Service

Industrial Generator Sets

Models:
20--300 kW
Alternators:

Fast-Responset III (Wound Field Alternator)

TP-6349 6/07b
 California Proposition 65

WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts. Controller Identification

Record the product identification numbers in the spaces
Record the controller description from the generator set
below immediately after unpacking the products so that
operation manual, spec sheet, or sales invoice.
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the Controller Description
kits.
Generator Set Identification Numbers Engine Identification
Record the product identification numbers from the Record the product identification information from the
generator set nameplate(s). engine nameplate.

Model Designation Manufacturer

Specification Number Model Designation
Serial Number Serial Number

Accessory Number Accessory Description

2 TP-6349 6/07
 Table of Contents

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Wound Field Alternator Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Specifications, Resistance Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Specifications, Electrical Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Specifications, Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Alternator Adapter to Flywheel Housing Torque Values . . . . . . . . . . . . . . . . . . . . . 16
1.7 Drive Discs to Flywheel Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.8 Terminal Block Reconnection Decal, 80--300 kW . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Section 3 Alternator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Wound Field Voltage Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4.1 Unstable Voltage Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4.2 Voltage Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4.3 Voltage Regulator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.5 Exciter Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.6 Exciter Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.7 Rotating Rectifier Assembly (RRA)/Varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.8 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.9 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.10 Speed Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.11 Interface Circuit Board GM11718 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Section 4 Alternator Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

TP-6349 6/07 Table of Contents 3

 Notes

4 Table of Contents TP-6349 6/07

 Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can cause
DANGER severe injury or death. Battery acid
can cause blindness and burn skin.
Disabling the generator set. Always wear splashproof safety
Danger indicates the presence of a
Accidental starting can cause goggles, rubber gloves, and boots
hazard that will cause severe
severe injury or death. Before when servicing the battery. Do not
personal injury, death, or substantial
working on the generator set or open a sealed battery or mutilate the
property damage.
connected equipment, disable the battery case. If battery acid splashes in
generator set as follows: (1) Move the the eyes or on the skin, immediately
generator set master switch to the OFF flush the affected area for 15 minutes
WARNING
position. (2) Disconnect the power to with large quantities of clean water.
the battery charger. (3) Remove the Seek immediate medical aid in the case
Warning indicates the presence of a battery cables, negative (--) lead first. of eye contact. Never add acid to a
hazard that can cause severe Reconnect the negative (--) lead last battery after placing the battery in
personal injury, death, or substantial when reconnecting the battery. Follow service, as this may result in hazardous
property damage. these precautions to prevent starting of spattering of battery acid.
the generator set by an automatic
transfer switch, remote start/stop Battery acid cleanup. Battery acid
CAUTION switch, or engine start command from a can cause severe injury or death.
remote computer. Battery acid is electrically conductive
Caution indicates the presence of a and corrosive. Add 500 g (1 lb.) of
hazard that will or can cause minor bicarbonate of soda (baking soda) to a
personal injury or property damage. Battery container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
NOTICE neutralizing solution on the spilled
battery acid and continue to add the
Notice communicates installation, WARNING neutralizing solution to the spilled
operation, or maintenance information
battery acid until all evidence of a
that is safety related but not hazard
chemical reaction (foaming) has
related.
ceased. Flush the resulting liquid with
Safety decals affixed to the equipment water and dry the area.
in prominent places alert the operator
or service technician to potential Sulfuric acid in batteries.
hazards and explain how to act safely. Can cause severe injury or death.
The decals are shown throughout this
publication to improve operator Wear protective goggles and
recognition. Replace missing or clothing. Battery acid may cause
damaged decals. blindness and burn skin.

TP-6349 6/07 Safety Precautions and Instructions 5

Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms.
severe injury or death. Battery gases fire can cause severe injury or death. Carbon monoxide can cause severe
can cause an explosion. Do not smoke Do not smoke or permit flames or nausea, fainting, or death. Carbon
or permit flames or sparks to occur near sparks near the carburetor, fuel line, monoxide is a poisonous gas present in
a battery at any time, particularly when fuel filter, fuel pump, or other potential exhaust gases. Carbon monoxide
it is charging. Do not dispose of a sources of spilled fuels or fuel vapors. poisoning symptoms include but are
battery in a fire. To prevent burns and Catch fuels in an approved container not limited to the following:
sparks that could cause an explosion, when removing the fuel line or D Light-headedness, dizziness
avoid touching the battery terminals carburetor. D Physical fatigue, weakness in
with tools or other metal objects. joints and muscles
Remove all jewelry before servicing the Servicing the air cleaner. A sudden D Sleepiness, mental fatigue,
equipment. Discharge static electricity backfire can cause severe injury or inability to concentrate
from your body before touching death. Do not operate the generator or speak clearly, blurred vision
batteries by first touching a grounded set with the air cleaner removed. D Stomachache, vomiting, nausea
metal surface away from the battery. To Combustible materials. A fire can If experiencing any of these symptoms
avoid sparks, do not disturb the battery cause severe injury or death. and carbon monoxide poisoning is
charger connections while the battery Generator set engine fuels and fuel possible, seek fresh air immediately
is charging. Always turn the battery vapors are flammable and explosive. and remain active. Do not sit, lie down,
charger off before disconnecting the Handle these materials carefully to or fall asleep. Alert others to the
battery connections. Ventilate the minimize the risk of fire or explosion. possibility of carbon monoxide
compartments containing batteries to Equip the compartment or nearby area poisoning. Seek medical attention if
prevent accumulation of explosive with a fully charged fire extinguisher. the condition of affected persons does
gases. Select a fire extinguisher rated ABC or not improve within minutes of breathing
BC for electrical fires or as fresh air.
Battery short circuits. Explosion
can cause severe injury or death. recommended by the local fire code or
Short circuits can cause bodily injury an authorized agency. Train all
and/or equipment damage. personnel on fire extinguisher Fuel System
Disconnect the battery before operation and fire prevention
generator set installation or procedures.
maintenance. Remove all jewelry
WARNING
before servicing the equipment. Use
tools with insulated handles. Remove Exhaust System
the negative (--) lead first when
disconnecting the battery. Reconnect WARNING
the negative (--) lead last when
reconnecting the battery. Never Explosive fuel vapors.
connect the negative (--) battery cable Can cause severe injury or death.
to the positive (+) connection terminal
of the starter solenoid. Do not test the Use extreme care when handling,
battery condition by shorting the storing, and using fuels.
Carbon monoxide.
terminals together.
Can cause severe nausea,
fainting, or death. The fuel system. Explosive fuel
vapors can cause severe injury or
Engine Backfire/Flash The exhaust system must be death. Vaporized fuels are highly
leakproof and routinely inspected. explosive. Use extreme care when
Fire handling and storing fuels. Store fuels
Generator set operation. Carbon in a well-ventilated area away from
WARNING monoxide can cause severe nausea, spark-producing equipment and out of
fainting, or death. Carbon monoxide the reach of children. Never add fuel to
is an odorless, colorless, tasteless, the tank while the engine is running
nonirritating gas that can cause death if because spilled fuel may ignite on
inhaled for even a short time. Avoid contact with hot parts or from sparks.
breathing exhaust fumes when working Do not smoke or permit flames or
Fire. sparks to occur near sources of spilled
Can cause severe injury or death. on or near the generator set. Never
operate the generator set inside a fuel or fuel vapors. Keep the fuel lines
Do not smoke or permit flames or building unless the exhaust gas is and connections tight and in good
sparks near fuels or the fuel system. piped safely outside. Never operate condition. Do not replace flexible fuel
the generator set where exhaust gas lines with rigid lines. Use flexible
could accumulate and seep back inside sections to avoid fuel line breakage
a potentially occupied building. 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.

6 Safety Precautions and Instructions TP-6349 6/07

Explosive fuel vapors can cause Hazardous Noise
severe injury or death. Take WARNING
additional precautions when using the
following fuels: CAUTION
Gasoline—Store gasoline only in
approved red containers clearly
marked GASOLINE. Hazardous voltage.
Backfeed to the utility system can
Propane (LP)—Adequate ventilation
cause property damage, severe
is mandatory. Because propane is
Hazardous noise. injury, or death.
heavier than air, install propane gas
Can cause hearing loss.
detectors low in a room. Inspect the If the generator set is used for
detectors per the manufacturer’s Never operate the generator set standby power, install an automatic
instructions. without a muffler or with a faulty transfer switch to prevent inadvertent
Natural Gas—Adequate ventilation is exhaust system. interconnection of standby and
mandatory. Because natural gas rises, normal sources of supply.
install natural gas detectors high in a Engine noise. Hazardous noise can
room. Inspect the detectors per the cause hearing loss. Generator sets
manufacturer’s instructions. not equipped with sound enclosures CAUTION
can produce noise levels greater than
Fuel tanks. Explosive fuel vapors 105 dBA. Prolonged exposure to noise
can cause severe injury or death. levels greater than 85 dBA can cause
Gasoline and other volatile fuels stored permanent hearing loss. Wear hearing
in day tanks or subbase fuel tanks can protection when near an operating
cause an explosion. Store only diesel generator set.
fuel in tanks. Welding the generator set.
Can cause severe electrical
Draining the fuel system. Explosive
fuel vapors can cause severe injury Hazardous Voltage/ equipment damage.
or death. Spilled fuel can cause an Electrical Shock Never weld components of the
explosion. Use a container to catch fuel generator set without first
when draining the fuel system. Wipe up disconnecting the battery, controller
spilled fuel after draining the system. DANGER wiring harness, and engine electronic
Gas fuel leaks. Explosive fuel control module (ECM).
vapors can cause severe injury or
death. Fuel leakage can cause an Grounding electrical equipment.
explosion. Check the LP vapor gas or Hazardous voltage can cause
natural gas fuel system for leakage by Hazardous voltage. severe injury or death. Electrocution
using a soap and water solution with Will cause severe injury or death. is possible whenever electricity is
the fuel system test pressurized to present. Open the main circuit
6--8 ounces per square inch Disconnect all power sources before breakers of all power sources before
(10--14 inches water column). Do not opening the enclosure. servicing the equipment. Configure the
use a soap solution containing either installation to electrically ground the
ammonia or chlorine because both generator set, transfer switch, and
prevent bubble formation. A successful WARNING related equipment and electrical
test depends on the ability of the circuits to comply with applicable codes
solution to bubble. and standards. Never contact
electrical leads or appliances when
LP liquid withdrawal fuel leaks. standing in water or on wet ground
Explosive fuel vapors can cause because these conditions increase the
severe injury or death. Fuel leakage Hazardous voltage. Moving rotor. risk of electrocution.
can cause an explosion. Check the LP Can cause severe injury or death.
liquid withdrawal gas fuel system for High voltage test. Hazardous
leakage by using a soap and water Operate the generator set only when voltage can cause severe injury or
solution with the fuel system test all guards and electrical enclosures death. Follow the instructions of the
pressurized to at least 90 psi are in place. test equipment manufacturer when
(621 kPa). Do not use a soap solution performing high-voltage tests on the
containing either ammonia or chlorine rotor or stator. An improper test
because both prevent bubble procedure can damage equipment or
formation. A successful test depends lead to generator set failure.
on the ability of the solution to bubble.

TP-6349 6/07 Safety Precautions and Instructions 7

Welding on the generator set. Can Electrical backfeed to the utility. Hot Parts
cause severe electrical equipment Hazardous backfeed voltage can
damage. Before welding on the cause severe injury or death. Install
generator set perform the following a transfer switch in standby power WARNING
steps: (1) Remove the battery cables, installations to prevent the connection
negative (--) lead first. (2) Disconnect of standby and other sources of power.
all engine electronic control module Electrical backfeed into a utility
(ECM) connectors. (3) Disconnect all electrical system can cause severe
generator set controller and voltage injury or death to utility personnel
regulator circuit board connectors. working on power lines. Hot coolant and steam.
(4) Disconnect the engine battery- Can cause severe injury or death.
charging alternator connections. Testing live electrical circuits.
Hazardous voltage or current can Before removing the pressure cap,
(5) Attach the weld ground connection
cause severe injury or death. Have stop the generator set and allow it to
close to the weld location.
trained and qualified personnel take cool. Then loosen the pressure cap
Installing the battery charger. diagnostic measurements of live to relieve pressure.
Hazardous voltage can cause circuits. Use adequately rated test
severe injury or death. An equipment with electrically insulated
ungrounded battery charger may probes and follow the instructions of the WARNING
cause electrical shock. Connect the test equipment manufacturer when
battery charger enclosure to the ground performing voltage tests. Observe the
of a permanent wiring system. As an following precautions when performing
alternative, install an equipment voltage tests: (1) Remove all jewelry.
grounding conductor with circuit (2) Stand on a dry, approved electrically
conductors and connect it to the insulated mat. (3) Do not touch the Hot engine and exhaust system.
equipment grounding terminal or the enclosure or components inside the Can cause severe injury or death.
lead on the battery charger. Install the enclosure. (4) Be prepared for the
battery charger as prescribed in the system to operate automatically. Do not work on the generator set until
equipment manual. Install the battery (600 volts and under) it cools.
charger in compliance with local codes
and ordinances. Servicing the alternator. Hot parts
Connecting the battery and the
Heavy Equipment can cause severe injury or death.
Avoid touching the alternator field or
battery charger. Hazardous voltage exciter armature. When shorted, the
can cause severe injury or death. WARNING alternator field and exciter armature
Reconnect the battery correctly, become hot enough to cause severe
positive to positive and negative to burns.
negative, to avoid electrical shock and
damage to the battery charger and Checking the coolant level. Hot
battery(ies). Have a qualified coolant can cause severe injury or
electrician install the battery(ies). death. Allow the engine to cool.
Unbalanced weight. Release pressure from the cooling
Short circuits. Hazardous system before removing the pressure
voltage/current can cause severe Improper lifting can cause severe
injury or death and equipment cap. To release pressure, cover the
injury or death. Short circuits can pressure cap with a thick cloth and then
cause bodily injury and/or equipment damage.
slowly turn the cap counterclockwise to
damage. Do not contact electrical Do not use lifting eyes. the first stop. Remove the cap after
connections with tools or jewelry while pressure has been completely
Lift the generator set using lifting bars
making adjustments or repairs. released and the engine has cooled.
inserted through the lifting holes on
Remove all jewelry before servicing the Check the coolant level at the tank if the
the skid.
equipment. generator set has a coolant recovery
Engine block heater. Hazardous tank.
voltage can cause severe injury or Servicing the exhaust system. Hot
death. The engine block heater can parts can cause severe injury or
cause electrical shock. Remove the death. Do not touch hot engine parts.
engine block heater plug from the The engine and exhaust system
electrical outlet before working on the components become extremely hot
block heater electrical connections. during operation.

8 Safety Precautions and Instructions TP-6349 6/07

Moving Parts Tightening the hardware. Flying NOTICE
projectiles can cause severe injury Voltage reconnection. Affix a notice
or death. Loose hardware can cause to the generator set after reconnecting
WARNING the hardware or pulley to release from the set to a voltage different from the
the generator set engine and can cause voltage on the nameplate. Order
personal injury. Retorque all voltage reconnection decal 246242
crankshaft and rotor hardware after from an authorized service
servicing. Do not loosen the crankshaft distributor/dealer.
hardware or rotor thrubolt when making
Hazardous voltage. Moving rotor. adjustments or servicing the generator NOTICE
Can cause severe injury or death. set. Rotate the crankshaft manually in
Hardware damage. The engine and
a clockwise direction only. Turning the
Operate the generator set only when generator set may use both American
crankshaft bolt or rotor thrubolt
all guards and electrical enclosures Standard and metric hardware. Use
counterclockwise can loosen the
are in place. the correct size tools to prevent
hardware.
rounding of the bolt heads and nuts.
Servicing the generator set when it
WARNING is operating. Exposed moving parts NOTICE
can cause severe injury or death. When replacing hardware, do not
Keep hands, feet, hair, clothing, and substitute with inferior grade
test leads away from the belts and hardware. Screws and nuts are
pulleys when the generator set is available in different hardness ratings.
running. Replace guards, screens, and To indicate hardness, American
covers before operating the generator Standard hardware uses a series of
Rotating parts. set. markings, and metric hardware uses a
Can cause severe injury or death.
numeric system. Check the markings
Operate the generator set only when on the bolt heads and nuts for
all guards, screens, and covers are in Notice identification.
place.
NOTICE NOTICE
Canadian installations only. For
WARNING This generator set has been
standby service connect the output of
the generator set to a suitably rated
rewired from its nameplate voltage
transfer switch in accordance with
to
Canadian Electrical Code, Part 1.

Airborne particles.
246242
Can cause severe injury or
blindness.

Wear protective goggles and clothing

when using power tools, hand tools,
or compressed air.

TP-6349 6/07 Safety Precautions and Instructions 9

 Notes

10 Safety Precautions and Instructions TP-6349 6/07

 Introduction

This manual provides troubleshooting and repair The equipment service requirements are very important
instructions for the generator set models listed on the to safe and efficient operation. Inspect the parts often
front cover using wound field alternators. and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately
Wiring diagram manuals are available separately. skilled and suitably trained maintenance personnel
familiar with generator set operation and service.
Refer to the generator set controller operation manual
for operating instructions. Refer to the engine operation
manual for generator set engine scheduled List of Related Materials
maintenance information. Refer to the engine service
manual for generator set engine repair and overhaul Separate literature contains voltage regulator setup
information. information not provided in this manual when the
generator set has a 550 controller. Figure 1 lists the
Information in this publication represents data available available literature part numbers.
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented Manual Description Literature Part No.
without notice and without any obligation or liability
Voltage Reguator Spec Sheet G6-58
whatsoever.
550 Controller Operation Manual TP-6200
Read this manual and carefully follow all procedures
Figure 1 Related Literature
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.

TP-6349 6/07 Introduction 11

Service Assistance

For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955
D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444.
. (91) 80 3366231
D Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
ZI Senia 122
12, rue des Hauts Flouviers Latin America
94517 Thiais Cedex Latin America Regional Office
France Lakeland, Florida, USA
Phone: (33) 1 41 735500 Phone: (863) 619-7568
Fax: (33) 1 41 735501 Fax: (863) 701-7131

Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

12 Service Assistance TP-6349 6/07

 Section 1 Specifications

1.1 Introduction
The specification sheets for each generator set provide 1 2
specific alternator and engine information. Refer to the
respective specification sheet for data not supplied in
3
this manual. Consult the generator set operation
manual, installation manual, engine operation manual,
and engine service manual for additional specifications.

A wound field alternator is identified with a W as the last

digit. Example: Gen. Model 4S11W.
4

5
1.2 Wound Field Alternator
6
Concept
The alternator is a 4-pole, rotating-field unit with a
brushless, wound field (WF) excitation system. The
generator set excitation system uses a wound exciter
field and a three-phase exciter armature. The rotating
rectifier assembly (RRA) is rated for over five times full 7
load voltage and three times full load current with added
surge protection. See Figure 1-1. 8

The ±0.25% average voltage regulator is powered by a

stator auxiliary winding providing an independent power 9
source for the exciter field. In addition, a rare earth
permanent magnet is embedded in the exciter field for
positive voltage buildup during startup. The voltage
regulator has volt/Hz, stability, and voltage adjustments.

WF alternator sets offer the following advantages: 11

10 TP-6161-1

D Very good recovery characteristics because the

auxiliary power for the voltage regulator comes from 1. Rotor main field
an independent stator winding that actually boosts 2. Main alternator
the alternator’s output during heavy loads. 3. Stator auxiliary winding
4. Stator main windings
5. Exciter field winding
D The inherent ability to support short-circuit current 6. Exciter armature
allowing system coordination for tripping downstream 7. Exciter alternator
branch circuit breakers. 8. Rotating rectifier assembly (RRA) and
surge suppressor (varistor)
D For the duration of a short circuit in the load circuit(s), 9. Voltage regulator
10. Engine starting battery
the output voltage drops and the amperage 11. Safeguard circuit breaker (optional)
momentarily rises to 600%--1000% of the generator
set’s rated current. Figure 1-1 WF Alternator

D The voltage regulator requires low power and has

tight average voltage regulation.

D The safeguard circuit breaker kit collapses the

generator set’s main field during a sustained heavy
overload or short circuit.

TP-6349 6/07 Section 1 Specifications 13

1.3 Specifications, Resistance Values
Alternator Alternator Nominal Stator Main Winding, Stator Aux. Rotor Main Exciter Field Exciter
Model Leads kW milliohm Winding, ohms Field, ohms Winding, ohms Armature, ohms
4P4W 25 134 2.3 1.99
4P5W 30 101 2.1 2.25
12 1
12.1 08
0.8
4P5BW 35 97 2.3 2.28
4P7W 40 68 1.8 2.61
4P7BW 45 69 1.9 2.67
4P8W 50 47.2 1.5 2.88
4P10W 60 35.1 1.5 2.01
4S7W 12 (Three 80 39.3 2.5 1.79
17 3
17.3 04
0.4
4S9W Phase) 100 24.4 1.9 2.08
4S11W 125 19.1 1.4 1.49
4S13W 150 14.4 1.2 1.76
4S15W 170 10.5 1.0 2.14
4UA7W 180 15.5 1.9 1.56
4UA9W 230 9.7 1.2 1.83
10 8 *
10.8 03
0.3
4UA10W 275 8.1 1.5 1.94
4UA13W 300 5.5 1.0 2.54
4P4W 25 218 2.3 1.99
4P5W 30 149 2.1 2.25
12 1
12.1 08
0.8
4P5BW 35 152 2.3 2.28
4P7W 40 116 1.8 2.61
4P7BW 45 118 1.9 2.67
4P8W 50 88 1.5 2.88
4P10W 60 55 1.5 2.01
4S7W 80 61.5 2.5 1.79
6 (600 V) 17 3
17.3 04
0.4
4S9W 100 45.4 1.9 2.08
4S11W 125 36.6 1.4 1.49
4S13W 150 30.8 1.2 1.76
4S15W 170 15.9 1.0 2.14
4UA7W 180 28.3 1.9 1.56
4UA9W 230 17.6 1.2 1.83
10 8 *
10.8 03
0.3
4UA10W 275 18.8 1.5 1.94
4UA13W 300 12.1 1.0 2.28
4Q4W 30 50.5 2.4 1.99
4Q5W 35 34.7 1.9 2.25 12.1 0.8
4Q7W 40 25.8 1.7 2.61
4Q8W 4 (Single 45 23.6 1.6 2.88
4Q10W Phase) 55 17.5 1.3 2.01
4V7W 75 16.3 1.4 1.79 17.3 0.4
4V9W 95 10.6 1.1 2.08
4V11W 110 6.7 1.1 1.49
All resistance values are at 25_C (77_F) with ±12% tolerance.
* Early alternators with part numbers GM33000-xx have resistance values of 17.2 ohms.

14 Section 1 Specifications TP-6349 6/07

1.4 Specifications, Electrical 1.5 Specifications, Torque Values
Values Use the torque values shown in Figure 1-4 during
Use the values shown in Figure 1-2 and Figure 1-3 alternator assembly. For assembly torque values not
during alternator testing. shown use the guidelines in Appendix C, General
Torque Specifications.
Hot Exciter Field No Load
Readings at Rated Voltage Model,
Component kW Torque Value
Alternator Model Volts Amps
20--60 10.8 Nm (8 ft. lb.)
4P4W 7.4 0.6 Ground lug assembly nuts
80--300 45 Nm (34 ft. lb.)
4P5W 8.0 0.7
20--170 61 Nm (45 ft. lb.)
4P5BW 7.6 0.6 Drive discs to rotor shaft bolts
180--300 115 Nm (85 ft. lb.)
4P7W 9.4 0.8
20--170 26.4 Nm (19.5 ft. lb.)
4P7BW 9.0 0.7 Fan to rotor flange bolts
180--300 35 Nm (28 ft. lb.)
4P8W 10.7 0.9
End bracket to stator bolts 180--300 95 Nm (70 ft. lb.)
4P10W 9.6 0.8
Stator to generator adapter bolts 180--300 95 Nm (70 ft. lb.)
4S7W 7.8 0.5
Terminal block to stator bolts 180--300 9.5 Nm (7 ft. lb.)
4S9W 9.3 0.5
Terminal block link nuts 180--300 45 Nm (34 ft. lb.)
4S11W 8.6 0.5
End bracket grease fitting 180--300 9.5 Nm (7 ft. lb.)
4S13W 9.7 0.6
End bracket grease vent screw 180--300 9.5 Nm (7 ft. lb.)
4S15W 15.0 0.9
Rotating rectifier assembly
4UA7W 7.8 0.7 Mounting bolts 20--300 6.6 Nm (58 in. lb.)
4UA9W 7.8 0.7 AC exciter armature nuts 20--300 1.8 Nm (16 in. lb.)
F1/F2 main field nuts 20--300 2.9 Nm (26 in. lb.)
4UA10W 8.5 0.8
Alternator adapter to flywheel
4UA13W 10.2 0.8 housing bolt torque 20--300 See chart following
All values are at 25_C (77_F) Drive discs to flywheel bolt
torque 20--300 See chart following
Figure 1-2 Exciter Field Voltage/Current Values
Figure 1-4 Torque Values
Component Value
Stator output voltages with separately
excited alternator using a 12-volt battery
Stator main windings, volts >150 Volts
Stator auxiliary winding, volts >300 Volts
All values are at 25_C (77_F)

Figure 1-3 Stator Output Voltages

TP-6349 6/07 Section 1 Specifications 15

1.6 Alternator Adapter to Flywheel Housing Torque Values
Torque,
Model Alternator Engine Hardware Type, Nm (ft. lb.) Hardware Sequence
20--40 kW John Deere 3/8--16, grade 8 bolt 53 (39)
30--60 kW GM 3/8--16, grade 8 bolt 53 (39)
4P 4Q
4P,
3/8--16, grade 8 bolt
50/60 kW John Deere 53 (39)
M10, grade 10.9 bolt
60--125 kW GM 3/8--16 grade 8 bolt 53 (39)
3/8--16 grade 8 bolt 53 (39)
60--180 kW 4S,, 4V John Deere 7/16--14, grade 8 bolt 60 (44)
M10, grade 10.9 bolt 65 (48)
135/150 kW DDC Series 50/60 Gas 7/16--14, grade 8 bolt 60 (44) Bolt,, hardened washer
150--275 kW DDC Series 50/60 Gas 7/16--14, grade 8 bolt 85 (63)
200 kW DDC Series 40 3/8--16, grade 8 bolt 53 (39)
3/8--16, grade 8 bolt 53 (39)
200/230
/ kW John Deere 7/16--14, grade 8 bolt 85 (63)
4UA
M10, grade 10.9 bolt 65 (48)

Kohler Branded 7/16--14, grade 8 bolt 85 (63)

200 300 kW
200--300
D200/D250/D300 M10, grade 10.9 bolt 65 (48)
230--300 kW DDC Series 60 Diesel 7/16--14, grade 8 bolt 85 (63)

1.7 Drive Discs to Flywheel Torque Values

Hardware Torque,
Model Alternator Engine Type, Nm (ft. lb.) Hardware Sequence
20--40 kW John Deere 3/8--16, grade 8 stud 53 (39) Stud, spacer, hardened washer, grade 8 nut
30--60 kW 4P, 4Q GM
3/8--16, grade 8 stud 53 (39)
50/60 kW John Deere
Stud spacer
Stud, spacer, hardened washer,
washer nut
60--125 kW GM
3/8--16, grade 8 stud 53 (39)
80--180 kW 4S, 4V John Deere
135/150 kW DDC Series 50/60 Gas 1/2--13, grade 8 bolt 60 (44)
Bolt hardened washer
Bolt,
150--275 kW DDC Series 50/60 Gas 1/2--13, grade 8 bolt 130 (96)
200 kW DDC Series 40 3/8--16, grade 8 stud 53 (39) Stud, spacer, hardened washer, grade 8 nut
200/230 kW John Deere 1/2--13, grade 8 bolt 130 (96)
4UA
Kohler Branded 1/2--13, grade 8 bolt 130 (96)
200 300 kW
200--300 Bolt hardened washer
Bolt,
D200/D250/D300 M12, grade 10.9 bolt 122 (90)
230--300 kW DDC Series 60 Diesel 1/2--13, grade 8 bolt 130 (96)

16 Section 1 Specifications TP-6349 6/07

1.8 Terminal Block Reconnection
Decal, 80--300 kW
The terminal block decal shown in Figure 1-5 and
Figure 1-6 provide the voltage reconnection
combinations and terminal block hardware torque
values.

GM39937-

Figure 1-5 Load Connections

GM39792-B

Figure 1-6 Reconnection Decal

TP-6349 6/07 Section 1 Specifications 17

 Notes

18 Section 1 Specifications TP-6349 6/07

 Section 2 Troubleshooting

This section contains generator set troubleshooting, Maintain a record of repairs and adjustments performed
diagnostic, and repair information. on the equipment. If the procedures in this manual do
not explain how to correct the problem, contact an
Use the chart on the following pages to diagnose and authorized distributor/dealer. Use the record to help
correct common problems. First check for simple describe the problem and repairs or adjustments made
causes such as a dead engine starting battery or an to the equipment.
open circuit breaker. The chart includes a list of
common problems, possible causes of the problem,
recommended corrective actions, and references to
detailed information or repair procedures.

TP-6349 6/07 Section 2 Troubleshooting 19

20
Trouble Symptoms

Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Controller
x x Controller circuit board(s) inoperative Replace the controller circuit board. —

Section 4 Troubleshooting
x Controller fault Troubleshoot the controller.[ Generator set O/M
Controller fuse blown Replace the blown controller fuse. If the fuse blows W/D
x x x
again, troubleshoot the controller.[
x Controller master switch inoperative Replace the controller master switch. —
Controller master switch in the OFF/RESET Move the controller master switch to the RUN or AUTO Generator set O/M
x
position position.
Engine start circuit open Move the controller master switch to the RUN position Generator set
x to test the generator set. Troubleshoot the auto start O/M, W/D,
circuit and time delays. ATS O/M, S/M
Cooling System
x x Air openings clogged Clean the air openings. —
x Coolant level low Restore the coolant to normal operating level. Generator set O/M
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M
High temperature shutdown Allow the engine to cool down. Then troubleshoot the Generator set
x
cooling system. O/M, Eng. O/M
x Low coolant level shutdown, if equipped Restore the coolant to normal operating level. Generator set O/M
x Thermostat inoperative Replace the thermostat. Eng. S/M

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
] If the unit has a 550 controller, refer to the 550 controller operation manual for voltage regulator settings. Go to Menu 20, Factory Setup and verify that the application software (code version) is
correct for the generator set model and alternator voltage.

TP-6349 6/07
 Trouble Symptoms

TP-6349 6/07
Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Electrical System (DC circuits)
Battery connections loose, corroded, or Verify that the battery connections are correct, clean, Generator set O/M
x x
incorrect and tight.
Battery weak or dead Recharge or replace the battery. The spec sheet Generator set
x x
provides recommended battery CCA rating. O/M, S/S
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
TP-6349 6/07
Engine harness connector(s) not locked tight Disconnect the engine harness connector(s) then W/D
x x
reconnect it to the controller.
High water temperature switch inoperative Replace the inoperative switch. Engine S/M or
x
W/D
x Fault shutdown Reset the fault switches and troubleshoot the controller. Generator set O/M
High exhaust temperature switch inoperative Replace the inoperative switch. Engine S/M or
x
W/D
Engine
x x x x Air cleaner clogged Clean or replace the filter element. Eng. O/M
x x x x x Compression weak Check the compression.[ Eng. S/M
Engine overload Reduce the electrical load. See the generator set spec S/S
x x x x x
sheet for wattage specifications.
Exhaust system leak Inspect the exhaust system. Replace the inoperative I/M
x
exhaust system components.[
Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust I/M
x
system components.[
x x x x Governor inoperative Adjust the governor.[ Governor literature
x x Valve clearance incorrect Adjust the valves.[ Eng. S/M
x Vibration excessive Tighten all loose hardware. —
Ignition system inoperative (gas/gasoline only) Check the ignition system (spark plugs, spark plug Eng. O/M
x x x
wires, etc.).

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
] If the unit has a 550 controller, refer to the 550 controller operation manual for voltage regulator settings. Go to Menu 20, Factory Setup and verify that the application software (code version) is
correct for the generator set model and alternator voltage.

Section 4 Troubleshooting
21
22
Trouble Symptoms

Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Fuel System
x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M

Section 4 Troubleshooting
Ether canister empty or system inoperative, if Replace or repair the ether starting system. Eng. O/M
x x
equipped (diesel only)
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —
Fuel feed or injection pump inoperative (diesel Rebuild or replace the injection pump.[ Eng. S/M
x x x
only)
Fuel or fuel injectors dirty or faulty (diesel only) Clean, test, and/or replace the inoperative fuel Eng. S/M
x x x
injector.[
x x x x Fuel filter restriction Clean or replace the fuel filter. Eng. O/M
x Fuel solenoid inoperative Troubleshoot the fuel solenoid.[ Eng. S/M
x x Fuel pressure insufficient (gas only) Check the fuel supply and valves.[ S/S, Gen. O/M
Fuel injection timing out of adjustment (diesel Adjust the fuel injection timing.[ Eng. S/M
x x x x
only)
Alternator
AC output circuit breaker open Reset the breaker and check for AC voltage at the —
x
generator side of the circuit breaker.
Transfer switch test switch in the OFF position Move the transfer switch test switch to the AUTO ATS O/M
x
position.
Transfer switch fails to transfer load Move the ATS test switch to the AUTO position. ATS O/M, S/M
x
Troubleshoot the transfer circuit and time delays.
x Wiring, terminals, or pin in the exciter field open Check for continuity. Section 3, W/D
Main field (rotor) inoperative (open or Test and/or replace the rotor.[ Section 3
x
grounded)
x Stator inoperative (open or grounded) Test and/or replace the stator.[ Section 3
x Vibration excessive Tighten loose components.[ —
Voltage regulator digital settings incorrect Adjust the voltage regulator. Section 3 ]
x x
(digital controller only)
Voltage regulator inoperative Replace the voltage regulator fuse, If the fuse blows Section 3 ]
x x
again, troubleshoot the voltage regulator.
x x Voltage regulator out of adjustment Adjust the voltage regulator. Section 3 ]

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
] If the unit has a 550 controller, refer to the 550 controller operation manual for voltage regulator settings. Go to Menu 20, Factory Setup and verify that the application software (code version) is
correct for the generator set model and alternator voltage.

TP-6349 6/07
 Trouble Symptoms

TP-6349 6/07
Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Lube System
Crankcase oil type incorrect for ambient Change the oil. Use oil with a viscosity suitable for the Eng. O/M
x x x x
temperature operating climate.
Oil level low Restore the oil level. Inspect the generator set for oil Eng. O/M
x x x
leaks.
x Low oil pressure shutdown Check the oil level. Eng. O/M
TP-6349 6/07
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
] If the unit has a 550 controller, refer to the 550 controller operation manual for voltage regulator settings. Go to Menu 20, Factory Setup and verify that the application software (code version) is
correct for the generator set model and alternator voltage.

Section 4 Troubleshooting
23
 Notes

24 Troubleshooting TP-6349 6/07

 Section 3 Alternator Troubleshooting

3.1 General
Alternator has no
Before beginning the troubleshooting procedures, read
output
all the safety precautions at the beginning of this
manual. The following tests include additional safety
precautions; OBSERVE THESE PRECAUTIONS!
Separately
WARNING excite Alternator has output
alternator

Test voltage
Alternator has no
regulator &
Hazardous voltage. Moving rotor. output
wiring
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place. Exciter circuit and
rectifier module

Grounding electrical equipment. Hazardous voltage can

cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment. Test rotor Test stator
Configure the installation to electrically ground the generator
set, transfer switch, and related equipment and electrical TP-6349-3
circuits to comply with applicable codes and standards. Never
contact electrical leads or appliances when standing in water Figure 3-1 General Troubleshooting
or on wet ground because these conditions increase the risk of
electrocution.
Short circuits. Hazardous voltage/current can cause 3.3 Separate Excitation
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical By separately exciting the alternator to determine the
connections with tools or jewelry while making adjustments or presence of a faulty voltage regulator, it is possible to
repairs. Remove all jewelry before servicing the equipment. determine if a running fault exists in the rotor and/or
stator. A alternator component that appears good while
static (stationary) may exhibit a running open or short
3.2 General Troubleshooting circuit while dynamic (moving). Short circuits can be
caused by centrifugal forces acting on the windings
To determine the cause of no- or low-AC output , refer to
during rotation or insulation breakdown as temperatures
the following steps and the troubleshooting flow chart
increase.
(Figure 3-1).
1. Disconnect all of the leads from the voltage
1. Check the condition of the voltage regulator 10-
regulator.
amp fuse located in the junction box.
2. Disconnect the FP/FN connector.
2. If the fuse is good, separately excite the alternator
(see Section 3.3). The separate excitation test 3. Disconnect the exciter field winding leads.
duplicates the role of the voltage regulator in Connect an ohmmeter to the exciter field winding
providing the excitation current to the rotor. and measure the resistance.
3. If voltage regulator failure is suspected, go to
Section 3.4, Wound Field Voltage Regulators.

TP-6349 6/07 Section 3 Alternator Troubleshooting 25

 4. Connect separate excitation circuit as shown in Stable ammeter reading. If the ammeter is
Figure 3-2. Connect a DC ammeter in series with stable, continue with the next step.
FP. Note and record the ammeter reading.
7. Use a voltmeter and check for AC output across the
The approximate ammeter reading should be stator main windings and compare it to the values
battery voltage divided by the specified exciter field in Section 1, Specifications. If the stator main
winding resistances (cold). See Section 1, windings output varies considerably from those
Specifications, for the values. listed, a faulty stator, rotor, rotating rectifier
assembly, or exciter armature is likely.
Example:
8. Place the generator set master switch to the
12 Volts (Battery Voltage) 0.99 amps
OFF/RESET position to stop the generator set.
= Exciter Field
12.1 Ohms Winding Current
Exciter Field Winding If the AC output is not within specifications, the voltage
Resistance regulator is probably defective. If there is no alternator
output during normal operation, but output is available
when the generator set is separately excited, the
voltage regulator is probably defective.
+ — 1 2
Note: See Section 1, Specifications, for the stator
output voltages (with separately excited
alternator). These specifications are based on a
FP FN
battery voltage of 12. Should the battery voltage
6 vary (11--14 volts), the resulting stator output
— + values will also vary.
4
5
3
3.4 Wound Field Voltage
TP-6349-3
Regulators
1. Voltage regulator
2. DC ammeter
3. Battery 3.4.1 Unstable Voltage Troubleshooting
4. Ground to alternator frame
5. Exciter armature Before replacing the voltage regulator, use the flowchart
6. Exciter field winding in Figure 3-3 to troubleshoot the generator set when
unstable voltage is detected. The remaining parts of this
Figure 3-2 Separate Excitation Connections
section give additional and more detailed information
5. Move the generator set master switch to the RUN about the individual checks/tests mentioned in the
position to start the generator set. flowchart.

6. Check the ammeter values.

Unstable ammeter reading. An increasing meter

reading indicates a shorted exciter field. A
decreasing meter reading to zero, or unstable
reading, suggests a running open in the exciter.

26 Section 3 Alternator Troubleshooting TP-6349 6/07

 Unstable voltage

Does engine speed Yes Is the fuel filter clean? No Clean/replace

fluctuate?
Yes
No
Is the speed sensor okay? No Adjust/replace
Yes

Is the fuel injection pump No Rebuild/replace

okay?
Yes

Are the fuel injectors okay? No Clean/test/replace

Yes

Is the fuel injection timing

No Adjust timing
okay?
Yes

Does engine speed still No Is voltage stable?

fluctuate?
Yes No Yes

Refer to the engine Voltage

governor and ECM systems regulator checks
technical literature * out okay

Does the voltage regulator Are the wiring and Tighten connections or
Yes No
LED flicker? connectors okay? replace harness
No Yes

Are the main connections Turn the stability pot fully

No Are there load current
tight? clockwise, then slowly No
rotate counterclockwise. spikes?
Tighten Does the voltage change? No Yes
connections
Yes Yes Replace the
voltage regulator
Are the circuit breaker
No Adjust the stability pot
connections tight?
clockwise to just the point Determine the source of
Yes
of instability. Are there load the load disturbance and
Tighten
current spikes? check for faulty equipment
connections
Yes No

Does the voltage regulator

check out okay? See
Section 3.4.2
No

* Refer to the generator set controller

Contact the service operartion manual or the respective parts
department for assistance catalog for the list of related literature.

Figure 3-3 Troubleshooting Generator Set, Unstable Voltage

TP-6349 6/07 Section 3 Alternator Troubleshooting 27

3.4.2 Voltage Regulator Test The following components will be needed to test the
voltage regulator:
The generator set is equipped with a wound field voltage
D 12 volt battery or DC power supply, isolated
regulator. See Figure 3-4.
D Step-up transformer, 1:2, 120 volts to 240 volts
(1.0 amp min.)
1 D 1 kOhm 1/2 watt potentiometer
D Variable transformer, 0--140 volts (1.0 amp min.)
+ _
9 10 11 12
2 D Voltage regulator adapter harness (see Figure 3-5)
3 make from:
5 6 7 8
(1) plug, part no. GM11858
1 2 3 4 (10) terminals, part no. 337137
(10) leads, 18 ga., 610 mm (24 in.) long
11
5 6 + C4 R28 R32 LED1 LED2 D6 C32 R56 R60 D8
C
9 R9 R21
C14
R33
SHTDWN
OUT R50 R57 U7
10 R10
D3
C6
U2 C18
R34
C27 U6 C33

R11
D2 C35 C46
R22 C15 R35 Q1 C34 R58
R23 D7 R61 R71 V1
C16 Z1
R12
C5 C7
U3
C19
Q2 C36
C45 R72
9
L8
P40
12
D1 R5 R13 C8 R36 R45 R51 R62 L3
R6 R14 C9 C20
C24 C28 C29 C37 L4
R1 C2 R37
VR1 R59 R63
C1 U1 R24
R29 + C21 C38 R64
C10 R53 1 4
R2 C39 R65 L5
R73 R75
R3 C3 R15R25 R38 R42 C25 VADJ
C17 R66
8 R4 R7 R16 C11 U4
R17 C12
R39 R43 C26U5
R40 D4 R46
C30

L2
L1 C40

C41 R67
R74 R76
C31
R47 R77
R18 C13
C22 R54 C42 R68
R19R26 C23 D5 R48
R20 R27
R30
R31 R41 R44 R49
R55 C43 R69 L6
C44 R70 L7
T1 T2
R8 V/HZ R52 STAB VAR/PF--VAR/PF+
7
5 6
4 GM31850-E

TP-6349-3 3
1. 12 volt battery or DC voltage supply 241618A-BB/X-6295B-AW
2
2. Voltage regulator 12-pin plug (pin insertion end shown)
3. 250-volt, 100-watt lamp 1. Voltage regulator 12-pin socket
4. 200--240 VAC (optional) 2. GM11858 12-pin plug
5. 1-amp fuse 3. 337173 terminal (10) female 0.99 mm (0.39 in.) diameter
6. Single-pole single-throw switch
7. 1:2 step-up transformer Figure 3-5 Voltage Regulator Adapter Harness
8. White wire
9. 100--120 VAC D Lamp, 250-volt, 100-watt
10. Black wire D Fuse, 1-amp
11. Potentiometer (1 kOhm)
D Switch, 1 single-pole single-throw (SPST) 1 amp
Figure 3-4 Voltage Regulator Test with (minimum)
User-Fabricated Adapter Harness D Plug, 120-volt AC (200--240 volt AC plug optional)

The voltage regulator monitors output voltage D Stranded copper wire, #18 AWG
magnitude to control the current to the exciter field
windings. The voltage regulator has an underfrequency WARNING
unloading feature that is referred to as volts-per-Hz
(V/Hz). To determine if the voltage regulator is
functioning, reduce the engine speed (Hz), if possible,
and watch for a corresponding drop in the AC voltage.
The AC voltage should remain constant until the engine Hazardous voltage. Moving rotor.
speed drops below 57.5 Hz on 60 Hz models or 47.5 Hz Can cause severe injury or death.
on 50 Hz models.
Operate the generator set only when
all guards and electrical enclosures
When the frequency drops below either 57.5 or 47.5 Hz,
are in place.
the AC voltage should decline. Perform the following
test to check the voltage regulator output.

28 Section 3 Alternator Troubleshooting TP-6349 6/07

High voltage test. Hazardous voltage can cause severe Volts/Hz Potentiometer. Potentiometer adjustment
injury or death. Follow the instructions of the test equipment determines the engine speed (Hz) at which the
manufacturer when performing high-voltage tests on the rotor alternator output begins to drop.
or stator. An improper test procedure can damage equipment
or lead to generator set failure. Voltage Adjustment (remote only). Use the generator
set controller voltage adjustment control to adjust the
Voltage Regulator Test Procedure alternator output. See the respective generator set
operation manual for further information.
1. Connect the components as shown in Figure 3-4.
If a 200--240 volt power source is available, the
step-up transformer is not required. 1 2

2. Turn 1 kOhm potentiometer fully counterclockwise. + C4 R28 R32 LED1 LED2 D6 C32 R56 R60 D8
C
See Figure 3-4, item 11. R9
R10
D3
R21
C14
U2
R33
C18
SHTDWN
OUT
C27
R50
U6 C33
R57 U7

C6 R34
R11
D2 C35 C46
R22 C15 R35 Q1 C34 R58
D7 R61 R71 V1
3. Plug the power cord into the outlet. D1
R12
R23
C7 U3
C5
C16
C19
Z1
Q2 C36
C45 R72
9
L8
P40
12
R5 R13 C8 R36 R45 R51 R62 L3
R6 R14 C9 C20
C24 C28 C29 C37 L4
R1 C2 R37
VR1 R59 R63
4. Turn the power supply on. The 100-watt lamp C1

R2
U1 R24
C10
R29 + C21
R53 C39
C38 R64
R65 L5
1 4
R3 C3 R15R25 R38 R42 C25 VADJ R73 R75
should be off. If 100-watt lamp is lit, replace the R4 R7 R16
R17 C12
C17
C11 U4 U5
R39 R43 C26
R40 D4 R46
C30

L2
L1 C40

C41
R66
R67
R74 R76
C31
R77
voltage regulator. It is acceptable for the lamp to R18 C13
R19R26
C22
C23
R47
D5 R48
R54 C42 R68

R20 R27
R30
R31 R41 R44 R49
R55 C43 R69 L6
T1 T2
briefly illuminate at powerup. R8 V/HZ R52 STAB
C44 R70 L7
VAR/PF--VAR/PF+

GM31850A-E
5. Slowly turn the 1 kOhm potentiometer clockwise. 5 4 3
The 100-watt lamp should light. Replace the
voltage regulator if the 100-watt lamp does not 1. LED1 (red shutdown) 4. Stability potentiometer
light. 2. LED2 (green output) 5. Volts/Hz potentiometer
3. 12-pin socket P40

3.4.3 Voltage Regulator Adjustment Figure 3-6 Voltage Regulator Features

The voltage regulator is factory-set and, under normal

circumstances, requires no further adjustment. Socket
P40- Lead Description/Function
However, if the voltage regulator has been replaced, or
1 68 Remote voltage adjustment
tampered with, or if voltage/frequency reconnection has
been done, readjust the voltage regulator according to 2 V7 TB4-V7 sensing input
the following procedure. The voltage regulator 3 V8 TB4-V8 sensing input
components are identified and described in the 4 FP Exciter field output
following paragraphs. Figure 3-6 illustrates the voltage 5 67 Remote voltage adjustment
regulator features. Figure 3-7 identifies the voltage 6 EOV Overvoltage controller output signal
regulator connections to the P40 socket. 7 — Not used
8 FN Exciter field output
Note: Frequency reconnection. Refer to the respective
generator set spec sheet to determine if engine 9 7N TB11-7N (battery negative)
frequency (speed) is fixed or field-convertible. 10 1B Safeguard circuit breaker (battery positive)
11 55 Voltage regulator power supply
12 66 Voltage regulator power supply
Stability Potentiometer. Potentiometer fine tunes the
regulator circuitry to reduce light flicker. Figure 3-7 Voltage Regulator P40 Connections

TP-6349 6/07 Section 3 Alternator Troubleshooting 29

Voltage Regulator Adjustment Procedure 7. If the engine has a speed adjustment governor,
adjust the engine speed to the specified cut-in
Figure 3-8 illustrates the wiring connections necessary frequency as measured on the frequency meter.
for the voltage regulator adjustment procedure. The factory setting is 57.5--58 Hz for 60 Hz models
and 47.5--48 Hz for 50 Hz models.

9 10 11 12 Note: Some engines do not permit engine speed

5 6 7 8 adjustment.
1
1 2 3 4
8. Rotate the volts/Hz potentiometer clockwise until
the voltage level as measured on the voltmeter
begins to drop. When the regulator is set to these
specifications, the alternator will attempt to
8 maintain normal output until the engine speed
2 V7 V8 drops below the frequency set in step 7 as load is
applied.
F1 (F+) F2 (F--) 1 2 3 4
7 3 9. Readjust the engine speed to 1800 rpm for 60 Hz
models or1500 rpm for 50 Hz models.

AC
AC
F+
10. Readjust the voltage adjustment control (located at
AC F -- the generator set controller) until the desired output
is achieved.

6 66 55
11. Readjust the stability potentiometer until light
5 4 flicker minimizes.
TP-6349-4
1. Sensing leads
2. Stator main windings
12. Move the generator set master switch to the OFF/
3. Rotor main field RESET position.
4. Voltage regulator power supply leads
5. Rotating rectifier assembly (RRA)
6.
7.
Exciter armature
Exciter field winding
3.5 Exciter Field
8. Voltage regulator (P40 socket)
Direct current from the battery magnetizes the exciter
Figure 3-8 Voltage Regulator Connection field winding. When the exciter armature rotates within
the magnetized exciter field windings, an electrical
1. Verify that the generator set master switch is in the current develops within the exciter armature. Test the
OFF/RESET position. exciter field winding according to the following
procedure.
2. Turn the Volts/Hz and the stability potentiometers
fully counterclockwise. Connect the voltmeter to
Exciter Field Test Procedure
the AC circuit or an electrical outlet.
1. Place the generator set master switch to the
3. Move the generator set master switch to the RUN OFF/RESET position.
position.
2. Disconnect the generator set engine starting
4. Change the voltage adjustment control (located at battery, negative (--) lead first.
the generator set controller) until the desired output
voltage is achieved. 3. Disconnect the FP/FN leads.

5. Rotate the stability potentiometer clockwise until 4. Check the exciter field resistance by connecting an
light flicker minimizes. ohmmeter across exciter field FP and FN leads.
See Figure 3-9. See Section 1, Specifications, for
6. Readjust the voltage adjustment control (located at resistance reading for a cold exciter field winding.
the generator set controller) until the desired output
voltage is achieved.

30 Section 3 Alternator Troubleshooting TP-6349 6/07

 A reading of approximately 500 kOhms
(1/2 megohm) and higher indicates the exciter field
2 winding is good. A reading of less than
1
approximately 500 kOhms indicates deterioration
of the exciter field winding insulation and possible
current flow to ground. Replace the exciter field
winding.
FP FN 3

3.6 Exciter Armature

The exciter armature supplies excitation current to the
4
main field windings through the rotating rectifier
TP-6349-3
assembly (RRA). Test the exciter armature as
described in the following steps.
1. Voltage regulator 3. Exciter field winding
2. Ohmmeter 4. Exciter armature Exciter Armature Test Procedure
Figure 3-9 Exciter Field Winding Resistance Test 1. Disassemble the alternator. See Section 4,
Alternator Disassembly/Reassembly for the
A low reading indicates an internal short and a high
procedure.
reading indicates an open winding. Repair or
replace the exciter field winding if the ohmmeter 2. With the alternator disassembled, disconnect the
readings indicate an inoperative exciter field armature leads from the RRA AC terminals.
winding. If the resistance test is inconclusive,
perform a megohmmeter test on the exciter field 3. With an ohmmeter on the R x 1 scale, check the
winding as described in the next step. resistance across the exciter armature leads. See
Figure 3-11. See Section 1, Specifications, for the
5. Check the exciter field winding for a short to ground armature resistance. No continuity indicates an
condition. See Figure 3-10. Use a megohmmeter open armature winding. If the resistance test is
to apply 500 volts DC to the FP or FN lead and the inconclusive, perform a megohmmeter test on the
exciter field winding frame. Follow the exciter armature as described in the next step.
megohmmeter manufacturer’s instructions for
using the megohmmeter.

6 1

AC F+
2 AC
AC F--

5 3
5 2
FP FN
4

3
TP-6349-3
4
1. Rotor main field 4. Ohmmeter
TP-6349-3
2. Stator main windings 5. Exciter armature
3. Rotating rectifier assembly 6. Exciter field winding
1. Voltage regulator 4. Exciter armature (RRA)
2. Ohmmeter 5. Exciter field winding
3. Ground to exciter frame Figure 3-11 Exciter Armature Resistance Test

Figure 3-10 Megohmmeter Connections on Exciter

Field Winding

TP-6349 6/07 Section 3 Alternator Troubleshooting 31

 Note: Consider the exciter armature good if the Rotating Rectifier Assembly (RRA) Test Procedure
resistance reading (continuity) is low and 1. Disconnect the exciter armature and the rotor main
there is no evidence of a shorted winding field winding leads from the RRA. See Figure 3-13.
(heat discoloration).
Keep each lead electrically separated from the
other leads and any metal components.
4. Check the exciter armature for a short to ground
condition. Use a megohmmeter to apply 500 volts
DC to either armature lead and the armature frame.
1
Follow the megohmmeter manufacturer’s
instructions for using the megohmmeter. See
Figure 3-12. A reading of approximately
500 kOhms (1/2 megohm) and higher indicates the
exciter armature is good. A reading of less than
approximately 500 kOhms indicates deterioration
of the winding insulation and possible current flow
2
to ground. Replace the exciter armature. 4
GM32507/TP-6349-4
3

7 1 1. AC terminals 3. Diode terminal (F+)

2. Diode terminal (F--) 4. Varistor
AC F+
AC Figure 3-13 RRA Connections
AC F--

2. Use an ohmmeter on the R x 100 scale to check the

3 resistance between the RRA diodes as shown in
6 Figure 3-14. The ohmmeter should show a low
4 2 resistance in one direction and, upon reversing the
ohmmeter leads, a high resistance in the other
direction. Replace the diode assembly plates
5 (service part set) if any of the six diodes test
TP-6349-3 differently than described.

1. Rotor main field 5. Ground to exciter

2. Stator main windings armature frame
Note: Disconnect leads from rectifier
3. Rotating rectifier assembly 6. Exciter armature module before performing test.
(RRA) 7. Exciter field winding
4. Megohmmeter
1
Figure 3-12 Megohmmeter Connections on Exciter
4
Armature 2

3.7 Rotating Rectifier Assembly

(RRA)/Varistor 3

The RRA converts the AC from the exciter armature to GM31963/TP-6349-4

DC, which magnetizes the main field windings. Test the
RRA as described in the following steps. The RRA 1. Ohmmeter 3. Diode ground connection
consists of two diode assembly plates and varistor 2. Diodes (3 diodes per plate) 4. Diode terminal
attached to the diode assembly hub. The diode Figure 3-14 Diode Assembly Plate (part of RRA) Test
assembly plates are available only as a set when
ordering service parts. 3. Replace the varistor if there is evidence of heat
damage. Replace the diode assembly hub if any
damage is evident.

32 Section 3 Alternator Troubleshooting TP-6349 6/07

3.8 Rotor 3. Check the rotor main field for a short to ground
condition by using a megohmmeter. Apply
The rotor (magnetized by DC from the rotating rectifier 500 volts DC to either rotor main field lead and the
assembly) rotating within the stator induces AC in the main field frame. Follow the megohmmeter
stator windings. Test the rotor main field as described in manufacturer’s instructions for using the
the following steps. Disassemble the alternator prior to megohmmeter. See Figure 3-16.
performing this test. See Section 4, Alternator
Disassembly/Reassembly for the procedure. A reading of 500 kOhms (1/2 megohm) and higher
indicates the rotor main field is good. A reading of
less than 500 kOhms indicates deterioration of the
Generator Rotor Test Procedure
rotor main field winding insulation and possible
1. With the alternator disassembled, disconnect the current flow to ground. Replace the rotor.
rotor main field from the rotating rectifier assembly
(RRA) terminals F+ and F--.

2. Check the rotor main field resistance by connecting

an ohmmeter across leads field F+ and F--. See 7
1
Figure 3-15. See Section 1, Specifications for the AC F+
AC
resistance values. AC F--

6 4
6 1 2 3
AC F+
AC
AC F--
5

5
3
2 TP-6349-3
1. Rotor main field 5. Megohmmeter
4
2. Stator main windings 6. Exciter armature
3. Ground to stator frame 7. Exciter field windings
4. Rotating rectifier assembly
TP-6349-3
1. Rotor main field 4. Ohmmeter Figure 3-16 Megohmmeter Connections on Rotor
2. Stator main windings 5. Exciter armature Main Field
3. Rotating rectifier assembly 6. Exciter field winding

Figure 3-15 Rotor Resistance Test

3.9 Stator
A low reading indicates an internal short and a high
The stator consists of a series of coils of wire (windings)
reading indicates an open winding. Repair or
laid in a laminated steel frame. The stator leads supply
replace the rotor main field if the ohmmeter
voltage to the AC load and voltage regulator.
readings indicate the rotor main field is inoperative.
If the resistance test is inconclusive, perform a Before testing the stator, inspect it for heat discoloration
megohmmeter test on the rotor main field as and visible damage to the housing lead wires and
described in the next step. exposed and varnished areas of the frame laminations.
Be sure the stator is securely fastened in the stator
housing.

The stator produces electrical output (AC) as the

magnetized main field rotates within the stator windings.
Test the condition of the stator according to the following
procedure.

TP-6349 6/07 Section 3 Alternator Troubleshooting 33

Leads 1--4 (single phase) or leads 1--12 (three phase)
are the alternator AC output leads. Leads 55 and 66 are 2
the voltage regulator supply and sensing leads. Refer to
Figure 3-17 and Figure 3-18 (three phase) or
Figure 3-19 and Figure 3-20 (single phase) when 1 V7 V0 V8

performing the following tests.

FP FN
8 1 2 3 4
Between Leads Continuity
1 and 4 Yes AC F+
AC
2 and 5 Yes AC F-- 3
3 and 6 Yes
7 55 66
7 and 10 Yes
8 and 11 Yes 4
9 and 12 Yes 6
55 and 66 Yes 5
1 and 2, 5, 3, 6, 7, 10, 8, 11, 9, 12 No TP-6349-3

1 and 55, 66 No
1. Rotor main field
Any stator lead and ground No 2. Sensing leads (208--240 volts nominal)
3. Stator main windings
Figure 3-17 Stator Continuity, Three Phase 4. Voltage regulator power supply leads
5. Ohmmeter
6. Rotating rectifier assembly (RRA)
3
7. Exciter armature
2 V8 V7 8. Exciter field winding
1
Figure 3-20 Stator Ohmmeter Connections, Single
FP FN Phase
8
Stator Test Procedure
4
1. Move the generator set master switch to the
OFF/RESET position.
7
2. Disconnect the generator set engine starting
battery, negative (--) lead first.
6
5 3. Check the alternator output lead connections.
TP-6349-3 Refer to wiring diagram manual and/or generator
1. Rotor main field
2. Sensing leads (208--240 volts nominal) set operation manual.
3. Voltage regulator power supply leads
4. Stator main windings 4. Disconnect all the stator leads to isolate the
5. Ohmmeter windings. To check the stator continuity, set the
6. Rotating rectifier assembly (RRA) ohmmeter on the R x 1 scale. Check the stator
7. Exciter armature
8. Exciter field winding continuity by connecting the meter leads to the
stator leads as shown in Figure 3-20. Perform the
Figure 3-18 Stator Ohmmeter Connections, 3-Phase stator tests on all of the stator windings. For
single-phase alternators use Figure 3-19. For
three-phase alternators use Figure 3-17.
Between Leads Continuity
1 and 2 Yes 5. Contact the ohmmeter leads and readjust the
3 and 4 Yes ohmmeter to zero ohms. Check the cold
55 and 66 Yes resistance of the stator windings by connecting the
meter leads to the stator leads 1-2, 3-4, etc. See
1 and 3, 4, 33, 44 No
Section 1, Specifications, for the stator resistance
1 and 55 No
values. If the stator resistance test is inconclusive,
Any stator lead and ground No perform a megohmmeter test on the stator as
Figure 3-19 Stator Continuity, Single Phase described in the next step.

34 Section 3 Alternator Troubleshooting TP-6349 6/07

 Note: Consider the stator good if the resistance
reading (continuity) is low and there is no 3
evidence of shorted windings (heat 1 2 V8 V7

discoloration).
FP FN
Note: When taking an ohmmeter reading using
9
lead 55, make the connection prior to the
in-line fuse.
4
Note: The stator resistance varies directly with
increased temperature. 8
6. If any of the stator readings vary during the
previous checks, replace the stator. 7
5
6
7. Check the stator for a short to ground condition
TP-6349-3
using a megohmmeter. See Figure 3-21 and
Figure 3-22. 1. Rotor main field
2. Sensing leads (208--240 volts nominal)
3. Voltage regulator power supply leads
Apply 500 volts DC to any stator lead from each 4. Stator main windings
winding and the stator frame. Follow the 5. Ground to stator frame
megohmmeter manufacturer’s instructions for 6. Megohmmeter
using the megohmmeter. Repeat the test on the 7. Rotating rectifier assembly (RRA)
8. Exciter armature
other leads until all the stator windings have been 9. Exciter field winding
tested.
Figure 3-22 Megohmmeter Connections on Stator,
A reading of 500 kOhms (1/2 megohm) and higher Three Phase
indicates the stator is good. A reading of less than
500 kOhms indicates deterioration of the stator
winding insulation and possible current flow to
3.10 Speed Sensor Test
ground. Repair or replace the stator. Follow the procedure outlined below to determine if the
speed sensor (overspeed fault) is emitting a signal.
2
Note: During the test the controller leads must remain
connected to the speed sensor terminals. Slide
1 V7 V0 V8 leads from speed sensor terminals only enough
to expose connection for the test leads. Do not
disconnect the speed sensor leads.
9 FP FN
1 2 3 4
1. Move the generator set master switch to the
AC F+ OFF/RESET position.
AC
AC F-- 3
2. Connect a DC voltmeter between positive (+) lead
8 55 66
(wire 24) at speed sensor and ground (wire 2). The
4 voltmeter should indicate approximately 8-10 volts
7 DC.
5
6
3. Move the generator set master switch to the RUN
TP-6349-3
position to start the generator set.
1. Rotor main field
2. Sensing leads (208--240 volts nominal) 4. With generator set running, connect the DC
3. Stator main windings voltmeter negative probe to the 0 terminal (wire
4. Voltage regulator power supply leads
5. Ground to stator frame 16—white) on the speed sensor. Place the
6. Megohmmeter voltmeter positive probe on positive (+) terminal
7. Rotating rectifier assembly (RRA) (wire 24—red). The voltmeter should indicate
8. Exciter armature approximately 12 volts DC.
9. Exciter field winding

Figure 3-21 Megohmmeter Connections on Stator, If the speed sensor is emitting a signal, check the
Single Phase continuity of the speed sensor leads (wires 2, 16, and

TP-6349 6/07 Section 3 Alternator Troubleshooting 35

24) between the controller connector and lead terminals There is no field test for this circuit board. Use the
at speed sensor. following information to help troubleshoot the circuit
board.
If the speed sensor is not emitting a signal, test the
speed sensor using the following procedure:

1. Connect the speed sensor, voltmeter, and DC

voltage source as shown in Figure 3-23.

+ +
1

---
2

o + --- GM11718B-F

Figure 3-24 Interface Circuit Board GM11718

Verify connection and continuity of the wires shown in

3 Figure 3-25 and Figure 3-26. Check the wires for
broken strands and damaged insulation including cuts
TP-5353-7
1. DC Voltmeter
and chafing. Check the terminals for corrosion and
2. 12-Volt Battery or DC Power Supply loose electrical connections. Repair and/or replace any
3. Sensing Surface defective wiring.
Figure 3-23 Speed Sensor Test
Circuit Board
Wire Connection Component Connection
2. Touch the sensing surface with a flat piece of iron or
E12 P6-1 TB3-1
steel—at least 4 cm (1/4 cu. in.) in size.
N P6-2 TB3-7
3. The voltmeter test reading should equal the source EOV P6-3 TB4-4
voltage. 3B P6-4 P1-16
5B P6-5 P1-20
4. Remove the iron or steel from the sensing surface
Not used P6-6 none
and observe a no voltage reading on the voltmeter.
55 T1 Stator main field 55
66 T2 Stator main field 66
3.11 Interface Circuit Board
F1 T3 Exciter field IB-F (+)
GM11718 F2 T4 Exciter field IB-F (--)

The 550 controller has an integral voltage regulator. Figure 3-25 Interface Circuit Board Connections
Circuit board GM11718 interfaces between the wound
field alternator and 550 controller voltage regulator. See
Figure 3-24 for an illustration of the circuit board. The
circuit board is typically located in the junction box.

36 Section 3 Alternator Troubleshooting TP-6349 6/07

 T1 T2

T3

T4

GM35944-B

Figure 3-26 Interface Circuit Board Diagram with Wound Field Alternator

Do the checks shown in Figure 3-27. Shut down the unit If the circuit board is still suspected of questionable
after performing the start and run checks. function after the circuit board wiring checks out okay,
replace with a known good circuit board and test the
generator set for functionality.

Connections/Display Check Possible Causes

P6-E12 and P6-N connections 12 VDC supply
pp y from 550 Check battery and/or connections
controller
ll
Check P6 connector and wiring
P6-3B and P6-5B connections 1-3 VDC output
p Check controller interconnection P1 connector and wiring
(
(start and
d run unit
i for
f this
hi test))
Check T3 and T4 connections (field wires)
Check F1 and F2 winding and connections at exciter field
Field overvoltage fault display on 550 P6-EOV connection Check if P6-EOV is grounded
controller
T1 and T2 (PMG
( connections)) 200--230 VAC stator output
p Check T1 and T2 (PMG) connections
(
(start and
d run unit
i for
f this
hi test))
Check 55 and 66 winding and connections at stator
F+ and F-- connections DC voltage
g (values
( are Check T3 and T4 connections (field wires)
alternator
l d
dependant)
d )
Check F1 and F2 winding and connections at exciter field

Figure 3-27 Interface Circuit Board GM11718 Testing

TP-6349 6/07 Section 3 Alternator Troubleshooting 37

 Notes

38 Section 3 Alternator Troubleshooting TP-6349 6/07

 Section 4 Alternator Disassembly/Reassembly

4.1 General WARNING

Before beginning alternator disassembly procedure,
carefully read all safety precautions at the beginning of
this manual. Please observe these precautions and
those included in text during the disassembly/
reassembly procedure. Hot engine and exhaust system.
Can cause severe injury or death.
The following procedures cover many models and some Do not work on the generator set until
steps may not apply to a particular engine. Use it cools.
Figure 4-1 or Figure 4-2 to help understand component
descriptions and general configuration of the alternator. Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The
Use the disassembly procedure as a guideline to help engine and exhaust system components become extremely
take apart the alternator. The disassembly procedure hot during operation.
provides important information to minimize disassembly
time and indicates where special configurations exist
which may require taking notes. The reassembly WARNING
procedure includes important alignment steps and
provides special torque specs.

WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
Accidental starting.
Can cause severe injury or death. The fuel system. Explosive fuel vapors can cause severe
injury or death. Vaporized fuels are highly explosive. Use
Disconnect the battery cables before extreme care when handling and storing fuels. Store fuels in a
working on the generator set. well-ventilated area away from spark-producing equipment
Remove the negative (--) lead first and out of the reach of children. Never add fuel to the tank
when disconnecting the battery. while the engine is running because spilled fuel may ignite on
Reconnect the negative (--) lead last contact with hot parts or from sparks. Do not smoke or permit
when reconnecting the battery. 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
Disabling the generator set. Accidental starting can
flexible sections to avoid fuel line breakage caused by
cause severe injury or death. Before working on the
vibration. Do not operate the generator set in the presence of
generator set or connected equipment, disable the generator
fuel leaks, fuel accumulation, or sparks. Repair fuel systems
set as follows: (1) Move the generator set master switch to the
before resuming generator set operation.
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first. Explosive fuel vapors can cause severe injury or death.
Reconnect the negative (--) lead last when reconnecting the Take additional precautions when using the following fuels:
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote Gasoline—Store gasoline only in approved red containers
start/stop switch, or engine start command from a remote clearly marked GASOLINE.
computer.
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.

TP-6349 6/07 Section 4 Alternator Disassembly/Reassembly 39

 15

13

6 10
5 9
16
3 14
12
11
8

21
7
4

22

23
2 24

25
26 19
20
27 18 17

30

31
32

28 TP-6349-4
29

1. Screw 12. Elastic stop nut 23. Stator

2. Exciter field winding 13. Elastic stop nut 24. Adapter
3. End bracket 14. Varistor 25. Ball bearing
4. Magnetic actuator 15. Rotating rectifier assembly cover 26. Rotor
5. Speed sensor 16. Screw 27. Alternator fan
6. Screw 17. Plain washer 28. Plain washer
7. Screw 18. Screw 29. Screw
8. Rotating rectifier assembly hub 19. Screw 30. Drive discs (2)
9. Screw 20. Plain washer 31. Hardened washer
10. Nut 21. Terminal 32. Screw
11. Diode assembly plates (2 pieces—red and blue) 22. Equipment ground decal

Figure 4-1 4PW and 4QW Alternator Components, 20--60 kW

40 Section 4 Alternator Disassembly/Reassembly TP-6349 6/07

 15

13

5 6 10
9
16
3 12 14

11
8
33
7
4 34
35
37

36

2 21

1 22

23
24

25
26 19
20
27 18 17

30

31
32

28
TP--6349-4
29

1. Screw 14. Varistor 27. Alternator fan

2. Exciter field assembly 15. Rotating rectifier assembly cover 28. Plain washer
3. End bracket 16. Screw 29. Screw
4. Magnetic actuator 17. Plain washer 30. Drive discs, 3 with 4SW/4VW
5. Speed sensor 18. Screw and 4 with 4UAW
6. Screw 19. Screw 31. Hardened washer
7. Screw 20. Plain washer 32. Screw
8. Rotating rectifier assembly hub 21. Terminal 33. Screw
9. Screw 22. Equipment ground decal 34. Plain washer
10. Nut 23. Stator 35. Nut
11. Diode assembly plates (2 pieces—red and blue) 24. Adapter 36. Terminal block
12. Elastic stop nut 25. Ball bearing 37. Terminal block link
13. Elastic stop nut 26. Rotor

Figure 4-2 4SW, 4VW, and 4UAW Alternator Components, 60 kW IMS--300 kW

TP-6349 6/07 Section 4 Alternator Disassembly/Reassembly 41

Perform the following steps prior to disassembling the 9. Remove bolts from the alternator vibromounts.
generator set.
10. Suspend the alternator at both ends with hooks in
1. Disconnect (negative lead first) and remove the lifting eyes. Use a hoist to raise alternator end off
starting batteries from the work area to prevent a vibromounts. See Figure 4-4.
fire hazard. Disconnect AC-powered accessories,
such as the battery charger, block heater, and fuel 11. Support the engine by placing wood blocks under
transfer pump. the flywheel housing. Lower the alternator end
until the flywheel housing rests on the blocks. See
2. Shut off the fuel supply. Drain the fuel system as Figure 4-4.
necessary by emptying the fuel into proper
containers. Remove any fuel containers from the 12. Remove the bolts holding the adapter to the
work area to prevent a fire hazard. Ventilate the flywheel housing.
work area to clear fumes.
13. Remove the hardware attaching the drive discs to
3. Disconnect the fuel, cooling, and exhaust systems the flywheel.
as necessary to tilt the generator set. Disconnect
the output leads or load circuit cables at the 1
generator set.

4. Any cranes, hoists, or other lifting devices used in 6

the disassembly or reassembly procedure must be
rated for the weight of the generator set. Check the
generator set nameplate or spec sheet for weight. 5

5. Remove the junction box panels.

2
4
4.2 Disassembly 3 GM32507/TP-6349-4

1. AC terminals 4. Varistor
1. Disconnect all controller-to-engine and engine-to-
2. Diode terminal (F--) (red) 5. Mounting screws
alternator harnesses and wiring. Disconnect the 3. Diode terminal (F+) (blue) 6. Magnetic actuator
speed sensor wiring. Remove the junction box and
the controller as a unit. Figure 4-3 Rotating Rectifier Assembly Hub and
Components
2. Remove the fan guard.

3. Remove the rotating rectifier assembly housing.

4. Remove the alternator (rodent) guard on the end 1

bracket (if equipped).

5. Remove the speed sensor from the end bracket.

6. Remove all leads from the three AC terminals on

the rotating rectifier assembly hub. See
Figure 4-3. Make notes as needed for
reconnection later.

7. Remove the leads from the F+/F-- terminals on the

rotating rectifier assembly hub. Make notes as
needed for reconnection later. Remove the diode
assembly plates. The varistor is accessible after
the F+/F-- screws are removed. 3 2 3-083
R8371-17
1. Hook
8. Remove the two mounting screws. Lift off the 2. Alternator adapter
rotating rectifier assembly hub and magnetic 3. Wood block(s)
actuator.
Figure 4-4 Hoisting Generator

42 Section 4 Alternator Disassembly/Reassembly TP-6349 6/07

14. Work the drive discs over the studs (if equipped) to
separate the alternator from the engine. See
Figure 4-5. 1

3-093
1. Drive disc removal R8348-22
2. End bracket support

1 Figure 4-6 Alternator Support, Drive Discs, and Fan

3-084
1. Drive discs R8371-14 Removal

Figure 4-5 Separating Generator and Engine

15. Use a stud remover and remove the studs from the
flywheel, if damaged.

16. Set the alternator assembly on the floor in a

horizontal position. Remove the support slings or
chains.
1
17. To remove the rotor assembly, attach the hoist
hook to the adapter and lift the alternator assembly
to a vertical position. See Figure 4-6. Place boards
along the edge of the end bracket to prevent
damage to the rotating rectifier assembly hub and
magnetic actuator. Lower the rotor assembly.

18. Remove the drive discs and fan from the alternator
assembly. See Figure 4-6.

19. Fasten the lifting eye and hoist hook to the rotor
flange. Hoist the rotor carefully to avoid damaging
the exciter armature or exciter field winding. See
Figure 4-7.

3-090
R8348-19
1. Hoist hook locations

Figure 4-7 Rotor Removal

TP-6349 6/07 Section 4 Alternator Disassembly/Reassembly 43

20. Place a pallet or other wooden surface under the
rotor and slowly lower the rotor to a horizontal
position. Take care not to damage the windings,
laminations, or bearing. See Figure 4-8.

21. Make note of the bearing location dimensions from

the rotor shaft end for reference during installation
if the bearing will be removed. Use a hydraulic
press to remove the bearing, if needed.

22. Place the alternator assembly on the adapter end

in order to remove the adapter and end bracket
from the stator. Fasten chains to the adapter and
lower to a horizontal position. Fasten the hoist 1
hook to the end bracket eye and lift to a vertical
position. See Figure 4-9.

23. Remove the adapter mounting bolts. Fasten the

hoist hooks to the end bracket and raise the stator
assembly slightly. Tap adapter loose by using a
rubber mallet.
3-088
R8348-15
24. Lower the stator assembly. Remove the end 1. Rotor assembly
bracket mounting bolts. Separate the end bracket
from the stator by tapping loose with a rubber Figure 4-8 Lowering Rotor
mallet.

25. Remove the exciter field winding from the end

bracket.

4.3 Reassembly
2
Follow the general guidelines in the following
1
procedure. In addition, Figure 4-23, Figure 4-24, and
Figure 4-25 at the end of this section may provide some
detailed help during the reassembly procedure. 3

When torque specifications are not shown in Section 1,

Specifications, use the guidelines shown in Appendix C,
General Torque Specifications.

1. Attach the exciter field to the end bracket with four

mounting bolts. Torque to specifications. 4
2. Place the stator in a vertical position with the end
3-084
bracket side up. R8348-8
1. Hoist hook 3. End bracket
Note: The end bracket side of the stator has four 2. Hoist hook 4. Adapter
mounting bosses.
Figure 4-9 Removing Alternator Adapter

44 Section 4 Alternator Disassembly/Reassembly TP-6349 6/07

 3. Position the end bracket housing eye opposite the 9. Rotor shaft bearing installation. Use a hydraulic
stator mounting bracket during reassembly. See press, bearing heater, or heavy rubber mallet and a
Figure 4-10. piece of round steel stock with an outside diameter
less than the bearing inner race to install the new
Place the end bracket on the stator and use bolts to bearing using measurements taken during the
align the holes. Use a rubber mallet to mount the disassembly procedure.
end bracket flush with the stator.

1
1

2
3

TP-6349-4

TP-6349-4
1. End bracket lifting eye
1. Stator mounting bracket 2. Stator mounting bracket
2. End bracket lifting eye 3. Adapter lifting eye

Figure 4-10 Attaching End Bracket on Stator Figure 4-11 Aligning Adapter and Stator

4. Attach the end bracket to the stator using the

original hardware. Torque to specifications.

5. Attach the hoist hooks to the end bracket and

suspend the stator. Place the adaptor on the floor
and lower the stator to within 12.7--6.4 mm
(1/2--1/4 in.) of the adapter lip. See Figure 4-11.

6. Position the adapter hoisting eye opposite of the

stator mounting bracket and directly below the end
bracket hoisting eye.

Align the adapter with the stator and start the bolts
with washers. Lower the stator onto the adapter
and finish tightening the bolts. Torque to
specifications.

7. Lower the alternator assembly to a horizontal

position.

8. Attach the hoisting hooks to the adapter as shown

in Figure 4-12. Suspend the alternator assembly. 3-087
R8348-14
Before lowering the alternator assembly, place
boards along the edge of the end bracket. Maintain Figure 4-12 Supporting Alternator Assembly
a 25 mm (1 in.) clearance underneath the center of
the end bracket to allow for rotor shaft clearance.

TP-6349 6/07 Section 4 Alternator Disassembly/Reassembly 45

10. Fasten the lifting eye and hoist hook to the rotor
flange. See Figure 4-13. Hoist the rotor to a
vertical position taking care not to damage
windings, laminations, or bearing.

3-090
R8348-19
3-088
R8348-15 Figure 4-14 Installing Rotor
1. Hoist hook

Figure 4-13 Hoisting Rotor

3
1 2
11. Suspend the rotor over the alternator assembly.
Lower the rotor into the stator. Be extremely careful
while lowering the rotor to avoid damaging the
exciter field assembly, stator windings, or rotor
laminations. See Figure 4-14. Carefully align rotor
bearing into end bracket.
12. Place the fan over the rotor flange and the torque
bolts to specifications.

13. Align the individual drive disks with the hex holes
together and with the hole burr sides facing the
same direction. Temporarily place two alignment
pins (not supplied) or bolts in the outer holes at 5
4 G-626
opposite ends and 90° from the hex hole before
installing the drive disk to the rotor shaft. The pins
help maintain concentric alignment of the 1. Install alignment pins or bolts here
2. Rolled corner
individual drive disks during installation. See 3. Burr side
Figure 4-15. 4. 120° total; position drive disk hex hole at the
stator bottom position or within 60° CW or
Note: The user-supplied pins should be no smaller CCW from the stator bottom position
than 0.025 mm (0.001 in.) of the disc hole 5. Hex hole
diameter. Figure 4-15 Aligning and Mounting Drive Disks

46 Section 4 Alternator Disassembly/Reassembly TP-6349 6/07

14. Attach the drive disc(s) to end of rotor shaft with the 17. Apply LoctiteR No. 271 red to stud threads and
hole burr side toward the alternator fan and with the install into flywheel as shown in Figure 4-17. Install
hex hole at the stator bottom position or within 60° studs completely into flywheel. Apply LoctiteR No.
clockwise (CW) or counterclockwise (CCW) of the 242 blue to stud threads on nut side.
bottom position as viewed when the stator is
installed on the skid. Torque the drive disc(s)
mounting bolts to specifications. Remove the two 1
alignment pins or bolts.

15. Attach a hoist to the adapter eye and place the

alternator assembly in a horizontal position. Take
care not to damage the rotor or stator. Place the
hoisting eyes of the alternator to the top.

16. UA alternator only. Remove the vent/sight hole

screw from the end bracket located 180° from the
grease fitting. Use a grease gun and fill with
Chevron SRI2 or equivalent lithium-based grease
3-098
until the grease is visible at the vent/sight hole. R8371-9
Wipe excess grease from the end bracket. 1. Flywheel studs
Replace the vent/sight hole screw and torque to
Figure 4-17 Flywheel Studs
specifications. See Figure 4-16.
18. Place hoist hooks into the end bracket and adapter
eye. Raise the alternator assembly and align the
1 studs with the drive discs by turning the flywheel.
Move the alternator as necessary to work the drive
discs over the studs. When the drive discs are
about 25 mm (1 in.) over studs, install spacers if so
equipped. See Figure 4-18.

1 2 3

GM33000A-A
2

1. Grease fitting 2. Vent/sight screw

Figure 4-16 Applying Grease to UA Alternator

3-097
R8371-14
1. Drive discs
2. Studs
3. Spacers

Figure 4-18 Installing Spacers

LoctiteR is a registered trademark of Loctite Corporation.

TP-6349 6/07 Section 4 Alternator Disassembly/Reassembly 47

19. Move the alternator as necessary to align the 24. Replace the diode assembly plates and varistor if
adapter and the flywheel housing. Fasten and final removed. The diode assembly plates are color
tighten the adapter to the flywheel housing using coded. The positive diode assembly is blue and the
bolts and hardened lock washers. See negative diode assembly is red. See Figure 4-20.
Figure 4-19. Torque the bolts to specifications.

2
4
3 GM32507/TP-6349-4
1. AC terminals
2. Diode terminal (F--) (red)
3. Diode terminal (F+) (blue)
4. Varistor
3-083
5. Mounting screws
R8371-17 6. Magnetic actuator

Figure 4-19 Aligning Adapter to Flywheel Housing Figure 4-20 Rotating Rectifier Assembly Hub and
Components
20. Install the hardware attaching the drive discs to the
flywheel. Do not final tighten at this time. 25. Reconnect the wiring to the three AC terminals and
F+/F-- terminals of the rotating rectifier assembly
Note: Some applications use hardened washers. hub. See Figure 4-21. Torque to specifications.
Do not substitute with non-hardened
washers. 2
1 3
21. Hoist the alternator and engine slightly to remove
the wood block(s) from under the flywheel housing. 12
4
Align the alternator assembly and the skid. Lower
the alternator and tighten the vibromount mounting 11
5
bolts.
10 6
22. Remove the chains or slings from the alternator.
7
Final tighten the drive discs to the flywheel. Torque 9
the hardware to specifications. 8 GM32507/TP-6349-4
1. AC terminal no. 1
23. Mount the rotating rectifier assembly hub and 2. AC terminal no. 2
magnetic actuator to the rotor shaft using two 3. AC terminal no. 3
4. Blue diode terminal no. 3 (connect to AC terminal no. 3)
screws. Torque to specifications. 5. Blue diode terminal no. 2 (connect to AC terminal no. 2)
6. Blue diode terminal no. 1 (connect to AC terminal no. 1)
7. Diode terminal (F--) (red) (connect to main field F--)
8. Diode terminal (F+) (blue) (connect to main field F+)
9. Varistor (connect to diode terminals F-- and F+)
10. Red diode terminal no. 1 (connect to AC terminal no. 1)
11. Red diode terminal no. 2 (connect to AC terminal no. 2)
12. Red diode terminal no. 3 (connect to AC terminal no. 3)

Figure 4-21 Rotating Rectifier Assembly Hub

Electrical Connections

48 Section 4 Alternator Disassembly/Reassembly TP-6349 6/07

26. Attach the speed sensor to the end bracket using 27. Replace the alternator (rodent) guard on the end
two screws. Adjust the air gap. See Figure 4-22. bracket (if equipped).

28. Replace the rotating rectifier assembly housing.

3
4 29. Install the fan guard.

2 30. Reinstall the junction box and controller.

31. Reconnect all controller-to-engine and engine-to-

1 alternator harnesses and wiring. Reconnect the
speed sensor wiring. Refer to the respective wiring
0 + ---
diagram manual as required.

32. Replace the junction box panels.

5 33. Reconnect the fuel, cooling, and exhaust systems

that were disconnected during disassembly.
0.36--0.71 mm Reconnect the output leads or load circuit cables at
6 (0.014--0.028 in.) the alternator. Open the fuel supply valve.

34. Reconnect the starting batteries, negative lead

last. Connect any AC-powered accessories such
as the battery charger, block heater, fuel transfer
pump, etc.

TP-5353-8

1. Speed sensor
2. Wire 16: white/clear
3. Wire 24: red
4. Wire 2: black
5. Air Gap: 0.36--0.71 mm (0.014--0.028 in.)
6. Magnetic actuator

Figure 4-22 Speed Sensor Air Gap

TP-6349 6/07 Section 4 Alternator Disassembly/Reassembly 49

Figure 4-23 4PW and 4QW Alternator Components, 20--60 kW
50 Section 4 Alternator Disassembly/Reassembly TP-6349 6/07
 .

Figure 4-24 4SW and 4VW Alternator Components, 60 kW IMS--170 kW

TP-6349 6/07 Section 4 Alternator Disassembly/Reassembly 51
Figure 4-25 4UAW Alternator Components, 180--300 kW
52 Section 4 Alternator Disassembly/Reassembly TP-6349 6/07
 Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute est. estimated
ABDC after bottom dead center CG center of gravity E-Stop emergency stop
AC alternating current CID cubic inch displacement etc. et cetera (and so forth)
A/D analog to digital CL centerline exh. exhaust
ADC advanced digital control; cm centimeter ext. external
analog to digital converter CMOS complementary metal oxide F Fahrenheit, female
adj. adjust, adjustment substrate (semiconductor) fglass. fiberglass
ADV advertising dimensional cogen. cogeneration FHM flat head machine (screw)
drawing com communications (port) fl. oz. fluid ounce
Ah amp-hour coml commercial flex. flexible
AHWT anticipatory high water Coml/Rec Commercial/Recreational freq. frequency
temperature conn. connection FS full scale
AISI American Iron and Steel cont. continued
Institute ft. foot, feet
CPVC chlorinated polyvinyl chloride ft. lb. foot pounds (torque)
ALOP anticipatory low oil pressure
crit. critical ft./min. feet per minute
alt. alternator
CRT cathode ray tube ftp file transfer protocol
Al aluminum
CSA Canadian Standards g gram
ANSI American National Standards Association
Institute (formerly American ga. gauge (meters, wire size)
Standards Association, ASA) CT current transformer gal. gallon
AO anticipatory only Cu copper gen. generator
APDC Air Pollution Control District cUL Canadian Underwriter’s genset generator set
Laboratories
API American Petroleum Institute GFI ground fault interrupter
CUL Canadian Underwriter’s
approx. approximate, approximately Laboratories GND, ground
AQMD Air Quality Management District cu. in. cubic inch gov. governor
AR as required, as requested cw. clockwise gph gallons per hour
AS as supplied, as stated, as CWC city water-cooled gpm gallons per minute
suggested
cyl. cylinder gr. grade, gross
ASE American Society of Engineers
D/A digital to analog GRD equipment ground
ASME American Society of
Mechanical Engineers DAC digital to analog converter gr. wt. gross weight
assy. assembly dB decibel HxWxD height by width by depth
ASTM American Society for Testing dB(A) decibel (A weighted) HC hex cap
Materials DC direct current HCHT high cylinder head temperature
ATDC after top dead center DCR direct current resistance HD heavy duty
ATS automatic transfer switch deg., ° degree HET high exhaust temp., high
auto. automatic dept. department engine temp.
aux. auxiliary DFMEA Design Failure Mode and hex hexagon
avg. average Effects Analysis Hg mercury (element)
AVR automatic voltage regulator dia. diameter HH hex head
AWG American Wire Gauge DI/EO dual inlet/end outlet HHC hex head cap
AWM appliance wiring material DIN Deutsches Institut fur Normung HP horsepower
e. V. (also Deutsche Industrie hr. hour
bat. battery Normenausschuss)
BBDC before bottom dead center HS heat shrink
DIP dual inline package hsg. housing
BC battery charger, battery DPDT double-pole, double-throw
charging HVAC heating, ventilation, and air
DPST double-pole, single-throw conditioning
BCA battery charging alternator
DS disconnect switch HWT high water temperature
BCI Battery Council International
DVR digital voltage regulator Hz hertz (cycles per second)
BDC before dead center
E, emer. emergency (power source) IC integrated circuit
BHP brake horsepower
ECM electronic control module, ID inside diameter, identification
blk. black (paint color), block engine control module
(engine) IEC International Electrotechnical
EDI electronic data interchange Commission
blk. htr. block heater
EFR emergency frequency relay IEEE Institute of Electrical and
BMEP brake mean effective pressure
e.g. for example (exempli gratia) Electronics Engineers
bps bits per second
EG electronic governor IMS improved motor starting
br. brass
EGSA Electrical Generating Systems in. inch
BTDC before top dead center Association in. H2O inches of water
Btu British thermal unit EIA Electronic Industries in. Hg inches of mercury
Btu/min. British thermal units per minute Association in. lb. inch pounds
C Celsius, centigrade EI/EO end inlet/end outlet Inc. incorporated
cal. calorie EMI electromagnetic interference ind. industrial
CAN controller area network emiss. emission int. internal
CARB California Air Resources Board eng. engine int./ext. internal/external
CB circuit breaker EPA Environmental Protection I/O input/output
cc cubic centimeter Agency
IP iron pipe
CCA cold cranking amps EPS emergency power system
ISO International Organization for
ccw. counterclockwise ER emergency relay Standardization
CEC Canadian Electrical Code ES engineering special, J joule
cert. certificate, certification, certified engineered special
JIS Japanese Industry Standard
cfh cubic feet per hour ESD electrostatic discharge

TP-6349 6/07 Appendix 53

k kilo (1000) MTBO mean time between overhauls rms root mean square
K kelvin mtg. mounting rnd. round
kA kiloampere MTU Motoren-und Turbinen-Union ROM read only memory
KB kilobyte (210 bytes) MW megawatt rot. rotate, rotating
KBus Kohler communication protocol mW milliwatt rpm revolutions per minute
kg kilogram μF microfarad RS right side
kg/cm2 kilograms per square N, norm. normal (power source) RTU remote terminal unit
centimeter NA not available, not applicable RTV room temperature vulcanization
kgm kilogram-meter nat. gas natural gas RW read/write
kg/m3 kilograms per cubic meter NBS National Bureau of Standards SAE Society of Automotive
kHz kilohertz NC normally closed Engineers
kJ kilojoule NEC National Electrical Code scfm standard cubic feet per minute
km kilometer NEMA National Electrical SCR silicon controlled rectifier
kOhm, kΩ kilo-ohm Manufacturers Association s, sec. second
kPa kilopascal NFPA National Fire Protection SI Systeme international d’unites,
kph kilometers per hour Association International System of Units
kV kilovolt Nm newton meter SI/EO side in/end out
kVA kilovolt ampere NO normally open sil. silencer
kVAR kilovolt ampere reactive no., nos. number, numbers SN serial number
kW kilowatt NPS National Pipe, Straight SNMP simple network management
kWh kilowatt-hour NPSC National Pipe, Straight-coupling protocol
kWm kilowatt mechanical NPT National Standard taper pipe SPDT single-pole, double-throw
kWth kilowatt-thermal thread per general use SPST single-pole, single-throw
L liter NPTF National Pipe, Taper-Fine spec specification
LAN local area network NR not required, normal relay specs specification(s)
L x W x H length by width by height ns nanosecond sq. square
lb. pound, pounds OC overcrank sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet OD outside diameter sq. in. square inch
LCB line circuit breaker OEM original equipment SS stainless steel
manufacturer std. standard
LCD liquid crystal display
OF overfrequency stl. steel
ld. shd. load shed
opt. option, optional tach. tachometer
LED light emitting diode
OS oversize, overspeed TD time delay
Lph liters per hour
OSHA Occupational Safety and Health TDC top dead center
Lpm liters per minute Administration
LOP low oil pressure TDEC time delay engine cooldown
OV overvoltage TDEN time delay emergency to
LP liquefied petroleum oz. ounce normal
LPG liquefied petroleum gas p., pp. page, pages TDES time delay engine start
LS left side PC personal computer TDNE time delay normal to
Lwa sound power level, A weighted PCB printed circuit board emergency
LWL low water level pF picofarad TDOE time delay off to emergency
LWT low water temperature PF power factor TDON time delay off to normal
m meter, milli (1/1000) ph., ∅ phase temp. temperature
M mega (106 when used with SI PHC Phillipsr head Crimptiter term. terminal
units), male (screw) THD total harmonic distortion
m3 cubic meter PHH Phillipsr hex head (screw) TIF telephone influence factor
m3/hr. cubic meters per hour PHM pan head machine (screw) TIR total indicator reading
m3/min. cubic meters per minute PLC programmable logic control tol. tolerance
mA milliampere PMG permanent magnet generator turbo. turbocharger
man. manual pot potentiometer, potential typ. typical (same in multiple
max. maximum ppm parts per million locations)
MB megabyte (220 bytes) PROM programmable read-only UF underfrequency
MCCB molded-case circuit breaker memory UHF ultrahigh frequency
MCM one thousand circular mils psi pounds per square inch UL Underwriter’s Laboratories, Inc.
meggar megohmmeter psig pounds per square inch gauge UNC unified coarse thread (was NC)
MHz megahertz pt. pint UNF unified fine thread (was NF)
mi. mile PTC positive temperature coefficient univ. universal
mil one one-thousandth of an inch PTO power takeoff US undersize, underspeed
min. minimum, minute PVC polyvinyl chloride UV ultraviolet, undervoltage
misc. miscellaneous qt. quart, quarts V volt
MJ megajoule qty. quantity VAC volts alternating current
mJ millijoule R replacement (emergency) VAR voltampere reactive
mm millimeter power source VDC volts direct current
mOhm, mΩmilliohm rad. radiator, radius VFD vacuum fluorescent display
MOhm, MΩmegohm RAM random access memory VGA video graphics adapter
MOV metal oxide varistor RDO relay driver output VHF very high frequency
MPa megapascal ref. reference W watt
mpg miles per gallon rem. remote WCR withstand and closing rating
mph miles per hour Res/Coml Residential/Commercial w/ with
MS military standard RFI radio frequency interference w/o without
ms millisecond RH round head wt. weight
m/sec. meters per second RHM round head machine (screw) xfmr transformer
MTBF mean time between failure rly. relay

54 Appendix TP-6349 6/07

 Appendix B Common Hardware Application Guidelines

Use the information below and on the following pages to Steps for common hardware application:
identify proper fastening techniques when no specific
reference for reassembly is made. 1. Determine entry hole type: round or slotted.

Bolt/Screw Length: When bolt/screw length is not given, 2. Determine exit hole type: fixed female thread
use Figure 1 as a guide. As a general rule, a minimum (weld nut), round, or slotted.
length of one thread beyond the nut and a maximum
length of 1/2 the bolt/screw diameter beyond the nut is For round and slotted exit holes, determine if
the preferred method. hardware is greater than 1/2 inch in diameter, or
1/2 inch in diameter or less. Hardware that is
Washers and Nuts: Use split lock washers as a bolt greater than 1/2 inch in diameter takes a standard
locking device where specified. Use SAE flat washers nut and SAE washer. Hardware 1/2 inch or less in
with whiz nuts, spiralock nuts, or standard nuts and diameter can take a properly torqued whiz nut or
preloading (torque) of the bolt in all other applications. spiralock nut. See Figure 2.

See Appendix C, General Torque Specifications, and 3. Follow these SAE washer rules after determining
other torque specifications in the service literature. exit hole type:

a. Always use a washer between hardware and a

Preferred Nut/Bolt Clearance slot.
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. Cap screw
2. Entry hole types
3. Standard nut and SAE washer
4. Whiz nut or spiralock: up to 1/2 in. dia. hardware
5. Weld nuts: above 1/2 in. dia. hardware
6. Exit hole types

Figure 2 Acceptable Hardware Combinations

TP-6349 6/07 Appendix 55

Appendix C General Torque Specifications

American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel Assembled into
Torque
Torq e Aluminum
Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5
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) See Note 3
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)

Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into Cast Iron or Steel Assembled into
Aluminum
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9 Grade 5.8 or 8.8
M6 x 1.00 6.2 (4.6) 9.5 (7) 13.6 (10)
M8 x 1.25 15.0 (11) 23.0 (17) 33.0 (24)
M8 x 1.00 16.0 (11) 24.0 (18) 34.0 (25)
M10 x 1.50 30.0 (22) 45.0 (34) 65.0 (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) See Note 3
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)

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.

56 Appendix TP-6349 6/07

 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

Lock or Elastic Grade 5
with Washer

Flat Head (FHM) Square Grade 8

Grade 8/9 (Hex Socket

Round Head (RHM) Cap or Acorn
Head)
Metric
Pan Head Wing
Number stamped on 5.8
Hex Socket Head Cap or Washers hardware; 5.8 shown
Allent Head Cap
Washer Styles
Hex Socket Head or Allent
Head Shoulder Bolt Plain

Sheet Metal Screw Split Lock or Spring

Stud Spring or Wave

Drive Styles
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) Plain Washers
1/4-20 x 1 9/32 x 5/8 x 1/16
Length In Inches (Screws and Bolts) 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 Lock Washers
Length In Millimeters (Screws and Bolts) 5/8
Distance Between Threads In Millimeters Internal Dimension
Major Thread Diameter In Millimeters

TP-6349 6/07 Appendix 57

 Notes

58 Appendix TP-6349 6/07

 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
Kohler Power Systems
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TP-6349 6/07b 7 Jurong Pier Road
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