rotor and use a lathe to remove some of the
slip ring surface material.
Section 5 Component Testing and Adjustment
47
5.6 Brushes
The brushes transfer current from the SCR module to
the slip rings. The brushes should last the life of the
generator. Abrasive dust on the slip rings, however,
shortens the life of the brushes. Excessive arcing at the
brushes could damage the SCR module and the
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 rings or voltage regulator failure. Figure 5-10
shows the correct positioning of the brushes. Add or
remove shims as necessary to center the brushes on the
slip rings. Replace the brushes if they show uneven
wear or are worn to one half their original length.
1
2
Check the resistance through the brushes. Resistance
through the brushes should be low, 0.1--0.2 ohms
without meter lead resistance.
Front View
GM32849A-D
4
7
5
Side View
6
8
9
3
New 1.9 cm (0.75 in.)
2
2
3
TP5867
1.
2.
3.
4.
5.
6.
Brush holders (2)
Slip ring
Brush
Retainer wire
Shim
Spring
7. Brush holder
8. Correctly positioned
brush
9. Incorrectly positioned
brush
Figure 5-10 Brush Assembly
48
Section 5 Component Testing and Adjustment
TP-6198 10/04
5.7 Voltage
5.7.1
WARNING
Voltage Regulation
Voltage regulation is performed by the Advanced Digital
Control (ADC) and the SCR module. The ADC monitors
generator output voltage and adjusts the excitation
current to the rotor through the SCR module.
5.7.2
Hazardous voltage. Moving parts.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Voltage Adjustment
The factory sets the voltage for correct generator
operation under a variety of load conditions. Usually, the
voltage needs no further adjustment. Adjust the voltage
when necessary according to the following procedure.
The adjustment procedure requires a meter that can
measure voltage and frequency.
Use the ADC controller to adjust the voltage, gain, and
volts/hertz (Hz). Refer to Section 4.9.2 for instructions to
adjust each parameter and save changes using
controller keypad.
Note: The ADC controller will time out and exit the
adjustment mode after approximately 1 minute if
no buttons are pressed. Any unsaved changes
are discarded if the controller times out before the
settings are saved. Refer to Section 4.9.2 for
instructions to save your settings.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. 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. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk
of electrocution.
Voltage Adjustment Procedure
1. Connect a digital voltmeter from one side of the
circuit breaker to the L0 terminal on the end bracket
casting. See Figure 5-11. Set the meter to
measure voltage.
Voltage Adjustment.
Adjusts generator output
between 100 and 130 volts.
Gain (Stability) Adjustment.
circuitry to reduce light flicker.
Fine tunes regulator
2
1
Volts/Hz Adjustment. Determines frequency (Hz) at
which generator output voltage begins to drop.
3
The controller maintains generator output at the
specified voltage under load until the generator engine
speed drops to a preset level (factory setting 57.5 Hz on
60 Hz models and 47.5 Hz on 50 Hz models). Then the
controller allows the generator voltage and current to
drop. The 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.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
GM32850B-
1. Load connection terminal L0
2. Controller location
3. Line circuit breaker
Figure 5-11 Circuit Breaker and L0 Terminal Location
TP-6198 10/04
Section 5 Component Testing and Adjustment
49
Note: For 120- or 240-volt systems the voltage
measured from one side of the breaker to L0
should be approximately 120 VAC. For
240-volt systems, the voltage measured
from one side of the circuit breaker to the
other should be approximately 240 VAC.
2. Start the generator set.
3. Follow the controller instructions in Section 4.9.2 to
enter the adjustment mode and increase voltage or
decrease voltage (parameter 1P) until the output
reaches the desired voltage.
4. Follow the controller instructions to step to the
voltage gain adjustment menu. Adjust the voltage
gain (parameter 2P) until the light flicker minimizes.
Save the settings.
3P
Voltage Droop for Each Cycle
(Hz) Below Cut--in Frequency
0
0
1
0.5%
2
1.0%
3
1.5%
4
2.0%
5
2.5%
6
3.0%
7
3.5%
8
4.0%
9
4.5%
Figure 5-12 Voltage Droop Adjustments
5. Check and readjust the voltage if necessary.
1. Readjust the voltage stability (gain, parameter 2P),
if necessary.
6. Save the settings.
2. Readjust the voltage (parameter 1P), if necessary.
Note: The controller will revert to the previous
settings at the next startup if the changes are
not saved.
7. Stop the generator set.
Volts per Hertz Adjustments
The cut-in frequency is set at 57.5 Hz (60 Hz system) or
47.5 Hz (50 Hz system) and is not adjustable. When the
frequency falls below the cut-in, output voltage is
reduced to relieve the engine. The amount of the
voltage reduction is set by the 3P parameter. Monitor
engine speed and output voltage as loads are applied.
D If there is excessive droop in engine speed and little
droop in voltage, increase the 3P value.
D If there is little engine speed droop but excessive
3. Stop the generator set.
5.8 Voltage Reconnection
Voltage Reconnection is covered in the generator set
Installation Manual. See the List of Related Materials for
the document number.
5.9 Governor System
The frequency of the alternator output is determined by
the speed of the engine. A four-pole alternator must be
driven at 1800 rpm to provide 60 Hz. A two-pole
alternator must be driven at 3600 rpm to provide 60 Hz.
The engine speed is maintained by the Engine Control
Module (ECM). See the engine documentation for ECM
information.
voltage droop, decrease the 3P value.
The amount of voltage droop is approximately 0.5% of
system voltage for each step of 3P.
50
Section 5 Component Testing and Adjustment
TP-6198 10/04
5.10 Fault Shutdown 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.
Oil Pressure Sender (OPS, optional): Remove
connector P7 from the oil pressure sensor. Connect a
jumper between pins A and C on the connector. Start
the generator set and run for at least 35 seconds Verify
that the generator set shuts down and the ADC display
indicates an LOP fault. If the ADC does not shut down
on an LOP fault, test the OPS harness and connectors.
Overcrank Shutdown
WARNING
Hazardous voltage. Moving parts.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
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, and covers before operating the generator
set.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
5.10.1 Controller Fault Shutdown
Functions
Check the operation of the fault functions programmed
in the ADC 2100 by performing the following tests. If the
ADC 2100 does not operate as described, check the
controller configuration settings; see Section 4.9. Also
check the controller wiring and connections.
Disconnect the starter motor lead at the starter solenoid.
Move the controller master switch to the RUN position.
Observe that the generator set simulates cranking for
15 seconds and then rests for 15 seconds Check that
the generator set shuts down after the third crank/rest
cycle.
High Engine Temperature Shutdown
Remove the connector from the coolant temperature
sensor (CTS) and connect a jumper across terminals A
and B (black and white leads). Start the generator set.
Verify that the generator set shuts down and the ADC
display indicates fault HE approximately 5 seconds
after the generator set comes up to speed. Remove the
jumper wire. Start the generator set and run it for at least
30 seconds to verify that the generator set does not shut
down.
5.10.2 Fault Shutdown Switches
Check the low oil pressure and high engine temperature
shutdown switches on the engine by performing the
following tests. If the sensor does not function as
described, replace it.
WARNING
Low Oil Pressure (LOP) Shutdown
Hazardous voltage. Moving parts.
Can cause severe injury or death.
Oil Pressure Switch: Connect a jumper wire from the
LOP switch (lead 13) to the generator set ground. Start
the generator set. Verify that the generator set shuts
down on an LOP fault after approximately
25--35 seconds of operation. Remove the jumper wire
from the LOP switch and ground. Start the generator set
and run it for at least 25--35 seconds to verify that the
generator set does not shut down.
Operate the generator set only when
all guards and electrical enclosures
are in place.
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, and covers before operating the generator
set.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
TP-6198 10/04
Section 5 Component Testing and Adjustment
51
Temperature Sensor (CTS)
The coolant temperature sensor (CTS) is used to
monitor engine temperature for the high engine
temperature fault shutdown (HE). See Figure 5-14 for
the coolant temperature sensor location. Set the
generator set master switch to the OFF position and
allow the generator set to cool. Disconnect the CTS 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 5-13. If
the resistance is very low (indicating a short circuit) or
very high (indicating an open circuit) replace the CTS.
Temperature, _C (_F)
30 (86)
100 (212)
Resistance, Ohms
2100--2500
180--200
Figure 5-13 Coolant Temperature Sensor Resistance
Readings
1
tp6198
1. Low oil pressure switch
Figure 5-15 Low Oil Pressure Switch Location (fan
guard removed)
5.11 Fuel Systems
WARNING
1
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
tp6198
1. Coolant temperature sensor (CTS)
Figure 5-14 Coolant Temperature Sensor (CTS)
Low Oil Pressure (LOP) Switch
Remove the LOP switch and install an oil pressure
gauge to verify that the engine oil pressure is within the
range specified in Section 1, Specifications, before
testing or replacing the LOP switch. See Figure 5-15.
To test the LOP switch, reinstall the switch and start the
generator set. If the unit shuts down, disconnect lead 13
from the LOP switch and reset the controller. Restart the
generator set and verify that it does not shut down. A
successful restart indicates a bad LOP switch. Replace
the switch.
52
Section 5 Component Testing and Adjustment
The fuel supplier provides and maintains manual
shut-off valves and the primary regulator. Verify that the
fuel system capacity is adequate to supply the generator
set plus all other gas appliances.
A factory-installed secondary regulator and 12 VDC
solenoid valve are located in the front inlet air
compartment. The controller energizes the fuel
solenoid valve to open at startup and deenergizes the
valve to close at shutdown. The secondary fuel
regulator reduces fuel pressure for delivery to the fuel
block. The fuel flows from the fuel block to the
carburetor in a gaseous state. The carburetor mixes the
fuel with intake air for consumption by the engine.
TP-6198 10/04
Use a Universal Exhaust Gas Oxygen (UEGO) sensor
to check the fuel mixture after replacing the fuel
regulator, fuel mixer, or silencer. The engine should be
warm when the fuel mixture is checked. See the
generator set Installation Manual for instructions to
check the fuel mixture.
5.11.3 Fuel Conversion
The fuel system can be converted from natural gas to LP
vapor (or vice-versa) in the field. See the generator set
Installation Manual for fuel system conversion and fuel
mixture adjustment procedures.
Refer to the troubleshooting instructions in Section 3,
Troubleshooting, to identify generator set operation
problems that may be caused by an inadequate fuel
supply, incorrect adjustments, or damaged fuel system
components.
1
5.11.1 Fuel Solenoid Valve
A solenoid valve upstream of the regulator and the
flexible fuel connector provides automatic fuel on/off
control. The engine starting battery powers the solenoid
valve and the engine starting controls open the valve
when the engine cranks or runs.
Gas Valve Operation Test Procedure
1. Disconnect the positive (+) battery lead from the
gas valve terminal.
2. Apply 12 VDC to the gas valve terminal and listen
for an audible click, indicating that the valve
actuates.
3. Replace the gas valve if it does not actuate in
step 2.
5.11.2 Fuel Regulators
The typical gaseous fuel system uses two regulators.
The primary regulator reduces the line pressure to an
allowable inlet pressure for the secondary regulator.
The fuel supplier provides and maintains the primary
regulator. The secondary regulator is factory-installed
on the generator set and is designed for a maximum inlet
pressure of 2.7 kPa (6 oz./in.2) or 280 mm (11 in.) water
column.
4
2
3
1.
2.
3.
4.
Solenoid valve
Check inlet fuel pressure here
Secondary regulator (shown pointing down for LP)
Fuel supply connection
Note:
UL-listed models use a second fuel solenoid valve,
not shown.
Figure 5-16 Fuel System (LP gas setup shown)
5.12 Fuses
Three fuses protect the controller, SCR module, and
relay interface board. See Figure 5-17 for fuse ratings
and part numbers.
Always identify and correct the cause of a blown fuse
before restarting the generator set. Refer to Section 3,
Troubleshooting, for conditions that may indicate a
blown fuse. Replace blown fuses with identical
replacement parts.
Label
Part
Number
Location *
Auxiliary Winding,
10 amps
F1
358337
Lead 55
Relay Interface
Board, 10 amps
F2
223316
Lead PF2
Controller, 10 amps
F3
223316
Lead PF3
Fuse
Checking Fuel Pressure
Use a gauge or manometer to check the fuel pressure at
the secondary regulator inlet.
See Figure 5-16.
Measure the fuel pressure with the generator set
running at rated load. The fuel pressure should be
178--280 mm (7--11 in.) water column or 1.7--2.7 kPa
(4--6 oz./in.2). Contact the fuel supplier if the inlet
pressure is not within the specified range.
TP-6198 10/04
tp6329
* In engine harness on earlier models
Figure 5-17 Fuses
Section 5 Component Testing and Adjustment
53
Note: Disconnect the generator set battery before
performing continuity checks 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 6, 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 circuit.
1
Figure 5-19 illustrates the generator set master switch
continuity with the switch in the RUN and AUTO
positions.
Zero ohms (continuity) across RUN
and COM terminals
tp6198
5.13 Continuity Checks
AUTO
RUN
Figure 5-18 Fuse Location
COM
Master Switch in
RUN Position
3
1. Fuses
2
Some earlier models had inline fuses
located in the engine harness.
1
Note:
Zero ohms (continuity) across
COM and AUTO terminals
WARNING
AUTO
COM
RUN
3
Operate the generator set only when
all guards and electrical enclosures
are in place.
2
Hazardous voltage. Moving parts.
Can cause severe injury or death.
1
Master Switch in
AUTO Position
tp6196
Figure 5-19 Generator Set Master Switch Continuity
Checks (back view of switch)
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
54
Section 5 Component Testing and Adjustment
TP-6198 10/04
Section 6 Wiring Diagrams
6.1 Specification Numbers
6.2 Wiring Diagram Reference
At the time of print, this manual contained wiring
diagrams For the model numbers and specification
(spec) numbers in Figure 6-1. For other specification
numbers, refer to wiring diagram manual TP-6437. On
occasion, the manufacturer may provide this manual
with units that are not listed below, such as when similar
new specs are created prior to the updated reprint or in
other cases when the manual is a suitable substitute for
a manual under development.
Figure 6-2 lists the wiring diagram numbers and
locations.
Model No.
Spec. No.
15RYG
GM39949-GA21
15RES
GM39949-GA20
30RYG
GM39949-GA23
30RES
GM39949-GA22
Figure 6-1
Wiring Diagram
Description
Drawing
Number
Schematic Diagram
Sheet 1
Sheet 2
ADV-7287A-A
ADV-7287B-A
56
57
Point-to-Point Wiring Diagram
GM50548A-C
Sheet 1
GM50548B-C
Sheet 2
58
59
Figure 6-2
Page
Controller Wiring Diagrams
Generator Set Specification Numbers
TP-6198 10/04
Section 6 Wiring Diagrams
55
Figure 6-3
56
Schematic Diagram, ADV-7287A-A
Section 6 Wiring Diagrams
TP-6198 10/04
Figure 6-4
Schematic Diagram, ADV-7287B-A
TP-6198 10/04
Section 6 Wiring Diagrams
57
Figure 6-5
58
Point-to-Point Wiring Diagram, GM50548A-C
Section 6 Wiring Diagrams
TP-6198 10/04
Figure 6-6
Point-to-Point Wiring Diagram, GM50548B-C
TP-6198 10/04
Section 6 Wiring Diagrams
59
Notes
60
Section 6 Wiring Diagrams
TP-6198 10/04
Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp
ABDC
AC
A/D
ADC
adj.
ADV
Ah
AHWT
AISI
ALOP
alt.
Al
ANSI
AO
APDC
API
approx.
APU
AQMD
AR
AS
ASE
ASME
assy.
ASTM
ATDC
ATS
auto.
aux.
avg.
AVR
AWG
AWM
bat.
BBDC
BC
BCA
BCI
BDC
BHP
blk.
blk. htr.
BMEP
bps
br.
BTDC
Btu
Btu/min.
C
cal.
CAN
CARB
CAT5
CB
CC
cc
CCA
ccw.
CEC
cert.
cfh
ampere
after bottom dead center
alternating current
analog to digital
advanced digital control;
analog to digital converter
adjust, adjustment
advertising dimensional
drawing
amp-hour
anticipatory high water
temperature
American Iron and Steel
Institute
anticipatory low oil pressure
alternator
aluminum
American National Standards
Institute (formerly American
Standards Association, ASA)
anticipatory only
Air Pollution Control District
American Petroleum Institute
approximate, approximately
Auxiliary Power Unit
Air Quality Management District
as required, as requested
as supplied, as stated, as
suggested
American Society of Engineers
American Society of
Mechanical Engineers
assembly
American Society for Testing
Materials
after top dead center
automatic transfer switch
automatic
auxiliary
average
automatic voltage regulator
American Wire Gauge
appliance wiring material
battery
before bottom dead center
battery charger, battery
charging
battery charging alternator
Battery Council International
before dead center
brake horsepower
black (paint color), block
(engine)
block heater
brake mean effective pressure
bits per second
brass
before top dead center
British thermal unit
British thermal units per minute
Celsius, centigrade
calorie
controller area network
California Air Resources Board
Category 5 (network cable)
circuit breaker
crank cycle
cubic centimeter
cold cranking amps
counterclockwise
Canadian Electrical Code
certificate, certification, certified
cubic feet per hour
TP-6198 10/04
cfm
CG
CID
CL
cm
CMOS
cubic feet per minute
center of gravity
cubic inch displacement
centerline
centimeter
complementary metal oxide
substrate (semiconductor)
com
communications (port)
coml
commercial
Coml/Rec Commercial/Recreational
conn.
connection
cont.
continued
CPVC
chlorinated polyvinyl chloride
crit.
critical
CSA
Canadian Standards
Association
CT
current transformer
Cu
copper
cUL
Canadian Underwriter’s
Laboratories
CUL
Canadian Underwriter’s
Laboratories
cu. in.
cubic inch
cw.
clockwise
CWC
city water-cooled
cyl.
cylinder
D/A
digital to analog
DAC
digital to analog converter
dB
decibel
dB(A)
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-pole, double-throw
DPST
double-pole, single-throw
DS
disconnect switch
DVR
digital voltage regulator
E2PROM, EEPROM
electrically-erasable
programmable read-only
memory
E, emer. emergency (power source)
ECM
electronic control module,
engine control module
EDI
electronic data interchange
EFR
emergency frequency relay
e.g.
for example (exempli gratia)
EG
electronic governor
EGSA
Electrical Generating Systems
Association
EIA
Electronic Industries
Association
EI/EO
end inlet/end outlet
EMI
electromagnetic interference
emiss.
emission
eng.
engine
EPA
Environmental Protection
Agency
EPS
emergency power system
ER
emergency relay
ES
engineering special,
engineered special
ESD
electrostatic discharge
est.
estimated
E-Stop
emergency stop
etc.
et cetera (and so forth)
exh.
ext.
F
FHM
fl. oz.
flex.
freq.
FS
ft.
ft. lb.
ft./min.
ftp
g
ga.
gal.
gen.
genset
GFI
GND,
gov.
gph
gpm
gr.
GRD
gr. wt.
HxWxD
HC
HCHT
HD
HET
hex
Hg
HH
HHC
HP
hr.
HS
hsg.
HVAC
HWT
Hz
IBC
IC
ID
IEC
IEEE
IMS
in.
in. H2O
in. Hg
in. lb.
Inc.
ind.
int.
int./ext.
I/O
IP
ISO
J
JIS
k
K
kA
KB
KBus
kg
exhaust
external
Fahrenheit, female
flat head machine (screw)
fluid ounce
flexible
frequency
full scale
foot, feet
foot pounds (torque)
feet per minute
file transfer protocol
gram
gauge (meters, wire size)
gallon
generator
generator set
ground fault interrupter
ground
governor
gallons per hour
gallons per minute
grade, gross
equipment ground
gross weight
height by width by depth
hex cap
high cylinder head temperature
heavy duty
high exhaust temp., high
engine temp.
hexagon
mercury (element)
hex head
hex head cap
horsepower
hour
heat shrink
housing
heating, ventilation, and air
conditioning
high water temperature
hertz (cycles per second)
International Building Code
integrated circuit
inside diameter, identification
International Electrotechnical
Commission
Institute of Electrical and
Electronics Engineers
improved motor starting
inch
inches of water
inches of mercury
inch pounds
incorporated
industrial
internal
internal/external
input/output
internet protocol
International Organization for
Standardization
joule
Japanese Industry Standard
kilo (1000)
kelvin
kiloampere
kilobyte (210 bytes)
Kohler communication protocol
kilogram
Appendix 61
kg/cm2
kilograms per square
centimeter
kgm
kilogram-meter
kg/m3
kilograms per cubic meter
kHz
kilohertz
kJ
kilojoule
km
kilometer
kOhm, kΩ kilo-ohm
kPa
kilopascal
kph
kilometers per hour
kV
kilovolt
kVA
kilovolt ampere
kVAR
kilovolt ampere reactive
kW
kilowatt
kWh
kilowatt-hour
kWm
kilowatt mechanical
kWth
kilowatt-thermal
L
liter
LAN
local area network
L x W x H length by width by height
lb.
pound, pounds
lbm/ft3
pounds mass per cubic feet
LCB
line circuit breaker
LCD
liquid crystal display
LED
light emitting diode
Lph
liters per hour
Lpm
liters per minute
LOP
low oil pressure
LP
liquefied petroleum
LPG
liquefied petroleum gas
LS
left side
Lwa
sound power level, A weighted
LWL
low water level
LWT
low water temperature
m
meter, milli (1/1000)
M
mega (106 when used with SI
units), male
cubic meter
m3
m3/hr.
cubic meters per hour
m3/min.
cubic meters per minute
mA
milliampere
man.
manual
max.
maximum
MB
megabyte (220 bytes)
MCCB
molded-case circuit breaker
MCM
one thousand circular mils
meggar
megohmmeter
MHz
megahertz
mi.
mile
mil
one one-thousandth of an inch
min.
minimum, minute
misc.
miscellaneous
MJ
megajoule
mJ
millijoule
mm
millimeter
mOhm, mΩmilliohm
MOhm, MΩmegohm
MOV
metal oxide varistor
MPa
megapascal
mpg
miles per gallon
mph
miles per hour
MS
military standard
ms
millisecond
m/sec.
meters per second
mtg.
mounting
MTU
Motoren-und Turbinen-Union
MW
megawatt
mW
milliwatt
μF
microfarad
N, norm. normal (power source)
NA
not available, not applicable
nat. gas natural gas
62 Appendix
NBS
NC
NEC
NEMA
National Bureau of Standards
normally closed
National Electrical Code
National Electrical
Manufacturers Association
NFPA
National Fire Protection
Association
Nm
newton meter
NO
normally open
no., nos. number, numbers
NPS
National Pipe, Straight
NPSC
National Pipe, Straight-coupling
NPT
National Standard taper pipe
thread per general use
NPTF
National Pipe, Taper-Fine
NR
not required, normal relay
ns
nanosecond
OC
overcrank
OD
outside diameter
OEM
original equipment
manufacturer
OF
overfrequency
opt.
option, 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
Phillipsr head Crimptiter
(screw)
PHH
Phillipsr hex head (screw)
PHM
pan head machine (screw)
PLC
programmable logic control
PMG
permanent magnet generator
pot
potentiometer, potential
ppm
parts per million
PROM
programmable read-only
memory
psi
pounds per square inch
psig
pounds per square inch gauge
pt.
pint
PTC
positive temperature coefficient
PTO
power takeoff
PVC
polyvinyl chloride
qt.
quart, quarts
qty.
quantity
R
replacement (emergency)
power source
rad.
radiator, radius
RAM
random access memory
RDO
relay driver output
ref.
reference
rem.
remote
Res/Coml Residential/Commercial
RFI
radio frequency interference
RH
round head
RHM
round head machine (screw)
rly.
relay
rms
root mean square
rnd.
round
RO
read only
ROM
read only memory
rot.
rotate, rotating
rpm
revolutions per minute
RS
right side
RTDs
Resistance Temperature
Detectors
RTU
RTV
RW
SAE
scfm
SCR
s, sec.
SI
SI/EO
sil.
SMTP
SN
SNMP
SPDT
SPST
spec
specs
sq.
sq. cm
sq. in.
SMS
SS
std.
stl.
tach.
TB
TCP
TD
TDC
TDEC
TDEN
TDES
TDNE
TDOE
TDON
temp.
term.
THD
TIF
tol.
turbo.
typ.
UF
UHF
UIF
UL
UNC
UNF
univ.
URL
US
UV
V
VAC
VAR
VDC
VFD
VGA
VHF
W
WCR
w/
WO
w/o
wt.
xfmr
remote terminal unit
room temperature vulcanization
read/write
Society of Automotive
Engineers
standard cubic feet per minute
silicon controlled rectifier
second
Systeme international d’unites,
International System of Units
side in/end out
silencer
simple mail transfer protocol
serial number
simple network management
protocol
single-pole, double-throw
single-pole, single-throw
specification
specification(s)
square
square centimeter
square inch
short message service
stainless steel
standard
steel
tachometer
terminal block
transmission control protocol
time delay
top dead center
time delay engine cooldown
time delay emergency to
normal
time delay engine start
time delay normal to
emergency
time delay off to emergency
time delay off to normal
temperature
terminal
total harmonic distortion
telephone influence factor
tolerance
turbocharger
typical (same in multiple
locations)
underfrequency
ultrahigh frequency
user interface
Underwriter’s Laboratories, Inc.
unified coarse thread (was NC)
unified fine thread (was NF)
universal
uniform resource locator
(web address)
undersize, underspeed
ultraviolet, undervoltage
volt
volts alternating current
voltampere reactive
volts direct current
vacuum fluorescent display
video graphics adapter
very high frequency
watt
withstand and closing rating
with
write only
without
weight
transformer
TP-6198 10/04
Appendix B Common Hardware Application Guidelines
Use the information below and on the following pages to
identify proper fastening techniques when no specific
reference for reassembly is made.
Bolt/Screw Length: When bolt/screw length is not given,
use Figure 1 as a guide. As a general rule, a minimum
length of one thread beyond the nut and a maximum
length of 1/2 the bolt/screw diameter beyond the nut is
the preferred method.
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.
Washers and Nuts: Use split lock washers as a bolt
locking device where specified. Use SAE flat washers
with whiz nuts, spiralock nuts, or standard nuts and
preloading (torque) of the bolt in all other applications.
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 standard
nut and SAE washer. Hardware 1/2 inch or less in
diameter can take a properly torqued whiz nut or
spiralock nut. See Figure 2.
See Appendix C, General Torque Specifications, and
other torque specifications in the service literature.
3. Follow these SAE washer rules after determining
exit hole type:
a. Always use a washer between hardware and a
slot.
Preferred Nut/Bolt Clearance
1
2
b. Always use a washer under a nut (see 2 above
for exception).
c. Use a washer under a bolt when the female
thread is fixed (weld nut).
4. Refer to Figure 2, which depicts the preceding
hardware configuration possibilities.
Unacceptable Nut/Bolt Clearance
3
2
1
3
G-585
1. 1/2 of bolt diameter
2. Min. 1 full thread beyond top of nut
3. Below top of nut
Figure 1
Acceptable Bolt Lengths
5
4
6
G-585
1.
2.
3.
4.
5.
6.
Cap screw
Entry hole types
Standard nut and SAE washer
Whiz nut or spiralock: up to 1/2 in. dia. hardware
Weld nuts: above 1/2 in. dia. hardware
Exit hole types
Figure 2
TP-6198 10/04
Acceptable Hardware Combinations
Appendix
63
Appendix C General Torque Specifications
American Standard Fasteners Torque Specifications
Size
Assembled into
Aluminum
Grade 2 or 5
Assembled into Cast Iron or Steel
Torque
Measurement
Grade 2
Grade 5
Grade 8
8-32
Nm (in. lb.)
1.8
(16)
2.3
(20)
—
10-24
Nm (in. lb.)
2.9
(26)
3.6
(32)
—
10-32
Nm (in. lb.)
2.9
(26)
3.6
(32)
1/4-20
Nm (in. lb.)
6.8
(60)
10.8
(96)
14.9
(132)
1/4-28
Nm (in. lb.)
8.1
(72)
12.2
(108)
16.3
(144)
5/16-18
Nm (in. lb.)
13.6
(120)
21.7
(192)
29.8
(264)
5/16-24
Nm (in. lb.)
14.9
(132)
23.1
(204)
32.5
(288)
3/8-16
Nm (ft. lb.)
24.0
(18)
38.0
(28)
53.0
(39)
3/8-24
Nm (ft. lb.)
27.0
(20)
42.0
(31)
60.0
(44)
7/16-14
Nm (ft. lb.)
39.0
(29)
60.0
(44)
85.0
(63)
7/16-20
Nm (ft. lb.)
43.0
(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)
721.0
(532)
1109.0
(818)
1-12
Nm (ft. lb.)
283.0
(209)
789.0
(582)
1214.0
(895)
See Note 3
Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)
Assembled into
Assembled into Cast Iron or Steel
Aluminum
Grade 5.8 or 8.8
Grade 5.8
Grade 8.8
Grade 10.9
Size (mm)
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
(48)
M10 x 1.25
31.0
(23)
47.0
(35)
68.0
(50)
M12 x 1.75
53.0
(39)
80.0
(59)
115.0
(85)
M12 x 1.50
56.0
(41)
85.0
(63)
122.0
(90)
M14 x 2.00
83.0
(61)
126.0
(93)
180.0
(133)
M14 x 1.50
87.0
(64)
133.0
(98)
190.0
(140)
M16 x 2.00
127.0
(94)
194.0
(143)
278.0
(205)
M16 x 1.50
132.0
(97)
201.0
(148)
287.0
(212)
M18 x 2.50
179.0
(132)
273.0
(201)
390.0
(288)
M18 x 1.50
189.0
(140)
289.0
(213)
413.0
(305)
See Note 3
Notes:
1. The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or assembly
drawings when they differ from the above torque values.
2. The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are used.
3. Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to
prevent stripped threads.
4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength
and a friction coefficient of 0.125.
64
Appendix
TP-6198 10/04
Appendix D Common Hardware Identification
Screw/Bolts/Studs
Nuts
Hardness Grades
Head Styles
Nut Styles
American Standard
Hex Head or Machine Head
Hex Head
Grade 2
Hex Head or Machine Head
with Washer
Lock or Elastic
Grade 5
Flat Head (FHM)
Square
Grade 8
Round Head (RHM)
Cap or Acorn
Grade 8/9 (Hex Socket
Head)
Pan Head
Wing
Metric
Washers
Hex Socket Head Cap or
Allent Head Cap
5.8
Washer Styles
Hex Socket Head or Allent
Head Shoulder Bolt
Plain
Sheet Metal Screw
Split Lock or Spring
Stud
Spring or Wave
Drive Styles
Number stamped on
hardware; 5.8 shown
External Tooth Lock
Hex
Internal Tooth Lock
Hex and Slotted
Internal-External Tooth Lock
Phillipsr
Slotted
Hex Socket
Allent head screw is a trademark of Holo-Krome Co.
Phillipsr screw is a registered trademark of Phillips Screw Company.
Sample Dimensions
American Standard (Screws, Bolts, Studs, and Nuts)
1/4-20 x 1
Length In Inches (Screws and Bolts)
Plain Washers
9/32 x 5/8 x 1/16
Thickness
Threads Per Inch
External Dimension
Major Thread Diameter In Fractional Inches Or Screw Number Size
Internal Dimension
Metric (Screws, Bolts, Studs, and
Nuts)
M8-1.25 x 20
Length In Millimeters (Screws and Bolts)
Distance Between Threads In Millimeters
Lock Washers
5/8
Internal Dimension
Major Thread Diameter In Millimeters
TP-6198 10/04
Appendix 65
Appendix E Common Hardware List
The Common Hardware List lists part numbers and dimensions for common hardware items.
American Standard
Part No.
Dimensions
Hex Head Bolts (Grade 5)
Part No.
Dimensions
Hex Head Bolts, cont.
Part No.
X-465-17
X-465-6
X-465-2
X-465-16
X-465-18
X-465-7
X-465-8
X-465-9
X-465-10
X-465-11
X-465-12
X-465-14
X-465-21
X-465-25
X-465-20
1/4-20 x .38
1/4-20 x .50
1/4-20 x .62
1/4-20 x .75
1/4-20 x .88
1/4-20 x 1.00
1/4-20 x 1.25
1/4-20 x 1.50
1/4-20 x 1.75
1/4-20 x 2.00
1/4-20 x 2.25
1/4-20 x 2.75
1/4-20 x 5.00
1/4-28 x .38
1/4-28 x 1.00
X-6238-14
X-6238-16
X-6238-21
X-6238-22
3/8-24 x .75
3/8-24 x 1.25
3/8-24 x 4.00
3/8-24 x 4.50
X-6009-1
1-8
Standard
X-6024-5
X-6024-2
X-6024-8
X-6024-3
X-6024-4
X-6024-11
X-6024-12
7/16-14 x .75
7/16-14 x 1.00
7/16-14 x 1.25
7/16-14 x 1.50
7/16-14 x 2.00
7/16-14 x 2.75
7/16-14 x 6.50
X-6210-3
X-6210-4
X-6210-5
X-6210-1
6-32
8-32
10-24
10-32
Whiz
Whiz
Whiz
Whiz
X-125-33
X-125-23
X-125-3
X-125-31
X-125-5
X-125-24
X-125-34
X-125-25
X-125-26
230578
X-125-29
X-125-27
X-125-28
X-125-22
X-125-32
X-125-35
X-125-36
X-125-40
5/16-18 x .50
5/16-18 x .62
5/16-18 x .75
5/16-18 x .88
5/16-18 x 1.00
5/16-18 x 1.25
5/16-18 x 1.50
5/16-18 x 1.75
5/16-18 x 2.00
5/16-18 x 2.25
5/16-18 x 2.50
5/16-18 x 2.75
5/16-18 x 3.00
5/16-18 x 4.50
5/16-18 x 5.00
5/16-18 x 5.50
5/16-18 x 6.00
5/16-18 x 6.50
X-129-15
X-129-17
X-129-18
X-129-19
X-129-20
X-129-21
X-129-22
X-129-23
X-129-24
X-129-25
X-129-27
X-129-29
X-129-30
X-463-9
X-129-44
1/2-13 x .75
1/2-13 x 1.00
1/2-13 x 1.25
1/2-13 x 1.50
1/2-13 x 1.75
1/2-13 x 2.00
1/2-13 x 2.25
1/2-13 x 2.50
1/2-13 x 2.75
1/2-13 x 3.00
1/2-13 x 3.50
1/2-13 x 4.00
1/2-13 x 4.50
1/2-13 x 5.50
1/2-13 x 6.00
X-6210-2
X-6210-6
X-6210-7
X-6210-8
X-6210-9
X-6210-10
X-6210-11
X-6210-12
X-6210-15
X-6210-14
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
1/2-13
7/16-20
1/2-20
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
X-85-3
X-88-12
X-89-2
5/8-11
3/4-10
1/2-20
Standard
Standard
Standard
X-129-51
X-129-45
X-129-52
1/2-20 x .75
1/2-20 x 1.25
1/2-20 x 1.50
X-125-43
X-125-44
X-125-30
X-125-39
X-125-38
5/16-24 x 1.75
5/16-24 x 2.50
5/16-24 x .75
5/16-24 x 2.00
5/16-24 x 2.75
X-6238-2
X-6238-10
X-6238-3
X-6238-11
X-6238-4
X-6238-5
X-6238-1
X-6238-6
X-6238-17
X-6238-7
X-6238-8
X-6238-9
X-6238-19
X-6238-12
X-6238-20
X-6238-13
X-6238-18
X-6238-25
3/8-16 x .62
3/8-16 x .75
3/8-16 x .88
3/8-16 x 1.00
3/8-16 x 1.25
3/8-16 x 1.50
3/8-16 x 1.75
3/8-16 x 2.00
3/8-16 x 2.25
3/8-16 x 2.50
3/8-16 x 2.75
3/8-16 x 3.00
3/8-16 x 3.25
3/8-16 x 3.50
3/8-16 x 3.75
3/8-16 x 4.50
3/8-16 x 5.50
3/8-16 x 6.50
X-6021-3
X-6021-4
X-6021-2
X-6021-1
273049
X-6021-5
X-6021-6
X-6021-7
X-6021-12
X-6021-11
X-6021-10
5/8-11 x 1.00
5/8-11 x 1.25
5/8-11 x 1.50
5/8-11 x 1.75
5/8-11 x 2.00
5/8-11 x 2.25
5/8-11 x 2.50
5/8-11 x 2.75
5/8-11 x 3.75
5/8-11 x 4.50
5/8-11 x 6.00
X-6021-9
5/8-18 x 2.50
X-6239-1
X-6239-8
X-6239-2
X-6239-3
X-6239-4
X-6239-5
X-6239-6
3/4-10 x 1.00
3/4-10 x 1.25
3/4-10 x 1.50
3/4-10 x 2.00
3/4-10 x 2.50
3/4-10 x 3.00
3/4-10 x 3.50
X-792-1
X-792-5
X-792-8
1-8 x 2.25
1-8 x 3.00
1-8 x 5.00
66 Appendix
Dimensions
Type
Hex Nuts
Washers
Part No.
ID
X-25-46
.125
X-25-9
.156
X-25-48
.188
X-25-36
.219
X-25-40
.281
X-25-85
.344
X-25-37
.406
X-25-34
.469
X-25-26
.531
X-25-15
.656
X-25-29
.812
X-25-127 1.062
OD
.250
.375
.438
.500
.625
.687
.812
.922
1.062
1.312
1.469
2.000
Bolt/
Thick. Screw
.022
.049
.049
.049
.065
.065
.065
.065
.095
.095
.134
.134
#4
#6
#8
#10
1/4
5/16
3/8
7/16
1/2
5/8
3/4
1
TP-6198 10/04
Metric
Hex head bolts are hardness grade 8.8 unless noted.
Part No.
Dimensions
Hex Head Bolts (Partial Thread)
M931-05055-60
M931-06040-60
M931-06055-60
M931-06060-60
M931-06060-SS
M931-06070-60
M931-06070-SS
M931-06075-60
M931-06090-60
M931-06145-60
M931-06150-60
M5-0.80 x 55
M6-1.00 x 40
M6-1.00 x 55
M6-1.00 x 60
M6-1.00 x 60
M6-1.00 x 70
M6-1.00 x 70
M6-1.00 x 75
M6-1.00 x 90
M6-1.00 x 145
M6-1.00 x 150
M931-08035-60
M931-08040-60
M931-08045-60
M931-08050-60
M931-08055-60
M931-08055-82
M931-08060-60
M931-08070-60
M931-08070-82
M931-08075-60
M931-08080-60
M931-08090-60
M931-08095-60
M931-08100-60
M931-08110-60
M931-08120-60
M931-08130-60
M931-08140-60
M931-08150-60
M931-08200-60
M8-1.25 x 35
M8-1.25 x 40
M8-1.25 x 45
M8-1.25 x 50
M8-1.25 x 55
M8-1.25 x 55*
M8-1.25 x 60
M8-1.25 x 70
M8-1.25 x 70*
M8-1.25 x 75
M8-1.25 x 80
M8-1.25 x 90
M8-1.25 x 95
M8-1.25 x 100
M8-1.25 x 110
M8-1.25 x 120
M8-1.25 x 130
M8-1.25 x 140
M8-1.25 x 150
M8-1.25 x 200
M931-10040-82
M931-10040-60
M931-10045-60
M931-10050-60
M931-10050-82
M931-10055-60
M931-10060-60
M931-10065-60
M931-10070-60
M931-10080-60
M931-10080-82
M931-10090-60
M931-10090-82
M931-10100-60
M931-10110-60
M931-10120-60
M931-10130-60
M931-10140-60
M931-10180-60
M931-10235-60
M931-10260-60
M960-10330-60
M10-1.25 x 40*
M10-1.50 x 40
M10-1.50 x 45
M10-1.50 x 50
M10-1.25 x 50*
M10-1.50 x 55
M10-1.50 x 60
M10-1.50 x 65
M10-1.50 x 70
M10-1.50 x 80
M10-1.25 x 80*
M10-1.50 x 90
M10-1.50 x 90*
M10-1.50 x 100
M10-1.50 x 110
M10-1.50 x 120
M10-1.50 x 130
M10-1.50 x 140
M10-1.50 x 180
M10-1.50 x 235
M10-1.50 x 260
M10-1.25 x 330
M931-12045-60
M960-12050-60
M960-12050-82
M931-12050-60
M931-12050-82
M931-12055-60
M931-12060-60
M931-12060-82
M931-12065-60
M931-12075-60
M931-12080-60
M931-12090-60
M931-12100-60
M931-12110-60
M12-1.75 x 45
M12-1.25 x 50
M12-1.25 x 50*
M12-1.75 x 50
M12-1.75 x 50*
M12-1.75 x 55
M12-1.75 x 60
M12-1.75 x 60*
M12-1.75 x 65
M12-1.75 x 75
M12-1.75 x 80
M12-1.75 x 90
M12-1.75 x 100
M12-1.75 x 110
Part No.
Dimensions
Hex Head Bolts (Partial Thread),
continued
Part No.
Dimensions
Hex Head Bolts (Full Thread),
continued
M960-16090-60
M931-16090-60
M931-16100-60
M931-16100-82
M931-16120-60
M931-16150-60
M16-1.50 x 90
M16-2.00 x 90
M16-2.00 x 100
M16-2.00 x 100*
M16-2.00 x 120
M16-2.00 x 150
M931-20065-60
M931-20090-60
M931-20100-60
M931-20120-60
M931-20140-60
M931-20160-60
M20-2.50 x 65
M20-2.50 x 90
M20-2.50 x 100
M20-2.50 x 120
M20-2.50 x 140
M20-2.50 x 160
M933-12016-60
M933-12020-60
M961-12020-60F
M933-12025-60
M933-12025-82
M961-12030-60
M933-12030-82
M961-12030-82F
M933-12030-60
M933-12035-60
M961-12040-82
M933-12040-60
M933-12040-82
M12-1.75 x 16
M12-1.75 x 20
M12-1.50 x 20
M12-1.75 x 25
M12-1.75 x 25*
M12-1.25 x 30
M12-1.75 x 30*
M12-1.50 x 30*
M12-1.75 x 30
M12-1.75 x 35
M12-1.25 x 40*
M12-1.75 x 40
M12-1.75 x 40*
M931-22090-60
M931-22120-60
M931-22160-60
M22-2.50 x 90
M22-2.50 x 120
M22-2.50 x 160
M961-14025-60
M933-14025-60
M961-14050-82
M14-1.50 x 25
M14-2.00 x 25
M14-1.50 x 50*
M931-24090-60
M931-24120-60
M931-24160-60
M931-24200-60
M24-3.00 x 90
M24-3.00 x 120
M24-3.00 x 160
M24-3.00 x 200
M961-16025-60
M933-16025-60
M961-16030-82
M933-16030-82
M933-16035-60
M961-16040-60
M933-16040-60
M961-16045-82
M933-16045-82
M933-16050-60
M933-16050-82
M933-16060-60
M933-16070-60
M16-1.50 x 25
M16-2.00 x 25
M16-1.50 x 30*
M16-2.00 x 30*
M16-2.00 x 35
M16-1.50 x 40
M16-2.00 x 40
M16-1.50 x 45*
M16-2.00 x 45*
M16-2.00 x 50
M16-2.00 x 50*
M16-2.00 x 60
M16-2.00 x 70
M933-18035-60
M933-18050-60
M933-18060-60
M18-2.50 x 35
M18-2.50 x 50
M18-2.50 x 60
M933-20050-60
M933-20055-60
M20-2.50 x 50
M20-2.50 x 55
M933-24060-60
M933-24065-60
M933-24070-60
M24-3.00 x 60
M24-3.00 x 65
M24-3.00 x 70
Hex Head Bolts (Full Thread)
M933-04006-60
M4-0.70 x 6
M933-05030-60
M933-05035-60
M933-05050-60
M5-0.80 x 30
M5-0.80 x 35
M5-0.80 x 50
M933-06010-60
M933-06012-60
M933-06014-60
M933-06016-60
M933-06020-60
M933-06025-60
M933-06030-60
M933-06040-60
M933-06050-60
M6-1.00 x 10
M6-1.00 x 12
M6-1.00 x 14
M6-1.00 x 16
M6-1.00 x 20
M6-1.00 x 25
M6-1.00 x 30
M6-1.00 x 40
M6-1.00 x 50
M933-07025-60
M7-1.00 x 25
M933-08010-60
M933-08012-60
M933-08016-60
M933-08020-60
M933-08025-60
M933-08030-60
M933-08030-82
M8-1.25 x 10
M8-1.25 x 12
M8-1.25 x 16
M8-1.25 x 20
M8-1.25 x 25
M8-1.25 x 30
M8-1.25 x 30*
M933-10012-60
M961-10020-60
M933-10020-60
M933-10025-60
M961-10025-60
M933-10025-82
M961-10030-60
M933-10030-60
M933-10030-82
M961-10035-60
M933-10035-60
M933-10035-82
M961-10040-60
M10-1.50 x 12
M10-1.25 x 20
M10-1.50 x 20
M10-1.50 x 25
M10-1.25 x 25
M10-1.50 x 25*
M10-1.25 x 30
M10-1.50 x 30
M10-1.50 x 30*
M10-1.25 x 35
M10-1.50 x 35
M10-1.50 x 35*
M10-1.25 x 40
Pan Head Machine Screws
M7985A-03010-20 M3-0.50 x 10
M7985A-03012-20 M3-0.50 x 12
M7985A-04010-20
M7985A-04016-20
M7985A-04020-20
M7985A-04050-20
M7985A-04100-20
M4-0.70 x 10
M4-0.70 x 16
M4-0.70 x 20
M4-0.70 x 50
M4-0.70 x 100
M7985A-05010-20
M7985A-05012-20
M7985A-05016-20
M7985A-05020-20
M7985A-05025-20
M7985A-05030-20
M7985A-05080-20
M7985A-05100-20
M5-0.80 x 10
M5-0.80 x 12
M5-0.80 x 16
M5-0.80 x 20
M5-0.80 x 25
M5-0.80 x 30
M5-0.80 x 80
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
M965A-05016-20
M965A-06012-20
M5-0.80 x 12
M5-0.80 x 16
M6-1.00 x 12
* This metric hex bolt’s hardness is grade 10.9.
TP-6198 10/04
Appendix 67
Metric, continued
Part No.
Hex Nuts
Dimensions
Type
M934-03-50
M3-0.50
Standard
M934-04-50
M934-04-B
M4-0.70
M4-0.70
Standard
Brass
M934-05-50
M5-0.80
Standard
M934-06-60
M934-06-64
M6923-06-80
M982-06-80
M6-1.00
M6-1.00
M6-1.00
M6-1.00
Standard
Std. (green)
Spiralock
Elastic Stop
M934-08-60
M6923-08-80
M982-08-80
M8-1.25
M8-1.25
M8-1.25
Standard
Spiralock
Elastic Stop
M934-10-60
M934-10-60F
M6923-10-80
M6923-10-62
M982-10-80
M10-1.50
M10-1.25
M10-1.50
M10-1.50
M10-1.50
Standard
Standard
Spiralock
Spiralock[
Elastic Stop
M934-12-60
M934-12-60F
M6923-12-80
M982-12-80
M12-1.75
M12-1.25
M12-1.75
M12-1.75
Standard
Standard
Spiralock
Elastic Stop
M982-14-60
M14-2.00
Elastic Stop
M6923-16-80
M982-16-80
M16-2.00
M16-2.00
Spiralock
Elastic Stop
M934-18-80
M982-18-60
M18-2.5
M18-2.50
Standard
Elastic Stop
M934-20-80
M982-20-80
M20-2.50
M20-2.50
Standard
Elastic Stop
M934-22-60
M22-2.50
Standard
M934-24-80
M982-24-60
M24-3.00
M24-3.00
Standard
Elastic Stop
M934-30-80
M30-3.50
Standard
Washers
Part No.
M125A-03-80
M125A-04-80
M125A-05-80
M125A-06-80
M125A-08-80
M125A-10-80
M125A-12-80
M125A-14-80
M125A-16-80
M125A-18-80
M125A-20-80
M125A-24-80
ID
3.2
4.3
5.3
6.4
8.4
10.5
13.0
15.0
17.0
19.0
21.0
25.0
Bolt/
OD Thick. Screw
7.0
9.0
10.0
12.0
16.0
20.0
24.0
28.0
30.0
34.0
37.0
44.0
0.5
0.8
1.0
1.6
1.6
2.0
2.5
2.5
3.0
3.0
3.0
4.0
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M24
[ This metric hex nut’s hardness is grade 8.
68 Appendix
TP-6198 10/04
Notes
TP-6198 10/04
69
Notes
70
TP-6198 10/04
KOHLER CO. 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
TP-6198 10/04a
E 2004, 2009 by Kohler Co. All rights reserved.
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455