Alternadores

Service
Industrial Generator Sets
Models:
300--3250 kW
Alternators:
TR II-Seriest
(Pilot-Excited, Permanent Magnet Alternator)
4M
5M
7M
10M
TP-6373 11/10c
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
Product Identification Information

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

Table of Contents
Product Identification Information 2

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 Pilot-Excited Permanent Magnet Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Digital DVRr2000E Voltage Regulator Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Voltage Regulator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Alternator Adapter to Flywheel Housing Torque Values . . . . . . . . . . . . . . . . . . . . . 15
1.6 Drive Discs to Flywheel Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Interface Circuit Board GM11718 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 3 Alternator Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Reassembly, Vibromount Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Reassembly, Rigid Mount Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4 Dual Bearing Alternator Installation and Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4.2 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4.4 Electrical Test/Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.5 Fan Pulley Alignment with Pillow Block Idler Pulley Design,
1250--3250 kW with DD/MTU Series 4000 Engines . . . . . . . . . . . . . . . . . . . . . . . . 38
3.5.2 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.5.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.6 Fan Pulley Alignment with Tensioning Arm Idler Pulley Design,
1350--3250 kW with DD/MTU Series 4000 Engines . . . . . . . . . . . . . . . . . . . . . . . . 41
3.6.2 Required Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.6.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TP-6373 11/10 Table of Contents 3

Notes
4 Table of Contents TP-6373 11/10

Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can cause
DANGER severe injury or death. Battery acid
can cause blindness and burn skin.
Disabling the generator set. Always wear splashproof safety
Danger indicates the presence of a
Accidental starting can cause goggles, rubber gloves, and boots
hazard that will cause severe
severe injury or death. Before when servicing the battery. Do not
personal injury, death, or substantial
working on the generator set or open a sealed battery or mutilate the
property damage.
connected equipment, disable the battery case. If battery acid splashes in
generator set as follows: (1) Move the the eyes or on the skin, immediately
generator set master switch to the OFF flush the affected area for 15 minutes
WARNING
position. (2) Disconnect the power to with large quantities of clean water.
the battery charger. (3) Remove the Seek immediate medical aid in the case
Warning indicates the presence of a battery cables, negative (--) lead first. of eye contact. Never add acid to a
hazard that can cause severe Reconnect the negative (--) lead last battery after placing the battery in
personal injury, death, or substantial when reconnecting the battery. Follow service, as this may result in hazardous
property damage. these precautions to prevent starting of spattering of battery acid.
the generator set by an automatic
transfer switch, remote start/stop Battery acid cleanup. Battery acid
CAUTION switch, or engine start command from a can cause severe injury or death.
remote computer. Battery acid is electrically conductive
Caution indicates the presence of a and corrosive. Add 500 g (1 lb.) of
hazard that will or can cause minor bicarbonate of soda (baking soda) to a
personal injury or property damage. Battery container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
NOTICE neutralizing solution on the spilled
battery acid and continue to add the
Notice communicates installation, WARNING neutralizing solution to the spilled
operation, or maintenance information
battery acid until all evidence of a
that is safety related but not hazard
chemical reaction (foaming) has
related.
ceased. Flush the resulting liquid with
Safety decals affixed to the equipment water and dry the area.
in prominent places alert the operator
or service technician to potential Sulfuric acid in batteries.
hazards and explain how to act safely. Can cause severe injury or death.
The decals are shown throughout this
publication to improve operator Wear protective goggles and
recognition. Replace missing or clothing. Battery acid may cause
damaged decals. blindness and burn skin.
TP-6373 11/10 Safety Precautions and Instructions 5

Battery gases. Explosion can cause Engine Backfire/Flash Exhaust System
severe injury or death. Battery gases
can cause an explosion. Do not smoke Fire
or permit flames or sparks to occur near WARNING
a battery at any time, particularly when WARNING
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. Carbon monoxide.
Remove all jewelry before servicing the Fire. Can cause severe nausea,
equipment. Discharge static electricity Can cause severe injury or death. fainting, or death.
from your body before touching
batteries by first touching a grounded Do not smoke or permit flames or The exhaust system must be
metal surface away from the battery. To sparks near fuels or the fuel system. leakproof and routinely inspected.
avoid sparks, do not disturb the battery
charger connections while the battery Servicing the fuel system. A flash Generator set operation. Carbon
is charging. Always turn the battery fire can cause severe injury or death. monoxide can cause severe nausea,
charger off before disconnecting the Do not smoke or permit flames or fainting, or death. Carbon monoxide
battery connections. Ventilate the sparks near the fuel injection system, is an odorless, colorless, tasteless,
compartments containing batteries to fuel line, fuel filter, fuel pump, or other nonirritating gas that can cause death if
prevent accumulation of explosive potential sources of spilled fuels or fuel inhaled for even a short time. Avoid
gases. vapors. Catch fuels in an approved breathing exhaust fumes when working
container when removing the fuel line on or near the generator set. Never
Battery short circuits. Explosion or fuel system. operate the generator set inside a
can cause severe injury or death.
building unless the exhaust gas is piped
Short circuits can cause bodily injury Servicing the air cleaner. A sudden
safely outside. Never operate the
and/or equipment damage. backfire can cause severe injury or
generator set where exhaust gas could
Disconnect the battery before death. Do not operate the generator
accumulate and seep back inside a
generator set installation or set with the air cleaner removed.
potentially occupied building.
maintenance. Remove all jewelry
before servicing the equipment. Use Combustible materials. A fire can
Carbon monoxide symptoms.
tools with insulated handles. Remove cause severe injury or death.
Carbon monoxide can cause severe
the negative (--) lead first when Generator set engine fuels and fuel
nausea, fainting, or death. Carbon
disconnecting the battery. Reconnect vapors are flammable and explosive.
monoxide is a poisonous gas present in
the negative (--) lead last when Handle these materials carefully to
exhaust gases. Carbon monoxide is an
reconnecting the battery. Never minimize the risk of fire or explosion.
odorless, colorless, tasteless,
connect the negative (--) battery cable Equip the compartment or nearby area
nonirritating gas that can cause death if
to the positive (+) connection terminal with a fully charged fire extinguisher.
inhaled for even a short time. Carbon
of the starter solenoid. Do not test the Select a fire extinguisher rated ABC or
monoxide poisoning symptoms include
battery condition by shorting the BC for electrical fires or as
but are not limited to the following:
recommended by the local fire code or
terminals together. D Light-headedness, dizziness
an authorized agency. Train all
D Physical fatigue, weakness in
personnel on fire extinguisher
joints and muscles
operation and fire prevention
D Sleepiness, mental fatigue,
procedures.
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
6 Safety Precautions and Instructions TP-6373 11/10

Fuel System Draining the fuel system. Explosive Hazardous Voltage/
fuel vapors can cause severe injury
or death. Spilled fuel can cause an Moving Parts
WARNING explosion. Use a container to catch fuel
when draining the fuel system. Wipe up DANGER
spilled fuel after draining the system.
Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
Explosive fuel vapors. explosion. Check the LP vapor gas or
natural gas fuel system for leakage by Hazardous voltage.
Can cause severe injury or death. Will cause severe injury or death.
using a soap and water solution with the
Use extreme care when handling, fuel system test pressurized to
Disconnect all power sources before
storing, and using fuels. 6--8 ounces per square inch
opening the enclosure.
(10--14 inches water column). Do not
use a soap solution containing either
The fuel system. Explosive fuel ammonia or chlorine because both
vapors can cause severe injury or WARNING
prevent bubble formation. A successful
death. Vaporized fuels are highly test depends on the ability of the
explosive. Use extreme care when solution to bubble.
handling and storing fuels. Store fuels
in a well-ventilated area away from LP liquid withdrawal fuel leaks.
spark-producing equipment and out of Explosive fuel vapors can cause
the reach of children. Never add fuel to severe injury or death. Fuel leakage Hazardous voltage. Moving parts.
the tank while the engine is running can cause an explosion. Check the LP Can cause severe injury or death.
because spilled fuel may ignite on liquid withdrawal gas fuel system for Operate the generator set only when
contact with hot parts or from sparks. leakage by using a soap and water all guards and electrical enclosures
Do not smoke or permit flames or solution with the fuel system test are in place.
sparks to occur near sources of spilled pressurized to at least 90 psi
fuel or fuel vapors. Keep the fuel lines (621 kPa). Do not use a soap solution
and connections tight and in good containing either ammonia or chlorine
condition. Do not replace flexible fuel because both prevent bubble WARNING
lines with rigid lines. Use flexible formation. A successful test depends
sections to avoid fuel line breakage on the ability of the solution to bubble.
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks. Hazardous Noise Hazardous voltage.
Repair fuel systems before resuming
generator set operation. Backfeed to the utility system can
CAUTION cause property damage, severe
Explosive fuel vapors can cause injury, or death.
severe injury or death. Take
additional precautions when using the If the generator set is used for
following fuels: standby power, install an automatic
transfer switch to prevent inadvertent
Propane (LP)—Adequate ventilation is interconnection of standby and
mandatory. Because propane is Hazardous noise. normal sources of supply.
heavier than air, install propane gas Can cause hearing loss.
detectors low in a room. Inspect the
detectors per the manufacturer’s Never operate the generator set
instructions. without a muffler or with a faulty
exhaust system.
Natural Gas—Adequate ventilation is
mandatory. Because natural gas rises,
Engine noise. Hazardous noise can
install natural gas detectors high in a
cause hearing loss. Generator sets
room. Inspect the detectors per the
not equipped with sound enclosures
manufacturer’s instructions.
can produce noise levels greater than
Fuel tanks. Explosive fuel vapors 105 dBA. Prolonged exposure to noise
can cause severe injury or death. levels greater than 85 dBA can cause
Gasoline and other volatile fuels stored permanent hearing loss. Wear hearing
in day tanks or subbase fuel tanks can protection when near an operating
cause an explosion. Store only diesel generator set.
fuel in tanks.

High voltage test. Hazardous Handling the capacitor. Hazardous
CAUTION voltage can cause severe injury or voltage can cause severe injury or
death. Follow the instructions of the death. Electrical shock results from
test equipment manufacturer when touching the charged capacitor
performing high-voltage tests on the terminals. Discharge the capacitor by
rotor or stator. An improper test shorting the terminals together.
procedure can damage equipment or (Capacitor-excited models only)
lead to generator set failure.
Welding the generator set. Electrical backfeed to the utility.
Can cause severe electrical Welding on the generator set. Can Hazardous backfeed voltage can
equipment damage. cause severe electrical equipment cause severe injury or death. Install
damage. Before welding on the a transfer switch in standby power
Never weld components of the
generator set perform the following installations to prevent the connection
generator set without first steps: (1) Remove the battery cables, of standby and other sources of power.
disconnecting the battery, controller negative (--) lead first. (2) Disconnect Electrical backfeed into a utility
wiring harness, and engine electronic all engine electronic control module electrical system can cause severe
control module (ECM).
(ECM) connectors. (3) Disconnect all injury or death to utility personnel
generator set controller and voltage working on power lines.
Servicing the generator set when it regulator circuit board connectors.
is operating. Exposed moving parts (4) Disconnect the engine battery- Testing live electrical circuits.
can cause severe injury or death. charging alternator connections. Hazardous voltage or current can
Keep hands, feet, hair, clothing, and (5) Attach the weld ground connection cause severe injury or death. Have
test leads away from the belts and close to the weld location. trained and qualified personnel take
pulleys when the generator set is diagnostic measurements of live
running. Replace guards, screens, and Installing the battery charger. circuits. Use adequately rated test
covers before operating the generator Hazardous voltage can cause equipment with electrically insulated
set. severe injury or death. An probes and follow the instructions of the
ungrounded battery charger may test equipment manufacturer when
Grounding electrical equipment. cause electrical shock. Connect the performing voltage tests. Observe the
Hazardous voltage can cause battery charger enclosure to the ground following precautions when performing
severe injury or death. Electrocution of a permanent wiring system. As an voltage tests: (1) Remove all jewelry.
is possible whenever electricity is alternative, install an equipment (2) Stand on a dry, approved electrically
present. Ensure you comply with all grounding conductor with circuit insulated mat. (3) Do not touch the
applicable codes and standards. conductors and connect it to the enclosure or components inside the
Electrically ground the generator set, equipment grounding terminal or the enclosure. (4) Be prepared for the
transfer switch, and related equipment lead on the battery charger. Install the system to operate automatically.
and electrical circuits. Turn off the main battery charger as prescribed in the (600 volts and under)
circuit breakers of all power sources equipment manual. Install the battery
before servicing the equipment. Never charger in compliance with local codes
contact electrical leads or appliances and ordinances.
when standing in water or on wet
ground because these conditions Connecting the battery and the
increase the risk of electrocution. battery charger. Hazardous voltage
Disconnecting the electrical load. Reconnect the battery correctly,
Hazardous voltage can cause positive to positive and negative to
severe injury or death. Disconnect negative, to avoid electrical shock and
the generator set from the load by damage to the battery charger and
turning off the line circuit breaker or by battery(ies). Have a qualified
disconnecting the generator set output electrician install the battery(ies).
leads from the transfer switch and
heavily taping the ends of the leads. Short circuits. Hazardous
High voltage transferred to the load voltage/current can cause severe
during testing may cause personal injury or death. Short circuits can
injury and equipment damage. Do not cause bodily injury and/or equipment
use the safeguard circuit breaker in damage. Do not contact electrical
place of the line circuit breaker. The connections with tools or jewelry while
safeguard circuit breaker does not making adjustments or repairs.
disconnect the generator set from the Remove all jewelry before servicing the
load. equipment.
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.

Heavy Equipment Hot Parts Notice
WARNING WARNING NOTICE
This generator set has been
rewired from its nameplate voltage
to
Hot coolant and steam.
Can cause severe injury or death.
Unbalanced weight.
Improper lifting can cause severe Before removing the pressure cap, 246242
injury or death and equipment stop the generator set and allow it to
damage. cool. Then loosen the pressure cap
to relieve pressure. NOTICE
Do not use lifting eyes.
Lift the generator set using lifting bars Voltage reconnection. Affix a notice
inserted through the lifting holes on to the generator set after reconnecting
the skid. WARNING the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
Hot engine and exhaust system. NOTICE

Can cause severe injury or death. Canadian installations only. For
Do not work on the generator set until standby service connect the output of
it cools. the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
Servicing the alternator. Hot parts
Avoid touching the alternator field or
exciter armature. When shorted, the
alternator field and exciter armature
become hot enough to cause severe
burns.
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.
Servicing the engine heater. Hot
parts can cause minor personal
injury or property damage. Install the
heater before connecting it to power.
Operating the heater before installation
can cause burns and component
damage. Disconnect power to the
heater and allow it to cool before
servicing the heater or nearby parts.

Notes

Introduction
This manual provides repair instructions for the The equipment service requirements are very important
pilot-excited, permanent magnet alternators using on to safe and efficient operation. Inspect the parts often
the generator set models listed on the front cover. and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately
Wiring diagram manuals are available separately. skilled and suitably trained maintenance personnel
familiar with generator set operation and service.
Refer to the generator set controller operation manual
for operating instructions. Refer to the engine operation
manual for the generator set engine scheduled List of Related Materials
maintenance information. Refer to the engine service
manual for generator set engine repair and overhaul Separate literature contains alternator and voltage
information. regulator troubleshooting and repair information not
provided in this manual. Figure 1 lists the available
Information in this publication represents data available literature part numbers.
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented Manual Description Literature Part No.
without notice and without any obligation or liability
Voltage Regulator Spec Sheet G6--58
whatsoever.
Installation, Operation, and Maintenance
Manual (up to 600 V Alternators) TP-5578
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment Technical Manual for DVRr2000 Voltage
TP-5579
Regulator
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the Installation, Operation, and Maintenance
TP-6199
beginning of this manual. Keep this manual with the Manual for DVRr2000E Voltage Regulator
equipment for future reference. Installation, Operation, and Maintenance
TP-6221
Manual (Medium Voltage Alternators)
Decision-Makerr 550 Controller Operation

Manual TP-6200
Decision-Makerr 6000 Controller

Operation Manual TP-6750
Figure 1 Related Literature
DVRr is a registered trademark of Marathon Electric Mfg. Corp.
TP-6373 11/10 Introduction 11

Service Assistance
For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955
D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444. (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
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
Latin America
93200 Saint Denis
Latin America Regional Office
France
Lakeland, Florida, USA
Phone: (33) 1 49 178300
Phone: (863) 619-7568
Fax: (33) 1 49 178301
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-6373 11/10

Section 1 Specifications
1.1 Introduction D Provisions are included in the regulator to allow the

paralleling of two or more generator sets using either
The specification sheets for each generator set provide reactive droop or reactive differential (cross current)
specific alternator and engine information. Refer to the compensation with the addition of an external 5-amp
respective specification sheet for data not supplied in 5VA current transformer (paralleling capability with
this manual. Consult the generator set operation optional DVRr 2000EC model only).
manual, installation manual, engine operation manual,
and engine service manual for additional specifications. D The underfrequency function allows the generator
set to operate with a constant volts-per-hertz
characteristic.
1.2 Pilot-Excited Permanent
D The over-excitation function monitors the voltage
Magnet Alternator regulator output voltage and causes the voltage
The generator set alternator is a 4 pole, rotating-field regulator to shut down when the output voltage
with brushless, pilot-excited (PE), permanent magnet exceeds the preset trip level of 80 volts for
(PM) excitation system. The PE system provides 15 seconds.
short-circuit excitation current up to 300% at 60 Hz
D The overvoltage function monitors the voltage
(approximately 275% at 50 Hz) for a minimum of
regulator sensed voltage and causes the voltage
10 seconds to allow selective circuit breaker tripping.
regulator to shut down when the sensed voltage
Solid state voltage regulator is PM powered, exceeds the preset trip levels of 120% for
maintenance free, and encapsulated for moisture 0.75 seconds.
protection. The voltage regulator provides ±1/2%,
D The voltage regulator is equipped with a sensor that
no-load to full-load voltage regulation, adjustable
monitors the ambient temperature and will turn itself
volts/Hz, underspeed protection, 3-phase RMS
off when the temperature exceeds 70_C (158_F).
sensing, paralleling protection, and over-excitation
protection as standard. D The loss of the sensing function causes the voltage
regulator to shut down if an open circuit occurs in one
This series of generator sets use the digital DVRr2000E
or more of the sensing leads.
voltage regulator when the generator set controller is
not equipped with an integral voltage regulator. D The field current limit function monitors voltage
regulator output current and limits current should a
heavy load or short circuit occur across the field
1.3 Digital DVRr2000E Voltage output terminals.
Regulator Features
D The manual mode of field current controls aid in setup
D The sealed electronic, solid-state microprocessor- and troubleshooting.
based digital voltage regulator controls the generator
set output by regulating the current flow into the D The alarm output contacts provide remote indication
exciter field. of fault condition.
D The digital voltage regulator is equipped with single-

and/or three-phase sensing. Single-phase sensing is
achieved by connecting terminals E2 and E3 to the
same generator set terminal.
TP-6373 11/10 Section 1 Specifications 13

Status and Mode Adjustments Adjustments
Status and Shutdown Indicators D Coarse Voltage Adjustment

D Droop
D Field Amp Limit
D Fine Voltage Adjustment
D Loss of Sensing
D Gain
D Manual Mode
D Manual Mode Adjustment
D Over Excitation
D Manual Mode On/Off
D Over Temperature
D Phase Sensing, 1--3
D Over Voltage
D Stability Range
D Under Frequency
D Under Frequency
D VAR/PF Active
D VAR/PF Adjustment
D VAR/PF Select
1.4 Voltage Regulator Specifications

Voltage Regulator Type
Integral with Decision-Makerr 550 and
Specification/Feature 6000 Controllers Digital DVRr 2000E
Generator set capability 20--3250 kW Models 300--2250 kW Models
Type Microprocessor based
Status and shutdown indicators LEDs and Digital Display LEDs
Operating temperature --40_C to 70_C (--40_F to 158_F)
Storage temperature --40_C to 85_C (--40_F to 185_F)
Humidity 5--95% Non-Condensing MIL-STD-750, Method 711-1C Compliant
Circuit protection Solid-State, Redundant Software and Fuses 5 Amp Ceramic Fuse
Sensing, nominal 100--240 Volts (L-N), 50--60 Hz 95--600 Volts (L-L), 25--420 Hz
Sensing mode RMS, Single- or 3-Phase
Input requirements 8--36 VDC 180--240 VAC, 200--360 Hz (PMG)
Continuous output 100 mA at 12 VDC 3 Amps at 75 VDC
Maximum output 100 mA at 12 VDC 7.5 Amps at 150 VDC (1 minute)
Transition frequency 50--70 Hz 40--70 Hz
Exciter field resistance NA 18--25 Ohms
No-load to full-load voltage regulation ±0.25% ±0.25%
Less than 0.5% for 40_C (104_F)
<0.5%
Thermal drift Ambient Temperature Change
(--40_C to 70_C range) [--40_F to 158_F]
(15_C to 70_C range) [59_F to 158_F]
Response time Less Than 5μS Less Than 7μS
Voltage adjustment (of system voltage) ±10%
Voltage adjustment Controller Keypad Pushbutton Switches
Digital Input Standard/ Remote-Mounted Digital or Analog Input
Remote voltage adjustment
Analog 0--5 VDC Input Optional Optional, 46 m (150 ft.) Max.
Paralleling capability Reactive Droop Standard Optional Reactive Droop Kit Required
VAR/PF control input Standard Optional
14 Section 1 Specifications TP-6373 11/10

1.5 Alternator Adapter to Flywheel Housing Torque Values
Torque, Hardware
Model Engine Alternator Hardware Type Nm (ft. lb.) Sequence
85 (63) steel/cast iron
300--400 kW Doosan 5M M10-1.5, grade 10.9 bolt Bolt, hardened washer
60 (44) aluminum
400--800 kW Waukesha 5M 1/2-13, grade 8 bolt 130 (96) Bolt, hardened washer
M10-1.5, grade 10.9 bolt 53 (39)
350--600 kW Volvo 4M, 5M Bolt, hardened washer
7/16-14, grade 8 bolt 85 (63)
600 kW Mitsubishi 5M M12-1.25, grade 10.9 bolt 115 (85) Bolt, plain washer
750/800 kW Mitsubishi 5M M12-1.25, grade 10.9 bolt 115 (85) Bolt, hardened washer
900/1000 kW Mitsubishi 5M M12-1.25, grade 10.9 bolt 115 (85) Bolt, plain washer
1250--2000 kW Mitsubishi 7M M14-1.5, grade 10.9 bolt 190 (140) Bolt, plain washer
350/400 kW DDC Series 60 4M, 5M 7/16-14, grade 8 bolt Bolt, hardened washer
60 (44) aluminum
450 kW DDC Series 60 5M 7/16-14, grade 8 bolt Bolt, hardened washer
60 (44) aluminum
450--600 kW DDC Series 2000 5M M10-1.5, grade 10.9 bolt 53 (39) Bolt, plain washer
650/750 kW DDC/MTU Series 2000 5M
M12-1.75, grade 10.9 bolt 115 (85) Bolt, plain washer
900/1000 kW DDC/MTU Series 2000 5M, 7M
1350--2250 kW DDC/MTU Series 4000 7M M12-1.75, grade 10.9 bolt 115 (85) Bolt, hardened washer
2500--3250 kW DDC/MTU Series 4000 10M M16-2.0, grade 10.9 bolt 244 ±12 (180 ±9) Bolt, hardened washer
1.6 Drive Discs to Flywheel Torque Values

Torque, Hardware
Model Engine Alternator Hardware Type Nm (ft. lb.) Sequence
300--400 kW Doosan 5M M12-1.75, grade 10.9 bolt 115 (85)
400--800 kW Waukesha 5M 5/8-11, grade 8 bolt 259 (191)
M12-1.75, grade 10.9 bolt 115 (85)
350--600 kW Volvo 4M, 5M
1/2-13, grade 8 bolt 130 (96)
600 kW Mitsubishi 5M M16-1.5, grade 10.9 bolt 244 ±12 (180 ±9)
750/800 kW Mitsubishi 5M
M16-2.0, grade 10.9 bolt 244 ±12 (180 ±9)
900/1000 kW Mitsubishi 5M, 7M
Bolt, hardened washer
1250--2000 kW Mitsubishi 7M M16-1.5, grade 10.9 bolt 244 ±12 (180 ±9)
350/400 kW DDC Series 60 4M, 5M
450 kW DDC Series 60 5M 1/2-13, grade 8 bolt 130 (96)
450--600 kW DDC Series 2000 5M
650/750 kW DDC/MTU Series 2000 5M
900/1000 kW DDC/MTU Series 2000 5M, 7M M16-2.0, grade 10.9 bolt 244 ±12 (180 ±9)
1350--2250 kW DDC/MTU Series 4000 7M
2500--3250 kW DDC/MTU Series 4000 10M See Section 3, Dual Bearing Alternator Installation and Alignment
TP-6373 11/10 Section 1 Specifications 15

Notes
16 Section 1 Specifications TP-6373 11/10

Section 2 Troubleshooting
This section contains generator set troubleshooting, Maintain a record of repairs and adjustments performed
diagnostic, and repair information. Refer to the List of on the equipment. If the procedures in this manual do
Related Materials in the Introduction section for not explain how to correct the problem, contact an
alternator service and technical literature. authorized distributor/dealer. Use the record to help
describe the problem and repairs or adjustments made
to the equipment.
2.1 Troubleshooting Charts
Use the chart on the following pages to diagnose and
correct common problems. First check for simple
causes such as a dead engine starting battery or an
open circuit breaker. The chart includes a list of
common problems, possible causes of the problem,
recommended corrective actions, and references to
detailed information or repair procedures.
TP-6373 11/10 Section 2 Troubleshooting 17

18
Trouble Symptoms
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Probable Causes Recommended Actions Reference*
Controller
x x Controller circuit board(s) inoperative Replace the controller circuit board. —
x Controller fault Troubleshoot the controller.[ Generator set O/M
Controller fuse blown Replace the blown controller fuse. If the fuse blows again, W/D
x x x
troubleshoot the controller.[
x Controller master switch inoperative Replace the controller master switch. —
Controller master switch in the Move the controller master switch to the RUN or AUTO Generator set O/M
x
OFF/RESET position position.
Engine start circuit open Move the controller master switch to the RUN position to test Generator set O/M,
x the generator set. Troubleshoot the auto start circuit and time W/D,
delays. ATS O/M, S/M
Cooling System
x x Air openings clogged Clean the air openings. —
x Coolant level low Restore the coolant to normal operating level. Generator set O/M
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M
High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling Generator set O/M,
x
system. Eng. O/M
Low coolant level shutdown, if Restore the coolant to normal operating level. Generator set O/M
x
equipped
x Thermostat inoperative Replace the thermostat. Eng. S/M
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service
Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
] If the unit has a Decision-Makerr 550 or 6000 controller, refer to the respective controller operation manual for voltage regulator settings. Check that the application software (code version) is
correct for the generator set model and alternator voltage.
TP-6373 11/10
Trouble Symptoms
TP-6373 11/10
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Electrical System (DC circuits)
Battery connections loose, corroded, Verify that the battery connections are correct, clean, and tight. Generator set O/M
x x
or incorrect
Battery weak or dead Recharge or replace the battery. The spec sheet provides Generator set O/M,
x x
recommended battery CCA rating. S/S
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
Engine
TP-6373 harness connector(s) not
11/10 Disconnect the engine harness connector(s) then reconnect it W/D
x x
locked tight to the controller.
High water temperature switch Replace the inoperative switch. Engine S/M, or W/D
x
inoperative
x Fault shutdown Reset the fault switches and troubleshoot the controller. Generator set O/M
High exhaust temperature switch Replace the inoperative switch. Engine S/M, or W/D
x
inoperative
Engine
x x x x Air cleaner clogged Clean or replace the filter element. Eng. O/M
x x x x x Compression weak Check the compression.[ Eng. S/M
Engine overload Reduce the electrical load. See the generator set spec sheet S/S
x x x x x
for wattage specifications.
Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust I/M
x
system components.[
Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system I/M
x
components.[
x x x x Governor inoperative Adjust the governor.[ Governor literature
x x Valve clearance incorrect Adjust the valves.[ Eng. S/M
x Vibration excessive Tighten all loose hardware. —
Ignition system inoperative Check the ignition system (spark plugs, spark plug wires, etc.). Eng. O/M
x x x
(gas/gasoline only)
19
20
Trouble Symptoms
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Fuel System
x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M
Ether canister empty or system Replace or repair the ether starting system. Eng. O/M
x x
inoperative, if equipped (diesel only)
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —
Fuel feed or injection pump Rebuild or replace the injection pump.[ Eng. S/M
x x x
inoperative (diesel only)
Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel injector.[ Eng. S/M
x x x
(diesel only)
x x x x Fuel filter restriction Clean or replace the fuel filter. Eng. O/M
x Fuel solenoid inoperative Troubleshoot the fuel solenoid.[ Eng. S/M
x x Fuel pressure insufficient (gas only) Check the fuel supply and valves.[ S/S, Gen. O/M
Fuel injection timing out of adjustment Adjust the fuel injection timing.[ Eng. S/M
x x x x
(diesel only)
Alternator
AC output circuit breaker open Reset the breaker and check for AC voltage at the generator —
x
side of the circuit breaker.
Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO position. ATS O/M
x
position
Transfer switch fails to transfer load Move the ATS test switch to the AUTO position. Troubleshoot ATS O/M, S/M
x
the transfer circuit and time delays.
Wiring, terminals, or pin in the exciter Check for continuity. Alternator Technical
x
field open Manual, W/D
Main field (rotor) inoperative (open or Test and/or replace the rotor.[ Alternator Technical
x
grounded) Manual
Stator inoperative (open or grounded) Test and/or replace the stator.[ Alternator Technical
x
Manual
x Vibration excessive Tighten loose components.[ —
Voltage regulator digital settings Adjust the voltage regulator. Voltage Regulator
x x incorrect (digital controller only) Technical Manual ]
Voltage regulator inoperative Replace the voltage regulator fuse, If the fuse blows again, Voltage Regulator
x x troubleshoot the voltage regulator. Technical Manual ]
TP-6373 11/10
Trouble Symptoms
TP-6373 11/10
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Voltage regulator out of adjustment Adjust the voltage regulator. Voltage Regulator
x x
Technical Manual ]
Lube System
Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the Eng. O/M
x x x x
ambient temperature operating climate.
x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M
x TP-6373 11/10
Low oil pressure shutdown Check the oil level. Eng. O/M
21
2.2 Interface Circuit Board Verify connection and continuity of the wires shown in
Figure 2-2 and Figure 2-3. Check the wires for broken
GM11718 strands and damaged insulation including cuts and
The 550 controller has an integral voltage regulator. chafing. Check the terminals for corrosion and loose
Circuit board GM11718 interfaces between the PMG electrical connections. Repair and/or replace any
alternator and 550 controller voltage regulator. See defective wiring.
Figure 2-1 for an illustration of the circuit board. The
circuit board is typically located in the junction box. Circuit Board
Wire Connection Component Connection
There is no field test for this circuit board. Use the E12 P6-1 TB3-1
following information to help troubleshoot the circuit N P6-2 TB3-7
board.
EOV P6-3 TB4-4
3B P6-4 P1-16
5B P6-5 P1-20
Not used P6-6 none
PMG T1 PMG stator
PMG T2 PMG stator
F1 T3 F1 exciter stator
F2 T4 F2 exciter stator
Figure 2-2 Interface Circuit Board Connections
GM11718B-F
Figure 2-1 Interface Circuit Board GM11718
F2 F1 EXCITER
STATOR
RECTIFIER
MODULE PMG
ROTOR
AC F--
MAIN
AC ROTOR
T1 T2
F+ PMG
AC
STATOR STATOR
EXCITER
ROTOR
T3
F1 PMG
PMG
T4 CAPACITOR
F2
GM34560A-C
Figure 2-3 Interface Circuit Board Diagram with PMG Alternator
22 Section 2 Troubleshooting TP-6373 11/10

Do the checks shown in Figure 2-4. Shut down the unit If the circuit board is still suspected of questionable
after performing the start and run checks. function after the circuit board wiring checks out okay,
replace with a known good circuit board and test the
generator set for functionality.
Connections/Display Check Possible Causes

P6-E12 and P6-N connections 12 VDC supply from 550 Check battery and/or connections
controller
Check P6 connector and wiring
P6-3B and P6-5B connections 1-3 VDC output Check controller interconnection P1 connector and
(start and run unit for this test) wiring
Check T3 and T4 connections (field wires)
Check F1 and F2 winding and connections at exciter
stator
Field overvoltage fault display on 550 P6-EOV connection Check that P6-EOV to TB4-4 wire is not grounded
controller
T1 and T2 (PMG connections) 200--230 VAC stator Check T1 and T2 (PMG) connections
(start and run unit for this test) output
Check PMG stator winding and connections
F+ and F-- connections DC voltage (values are Check T3 and T4 connections (field wires)
alternator dependant)
Check F1 and F2 exciter stator winding and
connections
Figure 2-4 Interface Circuit Board GM11718 Testing
TP-6373 11/10 Section 2 Troubleshooting 23

Notes
24 Section 2 Troubleshooting TP-6373 11/10

Section 3 Alternator Disassembly/Reassembly
Before beginning alternator disassembly procedure, Use disassembly procedure as a step-by-step means to
carefully read all safety precautions at the beginning of help disassemble the alternator. The disassembly
this manual. Please observe these precautions and procedure provides important information to minimize
those included in text during the disassembly/ disassembly time and indicates where special
reassembly procedure. configurations exist that may require taking notes. The
reassembly procedure includes important alignment
The following procedures cover many models and some steps and provides critical torque specs.
steps may not apply to a particular engine. Use
Figure 3-1 or Figure 3-2 to help understand component
descriptions and general configuration of the alternator.
4 19
3
2
1 5 20
6 25 21
22
23
6
24
7 View B
8
17 9
18 26
10 Junction Box 27
16 Door
11 33
Drive Discs, part of 29
12 32
item 2, alternator
assembly 30
15 13
14 31
28
View A
Alternator Parts
TP-6185 10/03
1. Screen 12. Plate, alternator mounting 23. Washer, plain

2. Alternator assembly 13. Washer, plain 24. Nut, hex elastic stop
3. Junction box assembly 14. Screw, hex head 25. Screw, hex
4. Cover, top back 15. Spacer 26. Exciter rectifier assembly (includes items 27--29)
5. Screw, hex flange 16. Screw, hex 27. Diode standard polarity
6. Cover, louvered 17. Screw, hex cap 28. Surge suppressor
7. Screw, hex cap 18. Washer, hardened 29. Diode, reverse polarity
8. Washer, hardened 19. Bolt, hex cap 30. Fuse, 5 amp
9. Nut, hex elastic stop 20. Washer, plain 31. Fuse cap
10. Washer, plain 21. Vibromount 32. Capacitor
11. Vibromount 22. Plate, alternator mounting 33. Voltage regulator
Figure 3-1 Alternator Components, Slanted Box Type
TP-6373 11/10 Section 3 Alternator Disassembly/Reassembly 25

12
13 22 23
21
2 11 20
1 10
9
3
26
8 25 24
15 Insulated Standoffs
16 27
7 28
14
4 19 30
18 29
6
17
5
34
32
33
31
Drive Discs, Alternator 38

part of item 2,
36
alternator 37
assembly 45
39
35 58 44
54 55 57 42 40
43
67
41
66 56 Skid
59 Solid Mount Isolation Mount
53 Alternator Parts 47
46
52
65 49
61 60
64 48
62 51 50
63 Inner Panel Inner Panel Side View TP-6057 4/04
1. Door panel mounting bracket (top) 24. Plain washer 46. Exciter rectifier assembly
2. Vibromount 25. Spring washer 47. Standard polarity diode
3. Inner door panel 26. Threaded rod 48. Surge suppressor
4. Door panel mounting bracket (bottom) 27. Junction box panel (front) 49. Reversing polarity diode
5. Slotted pan head machine screw 28. Hex flange machine screw 50. Fuse cap
6. Access cover 29. Louvered cover 51. 5 amp fuse
7. Hex flange machine screw and retainer 30. Ground bus 52. Capacitor
8. Junction box door 31. Hex nut 53. Voltage regulator
9. DVR access cover 32. Lock washer 54. Relay
10. Threaded 1/4--20 in. insert 33. Spring washer 55. Relay
11. Junction box door 34. Plain washer 56. Lock washer
12. Governor controller 35. Alternator guard 57. Hex nut
13. Governor mounting bracket, vibromount, and lock washer 36. Hex cap screw 58. Controller Mount
14. Hex flange machine screw and retainer 37. Hardened washer 59. Inner panel mounting bracket
15. Access cover 38. Hex cap screw 60. Inner panel retainer
16. Hex flange machine screw 39. Vibromount 61. Controller mount
17. Screen 40. Mounting plate 62. Lock washer
18. Hex cap screw and hardened washer 41. Hex elastic stop nut 63. Bushing
19. Alternator assembly 42. Plain washer 64. Terminal block
20. Bushing 43. Hex nut 65. Thread cutting screw
21. Plain washer 44. Mounting plate 66. Bushing
22. Hex nut 45. Shim 67. Inner panel junction box
23. Standoff insulator
Figure 3-2 Alternator Components, Square Box Type
26 Section 3 Alternator Disassembly/Reassembly TP-6373 11/10

The fuel system. Explosive fuel vapors can cause severe
WARNING injury or death. Vaporized fuels are highly explosive. Use
extreme care when handling and storing fuels. Store fuels in a
well-ventilated area away from spark-producing equipment
and out of the reach of children. Never add fuel to the tank
while the engine is running because spilled fuel may ignite on
contact with hot parts or from sparks. Do not smoke or permit
Accidental starting. flames or sparks to occur near sources of spilled fuel or fuel
Can cause severe injury or death. vapors. Keep the fuel lines and connections tight and in good
condition. Do not replace flexible fuel lines with rigid lines. Use
Disconnect the battery cables before flexible sections to avoid fuel line breakage caused by
working on the generator set. vibration. Do not operate the generator set in the presence of
Remove the negative (--) lead first fuel leaks, fuel accumulation, or sparks. Repair fuel systems
when disconnecting the battery. before resuming generator set operation.
Reconnect the negative (--) lead last
when reconnecting the battery. Explosive fuel vapors can cause severe injury or death.
Take additional precautions when using the following fuels:
Disabling the generator set. Accidental starting can Propane (LP)—Adequate ventilation is mandatory. Because
cause severe injury or death. Before working on the propane is heavier than air, install propane gas detectors low in
generator set or connected equipment, disable the generator a room. Inspect the detectors per the manufacturer’s
set as follows: (1) Move the generator set master switch to the instructions.
OFF position. (2) Disconnect the power to the battery charger. Natural Gas—Adequate ventilation is mandatory. Because
(3) Remove the battery cables, negative (--) lead first. natural gas rises, install natural gas detectors high in a room.
Reconnect the negative (--) lead last when reconnecting the Inspect the detectors per the manufacturer’s instructions.
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote Perform the following steps prior to disassembling the
start/stop switch, or engine start command from a remote generator set.
computer.
1. Disconnect (negative lead first) and remove
WARNING starting batteries from work area to prevent fire
hazard. Disconnect AC-powered accessories,
such as battery charger, block heater, and fuel
transfer pump.
Hot engine and exhaust system. 2. Shut off fuel supply. Drain fuel system as
Can cause severe injury or death. necessary by emptying fuel into proper containers.
Remove any fuel containers from work area to
Do not work on the generator set until prevent fire hazard. Ventilate work area to clear
it cools.
fumes.
Servicing the exhaust system. Hot parts can cause 3. Disconnect fuel, cooling, and exhaust systems as
severe injury or death. Do not touch hot engine parts. The necessary to tilt generator set. Disconnect output
engine and exhaust system components become extremely
leads or load circuit cables at generator set.
hot during operation.
4. Any cranes, hoists, or other lifting devices used in
WARNING the disassembly or reassembly procedure must be
rated for the weight of the generator set. Check
generator set nameplate or spec sheet for weight.
Explosive fuel vapors.

Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.

3.1 Disassembly
1
1. Disconnect all controller-to-engine and engine-to-
alternator harnesses and wiring. Disconnect alarm
horn circuit board connector, if equipped. Remove
the controller as a unit.
2. Remove bolts (and shims, if used) between the

alternator assembly and skid.
3. Vibromount models. Suspend the alternator at

both ends with hooks in lifting eyes. Use a hoist to 3-098
raise the alternator end off the vibromounts. R8371-9
1. Flywheel studs
Rigid mount models. Suspend the alternator at
both ends with hooks in lifting eyes. Use a hoist to Figure 3-3 Flywheel Studs, Typical
raise the alternator end from skid.
3. Attach hoist to lifting eyes and place alternator
4. Support the engine by placing wood blocks under assembly in a horizontal position. Take care not to
flywheel housing. Lower alternator end until damage rotor or stator. Place hoisting eyes of
alternator flywheel housing rests on blocks. alternator to the top.
5. Remove fan guard. Remove bolts holding adapter 4. Raise the alternator assembly as necessary to
to flywheel housing. align the alternator adapter to the flywheel housing.
Install the hardware and torque to value given in
6. Remove hardware attaching drive discs to Section 1, Specifications.
flywheel.
5. Align drive discs to flywheel. Turn the flywheel as
7. Separate alternator from engine. necessary to align holes. Install hardware
attaching drive discs to flywheel. Do not final
8. Set alternator assembly on the floor in a horizontal tighten hardware at this time.
position. Remove support slings or chains.
6. Hoist alternator and engine slightly to remove
9. Use the appropriate technical manual for alternator wood block(s) from under flywheel housing. Align
assembly. alternator assembly and vibromounts. Lower
alternator and tighten vibromount mounting bolts.
3.2 Reassembly, 7. Remove chains or slings used for suspending

alternator. Final tighten drive discs to flywheel.
Vibromount Models Torque hardware to values given in Section 1,
Vibromount models use rubber cushion mounts Specifications.
between the generator set and skid.
8. Install fan guard.
Use the torque values given in Section 1, Specifications,
for torquing alternator adapter to flywheel housing and 9. Reinstall controller. Reconnect all controller-to-
drive discs to flywheel. Use Appendix C, General engine and engine-to-alternator harnesses and
Torque Specifications, when no specific values are wiring. Refer to wiring diagram manual as
shown in the reassembly procedure. required.
1. Use the appropriate technical manual for alternator 10. Reconnect fuel, cooling, and exhaust systems that
reassembly. were disconnected during disassembly.
Reconnect output leads or load circuit cables at
2. If studs are used, apply Loctiter No. 271 red to stud alternator. Refer to wiring diagram manual as
threads and install into flywheel as shown in required. Open fuel supply valve.
Figure 3-3. Install studs completely into flywheel.
Apply Loctiter No. 242 blue to stud threads on nut 11. Reconnect starting batteries, negative lead last.
side. Connect any AC-powered accessories such as
battery charger, block heater, fuel transfer pump,
etc.
Loctiter is a registered trademark of Loctite Corporation.

3.3 Reassembly, 10. Install alternator drive discs guide pin(s), if used, to
flywheel.
Rigid Mount Models
Note: Use a stud as a drive disc guide pin or
Rigid mount models do not use rubber cushion mounts
fabricate one by removing the hex head
between the generator set and skid. The alternator is
from a bolt. Remove any burrs.
mounted directly to the skid. This reassembly
procedure is intended to minimize bending at the rear 11. Clean all dust and debris from the alternator drive
face of the engine block and to ensure correct disc.
engagement of the generator set drive discs into the
pilot bore of the flywheel. To provide complete 12. Position the alternator behind the engine. Lower
reassembly information, this procedure includes the alternator behind the engine and engage flex
installation of the engine to the generator set skid. drive with guide pin(s), align as necessary. Do not
force the alignment of the components. Shift the
The shimming procedure will only apply to engines alternator from side to side or raise or lower with a
attached rigidly to the generator set skid. Shims are hoist, as necessary.
available as service parts, see Figure 3-4.
13. Install mounting bolts between the alternator
Qty. Description Part No. adapter and flywheel housing. Do not final tighten
As required Shim, 16 ga. 290743 at this time.
As required Shim, 7 ga. 290744
14. Tighten the extreme bottom four bolts to seat
As required Shim, 0.25 mm (0.01 in.) 291191 adapter plate to the flywheel housing.
Figure 3-4 Generator Set Shims
15. Place a 0.13 mm (0.005 in.) feeler gauge between
Use the torque values given in Section 1, Specifications, the adapter plate and flywheel housing at the
for torquing alternator adapter to flywheel housing and extreme top position. Raise the alternator until the
drive discs to flywheel. Use Appendix C, General gauge is snug. Reduce tension enough to remove
Torque Specifications, when no specific values are the feeler gauge. Tighten and torque all the
shown in the reassembly procedure. alternator adapter bolts to the flywheel housing.
Torque hardware to values given in Section 1,
1. Use the appropriate technical manual for alternator Specifications.
reassembly.
16. Align drive discs to flywheel. Turn the flywheel as
2. If studs are used, apply Loctiter No. 271 red to stud necessary to align holes. Install hardware
threads and install into flywheel as shown in attaching drive discs to flywheel. Do not final
Figure 3-3. Install studs completely into flywheel. tighten hardware at this time.
Apply Loctiter No. 242 blue to stud threads on nut
side. 17. Check for complete drive disc engagement of the
pilot diameter of the flywheel. If the drive discs are
3. Lift engine with hoist. not completely engaged into the pilot diameter,
note location of improper engagement and go to
4. Position engine over skid and lower front of engine
step 26, Prestart Test Sequence.
to skid.
18. At this point in the assembly procedure, the weight
5. Assemble mounting hardware to front engine
of the rear portion of the engine and alternator can
mounting supports.
be supported by a single hoist.
6. Attach rear engine mounting supports to engine (if
19. Install shims at the front alternator crossmember to
used), install the hardware tight enough to hold the
support the engine/alternator at the present height.
mounting plate to the flywheel housing.
Lower the alternator down onto the shims.
7. Position and lower rear of engine to skid.
20. Install shims at the rear alternator crossmember.
8. Assemble mounting hardware to rear engine Place shims so that the force is equally distributed
mounts and skid. Do not tighten at this time. to all shim stacks.
9. Clean all preservative materials from machined 21. Install alternator mounting bolts through all shim
surfaces of the flywheel and flywheel housing. stacks, tighten and torque the hardware.
Loctiter is a registered trademark of Loctite Corporation.

22. Tighten and torque the hardware that retains the 37. Reconnect starting batteries, negative lead last.
rear engine supports to the skid and flywheel Connect any AC-powered accessories such as
housing. battery charger, block heater, fuel transfer pump,
etc.
23. Remove chains or slings used for suspending
alternator.
24. Tighten and torque engine front mounting bolts.

15 1 16
14 17
25. Do not install the alternator fan guard at this time. 13 18
12 4
26. Prestart Test Sequence. Use the following steps 18-Bolt
to assure complete seating of the alternator drive 3 5
discs in the pilot diameter of the flywheel. 11 6
10 7
9 2 8
27. Verify that the fuel rack is closed. Refer to the
engine literature as needed.
1 1
28. Disconnect the DC power leads to the governor 8 9
actuator. Tape to insulate the DC power lead 3 6
terminals. 3 4
9-Bolt 6-Bolt
29. Connect the starting batteries to the engine,
negative lead last. 7 5 5 4
6 2 2
30. Place the generator set master switch to the RUN
position to crank the engine for approximately
TP-5583-8
5 seconds or long enough to provide at least
10 engine revolutions. Return the generator set Figure 3-5 Drive Disc Bolt Tightening Sequence
switch to the OFF/RESET position.
31. Disconnect the starting batteries, negative lead

first. 3.4 Dual Bearing Alternator
Installation and Alignment
32. Torque the drive disc bolts using the values given in
Section 1, Specifications, and in the sequence Adapted from Service Bulletin SB-566 10/10b.
shown in Figure 3-5. Recheck the bolt torque.
Perform the following procedure before operating
33. Check the torque on all engine mounting hardware. the generator set to 1) prevent alternator failure and
2) maintain the warranty coverage.
34. Install the fan guard.
Align the alternator to the engine to ensure proper
35. Reinstall controller. Reconnect all controller-to- alternator bearing operation and long life. Excessive
engine and engine-to-alternator harnesses and misalignment causes vibration, noisy operation,
wiring. Refer to wiring diagram manual as coupling wear, and premature bearing failure.
required.
Check and adjust, if necessary, the angular, axial, and
36. Reconnect fuel, cooling, and exhaust systems that parallel alignment of the coupling any time the generator
were disconnected during disassembly. set is moved. Insert dowels into the generator set frame
Reconnect output leads or load circuit cables at through the mounting base to ensure that no movement
alternator. Refer to wiring diagram manual as in the alignment occurs during operation after generator
required. Open the fuel supply valve. set installation and coupling alignment. Follow the
general recommendations provided to ensure correct
alignment of the alternator to the engine.

3.4.1 Safety Precautions D Drill bit and reamer,
25.30--25.32 mm (0.996--0.997 in.)
D Sledge hammer
WARNING
D Brass drift
3.4.3 Procedure
1. Disable generator set.
Accidental starting.
Can cause severe injury or death. a. Place the generator set master switch in the
OFF/RESET position.
Disconnect the battery cables before
working on the generator set.
b. Disconnect the power to the battery charger, if
when disconnecting the battery. equipped.
when reconnecting the battery. c. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the 2. Prepare for alignment.
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the a. Locate and level the alternator and engine on
OFF position. (2) Disconnect the power to the battery charger. the mounting pad. Install spring isolators using
(3) Remove the battery cables, negative (--) lead first. the location shown in the dimension drawing.
Reconnect the negative (--) lead last when reconnecting the See the generator set installation manual for
battery. Follow these precautions to prevent starting of the more information on mounting and vibration
generator set by an automatic transfer switch, remote isolation.
start/stop switch, or engine start command from a remote
computer.
b. Remove both the top and bottom coupling
High voltage test. Hazardous voltage can cause severe guards. See Figure 3-6.
injury or death. Follow the instructions of the test equipment
manufacturer when performing high-voltage tests on the rotor c. Remove right side flywheel cover plate from the
or stator. An improper test procedure can damage equipment engine. See Figure 3-6.
or lead to generator set failure.
d. Mount the engine barring tool where the cover
NOTICE plate was removed.
The engine and generator set may use both American
Standard and metric hardware. Use the correct size
tools to prevent rounding of the bolt heads and nuts.
1
3.4.2 Required Tools
D Assorted combination wrenches
D Assorted socket wrenches and ratchet
D Torque wrench and/or torque multiplier capable of
1060 Nm (782 ft. lb.)
D Straight edge (to measure axial gap)
D 12 in. ruler graduated in 1/32 in.
(to measure axial gap) 4 3 2 GM29817-B
D Two dial indicators

(measure parallel and angular alignment)
D Magnetic bases, posts, and clamps for indicators 1. Top half coupling guard
(to measure parallel and angular alignment) 2. Right side flywheel cover plate
3. Bottom half coupling guard
D Feeler gauges 4. Screw jack
D Mirror with extended handle to read indicator in tight
spots (to measure parallel and angular alignment) Figure 3-6 2000--3250 kW Assembly Drawing,
Typical
D Engine barring tool
D Drill (1/2 in. minimum)

e. Remove or reposition the following items (as Note: If flexible coupling requires replacement,
necessary) on the generator set to provide mark the engine-mounted coupling and
better access to the coupling: the alternator-mounted coupling so that
the set is recoupled exactly as it was
D Air cleaner and supports uncoupled.
D Battery charger
D Fuel filter mounting D E
D Fuel line mounting
3. Attach and set up dial.

B
a. Attach the dial indicator bases to one of the
A
coupling halves and locate the dial indicators for
measurements as shown in Figure 3-7 and
Figure 3-8.
b. Place one dial indicator with the tip on the

outside diameter and perpendicular to the shaft C
(parallel alignment).
c. Place the other dial indicator with the tip located

on the coupling face as close to the outside
diameter as possible (angular alignment).
d. Set each plunger at the midpoint of travel. Face A

Rotate the indicators so that they are at the top Face B minus Face A = average axial gap
location and zero the indicator. Mount dial indicator on shaft at C
Locate dial indicator pointer at D for radial alignment
Locate dial indicator pointer at E for angular alignment
e. Mark the coupling hub at 0°, 90°, 180°, and
270° and make a reference mark on the Figure 3-7 Dial Indicator Setup
stationary portion of the unit.
Value A
Value B
Engine Gen. Engine Gen. Engine Gen.

Side Side Side Side Side Side
1. Axial Gap Measurement 2. Angular Alignment Setup 3. Parallel Alignment Setup
A. Average Axial Gap: B. Radius of Angular Measurement Point:
Figure 3-8 Dial Indicator Setup

4. Types of coupling alignment.
Example A
The coupling has three basic alignment dimensions— Parallel (Radial) Measurements
axial, angular, and parallel. Misalignment of any one
0.000 in.
or more of the above can cause coupling
misalignment. See Figure 3-9. Figure 3-10 shows
a typical set of measurements and their
--0.002 in. +0.002 in.
corresponding Total Indicator Readings (TIR).
(--0.002)--(0.002)=--0.004 TIR
0.005 in.
(0.000)--(0.005)=--0.005 TIR
Example B
Angular (Face) Measurements

Axial
0.000 in.
+0.002 in. --0.001 in.
(+0.002)--(--0.001) = 0.003 TIR

--0.004 in.
Angular (Face)
(0.000)--(--0.004) = 0.004 TIR
Radius of Measurement Point = 10 in.

Allowable Misalignment = 0.0006 x 10 = 0.006 in. TIR
Figure 3-10 Sample Measurements
Parallel (Radial)
SB560
Angular Parallel
TIR* TIR*
*TIR—Total Indicator Runout
Figure 3-9 Alignment Types

5. Align.
a. Inspect axial alignment. Use a graduated ruler

or inside caliper and straight edge to measure 1
axial alignment. See Figure 3-7, Figure 3-8,
Figure 3-9, Figure 3-11, or Figure 3-12. Keep
straight edge away from the inside radius. 2
b. Inspect angular and parallel alignment. See

Figure 3-14 for documenting alignment data.
Make copies of Alignment Worksheet, as
necessary.
Rotate both shafts together when taking

measurements. Take measurements at 90°
increments and return coupling to initial
position to check that indicators are at zero. If
indicators are not at zero, reset indicators and
repeat alignment measurement.
Make parallel and angular alignment

measurements at the same time from the same
position, if possible. If measurements are not
made at the same time, mark the coupling and
SB-566-S
take measurements from the same position
(degrees) for each measurement. 1. Angular (face)
2. Axial
Figure 3-12 Axial Alignment Measurement with HTB

Coupling
1
c. Compare the measurement values to the
maximum allowable shaft misalignment values
shown in Figure 3-13.
Axial Angular Parallel

Measurement, (Face), (Radial),
Model mm (in.) mm (in.) mm (in.)
2000-3250 kW
1.0 1.5
(Arcusaflexr ᐔ4 (ᐔ0.157)
(0.039) (0.059)
Coupling AC 11)
2000 kW
216.0 ᐔ0.8 0.015 0.13
(Atra--Flexr
(8.5 ᐔ1/32) (0.0006) (0.005)
Coupling)
2000 kW 0.61 0.30 2.54
(RB Coupling) (0.024) (0.012) (0.10)
1 2500 kW/
2800 kW 23.11 ᐔ1.0 0.41
0 (0)
new (0.91 ᐔ0.04) (0.016)
(HTB Coupling)
216.0 mm ± 0.8 mm
(8.50 in. ± 1/32 in.) 2500 kW/
347468-E
2800 kW 23.11 ᐔ1.0 1.5
0 (0)
used * (0.91 ᐔ0.10) (0.060)
(HTB Coupling)
1. Straight edge location
* Inspect after approximately 10000 hours.
Figure 3-11 Axial Alignment Measurement with
Figure 3-13 Maximum Allowable Shaft Misalignment
Atraflex Coupling
Arcusaflexr is a registered trademark of Reich--Kupplungen,

Germany.
Atra--Flexr is a registered trademark of ATR Sales, Inc.

Parallel Alignment Measurements Angular Alignment Measurements
1. 2. 1. 2.
3. 4. 3. 4.
1. 2. 1. 2.
3. 4. 3. 4.
1. 2. 1. 2.
3. 4. 3. 4.
Figure 3-14 Alignment Worksheet (photocopy as necessary)

6. Correct alignment. c. Check the alternator for soft foot condition.
a. Go to step 7.a. if measurements meet the If no soft foot exists, go to step 6.d. If soft foot
specifications. Go to the next step if the needs correction, perform the following steps.
measurements do not meet the specifications.
D Tighten the eight alignment bolts to 136 Nm
It is good practice to first correct the parallel and (100 ft. lb.) against the alternator to prevent
angular misalignment in the horizontal plane. it from moving.
Jack screws attached to the skid can be used to
adjust the location in the horizontal plane. After D Loosen the four alternator mounting bolts
following the alignment corrections, a new set one at a time and measure the relative
of alignment measurements should be made. If movement with a dial indicator.
the alignment in the horizontal plane are within
limits, proceed with correction in the vertical D Shim the alternator for soft foot using jack
plane. screws and supplied shims to eliminate that
relative movement. The relative movement
Evaluate the measurements and determine the should not exceed 0.13 mm (0.005 in.).
correction process. Corrections for parallel and Shims with burrs on the edges can contribute
angular misalignment can be made at the same to the soft foot condition.
time. Take new measurements after
corrections are made. D Tighten the alternator mounting bolts.
Note: The factory ships the adjustment block d. Check angular, axial, and parallel alignments.
bolts, shims, and dowel pins loose with See Figure 3-15. Use the jack screws and
the generator set. shims to adjust the height of the alternator. Use
adjustment bolts to adjust horizontal position of
b. Install the eight adjustment bolts into the four the alternator. Loosen opposing adjustment
adjustment blocks on the generator set skid. bolt prior to tightening an adjustment bolt.
See Figure 3-15. Keep the eight adjustment
screws loose so they do not affect soft foot Note: Replace all damaged hardware. Do not
measurements. Soft foot exists when the reuse crushed, cupped, or otherwise
alternator does not rest flat on its base and only distorted washers or shims.
three of the four mounting points support the D Loosen the alternator mounting bolts.
alternator.
D Make adjustments to the horizontal plane.
D Tighten alternator mounting bolts.
D Reinspect alignment.
D Loosen alternator mounting bolts.
D Make adjustments to the vertical plane.
D Tighten alternator mounting bolts.
D Reinspect alignment.
e. Verify that alignment meets specifications.
f. Tighten all adjustment blocks to 136 Nm

GM29817-B
(100 ft. lb.) to prevent movement during
1 2 3 4 torquing.
g. Torque mounting bolts to 407 Nm (300 ft. lb.) in

a clockwise bolt pattern sequence. Then
torque mounting bolts to 1060 Nm ±10%
(782 ft. lb. ±10%) in a clockwise bolt pattern
sequence.
View C-C
5 h. Recheck all alignment measurements after
1. Adjustment blocks (4) 4. Jack screws (4) torquing. Repeat alignment procedure if
2. Alternator mounting bolts (4) 5. Adjustment block bolts (8) measurements do not meet specifications.
3. Dowel location (4)
Figure 3-15 Alternator Adjustment Layout

7. Assemble components. 3.4.4 Electrical Test/Long Term Storage
a. Record the final alignment measurements for If the generator set is exposed to extreme dampness
reference purposes. during shipment or storage, an initial period of operation
may be necessary to dry all windings. Determine the
b. Remove engine barring tool from the starter need for drying out by measuring the stator insulation
mounting location. resistance with a megohmmeter. Connect the
megohmmeter between the stator terminal and
c. Reinstall engine starter motor. generator set frame. The one-minute test of the stator
resistance at an ambient temperature of 40_C (104_F)
d. Reposition or reinstall any items moved during
must be at least:
the alignment procedure.
Rated voltage of unit/1000 +1 = Minimum resistance value (megohms)
e. Reinstall the top and bottom coupling guards.
See Figure 3-6. If the stator insulation resistance measures less than
specified for the generator set voltage rating, the unit
8. Install dowel pin.
must be dried out until at least the minimum
a. Select opposite corner dowel pin mounting recommended resistance value is obtained. Dry out the
locations. See Figure 3-15. unit by applying an external heat to obtain an end-
winding temperature of 75_C (167_F) using a
b. Drill and ream the existing 22.22 mm (0.875 in.) thermometer. Apply heat evenly and slowly to avoid
hole in the skid to 25.30--25.32 mm (0.996-- excessive vapor or gas pressure harmful to insulation.
0.997 in.). Do not exceed a temperature rise of 10_C (18_F) per
hour.
c. Drive in the supplied dowel pins using a brass
drift and sledge hammer within 12.70-- The easiest and most convenient method of drying out
15.87 mm (0.50--0.63 in.) from the alternator the alternator is by placing the complete or partially
base. disassembled alternator in an oven. Apply external heat
using space heaters beneath the alternator to obtain an
9. Place generator set back in service. even distribution of heat along the length of the unit. Be
sure to provide adequate air circulation to ensure a
a. Place the generator set master switch in the complete and thorough drying out process.
OFF/RESET position.
When the generator set is placed in storage or not in
b. Reconnect the generator set engine starting use, the alternator strip heaters should be energized
battery(ies), negative (--) lead last. unless the unit is in a humidity controlled environment.
When in storage, the unit should have adequate air
c. Reconnect the power to the battery charger, if circulation for moisture removal and prevention of
equipped. overheating.
d. Move the generator set master switch to AUTO
for startup by remote transfer switch or remote
start/stop switch.

3.5 Fan Pulley Alignment with 3.5.2 Required Tools
Pillow Block Idler Pulley D Straight edge (machinist’s ruler), 610 mm (24 in.)
Design, 1250--3250 kW with D Belt tension gauge (Kent-Moore BT-3384 or
DD/MTU Series 4000 Engines equivalent)
Adapted from Service Bulletin SB-582 10/06a. 3.5.3 Procedure

Use this information when aligning the fan pulley and 1. Disable the generator set.
engine drive pulley. Perform the alignment procedure at
initial startup or when reassembling the generator set a. Place the generator set master switch in the
after component replacement. Failure to perform this OFF position.
procedure may cause generator set cooling system
problems and/or premature pulley belt failure. b. Disconnect the power to the battery charger
and block heater, if equipped.
3.5.1 Safety Precautions c. Disconnect the generator set engine starting
Observe the following safety precautions while
performing the fan pulley alignment procedure. d. Remove the belt guards, as necessary, to
access the poly-V belt and the pulleys if not
WARNING already removed.
2. Pulley alignment.
a. Align the fan pulley with the engine drive pulley.

The second groove of the engine drive pulley
must align with the first groove of the fan pulley.
Can cause severe injury or death. See Figure 3-16.
Disconnect the battery cables before (1) Place a straight edge (machinist’s ruler) on
working on the generator set. the left side, as viewed from the radiator
Remove the negative (--) lead first end, of the fan shaft along the face of the
when disconnecting the battery. engine drive pulley and adjust the fan shaft
when reconnecting the battery.
so that the measurement between the
straight edge and the first groove of the fan
pulley is 13.5 mm (0.53 in.).
cause severe injury or death. Before working on the Adjust the front-to-back pulley alignment
generator set or connected equipment, disable the generator
by loosening the fan shaft set screws. See
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger. Figure 3-17. Adjust the left-to-right pulley
(3) Remove the battery cables, negative (--) lead first. alignment by loosening the fan shaft pillow
Reconnect the negative (--) lead last when reconnecting the block mounting hardware. See Figure 3-16.
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote (2) Repeat above procedure using the straight
start/stop switch, or engine start command from a remote edge on the right side, as viewed from the
computer. radiator end, of the fan shaft.
Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death. Keep The pulley alignment measurement on
hands, feet, hair, clothing, and test leads away from the belts both the left and the right side of the fan
and pulleys when the generator set is running. Replace pulley must be 13.5 mm (0.53 in.) as
guards, screens, and covers before operating the generator viewed from the radiator end. Adjust the
set. fan shaft pillow block as required so that
both the left and right measurements are
13.5 mm (0.53 in.).

(3) Make sure the fan shaft pillow block
13.5 mm (0.53 in.) mounting hardware is tight. Hold the bolts
while tightening the nuts. Torque the
1
mounting hardware to 325 Nm (240 ft. lb.).
2
3 4
(4) Verify the pulley alignment by measuring
the distance from the straight edge to the
8 first groove on the fan pulley and from the
straight edge to the second groove on the
engine drive pulley. Measure the distance
on both the left and right sides of the fan
shaft.
The measurement from the straight edge

to the first groove on the fan pulley and the
measurement from the straight edge to the
second groove on the engine drive pulley
Engine Fan must be 13.5 mm (0.53 in.) on both sides.
Side Side
If the measurements are not 13.5 mm
7 (0.53 in.), adjust the fan shaft as required to
achieve 13.5 mm (0.53 in.) measurement.
6
Note: Fan and engine drive pulleys must
be parallel with grooves aligned.
b. Verify that the idler pulley shaft set screws are

torqued to 19 Nm (14 ft. lb.).
c. Verify that the fan shaft set screws are torqued

to 33 Nm (24 ft. lb.). See Figure 3-17.
5
1. Straight edge (machinist’s ruler) SB-582
d. Recheck the alignment of the fan and engine
2. Fan pulley (use first groove for item 7) pulleys as described in step 2.a.
3. Fan shaft pillow block
4. Fan shaft pillow block mounting hardware
5. Engine drive pulley (use second groove for item 7)
6. Idler pulley shaft
7. Groove alignment (align first groove of fan pulley with
second groove of engine drive pulley)
8. Fan shaft
Figure 3-16 Pulley Alignment, Side View
View A-A
Fan Side
A A
3
1
1. Fan shaft pillow block 3 SB-582

2. Idler pulley shaft pillow block
3. Set screws
Figure 3-17 Fan Shaft Set Screws

3. Inspect drive belt. 4. Adjust the idler slide block.
a. Inspect the fan drive belt for damage or wear. a. Verify that the idler pulley pillow block to idler
Replace the belt if it is damaged or worn. slide block mounting bolts (topside) are torqued
to 92 Nm (68 ft. lb.) See Figure 3-19.
b. Install the poly-V belt. Align the poly-V belt with
the second groove on the engine drive pulley
and the first groove on the fan pulley from the
fan side. See Figure 3-16 and Figure 3-18.
Note: The engine drive pulley will have two

1
open grooves on the engine side.
6
c. Center the idler pulley on the poly-V belt.
1 5 2
2
3
Engine Fan
TT--852
Side Side
1. Vertical bearing support
2. Idler pulley adjusting bolts (belt tension)
6
3. Idler bearing support
4. Idler slide block locking bolts
5. Idler slide block
6. Idler pulley pillow block mounting bolts
5
Figure 3-19 Idler Pulley Pillow Block Mounting on
Fan-Bearing Support, Rear View
b. Loosen the idler slide block to idler bearing

support locking bolts (underside).
c. Adjust the idler pulley by turning the two

4 3 SB-582 adjusting bolts located on the side of the
1. Fan pulley (use first groove for poly-V belt ) vertical fan bearing support.
2. Poly-V belt
3. Engine drive pulley (use second groove for poly-V belt) d. Verify that the fan belt is seated in the second
4. Engine drive pulley with two grooves open groove on the engine drive pulley and the first
5. Engine drive shaft
6. Idler pulley groove on the fan pulley from the fan side.
7. Fan shaft
Figure 3-18 Belt Installation

e. Check the fan belt tension using a poly-V
(serpentine) belt tension gauge. See
Figure 3-20 for belt tension specifications.
Adjust the belt tension by turning the two idler 1
pulley adjusting bolts. See Figure 3-19 for
location. 2
New Belt, N (lbf.) Used Belt, N (lbf.) * 3
2450--2890 (550--650) 1650--1910 (370--430)

* A belt is considered used after 50 hours of service.
Figure 3-20 Poly-V Belt Tension Specifications

GM35186B-F
f. Tighten the idler slide block to idler bearing 1. Fan shaft pillow block 3. Idler pulley tensioning arm
2. Idler pulley
support locking bolts (underside) after reaching
the specified belt tension. Torque the bolts to Figure 3-21 Tensioning Arm Design
92 Nm (68 ft. lb.).
g. Reinstall belt guards using original hardware. 3.6.1 Safety Precautions

5. Place the unit back in service.
WARNING
a. Reconnect the generator set engine starting
battery(ies), negative (--) lead last.
b. Move the generator set master switch to the

RUN position to start the generator set.
c. Listen for a squeaking or squealing noise from Can cause severe injury or death.
the fan belt, which indicates a slipping belt. Disconnect the battery cables before
Stop the generator set. working on the generator set.
If the fan belt slips, disconnect the engine when disconnecting the battery.
starting battery(ies). Increase the belt tension Reconnect the negative (--) lead last
to eliminate slippage using the procedure when reconnecting the battery.
starting with step 4.b.
d. Reconnect the power to the battery charger cause severe injury or death. Before working on the
and block heater, if equipped. generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
3.6 Fan Pulley Alignment with (3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
Tensioning Arm Idler Pulley battery. Follow these precautions to prevent starting of the
Design, 1350--3250 kW with generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
DD/MTU Series 4000 Engines computer.
Adapted from Service Bulletin SB-663 10/06. Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death. Keep
Use this information when aligning the fan pulley and hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
engine drive pulley with the tensioning arm design; see
guards, screens, and covers before operating the generator
Figure 3-21. Perform the alignment procedure at initial set.
startup or when reassembling the generator set after
component replacement. Failure to perform this
procedure may cause generator set cooling system
problems and/or premature poly-V belt failure.

3.6.2 Required Tools and Supplies c. Adjust the idler pulley parallel alignment. Use
this adjustment to correct for nonparallel
D Straight edge (machinist’s ruler), 610 mm (24 in.) alignment with the engine drive pulley.
D Poly-V belt tension gauge (Kent-Moore BT-3384 or
equivalent) (1) Adjust the idler pulley assembly using the
adjusting screws shown in Figure 3-23.
D PERMA-LOCr MM-115 (blue) or equivalent thread
locking compound (PERMA-LOCr is a registered (2) Check that the inside and outside left-to-
trademark of Permabond, a National Starch and right screws are tight.
Chemical Company)
Observe the safety precautions while performing the fan (3) Loosen the pivot screw on the idler arm
pulley alignment procedure. mounting bracket.
(4) Loosen the pivot screw on the 3-hole

3.6.3 Procedure mounting plate.
1. Remove the generator set from service. (5) Loosen the front-to-back adjusting screws.
a. Place the generator set master switch in the

OFF position. 7 mm
(0.275 in.)
b. Disconnect the power to the battery charger
and block heater, if equipped.
c. Disconnect the generator set engine starting 4 1

2. Align the idler pulley. Fan Side Engine Side
2
a. Remove the belt guards, as necessary, to
access the poly-V belt and pulleys, if not
already removed.
b. Check the alignment of the idler pulley to the

3
engine drive pulley.
Place a straight edge (machinist’s ruler) on the SB-663
engine drive pulley and check the distance that

1. Idler pulley 3. Straight edge (machinist’s ruler)
the idler pulley is set back from the front of the 2. Engine drive pulley 4. Idler pulley offset
engine drive pulley at four opposing points
(rotate the idler pulley 90_ per check). See Figure 3-22 Pulley Alignment, Side View
Figure 3-22. The offset should be 7 mm
(0.275 in.) and the difference between each
measurement should not exceed 4 mm
(0.015 in.).
If the alignment is correct, go to step 3.
If the alignment is incorrect, go to step 2.c.

and/or step 2.d.

(6) Loosen the two adjusting screws and (11) Tighten the pivot screw on the idler arm
mounting bracket screw. mounting bracket.
(7) Adjust, as necessary, the idler pulley (12) Tighten the inside and outside left-to-right
horizontal parallel alignment to the engine adjusting screws.
drive pulley. This adjustment is made by
lightly tapping the idler arm mounting (13) Recheck that the idler pulley is parallel to
bracket and 3-hole mounting plate with a the engine drive pulley.
hammer.
(14) Recheck the idler pulley offset.
(8) Tighten the two front-to-back adjusting
screws and pivot screw on the 3-hole (15) If the alignment is correct, go to step 3. If
mounting plate. the idler pulley offset is incorrect, go to
step 2.d. to change the offset.
(9) Loosen the inside and outside left-to-right
adjusting screws. d. Adjust the idler pulley offset alignment. Use
this adjustment to change the offset of the idler
(10) Temporarily install (user-supplied) two pulley from the engine drive pulley.
screws M10-1.5 x 30, grade 8.8 (M933-
10030-60) with nuts M10-1.5 as shown in Adding a washer decreases the offset and
Figure 3-23. Use these two screws to removing a washer increases the offset. Use at
adjust the vertical parallel alignment of the least one washer and do not exceed three
idler arm mounting bracket. Use the nuts to washers.
lock to screw positions.
Keep these screws/nuts installed until

instructed to remove them later in the belt
tension procedure.
2
7
H H
3
4
View H-H
See Detail G 6 5
8 Detail G
GM35186B-F
1. Inside left-to-right adjusting screw 5. Pivot screw on idler arm mounting bracket
2. 3-hole mounting plate 6. Idler arm mounting bracket
3. Pivot screw on 3-hole mounting plate 7. Outside left-to-right adjusting screw
4. Front-to-back adjusting screws 8. Mounting bracket positioning screws/nuts (user-supplied)
Figure 3-23 Idler Pulley Arm Bracket and Plate Adjustment

(1) Remove the tensioner arm nut. See (6) Install the tensioner arm nut and tighten.
Figure 3-24.
(7) Repeat step 2.b.
(2) Remove the idler pulley and hardware from
the tensioner arm. 3. Align the fan pulley.
Note: Mark the hole in the tensioner arm a. Check the alignment of the fan pulley with the
that mounts the idler pulley. engine drive pulley by placing a straight edge
(machinist’s ruler) on the engine drive pulley
(3) Add one plain washer X-25-29, 20.62 x left side as viewed from the radiator end. The
37.31 x 3.4 mm (0.812 x 1.469 x 0.134 in.), second groove of the engine drive pulley must
to the tensioner arm bolt for a total of three align with first groove of the fan pulley. See
washers to decrease the offset. Figure 3-26 for the straight edge position and
for clearance specifications.
If three washers are already present, one
can be removed to increase the offset. b. Repeat step 3.a. using the straight edge on the
engine drive pulley right side as viewed from
the radiator end.
7 1
If the alignment is incorrect, go to step 3.c.
6
If the alignment is correct, go to step 4.
5 c. Adjust the fan pulley shaft so that it extends
209 mm (8.23 in.) behind fan tower. See
4 Figure 3-25.
Detail F
3
See Detail F
1 2
GM35186B-F
1. Idler pulley
2. Engine pulley 4
3. 1.5 mm ((0.06 in.) clearance required between tensioner
arm and pulley
4. Tensioner arm
5. Tighten nut finger tight against the bearing, 6.8 Nm
(60 in. lb.) max. torque
6. Tensioner arm nut
7. Washer
Figure 3-24 Idler Pulley Arm and Pulley Assembly
(4) The nut between the idler arm and pulley GM35186B-F
must be only finger tight against bearing. 1. Fan shaft pillow block adjusting bolts (qty. 4)
2. Fan shaft pillow block (qty. 2)
Do not exceed 6.8 Nm (60 in. lb.) or (each pillow block has two set screws located on top)
bearing failure may result. 3. Fan shaft
4. Fan tower
(5) Mount the idler pulley and hardware to the
tensioner arm in the original hole as noted Figure 3-25 Idler Pulley Arm and Pulley Assembly
in step 2.d.(2).

d. Loosen the four fan shaft pillow block adjusting
3.82 mm (0.15 in.) bolts.
Note: If the fan shaft pillow block is replaced,

use GM30510 shims (16 ga.) as
needed.
1
e. Loosen and remove set screws from the fan
shaft pillow blocks. See Figure 3-25.
f. Remove thread-locking compound from set

screws using solvent (lacquer thinner) or use
new set screws.
6
g. Tighten the fan shaft pillow block adjusting bolts
sufficiently to check alignment and prevent
unwanted movement.
Fan Side Engine Side
h. Check that the fan pulley is parallel to the
engine drive pulley by measuring the fan pulley
2
distance from an engine machined surface.
Rotate the fan pulley 180_ and measure again.
3 The two values should not differ by more than
7 mm 0.4 mm (1/64 in.).
(0.275 in.) 4
Adjust the fan shaft pillow blocks as needed to
meet the specification and to center the fan
5 blades within the radiator shroud opening.
i. Torque the four fan shaft pillow block adjusting

bolts to 375 Nm (276 ft. lb.).
j. With set screws clean and dry, apply PERMA-

LOCr MM-115 (blue) or equivalent to the set
screws and install in the fan shaft pillow blocks.
k. Torque the set screws to 33 Nm (24 ft. lb.).

SB-663
4. Adjust the belt tension.
1. Fan pulley
2. Groove alignment (first groove of fan pulley) a. Inspect the poly-V belt for damage or wear.
3. Idler pulley
4. Groove alignment (second groove of engine drive pulley)
Replace the poly-V belt if it is damaged or worn.
5. Engine drive pulley
6. Straight edge (machinist’s ruler)
Figure 3-26 Pulley Alignment, Side View

b. Loosen the belt tensioner M20 screw and f. Check the fan belt tension using a poly-V
tension adjustment M10 screw/nut to remove (serpentine) belt tension gauge. See
the tension on the idler arm if not already done. Figure 3-28 for belt tension specifications.
See Figure 3-27.
New Belt, N (lbf.) Used Belt, N (lbf.) *
1334 ±111 (300 ±25) 1112 ±111 (250 ±25)
* A belt is considered used after 50 hours of service.
Figure 3-28 Poly-V Belt Tension Specifications
See Detail G
g. Tighten the tension adjustment M10 screw/nut.
h. Tighten the belt tensioner M20 screw.
i. Verify that the fan belt is seated in the second

groove on the engine drive pulley and the first
groove on the fan pulley from the fan side.
j. Recheck the fan belt tension using a poly-V

(serpentine) belt tension gauge. See
Figure 3-28 for belt tension specifications.
1
If the belt tension is correct, go to step 4.k.
2
If the belt tension is incorrect, go back to
step 4.e.
3
k. Final tighten the tension adjustment M10
4 screw/nut to lock the belt tension.
5 l. Torque the belt tensioner M20 screw to 410 Nm

(302 ft. lb.).
6 Detail G
GM35186B-F
m. Remove the user-supplied positioning screws
1. Idler arm
2. Square body of belt tensioner (use pipe wrench to adjust and nuts installed in the bottom of the mounting
tension) bracket. See Figure 3-27.
3. Belt tensioner M20 screw
4. Tension adjustment M10 screw/nut (tighten to lock tension)
5. Idler arm mounting bracket n. Reinstall the belt guards using the original
6. Mounting bracket positioning screws/nuts (user-supplied) hardware.
Figure 3-27 Belt Tension Adjustment 5. Restore the generator set to service.
c. Install the poly-V belt. Align the poly-V belt with a. Reconnect the generator set engine starting
the second groove on the engine drive pulley battery(ies), negative (--) lead last.
and the first groove on the fan pulley from the
fan side. See Figure 3-26. b. Move the generator set master switch to the
RUN position to start the generator set.
d. Center the idler pulley on the poly-V belt so the
poly-V belt is approximately vertical. c. Listen for a squeaking or squealing noise from
the fan belt, which indicates a slipping belt.
e. Set the belt tension by placing a long-handled Stop the generator set.
(24 in. min.) pipe wrench on the square body of
the belt tensioner and turning inward toward the If the fan belt slips, disconnect the engine
center of the drive and fan pulleys. starting battery(ies). Increase the belt tension
to eliminate slippage using the procedure
Note: It is recommended that the adjustment starting with step 4.e.
procedure have two technicians
present; one to set the belt tension and d. Reconnect the power to the battery charger
one to check the belt tension and then and block heater, if equipped.
tighten the screws.

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cm centimeter fl. oz. fluid ounce
ABDC after bottom dead center CMOS complementary metal oxide flex. flexible
AC alternating current substrate (semiconductor) freq. frequency
A/D analog to digital cogen. cogeneration FS full scale
ADC advanced digital control; com communications (port) ft. foot, feet
analog to digital converter coml commercial ft. lb. foot pounds (torque)
adj. adjust, adjustment Coml/Rec Commercial/Recreational ft./min. feet per minute
ADV advertising dimensional conn. connection ftp file transfer protocol
drawing cont. continued g gram
Ah amp-hour CPVC chlorinated polyvinyl chloride ga. gauge (meters, wire size)
AHWT anticipatory high water crit. critical gal. gallon
temperature CRT cathode ray tube gen. generator
AISI American Iron and Steel CSA Canadian Standards genset generator set
Institute Association GFI ground fault interrupter
ALOP anticipatory low oil pressure CT current transformer
alt. alternator GND, ground
Cu copper
Al aluminum gov. governor
cUL Canadian Underwriter’s
ANSI American National Standards gph gallons per hour
Laboratories
Institute (formerly American gpm gallons per minute
CUL Canadian Underwriter’s
Standards Association, ASA) Laboratories gr. grade, gross
AO anticipatory only cu. in. cubic inch GRD equipment ground
APDC Air Pollution Control District cw. clockwise gr. wt. gross weight
API American Petroleum Institute CWC city water-cooled HxWxD height by width by depth
approx. approximate, approximately cyl. cylinder HC hex cap
AQMD Air Quality Management District D/A digital to analog HCHT high cylinder head temperature
AR as required, as requested DAC digital to analog converter HD heavy duty
AS as supplied, as stated, as dB decibel HET high exhaust temp., high
suggested engine temp.
dB(A) decibel (A weighted)
ASE American Society of Engineers hex hexagon
DC direct current
ASME American Society of Hg mercury (element)
DCR direct current resistance
Mechanical Engineers HH hex head
deg., ° degree
assy. assembly HHC hex head cap
dept. department
ASTM American Society for Testing HP horsepower
DFMEA Design Failure Mode and
Materials Effects Analysis hr. hour
ATDC after top dead center dia. diameter HS heat shrink
ATS automatic transfer switch DI/EO dual inlet/end outlet hsg. housing
auto. automatic DIN Deutsches Institut fur Normung HVAC heating, ventilation, and air
aux. auxiliary e. V. (also Deutsche Industrie conditioning
avg. average Normenausschuss) HWT high water temperature
AVR automatic voltage regulator DIP dual inline package Hz hertz (cycles per second)
AWG American Wire Gauge DPDT double-pole, double-throw IC integrated circuit
AWM appliance wiring material DPST double-pole, single-throw ID inside diameter, identification
bat. battery DS disconnect switch IEC International Electrotechnical
BBDC before bottom dead center DVR digital voltage regulator Commission
BC battery charger, battery E, emer. emergency (power source) IEEE Institute of Electrical and
charging Electronics Engineers
ECM electronic control module,
BCA battery charging alternator engine control module IMS improved motor starting
BCI Battery Council International EDI electronic data interchange in. inch
BDC before dead center EFR emergency frequency relay in. H2O inches of water
BHP brake horsepower e.g. for example (exempli gratia) in. Hg inches of mercury
blk. black (paint color), block EG electronic governor in. lb. inch pounds
(engine) EGSA Electrical Generating Systems Inc. incorporated
blk. htr. block heater Association ind. industrial
BMEP brake mean effective pressure EIA Electronic Industries int. internal
bps bits per second Association int./ext. internal/external
br. brass EI/EO end inlet/end outlet I/O input/output
BTDC before top dead center EMI electromagnetic interference IP iron pipe
Btu British thermal unit emiss. emission ISO International Organization for
Btu/min. British thermal units per minute eng. engine Standardization
C Celsius, centigrade EPA Environmental Protection J joule
cal. calorie Agency JIS Japanese Industry Standard
CAN controller area network EPS emergency power system k kilo (1000)
CARB California Air Resources Board ER emergency relay K kelvin
CB circuit breaker ES engineering special, kA kiloampere
cc cubic centimeter engineered special KB kilobyte (210 bytes)
CCA cold cranking amps ESD electrostatic discharge KBus Kohler communication protocol
ccw. counterclockwise est. estimated kg kilogram
CEC Canadian Electrical Code E-Stop emergency stop kg/cm2 kilograms per square
cert. certificate, certification, certified etc. et cetera (and so forth) centimeter
cfh cubic feet per hour exh. exhaust kgm kilogram-meter
cfm cubic feet per minute ext. external kg/m3 kilograms per cubic meter
CG center of gravity F Fahrenheit, female kHz kilohertz
CID cubic inch displacement fglass. fiberglass kJ kilojoule
CL centerline FHM flat head machine (screw) km kilometer
TP-6373 11/10 Appendix 47

kOhm, kΩ kilo-ohm NBS National Bureau of Standards rpm revolutions per minute
kPa kilopascal NC normally closed RS right side
kph kilometers per hour NEC National Electrical Code RTU remote terminal unit
kV kilovolt NEMA National Electrical RTV room temperature vulcanization
kVA kilovolt ampere Manufacturers Association RW read/write
kVAR kilovolt ampere reactive NFPA National Fire Protection SAE Society of Automotive
kW kilowatt Association Engineers
kWh kilowatt-hour Nm newton meter scfm standard cubic feet per minute
kWm kilowatt mechanical NO normally open SCR silicon controlled rectifier
kWth kilowatt-thermal no., nos. number, numbers s, sec. second
L liter NPS National Pipe, Straight SI Systeme international d’unites,
LAN local area network NPSC National Pipe, Straight-coupling International System of Units
LxWxH length by width by height NPT National Standard taper pipe SI/EO side in/end out
lb. pound, pounds thread per general use sil. silencer
lbm/ft3 pounds mass per cubic feet NPTF National Pipe, Taper-Fine SN serial number
LCB line circuit breaker NR not required, normal relay SNMP simple network management
LCD liquid crystal display ns nanosecond protocol
ld. shd. load shed OC overcrank SPDT single-pole, double-throw
LED light emitting diode OD outside diameter SPST single-pole, single-throw
Lph liters per hour OEM original equipment spec specification
Lpm liters per minute manufacturer specs specification(s)
LOP low oil pressure OF overfrequency sq. square
LP liquefied petroleum opt. option, optional sq. cm square centimeter
LPG liquefied petroleum gas OS oversize, overspeed sq. in. square inch
LS left side OSHA Occupational Safety and Health SS stainless steel
Lwa sound power level, A weighted Administration std. standard
LWL low water level OV overvoltage stl. steel
LWT low water temperature oz. ounce tach. tachometer
m meter, milli (1/1000) p., pp. page, pages TD time delay
M mega (106 when used with SI PC personal computer TDC top dead center
units), male PCB printed circuit board TDEC time delay engine cooldown
m3 cubic meter pF picofarad TDEN time delay emergency to
m3/hr. cubic meters per hour PF power factor normal
m3/min. cubic meters per minute ph., ∅ phase TDES time delay engine start
mA milliampere PHC Phillipsr head Crimptiter TDNE time delay normal to
man. manual (screw) emergency
max. maximum PHH Phillipsr hex head (screw) TDOE time delay off to emergency
MB megabyte (220 bytes) PHM pan head machine (screw) TDON time delay off to normal
MCCB molded-case circuit breaker PLC programmable logic control temp. temperature
MCM one thousand circular mils PMG permanent magnet generator term. terminal
meggar megohmmeter pot potentiometer, potential THD total harmonic distortion
MHz megahertz ppm parts per million TIF telephone influence factor
mi. mile PROM programmable read-only TIR total indicator reading
memory tol. tolerance
mil one one-thousandth of an inch
psi pounds per square inch turbo. turbocharger
min. minimum, minute
psig pounds per square inch gauge typ. typical (same in multiple
misc. miscellaneous
pt. pint locations)
MJ megajoule
PTC positive temperature coefficient UF underfrequency
mJ millijoule
PTO power takeoff UHF ultrahigh frequency
mm millimeter
PVC polyvinyl chloride UL Underwriter’s Laboratories, Inc.
mOhm, mΩmilliohm
qt. quart, quarts UNC unified coarse thread (was NC)
MOhm, MΩmegohm
qty. quantity UNF unified fine thread (was NF)
MOV metal oxide varistor
R replacement (emergency) univ. universal
MPa megapascal
power source US undersize, underspeed
mpg miles per gallon
rad. radiator, radius UV ultraviolet, undervoltage
mph miles per hour
RAM random access memory V volt
MS military standard
RDO relay driver output VAC volts alternating current
ms millisecond
ref. reference VAR voltampere reactive
m/sec. meters per second
rem. remote VDC volts direct current
MTBF mean time between failure
Res/Coml Residential/Commercial VFD vacuum fluorescent display
MTBO mean time between overhauls
RFI radio frequency interference VGA video graphics adapter
mtg. mounting
RH round head VHF very high frequency
MTU Motoren-und Turbinen-Union
RHM round head machine (screw) W watt
MW megawatt
rly. relay WCR withstand and closing rating
mW milliwatt
rms root mean square w/ with
μF microfarad
rnd. round w/o without
N, norm. normal (power source)
ROM read only memory wt. weight
NA not available, not applicable
rot. rotate, rotating xfmr transformer
nat. gas natural gas
48 Appendix TP-6373 11/10

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 NO TAG, General Torque Specifications, 3. Follow these SAE washer rules after determining
and 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
Assembled into Cast Iron or Steel
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 (18) 38 (28) 53 (39)
3/8-24 Nm (ft. lb.) 27 (20) 42 (31) 60 (44)
7/16-14 Nm (ft. lb.) 39 (29) 60 (44) 85 (63)
7/16-20 Nm (ft. lb.) 43 (32) 68 (50) 95 (70) See Note 3
1/2-13 Nm (ft. lb.) 60 (44) 92 (68) 130 (96)
1/2-20 Nm (ft. lb.) 66 (49) 103 (76) 146 (108)
9/16-12 Nm (ft. lb.) 81 (60) 133 (98) 187 (138)
9/16-18 Nm (ft. lb.) 91 (67) 148 (109) 209 (154)
5/8-11 Nm (ft. lb.) 113 (83) 183 (135) 259 (191)
5/8-18 Nm (ft. lb.) 128 (94) 208 (153) 293 (216)
3/4-10 Nm (ft. lb.) 199 (147) 325 (240) 458 (338)
3/4-16 Nm (ft. lb.) 222 (164) 363 (268) 513 (378)
1-8 Nm (ft. lb.) 259 (191) 721 (532) 1109 (818)
1-12 Nm (ft. lb.) 283 (209) 789 (582) 1214 (895)
Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into
Assembled into Cast Iron or Steel
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 (11) 23 (17) 33 (24)
M8 x 1.00 16 (11) 24 (18) 34 (25)
M10 x 1.50 30 (22) 45 (34) 65 (48)
M10 x 1.25 31 (23) 47 (35) 68 (50)
M12 x 1.75 53 (39) 80 (59) 115 (85)
M12 x 1.50 56 (41) 85 (63) 122 (90)
M14 x 2.00 83 (61) 126 (93) 180 (133)
M14 x 1.50 87 (64) 133 (98) 190 (140)
M16 x 2.00 127 (94) 194 (143) 278 (205)
M16 x 1.50 132 (97) 201 (148) 287 (212)
M18 x 2.50 179 (132) 273 (201) 390 (288) See Note 3
M18 x 1.50 189 (140) 289 (213) 413 (305)
M20 x 2.50 245 (181) 374 (276) 535 (395)
M20 x 1.50 264 (195) 402 (297) 576 (425)
M22 x 2.50 332 (245) 507 (374) 725 (535)
M22 x 1.50 351 (259) 535 (395) 766 (565)
M24 x 3.00 425 (314) 649 (479) 928 (685)
M24 x 2.00 447 (330) 682 (503) 976 (720)
M27 x 3.00 — 937 (692) 1341 (990)
M27 x 2.00 — 985 (727) 1409 (1040)
M30 x 3.50 — 1278 (943) 1829 (1350)
M30 x 2.00 — 1349 (996) 1931 (1425)
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

Notes

Notes
TP-6373 11/10 53
Notes
54 TP-6373 11/10
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, 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-6373 11/10c 7 Jurong Pier Road
Singapore 619159
E 2005, 2006, 2007, 2008, 2010 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455

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TP-6373 11/10 Table of Contents 3

4 Table of Contents TP-6373 11/10

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

TP-6373 11/10 Safety Precautions and Instructions 5

6 Safety Precautions and Instructions TP-6373 11/10

TP-6373 11/10 Safety Precautions and Instructions 7

8 Safety Precautions and Instructions TP-6373 11/10

Hot engine and exhaust system. NOTICE

TP-6373 11/10 Safety Precautions and Instructions 9

10 Safety Precautions and Instructions TP-6373 11/10

Decision-Makerr 550 Controller Operation

Decision-Makerr 6000 Controller

Figure 1 Related Literature

DVRr is a registered trademark of Marathon Electric Mfg. Corp.

TP-6373 11/10 Introduction 11

For professional advice on generator set power China

12 Service Assistance TP-6373 11/10

1.1 Introduction D Provisions are included in the regulator to allow the

D The digital voltage regulator is equipped with single-

DVRr is a registered trademark of Marathon Electric Mfg. Corp.

TP-6373 11/10 Section 1 Specifications 13

Status and Shutdown Indicators D Coarse Voltage Adjustment

1.4 Voltage Regulator Specifications

14 Section 1 Specifications TP-6373 11/10

1.6 Drive Discs to Flywheel Torque Values

TP-6373 11/10 Section 1 Specifications 15

16 Section 1 Specifications TP-6373 11/10

TP-6373 11/10 Section 2 Troubleshooting 17

Figure 2-2 Interface Circuit Board Connections

Figure 2-1 Interface Circuit Board GM11718

Figure 2-3 Interface Circuit Board Diagram with PMG Alternator

22 Section 2 Troubleshooting TP-6373 11/10

Connections/Display Check Possible Causes

Figure 2-4 Interface Circuit Board GM11718 Testing

TP-6373 11/10 Section 2 Troubleshooting 23

24 Section 2 Troubleshooting TP-6373 11/10

1. Screen 12. Plate, alternator mounting 23. Washer, plain

Figure 3-1 Alternator Components, Slanted Box Type

TP-6373 11/10 Section 3 Alternator Disassembly/Reassembly 25

Drive Discs, Alternator 38

63 Inner Panel Inner Panel Side View TP-6057 4/04

Figure 3-2 Alternator Components, Square Box Type

26 Section 3 Alternator Disassembly/Reassembly TP-6373 11/10

Explosive fuel vapors.

TP-6373 11/10 Section 3 Alternator Disassembly/Reassembly 27

2. Remove bolts (and shims, if used) between the

3. Vibromount models. Suspend the alternator at

3.2 Reassembly, 7. Remove chains or slings used for suspending

Loctiter is a registered trademark of Loctite Corporation.

28 Section 3 Alternator Disassembly/Reassembly TP-6373 11/10

Loctiter is a registered trademark of Loctite Corporation.

TP-6373 11/10 Section 3 Alternator Disassembly/Reassembly 29

24. Tighten and torque engine front mounting bolts.

31. Disconnect the starting batteries, negative lead

30 Section 3 Alternator Disassembly/Reassembly TP-6373 11/10

D Two dial indicators

TP-6373 11/10 Section 3 Alternator Disassembly/Reassembly 31