Service: Residential/Commercial Generator Sets

Service
Residential/Commercial Generator Sets
Models:
15/30RYG
15/30RES
Controller:
Advanced Digital Control
TP-6198 10/04a
Table of Contents
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Generator Set Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7 Service View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 2 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.1 Cleaning Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.2 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Section 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Section 4 Controller ....................................................................... 27
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Controller Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3 Master Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4.1 Starting Sequence, Master Switch Moved to RUN . . . . . . . . . . . . . . . . . 29
4.4.2 Starting Sequence, Remote Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4.3 Running Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4.4 Stopping Sequence, Master Switch Moved to OFF/RESET . . . . . . . . . . 29
4.4.5 Stopping Sequence, Remote Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5.2 Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.6 Relay Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.7 Silicon Controlled Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.8 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.9 Controller Configuration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.9.1 Voltage Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.9.2 Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.10 Continuous Power Mode Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
TP-6198 10/04 Table of Contents

Table of Contents, continued
Section 5 Component Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.4 Main Field (Rotor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.5 Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.6 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.7 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.7.1 Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.7.2 Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.8 Voltage Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.9 Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.10 Fault Shutdown Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.10.1 Controller Fault Shutdown Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.10.2 Fault Shutdown Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.11 Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.11.1 Fuel Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.11.2 Fuel Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.11.3 Fuel Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.12 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.13 Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Section 6 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1 Specification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2 Wiring Diagram Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Appendix E Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table of Contents TP-6198 10/04

Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and WARNING
accessories, 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 working on the generator set.
safety precautions and instructions: explosive fumes.
Remove the negative (--) lead first
Danger, 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 severe injury or death. Battery
DANGER acid can cause blindness and burn
Disabling the generator set. skin. Always wear splashproof safety
Accidental starting can cause goggles, rubber gloves, and boots
Danger indicates the presence of a severe injury or death. Before when servicing the battery. Do not
hazard that will cause severe working on the generator set or open a sealed battery or mutilate the
personal injury, death, or connected equipment, disable the battery case. If battery acid splashes in
substantial property damage. 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
position. (2) Disconnect the power to with large quantities of clean water.
WARNING the battery charger. (3) Remove the Seek immediate medical aid in the
battery cables, negative (--) lead first. case of eye contact. Never add acid to
Reconnect the negative (--) lead last a battery after placing the battery in
Warning indicates the presence of a when reconnecting the battery. Follow service, as this may result in
hazard that can cause severe these precautions to prevent starting of hazardous spattering of battery acid.
personal injury, death, or the generator set by an automatic
substantial property damage. transfer switch, remote start/stop Battery acid cleanup. Battery acid
switch, or engine start command from a can cause severe injury or death.
remote computer. Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
CAUTION bicarbonate of soda (baking soda) to a
Battery container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
Caution indicates the presence of a neutralizing solution on the spilled
hazard that will or can cause minor battery acid and continue to add the
personal injury or property damage. WARNING neutralizing solution to the spilled
battery acid until all evidence of a
NOTICE chemical reaction (foaming) has
Notice communicates installation, ceased. Flush the resulting liquid with
operation, or maintenance information water and dry the area.
that is safety related but not hazard
related.
Sulfuric acid in batteries.
Safety decals affixed to the equipment Can cause severe injury or death.
in prominent places alert the operator
Wear protective goggles and
or service technician to potential
clothing. Battery acid may cause
hazards and explain how to act safely.
blindness and burn skin.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
TP-6198 10/04 Safety Precautions and Instructions 5

Battery gases. Explosion can cause Engine Backfire/Flash Engine Fluids and
severe injury or death. Battery gases
can cause an explosion. Do not smoke Fire Chemical Products
or permit flames or sparks to occur
near a battery at any time, particularly WARNING WARNING
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 Fire.
the equipment. Discharge static Can cause severe injury or death. Handling caustic engine fluids and
electricity from your body before chemical products.
touching batteries by first touching a Do not smoke or permit flames or Can cause severe chemical burns,
grounded metal surface away from the sparks near fuels or the fuel system. nausea, fainting, or death.
battery. To avoid sparks, do not disturb Most chemicals such as used engine
the battery charger connections while Servicing the fuel system. A flash oil, antifreeze/coolant, rustproofing
the battery is charging. Always turn the fire can cause severe injury or agent, inhibiting oil, degreasing
battery charger off before death. Do not smoke or permit flames agent, spray paint, and adhesives
disconnecting the battery connections. or sparks near the carburetor, fuel line, are hazardous to health. Read and
Ventilate the compartments containing fuel filter, fuel pump, or other potential follow the user information found on
batteries to prevent accumulation of sources of spilled fuels or fuel vapors. the packaging. Avoid inhalation and
explosive gases. Catch fuels in an approved container skin contact. Use only in
when removing the fuel line or well-ventilated areas and use a pro-
Battery short circuits. Explosion carburetor.
can cause severe injury or death. tective mask when spraying. Store
Short circuits can cause bodily injury Servicing the air cleaner. A sudden engine fluids and chemical products
and/or equipment damage. backfire can cause severe injury or in a locked cabinet. Contact your lo-
Disconnect the battery before death. Do not operate the generator cal recycling center for disposal infor-
generator set installation or set with the air cleaner removed. mation and locations.
maintenance. Remove all jewelry
before servicing the equipment. Use Combustible materials. A fire can
tools with insulated handles. Remove cause severe injury or death. WARNING
the negative (--) lead first when Generator set engine fuels and fuel
disconnecting the battery. Reconnect vapors are flammable and explosive.
the negative (--) lead last when Handle these materials carefully to
reconnecting the battery. Never minimize the risk of fire or explosion.
connect the negative (--) battery cable Equip the compartment or nearby area
to the positive (+) connection terminal with a fully charged fire extinguisher. Flammable engine solvents and
of the starter solenoid. Do not test the Select a fire extinguisher rated ABC or cleaners.
BC for electrical fires or as Can cause severe injury or death.
battery condition by shorting the
terminals together. recommended by the local fire code or
an authorized agency. Train all Do not smoke or permit flames or
personnel on fire extinguisher sparks near flammable engine
operation and fire prevention solvents and cleaners. Read and
procedures. follow the user information found on
the packaging. Use only in well-
ventilated areas. Never use gasoline
or low flash-point solvents as
cleaning agents.
Leaking or accumulated engine

fluids. A fire can cause severe injury
or death. Clean up engine fluids
including fuel, oil, grease, and coolant.
Determine the source of engine leaks
and correct before starting the
generator set. Keep the generator set
area clean and remove combustible
materials.
6 Safety Precautions and Instructions TP-6198 10/04

Used engine oil. Contact with used Carbon monoxide symptoms. The fuel system. Explosive fuel
engine oil may cause severe skin Carbon monoxide can cause severe vapors can cause severe injury or
irritation. Repeated and prolonged nausea, fainting, or death. Carbon death. Vaporized fuels are highly
skin exposure may have other monoxide is a poisonous gas present explosive. Use extreme care when
health risks. Used engine oil is a in exhaust gases. Carbon monoxide is handling and storing fuels. Store fuels
suspected carcinogen. Avoid contact an odorless, colorless, tasteless, in a well-ventilated area away from
with skin. Thoroughly wash your nonirritating gas that can cause death if spark-producing equipment and out of
hands and nails with soap and water inhaled for even a short time. Carbon the reach of children. Never add fuel to
shortly after handling used engine oil. monoxide poisoning symptoms the tank while the engine is running
Wash or dispose of clothing or rags include but are not limited to the because spilled fuel may ignite on
containing used engine oil. Dispose of following: contact with hot parts or from sparks.
used engine oil in a responsible D Light-headedness, dizziness Do not smoke or permit flames or
manner. Contact your local recycling D Physical fatigue, weakness in sparks to occur near sources of spilled
center for disposal information and joints and muscles fuel or fuel vapors. Keep the fuel lines
locations. D Sleepiness, mental fatigue, and connections tight and in good
inability to concentrate condition. Do not replace flexible fuel
Fire-damaged or burned O-rings or speak clearly, blurred vision lines with rigid lines. Use flexible
may cause the formation of D Stomachache, vomiting, nausea sections to avoid fuel line breakage
hydrofluoric acid. Contact with If experiencing any of these symptoms caused by vibration. Do not operate
hydrofluoric acid may cause severe and carbon monoxide poisoning is the generator set in the presence of
skin irritation and chemical burns. possible, seek fresh air immediately fuel leaks, fuel accumulation, or
O-rings and other fluoroelastomer and remain active. Do not sit, lie down, sparks. Repair fuel systems before
seals exposed to fire or temperatures or fall asleep. Alert others to the resuming generator set operation.
above 316_C (600_F) (i.e., during possibility of carbon monoxide
welding) may decompose forming poisoning. Seek medical attention if Explosive fuel vapors can cause
hydrofluoric acid. Avoid inhalation or the condition of affected persons does severe injury or death. Take
skin contact. Do not incinerate not improve within minutes of breathing additional precautions when using the
O-rings. Dispose of O-ring waste fresh air. following fuels:
material in a responsible manner.
Carbon monoxide detectors. Propane (LP)—Adequate ventilation
Carbon monoxide can cause severe is mandatory. Because propane is
heavier than air, install propane gas
Exhaust System nausea, fainting, or death. Install
detectors low in a room. Inspect the
carbon monoxide detectors on each
detectors per the manufacturer’s
WARNING level of the building. Locate the instructions.
detectors to adequately warn the
building’s occupants of the presence of Natural Gas—Adequate ventilation is
carbon monoxide. Keep the detectors mandatory. Because natural gas rises,
operational at all times. Periodically install natural gas detectors high in a
test and replace the carbon monoxide room. Inspect the detectors per the
detectors according to the manufacturer’s instructions.
Carbon monoxide.
Can cause severe nausea, manufacturer’s instructions. Gas fuel leaks. Explosive fuel
fainting, or death. vapors can cause severe injury or
death. Fuel leakage can cause an
The exhaust system must be Fuel System explosion. Check the LP vapor gas or
leakproof and routinely inspected. natural gas fuel system for leakage by
using a soap and water solution with
Carbon monoxide detectors. WARNING the fuel system test pressurized to
Carbon monoxide can cause severe 6--8 ounces per square inch
nausea, fainting, or death. Install (10--14 inches water column). Do not
carbon monoxide detectors on each use a soap solution containing either
level of the building. Locate the ammonia or chlorine because both
detectors to adequately warn the prevent bubble formation. A
building’s occupants of the presence of successful test depends on the ability
Explosive fuel vapors. of the solution to bubble.
carbon monoxide. Keep the detectors Can cause severe injury or death.
operational at all times. Periodically
test and replace the carbon monoxide Use extreme care when handling,
detectors according to the storing, and using fuels.
manufacturer’s instructions.

LP liquid withdrawal fuel leaks.
Explosive fuel vapors can cause WARNING CAUTION
severe injury or death. Fuel leakage
can cause an explosion. Check the LP
liquid withdrawal gas fuel system for
leakage by using a soap and water
solution with the fuel system test
pressurized to at least 90 psi Hazardous voltage. Moving parts.
Can cause severe injury or death. Welding the generator set.
(621 kPa). Do not use a soap solution
Can cause severe electrical
containing either ammonia or chlorine Operate the generator set only when equipment damage.
because both prevent bubble all guards and electrical enclosures
formation. A successful test depends are in place. Never weld components of the
on the ability of the solution to bubble. generator set without first
disconnecting the battery, controller
WARNING wiring harness, and engine
Hazardous Noise electronic control module (ECM).
CAUTION Grounding electrical equipment.

Hazardous voltage can cause
severe injury or death. Electrocution
Hazardous voltage. is possible whenever electricity is
Backfeed to the utility system can present. Ensure you comply with all
cause property damage, severe applicable codes and standards.
injury, or death. Electrically ground the generator set,
Hazardous noise. transfer switch, and related equipment
Can cause hearing loss. If the generator set is used for and electrical circuits. Turn off the
standby power, install an automatic main circuit breakers of all power
Never operate the generator set transfer switch to prevent inadvertent sources before servicing the
without a muffler or with a faulty interconnection of standby and equipment. Never contact electrical
exhaust system. normal sources of supply. leads or appliances when standing in
water or on wet ground because these
Engine noise. Hazardous noise can conditions increase the risk of
cause hearing loss. Generator sets electrocution.
not equipped with sound enclosures
can produce noise levels greater than Disconnecting the electrical load.
105 dBA. Prolonged exposure to Hazardous voltage can cause
noise levels greater than 85 dBA can severe injury or death. Disconnect
cause permanent hearing loss. Wear the generator set from the load by
hearing protection when near an turning off the line circuit breaker or by
operating generator set. disconnecting the generator set output
leads from the transfer switch and
heavily taping the ends of the leads.
Hazardous Voltage/ High voltage transferred to the load
during testing may cause personal
Moving Parts injury and equipment damage. Do not
use the safeguard circuit breaker in
DANGER place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

Welding on the generator set. Can Engine block heater. Hazardous Heavy Equipment
cause severe electrical equipment voltage can cause severe injury or
damage. Before welding on the death. The engine block heater can
generator set perform the following cause electrical shock. Remove the WARNING
steps: (1) Remove the battery cables, engine block heater plug from the
negative (--) lead first. (2) Disconnect electrical outlet before working on the
all engine electronic control module block heater electrical connections.
(ECM) connectors. (3) Disconnect all
generator set controller and voltage Electrical backfeed to the utility.
regulator circuit board connectors. Hazardous backfeed voltage can
(4) Disconnect the engine battery- cause severe injury or death. Install
Unbalanced weight.
charging alternator connections. a transfer switch in standby power
installations to prevent the connection Improper lifting can cause severe
(5) Attach the weld ground connection injury or death and equipment
close to the weld location. of standby and other sources of power.
Electrical backfeed into a utility damage.
Installing the battery charger. electrical system can cause severe Do not use lifting eyes.
Hazardous voltage can cause injury or death to utility personnel Lift the generator set using lifting bars
severe injury or death. An working on power lines. inserted through the lifting holes on
ungrounded battery charger may the skid.
cause electrical shock. Connect the WARNING
battery charger enclosure to the
ground of a permanent wiring system.
As an alternative, install an equipment Hot Parts
grounding conductor with circuit
conductors and connect it to the
equipment grounding terminal or the WARNING
lead on the battery charger. Install the Airborne particles.
battery charger as prescribed in the Can cause severe injury or blind-
equipment manual. Install the battery ness.
charger in compliance with local codes
and ordinances. Wear protective goggles and clothing
when using power tools, hand tools, Hot engine and exhaust system.
High voltage test. Hazardous or compressed air. Can cause severe injury or death.
voltage can cause severe injury or
Do not work on the generator set until
death. Follow the instructions of the
Servicing the generator set when it it cools.
test equipment manufacturer when
is operating. Exposed moving parts
performing high-voltage tests on the
can cause severe injury or death.
rotor or stator. An improper test
Keep hands, feet, hair, clothing, and WARNING
procedure can damage equipment or
test leads away from the belts and
lead to generator set failure.
pulleys when the generator set is
Connecting the battery and the running. Replace guards, screens,
battery charger. Hazardous voltage and covers before operating the
can cause severe injury or death. generator set.
Reconnect the battery correctly, Hot coolant and steam.
positive to positive and negative to Can cause severe injury or death.
negative, to avoid electrical shock and
damage to the battery charger and Before removing the pressure cap,
battery(ies). Have a qualified stop the generator set and allow it to
electrician install the battery(ies). cool. Then loosen the pressure cap
to relieve pressure.
Short circuits. Hazardous
voltage/current can cause severe
Servicing the alternator. Hot parts
injury or death. Short circuits can
can cause severe injury or death.
cause bodily injury and/or equipment
Avoid touching the alternator field or
damage. Do not contact electrical
exciter armature. When shorted, the
connections with tools or jewelry while
alternator field and exciter armature
making adjustments or repairs.
become hot enough to cause severe
Remove all jewelry before servicing
burns.
the equipment.

Servicing the exhaust system. Hot Notice NOTICE
parts can cause severe injury or Electrostatic discharge damage.
death. Do not touch hot engine parts. NOTICE Electrostatic discharge (ESD)
The engine and exhaust system damages electronic circuit boards.
Canadian installations only. For
components become extremely hot Prevent electrostatic discharge
standby service connect the output of
during operation. damage by wearing an approved
the generator set to a suitably rated
Servicing the engine heater. Hot transfer switch in accordance with grounding wrist strap when handling
parts can cause minor personal Canadian Electrical Code, Part 1. electronic circuit boards or integrated
injury or property damage. Install the circuits. An approved grounding wrist
heater before connecting it to power. strap provides a high resistance (about
Operating the heater before 1 megohm), not a direct short, to
installation can cause burns and ground.
component damage. Disconnect
power to the heater and allow it to cool
before servicing the heater or nearby
parts.

Introduction
This manual provides troubleshooting and repair Routine Service Parts

instructions for the generator set models listed on the
front cover. Figure 2 and Figure 3 contain part numbers for
recommended spare parts. Contact your Kohler
For engine service procedures not covered in this generator distributor/dealer for a complete list of service
manual, refer to the Engine Service Manual listed below. parts for your generator set or for models or spec
numbers not listed here.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
Part Description Part Number
change this publication and the products represented
without notice and without any obligation or liability Maintenance kit (includes air cleaner
whatsoever. element, belt, and oil filter):
15RYG/RES GM35030-KP1
30RYG/RES GM35030-KP2
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment Air cleaner element GM16944
operation and to avoid bodily injury. Read and follow the Belt
Safety Precautions and Instructions section at the 15RYG/RES GM28353
beginning of this manual. Keep this manual with the 30RYG/RES GM28352
equipment for future reference. Oil filter GM28351
Spark plug GM35826
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often Auxiliary winding fuse, 10 amp (F1) 358337
and perform required service at the prescribed intervals. Relay interface board fuse, 10 amp (F2) 223316
Maintenance work must be performed by appropriately Controller fuse, 10 amp (F3) 223316
skilled and suitably trained maintenance personnel
familiar with generator set operation and service. Figure 2 Recommended Spare Parts
List of Related Materials Model Circuit Breaker Part Number

GM28743
Separate manuals contain operation, installation, and 15RES
(70 amp, 2 pole, 240 volt)
parts information not provided in this manual. A
separate engine service manual is also available. GM28792
30RES
Figure 1 lists the available manual part numbers. (125 amp, 2 pole, 240 volt)
Figure 3 Circuit Breakers

Document Description Part Number
(Standard on RES Models)
Operation Manual, 15/30RYG TP-6197
Installation Manual, 15/30RYG TP-6329
Operation Manual, 15/30RES TP-6344
Installation Manual, 15/30RES TP-6341
Parts Catalog, 15/30RYG/RES * TP-6319
Wiring Diagram Manual, 15/30RYG/RES TP-6437
Engine Service Manual TP-6362
* One parts catalog combines generator and engine information.
Figure 1 Related Literature
TP-6198 10/04 Introduction 11

Service Assistance
For professional advice on generator power 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
3 rue de Brennus
93200 Saint Denis Latin America
France Latin America Regional Office
Phone: (33) 1 49 178300 Lakeland, Florida, USA
Fax: (33) 1 49 178301 Phone: (863) 619-7568
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-6198 10/04

Section 1 Specifications
1.1 Introduction 1.2 Generator Set Ratings

The spec sheets for each generator set provide specific See the generator set ratings table in Figure 1-1.
generator and engine information. Refer to the Consult generator set nameplate for specific generator
generator set spec sheet for data not supplied in this set ratings.
manual. Consult the generator set installation manual,
engine operation manual, and engine service manual
for additional specifications.
Natural Gas Rating LP Rating

Model
Series Alternator Voltage Ph Hz kW/kVA Amps kW/kVA Amps
4H7 120/240 1 60 13.0/13.0 54 15.0/15.0 63
120/208 3 60 13.0/16.2 45 15.0/18.8 52
120/240 3 60 13.0/16.2 39 15.0/18.8 45
15RYG
4J7 127/220 3 60 13.0/16.2 43 15.0/18.8 49
139/240 3 60 13.0/16.2 39 15.0/18.8 45
277/480 3 60 13.0/16.2 20 15.0/18.8 22
15RES 4H7 120/240 1 60 13.0/13.0 54 15.0/15.0 63
2F5 120/240 1 60 24.0/24.0 100 24.0/24.0 100
120/208 3 60 19.0/23.7 66 19.0/23.7 66
120/240 3 60 19.0/23.7 57 19.0/23.7 57
2G5 127/220 3 60 19.0/23.7 62 19.0/23.7 62
139/240 3 60 20.0/24.9 60 20.0/24.9 60
277/480 3 60 20.0/24.9 30 20.0/24.9 30
30RYG
2F7 120/240 1 60 27.0/27.0 112 30.0/30.0 125
120/208 3 60 26.0/32.4 90 26.0/32.4 90
120/240 3 60 26.0/32.4 78 26.0/32.4 78
2G7 127/220 3 60 26.0/32.4 85 26.0/32.4 85
139/240 3 60 27.0/33.6 81 27.0/33.6 81
277/480 3 60 27.0/33.6 41 27.0/33.6 41
30RES 2F7 120/240 1 60 27.0/27.0 112 30.0/30.0 125
RATINGS: All three-phase units are rated at 0.8 power factor. Standby Ratings: Standby ratings apply to installations served by a reliable
utility source. The standby rating is applicable to varying loads for the duration of a power outage. There is no overload capability for this
rating. Ratings are in accordance with ISO-3046/1, BS 5514, AS 2789, and DIN 6271. Prime Power Ratings: Prime power ratings apply to
installations where utility power is unavailable or unreliable. At varying load, the number of generator set operating hours is unlimited. A
10% overload capacity is available for one hour in twelve. Ratings are in accordance with ISO-8528/1, overload power in accordance with
ISO-3046/1, BS 5514, AS 2789, and DIN 6271. For limited running time and base load ratings, consult the factory. Obtain the technical
information bulletin (TIB-101) on ratings guidelines for the complete ratings definitions. The generator set manufacturer reserves the right to
change the design or specifications without notice and without any obligation or liability. GENERAL GUIDELINES FOR DERATION:
Altitude: Derate 1.5% per 305 m (1000 ft.) elevation above 1006 m (3300 ft.). Temperature: Derate 2.0% per 5.5_C (10_F) temperature
above 21_C (70_F).
Figure 1-1 Generator Set Ratings
TP-6198 10/04 Section 1 Specifications 13

1.3 Controller Specifications 1.4 Engine Specifications
The generator set is equipped with the ADC 2100. For a 15RYG/RES 30RYG/RES
specific description of the controller, see Section 2, Engine Specification (60 Hz) (60 Hz)
Operation, in the operation manual. Manufacturer GM
Model 1.6L OHC
Environmental Specification 15/30RYG/RES
Cycle 4
--20_ to 70_C Number of cylinders 4
Operating temperature
(--4_ to 158_F)
Compression ratio 9.4:1
--60_ to 70_C
Storage temperature Displacement, L (cu. in.) 1.6 (98)
(--76_ to 158_F)
Rated power, propane fuel,
Humidity 0%--95% condensing 19.0 (25.5) 37.2 (50)
kWm (BHP)
Power requirements:
Rpm 1800 3600
Voltage 12 VDC
Bore x stroke, mm (in.) 79 x 81.5 (3.11 x 3.21)
Current 250 mA @ 12 VDC Valve (exhaust) material High alloy steel
Cylinder head material Aluminum
Piston rings 2 compression/1 oil control
High silicon content alumi-
Piston material
num
Crankshaft material Cast iron
Main bearings: quantity,
5, replaceable inserts
type
Governor Electronic
Lubrication system Full pressure
Oil capacity (w/filter), L (qt.) 3.5 (3.7)
Oil pressure, kPa (psi) 150 (22)
Fuel system LP gas or natural gas
LP/natural gas minimum
supply pressure, 4--6 (7.11)
oz./in.2 (in. H2O)
Battery voltage 12 VDC
Battery ground Negative
Spark plug gap, mm (in.) 0.8--0.9 (0.031--0.035)
Ignition system Distributorless electronic
Starter motor Solenoid-actuated pinion
Cooling system Water-cooled
Valve material
Intake Chrome/silicone steel
Exhaust Stellite F
14 Section 1 Specifications TP-6198 10/04

1.5 Torque Specifications 1.6 Alternator Specifications
Follow the general torque specification found in Alternator Specification 15/30RYG/RES
Appendix C of this manual unless noted below or listed Frequency Hz 60 Hz
in the engine service manual.
Excitation method Brush type
Torque Specifications 15/30RYG/RES Voltage regulator type Digital
Alternator overbolts 34 Nm (25 ft. lb.) Coupling type Flexible disc
Drive disk to flywheel 16.5 Nm (12 ft. lb.) Winding material Class H
Cylinder head nuts 25 Nm (18 ft. lb.) Bearing, quantity and type 1 sealed
Drive disk to rotor 38 Nm (28 ft. lb)
Circuit protection
Muffler flange bolts 50 Nm (35 ft. lb.)
Controller (F3) 10-amp fuse
Spark plug 25 Nm (18 ft. lb.)
Aux. winding (F1) 10-amp fuse
Radiator fan fasteners 22.5 Nm (17 ft. lb.)
Relay Interface Board (F2) 10-amp fuse
Brush length, new 1.9 cm (0.75 in.)
15RES 30RES
and and
Alternator Specification 15RYG 15RYG 30RYG 30RYG 30RYG 30RYG
Alternator model 4H7 4J7 2F5 2G5 2F7 2G7
Stator leads, qty. 4 12 4 12 4 12
Phase 1 3 1 3 1 3
Rotor resistance, ohms, cold 3.0 3.0 4.2 4.2 5.6 5.6
Stator resistance, ohms,* cold
Main winding: 1-2, 3-4 0.07 — 0.03 — 0.02 —
Main winding: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12 — 0.04 — 0.09 — 0.06
Aux. winding: 55-66 1.26 1.3 0.53 0.19 0.44 0.18
Stator output AC voltage with separately excited rotor using 12-volt battery, minimum
Main winding: 1-2, 3-4 105 — 105 — 88 —
Main winding: 1-2, 3-4, 5-6, 7-8, 9-10, 11-12 — 120 — 140 — 112
Aux. winding: 55-66 130 150 140 190 117 150
Rotor field DC voltage/current readings at rated output voltage, hot
No load 16V/4.5A 16V/4.5A 16V/3.9A 12V/2.5A 19V/3.9A 15V/2.2A
Full load 36V/8.6A 40V/9.5A 46V/7.6A 63V/9.8A 53V/7.4A 69V/9.6A
* Most ohmmeters do not give accurate readings when measuring less than 1 ohm. The stator can be considered good if a low resistance
reading (continuity) is obtained and there is no evidence of shorted windings (discoloration). Do not confuse a low resistance reading with
a reading indicating a shorted winding.
TP-6198 10/04 Section 1 Specifications 15

1.7 Service View
7 9 10 11
6
5 Service-Side View 12
8
4
3
13
14
1 15
24 23 22 21 20 19 18 17 16
Non Service-Side View

25
26
27
28
32
GM32850D-J
31 30 29
1. Fuses (F1, F2, and F3) 17. Coolant overflow bottle (daily coolant check/fill location)
2. Generator set master switch (RUN\OFF/RESET\AUTO) 18. Secondary fuel regulator
3. Advanced Digital Control (ADC 2100) 19. Fuel solenoid valve
4. Runtime hour display 20. Oil drain valve
5. Nameplate 21. Positive (+) battery connection point
6. Air cleaner 22. Fuel inlet
7. Oil check 23. Engine control module (ECM)
8. Oil fill (on valve cover) 24. AC line circuit breaker panel
9. Coolant temperature sender 25. Exhaust connection
10. Fuel/air mixer 26. Spark plugs
11. Pressure cap (engine water fill) 27. Remote customer interface connector
12. Coolant overflow tube 28. Customer load lead access
13. Radiator 29. Oil filter
14. Belt guard 30. Negative (--) battery connection point
15. Battery charging alternator 31. Coolant drain
16. Low oil pressure switch 32. Cooling air inlet
Figure 1-2 Generator Set Service View
16 Section 1 Specifications TP-6198 10/04

Section 2 Scheduled Maintenance
Alternator Service. Under normal operating conditions

WARNING the generator set alternator does not require scheduled
service. Refer to the service schedule for items that
require maintenance.
Engine Service. Perform generator set engine service

at the intervals specified by the engine service literature.
Accidental starting.
Contact an authorized Kohlerr distributor/dealer to
Can cause severe injury or death.
obtain engine service literature.
Disconnect the battery cables before
working on the generator set. All generator sets have emission-certified engines. The
Remove the negative (--) lead first carburetors on emission-certified engines are not
when disconnecting the battery. adjustable.
Reconnect the negative (--) lead last
when reconnecting the battery. Generator Set Service. See the Safety Precautions
and Instructions at the beginning of this manual before
Disabling the generator set. Accidental starting can attempting to service, repair, or operate the generator
cause severe injury or death. Before working on the set. Have an authorized Kohlerr distributor/dealer
generator set or connected equipment, disable the generator perform all generator service.
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery Routine Maintenance. Refer to the following generator
charger. (3) Remove the battery cables, negative (--) lead set service schedule, the engine service schedule, and
first. Reconnect the negative (--) lead last when reconnecting
the runtime hours displayed on the ADC 2100 to
the battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote determine when to schedule routine maintenance.
start/stop switch, or engine start command from a remote Service the generator set more frequently if it is subject
computer. to extreme weather, long operating hours, or dusty or
dirty conditions.
WARNING Service Schedule. Perform maintenance on each item
in the service schedule at the designated interval for the
life of the generator set.
Tools. Tools and instruments used to perform some

Hot engine and exhaust system. maintenance items are not generally available to the
Can cause severe injury or death. generator set owner. Therefore, have service
Do not work on the generator set until performed by an authorized distributor/dealer.
it cools.
Servicing the exhaust system. Hot parts can cause 2.1 Service Schedule
severe injury or death. Do not touch hot engine parts. The
engine and exhaust system components become extremely Perform the items listed in the service schedule at the
hot during operation. designated intervals for the life of the generator set. For
example, an item serviced every 100 hours or 3 months
WARNING must also be serviced after 200 hours or 6 months,
300 hours or 9 months, etc.
Note: See the generator set operation manual and the

engine service manual for service procedures not
included in this manual.
Hazardous voltage. Moving parts.
Operate the generator set only when
all guards and electrical enclosures
are in place.
TP-6198 10/04 Section 2 Scheduled Maintenance 17

Before 100 Hr. 300 Hr. 400 Hr.
Perform Service at Intervals Indicated (X) Starting Weekly (3 Mo.) (6 Mo.) (Yearly)
Fuel System
Check the fuel level and fill as necessary (LP) X
Check the solenoid valve operation * X
Check the fuel lines and replace as necessary * X
Lubrication System
Check the crankcase oil level and add oil as necessary X
24 hr.
Replace the oil in the crankcase X
200 hr.
Replace the lube oil filter element X
200 hr.
Cooling System
Check the coolant level and fill as necessary X
Inspect the radiator and hoses X
Check the belt tension and condition * X
Check the coolant protection and tighten the hose clamps * X
Flush the cooling system * X
800 hr.
Ignition System
Clean and regap the spark plugs X
Replace the spark plugs X
800 hr.
Intake/Exhaust System
Inspect the exhaust system components * X
Check the installation and operation of CO detectors X
Check the exhaust gas condition during operation X
Inspect and clean the air cleaner element X
Replace the air cleaner element X
Inspect the complete exhaust system ] X
Electrical System
Keep the battery charged and in good condition w X
Check and tighten electrical connections X
Clean the battery cables as required * X
Engine and Mounting
Check for fuel, coolant, and oil leakage *[ X
Retighten all nuts and bolts as required X
Check tightness of mounting bolts/vibromounts X
Remote Control System
Check the remote control operation X X
Generator Set
Test run the generator set X
Blow dust out of the generator * X
Clean collector ring and inspect brushes * X
1000 hr.
* Consult your local distributor/dealer for service.
[ Read WARNING found at the beginning of manual regarding moving parts.
] Should be performed by your local distributor/dealer.
w Consult battery manufacturer’s instructions.
Note: Hr. refers to hours of generator set operation.
Figure 2-1 Service Schedule
18 Section 2 Scheduled Maintenance TP-6198 10/04

2.2 Battery Use a 12-volt battery with a minimum rating of 525 cold
cranking amps at --18_C (0_F) The generator set uses a
negative ground with a 12-volt engine electrical system.
WARNING Make sure that the battery is correctly connected and
the terminals are tight. See Figure 2-2.
Note: The generator set will not start and circuit board
damage may result if the battery is connected in
reverse.
Sulfuric acid in batteries.
1 2
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
Battery electrolyte is a diluted sulfuric acid. Battery acid

can cause severe injury or death. Battery acid can cause EZ-273000-J
blindness and burn skin. Always wear splashproof safety
goggles, rubber gloves, and boots when servicing the battery. 1. To positive (+) terminal on starter solenoid.
Do not open a sealed battery or mutilate the battery case. If 2. To ground (--) terminal on or near starter motor.
battery acid splashes in the eyes or on the skin, immediately
flush the affected area for 15 minutes with large quantities of Figure 2-2 12-Volt Engine Electrical System Single
clean water. Seek immediate medical aid in the case of eye Starter Motor, Typical Battery Connection
contact. Never add acid to a battery after placing the battery in
service, as this may result in hazardous spattering of battery Clean the battery and cables and tighten battery
acid. terminals using the service schedule recommendations.
Battery acid cleanup. Battery acid can cause severe Clean the battery by wiping it with a damp cloth. Keep
injury or death. Battery acid is electrically conductive and the electrical connections dry and tight.
corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
soda) to a container with 4 L (1 gal.) of water and mix the Consult the battery manufacturer’s instructions for
neutralizing solution. Pour the neutralizing solution on the battery care and maintenance.
spilled battery acid and continue to add the neutralizing
solution to the spilled battery acid until all evidence of a
chemical reaction (foaming) has ceased. Flush the resulting 2.2.1 Cleaning Battery
liquid with water and dry the area.
To prevent dirt and grime buildup, occasionally wipe the
Battery gases. Explosion can cause severe injury or battery with a damp cloth.
death. Battery gases can cause an explosion. Do not smoke
or permit flames or sparks to occur near a battery at any time, To prevent corrosion, maintain tight, dry electrical
particularly when it is charging. Do not dispose of a battery in connections at the battery terminals. To remove
a fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or
corrosion from battery terminals, disconnect the cables
other metal objects. Remove all jewelry before servicing the from the battery and scrub the terminals with a wire
equipment. Discharge static electricity from your body before brush. Clean the battery and cables with a solution of
touching batteries by first touching a grounded metal surface baking soda and water. Do not allow the cleaning
away from the battery. To avoid sparks, do not disturb the solution to enter the battery’s cells. After cleaning, flush
battery charger connections while the battery is charging. the battery and cables with clean water and wipe them
Always turn the battery charger off before disconnecting the with a dry, lint-free cloth.
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases. After reconnecting the battery cables, coat the battery
Battery short circuits. Explosion can cause severe injury terminals with petroleum jelly, silicone grease, or other
or death. Short circuits can cause bodily injury and/or nonconductive grease.
equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the
battery. Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--)
battery cable to the positive (+) connection terminal of the
starter solenoid. Do not test the battery condition by shorting
the terminals together.
TP-6198 10/04 Section 2 Scheduled Maintenance 19

2.2.2 Battery Charger
Generator sets may be equipped with a factory-installed
battery charger to keep the starting battery fully
charged. Observe the battery polarity when connecting
the battery charger. Check the battery charger fuse and
power supply.
See the instruction sheet supplied with the battery

charger for information about battery charger operation
and troubleshooting.
20 Section 2 Scheduled Maintenance TP-6198 10/04

Section 3 Troubleshooting
3.1 Introduction D Fault shutdown. Check for a fault code on the

ADC 2100 display. Section 4.5 describes the
Corrective action and testing in many cases requires warning and shutdown fault codes.
knowledge of electrical systems and electronic circuits.
Have an authorized distributor/dealer or trained service D Blown fuses. Fuses protect the controller, SCR
technician perform testing and service. module, and relay interface board. Always check and
replace the fuses before replacing other components.
Refer to the engine service manual for engine service
information. D Incorrect controller settings. Always check the
controller configuration settings before replacing the
The first step in troubleshooting the generator set controller. Section 4.9 explains how to check and
controls is to verify that the controller is correctly change the controller settings.
configured for the generator set. The generator set
installation manual explains how to check and change D Inadequate fuel supply. Check for damaged
the controller configuration. primary or secondary fuel regulators, loose
connections to the fuel solenoid valve, a damaged or
If the troubleshooting procedures in this section identify closed fuel shutoff valve, an empty LP fuel tank, or
a bad part, refer to the parts catalog for replacement part other problems with the fuel supply. Check the fuel
numbers. See the List of Related Materials in the supply pressure to the generator set. See
Introduction for the literature part numbers. Section 5.11, Fuel Systems.
3.2 Initial Checks 3.3 Troubleshooting Chart

When troubleshooting, always check for simple Use the following table as a reference in troubleshooting
problems first. Check for the following common individual problems. Generator set faults are listed in
problems before replacing parts: groups and include likely causes and remedies. The
simplest and most likely causes of the problem are listed
D Loose connections or damaged wiring. first; follow the recommendations in the order shown.
The reference column provides additional sources of
D Dead battery. information in this and related manuals regarding the
problem and solution.
Troubleshooting Chart
Problem Possible Cause Corrective Action Reference
Generator Weak or dead battery Recharge or replace battery. O/M
set does not If battery is weak or dead, check battery charger fuse, power
crank supply, and operation.
Battery connections Check for reversed or poor battery connections. —
Open circuit in engine/ Check for loose connections. Section 6
controller connections Check the wire harness continuity.
Blown fuse F3, controller Replace fuse; if fuse blows again, check circuit and Section 5.12
components. Section 6
Blown fuse F2, relay Replace fuse. Section 5.12
interface board (RIB) If fuse blows again, disconnect the board leads one at a time to Section 6
identify the cause of the blown fuse:
Lead 70A at the fuel valve
Lead 71A at P30
Leads FP and FN at the rotor
Repair or replace the component causing the blown fuse.
Engine S/M: Engine Service Manual I/M: Generator Set Installation Manual O/M: Generator Set Operation Manual
TP-6198 10/04 Section 3 Troubleshooting 21

Generator Blown fuse F2, relay If fuse continues to blow and the previous step did not identify Section 6
set does not interface board (RIB), the cause, check the continuity of leads FP and FN and the Section 4.6
crank, continued leads from the P14 connector. Replace any bad leads. Use a
continued pin pusher, part #241918 (large) or #241919 (small) to remove
leads from the connector, if necessary. If replacing the leads
does not solve the problem, replace the RIB.
Crank relay on relay Check connections to the RIB. Check for 12VDC to the RIB on Section 4.6
interface board (RIB) lead 71N. Section 6
Check for a good ground connection (lead N) Section 6
Check crank relay K2 operation (LED3). Replace the RIB if Section 4.6
relay does not operate.
Generator set master Check connections to the master switch on the ADC 2100. Section 4.3
switch Section 5.13
Test function of switch. Section 5.13
Poor ground (--) Clean and retighten. —
connection
Starter Check starter connections. Section 6
Rebuild or replace starter. Engine S/M
Controller Check controller connections and operation. Check for power Section 4
to the controller. Move generator set master switch to OFF/ Section 6
RESET and then to RUN.
Cranks but No fuel Open (turn on) manual fuel valve. Check fuel supply tank (LP). —
does not Insufficient fuel pressure Check fuel pressure to the generator set. Verify adequate fuel I/M
start pressure and pipe size for the generator set plus all other gas
appliances.
Fuel regulator/valve Check regulator/valve operation. I/M
Spark plugs or spark plug Check spark plug wires and connections. Replace or clean O/M
connections and regap spark plugs.
Loose connection or open Check for loose or open connections at the fuel valve (lead Section 6
circuit 70A) and at the engine control module. Check
controller/engine wiring continuity.
Air cleaner clogged Clean or replace. O/M
Incorrect controller Check for correct controller configuration parameters: unit Section 4.9
configuration configuration (UC) and engine configuration (EC).
Ignition system spark Test and/or replace components. Engine S/M
control or ignition coil
Fuel select leads 65 and Connect for natural gas. Disconnect for LP. I/M
70A leads incorrectly
connected or
disconnected
No engine rotation Check for locked rotor. Section 5.4
sensed (check for an
overcrank fault shutdown)
Starts hard Low battery voltage Check battery voltage and battery charger connections, power O/M
supply, and operation.
Air cleaner clogged Replace element. O/M
Fuel mixture adjustment Adjust fuel valve. O/M
incorrect
connected or
disconnected
Spark plug(s) Replace or regap spark plug(s). O/M
22 Section 3 Troubleshooting TP-6198 10/04

Starts hard, Spark plug wire(s) Check spark plug wires and connections. Replace spark plug Engine S/M
continued wires.
Ignition components Test/replace ignition components. Engine S/M
(spark control or ignition
module)
Insufficient fuel pressure Check fuel pressure I/M
Worn piston rings, valves Check compression. Engine S/M
Starts but Fault shutdown Check for a fault shutdown code on the controller’s LED Section 4.5
shuts down display. Correct the fault and then move the generator set Section 5.10
master switch to OFF/RESET to reset the controller.
Stops Fault shutdown Check for a fault shutdown code on the controller’s LED Section 4.5
suddenly display. Correct the fault and then move the generator set Section 5.10
master switch to OFF/RESET to reset the controller.
No fuel Turn on fuel supply. —
Fuel line restriction Inspect fuel lines. —
Fuel lines too long Check fuel line length. I/M
Air cleaner clogged Replace element. O/M
Blown controller fuse (F3) Replace fuse. Section 5.12
Blown auxiliary winding Replace fuse. If fuse blows again, test generator components. Section 5.12
fuse (F1)
Blown relay interface Replace fuse. Section 5.12
board (RIB) fuse (F2)
Spark plug(s) Replace and regap plug(s). Engine S/M
Engine overheated (hot Check air intake, fuel adjustment, oil level, air inlet/outlet. O/M and I/M
engine only)
Low oil pressure (LOP) Attempt startup. If unit shuts down, remove lead from LOP Engine S/M
switch switch and reset controller. A successful restart attempt
indicates a faulty LOP shutdown switch.
Note: Check engine oil pressure before performing test and/or
replacing LOP shutdown switch.
Fuel valve/fuel regulator Check regulator/valve operation. O/M and I/M
Engine overloaded Reduce electrical load. I/M
Loss of generator output Check connections at P15 plug. Section 6
voltage to controller Check continuity of AC sensing leads 11 and 44 (1-phase
models) or V7, V8, and V9 (3-phase models).
Ignition module Test and/or replace. Engine S/M
K3 (flash) relay Check for Flash LED illumination. Check RIB fuse. Replace Section 4.6
relay board.

Operates Air cleaner clogged Replace element. O/M
erratically Spark plug(s) Replace and regap plugs. O/M
Spark plug wire(s) Replace spark plug wires. Engine S/M
connected or
disconnected
Fuel line restriction Check fuel lines. —
Fuel mixture adjustment Check and/or adjust. I/M
incorrect
Ignition system Test and/or replace components. Engine S/M
Inadequate cooling Inspect air inlet and outlet. —
(hot engine only)
Carbon buildup in engine Clean cylinder head. Engine S/M
Engine valves not seating Check cylinder pressures with leakdown test. Inspect valves Engine S/M
correctly and valve seats.
Lacks Air intake restriction, Inspect air intakes and exhaust for obstructions. —
power inadequate cooling Check air cleaner.
Generator overloaded Reduce load. —
Spark plug(s) Replace and regap plug(s). O/M
Spark plug wire(s) Replace spark plug wires. Engine S/M
70A incorrectly connected
or disconnected
Insufficient fuel pressure Check fuel pressure at carburetor outlet. I/M
Fuel line restriction Check fuel pipe size. I/M
Fuel regulator Check function of fuel regulator. I/M
Engine not running at Check controller settings for unit configuration (UC) and engine Section 4.9.2
rated rpm type (EC).
Engine power loss Refer to the engine service manual for troubleshooting and Engine S/M
repair instructions.
Ignition system Test and/or replace. Engine S/M
Overheats Inadequate cooling Inspect cooling system for air intake obstructions. —
Fuel mixture adjustment Readjust fuel mixture. I/M
incorrect

Low output Generator overloaded Reduce load. —
or
Incorrect controller Check and adjust the controller configuration parameters. Section 4.9.2
excessive
configuration
drop in
voltage Incorrect controller Check and adjust the controller voltage settings. Section 4.9.2
voltage settings
Alternator or control Perform separate excitation procedure to isolate problem to the Section 5.2
system alternator or the control system.
SCR module Check wiring and connections to the SCR module. Section 5.12
Check auxiliary winding fuse F1 (lead 55). Section 4.7
Replace SCR module and test voltage.
Controller Check controller settings. Check controller fuse, wiring and Section 4.9.2
connections.
Before replacing controller, replace SCR module and test Section 4.8
voltage.
Rotor (open, grounded, or Test and/or replace. Section 5.4
shorted windings)
Stator (open, grounded, Test and/or replace. Section 5.3
or shorted windings)
Brush connection Check for loose brush connections. Section 5.6
Check the resistance through the brushes. Resistance through
the brushes should be low, 0.1--0.2 ohms without meter lead
resistance.
Low engine speed Check system voltage/frequency (Uu) and engine type (Ec) Section 4.9.2
causing voltage roll-off parameters
Troubleshoot engine Engine S/M
Light flicker Voltage stability (gain) Check and adjust the voltage stability (gain) setting using the Section 5.7
setting ADC 2100.
High output Incorrect controller Check and adjust the controller configuration parameters. Section 4.9.2
voltage configuration
Incorrect controller Check and adjust the controller voltage settings. Section 5.7
voltage settings
Loose voltage sensing Check connections: stator leads 11 and 44 (1-phase models) Section 6
connections or V7, V8, and V9 (3-phase models) and P15 controller
connection.
High output SCR module Check wiring and connections to the SCR module. Section 4.7
voltage, Check auxiliary winding fuse F1 (lead 55). Section 5.12
continued Replace SCR module and recheck voltage. Section 4.7
Controller Check fuses, wiring and connections. Before replacing Section 4.8
controller, replace SCR module and test voltage.

No output AC output circuit breaker Check for AC voltage on the generator side of circuit breaker. —
voltage open If there is AC voltage on the generator side of the breaker, then
a problem in the load circuits is causing the line circuit breaker
to trip. Check for and correct short circuits or overloading on
the load side before resetting the circuit breaker.
Alternator or control Perform separate excitation procedure to isolate the problem to Section 5.2
system the alternator or the control system. Then troubleshoot the
alternator or control system components as follows.
Aux. winding fuse blown Replace blown fuse. If fuse blows again, check stator. Section 5.3
(lead 55)
SCR module Check auxiliary winding fuse F1 (lead 55). Section 5.12
Replace SCR module and test voltage. Section 4.7
Controller Check controller settings. Check wiring and connections. Section 4.9.2
Before replacing controller, replace SCR module and check Section 4.8
voltage.
Open wiring, terminal, or Check continuity. Section 5.13
pin in buildup circuit or Section 6
SCR module circuit
Brushes Inspect brushes and replace if worn Section 5.6
Check for brushes sticking in brush holder or broken brush Section 5.6
spring
Rotor connections Check for open circuit in rotor connection circuit (leads FN and Section 6
FP to SCR and RIB)
Rotor slip rings dirty or Check slip ring condition. Section 5.4
corroded
Rotor (open, grounded, or Check voltage and continuity. Section 5.4
shorted windings)
Stator (open, grounded, Check voltage and continuity. Section 5.3
or shorted windings)
Flash relay (K3) on relay Check flash LED on RIB. Section 4.6
interface board (RIB) Check fuse F2 and troubleshoot RIB.
Noisy Exhaust system leaks Check and replace as necessary. O/M
operation Engine not running See “Generator set operates erratically,” this table —
smoothly
Broken or damaged Check and replace as necessary. —
vibromount(s)
Loose or vibrating sheet Retighten screws, replace rivets.
—
metal/housing
Exhaust piping or air Inspect for loose parts and secure, if necessary. —
inlets/outlets not securely
installed
Excessive engine/ Check, rotor, crankshaft, bearing, etc. (disassembly of engine Engine S/M
generator vibration and/or alternator may be required).

Section 4 Controller
4.1 Introduction A relay interface board (RIB) is used with the controller.
Section 4.6 describes the standard and optional RIBs.
This section describes the operation and replacement of
the ADC 2100 controller. Controller configuration and A silicon controlled rectifier (SCR) module works with
adjustment are explained Section 4.9. See Section 3 for the controller to regulate the output voltage. See
troubleshooting procedures. Section 4.7.
See Figure 4-1 for the locations of the ADC 2100

controller and related components.
Service-Side View Alternator-End View

7
1
4 6 8
2 5
GM32850B-
1. ADC 2100 controller

2. Fuse location (F1, F2, and F3) Note: Some earlier models had inline fuses located in the engine harness. See Section 5.12.
3. Line circuit breaker panel (load connection)
4. Generator set master switch
5. L0 stud
6. Ground stud
7. Relay interface board (RIB)
8. SCR module
Figure 4-1 Advanced Digital Control (ADC 2100)
TP-6198 10/04 Section 4 Controller 27

4.2 Controller Display and Keypad A password key sequence is required to enter the
configuration and adjustment menus. Section 4.9
The controller has an LED display and a three-button contains the instructions to enter the configuration and
keypad. See Figure 4-2. The LED display shows adjustment menus and change the settings using the
runtime hours, fault codes, application program version controller keypad.
number, or controller parameters during configuration
and adjustment. See Figure 4-3. The keypad is used to
enter the controller’s configuration and adjustment 4.3 Master Switch
menus, and to change the controller settings.
The generator set master switch is a three-position
(RUN\OFF/RESET\AUTO) rocker switch. The leads
1 connecting to the master switch are labeled RUN, VBAT,
and AUTO. Check that the three pink connectors are
3 connected to the terminals on the back of the switch as
2 shown in Figure 4-4. Be careful not to reverse the RUN
and AUTO leads.
4
GM28707A-C
1. LED display
2. Select button (for setup and adjustment only)
3. Up and down arrow buttons (for setup and adjustment only)
4. Generator set master switch
Figure 4-2 ADC Controller
Item Description
Crank Displays CC_1, CC_2, or CC_3 to
indication indicate the first, second, or third
attempt to start the engine. The last
digit flashes during the crank cycle rest
periods. tp6196
AUTO
5 4 3
RUN
VBAT
Runtime hours Displays total generator set runtime

hours when no other code is displayed.
Fault codes Flashes a 2- or 3-letter fault code to
indicate various fault conditions. See 1. Engine wiring harness connector plug (P1)
Section 4.5. 2. Continuous power mode jumper location (P7)
3. J15 connector
System Displays 2-letter codes or 4-digit 4. J16 connector
parameters alphanumeric codes during system 5. Generator set master switch
configuration or adjustment. See
Section 4.9.2. Figure 4-4 Controller Connections
Application Displays the version number of the
program controller’s application program before
version number entering the configuration or adjustment
mode. See Section 4.9.2.
Figure 4-3 ADC Controller LED Display
28 Section 4 Controller TP-6198 10/04

4.4 Sequence of Operation 4.4.2 Starting Sequence, Remote Start
The following sections describe the controller sequence When the master switch is set to the AUTO position, the
of operation during generator start, run, stop, and fault generator set starts when the remote start switch or
shutdown modes. Use this as a starting point for transfer switch engine start contacts close.
controller and relay board fault identification. Refer to
the wiring diagrams in Section 6 to assist in the The start sequence proceeds as described in
troubleshooting procedure. Section 4.4.1, Starting Sequence, Master Switch
Moved to RUN.
4.4.1 Starting Sequence, Master Switch

4.4.3 Running Sequence
Moved to RUN
When the engine speed reaches 750 rpm, the crank
When the master switch is moved to the RUN position,
relay deenergizes and the crank LED (3) turns off.
there is a delay of about 2 sec. before the controller
When the output voltage on leads 11 and 44 (1-phase
attempts to start the engine. The run relay energizes
models) or V7, V8, and V9 (3-phase models) reaches
and the run LED (1) turns on. The crank and flash relays
about 30 VAC, the flash relay deenergizes and the flash
energize and the corresponding LEDs (2 and 3) turn on
LED (2) turns off.
0.5 sec. later. The controller display indicates the crank
cycle 1 code, CC 1.
4.4.4 Stopping Sequence, Master
The controller attempts to start the generator set three Switch Moved to OFF/RESET
times (three crank cycles, 15 sec. crank and 15 sec. off).
If the generator set does not start in three attempts, the Place the generator master switch in the OFF/RESET
system shuts down on an overcrank fault. position. The run relay deenergizes and the run LED (1)
turns off. The generator set stops.
When the engine comes up to speed, the low oil
pressure switch contacts open.
4.4.5 Stopping Sequence, Remote Stop
Note: The controller circuit board prevents fault
shutdowns during startup until the crank When the remote start contacts open, the run relay
disconnect relay energizes. deenergizes and the run LED (1) turns off, but the
controller does not power down. The controller remains
The cyclic cranking cycle is programmed into controller’s powered and displays the engine runtime hours.
application code and is not adjustable in the field.
Note: Disconnecting the P7 jumper inside the controller
The factory sets the cranking cycle for three cycles of will allow the controller to power down 48 hours
15 sec. on time and 15 sec. off time. If the cranking after generator set shutdown. See Section 4.10
cycle seems shorter than the factory setting, check the for instructions.
engine starting battery.

4.5 Faults
4.5.1 Warnings
The fault conditions listed in Figure 4-5 will cause the
controller to display a fault code but will not shut down
the generator set.
Code Fault Description Check

HB High Fault code is displayed if the engine starting battery voltage rises Check the battery rating and
battery above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC condition. Replace the battery as
voltage system for more than 10 sec. when the engine is not running. This needed.
warning fault condition does not inhibit engine starting.
The fault condition clears when the battery voltage returns to a
voltage within the limits for more than 10 sec.
LB Low Fault code is displayed if the engine starting battery voltage falls Check the battery rating and
battery below 9.5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC condition.
voltage system for more than 10 sec. when the engine is not running. This
Charge or replace the battery.
warning fault condition does not inhibit engine starting.
The fault condition clears when the battery voltage returns to a
voltage within the limits for more than 10 sec.
Figure 4-5 Fault Warning Codes
4.5.2 Shutdowns
7
Under the fault conditions listed in Figure 4-8, the 1 4
controller displays a fault code and the generator set 3 1
COMMON AUX
shuts down. K1 FAULT K4 RUN
2
D1
Always identify and correct the cause of a fault 6

P13
4
5
shutdown before restarting the generator set. Refer to
K2
CRANK P14 K5
Section 3, Troubleshooting, for instructions to identify
D6
D7
RUN
D2
and correct the cause of the fault. 3 1
3
Move the generator set master switch to the OFF/ 9 7
RESET position to reset the controller after a fault

D3
R1
shutdown. Then move the switch to the AUTO or RUN T1
R2
R3
FN LED1
RUN
VBAT LED2
position. FLASH R
R
LED3
K3 FLASH FP CRANK
D4
D5
T2 R
4.6 Relay Interface Board 1. K1 common fault relay (optional) 6

GM29671-A
2. K2 crank relay (standard)

The standard Relay Interface Board (RIB) contains the 3. K3 flash relay (standard)
K2 crank, K3 flash, and K5 run relays. Three LEDs 4. K4 auxiliary run relay (optional)
indicate relay operation. See Figure 4-6. 5. K5 run relay (standard)
6. P14, engine harness connection (standard)
7. P13, connection to optional relay harness (optional)
Figure 4-6 Relay Board

Refer to the schematic diagram in Section 6 for the The generator set may be equipped with an optional
standard relay board connections. RIB, which contains the K4 auxiliary run relay and K1
common fault relay in addition to the standard relays.
The RIB is protected by a 10 amp fuse (F2). If the fuse The optional relay board kit includes a wiring harness for
blows repeatedly, disconnect the board loads one at a connection of customer equipment to the K1 and K4
time to identify the cause of the blown fuse: relays. See Figure 4-7 for optional relay connections.
D Lead 70A at the fuel select QCON2 connector
Harness
D Lead 71A starter lead at the engine ECM connector Lead Connector
D Leads FP and FN at the rotor Number Pin Number Connection
88 6 Common fault normally open
If fuse continues to blow and disconnecting components 89 2 Common fault common
did not identify the cause, remove the leads from the
90 3 Common fault normally closed
P14 connector using a pin pusher, part #241918 (large)
91 4 Run relay normally open
or #241919 (small). If replacing the leads does not solve
the problem, replace the RIB. 92 1 Run relay common
93 5 Run relay normally closed
The individual relays are not replaceable. If one or more
relays are faulty, replace the entire RIB.
To replace the RIB:
1. Disconnect P14 and the brush leads FP and FN.

Figure 4-7 Optional Common Fault and Run Relay
2. Pull the board straight off the mounting stand-offs. Board Harness Connections
3. Snap the new board onto the stand-offs and

reconnect P14 and the brush leads.

Code Fault Description Check Reference
AF Auxiliary fault Input from a user-supplied switch that closes Check the condition and operation of the —
when the fault is active. The generator set customer-supplied equipment connected to
shuts down 0.3 sec. after the fault is detected the auxiliary fault input P21-6.
and will not start when the fault is active (input is
grounded). This protection becomes active
3 sec. after crank disconnect.
HE High engine Shutdown occurs if the engine coolant Check for blocked air inlets and exhaust Section 1.7
temperature temperature exceeds the maximum temperature outlets.
for more than 5 sec. This protective becomes
active after engine reaches the crank disconnect
speed.
LCL Low coolant level Not used. — —
LOC Loss of coolant Not used. — —
LOP Low oil pressure Shutdown occurs if a low oil pressure condition Check for leaks in the lubrication system. O/M
exists for more than 5 sec. This protective
Check the oil level and add oil if the level is
becomes active 30 sec. after the engine has
low. O/M
reached crank disconnect speed (30-sec.
inhibit). Check low oil pressure switch connections
and operation. Section 5.10
Note: The low oil pressure shutdown does not
protect against low oil level. Check the oil level Check the oil pump and lubrication system.
at the engine. Engine S/M
OC Overcrank Shutdown occurs after 3 unsuccessful starting Check the fuel supply valves and pressure. I/M
attempts. The crank cycle is set for three
Check spark plug and battery.
starting attempts of 15 sec. cranking and
O/M
15 sec. rest. See Troubleshooting Chart, generator set
cranks but does not start. Section 3.3
The generator set shuts down on an overcrank Check for a locked rotor. Section 5.4
fault if no engine rotation is sensed. Shuts
down after 3 sec. of cranking or 1 sec. after the
fault is detected.
OF Overfrequency Shutdown occurs when the governed frequency Check system frequency setting (parameter Section 4.9
exceeds 110% of the system’s frequency UU) on controller.
setpoint for more than 5 sec. This protective
becomes active 10 sec. after engine start Check engine governing system, controlled Engine S/M
(10-sec. inhibit). by the engine ECM.
OS Overspeed Shutdown occurs if the engine speed exceeds Check engine governing system, controlled Engine S/M
115% of the normal running speed for more than by the engine ECM.
0.3 sec.
OU Overvoltage Shutdown occurs if the voltage exceeds 120% Check AC voltage. Section 5.7
of the system nominal voltage for more than
Check wiring and connections. Section 6
2 sec.
UF Underfrequency Shutdown occurs when the governed frequency Reduce the load and restart the generator —
falls blow 90% of the nominal system frequency set.
for more than 5 sec. or below 59 Hz for more
than 60 sec. This protective becomes active
10 sec. after engine start. (10-sec. inhibit).
UU Undervoltage Shutdown occurs if the voltage falls below 80% Reduce the load and restart the generator —
of the nominal system voltage for more than set.
10 sec.
Check wiring and connections. Section 6
Check controller configuration, system Section 4.9
voltage and frequency (parameter UU).
Check AC voltage and adjust, if necessary. Section 5.7
Replace the SCR module and test voltage Section 4.7

again.
Separately excite unit. Section 5.2
Check stator continuity. Section 5.3
SCF0 Software Indicates a software or communication problem Replace the controller. Section 4.8
Communication within the ADC 2100.
Fault 0
Note: O/M = Generator Set Operation Manual; I/M = Generator Set Installation Manual
Figure 4-8 Fault Shutdown Codes

4.7 Silicon Controlled Rectifier 3. Connect the ohmmeter from AC1 to (+) on the SCR
module. You should read high resistance in both
Module directions.
The silicon controlled rectifier (SCR) module works with
4. Connect the ohmmeter from AC1 to (--) on the SCR
the ADC 2100 to regulate the output voltage. The ADC
module. You should read high resistance in one
2100 monitors generator output voltage and adjusts the
direction and low resistance in the other.
excitation current to the rotor through the SCR module.
The SCR module location is shown in Figure 4-1. 5. Repeat steps 3 and 4 for AC2.
The SCR module is powered through stator leads 55 6. Connect the ohmmeter from G1 to (+) on the SCR
and 66 connected to SCR terminals AC1 and AC2. module. You should read low resistance in both
Leads G connected to terminals G1 and G2 provide the directions.
controller signal. Leads FP and FN connected to the
positive (+) and negative (--) SCR terminals provide 7. Repeat step 6 for G2. You should read low
excitation current to the rotor. See Figure 4-9 and the resistance in both directions.
wiring diagrams in Section 6.
8. See Figure 4-10. Connect the negative (--) lead
from the DC power source to the positive (+)
terminal on the SCR module.
AC1 G1 --
Note: The SCR module may be damaged if the
power supply is connected incorrectly. Be
sure to connect the negative lead from the
AC2 G2 + battery to the positive terminal on the SCR
module.
GM28483
Figure 4-9 Silicon Controlled Rectifier (SCR) (--) (+) 2

Module
The SCR module is protected by a 10-amp fuse (F1) in

lead 55 in the wiring harness. Check the fuse and 1
replace it, if blown. 4
In the case of output voltage problems, check the

controller configuration and settings. Then test the SCR 5
module using the following procedure.
3
SCR Module Test Procedure G1
Required equipment:
AC1
D Ohmmeter
D 12-volt test lamp (or voltmeter) (+) AC2
(--)
D 12-volt DC power source
D 100--500 ohm resistor G2
tp6198
D Jumper
1. 12VDC power source

1. Set the ohmmeter to the R X 1 scale. 2. 12 VDC test lamp
3. SCR module
2. Connect the ohmmeter from (+) to (--) on the SCR 4. Jumper
5. 100--500 ohm resister
module. You should read high resistance in one
direction and low resistance in the other (reverse Figure 4-10 SCR Test
the leads).

9. Connect the positive (+) lead from the DC power 6. Disconnect plugs P1, P15, and P16 from the ADC
source, with the lamp in series, to terminal AC1 on controller. See Figure 4-11.
the SCR module. The lamp should not glow.
7. Attach plugs P1, P15, and P16 to the new
10. Connect the jumper, with the resistor in series, from controller.
the positive lead of the DC power source to terminal
G1 on the SCR module. The lamp should glow. 8. Place the new controller into position and install the
four mounting screws.
11. Repeat steps 9 and 10, with the positive (+) lead
and lamp connected to terminal AC2 on the SCR 9. Verify that the generator set master switch is in the
module, and connecting the jumper with resister to OFF position.
terminal G2.
12. If any of the above checks indicates a bad SCR

module, replace the module.
1
4.8 Controller Replacement

If the troubleshooting procedures in Section 3 identify a
bad controller, use the procedure in this section for
controller replacement. Always check the controller
configuration, fuse, wiring, and connections before
replacing the controller. For output voltage problems,
replace the SCR module and check the operation again
before replacing the controller.
After replacing the controller, verify that the new

controller’s configuration settings match the generator
set system voltage and frequency, unit configuration,
engine type, engine data input types, battery voltage,
and communications settings. Refer to Section 4.9 for
instructions to check the controller configuration and to
change the settings, if necessary.
After the controller configuration has been checked and

set to match the generator set, use a voltmeter to check tp6196
the generator set output voltage. If the output voltage 3 2
needs adjustment, use the Voltage Adjustment
1. Engine wiring harness connector plug (P1)
Procedure in Section 5.7.2 and the controller voltage 2. J15 connector
adjustment instructions in Section 4.9. 3. J16 connector
ADC 2100 Controller Replacement Procedure Figure 4-11 Controller Connections
1. Place the generator set master switch in the OFF 10. Reconnect the engine starting battery, negative (--)
position. lead last.
2. Disconnect power to the battery charger. 11. Reconnect power to the battery charger, if
equipped.
3. Disconnect the generator set engine starting
battery, negative (--) lead first. 12. Follow the instructions in Section 4.9 to change the
new controller’s configuration settings to match the
4. Remove four mounting screws from the front of the generator set system voltage and frequency, unit
controller. configuration, engine type, engine data input
types, battery voltage, and communications
5. Carefully pull the controller forward, angling it so settings.
that the P1 connector on the right side clears the
opening in the mounting plate.

13. Use a voltmeter to check the output voltage. Follow Note: A digital voltmeter is required for these
instructions in Section 5.7.2, Voltage Adjustment, adjustments.
to adjust the output voltage and stability.
Use a voltmeter to check the output voltage. If the output
14. Place the generator set master switch in the AUTO voltage is not within specifications, use the ADC
position if an ATS or remote start/stop switch is controller to adjust the output voltage while the
used. generator set is running. The flowcharts in Figure 4-13
and Figure 4-14 outline the adjustment procedures.
4.9 Controller Configuration and Note: Be sure to save your settings before exiting the
Adjustment configuration mode.
This section contains instructions for using the Voltage changes are lost if they are not saved before the
controller’s password-protected menus to check and generator set shuts down. The generator set continues
adjust the generator output and controller configuration. to run with the new settings until it shuts down but then
The controller configuration and generator set output reverts to the previous settings at the next startup if the
are factory-set and should not require field adjustment changes have not been saved.
under normal circumstances. Check and adjust the
configuration and/or output in the following cases: Pressing the Select button when SAVE is displayed
returns to the first parameter, voltage adjust (1P).
D Check and adjust the controller configuration and
generator output after generator set reconnection to a Note: Refer to the flowcharts in Figure 4-13 and
different voltage. Figure 4-14 during the voltage adjustment
procedure.
D Check controller configuration when troubleshooting
generator set problems. Voltage Adjustment Procedure
D Check and adjust the generator set output after 1. With the generator set off, connect a digital
installation if the voltage requires adjustment for a multimeter to the output leads or an electrical outlet
particular application. on the load side of the generator set. Set the meter
to measure AC voltage.
4.9.1 Voltage Adjustments 2. Start the generator set by moving the generator set
master switch to the RUN position.
WARNING
3. Use the ADC controller to adjust the voltage
(parameter 1P) until the output voltage reaches the
desired value. See Figure 4-12 for the
approximate change in voltage per step in
parameter 1P.
Voltage Change per Step, VAC
Operate the generator set only when Measured
all guards and electrical enclosures Voltage, VAC Coarse Adjust Fine Adjust
are in place. 85--132 5 0.5
180--251 7 0.7
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury Figure 4-12 Voltage Adjustment (approximate)
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or 4. Adjust the voltage stability (gain, parameter 2P) to
repairs. Remove all jewelry before servicing the equipment. minimize light flicker.
The controller’s adjustment mode allows adjustment of 5. Readjust the voltage, if necessary.
the output voltage, if necessary. Have adjustments
performed by an authorized distributor/dealer or service 6. Stop the generator set.
technician.

Output Voltage Adjustment Mode: Display :*
Move the generator set master switch to the RUN position. The generator set x x x x
engine starts and the controller display shows the engine runtime hours.
Hold:
Wait about 5 sec. until the display changes from runtime hours to
the program version number.
x. x x
Press the down arrow key and then the up arrow key 3 times to
enter the adjustment mode. (This is the controller “password.”)
1 P x x
The controller is now in the voltage coarse adjustment mode.
Press:
or
To raise or lower the voltage in large increments 1 P x x
(approximately 5--7 volts per step).
To enter fine voltage adjustment mode.

1 P x x
To raise or lower the voltage in smaller increments
or
(approximately 0.5--0.7 volts per step).
To enter coarse voltage stability (gain) adjustment mode.

2 P x x
To raise or lower the voltage stability (gain) in large
or increments.
To enter fine voltage stability (gain) adjustment mode.

2 P x x
or To raise or lower the voltage stability (gain) in smaller
increments.
To enter volts/Hz adjustment mode.

3 P 0 x
or To raise or lower the volts/Hz:
0.5% per step 00=0; 09 = 4.5%
Continued on Figure 4-14.

* Shaded boxes show which character in the controller display changes for each adjustment. X in the
examples above denotes any number from 0 to 9. The actual values may vary from model-to-model. TP6196
Figure 4-13 Output Voltage Adjustments

Continued from Figure 4-13: Display : *
To enter SAVE mode. S AV E
Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to
the last saved settings when the master switch is moved to the OFF/RESET position.
There are 3 options when the display says SAVE: S AV E

Press:
To return to the first parameter, coarse voltage adjustment, to check 1 P x x
or change settings before saving. See Figure 4-13.
or
To save changes. Y E S
or
To discard changes without saving. n o
“Yes”or “no” flashes when the up or down arrow is pressed and then the
controller exits the configuration mode. The display returns to the x x x x
runtime hours.
Now move the master switch to OFF/RESET.
* X in the examples above denotes any number from 0 to 9. The actual values
may vary from model-to-model.
Figure 4-14 Output Voltage Adjustments, Continued

4.9.2 Controller Configuration
The controller configuration for each generator model is
set at the factory and should not normally require
changes. The controller’s configuration mode allows
adjustment of the system parameters listed in this
section. Use the instructions in this section to check the
configuration after installation and change them to
match the settings shown in Figure 4-15, if necessary.
Parameter Setting Definition

Unit’s system voltage and frequency Uu01 Single phase, 60 Hz, 120/240 VAC
Uu04 Three phase, 60 Hz, 138/277 or 240/480 VAC
Unit configuration Uc01 * Standby
Engine type Ec03 * 15RYG/RES
Ec06 * 30RYG/RES
Engine data input types Ed01 * 15/30RYG/RES
See Figure 4-16.
Ed02 15/30RYG/RES with Remote Digital Gauge
Battery voltage Bt12 * Battery voltage 12 VDC
Bt24 Battery voltage 24 VDC
Communications Cn00 * No CAN communications
Cn01 J1939 (use for Remote Digital Gauge)
* Factory settings.
Figure 4-15 Configuration Parameters
Parameter Low Coolant Level Sensor Pressure Sensor Temperature Sensor Magnetic Pickup
Ed00 Digital Switch Digital Switch Digital Switch No
Ed01 Digital Switch Digital Switch Analog Sender No
Ed02 Digital Switch Analog Sender Digital Switch No
Ed03 Digital Switch Analog Sender Analog Sender No
Ed04 Digital Switch Digital Switch Digital Switch Yes
Ed05 * Digital Switch Digital Switch Analog Sender Yes
Ed06 Digital Switch Analog Sender Digital Switch Yes
Ed07 Digital Switch Analog Sender Analog Sender Yes
Ed08 Analog Sender Digital Switch Digital Switch No
Ed09 Analog Sender Digital Switch Analog Sender No
Ed10 Analog Sender Analog Sender Digital Switch No
Ed11 Analog Sender Analog Sender Analog Sender No
Ed12 Analog Sender Digital Switch Digital Switch Yes
Ed13 Analog Sender Digital Switch Analog Sender Yes
Ed14 Analog Sender Analog Sender Digital Switch Yes
Ed15 Analog Sender Analog Sender Analog Sender Yes
* Factory setting for replacement controllers. See Figure 4-15 for the default settings for certain models. The installation of optional sender
kits (available for some models) may require a different Ed setting.
Figure 4-16 Engine Data Input Types, Parameter Ed

The controller will automatically exit the configuration Advanced configuration mode (Adnc). The data
mode without saving any changes after about 1 minute input types, battery voltage, and communications
if no buttons are pressed. Start the configuration setting can be changed in the advanced configuration
procedure over again from the beginning if the controller mode. Press the up arrow button when Adnc is
exits the configuration mode before the settings have displayed to enter the advanced configuration mode.
been saved.
Engine data input types (Ed). This setting defines the
Follow the instructions in Figure 4-17 to enter the type of senders used on the generator set engine. Use
configuration mode while the engine is not running and Ed01 for the 15/30RYG/RES.
then step through the following parameters. Use the up
(∧) and down (∨) arrow buttons to select the appropriate The remote digital gauge requires the optional analog oil
setting for the application. pressure sender. Install the optional sender and change
the Ed parameter to Ed02.
Voltage/frequency setting (Uu). Select the system
voltage and frequency from the table in Figure 4-15. For Battery voltage (Bt). This setting toggles between 12
system voltages not listed in the table, select the setting and 24 VDC for the engine starting battery voltage.
closest to the system voltage and then adjust the output
voltage to the desired level using the instructions in Communications setting (Cn). This setting allows the
Section 4.9.1. user to set the controller for communication with
optional meters. The 15/30RYG/RES is factory-set for
Note: This parameter sets the nominal system voltage no CAN communications, Cn00. Change this setting to
and frequency. To adjust the output (measured) Cn01 if the optional Remote Digital Gauge is used.
voltage, see Section 4.9.
Note: Be sure to save your settings before exiting the
Unit configuration (Uc). This parameter sets the configuration mode. The controller reverts to the
generator set type: marine, standby, or mobile. last saved settings when the master switch is
moved to the OFF/RESET position.
Engine configuration (Ec). The engine configuration
must match the generator set engine type.

Controller Configuration Mode:
Hold the Select button: Display:

Move the generator set master switch to the . 0
RUN position. (The generator set engine will
not start.)
Wait about 5 sec. until the display shows the
program version number. (The number may be 1 0 4
different than the one shown here.)
Press the down arrow key and then the up arrow

key 3 times to enter the configuration mode.
(This is the controller “password.”)
Uu 0 1
Now release the Select button.

Press:
To set the voltage/frequency setting. See Uu 0 1

or
Figure 4-15.
To step to the next parameter, unit configuration

Uc.
To set the unit configuration setting to Uc01, if

or
necessary.
Uc 0 1
To step to the next parameter, engine type Ec.
or To set the engine type, if necessary.

See Figure 4-15. E c 0 6
To step to the next parameter, advanced Ad n c
configuration mode or save mode selection.
Now either save your settings or enter the Advanced Configuration Mode to
set the engine data inputs, battery voltage, and communications.
Press:
To enter advanced configuration mode. E d 0 1
Go to Figure 4-18.
or
or To proceed to the save mode without
entering the advanced configuration mode. S AV E
Go to Figure 4-19.
Note: Shaded boxes show which number in the controller display changes when the up or down arrow
key is pressed.
Figure 4-17 Configuration Mode (system voltage/frequency, unit configuration, and engine type parameters)

Pressing the up arrow key at the Adnc display (See Figure 4-17) puts you
into the Advanced Configuration Mode.
Press:
or To set the engine data input type to Ed01. E d 0 1

See Figure 4-15.
To enter battery voltage selection mode.
or To toggle between 12 and 24 VDC. Set this B t 1 2

parameter to 12 VDC.
To enter communications selection mode.
To set the communications parameter to C n 0 0

or Cn00 or Cn01. See Figure 4-15.
To enter SAVE mode. Go to Figure 4-19.

S AV E
Note: Be sure to save your settings before exiting the configuration mode. The controller reverts
to the last saved settings when the master switch is moved to the OFF/RESET position.
Figure 4-18 Advanced Configuration Mode (engine data input types, battery voltage, and engine
communications)
There are 3 options when the display says SAVE: S AV E

Press:
To return to the first parameter, system voltage/frequency
Uu, to check or change settings before saving. See Uu 0 1
Figure 4-17.
or
To save changes. Y E S
or
To discard changes without saving. n o
“Yes”or “no” flashes when the up or down arrow is pressed and then
the controller exits the configuration mode. The display returns to
the runtime hours.
x x x x
Now move the master switch to OFF/RESET.
* X in the runtime hours display above denotes any number from 0 to 9.
Figure 4-19 Save Mode (after configuring generator set parameters)

4.10 Continuous Power Mode 4. Locate the P7 connector near the top of the
controller. See Figure 4-20. Remove the jumper
Jumper from pins 1 and 2 of the P7 connector. If the P7
A jumper across controller pins P7-1 and P7-2 maintains connector has three pins, connect the jumper
power to the controller at all times. See Figure 4-20. across pins 2 and 3 for storage.
Controllers are shipped with the jumper connected for
5. Replace the controller’s back cover and secure the
continuous power.
cover screws.
The P7 connector has either 2 or 3 pins. Disconnecting
6. Reconnect the three pink connectors to the
the jumper or moving the jumper to pins P7-2 and P7-3
generator set master switch.
allows the controller to power down automatically
48 hours after the generator set shuts down if the 7. Reconnect the P1, J15, and J16 connectors.
generator set master switch is in the AUTO position. A
remote start signal (from a transfer switch or a remote 8. Reinstall the controller in the generator set.
start/stop switch connected to controller leads 3 and 4)
or moving the generator set master switch to the RUN 9. Reconnect the generator set engine starting
position turns the controller back on. battery, negative (--) lead last.
Note: The jumper must be connected for continuous 10. Reconnect power to the battery charger, if
power if the optional Remote Digital Gauge is equipped.
used.
11. Place the generator set master switch in the AUTO
Use the following procedure to disconnect the jumper, if position.
desired.
2
Procedure to disconnect the continuous power
mode jumper (optional). 1
1. Prevent the generator set from starting.
a. Move the generator set master switch to the

OFF/RESET position.
b. Disconnect power to the battery charger, if

equipped.
c. Disconnect the generator set engine starting

battery, negative (--) lead first.
2. Remove the controller from the generator set

housing.
a. Disconnect the engine wiring harness

connector P1 plug (35-pin) from the controller.
Disconnect the J15 and J16 connectors. See
Figure 4-20.
b. Remove controller from generator set housing

in order to access the back of the controller.
tp6195
5 4 3
3. Remove controller’s back cover to access jumper.
1. Engine wiring harness connector plug (P1)
a. Note the labels on the three leads connected to 2. Continuous power mode jumper location (P7)
the generator set master switch for 3. J15 connector
reconnection later. Disconnect the leads at the 4. J16 connector
5. Generator set master switch connectors
pink connectors. See Figure 4-20.
Figure 4-20 Advanced Digital Control Connections
b. Remove the cover screws and remove the
controller’s back cover. See Figure 4-20.

Section 5 Component Testing and Adjustment
5.1 Theory of Operation 5.2 Separate Excitation

Model 15/30RYG/RES generator sets utilize a To determine the cause of no or low AC output, refer to
rotating-field alternator to produce AC voltage. Upon the troubleshooting flow chart in Figure 5-2. Before
activation of the generator master switch, DC current beginning the test procedures, read all safety
from the battery magnetizes the rotor (field). When the precautions at the beginning of this manual. Many of the
magnetized rotor rotates within the stator windings, an test procedures include additional safety precautions.
electrical voltage develops within the stator. As engine
speed and generator output increase, the SCR module
feeds rectified stator output current to the rotor through No Generator Output
the brushes/slip rings to increase the strength of the
rotor field. As the rotor field increases in strength,
generator output also increases. The ADC 2100 Output within Specifi-
controller monitors the generator output voltage through Separate Excitation cations
leads 11 and 44 (single-phase) or leads V7, V8, and V9
(three-phase) and adjusts the DC current from the SCR
module to the rotor to meet load requirements. See Check Wiring, Fuses,
Figure 5-1. Erratic or No Output SCR Module and
Controller
1
Check Rotor Check Stator
55
66
ADC 2100 TP563273
55 AC1 SCR 2
66 AC2
G1 Figure 5-2 Generator Troubleshooting
G G2
F+ (+)
FP (--) Check the condition of the alternator fuse before
3
performing the separate excitation procedure. See
FN
Figure 5-1. The inline fuse is located in lead 55 of the
wiring harness (for earlier models) or on the fuse panel
FP (for later models). See Figure 4-1 for the fuse panel
11
FN location. If the fuse is not blown, use the following
44 4 3 2 1 11
55 66 procedure to separately excite the generator using an
44
external voltage source (a 12-volt automotive battery).
8
7 Separately exciting the generator can identify faulty
4 voltage regulation by the ADC controller or reveal a
running fault in the rotor and/or stator. An external
6 5 power source duplicates the role of the voltage regulator
TP6198
and excites the generator field (rotor). A generator
1. Fuse 5. Slip rings component that appears to be in good condition while
2. Power lead (55) 6. Main field (rotor) stationary may exhibit a running open or short circuit
3. Excitation to rotor 7. Stator windings while moving. Centrifugal forces acting on the windings
4. Brushes 8. Sensing leads (11--44)
during rotation cause a broken circuit to open, or
Figure 5-1 Single-Phase Generator Schematic increasing temperatures cause the insulation to break
down, resulting in a running fault. If this test shows that
the rotor and stator are in good condition, test the
voltage regulation using the tests in Section 5.12.
TP-6198 10/04 Section 5 Component Testing and Adjustment 43

Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all 1 2 3 4
5
power sources before servicing the equipment. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk
of electrocution. FN FP
Short circuits. Hazardous voltage/current can cause - + 7 6

+ -
severe injury or death. Short circuits can cause bodily injury
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment. 9 8
TP563274
Separate Excitation Procedure

1. SCR module
Perform the following procedure to use an external 2. FN lead disconnected from SCR
voltage source to excite the main field (rotor). 3. FP lead disconnected from SCR
4. 10-amp fuse
1. Disconnect the black FN and FP leads from the 5. DC ammeter
6. 12V battery
alternator at the SCR module (+) and (--) terminals.
7. Brushes
8. Slip rings
2. Connect a DC ammeter, 10-amp fuse, and a 9. Main field (rotor)
12-volt automotive battery to the positive (FP) and
negative (FN) brush leads as shown in Figure 5-3. Figure 5-3 Separate Excitation Connections
Note and record the ammeter reading.
Note: The approximate ammeter reading should 5.3 Stator

be the battery voltage divided by the
The stator contains a series of coils of wire laid in a
specified rotor resistance. See Section 1,
laminated steel frame. The stator leads supply AC
Specifications, for specified rotor resistance
voltage to the load and voltage regulator. Before testing
values.
the stator, inspect it for heat discoloration and visible
Example: damage to housing lead wires, exposed coil windings,
12 volts (battery voltage) 4.0 amps and exposed areas of frame laminations. Be sure the
= (rotor
3.0 ohms (rotor resistance) stator is securely fastened to the stator housing.
current)
Note: Disconnect all stator leads before performing all
3. Start the engine and check that the ammeter stator tests.
reading remains stable. An increasing meter
reading indicates a shorted rotor. A meter reading
decreasing to zero or an unstable reading WARNING
suggests a running open. Refer to Section 5.4,
Main Field (Rotor), to test the rotor. If the ammeter
reading is stable, proceed to step 4.
4. Check for AC output across the stator leads; see Hazardous voltage. Moving parts.
Section 5.3, Stator. Compare the readings to the Can cause severe injury or death.
AC output values shown in Section 1,
Specifications. If the readings vary considerably, a
faulty stator is likely. Refer to Section 5.3, Stator, are in place.
for further information.
High voltage test. Hazardous voltage can cause severe
5. If this test shows that the rotor and stator are in
injury or death. Follow the instructions of the test equipment
good condition, check the wiring and fuses. Check manufacturer when performing high-voltage tests on the rotor
the SCR module. See Section 4.7, Silicon or stator. An improper test procedure can damage equipment
Controlled Rectifier (SCR) Module. Check the or lead to generator set failure.
controller settings and connections. See
Section 4, Controller.
44 Section 5 Component Testing and Adjustment TP-6198 10/04

severe injury or death. Short circuits can cause bodily injury 4 44
connections with tools or jewelry while making adjustments or 3
repairs. Remove all jewelry before servicing the equipment.
66
Stator Continuity and Resistance Tests
55
1. Place the generator set master switch in the OFF
position. 2
2. Disconnect power to the battery charger. 1 11

6198
3. Disconnect the generator set engine starting
battery, negative (--) lead first. Figure 5-5 Single-Phase Alternator Stator Leads
4. Disconnect all stator leads before performing all Note: For three-phase models, leads 1--12 are the
stator tests. generator output leads. Leads V7, V8, V9, 55,
and 66 are the controller and SCR module
5. To check for stator continuity, set the ohmmeter on sensing and supply leads. Refer to the schematic
R x 1 scale. First set the ohmmeter zero by holding in Figure 5-6 when performing the following
the red and black meter leads together and setting steps.
the ohmmeter reading to zero. Then check the
stator continuity by connecting the meter leads to
the stator leads as shown in Figure 5-4.
R14807-14 tp6198
Figure 5-4 Testing Stator Windings

Figure 5-6 Three-Phase Alternator Stator Leads
Note: For single-phase models, leads 1--4 are the
generator output leads. Leads 11, 44, 55, and 66 6. Contact the ohmmeter leads and readjust the
are the controller and SCR module sensing and ohmmeter to read zero ohms.
supply leads. Refer to the schematic in
Figure 5-5 when performing the following steps. 7. Check the cold resistance of the stator windings by
connecting the meter leads to the stator leads. See
Note: When taking an ohmmeter reading using lead 55, Section 1.6, Alternator Specifications, for stator
make the connection before the inline fuse. winding resistances.

Note: Most ohmmeters do not provide accurate 9. Use a megohmmeter to determine whether the
readings below 1 ohm. Low resistance stator is shorted to ground.
readings (continuity) and no evidence of
shorted windings (heat discoloration) a. Apply 500 volts DC to any stator lead and the
indicate a stator in good condition. See stator frame. Perform the megohmmeter test
Figure 5-7 or Figure 5-8. following the instructions of the megohmmeter
manufacturer.
Leads Continuity
b. Repeat the test on the other stator leads until
1 and 2 each coil is tested.
1 and 11
2 and 11 Note: A reading of approximately 500 kOhms
3 and 4 Yes (1/2 megohm) and higher indicates a
3 and 44 good stator.
4 and 44
c. Repair or replace the stator if any reading is
55 and 66 less than approximately 500 kOhms. A reading
1 and 3, 4, 44, 55, or 66 of less than 500 kOhms indicates deterioration
2 and 3, 4, 44, 55, or 66 of the winding insulation and possible current
3 and 1, 2, 11, 55, or 66 flow to ground.
No
4 and 1, 2, 11, 55, or 66
Any stator lead and ground on stator
housing or frame laminations 5.4 Main Field (Rotor)
Figure 5-7 Continuity Test Results on a Good Stator The two-pole rotor creates the magnetic field needed to
(Single-Phase) produce alternating current in the stator windings.
Before testing, inspect the rotor for visible damage to
pole shoes, insulation, exposed coil windings, and slip
Leads Continuity
ring surfaces. Rotate the bearing to check for wear, heat
1 and 4
discoloration, or noise.
2 and 5
3 and 6
Rotor Continuity and Resistance Tests
7 and 10 Yes
8 and 11 WARNING
9 and 12
55 and 66
1 and 2, 3, 7, 8, or 9
1 and 55 No
Any stator lead and ground Hazardous voltage. Moving parts.
Figure 5-8 Continuity Test Results on a Good Stator
(Three-Phase) Operate the generator set only when
8. If the resistance test proves inconclusive, use a are in place.
megohmmeter to test the stator as described in the
next step. High voltage test. Hazardous voltage can cause severe
injury or death. Follow the instructions of the test equipment
Note: Because ohmmeter accuracy varies, manufacturer when performing high-voltage tests on the rotor
resistance readings are approximate or stator. An improper test procedure can damage equipment
or lead to generator set failure.
readings. Take readings of the rotor and
stator at room temperature. Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
Note: Make sure that all stator leads are whenever electricity is present. Ensure you comply with all
disconnected before running the applicable codes and standards. Electrically ground the
megohmmeter test. generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
contact electrical leads or appliances when standing in water
of electrocution.

Rotor Test Procedure 6. Perform a megohmmeter test to determine
whether the rotor is shorted to ground.
1. Place the generator set master switch in the OFF
position. a. Raise and secure the brushes away from the
slip rings by inserting a retaining wire in the
2. Disconnect power to the battery charger. brush holder hole.
3. Disconnect the generator set engine starting b. Using a megohmmeter, apply 500 volts DC to
battery, negative (--) lead first. one rotor slip ring and the rotor poles or shaft.
Follow the instructions of the megohmmeter
4. Remove the brush cover from the alternator end
manufacturer when performing this test.
bracket.
Note: A reading of approximately 500 kOhms
5. Check the rotor for continuity and resistance.
(1/2 megohm) or higher indicates a
Raise the brushes from the slip rings while
good rotor.
performing ohmmeter tests. Measure the rotor
resistance (ohms) between the two slip rings; see c. Repair or replace the rotor if the reading is less
Figure 5-9. See Section 1.6, Alternator than approximately 500 kOhms. A reading of
Specifications, for rotor resistance readings. If the less than 500 kOhms indicates deterioration of
resistance readings are low, perform a the winding insulation and possible current flow
megohmmeter test on rotor as described in the to ground.
next step.
d. Following the test, remove the retainer wire
Note: Because ohmmeter accuracy varies, from the brush holder and check the brush
resistance readings are approximate. Take positions on the slip rings. See Section 5.6,
readings at room temperature. Brushes.
e. Reinstall the brush cover on the end bracket.
5.5 Slip Rings

Slip rings acquire a glossy brown finish in normal
operation. Do not attempt to maintain a bright,
newly-machined appearance on the slip rings. Cleaning
with a dry, lint-free cloth is usually sufficient. Use very
fine sandpaper (#00) and apply light pressure to remove
roughness. Do not use emery or carborundum paper or
2-221 cloth. Clean all carbon dust from the generator after
R13929-7
sanding the slip rings. If the rings are black or pitted,
Figure 5-9 Rotor Resistance Check remove the rotor and use a lathe to remove some of the
slip ring surface material.

5.6 Brushes
The brushes transfer current from the SCR module to
the slip rings. The brushes should last the life of the
generator. Abrasive dust on the slip rings, however,
shortens the life of the brushes. Excessive arcing at the
brushes could damage the SCR module and the
controller. Weak springs, damaged slip rings, sticking
brushes, a loose brush holder, or poor brush contact
causes arcing.
The brushes must be free to move within the holder and

be held in contact with the slip rings by the springs.
When correctly positioned, spring pressure on the brush
surface causes the brush to wear evenly. The entire
brush must ride on the ring or arcing occurs and causes 1
burned rings or voltage regulator failure. Figure 5-10
shows the correct positioning of the brushes. Add or
remove shims as necessary to center the brushes on the
slip rings. Replace the brushes if they show uneven
wear or are worn to one half their original length. 2
Check the resistance through the brushes. Resistance

through the brushes should be low, 0.1--0.2 ohms Front View
without meter lead resistance. GM32849A-D
7 5
Side View
6
8 9
3
New 1.9 cm (0.75 in.)
2 2
3
TP5867
1. Brush holders (2) 7. Brush holder
2. Slip ring 8. Correctly positioned
3. Brush brush
4. Retainer wire 9. Incorrectly positioned
5. Shim brush
6. Spring
Figure 5-10 Brush Assembly

5.7 Voltage WARNING
5.7.1 Voltage Regulation

Voltage regulation is performed by the Advanced Digital
Control (ADC) and the SCR module. The ADC monitors Hazardous voltage. Moving parts.
generator output voltage and adjusts the excitation Can cause severe injury or death.
current to the rotor through the SCR module.
5.7.2 Voltage Adjustment are in place.
The factory sets the voltage for correct generator Grounding electrical equipment. Hazardous voltage can
operation under a variety of load conditions. Usually, the cause severe injury or death. Electrocution is possible
voltage needs no further adjustment. Adjust the voltage whenever electricity is present. Ensure you comply with all
when necessary according to the following procedure. applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
The adjustment procedure requires a meter that can
measure voltage and frequency. contact electrical leads or appliances when standing in water
Use the ADC controller to adjust the voltage, gain, and of electrocution.
volts/hertz (Hz). Refer to Section 4.9.2 for instructions to
adjust each parameter and save changes using
Voltage Adjustment Procedure
controller keypad.
1. Connect a digital voltmeter from one side of the
Note: The ADC controller will time out and exit the circuit breaker to the L0 terminal on the end bracket
adjustment mode after approximately 1 minute if casting. See Figure 5-11. Set the meter to
no buttons are pressed. Any unsaved changes measure voltage.
are discarded if the controller times out before the
settings are saved. Refer to Section 4.9.2 for
instructions to save your settings.
Voltage Adjustment. Adjusts generator output

between 100 and 130 volts. 2
1
Gain (Stability) Adjustment. Fine tunes regulator
circuitry to reduce light flicker.
Volts/Hz Adjustment. Determines frequency (Hz) at

which generator output voltage begins to drop.
The controller maintains generator output at the 3

specified voltage under load until the generator engine
speed drops to a preset level (factory setting 57.5 Hz on
60 Hz models and 47.5 Hz on 50 Hz models). Then the
controller allows the generator voltage and current to
drop. The voltage/current drop enables the engine to
pick up the load. When the generator speed returns to
normal (60 Hz or 50 Hz) as load is accepted, the
generator output also returns to normal.
Short circuits. Hazardous voltage/current can cause GM32850B-
severe injury or death. Short circuits can cause bodily injury 1. Load connection terminal L0
and/or equipment damage. Do not contact electrical 2. Controller location
connections with tools or jewelry while making adjustments or 3. Line circuit breaker
Figure 5-11 Circuit Breaker and L0 Terminal Location

Note: For 120- or 240-volt systems the voltage Voltage Droop for Each Cycle
measured from one side of the breaker to L0 3P (Hz) Below Cut--in Frequency
should be approximately 120 VAC. For
0 0
240-volt systems, the voltage measured
from one side of the circuit breaker to the 1 0.5%
other should be approximately 240 VAC. 2 1.0%
3 1.5%
2. Start the generator set.
4 2.0%
3. Follow the controller instructions in Section 4.9.2 to 5 2.5%
enter the adjustment mode and increase voltage or 6 3.0%
decrease voltage (parameter 1P) until the output
reaches the desired voltage. 7 3.5%
8 4.0%
4. Follow the controller instructions to step to the 9 4.5%
voltage gain adjustment menu. Adjust the voltage
gain (parameter 2P) until the light flicker minimizes. Figure 5-12 Voltage Droop Adjustments
Save the settings.
1. Readjust the voltage stability (gain, parameter 2P),
5. Check and readjust the voltage if necessary. if necessary.
6. Save the settings. 2. Readjust the voltage (parameter 1P), if necessary.
Note: The controller will revert to the previous 3. Stop the generator set.
settings at the next startup if the changes are
not saved.
5.8 Voltage Reconnection
7. Stop the generator set.
Voltage Reconnection is covered in the generator set
Installation Manual. See the List of Related Materials for
Volts per Hertz Adjustments
the document number.
The cut-in frequency is set at 57.5 Hz (60 Hz system) or
47.5 Hz (50 Hz system) and is not adjustable. When the
frequency falls below the cut-in, output voltage is 5.9 Governor System
reduced to relieve the engine. The amount of the
The frequency of the alternator output is determined by
voltage reduction is set by the 3P parameter. Monitor
the speed of the engine. A four-pole alternator must be
engine speed and output voltage as loads are applied.
driven at 1800 rpm to provide 60 Hz. A two-pole
D If there is excessive droop in engine speed and little
alternator must be driven at 3600 rpm to provide 60 Hz.
droop in voltage, increase the 3P value. The engine speed is maintained by the Engine Control
Module (ECM). See the engine documentation for ECM
D If there is little engine speed droop but excessive information.
voltage droop, decrease the 3P value.
The amount of voltage droop is approximately 0.5% of

system voltage for each step of 3P.

5.10 Fault Shutdown Tests Oil Pressure Sender (OPS, optional): Remove
connector P7 from the oil pressure sensor. Connect a
Verify the operation of the generator set overspeed, jumper between pins A and C on the connector. Start
overcrank, and low oil pressure shutdowns by the generator set and run for at least 35 seconds Verify
performing the following tests. If these tests are that the generator set shuts down and the ADC display
inconclusive, test individual shutdown circuit indicates an LOP fault. If the ADC does not shut down
components (wiring harness, switch, etc.) as described on an LOP fault, test the OPS harness and connectors.
elsewhere in this section.
Overcrank Shutdown
WARNING
Disconnect the starter motor lead at the starter solenoid.
Move the controller master switch to the RUN position.
Observe that the generator set simulates cranking for
15 seconds and then rests for 15 seconds Check that
the generator set shuts down after the third crank/rest
cycle.
High Engine Temperature Shutdown
are in place.
Remove the connector from the coolant temperature
sensor (CTS) and connect a jumper across terminals A
Servicing the generator set when it is operating. Exposed and B (black and white leads). Start the generator set.
moving parts can cause severe injury or death. Keep
Verify that the generator set shuts down and the ADC
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
display indicates fault HE approximately 5 seconds
guards, screens, and covers before operating the generator after the generator set comes up to speed. Remove the
set. jumper wire. Start the generator set and run it for at least
30 seconds to verify that the generator set does not shut
down.
connections with tools or jewelry while making adjustments or 5.10.2 Fault Shutdown Switches
Check the low oil pressure and high engine temperature
5.10.1 Controller Fault Shutdown shutdown switches on the engine by performing the
following tests. If the sensor does not function as
Functions described, replace it.
Check the operation of the fault functions programmed
in the ADC 2100 by performing the following tests. If the WARNING
ADC 2100 does not operate as described, check the
controller configuration settings; see Section 4.9. Also
check the controller wiring and connections.

Low Oil Pressure (LOP) Shutdown Can cause severe injury or death.
Oil Pressure Switch: Connect a jumper wire from the Operate the generator set only when
LOP switch (lead 13) to the generator set ground. Start all guards and electrical enclosures
the generator set. Verify that the generator set shuts are in place.
down on an LOP fault after approximately
25--35 seconds of operation. Remove the jumper wire Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death. Keep
from the LOP switch and ground. Start the generator set
hands, feet, hair, clothing, and test leads away from the belts
and run it for at least 25--35 seconds to verify that the and pulleys when the generator set is running. Replace
generator set does not shut down. guards, screens, and covers before operating the generator
set.

Temperature Sensor (CTS)
The coolant temperature sensor (CTS) is used to
monitor engine temperature for the high engine
temperature fault shutdown (HE). See Figure 5-14 for
the coolant temperature sensor location. Set the
generator set master switch to the OFF position and
allow the generator set to cool. Disconnect the CTS and
use an ohmmeter to measure the resistance across the 1
sensor. The sensor resistance varies with temperature
and should be within the values shown in Figure 5-13. If
the resistance is very low (indicating a short circuit) or
very high (indicating an open circuit) replace the CTS.
Temperature, _C (_F) Resistance, Ohms

30 (86) 2100--2500
100 (212) 180--200 tp6198
1. Low oil pressure switch
Figure 5-13 Coolant Temperature Sensor Resistance
Readings Figure 5-15 Low Oil Pressure Switch Location (fan
guard removed)
5.11 Fuel Systems
WARNING
1
Explosive fuel vapors.

Use extreme care when handling,
storing, and using fuels.
tp6198
1. Coolant temperature sensor (CTS) The fuel supplier provides and maintains manual
shut-off valves and the primary regulator. Verify that the
Figure 5-14 Coolant Temperature Sensor (CTS) fuel system capacity is adequate to supply the generator
set plus all other gas appliances.
Low Oil Pressure (LOP) Switch A factory-installed secondary regulator and 12 VDC
solenoid valve are located in the front inlet air
Remove the LOP switch and install an oil pressure
compartment. The controller energizes the fuel
gauge to verify that the engine oil pressure is within the
solenoid valve to open at startup and deenergizes the
range specified in Section 1, Specifications, before
valve to close at shutdown. The secondary fuel
testing or replacing the LOP switch. See Figure 5-15.
regulator reduces fuel pressure for delivery to the fuel
To test the LOP switch, reinstall the switch and start the
block. The fuel flows from the fuel block to the
generator set. If the unit shuts down, disconnect lead 13
carburetor in a gaseous state. The carburetor mixes the
from the LOP switch and reset the controller. Restart the
fuel with intake air for consumption by the engine.
generator set and verify that it does not shut down. A
successful restart indicates a bad LOP switch. Replace
the switch.

Use a Universal Exhaust Gas Oxygen (UEGO) sensor 5.11.3 Fuel Conversion
to check the fuel mixture after replacing the fuel
regulator, fuel mixer, or silencer. The engine should be The fuel system can be converted from natural gas to LP
warm when the fuel mixture is checked. See the vapor (or vice-versa) in the field. See the generator set
generator set Installation Manual for instructions to Installation Manual for fuel system conversion and fuel
check the fuel mixture. mixture adjustment procedures.
Refer to the troubleshooting instructions in Section 3,
Troubleshooting, to identify generator set operation
problems that may be caused by an inadequate fuel 1
supply, incorrect adjustments, or damaged fuel system
components.
5.11.1 Fuel Solenoid Valve
A solenoid valve upstream of the regulator and the

flexible fuel connector provides automatic fuel on/off
control. The engine starting battery powers the solenoid
valve and the engine starting controls open the valve 4
2
when the engine cranks or runs. 3
1. Solenoid valve tp6329
Gas Valve Operation Test Procedure 2. Check inlet fuel pressure here
3. Secondary regulator (shown pointing down for LP)
1. Disconnect the positive (+) battery lead from the 4. Fuel supply connection
gas valve terminal. Note: UL-listed models use a second fuel solenoid valve,
not shown.
2. Apply 12 VDC to the gas valve terminal and listen
for an audible click, indicating that the valve Figure 5-16 Fuel System (LP gas setup shown)
actuates.
3. Replace the gas valve if it does not actuate in 5.12 Fuses

step 2.
Three fuses protect the controller, SCR module, and
5.11.2 Fuel Regulators relay interface board. See Figure 5-17 for fuse ratings
and part numbers.
The typical gaseous fuel system uses two regulators.
The primary regulator reduces the line pressure to an Always identify and correct the cause of a blown fuse
allowable inlet pressure for the secondary regulator. before restarting the generator set. Refer to Section 3,
The fuel supplier provides and maintains the primary Troubleshooting, for conditions that may indicate a
regulator. The secondary regulator is factory-installed blown fuse. Replace blown fuses with identical
on the generator set and is designed for a maximum inlet replacement parts.
pressure of 2.7 kPa (6 oz./in.2) or 280 mm (11 in.) water
column. Part
Fuse Label Number Location *
Checking Fuel Pressure Auxiliary Winding, F1 358337 Lead 55
10 amps
Use a gauge or manometer to check the fuel pressure at
Relay Interface F2 223316 Lead PF2
the secondary regulator inlet. See Figure 5-16.
Board, 10 amps
Measure the fuel pressure with the generator set
running at rated load. The fuel pressure should be Controller, 10 amps F3 223316 Lead PF3
178--280 mm (7--11 in.) water column or 1.7--2.7 kPa * In engine harness on earlier models
(4--6 oz./in.2). Contact the fuel supplier if the inlet
Figure 5-17 Fuses
pressure is not within the specified range.

Note: Disconnect the generator set battery before
performing continuity checks to prevent damage
to the ohmmeter.
To further check generator set components, disconnect

the battery and remove wiring harness plugs from the
controller circuit board. Refer to the wiring diagrams in
Section 6, and use an ohmmeter to check for continuity
and good ground connections. A zero reading on the
ohmmeter indicates continuity. No ohmmeter reading
1 indicates very high resistance or an open circuit.
Figure 5-19 illustrates the generator set master switch

continuity with the switch in the RUN and AUTO
positions.
Zero ohms (continuity) across RUN

and COM terminals
tp6198
Note: Some earlier models had inline fuses 3 2 1

located in the engine harness.
Master Switch in
1. Fuses RUN Position
Figure 5-18 Fuse Location
COM
RUN
AUTO
5.13 Continuity Checks Zero ohms (continuity) across
COM and AUTO terminals
WARNING
3 2 1
Master Switch in
AUTO Position
COM
RUN
AUTO
Can cause severe injury or death. tp6196
Operate the generator set only when Figure 5-19 Generator Set Master Switch Continuity
Checks (back view of switch)
are in place.


Section 6 Wiring Diagrams
6.1 Specification Numbers 6.2 Wiring Diagram Reference

At the time of print, this manual contained wiring Figure 6-2 lists the wiring diagram numbers and
diagrams For the model numbers and specification locations.
(spec) numbers in Figure 6-1. For other specification
numbers, refer to wiring diagram manual TP-6437. On Wiring Diagram Drawing
occasion, the manufacturer may provide this manual Description Number Page
with units that are not listed below, such as when similar
new specs are created prior to the updated reprint or in Schematic Diagram
other cases when the manual is a suitable substitute for Sheet 1 ADV-7287A-A 56
Sheet 2 ADV-7287B-A 57
a manual under development.
Point-to-Point Wiring Diagram
Sheet 1 GM50548A-C 58
Model No. Spec. No.
Sheet 2 GM50548B-C 59
15RYG GM39949-GA21
15RES GM39949-GA20
Figure 6-2 Controller Wiring Diagrams
30RYG GM39949-GA23
30RES GM39949-GA22
Figure 6-1 Generator Set Specification Numbers
TP-6198 10/04 Section 6 Wiring Diagrams 55

Figure 6-3 Schematic Diagram, ADV-7287A-A
56 Section 6 Wiring Diagrams TP-6198 10/04

Figure 6-4 Schematic Diagram, ADV-7287B-A

Figure 6-5 Point-to-Point Wiring Diagram, GM50548A-C

Figure 6-6 Point-to-Point Wiring Diagram, GM50548B-C

Notes

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute exh. exhaust
ABDC after bottom dead center CG center of gravity ext. external
AC alternating current CID cubic inch displacement F Fahrenheit, female
A/D analog to digital CL centerline FHM flat head machine (screw)
ADC advanced digital control; cm centimeter fl. oz. fluid ounce
analog to digital converter CMOS complementary metal oxide flex. flexible
adj. adjust, adjustment substrate (semiconductor) freq. frequency
ADV advertising dimensional com communications (port) FS full scale
drawing coml commercial ft. foot, feet
Ah amp-hour Coml/Rec Commercial/Recreational ft. lb. foot pounds (torque)
AHWT anticipatory high water conn. connection ft./min. feet per minute
temperature cont. continued ftp file transfer protocol
AISI American Iron and Steel CPVC chlorinated polyvinyl chloride g gram
Institute crit. critical ga. gauge (meters, wire size)
ALOP anticipatory low oil pressure CSA Canadian Standards gal. gallon
alt. alternator Association gen. generator
Al aluminum CT current transformer genset generator set
ANSI American National Standards Cu copper
Institute (formerly American GFI ground fault interrupter
cUL Canadian Underwriter’s
Standards Association, ASA) Laboratories GND, ground
AO anticipatory only CUL Canadian Underwriter’s gov. governor
APDC Air Pollution Control District Laboratories gph gallons per hour
API American Petroleum Institute cu. in. cubic inch gpm gallons per minute
approx. approximate, approximately cw. clockwise gr. grade, gross
APU Auxiliary Power Unit CWC city water-cooled GRD equipment ground
AQMD Air Quality Management District cyl. cylinder gr. wt. gross weight
AR as required, as requested D/A digital to analog HxWxD height by width by depth
AS as supplied, as stated, as DAC digital to analog converter HC hex cap
suggested dB decibel HCHT high cylinder head temperature
ASE American Society of Engineers dB(A) decibel (A weighted) HD heavy duty
ASME American Society of DC direct current HET high exhaust temp., high
Mechanical Engineers engine temp.
DCR direct current resistance
assy. assembly hex hexagon
deg., ° degree
ASTM American Society for Testing Hg mercury (element)
Materials dept. department
dia. diameter HH hex head
ATDC after top dead center HHC hex head cap
ATS automatic transfer switch DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung HP horsepower
auto. automatic hr. hour
e. V. (also Deutsche Industrie
aux. auxiliary Normenausschuss) HS heat shrink
avg. average DIP dual inline package hsg. housing
AVR automatic voltage regulator DPDT double-pole, double-throw HVAC heating, ventilation, and air
AWG American Wire Gauge DPST double-pole, single-throw conditioning
AWM appliance wiring material DS disconnect switch HWT high water temperature
bat. battery DVR digital voltage regulator Hz hertz (cycles per second)
BBDC before bottom dead center E2PROM, EEPROM IBC International Building Code
BC battery charger, battery electrically-erasable IC integrated circuit
charging programmable read-only ID inside diameter, identification
BCA battery charging alternator memory IEC International Electrotechnical
BCI Battery Council International E, emer. emergency (power source) Commission
BDC before dead center ECM electronic control module, IEEE Institute of Electrical and
BHP brake horsepower engine control module Electronics Engineers
blk. black (paint color), block EDI electronic data interchange IMS improved motor starting
(engine) EFR emergency frequency relay in. inch
blk. htr. block heater e.g. for example (exempli gratia) in. H2O inches of water
BMEP brake mean effective pressure EG electronic governor in. Hg inches of mercury
bps bits per second EGSA Electrical Generating Systems in. lb. inch pounds
br. brass Association Inc. incorporated
BTDC before top dead center EIA Electronic Industries ind. industrial
Btu British thermal unit Association int. internal
Btu/min. British thermal units per minute EI/EO end inlet/end outlet int./ext. internal/external
C Celsius, centigrade EMI electromagnetic interference I/O input/output
cal. calorie emiss. emission IP internet protocol
CAN controller area network eng. engine ISO International Organization for
CARB California Air Resources Board EPA Environmental Protection Standardization
CAT5 Category 5 (network cable) Agency J joule
CB circuit breaker EPS emergency power system JIS Japanese Industry Standard
CC crank cycle ER emergency relay k kilo (1000)
cc cubic centimeter ES engineering special, K kelvin
CCA cold cranking amps engineered special kA kiloampere
ccw. counterclockwise ESD electrostatic discharge KB kilobyte (210 bytes)
CEC Canadian Electrical Code est. estimated KBus Kohler communication protocol
cert. certificate, certification, certified E-Stop emergency stop kg kilogram
cfh cubic feet per hour etc. et cetera (and so forth)
TP-6198 10/04 Appendix 61

kg/cm2 kilograms per square NBS National Bureau of Standards RTU remote terminal unit
centimeter NC normally closed RTV room temperature vulcanization
kgm kilogram-meter NEC National Electrical Code RW read/write
kg/m3 kilograms per cubic meter NEMA National Electrical SAE Society of Automotive
kHz kilohertz Manufacturers Association Engineers
kJ kilojoule NFPA National Fire Protection scfm standard cubic feet per minute
km kilometer Association SCR silicon controlled rectifier
kOhm, kΩ kilo-ohm Nm newton meter s, sec. second
kPa kilopascal NO normally open SI Systeme international d’unites,
kph kilometers per hour no., nos. number, numbers International System of Units
kV kilovolt NPS National Pipe, Straight SI/EO side in/end out
kVA kilovolt ampere NPSC National Pipe, Straight-coupling sil. silencer
kVAR kilovolt ampere reactive NPT National Standard taper pipe SMTP simple mail transfer protocol
kW kilowatt thread per general use SN serial number
kWh kilowatt-hour NPTF National Pipe, Taper-Fine SNMP simple network management
kWm kilowatt mechanical NR not required, normal relay protocol
kWth kilowatt-thermal ns nanosecond SPDT single-pole, double-throw
L liter OC overcrank SPST single-pole, single-throw
LAN local area network OD outside diameter spec specification
L x W x H length by width by height OEM original equipment specs specification(s)
lb. pound, pounds manufacturer sq. square
lbm/ft3 pounds mass per cubic feet OF overfrequency sq. cm square centimeter
LCB line circuit breaker opt. option, optional sq. in. square inch
LCD liquid crystal display OS oversize, overspeed SMS short message service
LED light emitting diode OSHA Occupational Safety and Health SS stainless steel
Administration std. standard
Lph liters per hour
OV overvoltage stl. steel
Lpm liters per minute
oz. ounce tach. tachometer
LOP low oil pressure
p., pp. page, pages TB terminal block
LP liquefied petroleum
PC personal computer TCP transmission control protocol
LPG liquefied petroleum gas
PCB printed circuit board TD time delay
LS left side
pF picofarad TDC top dead center
Lwa sound power level, A weighted
PF power factor TDEC time delay engine cooldown
LWL low water level
ph., ∅ phase TDEN time delay emergency to
LWT low water temperature
PHC Phillipsr head Crimptiter normal
m meter, milli (1/1000) (screw)
M mega (106 when used with SI TDES time delay engine start
PHH Phillipsr hex head (screw) TDNE time delay normal to
units), male
PHM pan head machine (screw) emergency
m3 cubic meter
PLC programmable logic control TDOE time delay off to emergency
m3/hr. cubic meters per hour
PMG permanent magnet generator TDON time delay off to normal
m3/min. cubic meters per minute
pot potentiometer, potential temp. temperature
mA milliampere
ppm parts per million term. terminal
man. manual
PROM programmable read-only THD total harmonic distortion
max. maximum memory
MB megabyte (220 bytes) TIF telephone influence factor
psi pounds per square inch tol. tolerance
MCCB molded-case circuit breaker psig pounds per square inch gauge
MCM one thousand circular mils turbo. turbocharger
pt. pint typ. typical (same in multiple
meggar megohmmeter PTC positive temperature coefficient locations)
MHz megahertz PTO power takeoff UF underfrequency
mi. mile PVC polyvinyl chloride UHF ultrahigh frequency
mil one one-thousandth of an inch qt. quart, quarts UIF user interface
min. minimum, minute qty. quantity UL Underwriter’s Laboratories, Inc.
misc. miscellaneous R replacement (emergency) UNC unified coarse thread (was NC)
MJ megajoule power source UNF unified fine thread (was NF)
mJ millijoule rad. radiator, radius univ. universal
mm millimeter RAM random access memory URL uniform resource locator
mOhm, mΩmilliohm RDO relay driver output (web address)
MOhm, MΩmegohm ref. reference US undersize, underspeed
MOV metal oxide varistor rem. remote UV ultraviolet, undervoltage
MPa megapascal Res/Coml Residential/Commercial V volt
mpg miles per gallon RFI radio frequency interference VAC volts alternating current
mph miles per hour RH round head VAR voltampere reactive
MS military standard RHM round head machine (screw) VDC volts direct current
ms millisecond rly. relay VFD vacuum fluorescent display
m/sec. meters per second rms root mean square VGA video graphics adapter
mtg. mounting rnd. round VHF very high frequency
MTU Motoren-und Turbinen-Union RO read only W watt
MW megawatt ROM read only memory WCR withstand and closing rating
mW milliwatt rot. rotate, rotating w/ with
μF microfarad rpm revolutions per minute WO write only
N, norm. normal (power source) RS right side w/o without
NA not available, not applicable RTDs Resistance Temperature wt. weight
nat. gas natural gas Detectors xfmr transformer
62 Appendix TP-6198 10/04

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

Appendix C General Torque Specifications
American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel Assembled into
Torque 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.

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

Appendix E Common Hardware List
The Common Hardware List lists part numbers and dimensions for common hardware items.
American Standard
Part No. Dimensions Part No. Dimensions Part No. Dimensions Type
Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts
X-465-17 1/4-20 x .38 X-6238-14 3/8-24 x .75 X-6009-1 1-8 Standard
X-465-6 1/4-20 x .50 X-6238-16 3/8-24 x 1.25
X-465-2 1/4-20 x .62 X-6238-21 3/8-24 x 4.00 X-6210-3 6-32 Whiz
X-465-16 1/4-20 x .75 X-6238-22 3/8-24 x 4.50 X-6210-4 8-32 Whiz
X-465-18 1/4-20 x .88 X-6210-5 10-24 Whiz
X-465-7 1/4-20 x 1.00 X-6024-5 7/16-14 x .75
X-6024-2 7/16-14 x 1.00 X-6210-1 10-32 Whiz
X-465-8 1/4-20 x 1.25
X-465-9 1/4-20 x 1.50 X-6024-8 7/16-14 x 1.25 X-6210-2 1/4-20 Spiralock
X-465-10 1/4-20 x 1.75 X-6024-3 7/16-14 x 1.50 X-6210-6 1/4-28 Spiralock
X-465-11 1/4-20 x 2.00 X-6024-4 7/16-14 x 2.00 X-6210-7 5/16-18 Spiralock
X-465-12 1/4-20 x 2.25 X-6024-11 7/16-14 x 2.75 X-6210-8 5/16-24 Spiralock
X-465-14 1/4-20 x 2.75 X-6024-12 7/16-14 x 6.50
X-6210-9 3/8-16 Spiralock
X-465-21 1/4-20 x 5.00 X-129-15 1/2-13 x .75 X-6210-10 3/8-24 Spiralock
X-465-25 1/4-28 x .38 X-129-17 1/2-13 x 1.00 X-6210-11 7/16-14 Spiralock
X-465-20 1/4-28 x 1.00 X-129-18 1/2-13 x 1.25 X-6210-12 1/2-13 Spiralock
X-125-33 5/16-18 x .50 X-129-19 1/2-13 x 1.50 X-6210-15 7/16-20 Spiralock
X-125-23 5/16-18 x .62 X-129-20 1/2-13 x 1.75 X-6210-14 1/2-20 Spiralock
X-125-3 5/16-18 x .75 X-129-21 1/2-13 x 2.00
X-129-22 1/2-13 x 2.25 X-85-3 5/8-11 Standard
X-125-31 5/16-18 x .88 X-88-12 3/4-10 Standard
X-125-5 5/16-18 x 1.00 X-129-23 1/2-13 x 2.50
X-129-24 1/2-13 x 2.75 X-89-2 1/2-20 Standard
X-125-24 5/16-18 x 1.25
X-125-34 5/16-18 x 1.50 X-129-25 1/2-13 x 3.00
X-125-25 5/16-18 x 1.75 X-129-27 1/2-13 x 3.50
X-125-26 5/16-18 x 2.00 X-129-29 1/2-13 x 4.00 Washers
230578 5/16-18 x 2.25 X-129-30 1/2-13 x 4.50 Bolt/
X-125-29 5/16-18 x 2.50 X-463-9 1/2-13 x 5.50
X-129-44 1/2-13 x 6.00 Part No. ID OD Thick. Screw
X-125-27 5/16-18 x 2.75
X-125-28 5/16-18 x 3.00 X-129-51 1/2-20 x .75 X-25-46 .125 .250 .022 #4
X-125-22 5/16-18 x 4.50 X-129-45 1/2-20 x 1.25 X-25-9 .156 .375 .049 #6
X-125-32 5/16-18 x 5.00 X-129-52 1/2-20 x 1.50 X-25-48 .188 .438 .049 #8
X-125-35 5/16-18 x 5.50 X-25-36 .219 .500 .049 #10
X-125-36 5/16-18 x 6.00 X-6021-3 5/8-11 x 1.00 X-25-40 .281 .625 .065 1/4
X-125-40 5/16-18 x 6.50 X-6021-4 5/8-11 x 1.25 X-25-85 .344 .687 .065 5/16
X-6021-2 5/8-11 x 1.50 X-25-37 .406 .812 .065 3/8
X-125-43 5/16-24 x 1.75 X-6021-1 5/8-11 x 1.75 X-25-34 .469 .922 .065 7/16
X-125-44 5/16-24 x 2.50 273049 5/8-11 x 2.00
X-125-30 5/16-24 x .75 X-25-26 .531 1.062 .095 1/2
X-6021-5 5/8-11 x 2.25 X-25-15 .656 1.312 .095 5/8
X-125-39 5/16-24 x 2.00 X-6021-6 5/8-11 x 2.50
X-125-38 5/16-24 x 2.75 X-25-29 .812 1.469 .134 3/4
X-6021-7 5/8-11 x 2.75
X-25-127 1.062 2.000 .134 1
X-6238-2 3/8-16 x .62 X-6021-12 5/8-11 x 3.75
X-6238-10 3/8-16 x .75 X-6021-11 5/8-11 x 4.50
X-6238-3 3/8-16 x .88 X-6021-10 5/8-11 x 6.00
X-6238-11 3/8-16 x 1.00 X-6021-9 5/8-18 x 2.50
X-6238-4 3/8-16 x 1.25
X-6238-5 3/8-16 x 1.50 X-6239-1 3/4-10 x 1.00
X-6238-1 3/8-16 x 1.75 X-6239-8 3/4-10 x 1.25
X-6238-6 3/8-16 x 2.00 X-6239-2 3/4-10 x 1.50
X-6238-17 3/8-16 x 2.25 X-6239-3 3/4-10 x 2.00
X-6238-7 3/8-16 x 2.50 X-6239-4 3/4-10 x 2.50
X-6238-8 3/8-16 x 2.75 X-6239-5 3/4-10 x 3.00
X-6238-9 3/8-16 x 3.00 X-6239-6 3/4-10 x 3.50
X-6238-19 3/8-16 x 3.25 X-792-1 1-8 x 2.25
X-6238-12 3/8-16 x 3.50 X-792-5 1-8 x 3.00
X-6238-20 3/8-16 x 3.75 X-792-8 1-8 x 5.00
X-6238-13 3/8-16 x 4.50
X-6238-18 3/8-16 x 5.50
X-6238-25 3/8-16 x 6.50

Metric
Hex head bolts are hardness grade 8.8 unless noted.
Part No. Dimensions Part No. Dimensions Part No. Dimensions

Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), Hex Head Bolts (Full Thread),
M931-05055-60 M5-0.80 x 55 continued continued
M931-06040-60 M6-1.00 x 40 M960-16090-60 M16-1.50 x 90 M933-12016-60 M12-1.75 x 16
M931-06055-60 M6-1.00 x 55 M931-16090-60 M16-2.00 x 90 M933-12020-60 M12-1.75 x 20
M931-06060-60 M6-1.00 x 60 M931-16100-60 M16-2.00 x 100 M961-12020-60F M12-1.50 x 20
M931-06060-SS M6-1.00 x 60 M931-16100-82 M16-2.00 x 100* M933-12025-60 M12-1.75 x 25
M931-06070-60 M6-1.00 x 70 M931-16120-60 M16-2.00 x 120 M933-12025-82 M12-1.75 x 25*
M931-06070-SS M6-1.00 x 70 M931-16150-60 M16-2.00 x 150 M961-12030-60 M12-1.25 x 30
M931-06075-60 M6-1.00 x 75 M933-12030-82 M12-1.75 x 30*
M931-06090-60 M6-1.00 x 90 M931-20065-60 M20-2.50 x 65 M961-12030-82F M12-1.50 x 30*
M931-06145-60 M6-1.00 x 145 M931-20090-60 M20-2.50 x 90 M933-12030-60 M12-1.75 x 30
M931-06150-60 M6-1.00 x 150 M931-20100-60 M20-2.50 x 100 M933-12035-60 M12-1.75 x 35
M931-20120-60 M20-2.50 x 120 M961-12040-82 M12-1.25 x 40*
M931-08035-60 M8-1.25 x 35 M931-20140-60 M20-2.50 x 140 M933-12040-60 M12-1.75 x 40
M931-08040-60 M8-1.25 x 40 M931-20160-60 M20-2.50 x 160 M933-12040-82 M12-1.75 x 40*
M931-08045-60 M8-1.25 x 45
M931-08050-60 M8-1.25 x 50 M931-22090-60 M22-2.50 x 90 M961-14025-60 M14-1.50 x 25
M931-08055-60 M8-1.25 x 55 M931-22120-60 M22-2.50 x 120 M933-14025-60 M14-2.00 x 25
M931-08055-82 M8-1.25 x 55* M931-22160-60 M22-2.50 x 160 M961-14050-82 M14-1.50 x 50*
M931-08060-60 M8-1.25 x 60 M931-24090-60 M24-3.00 x 90
M931-08070-60 M8-1.25 x 70 M961-16025-60 M16-1.50 x 25
M931-24120-60 M24-3.00 x 120 M933-16025-60 M16-2.00 x 25
M931-08070-82 M8-1.25 x 70* M931-24160-60 M24-3.00 x 160
M931-08075-60 M8-1.25 x 75 M961-16030-82 M16-1.50 x 30*
M931-24200-60 M24-3.00 x 200 M933-16030-82 M16-2.00 x 30*
M931-08080-60 M8-1.25 x 80
M931-08090-60 M8-1.25 x 90 M933-16035-60 M16-2.00 x 35
M931-08095-60 M8-1.25 x 95 Hex Head Bolts (Full Thread) M961-16040-60 M16-1.50 x 40
M931-08100-60 M8-1.25 x 100 M933-16040-60 M16-2.00 x 40
M933-04006-60 M4-0.70 x 6 M961-16045-82 M16-1.50 x 45*
M931-08110-60 M8-1.25 x 110
M931-08120-60 M8-1.25 x 120 M933-05030-60 M5-0.80 x 30 M933-16045-82 M16-2.00 x 45*
M931-08130-60 M8-1.25 x 130 M933-05035-60 M5-0.80 x 35 M933-16050-60 M16-2.00 x 50
M931-08140-60 M8-1.25 x 140 M933-05050-60 M5-0.80 x 50 M933-16050-82 M16-2.00 x 50*
M931-08150-60 M8-1.25 x 150 M933-16060-60 M16-2.00 x 60
M933-06010-60 M6-1.00 x 10 M933-16070-60 M16-2.00 x 70
M931-08200-60 M8-1.25 x 200 M933-06012-60 M6-1.00 x 12
M931-10040-82 M10-1.25 x 40* M933-06014-60 M6-1.00 x 14 M933-18035-60 M18-2.50 x 35
M931-10040-60 M10-1.50 x 40 M933-06016-60 M6-1.00 x 16 M933-18050-60 M18-2.50 x 50
M931-10045-60 M10-1.50 x 45 M933-06020-60 M6-1.00 x 20 M933-18060-60 M18-2.50 x 60
M931-10050-60 M10-1.50 x 50 M933-06025-60 M6-1.00 x 25 M933-20050-60 M20-2.50 x 50
M931-10050-82 M10-1.25 x 50* M933-06030-60 M6-1.00 x 30 M933-20055-60 M20-2.50 x 55
M931-10055-60 M10-1.50 x 55 M933-06040-60 M6-1.00 x 40
M931-10060-60 M10-1.50 x 60 M933-06050-60 M6-1.00 x 50 M933-24060-60 M24-3.00 x 60
M931-10065-60 M10-1.50 x 65 M933-24065-60 M24-3.00 x 65
M933-07025-60 M7-1.00 x 25 M933-24070-60 M24-3.00 x 70
M931-10070-60 M10-1.50 x 70
M931-10080-60 M10-1.50 x 80 M933-08010-60 M8-1.25 x 10
M931-10080-82 M10-1.25 x 80* M933-08012-60 M8-1.25 x 12 Pan Head Machine Screws
M931-10090-60 M10-1.50 x 90 M933-08016-60 M8-1.25 x 16
M931-10090-82 M10-1.50 x 90* M933-08020-60 M8-1.25 x 20 M7985A-03010-20 M3-0.50 x 10
M931-10100-60 M10-1.50 x 100 M933-08025-60 M8-1.25 x 25 M7985A-03012-20 M3-0.50 x 12
M931-10110-60 M10-1.50 x 110 M933-08030-60 M8-1.25 x 30 M7985A-04010-20 M4-0.70 x 10
M931-10120-60 M10-1.50 x 120 M933-08030-82 M8-1.25 x 30* M7985A-04016-20 M4-0.70 x 16
M931-10130-60 M10-1.50 x 130 M7985A-04020-20 M4-0.70 x 20
M931-10140-60 M10-1.50 x 140 M933-10012-60 M10-1.50 x 12
M961-10020-60 M10-1.25 x 20 M7985A-04050-20 M4-0.70 x 50
M931-10180-60 M10-1.50 x 180 M7985A-04100-20 M4-0.70 x 100
M931-10235-60 M10-1.50 x 235 M933-10020-60 M10-1.50 x 20
M931-10260-60 M10-1.50 x 260 M933-10025-60 M10-1.50 x 25 M7985A-05010-20 M5-0.80 x 10
M960-10330-60 M10-1.25 x 330 M961-10025-60 M10-1.25 x 25 M7985A-05012-20 M5-0.80 x 12
M933-10025-82 M10-1.50 x 25* M7985A-05016-20 M5-0.80 x 16
M931-12045-60 M12-1.75 x 45 M961-10030-60 M10-1.25 x 30 M7985A-05020-20 M5-0.80 x 20
M960-12050-60 M12-1.25 x 50 M933-10030-60 M10-1.50 x 30 M7985A-05025-20 M5-0.80 x 25
M960-12050-82 M12-1.25 x 50* M933-10030-82 M10-1.50 x 30* M7985A-05030-20 M5-0.80 x 30
M931-12050-60 M12-1.75 x 50 M961-10035-60 M10-1.25 x 35 M7985A-05080-20 M5-0.80 x 80
M931-12050-82 M12-1.75 x 50* M933-10035-60 M10-1.50 x 35 M7985A-05100-20 M5-0.80 x 100
M931-12055-60 M12-1.75 x 55 M933-10035-82 M10-1.50 x 35*
M931-12060-60 M12-1.75 x 60 M961-10040-60 M10-1.25 x 40 M7985A-06100-20 M6-1.00 x 100
M931-12060-82 M12-1.75 x 60*
M931-12065-60 M12-1.75 x 65 Flat Head Machine Screws
M931-12075-60 M12-1.75 x 75
M931-12080-60 M12-1.75 x 80 M965A-04012-SS M4-0.70 x 12
M931-12090-60 M12-1.75 x 90 M965A-05012-SS M5-0.80 x 12
M931-12100-60 M12-1.75 x 100 M965A-05016-20 M5-0.80 x 16
M931-12110-60 M12-1.75 x 110 M965A-06012-20 M6-1.00 x 12
* This metric hex bolt’s hardness is grade 10.9.

Metric, continued
Part No. Dimensions Type
Hex Nuts
M934-03-50 M3-0.50 Standard
M934-04-50 M4-0.70 Standard
M934-04-B M4-0.70 Brass
M934-05-50 M5-0.80 Standard
M934-06-60 M6-1.00 Standard
M934-06-64 M6-1.00 Std. (green)
M6923-06-80 M6-1.00 Spiralock
M982-06-80 M6-1.00 Elastic Stop
M934-08-60 M8-1.25 Standard
M6923-08-80 M8-1.25 Spiralock
M934-10-60 M10-1.50 Standard
M934-10-60F M10-1.25 Standard
M6923-10-80 M10-1.50 Spiralock
M6923-10-62 M10-1.50 Spiralock[
M934-12-60 M12-1.75 Standard
M934-12-60F M12-1.25 Standard
M6923-12-80 M12-1.75 Spiralock
M6923-16-80 M16-2.00 Spiralock
M934-18-80 M18-2.5 Standard
M934-20-80 M20-2.50 Standard
M934-22-60 M22-2.50 Standard
M934-24-80 M24-3.00 Standard
M934-30-80 M30-3.50 Standard
Washers
Bolt/
Part No. ID OD Thick. Screw
M125A-03-80 3.2 7.0 0.5 M3
M125A-04-80 4.3 9.0 0.8 M4
M125A-05-80 5.3 10.0 1.0 M5
M125A-06-80 6.4 12.0 1.6 M6
M125A-08-80 8.4 16.0 1.6 M8
M125A-10-80 10.5 20.0 2.0 M10
M125A-12-80 13.0 24.0 2.5 M12
M125A-14-80 15.0 28.0 2.5 M14
M125A-16-80 17.0 30.0 3.0 M16
M125A-18-80 19.0 34.0 3.0 M18
M125A-20-80 21.0 37.0 3.0 M20
M125A-24-80 25.0 44.0 4.0 M24
[ This metric hex nut’s hardness is grade 8.

Notes
TP-6198 10/04 69
Notes
70 TP-6198 10/04
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6198 10/04a 7 Jurong Pier Road
Singapore 619159
E 2004, 2009 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455

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

TP-6198 10/04 Table of Contents

Section 5 Component Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Table of Contents TP-6198 10/04

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

TP-6198 10/04 Safety Precautions and Instructions 5

Leaking or accumulated engine

6 Safety Precautions and Instructions TP-6198 10/04

TP-6198 10/04 Safety Precautions and Instructions 7

CAUTION Grounding electrical equipment.

8 Safety Precautions and Instructions TP-6198 10/04

TP-6198 10/04 Safety Precautions and Instructions 9

10 Safety Precautions and Instructions TP-6198 10/04

This manual provides troubleshooting and repair Routine Service Parts

List of Related Materials Model Circuit Breaker Part Number

Figure 3 Circuit Breakers

Figure 1 Related Literature

TP-6198 10/04 Introduction 11

For professional advice on generator power China

12 Service Assistance TP-6198 10/04

1.1 Introduction 1.2 Generator Set Ratings

Natural Gas Rating LP Rating

Figure 1-1 Generator Set Ratings

TP-6198 10/04 Section 1 Specifications 13

14 Section 1 Specifications TP-6198 10/04

TP-6198 10/04 Section 1 Specifications 15

Non Service-Side View

Figure 1-2 Generator Set Service View

16 Section 1 Specifications TP-6198 10/04

Alternator Service. Under normal operating conditions

Engine Service. Perform generator set engine service

Tools. Tools and instruments used to perform some

Note: See the generator set operation manual and the

TP-6198 10/04 Section 2 Scheduled Maintenance 17

Figure 2-1 Service Schedule

18 Section 2 Scheduled Maintenance TP-6198 10/04

Battery electrolyte is a diluted sulfuric acid. Battery acid

TP-6198 10/04 Section 2 Scheduled Maintenance 19

See the instruction sheet supplied with the battery

20 Section 2 Scheduled Maintenance TP-6198 10/04

3.1 Introduction D Fault shutdown. Check for a fault code on the

3.2 Initial Checks 3.3 Troubleshooting Chart

TP-6198 10/04 Section 3 Troubleshooting 21

22 Section 3 Troubleshooting TP-6198 10/04

TP-6198 10/04 Section 3 Troubleshooting 23

24 Section 3 Troubleshooting TP-6198 10/04

TP-6198 10/04 Section 3 Troubleshooting 25

26 Section 3 Troubleshooting TP-6198 10/04

See Figure 4-1 for the locations of the ADC 2100

Service-Side View Alternator-End View

1. ADC 2100 controller

Figure 4-1 Advanced Digital Control (ADC 2100)

TP-6198 10/04 Section 4 Controller 27

Figure 4-2 ADC Controller

Runtime hours Displays total generator set runtime

Figure 4-3 ADC Controller LED Display