Operation and Service Commercial Generator Sets Models: COM5 TP-6482 8/06
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. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 5.4 Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 Governor Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 Stepper Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS. This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment.
Hazardous Noise CAUTION Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.
Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set. Notice NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.
Introduction This manual provides operation, troubleshooting, and repair instructions for model Alpha 5 and COM5 generator sets and controllers. The generator sets use a Kohlerr CV-14 engine with modified ignition, governor, and fuel systems. Refer to the engine service manual for engine information not covered in this manual. Information in this publication represents data available at the time of print. Kohler Co.
Maintenance and Service Parts Figure 1 lists some routine maintenance and service parts for your generator set. Parts Catalog TP-6091 provides a complete list of replacement parts.
Section 1 Specifications 1.1 System Description 1.3 Specifications The COM5 generator set provides reliable backup DC power to cable TV systems or telecommunication sites in place of, or in addition to, batteries. The COM5 is available in 36 and 48 VDC models. The generator set nameplate indicates the unit’s rated voltage. Figure 1-1, Figure 1-2, and Figure 1-3 contain generator set, alternator, and engine specifications. Refer to Section 3, Scheduled Maintenance, for service details.
Item Specification Manufacturer Kohler Make/model CV14 Cycle 4 Compression ratio 8.5:1 Displacement, cc (cu. in.) 398 (24.3) Rated horsepower (using natural gas fuel), HP 10.5 Engine speed, rpm 2800--3600 Overspeed shutdown, rpm 3750 Bore, mm (in.) 87 (3.43) Stroke, mm (in.) 67 (2.64) Valve train Overhead Valve Valve material: Intake Steel Exhaust Stelliter Face Cylinders, qty.
1.4 Service Views 12 4 3 1 2 11 5 6 21 13 20 + 7 -- 14 8 15 G LP 16 NG 17 9 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 18 Left Side View Decal, engine serial number Decal, emission Engine interface connector Engine starting battery connector Ignition module Engine oil fill and dipstick Ignition coil Spark plug (not visible) Fuel supply connection (3/4 in.
1 2 3 4 9 5 6 10 11 12 7 8 Left Side View 15 14 13 Front View 16 17 18 23 22 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Section 2 Operation WARNING Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher.
2.3 Controller Operation 1 Microprocessor-based controls provide complete control of the engine and generator. The control system accepts remote control inputs for generator start and run and delivers local and remote annunciation of unit status. Internal functions of the controls include start and stop logic, fault monitoring, generator voltage and engine speed governing, and fault annunciation through local LEDs.
GM14245-A Figure 2-4 Cabinet Interface Harness Connectors Abbreviation Definition 70 Run 71 Crank AC1 Speed sensing AC2 Speed sensing DCN DC negative DCP DC positive LOP Low oil pressure M1 Throttle control M2 Throttle control M3 Throttle control M4 Throttle control N Ground N/C Not connected OVC Overcrank OVS Overspeed OVT Overtemperature P Positive STP Stop STT Start Figure 2-5 TP-6482 8/06 Pin Abbreviations Section 2 Operation 17
GM14244-B Figure 2-6 2.3.2 Engine Interface Harness Connectors Remote Start/Stop Connections To operate the generator set from a remote location, use a three-wire start/stop switch connected to pins 5, 6, and 7 of connector P6 on the cabinet interface harness. See the wiring diagrams in Section 8. Set the generator set master switch to the AUTO position for remote operation. To start the generator set, open a contact between pins 6 and 7 and close a contact between pins 5 and 6 of connector P6.
2.3.4 Stopping Generator Set LED The following procedures describe the actions required to stop the generator set. Local Stopping. Move the generator set master switch to the STOP position. The generator set stops immediately. Remote Stopping. Close a remote contact between pins 6 and 7 of connector P6 of the cabinet interface harness. The generator set shuts down regardless of the generator set master switch position.
2.3.6 Fault Shutdowns The generator set shuts down automatically under the fault conditions listed in Figure 2-9 and cannot be restarted until the controls are reset. Reset the controller by placing either the remote control switch or the generator set master switch in the STOP position. The high engine temperature fault automatically resets when the generator set cools. Fault Description High engine Shuts down 5 seconds after the fault.
Section 3 Scheduled Maintenance WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death.
Tools. Tools and instruments used to perform some maintenance are not generally available to the generator set owner. It is recommended that service requiring special tools be performed by an authorized distributor/dealer. 3.2 Service Schedule Perform the service listed in Figure 3-1 at the designated intervals for the life of the generator set. Refer to the service views in Section 1.4 for system component locations. Procedure System Component or Procedure Fuel Inspect flexible lines and connections.
3.3 Service Access Use the following procedure to gain access to the generator set for maintenance or service. See Figure 3-2 and Figure 3-3. A key is required to open the enclosure. Obtain the enclosure key from the equipment owner. Use the following procedure to gain access to the generator set for maintenance or service. See Figure 3-3. Refer to the enclosure manufacturer’s instruction manual for more information. Note: Allow the exhaust system to cool before disconnecting the exhaust pipe.
Return to Operation Slide the generator set back into the enclosure and reconnect the exhaust pipe, fuel system, and wiring harnesses as described below. 1. Verify that the generator set master switch is in the STOP position. 2. Slide the generator set back into the enclosure. 3. Install the exhaust gasket and reconnect the exhaust pipe. 4. Reinstall the enclosure back panel. 10. Reinstall the generator set compartment front panel. 11. Reinstall the enclosure door. 3.
3 1 M-337000B-B 5 2 1. Oil check, fill 2. Exhaust pipe connection 3. Oil cooler Figure 3-5 3.4.2 4. Oil filter 5. Oil drain Lubrication System, Specification Numbers GM14140-GA1 and above Engine Oil Recommendation Kohler Co. recommends API (American Petroleum Institute) Service Class SG, SH, or SJ 5W-30 synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves fewer deposits on the engine intake valves and pistons. 3.4.
6. Check for leaks. a. Start and run the generator set to allow the oil pressure to reach the operating range. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. 1 b. Check for oil leaks around the oil filter and oil drain plug. c. Stop the generator set and recheck the oil level. Tighten the oil filter to stop any leaks. Add oil to bring the level up to the F mark on the dipstick. 2 7.
2. Loosen the cover retaining knob and remove the cover. Remove the precleaner from the paper element. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry. 3. Saturate the precleaner with new engine oil. Squeeze out all of the excess oil. 7. Replace all damaged air cleaner components. Check the condition of the rubber seals and replace, if necessary. 8.
The manufacturer ships the generator set with the fuel system set for natural gas. To convert to LP gas, use the following procedure to move the fuel line from the natural gas inlet port to the LP inlet port in the fuel block (or from the LP inlet to the natural gas inlet to convert from LP to natural gas). See Figure 3-7 for the LP and natural gas fuel connection and fuel block locations. Also see the service views in Section 1.4. 1 7.
Refer to the cabinet manufacturer’s operation and maintenance manual for battery maintenance instructions. 3.8 Ignition System 3.8.1 Ignition System Description The generator set uses a battery-powered coil ignition system. Ignition system components include the ignition module, ignition coil, wiring, and spark plug. See the service views in Section 1.4 for ignition system component locations. Maintain the spark plug using the instructions in Section 3.8.2.
3.10 Electronic Governor The governor system consists of an electronic governor control and an electromechanical actuator. The system regulates engine speed to achieve specified DC output voltage. The generator supplies a speed signal to the governor control unit in the form of AC electrical pulses. The control unit compares the frequency of these pulses to a preset reference in the speed command and provides a control signal to the actuator. The actuator controls the carburetor and hence the engine speed.
Section 4 General Troubleshooting This section contains generator set troubleshooting and diagnostic information. Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery or loose connections. The generator set may be connected to a customersupplied remote control system. Disconnect the generator system from the remote control system at plug P6 and use the generator set master switch to operate the generator set.
WARNING Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. 4.1 Troubleshooting Chart The chart includes a list of common problems, possible causes, and recommended corrective actions.
Troubleshooting Chart (continued) Problem Possible Cause Corrective Action Reference Unit cranks but does not start, t t continued ti d Faulty spark plug Replace or regap spark plugs. Section 3.8.2 Loose spark plug wire connection Reconnect and/or tighten spark plug wire. Ignition system problem Test ignition system. Replace ignition module if faulty. Sections 6.5.4 and 5.5 Weak or dead battery Recharge or replace battery. Section 3.
4.2 Generator Set/Controller System Troubleshooting Flowcharts Move master switch to STOP position to reset controller faults. Unplug cabinet interface connector (P6) to disconnect remote control system. Does engine crank? Move master switch to RUN position. Yes Does engine start? No Go to A Yes No Connect the battery. Does unit stop while master switch is still in AUTO? Is the battery connected? No No Generator set is okay.
A Is fuel supply turned on? Yes Is fuel supply low? Check/replenish fuel supply. Yes No No Turn on fuel supply. Is gas pressure to system within specifications? No Have gas provider or owner correct fuel pressure problem. No Have the fuel supply installer purge the fuel lines. No Check/repair wiring.
B Does unit lack power or operate erratically? No Does unit stop while master switch is in AUTO and remote control system is disconnected? Yes Disconnect and reconnect the harness to verify a good connection. Repair/replace harness.
Lacks Power or Runs Erratically C Ensure that the main connector is tightly connected. Is any controller fault LED lit? Has air been purged from fuel lines? No Is fuel pressure 7-11 in. water? Have fuel supply installer correct fuel pressure problem. No Yes No Yes Correct fault and resume troubleshooting. Yes Are spark plug wire connections okay? Have fuel supply installer purge air. No Reconnect and/or tighten. Yes Are spark plugs okay? See Section 3.8.2. Regap or replace.
Lacks Power or Runs Erratically, continued D Is fuel solenoid and wiring okay? No Repair/replace faulty components. No Replace pressure regulator. No Adjust fuel metering valve.* Yes Is fuel pressure regulator okay? Verify that output pressure to engine is at zero—the engine must draw gas from regulator. Yes Check the fuel adjustment using an oxygen sensor. See Section 5.7. Is the fuel adjustment correct? Yes Test the ignition system. See Section 5.5.
Unit Stops After Normal Operation E Possible intermittent wiring problem or control board malfunction. Check all wiring and components. Start the unit. Does it stop after normal operation? Yes Is controller fault LED lit? No Done. Correct the fault and reset the controller. Yes No Are alternator output leads connected to AC terminals on the rectifier? No Connect/repair/replace alternator output leads. Yes Is air cleaner plugged? Yes Clean/replace air cleaner elements.
Notes 40 Section 4 General Troubleshooting TP-6482 8/06
Section 5 Component Testing and Adjustment Use the troubleshooting procedures in Section 4 and the wiring diagrams in Section 8 to diagnose problems with the generator set operation. For controller operation and test, refer to Section 6 of this manual and to the remote control manual. Use the procedures in this section to check generator components for proper operation and adjust components when necessary. See the service views in Section 1.4 for component locations. DANGER Hazardous voltage.
D Attach the exhaust pipe extension to the silencer. Verify that the test port is plugged or install the oxygen sensor in the port if needed for fuel adjustments. See Figure 5-1. D Connect a starting battery to the terminals shown in Figure 5-2. Connect the negative lead last. 5.1.2 Lifting Generator Set The generator set weighs approximately 68 kg (150 lb.). Use adequately rated equipment to lift the generator set. The generator set has two lifting eyes.
5.2 Circuit Protection A fuse on the output (DC) side of the voltage rectifier interrupts the generator output in the event of a 50% overload or a short circuit in the wiring between the generator and the load. See Figure 5-5. Replace the fuse if it blows. See Maintenance and Service Parts in the Introduction of this manual for the fuse part number. 1 2 The microprocessor controller monitors the DC output voltage.
below 8 volts DC making the control unit function erratically. D Check for stepper motor/throttle shaft linkage binding or wear. The linkage arm and lever arms must not bind or rub against other components while moving. D Verify that the governor stepper motor operates with steady and smooth movement. If the movement of the stepper motor is erratic or large changes in movement occur, check for shaft misalignment, linkage binding, or loose or broken wiring or plug connections.
3. Reconnect the battery. The stepper motor should move clockwise to the closed-throttle position with a noticeable clicking sound. If the stepper motor does not stay in the closed-throttle position, replace the stepper motor. Check the continuity of the spark plug lead. Check the condition of the lead insulation and spark plug boot. Refer to Section 3.8.2 for additional spark plug information. Figure 5-12 shows some ignition specifications.
Use a feeler gauge to check gap between ignition trigger coil and flywheel. See Figure 5-14 and Figure 5-15. Verify that the gap is set to 1.02 mm (0.040 in.). Note: The ignition module must be matched with the appropriate trigger coil. See Section 5.5.1 for information. 1 2 1 3 TP6092 1. Ignition trigger Figure 5-14 Ignition Trigger GM14140B-V 1. Ground connection 2. Ignition module 3.
5.5.3 Ignition Coil 5.6 Starter Use an ohmmeter or a test lamp to check the ignition coil primary winding. Measure the resistance across the positive (+) and negative (--) terminals and from one terminal to ground. If the test shows that the winding is open or grounded, replace the ignition coil. Check the starter if the generator set engine does not crank. Check the battery voltage and connections before proceeding. Check for a locked rotor or other fault condition that may have shut down the unit.
Move the generator set master switch to Start and check for 12 VDC to the starter relay on lead 71 during the crank attempt. See Figure 5-19. If there is no voltage to the starter during the crank cycle, check the connections. Then check for voltage from the controller at J4-1 and P2-1 (see the wiring diagram, Section 8). If there is no voltage at P2-1 during cranking, replace the control board.
5.7.1 Checking the Fuel Pressure Fuel Regulators Use a gauge or manometer to check the fuel pressure at the secondary regulator inlet. See Figure 5-20. Measure the fuel pressure with the generator set running at full load. The fuel pressure should be 178--280 mm (7--11 in. water column) or 1.7--2.7 kPa (4--6 oz./in.2). Contact the fuel supplier if the inlet pressure is not within the specified range. The typical gaseous fuel system uses two regulators.
5.7.2 Fuel Conversion Procedure Fuel Solenoid Valve The fuel solenoid valve is located on the outside of the enclosure. It is a 12 VDC valve energized by lead 70 when the generator set controller is in the crank or the run mode. The fuel solenoid valve is supplied with the enclosure. 1. Remove the enclosure front door and the generator compartment front panel to access the fuel system. 2. Move the generator set master switch to the STOP position. 1 2 tp6092 3 Figure 5-21 Fuel Solenoid Valve 5.7.
8. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant, and install it into the LP (or natural gas) inlet. 1 9. Slide the hose onto the hose fitting and secure it with the clamp. 10. Turn on the fuel supply and check for leaks using a gas leak detector. 2 11. Reconnect the battery harness. 12. Install the generator compartment front panel. Set the generator set master switch to the AUTO or center position to return the generator set to standby service. 13.
Stator Test Procedure 5.8 Alternator The alternator is connected directly to the engine. The alternator uses a permanent magnet rotor and a 3-lead 3-phase stator. See Figure 5-25. 1 2 3 4 1. Disconnect the power to the battery charger, if equipped. 2. Disconnect the generator set engine starting battery, negative (--) lead first. 3. Disconnect output connector P8 from the load. See Figure 5-27. 4. Disconnect the stator leads from the voltage rectifier. See Figure 5-27.
6. Check the cold resistance of the stator windings by connecting the meter leads to stator leads 1 and 2, 1 and 3, and 2 and 3. See Figure 5-28 for stator winding resistance values. Replace the stator if any of the resistance checks reveal an open winding. If the resistance test is not conclusive, perform a megohmmeter test on the stator as described in step 7. Note: Most ohmmeters do not measure very small resistance values accurately. Check for continuity of the windings with no shorts to ground.
Notes 54 Section 5 Component Testing and Adjustment TP-6482 8/06
Section 6 Controller Operation and Test This section describes troubleshooting procedures for the generator set control board, shown in Figure 6-1. Refer to the operation manual for operating instructions. Refer to the remote controller manufacturer’s instructions for troubleshooting and servicing remote controllers connected to the generator set. generator set master switch in the AUTO position, momentarily closing contacts P6-5 and P6-6 starts the generator set remotely.
6.2 Control Connections Wiring harnesses connect the generator set control board to the system remote controls and the engine. Figure 6-2 shows the wiring harness connections to the control board. See the wiring diagrams in Section 8 for pinouts and connection details. Figure 6-3 defines the abbreviations used in the wiring diagrams. P6 P1 P1 J4 P2 P2 P5 P3 P3 P1 6.2.3 R37 3 M-337000C-B 1. Generator set to remote control system interface harness, GM14245 2.
Fault Description Fault Condition/Possible Cause High engine temperature Shuts down 5 seconds after the fault. When the engine cools, the fault clears and allows the generator set to be started without resetting the controller. The high engine temperature shutdown is inhibited (does not function) during the first 30 seconds after startup. D Engine reaches shutdown Shuts down 5 seconds after the fault. The low oil pressure shutdown does not function during the first 30 seconds after startup.
WARNING Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set. Short circuits.
6.5 Control Board Tests Use the troubleshooting procedures in Section 4 to diagnose generator set and engine problems. If the troubleshooting procedures indicate a problem with the controller circuit board, use the tests in this section to check the board. Refer to the wiring diagrams in Section 8 when troubleshooting the generator set control circuit board.
6.5.4 Ignition Circuits 6.7 Control Board Replacement Move the generator set master switch to the START position. If the engine cranks but does not start, check for voltage from lead 70 to ground at terminal B on the ignition module and at the positive terminal of the ignition coil. If no voltage is present during cranking, replace the controller circuit board. If the ignition system is receiving 12 VDC, check the spark plug and test the other ignition system components. 6.
7. Install the control board and connect all connectors removed in step 5. 8. Verify board mounting and connections and then close the enclosure. 9. Check that the generator set master switch is in the OFF position. 10. Reconnect the generator set engine starting battery, negative (--) lead last. 11. Reconnect power to the battery charger, if equipped. Calibration Procedure Use the following procedure to calibrate the voltage. 1. Connect a voltmeter to the output terminals of the voltage rectifier. 2.
Notes 62 Section 6 Controller Operation and Test TP-6482 8/06
Section 7 Disassembly/Reassembly Before disassembly, remove the generator set from any enclosure. Refer to Section 3.3 for instructions. Disconnect the battery (negative [--] lead first), fuel line, exhaust system, remote start switch, load leads, and other wiring harnesses. In addition to the precautions included in the text, observe all safety precautions listed at the beginning of this manual during the disassembly/reassembly procedure. 7.1 Disassembly Procedure 1. Follow the instructions in Section 3.
3. Note the three stator lead connections to the voltage rectifier for reconnection later. Disconnect the stator leads from the voltage rectifier. See Figure 7-2. 1 2 3 + -- 1 2 + -- LP NG 1. 2. 3. 4. 3 Figure 7-3 1 TP--6092 4 Scroll Fan Fan screw (3 ea.) Stator Alternator with Fan 2 3 4 5 6 7 8 9 M-337000A-H 12 3 M--337000B-H 1. Output connector 2. Stator leads 3. Exhaust connection Figure 7-2 Generator Set 4. Disassemble the fan and alternator. Figure 7-3 and Figure 7-4.
d. Remove the three screws securing the spacer and rotor to the flywheel. Remove the spacer and the rotor. See Figure 7-5. 1 2 c. Use three 63.5 mm (3/8-16 x 2.5 in.) hex head screws to secure the spacer and rotor to the flywheel. See Figure 7-5. Do not tighten the screws. d. Place the stator in position as shown in Figure 7-6. Feed the stator leads through the opening in the alternator scroll. 1 2 5 1. 2. 3. 4. 5.
5. Follow the instructions in Section 3.3 to install the generator set in the cabinet. 1 2 3 4 6. Reconnect the generator set components. a. Reconnect the exhaust pipes at the lower left side of the generator set. 5 b. Reconnect the fuel line. c. Reconnect the wiring harnesses. d. Reconnect the engine starting battery, negative (--) lead last. TP--6092 1. 2. 3. 4. 5.
Section 8 Diagrams and Drawings Specification Numbers Drawing Description Drawing Number PA-195023,, PA-195027 Wiring Diagram GM11880-C Figure 8-1 Schematic ADV-6536-C Figure 8-2 Wiring Diagram GM14258-B Figure 8-3 GM14140-GA1, GM14140-GA2, GM14140-GA3, GM14140-GA4, GM14140-GA5, GM14140-GA6, GM14140-GA7, GM14140-GA8, GM14140-GA9, GM14140-GA10, GM14140-GA11 TP-6482 8/06 Figure Section 8 Diagrams and Drawings 67
Figure 8-1 68 Wiring Diagram, GM11880-C Section 8 Diagrams and Drawings TP-6482 8/06
Figure 8-2 TP-6482 8/06 Schematic Diagram, ADV-6536-C Section 8 Diagrams and Drawings 69
Figure 8-3 70 Wiring Diagram, GM14258-B Section 8 Diagrams and Drawings TP-6482 8/06
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV AHWT AISI ALOP alt. Al ANSI AO API approx. AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. A/V avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CARB CB cc CCA ccw. CEC cert.
kA KB kg kg/cm2 kiloampere kilobyte (210 bytes) kilogram kilograms per square centimeter kgm kilogram-meter kilograms per cubic meter kg/m3 kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb.
Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/Screw Length: When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method. Steps for common hardware application: 1.
Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Aluminum Grade 2 or 5 Assembled into Cast Iron or Steel Torque Torq e Measurement Size Grade 2 Grade 5 Grade 8 8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) — 10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) — 10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) 1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 (132) 1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144) 5/16-18 Nm (in. lb.) 13.
Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head with Washer Lock or Elastic Grade 5 Flat Head (FHM) Square Grade 8 Round Head (RHM) Cap or Acorn Grade 8/9 (Hex Socket Head) Pan Head Wing Hex Socket Head Cap or Allent Head Cap Washers Metric Number stamped on hardware; 5.8 shown 5.
Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Hex Head Bolts (Grade 5) Part No. Dimensions Hex Head Bolts, cont. Part No. X-465-17 X-465-6 X-465-2 X-465-16 X-465-18 X-465-7 X-465-8 X-465-9 X-465-10 X-465-11 X-465-12 X-465-14 X-465-21 X-465-25 X-465-20 1/4-20 x .38 1/4-20 x .50 1/4-20 x .62 1/4-20 x .75 1/4-20 x .88 1/4-20 x 1.00 1/4-20 x 1.25 1/4-20 x 1.50 1/4-20 x 1.75 1/4-20 x 2.
Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Hex Head Bolts (Partial Thread) M931-05055-60 M931-06040-60 M931-06055-60 M931-06060-60 M931-06060-SS M931-06070-60 M931-06070-SS M931-06075-60 M931-06090-60 M931-06145-60 M931-06150-60 M5-0.80 x 55 M6-1.00 x 40 M6-1.00 x 55 M6-1.00 x 60 M6-1.00 x 60 M6-1.00 x 70 M6-1.00 x 70 M6-1.00 x 75 M6-1.00 x 90 M6-1.00 x 145 M6-1.
Metric, continued Part No. Hex Nuts Dimensions Type M934-03-50 M3-0.50 Standard M934-04-50 M934-04-B M4-0.70 M4-0.70 Standard Brass M934-05-50 M5-0.80 Standard M934-06-60 M934-06-64 M6923-06-80 M982-06-80 M6-1.00 M6-1.00 M6-1.00 M6-1.00 Standard Std. (green) Spiralock Elastic Stop M934-08-60 M6923-08-80 M982-08-80 M8-1.25 M8-1.25 M8-1.25 Standard Spiralock Elastic Stop M934-10-60 M934-10-60F M6923-10-80 M6923-10-62 M982-10-80 M10-1.50 M10-1.25 M10-1.50 M10-1.50 M10-1.
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 KohlerPowerSystems.com TP-6482 8/06 E 2006 by Kohler Co. All rights reserved.
