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TP-6593 - Atlantis Marine Power

1. GM40265 D 1 P23 P24 P25 and P26 Relays Figure 4 12 Relay Location Starter solenoid Main power relay Injector CO Sensor Fuel Pumps Oxygen Sensor and Coils Seawater flow switch Figure 4 13 Relays SCHEMATIC SINGLE POLE DOUBLE THROW 12 VDC GM49746 T 133 mA 90 10 ohms Rated Voltage Operating Current Coil Resistance Pull In Voltage lt 8V Release Voltage 1 2V 14 4V Max Operating Voltage Figure 4 14 Relay Spec Section 4 Controller 39 4 6 Controller Replacement If the troubleshooting procedures in Section 3 identify a bad controller use the procedure in this section for controller replacement Always check the controller configuration fuse wiring and connections before replacing the controller After replacing the controller verify that the new controller s configuration settings match the generator set system voltage and frequency unit configuration engine data input types battery voltage and communications settings Refer to Section 4 7 for instructions to check the controller configuration and to change the settings if necessary After the controller configuration has been checked and set to match the generator set use a voltmeter to check the generator set
2. GM58159 E 1 Coolant temperature sensor CTS Figure 5 10 Coolant Temperature Sensor CTS 54 Section 5 Component Testing and Adjustment Seawater Pressure Switch See Figure 5 11 Remove the seawater pressure switch and install a pressure gauge to verify that the seawater pressure is within the range specified before testing or replacing the seawater pressure switch To test the seawater pressure switch reinstall the switch and start the generator set If the unit shuts down disconnect lead 87 from the seawater pressure switch and reset the controller Restart the generator set and verify that it does not shut down A successful restart indicates a bad seawater pressure switch Replace the switch The calibration pressure of the seawater pressure switch is 2 0 psi 0 5 Side View of Exhaust Manifold GM53065 1 Seawater pressure switch Figure 5 11 Seawater Pressure Switch Location TP 6593 10 13 TMAP Sensor The sensor monitors intake manifold temperature and pressure This allows the ADC full control to monitor actual airflow compared to desired airflow The TMAP sensor incorporates both intake manifold temperature and pressure measurements in one single unit See Figure 5 12 for the TMAP sensor location To test the TMAP sensor shutdown th
3. VIEW WITH END CAP REMOVED GM53065 B Figure 6 9 Exhaust Manifold 66 Section 6 Generator Disassembly Reassembly TP 6593 10 13 Section 7 Wiring Diagrams WARNING KS S Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer TP 6593 10 13 WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electric
4. 3 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 TP 6593 10 13 Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nut and SAE washer Hardware 1 2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut See Figure 2 3 Follow these SAE washer rules after determining exit hole type a Always use a washer between hardware and a slot b Alwaysuse a washer under a nut see 2 above for exception Use a washer under bolt when the female thread is fixed weld nut 4 Refer to Figure 2 which depicts the preceding hardware configuration possibilities D 8 4 Cap screw Entry hole types Standard nut and SAE washer Whiz nut or spiralock up to 1 2 in dia hardware Weld nuts above 1 2 in dia hardware Exit hole types Figure 2 Acceptable Hardware Combinations Appendix 73 Appendix General Torque Specifications American Standard Fasteners Torque Specifications Torque 8 32 Assembled
5. 16 Section 3 Troubleshooting 17 dntrod ction x ode t ee To tees 17 3 2 1c pete beu seein ese ater der edt is 17 3 3 Troubleshooting 17 Section 4 Controller p qe e eR RUE BOE A Bx RR e e ed Re 23 lntroduction serere I bb Rer Rea P iw NE 23 4 2 Advanced Digital Control 1 Operation 24 4 2 1 Controls and Indicators 24 4 2 2 Starting the Generator Set 25 423 Running Sequence 26 4 2 4 Stopping the Generator Set 26 4 2 5 Fault Shutdowns and Warnings 26 4 2 0 Resetting the Controller after a Fault Shutdown 38 42 7 0 5 38 4 3 Protection ene ee ede ae eee Landed Beene 38 4 3 1 Line Circuit 38 4 3 2 RII A EE 39 4 4 CO Sensor Module a pU aet 39 4 5 Relays d EE bb t aes 39 4 6 Controller Replacement 40 47 Controller
6. Figure 5 18 Ignition Coil Service Side Shown Ignition Coil Pin Resistance Check approx Pin A SIGNAL to Pin B 10 kOhms Pin A SIGNAL to Pin D 34 kOhms 15 kOhms 44 kOhms 26 kOhms 17 kOhms Pin A SIGNAL to Pin E PWR Pin B to Pin D Pin B to Pin E PWR Pin D to Pin E PWR Figure 5 19 Ignition Coil Resistance Check TP 6593 10 13 Heated Oxygen O5 Sensor The heated oxygen sensor is used to monitor in the exhaust See Figure 5 21 for the heated oxygen sensor location Note The heated oxygen sensor is calibrated to work with this system Do not use alternate sensors The oxygen sensor operates like an electrolyte with its platinum layers serving as electrodes After the internal element reaches approx 600 it becomes electrically conductive and attracts negatively charged ions of oxygen These ions collect on the inner and outer platinum surfaces A heater element is addedto the sensor housing in order for the sensor to conduct and create an electrical signal below 600 F Two wires provide 12VDC and a ground signal for the heater element A fourth wire provides an independent ground for the sensor The targeted air fuel ratio signal is approx 500mV and changes slightly based on speed and load conditions When the sensor sends a voltage signal less than 500mV the ADC interprets the air fuel mixture as lean so the ADC Il increases the duty cycle of th
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8. Section 4 Controller See Figure 4 1 for the locations of the ADC II controller and related components A silicon controlled rectifier SCR module which is integral with the controller regulates the output voltage Service Side View GM58162 1 Ground stud 2 LO stud 3 Relays P23 P24 P25 and P26 4 Line circuit breaker panel Figure 4 1 Advanced Digital Control ADC 11 TP 6593 10 13 g 5 ADC II controller 6 F5 fuse location 7 F1 F2 and fuse location 8 CO sensor module Section 4 Controller 23 4 2 Advanced Digital Control Operation Figure 4 2 illustrates the user interface on the Advanced Digital Control ADC 11 Note Have setup and adjustments of the Advanced Digital Control performed only by an authorized Kohler distributor dealer O CED DIGITAL CONTROL GM58225A LCD display Control knob Engine start stop button Power button LED status indicator Figure 4 2 Advanced Digital Control Il 421 Controls and Indicators
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11. 2540 1540 2 SNOUO3NNOO 1 2 84 8 AMALLVE T 1 MA MOSN3S AGO 581 MOlvIS 1915 YOLON 313415 WS HOLIMS M3lVM VIS 545 Q3T10MINOO NOOMIS NOS QuvOB 1 AJBWissv 30151533 bu 193NNOO 090 MOSN3S SO 5 unss3sd 10540 5 35 34055344 VIS MOT Qnis O1 01 M3MOd S gt 105 7109 N3TIOMINOO mni MOIO3NI 1303 NU 3504 3 FINGON x2018 983 HOLMS INY1009 519 GIONFIOS SO MOSN3S 5 4 599 089 ON3931 81 84 1 vc 8d 022 vf SNOILOJNNOO 61 96 84 20 8 8 XOL vf SNOIIOJNNOO 914 543 83 1 41 84 OZN 9 84 02 Nid 5 d Ov 4A ZZN 1 z983 z983
12. Push and Hold Knob Generator Running Example Event Log Sw version No Yes 0 1 23 1s 12 3 Engine stop Events listed from most to least recent up to See See 100 events stored Figure 4 17 Figure 4 18 Non Runtime Runtime Pushing the knob at any page will return user 2F 12 3 h back to the main menu Parameter Parameter 1 12 0 Mad RotateyKnob S Status event F Fault 3w 10 5 h Hi eng temp W Warning Rotate Knob Rotate JKnob B Rotate Knob Rotate Knob Event Page Format PUSH FOR Index Event Type Runtime hours EVENT LOG 4s 9 1h Event Descriptor Push Engine start Knob RotateyKnob Skipped if Genset is Running Rotate RETURN Knob CONFIRM CONFIRM PRIME PRIME NO PRIME YES Push Knob If Faulted Cannot prime Push when faulted Knob Figure 4 16 Advanced Digital Control Main Menu Flow 5 7 5 10 4 6 8EFKD Models 42 Section 4 Controller TP 6593 10 13 System Parameter Go to B System volt Push_ System volt Rotate 240 v Knob 240 v 120 240 115 230 volt Rotate Knob Frequency Push_ Frequency Rotate 60 Hz Knob 60 Hz 50 60 Hz Rotate Knob oil sensor Push oil sensor i Rotate Sender Knob Sender Sender switch Rotate Knob CAN A Push A Ro
13. Note The ADC II allows three 7 second crank cycle attempts before the overcrank shutdown occurs Remote communications require active powered up controller Be advised that when the generator is not running the Advanced Digital Control Il enters a low power state with an average current drain of approximately 100 uA The ADC II will power down 0 mA draw after 48 hours of inactivity Press the start switch button once for the remote start stop switch or twice for the remote digital gauge to wake up the ADC II and start the generator set 4 2 3 Running Sequence When the engine speed reaches 750 rpm the crank relay deenergizes When the output voltage on leads 11 and 44 reaches above 30 VAC the flash relay deenergizes 26 Section 4 Controller 4 2 4 Stopping the Generator Set The following procedures describe the actions required to stop the generator set Local Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 Press the Start Stop button to stop the generator set The engine stops 3 Press the Power Button to turn the controller off Remote Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 Thegenerator set stops when the remote start stop Switch or remote digital gauge contacts close momentarily Consult the instruction sheet supplied with the remote start stop switch or remote d
14. Replace heat exchanger anticorrosion zinc X Flush cooling system X 1000 hr 2 years Ignition System Check spark plugs condition and gap Replace spark plugs X 250 hr Intake Exhaust System Inspect exhaust system components X Check the exhaust gas condition X during operation Service backfire flame arrestor Check and or replace the catalyst assembly X Replace the CO sensor module X every 2 years Check the crankcase breather pipe for obstructions Inspect the complete exhaust system X Electrical System Keep battery charged and in good condition amp Check and tighten electrical connections Clean battery cables X 200 hr Engine And Mounting Check for water fuel coolant and oil leakage 11 Retighten all nuts and bolts Check tightness of mounting bolts vibromounts X 200 hr Remote Control System Check remote control operation X break in period Generator Test run generator set X weekly Blow dust out of generator X Clean slip rings and inspect brushes X 1000 hr Requires removal of sound shield if installed Consult your local distributor dealer for service Should be performed by your local distributor dealer Consult battery manufacturer s instructions Re
15. CO sensor fuel pumps oxygen sensor and coils GM47427 Fuse block position 8 Controller GM42337 Fuse holder Figure 5 24 Fuses 1 Fuse F5 2 Fuse block F1 F2 F3 and F4 Auxiliary winding Figure 5 25 Fuse Location 358337 GM58162 D TP 6593 10 13 5 12 Continuity Checks WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment TP 6593 10 13 Note Disconnect the generator set battery before performing continuity checks to prevent damage to the ohmmeter To further check generator set components disconnect the battery and remove wiring harness plugs from the controller circuit board Refer to the wiring diagrams in Section 7 and use an ohmmeter to check for continuity and good ground connections A zero reading on the ohmmeter indicates continuity No ohmmeter reading indicates very high resistan
16. To determine the cause of no or low AC output refer to the troubleshooting flow chart in Figure 5 1 Before beginning the test procedures read all safety precautions atthe beginning of this manual Many ofthe test procedures include additional safety precautions Check the condition of the alternator fuse F5 before performing the separate excitation procedure See Figure 5 2 See Figure 1 2 for the fuse location Ifthe fuse is not blown use the following procedure to separately excite the generator using an external voltage source a 12 volt automotive battery Separately exciting the generator can identify faulty voltage regulation by the ADC II controller or reveal a running fault in the rotor and or stator An external power source duplicates the role of the voltage regulator and excites the generator field rotor A generator component that appears to be in good condition while stationary may exhibit a running open or short circuit while moving Centrifugal forces acting on the windings during rotation cause a broken circuit to open or increasing temperatures cause the insulation to break down resulting in a running fault No Generator Output Separate Excitation Output within Specifications Check Wiring Fuses and Controller Erratic or No Output Check Rotor Check Stator TP563273 Figure 5 1 Generator Troubleshooting 55F Q
17. 2153 T OSN LEN 91 gt 6 14 GNNOYD 92 84 924 88 99 G Zd 1NdNI 99 55 amp gt 8 04 L Zd gt 9 1NdNI ZEN 2 24 1ndNI SNIGNIM 99 gt 1NdNI ONIGNIM N4 h 1 29 ONIGNIM 0133 gt 02 24 vla Z 1d dd N XOL XOL o v 9ld Hios 20 14 1 HOSN3S N39AXO vig ig 285 bleed 62 14 9 B a 540 22 14 86 gt 86 91 84 YS 11 14 1ndNI dW3L 1SnvHX3 8801 62 14 4 N3OnOSNvHL AS 222 gt gt zzZ m 06 14 8i8H 58 2540 E 1 amp 41 6 14 inani sar TWNOIS MOSN3S 38065384 01 14 4 2 3 1 s oT 1 12 84 22 gt gt 27 16 14 2 0 1580 j ooz 5 002 02 14 HOSN3S T oc gd zz LL iz a 12 14 HOSN3S IYW 61 84 515 ANNOYS MOSN3S NOlLISOd 3111ONHL 581 E 82 14 01 124 6 124 MOLOW M3l3vIS WS 26 14 INO 2051 HOLIMS VJS 545 8 124 m UE Pech 10 somas in 301
18. Btu min C cal CARB CB cc CCA CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per
19. Service Marine Generator Sets Models 5EKD 4EFKD Low CO 7 5EKD 6EFKD Low CO 10EKD 8EFKD Low CO Controller Advanced Digital Control P2901 POVVER SYSTEMS KOHLER Power Systems 6593 10 13 Table of Contents Safety Precautions and Instructions 5 Introduction neds eee 9 Service Assistance eu sas ag RE ER ERE ER 10 Section 1 Specifications TER EE ER nra Rid 11 T dntroduction RE See RT e ER eb CR ees 11 1 2 Generator Set Ratings 11 13 Controller Specifications 11 1 4 Alternator Specifications 12 1 5 Alternator Specifications Continued 12 1 6 Torque Specifications 13 17 Engine Specifications 13 1 8 Service cocco UE EPI de Une 14 Section 2 Scheduled Maintenance 15 24 Geheral zc a 15 2 2 Service Schedule
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21. 29 30 31 32 33 34 ADV7439A B GM58158 Fuel filter Fuel pump cooler Fuel pump Fuel inlet Filter screen Fuse block F1 F2 F3 and F4 Fuse F5 Cooling air inlet USB connection Catalyst assembly water outlet exhaust outlet nonservice side AC load lead connector nonservice side CO sensor module inside junction box Customer interface connection nonservice side Seawater flow switch nonservice side Seawater pressure switch nonservice side Note Consult installation drawings in Spec Sheet or Installation Manual for fuel and battery connection points TP 6593 10 13 WARNING KS S Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start
22. 5 13 Sensor Resistance Readings TMAP Sensor Pin Resistance Check TMAP Pin 1 GND to Pin 4 2 4 8 2 kOhms PRESSURE SIGNAL KPA TMAP Pin PWR to Pin 4 3 4 8 2 kOhms PRESSURE SIGNAL KPA TMAP Pin 1 GND to Pin 2 TEMPERATURE SIGNAL See Figure 5 13 Figure 5 14 TMAP Sensor Resistance Max Ratings of TMAP Sensor 16 volts Supply voltage 500 kPa Pressure Section 5 Component Testing and Adjustment 55 Crankshaft Position Sensor The crankshaft position sensor monitors speed control timing firing of spark plugs and fuel injection See Figure 5 15 for the crankshaft position sensor location The crankshaft position sensor is an electromagnetic device which contains a permanent magnet surrounded by a winding The sensor is used with the timing wheel at a precise location to allow the ADC a very accurate speed reference signal The timing wheel rotation near the sensor s tip changes the magnetic flux creating an analog voltage signal in the sensor coil The spark is sent to the appropriate cylinder via the spark plug wires The ADC II uses the signal from the crankshaft position sensor to determine the engine position and RPM This information together with the TPS and TMAP sensor information is used to calculate the correct ignition timing settings To test the crankshaft position sensor shutdown the generator set disconnect the battery negative lead first
23. Active State Inhibit Time Default Setting Check Aux input fault Auxiliary fault input shutdown Note Input from a customer supplied switch that closes when the fault is active Digital input Grounded sec N A Check the cause of the auxiliary fault Check the condition and operation of the customer supplied equipment connected to the auxiliary fault input Hi CO sensor fault Carbon monoxide presence detected from sensor Sensor fault shutdown occurs because of the presence of CO Pulsed signal Immediate service required Contact an authorized distributor dealer for service Ensure windows are open for proper ventilation Operate the blower to expel dangerous fumes Move the vessel away from other vessels as another vessel may be the source for the presence of the CO Check the generator exhaust system see the O M Hi CO engine fault Carbon monoxide shutdown fault detected from ADC II Shutdown occurs because of the presence of CO or deteriorating emission control components such as the catalyst ADC II data Control limit Immediate service required Contact an authorized distributor dealer for service Ensure windows are open for proper ventilation Operate the blower to expel dangerous fumes Move the vessel away from other vessels as another vessel may be the source for the presence of the CO Check the generator exhaust system se
24. LCD Display The LCD display is backlit any time the generator setis running or for atleast 30 seconds aftera user manipulates a button or the control knob The LCD displays generator status run time hours fault shutdowns and fault warnings Control Knob Rotate the control knob clockwise to increase a value or move down the menu structure See Figure 4 3 for menu items 24 Section 4 Controller Rotating the control knob to position Menu Item Hourmeter Status Voltage and Frequency Line 1 to neutral voltage and Line 2 to neutral voltage Engine temperature F Oil pressure psi Battery voltage RPM Next maintenance interval Software version ECM version Contrast lighting Event log Fuel prime Figure 4 3 Menu Items Engine Start Stop Button The Engine Start Stop button toggles the running state of the engine When the controller is off it has no effect When the controller is in a low power mode the Engine Start Stop button starts the engine Power Button The Power button toggles the controller between and off When the controller if off it does not respond to any input except the Power button LED Status Indicator The LED provides asummary of the generator state e Green indicates no known problem e Red indicates one or more faults i e the generator cannot operate e Amber indicates no faults but one or more warnings i e the generator
25. Low battery Low battery voltage warning This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits Analog input Below setting Standby Mode 11 volts for 12 volt system Run Mode 12 6 volts for 12 volt system Check the battery rating and condition Charge or replace the battery Weak battery Low cranking battery Analog input Below setting 2 sec during cranking 9 VDC Check the battery rating and condition Charge or replace the battery Hi CO engine High from ADC Fault code is displayed if the presence of CO is detected because of the time weighted average presence of CO Activates the CO cabin alarms ADC II data Control limit 5 sec Ensure windows are open for proper ventilation Operate the blower to expel dangerous fumes Move the vessel away from other vessels as another vessel may be the source for the presence of the CO Check the generator exhaust system see the O M Contact an authorized distributor dealer for service Hi CO sensor High CO from sensor Fault code is displayed if the presence of CO is detected Warning occurs if the sensor detects acceptable but increasing CO levels Pulsed signal Ensure windows are open for proper ventilation Operate the blower to expel dangerous fumes Move the vessel away from other vessels
26. MJ megajoule mJ millijoule mm millimeter mOhm mQ milliohm MOhm megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second 72 Appendix MTBF MTBO mtg MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns OC OD OEM OF opt OS OSHA OV 02 pF PF ph 2 PHC PHH PHM PLC PMG pot ppm PROM psi pt PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH mean time between failure mean time between overhauls mounting megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite scre
27. and allow the generator setto cool Disconnect the crankshaft position sensor and use an ohmmeter to measure the resistance across the sensor pins See Figure 5 17 GM58159 E 1 Crankshaft position sensor Figure 5 15 Crankshaft Position Sensor Location Crankshaft Position Sensor Gap between sensor and flywheel 0 76 1 52 mm 0 030 0 045 in Figure 5 16 Crankshaft Position Sensor Gap Crankshaft Position Sensor Pin Resistance approx Pin 1 to Pin 2 320 Ohms Figure 5 17 Crankshaft Position Sensor Resistance Check 56 Section 5 Component Testing and Adjustment Ignition Coil This system uses two ignition coils that receive firing signals from the controller s microprocessor See Figure 5 18 The microprocessor signals the coils to begin their cycle Then the coils wait for the trigger signal from the microprocessor To test the ignition coils shutdown the generator set disconnect the battery negative lead first and allow the generator set to cool Disconnect the ignition coils and use an ohmmeter to measure the resistance across the coil pins See Figure 5 19 for the coil resistance Connector End QNnOU5 AUVONOO3S 93N AYJLLY 504 AN311V 1S3 Wa Soy
28. check the wiring and fuses Check the controller settings and connections See Section 4 Controller TP563274 FN lead disconnected in step 1 FP lead disconnected in step 1 10 amp fuse DC ammeter 12V battery Brushes Slip rings Main field rotor Figure 5 3 Separate Excitation Connections TP 6593 10 13 5 3 Stator The stator contains a series of coils of wire laid in a laminated steel frame The stator leads supply AC voltage to the load and voltage regulator Before testing the stator inspect it for heat discoloration and visible damage to housing lead wires exposed coil windings and exposed areas of frame laminations Be sure the stator is securely fastened to the stator housing Note Disconnect all stator leads before performing all stator tests WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place High voltage test Hazardous voltage can cause severe injury or death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bo
29. 00 X 129 18 1 2 13 x 1 25 X 6210 12 1 2 13 Spiralock PoS X 129 19 1 2 13 1 50 6210 15 7116 20 Spiralock 125 99 5 16 18 x 50 X 129 20 1 2 13 x 1 75 X 6210 14 1 2 20 Spiralock X 125 23 5 16 18 x 62 X 125 3 5 16 18 75 X 129 21 1 2 13 x 2 00 129 22 1 2 13 2 25 85 3 5 8 11 Standard d 25 31 e 5 n6 X 129 23 1 2 13 x 2 50 X 88 12 3 4 10 Standard 125 5 3 16 18 x 1 X 129 24 1 2 13 x 2 75 X 89 2 1 2 20 Standard X 125 24 5 16 18 x 1 25 X 129 25 1 2 13 x 3 00 X 125 34 5 16 18 x 1 50 X 129 27 1 2 13 x 3 50 X 125 25 5 16 18 x 1 75 Wash X 129 29 1 2 13 x 4 00 5 125 26 5 16 18 2 00 129 30 1 2 13 4 50 230578 5 16 18 2 25 463 9 1 2 13 x 5 50 olt X 125 29 5 16 18 x 2 50 129 44 1 2 13 x 6 00 PartNo ID OD Thick Screw X 125 27 5 16 18 x 2 75 Msi ER din da X 125 28 5 16 18 x 3 00 X 129 51 1 2 20 x 75 T29 125 22 5 16 18 4 50 129 45 1 2 20 1 25 25 9 156 375 049 6 X 125 32 5 16 18 x 5 00 X 129 52 1 2 20 x 1 50 X 25 48 188 438 049 8 X 125 35 5 16 18 x 5 50 X 25 36 219 500 049 10 125 36 5 16 18 6 00 6021 3 5 8 11 1 00 X 25 40 281 625 065 1 4 125 40 5 16 18 6 50 2 15 25 85 344 687 065 5 16 6021 11 1 25 37 406 812 065 3 8 X 125 43 5 16 24 x 1 75 X 6021 1 5 8 11 x 1 75 DEC X 25 34 469 922 065 7 16 Z 12Sa X 2 90 273049 5 8 11 x 2 00 X 25 26 531 1 062 095 1 2 X 125 30 5 16 24 x 75 X 6021 5 5 8 11 x 2
30. 1 50 x 180 M10 1 50 x 235 M10 1 50 x 260 M10 1 25 x 330 M12 1 75 x 45 M12 1 25 x 50 M12 1 25 x 50 M12 1 75 x 50 M12 1 75 x 50 M12 1 75 x 55 M12 1 75 x 60 M12 1 75 x 60 M12 1 75 x 65 M12 1 75 x 75 M12 1 75 x 80 M12 1 75 x 90 M12 1 75 x 100 M12 1 75 x 110 Part No Hex Head Bolts Partial Thread continued M960 16090 60 M931 16090 60 M931 16100 60 M931 16100 82 M931 16120 60 M931 16150 60 M931 20065 60 M931 20090 60 M931 20100 60 M931 20120 60 M931 201 40 60 M931 20160 60 M931 22090 60 M931 22120 60 M931 22160 60 M931 24090 60 M931 24120 60 M931 24160 60 M931 24200 60 Dimensions M16 1 50 x 90 M16 2 00 x 90 M16 2 00 x 100 M16 2 00 x 100 M16 2 00 x 120 M16 2 00 x 150 M20 2 50 x 65 M20 2 50 x 90 M20 2 50 x 100 M20 2 50 x 120 M20 2 50 x 140 M20 2 50 x 160 M22 2 50 x 90 M22 2 50 x 120 M22 2 50 x 160 M24 3 00 x 90 M24 3 00 x 120 M24 3 00 x 160 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M933 05030 60 M933 05035 60 M933 05050 60 M933 06010 60 M933 0601 2 60 M933 0601 4 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06030 60 M933 06040 60 M933 06050 60 M933 07025 60 M933 0801 0 60 M933 0801 2 60 M933 08016 60 M933 08020 60 M933 08025 60 M933 08030 60 M933 08030 82 M933 10012 60 M961 10020 60 M933 10020 60 M933 10025 60 M961 10025 60 M933 10025 82 M961 10030 60 M933 10030 60 M933 10030 82 M961 10035 60 M933 10035
31. 519 8 14 8 4 a ved 1640 8 24 55 LM 6 Lad IM Hrd SNOILOANNOOD 69 Section 7 Wiring Diagrams Figure 7 2 Point to Point Wiring Diagram Sheet 2 of 2 TP 6593 10 13 ADV8631A TP 6593 10 13 Figure 7 3 Schematic Wiring Diagram Sheet 1 of 1 70 Section 7 Wiring Diagrams 4 M3TIOMINOO 033 01 S 01 OL Q3103NNOO 11 14 ONINIL xNVdS 1153 m UT cou p 1 20 84 Q3103NNOO l ivIS SNOILO3NNOO AINO AOL 804 WNYJIXI L Lde NHO 17227 3SVHd 10 5 8 61 14 p TIA md 1 15 33S SNOILO3NNOO 02 84 MOIVH3N39 N04 izn 12 aru 013 SALON ozz 022 9 81 14 Z
32. 60 M933 10035 82 M961 10040 60 M4 0 70 6 5 0 80 30 5 0 80 35 5 0 80 50 M6 1 00 x 10 M6 1 00 x 12 M6 1 00 x 14 M6 1 00 x 16 M6 1 00 x 20 M6 1 00 x 25 M6 1 00 x 30 M6 1 00 x 40 M6 1 00 x 50 M7 1 00 x 25 M8 1 25 x 10 M8 1 25 x 12 M8 1 25 x 16 M8 1 25 x 20 M8 1 25 x 25 M8 1 25 x 30 M8 1 25 x 30 M10 1 50 x 12 M10 1 25 x 20 M10 1 50 x 20 M10 1 50 x 25 M10 1 25 x 25 M10 1 50 x 25 M10 1 25 x 30 M10 1 50 x 30 M10 1 50 x 30 M10 1 25 x 35 M10 1 50 x 35 M10 1 50 x 35 M10 1 25 x 40 Part No Dimensions Hex Head Bolts Full Thread continued M933 12016 60 M933 12020 60 M961 12020 60F M933 12025 60 M933 12025 82 M961 12030 60 M933 12030 82 M961 12030 82F M933 12030 60 M933 12035 60 M961 12040 82 M933 12040 60 M933 12040 82 M961 14025 60 M933 14025 60 M961 14050 82 M961 16025 60 M933 16025 60 M961 16030 82 M933 16030 82 M933 16035 60 M961 16040 60 M933 16040 60 M961 16045 82 M933 16045 82 M933 16050 60 M933 16050 82 M933 16060 60 M933 16070 60 M933 18035 60 M933 18050 60 M933 18060 60 M933 20050 60 M933 20055 60 M933 24060 60 M933 24065 60 M933 24070 60 M12 1 75 x 16 M12 1 75 x 20 M12 1 50 x 20 M12 1 75 x 25 M12 1 75 x 25 M12 1 25 x 30 M12 1 75 x 30 M12 1 50 x 30 M12 1 75 x 30 M12 1 75 x 35 M12 1 25 x 40 M12 1 75 x 40 M12 1 75 x 40 M14 1 50 x 25 M14 2 00 x 25 M14 1 50 x 50 M16 1 50 x 25 M16 2 00 x 25 M16 1 50 x 30 M16
33. Number Customer connection Fuse block position 1 GM42337 1 Fuse block position 4 F3 Fuse block position 5 Voltage regulator GM42339 F2 Injector CO sensor fuel pumps oxygen sensor and coils GM47427 Fuse block Controller position 8 GM42337 Fuse holder Auxiliary winding 358337 Figure 3 1 Fuse Identification e Incorrect controller settings A ways check the controller configuration settings before replacing the controller Section 4 7 explains how to check and change the controller settings 3 3 Troubleshooting Chart Use the following table s as a reference in troubleshooting individual problems Generator set faults are listed in groups and include likely causes and remedies The simplest and most likely causes of the problem are listed first follow the recommendations in the order shown The reference column provides additional sources of information in this and related manuals regarding the problem and solution Note In the following table s O M refers to the Operation Manual I M refers to the Installation Manual and S M refers to the Service Manual Section 3 Troubleshooting 17 Troubleshooting Chart Problem Possible Cause Corrective Action Reference Generator Weak or dead battery Recharge or replace battery Generator O M set does Battery connections Check for reversed or poor battery connections not crank Open c
34. Rotor assembly Fan guard screws quantity 2 Generator overbolt quantity 4 Retainer wire Brush assembly mounting screws quantity 2 Bracket brush holder O ring End bracket Fan guard Figure 6 6 Alternator Assembly Components TP 6593 10 13 Section 6 Generator Disassembly Reassembly 63 6 2 Collector Ring and Bearing Replacement lM 35 AS SOLDERED 1 Unsolder the collector ring leads from the collector 221 ESSE ring terminals _ ZZ ne 4 m 2 Remove the collector rings with a three jaw puller 3 Remove the bearing with a three jaw puller 4 Press the new bearing onto the rotor shaft VIEW B B 5 Align the collector ring keyway with the keyway on SHEET SR the rotor shaft See Figure 6 8 em 6 Press the new collector rings onto the rotor shaft Note The new collector rings must be turned down to a 5 NA 3 finish of 32 micro inches using a lathe and commutator stones down the collector TERMINALS pas th t haft WRAP LEADS rings on the rotor shaft VITH THIS DIAMETER 7 Solder the leads onto the collector ring terminals 9058043 The connection is not to exceed 9 5 mm 0 37 in beyond the collector rings See Figure 6 8 Figure 8 Test to ensure continuity at the collector rings Min diameter mm in 57 15 2 250 Max finish 32 micro inches M
35. all jewelry before servicing the equipment Separate Excitation Procedure Perform the following procedure to use an external voltage source to excite the main field rotor 1 Remove the junction box cover and disconnect the black FN and FP leads from the alternator 2 Connect a DC ammeter 10 amp fuse and a 12 volt automotive battery to the positive FP and negative FN brush leads as shown in Figure 5 3 Note and record the ammeter reading Note The approximate ammeter reading should be the battery voltage divided by the specified rotor resistance See Section 1 Specifications for specified rotor resistance values Example 12 volts battery voltage _ 3 5 amps rotor current 3 4 ohms rotor resistance 48 Section 5 Component Testing and Adjustment 3 Start the engine and check that the ammeter reading remains stable An increasing meter reading indicates a shorted rotor A meter reading decreasing to zero or an unstable reading suggests a running open Refer to Section 5 4 Main Field Rotor to test the rotor If the ammeter reading is stable proceed to step 4 4 Check for AC output across the stator leads see Section 5 3 Stator Compare the readings to the AC output values shown Section 1 Specifications Ifthe readings vary considerably a faulty stator is likely Refer to Section 5 3 Stator for further information 5 If this test shows that the rotor and stator are in good condition
36. below or provided in the Engine Service Manual 5 7 5 10EKD Torque Specifications 4 6 8EFKD Rotor thru bolt 5 7 5EKD and 4 6EFKD 10EKD and 8EFKD 23 Nm 204 in Ibs 32 5 Nm 288 in Ibs Generator overbolts 13 Nm 120 in Ibs Lifting eye bolts 7 3 Nm 65 in Ibs Generator adapter to engine bolts 15 Nm 132 in 165 24 4 29 8 Nm Spark plugs 18 22 ft Ibs Tighten all hardware in the sequence shown in two Intake manifold to engine steps first to 7 4 Nm 66 in Ibs then to 9 9 Nm 88 in Ibs Catalyst assembly 9 5 Nm 7 ft Ibs Thermostat cover 9 9 Nm 88 in 165 Starter motor mounting bolts 15 3 Nm 135 in Ibs Exhaust manifold center mounting bolt to adapter 11 Nm 8 ft Ibs Exhaust manifold to engine 4 bolts 24 4 Nm 18 ft Ibs End bracket plate to alternator housing 7 Nm 60 in lbs TP 6593 10 13 1 7 Engine Specifications Engine Specification Manufacturer 5 7 5 10EKD 4 6 8EFKD Model Cycle Number of cylinders Compression ratio 8 5 1 Displacement L cu 0 674 41 1 Max power at rated rom HP 18 9 15 8 Rpm 3600 3000 Bore x stroke mm in 80 x 67 3 15 x 2 64 Cylinder head material Aluminum Cylinder block material Aluminum Piston rings 2 compression 1 oil Piston material Aluminum Crankshaf
37. cases both may occur simultaneously The ADC II protective monitor will react to only one shutdown condition therefore whichever of these faults is detected first will be indicated as the reason for the shutdown Fault appears if the sensor potentiometer has malfunctioned Check for dirt or oxidation on the sensor traces Check the throttle connector and pins for corrosion To check disconnect the throttle connector and measure the resistance of 1 25 kOhms 30 from TPS pin 2 GND to pin 6 TPS1 SIGNAL TPS pin 3 PWR to pin 6 TPSI SIGNAL Note Do not service this sensor Repair by replacing the throttle body assembly TPS input lo Throttle Position Sensor Input Low The TPS Range Low and TPS Input Low conditions are closely related If the input reaches 0 VDC the TPS Input Low condition is indicated The range error is dynamically determined and may or may not occur before reaching O VDC In some cases both may occur simultaneously The ADC II protective monitor will react to only one shutdown condition therefore whichever of these faults is detected first will be indicated as the reason for the shutdown A TPS Input Low condition exists when the closed loop feedback does not correspond with what the ADC II is expecting The threshold for the TPS Input Low is a signal voltage of 0 7 volts or lower The controller indicates a fault within 1 second of the condition being present Fault appears if the sensor signal wire is dis
38. configuration settings Section 4 7 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 4 7 Loose voltage sensing connections Check connections stator leads 11 and 44 and P2 controller connection Section 7 Controller Check fuses wiring and connections Section 4 No output voltage AC output circuit breaker open Check for AC voltage on the generator side of circuit breaker If there is AC voltage on the generator side of the breaker then a problem in the load circuits is causing the line circuit breaker to trip Check for and correct short circuits or overloading on the load side before resetting the circuit breaker Alternator or control system Perform separate excitation procedure to isolate the problem to the alternator or the control system Then troubleshoot the alternator or control system components as follows Section 5 2 Aux winding F5 fuse blown Replace blown fuse If fuse blows again check stator Section 5 3 Controller Check controller settings Check wiring and connections Section 4 7 Section 4 6 Open wiring terminal or pin in buildup circuit Check continuity Section 5 12 Section 7 Brushes Inspect brushes and replace if worn Section 5 6 Check for brushes sticking in brush holder or broken brush spring Section 5 6 Rotor connections Check for open circuit in rotor con
39. equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Rotor Test Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger if equipped 3 Disconnect the generator set engine starting battery negative lead first 4 Remove the brush cover from the alternator end bracket TP 6593 10 13 5 Check the rotor for continuity and resistance Raise the brushes from the slip rings while performing ohmmeter tests Measure the rotor resistance ohms between the two slip rings see Figure 5 7 See Section 1 4 Alternator Specifications for rotor resistance readings Ifthe resistance readings are low perform a megohmmeter test on rotor as described in the next step Note Because ohmmeter accuracy varies resistance readings are approximate Take readings at room temperature Figure 5 7 Rotor Resistance Check 6 Perform a megohmmeter test to determine whether the rotor is shorted to ground a Raise and secure the brushes away from the slip rings by inserting a retaining wire in the brush holder hole b Using megohmmeter apply 500 volts DC to one rotor slip ring and the rotor poles or shaft Follow the instructions of the megohmmeter manufacture
40. generator set use Operating the generator set Carbon monoxide can cause severe nausea fainting or death Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats and buildings 6 Safety Precautions and Instructions Fuel System WARNING 4 Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels WARNING Explosion Gasoline vapors cause explosion and severe injury or death Before starting the generator set operate the blower 4 minutes and check the engine compartment for gasoline vapors The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in go
41. hour TP 6593 10 13 cfm CG CID CL cm CMOS cogen com Coml Rec conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Enviro
42. insulation and possible current 4 and 1 2 11 55 or 66 flow to ground Any stator lead and ground on stator housing or frame laminations Figure 5 6 Continuity Test Results on a Good Stator Single Phase Figure 5 5 Single Phase Alternator Stator Leads 50 Section 5 Component Testing and Adjustment TP 6593 10 13 5 4 Main Field Rotor The two pole rotor creates the magnetic field needed to produce alternating current in the stator windings Before testing inspect the rotor for visible damage to pole shoes insulation exposed coil windings and slip ring surfaces Rotate the bearing to check for wear heat discoloration or noise 541 Rotor Continuity and Resistance Tests A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place High voltage test Hazardous voltage can cause severe injury or death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related
43. is overloaded If sensed the controller will display an overload warning for 30 seconds and if no action is taken to reduce the load during these 30 seconds the unit will shutdown on an overload fault Action to take Reduce the electrical load Review the troubleshooting chart in Section 3 Injector Injector Fault Fault appears when the power to the injector is low or missing Check injector connection Out of fuel Loss of fuel An out of fuel condition exists when the generator set shuts down for an unknown reason contributed to no or lack of fuel Note Available on software version 1 2 0 or below On software version 1 3 0 and higher this condition is displayed as Check engine Figure 4 7 Fault Shutdowns 6593 10 13 Section 4 Controller 35 Fault Warnings Text Displayed Description Check EST 1 Low Electronic Spark 1 Timing Low An EST failure condition exists when the spark signal is pulled high or low The controller indicates EST1 fault within 1 second of the condition being present The Electronic Spark Timing EST is a current driver signal This fault appears if the signal from the ADC is shorted to ground or the coil driver signal is low or undercurrent Check the coil driver wiring and connectors for shorts ADC II pin 17 to COIL pin A Verify GND on COIL pin B Verify GND on COIL pin C Verify GND on COIL pin D Verify 12VDC on COIL pin E To check th
44. phone 1 800 544 2444 KOHLERPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
45. pin plug from the ADC II 5 Loosen and remove the four controller mounting screws at the front of the controller See Figure 6 1 Remove the controller TP 6593 10 13 GM58162 D 1 Controller mounting screws 4 Figure 6 1 ADC II Mounting Screws 6 Disconnect the generator output leads from the circuit breaker and disconnect QCON1 and from the F5 fuse 7 Disconnect the LO and GRD lead connections See Figure 6 2 8 Disconnect the FP and FN leads 9 Remove the relays as necessary See Figure 6 2 GM58162 D 1 Ground stud 2 LO stud 3 Relays P23 P24 and P25 Figure 6 2 ADC II Controller 10 Remove the junction box from the support bracket Section 6 Generator Disassembly Reassembly 61 11 12 13 14 Disconnect the ground strap if necessary Remove the fuel inlet hose Close the seacock and remove the water inlet hose from the seawater pump Remove the fuel pumps and lines from the generator 15 Remove the end bracket cover plate See Figure 6 3 16 Push the brushes into the holder Secure the brushes into position by sliding a retainer into the brush keeping holder See Section 5 6 17 Remove the brush holder and carefully pull the leads out of
46. poor brush contact causes arcing The brushes must be free to move within the holder and be held in contact with the slip rings by the springs When correctly positioned spring pressure on the brush surface causes the brush to wear evenly The entire brush must ride on the ring or arcing occurs and causes burned rings or voltage regulator failure Figure 5 8 shows the correct positioning of the brushes Add or remove shims as necessary to center the brushes onthe slip rings Replace the brushes if they show uneven wear or are worn to one half their original length Check the resistance through the brushes Resistance through the brushes should be low 0 1 0 2 ohms without meter lead resistance 52 Section 5 Component Testing and Adjustment Alternator End View GM58162 GM53052 Side View 7 Brush holder 8 Correctly positioned Slip ring Brush holder Brush brush Retainer wire 9 Incorrectly positioned Shim brush Spring Figure 5 8 Brush Assembly TP 6593 10 13 5 7 Voltage Reconnection Voltage Reconnection is covered in the generator set Installation Manual See the List of Related Materials for the document number 5 8 Governor System The frequency of the alternator output is determined by the speed of the engine A two pole alternator must be driven at 3600 RPM to provide 60 Hertz and 3000 RPM to provide 50 Hertz The engine speed is maintained by the ADC 5 9 Fault Shu
47. s menus to check and adjust the generator output and controller configuration The controller configuration and generator set output are factory set and should not require field adjustment under normal circumstances Check and adjust the configuration and or output in the following cases e Check and adjust the controller configuration and generator output after generator set reconnection to a different voltage e Check the controller configuration when troubleshooting generator set problems e Check and adjust the generator set output after installation if the voltage requires adjustment for a particular application 4 7 4 Adjusting the Voltage Gain and Volts Hz After setting the system voltage check the output voltage and adjust if necessary using the following procedures Follow the instructions in Figure 4 18 to adjustthe voltage gain and volts Hz while the engine is running Rotate the control knob clockwise to increase a setting or counterclockwise to decrease the setting Note A digital multimeter that measures voltage and frequency is required for these adjustments 4 7 2 Voltage Adjustment A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not c
48. the stator housing See Figure 6 6 18 Remove the generator end vibromount hardware See Figure 6 3 Generator End View 2 1 Alternator cover plate 2 Vibromount hardware Figure 6 3 Alternator End Cover 19 Attach a hoist hook to the generator lifting eye Note The hoist capacity rating should be one half ton or greater 20 Tilt the generator set up and brace it with a block of wood See Figure 6 4 62 Section 6 Generator Disassembly Reassembly 1 Block of wood Figure 6 4 Raising the Generator 21 Remove the overbolts See Figure 6 6 Use a rubber mallet to separate the end bracket from the stator housing 22 Carefully remove the stator assembly from the generator adapter plate 23 Remove the rotor bolt and end drive fitting 24 Reinstall the rotor bolt without end fitting finger tighten and back off two turns 25 Strike the bolt with ahammer until the rotor is freed from the engine s tapered drive shaft Do not damage the through bolt threads or bolt head See Figure 6 5 1 Rotor bolt 2 Hammer Figure 6 5 Removing the Rotor TP 6593 10 13 Generator adapter bolt and washer quantity 4 Generator adapter Spring Brush holder Brush quantity 2 Brush holder shim Rotor thru bolt End bracket bearing Stator assembly 10 11 12 13 14 15 16 17 18 15 GM58162 D GM53052
49. tie wraps to secure the wires as necessary Reconnect the leads to the circuit breaker QCON1 and 2 to the F5 fuse FP and FN leads neutral stud LO and ground stud GRD as marked during disassembly Refer to the wiring diagrams in Section 7 Note Check the generator set nameplate to verify the original voltage configuration Reinstall the ADC Reconnect the P1 and P2 connectors Connectthe ground strap using bolt washer and lock washer install the lock washer against the ground strap Reconnect all of the external connections the exhaust line to the catalyst assembly the fuel line to the fuel pump filter inlet the water line to the seawater pump the remote interface connector the AC output leads and the battery cables to the battery negative lead last Verify that the generator set master switch is in the OFF position Reconnectthe engine starting battery negative lead last Reconnect power to the battery charger if equipped Section 6 Generator Disassembly Reassembly 65 6 4 Exhaust Manifold Heat Exchanger Instructions See Figure 6 9 for special exhaust manifold heat exchanger instructions if required NT OUTLET HOLE IN T BE LOCATED AT T MANIFOLD
50. valve Open the manual fuel shut off valve if equipped Start the generator set Press the generator set start stop button to start 6593 10 13 Note Opening seacock Before starting the generator set open the seacock to allow cooling water passage Failure to do so could damage the seawater pump impeller and cause serious engine overheating damage Note Transfer switch Check that the marine ship to shore transfer switch if equipped is in the ship position Note Close seacock if water enters the exhaust system f water enters the exhaust system close the seacock and drain the water from the exhaustsystem atthe silencer s drain plug before attempting to start the generator set water filled exhaust hose and silencer may hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valves Water ingested into the engine may cause major engine damage that the Kohler Co warranty does not cover f excessive cranking is a chronic problem have the unit including the exhaust system serviced by an authorized Kohler distributor dealer There is a delay of about 2 seconds before the controller attempts to start the engine The controller display indicates the crank cycle 1 code Cranking The controller attempts to start the generator set three times three crank cycles 7 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shu
51. will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6593 10 13 Accidental Starting WARNING KS 55 Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator 661 Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when rec
52. wire is disconnected or the circuit is open to the ADC Il Check the TMAP connector and IAT signal wiring for an open circuit TMAP pin 2 to ADC II pin 21 SIGNAL TMAP pin 1 to ADC pin 28 GND transducer ground TMAP pin 3 to ADC pin 27 OPS transducer ground To check the IAT sensor of the TMAP disconnect the TMAP connector and measure the resistance See Figure 5 14 IAT input lo Intake Air Temperature IAT Input Sensor Low The controller indicates an IAT Input High Low fault within 1 second of the condition being present Fault appears if the TMAP temperature signal wire has become shorted to ground shorted to the MAP signal the TMAP has failed or the ADC II has failed Check the TMAP connector and IAT signal wiring for an open circuit TMAP pin 2 to ADC pin 21 SIGNAL TMAP pin 1 to ADC pin 28 GND transducer ground TMAP pin 3 to ADC pin 27 OPS transducer ground To check the IAT sensor of the TMAP disconnect the TMAP connector and measure the resistance See Figure 5 14 ECT input hi Engine Coolant Temperature ECT Sensor Input High 34 Section 4 Controller The controller indicates an ECT Input High fault within 1 second of the condition being present and an ECT Input Low warning within 1 second of the condition being present Fault appears if the coolant sensor wire is disconnected or the circuit is opened to the ADC II Check if the sensor connector is disconnected or for a
53. 08100 60 M931 08110 60 M931 08120 60 M931 08130 60 M931 08140 60 M931 08150 60 M931 08200 60 M931 10040 82 M931 10040 60 M931 10045 60 M931 10050 60 M931 10050 82 M931 10055 60 M931 10060 60 M931 10065 60 M931 10070 60 M931 10080 60 M931 10080 82 M931 10090 60 M931 10090 82 M931 10100 60 M931 10110 60 M931 10120 60 M931 10130 60 M931 10140 60 M931 10180 60 M931 10235 60 M931 10260 60 M960 10330 60 M931 12045 60 M960 12050 60 M960 12050 82 M931 12050 60 M931 12050 82 M931 12055 60 M931 12060 60 M931 12060 82 M931 12065 60 M931 12075 60 M931 12080 60 M931 12090 60 M931 12100 60 M931 12110 60 This metric hex bolt s hardness is grade 10 9 TP 6593 10 13 Dimensions 5 0 80 x 55 M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M6 1 00 x 145 M6 1 00 x 150 M8 1 25 x 35 M8 1 25 x 40 M8 1 25 x 45 M8 1 25 x 50 M8 1 25 x 55 M8 1 25 x 55 M8 1 25 x 60 M8 1 25 x 70 M8 1 25 x 70 M8 1 25 x 75 M8 1 25 x 80 M8 1 25 x 90 M8 1 25 x 95 M8 1 25 x 100 M8 1 25 x 110 M8 1 25 x 120 M8 1 25 x 130 M8 1 25 x 140 M8 1 25 x 150 M8 1 25 x 200 M10 1 25 x 40 M10 1 50 x 40 M10 1 50 x 45 M10 1 50 x 50 M10 1 25 x 50 M10 1 50 x 55 M10 1 50 x 60 M10 1 50 x 65 M10 1 50 x 70 M10 1 50 x 80 M10 1 25 x 80 M10 1 50 x 90 M10 1 50 x 90 M10 1 50 x 100 M10 1 50 x 110 M10 1 50 x 120 M10 1 50 x 130 M10 1 50 x 140 M10
54. 2 00 x 30 M16 2 00 x 35 M16 1 50 x 40 M16 2 00 x 40 M16 1 50 x 45 M16 2 00 x 45 M16 2 00 x 50 M16 2 00 x 50 M16 2 00 x 60 M16 2 00 x 70 M18 2 50 x 35 M18 2 50 x 50 M18 2 50 x 60 M20 2 50 x 50 M20 2 50 x 55 M24 3 00 x 60 M24 3 00 x 65 M24 3 00 x 70 Pan Head Machine Screws 7985 03010 20 7985 03012 20 7985 04010 20 7985 04016 20 M7985A 04020 20 M7985A 04050 20 M7985A 04100 20 M7985A 05010 20 M7985A 0501 2 20 M7985A 05016 20 M7985A 05020 20 M7985A 05025 20 M7985A 05030 20 M7985A 05080 20 M7985A 05100 20 M7985A 06100 20 M3 0 50 x 10 M3 0 50 x 12 M4 0 70 x 10 M4 0 70 x 16 M4 0 70 x 20 M4 0 70 x 50 M4 0 70 x 100 5 0 80 10 5 0 80 x 12 5 0 80 x 16 5 0 80 x 20 5 0 80 x 25 5 0 80 x 30 5 0 80 x 80 5 0 80 x 100 M6 1 00 x 100 Flat Head Machine Screws M965A 04012 SS M965A 05012 SS M965A 0501 6 20 M965A 0601 2 20 M4 0 70 x 12 5 0 80 x 12 5 0 80 x 16 M6 1 00 x 12 Appendix 77 Metric continued Part No Hex Nuts M934 03 50 M934 04 50 M934 04 B M934 05 50 M934 06 60 M934 06 64 M6923 06 80 M982 06 80 M934 08 60 M6923 08 80 M982 08 80 M934 10 60 M934 10 60F M6923 10 80 M6923 10 62 M982 10 80 M934 12 60 M934 12 60F M6923 12 80 M982 12 80 M982 14 60 M6923 16 80 M982 16 80 M934 18 80 M982 18 60 M934 20 80 M982 20 80 M934 22 60 M934 24 80 M982 24 60 M934 30 80 Washers Part No M125A 03 80 M12
55. 20 120 240 Section 1 Specifications 1 3 Controller Specifications The generator set is equipped with the Advanced Digital Control Il Fora specific description ofthe controller see Section 2 Operation in the operation manual Environmental Specification 20 to 70 C 4 to 158 F 5 95 non condensing Operating temperature Humidity Power requirements Voltage Current draw max 12 VDC 250 mA 12 VDC 25 C 77 F 25 C 77 F Amps kW kVA 41 7 5 5 20 8 5 5 115 230 230 240 17 4 4 4 17 4 4 4 16 7 4 4 120 120 240 62 5 7 5 7 5 31 3 7 5 7 5 115 230 6EFKD 230 240 26 1 6 6 26 1 6 6 25 0 6 6 120 TOERE 120 240 83 3 10 10 41 7 10 10 115 230 8EFKD 2F4 230 240 34 8 8 8 50 34 8 8 8 33 3 8 8 RATINGS Marine continuous ratings per ISO 3046 ISO 8528 1 and Kohler ISO rating guideline 2 14 Obtain technical information bulletin TIB 101 on ratings guidelines for complete ratings definitions Figure 1 1 Generator Set Ratings TP 6593 10 13 Section 1 Specifications 11 1 4 Alternator Specifications Alternator Specification Alternator model 5EKD 4EFKD 7 5EKD 6EFKD 10EKD 8EFKD Stator leads qty Phase Rotor resistance ohms cold Stator resistance ohms cold Main winding 1 2 3 4 Aux wind
56. 25 25 15 656 1 312 095 5 8 X12399 31654x 2 00 X 6021 6 5 8 11 x 2 50 X 25 29 812 1469 134 3 4 125 38 5 16 24 2 75 6021 7 5 8 11 2 75 25 127 1 062 2 000 134 1 6021 12 5 8 11 x 3 75 6238 2 3 8 16 62 6021 11 5 8 11 x 4 50 X 6238 10 3 8 16 x 75 6021 10 5 8 11 6 00 6238 3 3 8 16 x 88 6238 11 3 8 16 1 00 6021 9 5 8 18 2 50 6238 4 3 8 16 1 25 6238 5 3 8 16 1 50 6239 1 3 4 10 1 00 6238 1 3 8 16 1 75 6239 8 3 4 10 1 25 6238 6 3 8 16 2 00 6239 2 3 4 10 1 50 6238 17 3 8 16 2 25 6239 3 3 4 10 2 00 6238 7 3 8 16 2 50 6239 4 3 4 10 2 50 6238 8 3 8 16 2 75 6239 5 3 4 10 3 00 6238 9 3 8 16 3 00 6239 6 3 4 10 3 50 6238 19 3 8 16 3 25 X 792 1 1 8x 2 25 X 6238 20 3 8 16 x 3 75 792 8 1 8 x 500 6238 13 3 8 16 4 50 6238 18 3 8 16 5 50 6238 25 3 8 16 6 50 76 Appendix TP 6593 10 13 Metric Hex head bolts are hardness grade 8 8 unless noted Part No Hex Head Bolts Partial Thread M931 05055 60 M931 06040 60 M931 06055 60 M931 06060 60 M931 06060 SS M931 06070 60 M931 06070 SS M931 06075 60 M931 06090 60 M931 06145 60 M931 06150 60 M931 08035 60 M931 08040 60 M931 08045 60 M931 08050 60 M931 08055 60 M931 08055 82 M931 08060 60 M931 08070 60 M931 08070 82 M931 08075 60 M931 08080 60 M931 08090 60 M931 08095 60 M931
57. 5 Section 5 9 No fuel Check the fuel supply Fuel line restriction Inspect fuel lines and fuel filters for blockage Backfire flame clogged Replace element O M Blown controller fuse F4 Replace fuse Check wiring to the controller Section 5 11 Blown auxiliary winding fuse F5 Replace fuse If fuse blows again test generator components Section 5 11 Blown voltage regulator fuse F2 Replace fuse Troubleshoot the voltage regulator Section 5 11 Spark plug s Replace and regap plug s Engine S M Engine overheated hot engine only Check air intake fuel oil level air inlet outlet and 1 Low oil pressure switch Attempt startup Shutdown should say Low oil pres if unit shuts down remove lead from LOP switch and reset controller A successful restart attempt indicates a faulty LOP shutdown switch Note Check engine oil pressure before performing test and or replacing LOP shutdown switch Engine S M Engine overloaded Reduce electrical load Shutdown on overload fault I M Loss of generator output voltage to controller Check connections at P2 plug Check continuity of AC sensing leads 11 and 44 Section 7 Intermittent wiring connections Inspect fuel pump wiring to ensure good connections Blown F3 fuse Verify line circuit Section 7 Blown F5 fuse Troubleshoot rotor and stator assembly and
58. 51534 66 14 NOSN3S MA 2 124 19005 4015 13415 1 8 14 Sita MOSNiS SO YOSNaS dV dV 8 124 HOLIMS 38085384 YILYM YIS 4 124 HOLMS 3NnSS3Nd 10 401 5 INSNI 1 14 YOSN3S 00 NMOGLNHS 61 14 9 124 M ms 109 QNI imum YINOLSNI 3snd 4 HOLIMS dW3l LSAVHX3 513 212 212 9 14 Gnd 1051 RE 7 NYO TWNYGINI 62 14 16 103 B 8 39 NYO 1 92 14 203 GIONSIOS JINYHO SO 22 uoivNe cV ov 1 1 id Nn MNo1vino3s 39VIL10 0td 1 064 804 voz voz voL 3 Za Sire 21 y 3504 5 LNVIO09 YOSN3S_NOILISOd Sd SNLVLS 09 089 AM3LIVE 937 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux AWG AWM bat BBDC BC BCA BDC BHP blk blk htr BMEP bps br BTDC Btu
59. 5A 04 80 M125A 05 80 M125A 06 80 M125A 08 80 M125A 10 80 M125A 12 80 M125A 14 80 M125A 16 80 M125A 18 80 M125A 20 80 M125A 24 80 Dimensions M3 0 50 M4 0 70 M4 0 70 5 0 80 6 1 00 6 1 00 6 1 00 6 1 00 8 1 25 8 1 25 8 1 25 10 1 50 10 1 25 10 1 50 10 1 50 10 1 50 12 1 75 12 1 25 12 1 75 12 1 75 14 2 00 16 2 00 16 2 00 18 2 5 18 2 50 20 2 50 20 2 50 22 2 50 M24 3 00 M24 3 00 M30 3 50 OD 32 7 0 43 9 0 53 10 0 64 12 0 8 4 16 0 10 5 20 0 13 0 24 0 15 0 28 0 17 0 30 0 19 0 34 0 21 0 37 0 25 0 44 0 Type Standard Standard Brass Standard Standard Std green Spiralock Elastic Stop Standard Spiralock Elastic Stop Standard Standard Spiralock Spiralockt Elastic Stop Standard Standard Spiralock Elastic Stop Elastic Stop Spiralock Elastic Stop Standard Elastic Stop Standard Elastic Stop Standard Standard Elastic Stop Standard Bolt Thick Screw 05 M3 08 M4 10 M5 16 M6 16 M8 2 0 M10 2 5 M12 25 M14 3 0 M16 3 0 M18 3 0 M20 40 M24 This metric hex nut s hardness is grade 8 78 Appendix TP 6593 10 13 6593 10 13 79 6593 10 136 2010 2011 and 2013 by Kohler Co All rights reserved KOHLER Power Systems KOHLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada
60. CON2 FUSE F5 CB2 CB 10 AMP 55 0 4 1 OPTIONAL FIELD WINDING 2 2 FIELD WINDING 2 1 AUX WINDING INPUT 2 4 AUX WINDING INPUT 2 3 A C INPUT 2 6 A C INPUT 2 7 A C INPUT 2 8 INPUT 2 5 5 66 Figure 5 2 Generator Schematic TP 6593 10 13 FN MAIN FIELD 7 BRUSHES AND STATOR SLIP RINGS Section 5 Component Testing and Adjustment 47 WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove
61. Configuration and Adjustment 41 4 7 1 Adjusting the Voltage Gain and Volts Hz 41 4 7 2 Voltage Adjustment 41 Section 5 Component Testing and 47 51 Theory of Operation eu e REN bee 47 5 2 Separate Excitation consiste bua te ee eno Vete IA ERR 47 5 37 vU itte tts ia 49 54 MainField Rotor clie eer t RE REP RE ERE 51 5 4 1 Rotor Continuity and Resistance 5 51 5 5 Slip HIfnigs scs pep ih MET Sa 52 5 65 Brushes a ae a 52 5 7 Voltage Reconnection eee ote et ee bord 53 5 8 Governor System beatae ee ete adie maine ee i dei ds 53 59 Fault Shutdown Tests 53 5 9 1 Fault Shutdown Switches Senders 53 TP 6593 10 13 Table of Contents 3 Table of Contents continued 5 10 Electronic Throttle Assembly 58 511 BUSES EE ei One p vele ee oe ete a 58 5 12 Continuity Checks tin ERR m d wads 59 Section 6 Generator Disassembly Reassembly 61 61 Disass
62. Low resistance readings continuity and no evidence of shorted windings heat discoloration indicate a stator in good condition See Figure 5 6 8 If the resistance test proves inconclusive use a megohmmeter to test the stator as described in the next step Note Because ohmmeter accuracy varies resistance readings are approximate readings Take readings of the rotor and stator at room temperature Note Make sure that all stator leads are disconnected before running megohmmeter test R14807 14 Figure 5 4 Testing Stator Windings Section 5 Component Testing and Adjustment 49 te stator is shorted to ground 1 and 2 a Apply 500 volts DC to any stator lead and the 11 stator frame Perform the megohmmeter test 1 and 88 for 5EKD 4EFKD models following the instructions of the megohmmeter 1 and 77 for 7 5EKD 6EFKD models manufacturer 2 and 11 3 and 4 b Repeat the test on the other stator leads until Sanaa each coil is tested an 4 and 44 Note A reading of approximately 500 kOhms 4 and 88 for 7 5EKD 6EFKD models 1 2 megohm and higher indicates a 4 and 77 for 10EKD 8EFKD models good stator 55 and 66 1 and 3 4 44 55 or 66 2 3 4 44 55 66 of less than 500 kOhms indicates deterioration 3 and 1 2 11 55 or 66 c Repair or replace the stator if any reading is less than approximately 500 kOhms Areading of the winding
63. Present Push Rotate Push Knob Knob Knob USB SAVE CONFIRM CONFIRM Saving Save PARAMS amp LOG SAVE NO SAVE YES complete Rotate Knob Skipped if Genset is Running Push Push Knob Knob USB LOAD Craft A Loading Load PARAMS PUSH TO LOAD Complete Rotate Knob Push Push Knob Knob USB LOAD MDC 1 2 1 Loading Load SOFTWARE PUSH TO LOAD Complete Rotate Knob SW version 0 1 23 Figure 4 19 Advanced Digital Control USB Flow 5 7 5 10EKD and 4 6 8EFKD Models TP 6593 10 13 Section 4 Controller 45 Notes 46 Section 4 Controller TP 6593 10 13 Section 5 Component Testing and Adjustment 5 1 Theory of Operation Model 5 7 5 10EKD and 4 6 8EFKD generator sets utilize a rotating field alternator to produce AC voltage Upon activation of the generator start button DC current from the battery magnetizes the rotor field When the magnetized rotor rotates within the stator windings an electrical voltage develops within the stator As engine speed and generator output increase the ADC II feeds rectified stator output current to the rotor through the brushes slip rings to increase the strength of the rotor field As the rotor field increases in strength generator output also increases The ADC II controller monitors the generator output voltage through leads 11 and 44 and adjusts the DC current to the rotor to meet load requirements See Figure 5 2 5 2 Separate Excitation
64. ad WARNING found at the beginning of manual regarding moving parts 16 Section 2 Scheduled Maintenance TP 6593 10 13 3 1 Introduction Corrective action and testing many cases requires knowledge of electrical systems and electronic circuits Have an authorized distributor dealer or trained service technician perform testing and service Refer to the Engine Service Manual 66 690 01 for engine service information The first step in troubleshooting the generator set controls is to verify that the controller is correctly configured for the generator set The Generator Set Installation Manual explains how to check and change the controller configuration If the troubleshooting procedures in this section identify abad part refer to the parts catalog for replacement part numbers See the List of Related Materials in the Introduction for the parts catalog number 3 2 Initial Checks When troubleshooting always check for simple problems first Check for the following common problems before replacing parts e Loose connections or damaged wiring e Dead battery e Fault shutdown Check for a fault code on the ADC II display Section 4 2 5 describes the warning and shutdown fault codes TP 6593 10 13 Section 3 Troubleshooting e Blown fuses See Figure 3 1 for fuse identification Always check and replace the fuses before replacing other components Schematic Diagram Fuse Reference Part Number Location Fuse
65. ad warning for 30 seconds and if no action is taken to reduce the load during these 30 seconds the unit will shutdown on an overload fault Action to take Reduce the electrical load Review the troubleshooting chart in Section 3 Section 4 Controller 37 4 2 6 Resetting the Controller after Fault Shutdown Note A fault is identified by a red blinking light in the LED status indicator Always identify and correct the cause of a fault shutdown before resetting the controller Use the following procedure to reset the generator set controller after a fault shutdown 1 Disconnect the generator set engine starting battery ies negative lead first 2 Disconnect the generator set from the load See the safety precautions at the beginning of this manual before proceeding 3 Identify and correct the cause of the fault shutdown See the safety precautions at the beginning of this manual before proceeding Refer to Section 3 Troubleshooting 4 Reconnect the generator set to the load 5 Reconnect the generator set engine starting battery negative lead last 6 Push the Advanced Digital Control knob 7 Rotate the control knob to CONFIRM CLR FAULT YES 8 Push the control knob 9 Start the generator set by pressing the generator set start stop button to START Test operate the generator set to verify that the cause of the shutdown has been corrected 10 Shut the generator off by pressing the generator se
66. ally available to the generator set owner Therefore have service performed by an authorized distributor dealer 2 1 General Perform the items listed in the service schedule at the designated intervals for the life of the generator set For example an item serviced every 100 hours or 3 months must also be serviced after 200 hours or 6 months 300 hours or 9 months etc Note See the generator set operation manual and the engine service manual for service procedures not included in this manual Section 2 Scheduled Maintenance 15 2 2 Service Schedule Perform Service at Intervals Indicated X Fuel System Before Starting After 50 Hr or 1 Month Every 100 Hr or 3 Months Every 300 Hr or 6 Months Check the fuel level and fill as necessary Check fuel lines and replace as necessary Replace the fuel filter Lubrication System Check crankcase oil level and add as necessary Replace the oil in crankcase X 200 hr Replace the lube oil filter element X 200 hr Cooling System Check coolant level and fill as necessary X Check seawater outlet and clean as necessary X during operation Check function of siphon break if equipped Check and clean seawater flow switch Replace seawater pump impeller Adjust seawater pump tension t X 200 hr Check heat exchanger anticorrosion zinc condition
67. ant temperature sensor CTS Attempt to start the generator set The unit should not start and the ADC II control should display fault ECT input hi To clear the fault see Section 4 2 6 Connect a jumper wire across terminals A and B of the connector shorting the wires Attempt to start the generator set The unit should start and run but the ADC should display warning code ECT input lo Shutdown the generator set If available insert a resistor 100 120 Ohm into the CTS connector Attempt to start the generator set Shortly after ignition the unit should shut down and the ADC control should display fault code Hi eng temp Replace the CTS connector onto the coolant temperature sensor To clear the fault see Section 4 2 6 5 9 1 Fault Shutdown Switches Senders Check the low oil pressure and high engine temperature shutdown switches on the engine by performing the following tests If the sensor does not function as described replace it WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Short circuits Haz
68. approx 3 0 Ohms 30 MAP input hi TP 6593 10 13 Manifold Air Pressure MAP Sensor Input High The controller indicates a MAP Input High Low fault within 1 second of the condition being present The manifold air pressure sensor fault appears if the TMAP pressure signal wire is shorted to power shorted to the IAT signal the TMAP has failed or the ADC II has failed Check the TMAP connector and MAP signal wiring for a shorted circuit TMAP pin 4 to ADC II pin 20 200 TMAP pin 1 to ADC II pin 28 XDRG transducer GND TMAP pin 3 to ADC II pin 27 OPS transducer GND Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP pin 1 GND to pin 4 PRESSURE SIGNAL KPA of 2 4 8 2 kOhms TMAP pin 3 PWR to pin 4 PRESSURE SIGNAL KPA of 3 4 8 2 kOhms Section 4 Controller 33 Fault Shutdowns Text Displayed Description Check MAP input lo Manifold Air Pressure MAP Sensor Input Low The controller indicates a MAP Input High Low fault within 1 second of the condition being present The manifold air pressure sensor fault appears if the TMAP pressure signal wire is disconnected or the circuit is opened to the ADC MAP input lo and IAT input hi are expected faults when the TMAP connector is unplugged Check the TMAP connector and MAP signal wiring for an open circuit TMAP pin 4 to ADC II pin 20 200 TMAP pin 1 to ADC II pin 28 XDRG transducer GND TMAP pin 3 t
69. ardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Temperature Sensor CTS The coolant temperature sensor CTS is used to monitor engine temperature for the high engine Section 5 Component Testing and Adjustment 53 temperature fault shutdown eng temp See Figure 5 10 for the coolant temperature sensor location Shutdown the generator set disconnect the battery negative lead first and allow the generator set to cool Disconnect the CTS and use an ohmmeter to measure the resistance across the sensor The sensor resistance varies with temperature and should be within the values shown in Figure 5 9 Ifthe resistance is very low indicating a short circuit or very high indicating an open circuit replace the CTS Temperature C Sensor Resistance Signal F Ohms Voltage 100 212 177 0 75 90 194 241 0 97 80 176 332 1 25 70 158 467 1 59 60 140 667 2 00 50 122 973 2 47 40 104 1459 2 97 30 86 2238 3 46 20 68 3520 3 89 10 50 5670 4 25 40 40 100700 4 95 Figure 5 9 Coolant Temperature Sensor Resistance Readings Top View
70. as another vessel may be the source for the presence of the CO Check the generator exhaust system see the O M Generator service for emissions required Contact an authorized distributor dealer for service CO sensr err Faulty CO sensor Fault code is displayed if the CO sensor is inoperative 30 Section 4 Controller Pulsed signal Replace the CO sensor Contact an authorized distributor dealer for service TP 6593 10 13 Warnings Code and Description Sensing Mechanism Active State Inhibit Time Default Setting Check Low oil pres Low oil pressure With the sender kit installed the controller displays a low oil pressure warning 30 seconds from engine start when the engine oil pressure is less than 17 psi The controller inhibits the warning for at least 30 seconds after crank disconnect speed is reached After the 30 second inhibit period there is no delay after going below 17 psi before the low oil pressure warning is indicated Analog Pressure below setpoint 30 sec 17 psi Check for leaks in the lubrication system Check the oil level and add oil if the level is low Hi eng temp High engine coolant temperature The controller displays a high engine temperature warning 30 seconds from engine start when the engine temperature is greater than 210 F The controller inhibits the warning for at least 30 seconds after crank disco
71. ax eccentricity mm in 0 08 0 003 out of round mm in 0 01 0 0002 Figure 6 7 Collector Ring Dimensions 64 Section 6 Generator Disassembly Reassembly TP 6593 10 13 6 3 Reassembly Note See Section 1 6 and Appendix for torque specifications Align the rotor onto the engine shaft and secure with the end drive fitting and rotor bolt Torque the rotor to 23 1 204 in 165 for 5 7 5EKD and 4 6EFKD models or 32 5 Nm 288 Ibs for 10EKD and 8EFKD models Carefully slide the stator assembly over the rotor Replace the end bracket o ring into the groove in the end bracket bearing insert See Figure 6 6 Install the end bracket and torque the overbolts to 13 6 Nm 120 in 105 Feed the brush leads inside the stator housing up through the opening Secure the brush holder using the original screws Remove the brush retainer and check the brush alignment See Section 5 6 Install the coverplate and torque the coverplate bolts to 6 8 Nm 60 Ibs Use the hoist to raise the alternator end Remove the wood block from under the locator plate Lower the generator set and install a bolt a large washer two small washers and a locknut on each vibromount Tighten the mounting bolts Reinstall the relays 6593 10 13 10 11 12 13 14 15 16 17 18 Reinstall the support bracket to mount junction box See Figure 4 1 Install
72. ay indicate a blown fuse Obtain service from an authorized distributor dealer Schematic Diagram Fuse Reference Number Location Fuse Fuse block position 1 F1 Customer connection Fuse block Fe position 4 Voltage regulator F3 Fuse block Injector CO sensor fuel position 5 pumps oxygen sensor and coils Fuse block Controller position 8 Fuse holder Auxiliary winding Figure 4 9 Fuses 4 4 Sensor Module The CO sensor module is located behind the ADC inside the junction box Replace the CO sensor module every two years See Figure 4 10 and Figure 4 11 Top View GM40265 D GM46362 Figure 4 11 CO Sensor Module TP 6593 10 13 4 5 Relays The junction box contains four relays See Figure 4 12 Figure 4 13 and Figure 4 14 for location and description Top View ai
73. call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Netherlands Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 331631 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 10 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 TP 6593 10 13 1 1 Introduction The spec sheets for each generator set provide specific generator and engine information Refer to the generator set spec sheet for data not supplied in this manual Consult the generator set installation manual engine operation manual and engine service manual for additional specifications 1 2 Generator Set Ratings See the generator set ratings in Figure 1 1 Consult generator set nameplate for specific generator set ratings Model Series Alternator Voltage 1
74. can operate e Slow blink indicates that the generator is not running e Steady indicates that the generator is running e Off indicates that the unit is off Figure 4 4 shows the possible LED displays TP 6593 10 13 LED Status Indicator Engine Condition Off Stopped Any Stopped No fault No warning No fault No warning Slow blink green Steady green Running Slow blink red Steady amber Stopped Fault Running Warning Slow blink amber Stopped Warning Figure 4 4 Possible LED Status Indicator Displays The controller is factory set and should not require configuration or adjustment under normal operating conditions If the generator set is reconnected to a different voltage and or frequency see Section 4 7 for system configuration and adjustment instructions 4 2 2 Starting the Generator Set The following procedures describe the actions required to start the generator set WARNING Explosion Gasoline vapors can cause explosion and severe injury or death Before starting the generator set operate the blower 4 minutes and check the engine compartment for gasoline vapors Action Operate the blower Operate the blower 4 minutes and check the engine compartment for gasoline vapors NOTE Many boat manufacturers recommend continuous blower operation while the generator set is operating Read the vessel s owner s manual for further information Open the fuel shut off
75. ce Section 3 Troubleshooting 19 Low output or excessive drop in voltage Possible Cause Generator overloaded Corrective Action Reduce load Reference Incorrect controller configuration Check and adjust the controller configuration settings Section 4 7 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 4 7 Alternator or control system Perform separate excitation procedure to isolate problem to the alternator or the control system Section 5 2 Intermittent wiring connection or lack of compression Check harness connections Check P2 plug and F5 fuse connections Section 5 11 Section 7 Controller Check controller settings Check controller fuse wiring and connections Section 4 7 Section 7 Rotor open grounded or shorted windings Test and or replace Section 5 4 Stator open grounded or shorted windings Test and or replace Section 5 3 Brush connection Check for loose brush connections Check the resistance through the brushes Resistance through the brushes should be low 0 1 0 2 ohms without meter lead resistance Section 5 6 Light flicker Voltage stability gain setting Check and adjust the voltage stability gain setting using the ADC Section 4 7 High output voltage Incorrect controller configuration Check and adjust the controller
76. ce or an open circuit Section 5 Component Testing and Adjustment 59 Notes 60 Section 5 Component Testing and Adjustment TP 6593 10 13 Section 6 Generator Disassembly Reassembly 6 1 Disassembly Disconnect all of the external connections battery cables at the battery negative lead first AC output leads remote interface connector Close the seacock Remove the water line at the seawater pump fuel line at the fuel pump filter inlet and exhaust line at the catalyst assembly Remove the sound shield enclosure if equipped Observe all of the safety precautions listed at the beginning of this manual during the disassembly reassembly procedures Note Because this manual covers several models the procedure for disassembly may vary because of product updates and the assembly variations Note Mark leads that are disconnected Refer to the wiring diagrams in Section 7 during reassembly 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger if equipped 3 Disconnect the generator set engine starting battery negative lead first WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery 4 Disconnect wiring harness plugs P1 35 pin plug and P2 8
77. ches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard Appendix 71 k kilo 1000 K kelvin kA kiloampere KB kilobyte 210 bytes kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display 1 shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 220 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous
78. command from a remote computer WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Alternator Service Under normal operating conditions the generator set alternator does not require scheduled service Refer to the service schedule for items that require maintenance TP 6593 10 13 Section 2 Scheduled Maintenance Engine Service Perform generator set engine service at the intervals specified by the engine service literature Contact an authorized Kohler service distributor dealer to obtain engine service literature Generator Set Service See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized Kohler service distributor dealer perform all generator service Routine Maintenance Refer to the following generator set service schedule the engine service schedule and the runtime hours displayed on the ADC II to determine when to schedule routine maintenance Service the generator set more frequently if it is subject to extreme weather long operating hours or dusty or dirty conditions Service Schedule Perform maintenance on each item inthe service schedule at the designated interval for the life of the generator set Tools Tools and instruments used to perform some maintenance items are not gener
79. connected or the circuit is opened to the ADC TPS range lo and TPS input lo are expected faults when the ETC connector is unplugged Check the throttle connector connection and sensor for an open circuit ETC pin 6 to ADC pin 9 217 ETC pin 2 to ADC pin 28 SG ETC sticking Electronic Throttle Control Sticking Fault appears if either of the electronic throttle control driver signals are opened or disconnected This happens if the throttle plate sticks inside the throttle body Check for debris or obstructions inside the throttle body a loose throttle plate or the throttle plate shaft for bearing wear Check the ETC driver wiring for an open circuit ETC pint to ADC pin 30 ETC pin 4 to ADC II pin 31 Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS pin 1 DRIVER to pin 4 DRIVER approx 3 0 Ohms 30 Note Do not service the throttle components Repair or replace the throttle body assembly ETC driver Electronic Throttle Control ETC Driver Fault Fault appears if an overcurrent condition occurs on either the ETC or ETC driver signals Check the ETC driver wiring for a shorted circuit ETC pin 1 to ADC II pin 30 ETC pin 4 to ADC II pin 31 Check the ETC internal motor drive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS pin 1 DRIVER to pin 4 DRIVER
80. ction at the 10P1 lead at the battery Poor connection at the incoming side of the F1 fuse Damaged F1 fuse holder or fuse Poor connection at the outgoing side of the F1 fuse High contact resistance across plug P24 An inoperative P25 relay coil An inoperative component connected to the customer connection plug P21 7 TPS input hi Throttle Position Sensor Input High The TPS Range High and TPS Input High conditions are closely related If the input reaches 5 VDC the TPS Input High condition is indicated The range error is dynamically determined and may or may not occur before reaching 5 VDC In some cases both may occur simultaneously The ADC II protective monitor will react to only one shutdown condition therefore whichever of these faults is detected first will be indicated as the reason for the shutdown A TPS Input High condition exists when the closed loop feedback does not correspond with what the ADC II is expecting The threshold for the TPS Input High is a signal voltage of 4 8 volts or greater The controller indicates the fault within 1 second of the condition being present Fault appears if the sensor signal wire is shorted or the sensor has failed Check the throttle connector and sensor wiring for a shorted circuit ETC pin 6 to ADC pin 9 217 ETC pin 2 to ADC pin 28 SG TPS range hi Throttle Position Sensor Range High The TPS Range High and TPS Input High conditions are closely related If the input reaches 5 VDC
81. ctor and measure the resistance from pin to pin See Figure 5 19 EST 2 High Electronic Spark 2 Timing High 36 Section 4 Controller An EST failure condition exists when the spark signal is pulled high or low The controller indicates EST2 fault within 1 second of the condition being present The Electronic Spark Timing EST is a current driver signal and this fault appears if the signal from the ADC is open lost or the coil driver signal is high or overcurrent Check the coil driver wiring for an open circuit or disconnected connector ADC II pin 18 to COIL pin A Verify GND on COIL pin B Verify GND on COIL pin C Verify GND on COIL pin D Verify 12VDC on COIL pin E To check the internal circuit disconnect the coil connector and measure the resistance from pin to pin See Figure 5 19 TP 6593 10 13 Fault Warnings Text Displayed Description Check Oil sens err Oil Pressure Sensor Available only when sender kit is installed The oil pressure input high warning can only be detected when the controller is configured to monitor an oil sending unit The controller indicates the warning after the input is set to a 5 0 volt signal for 0 3 seconds The oil pressure input low warning can only be detected when the controller is configured to monitor an oil sending unit The controller indicates the warning after the sender generates a 0 0 volt signal for 0 3 seconds ETC spring Ele
82. ctronic Throttle Body DETAIL A DETAIL A GM58159 E GM39605 1 Electronic throttle body assembly Figure 5 22 Electronic Throttle Body Assembly Shutdown the generator set disconnect the battery negative lead first and allow the generator set to cool Disconnect the TPS sensor and use an ohmmeter to measure the resistance across the sensor pins See Figure 5 23 TPS Electronic Throttle Sensor Pin Resistance Check approx 1 25 kOh Pin 2 GND to Pin 6 TPS1 SIGNAL A 1 25 Pin PWR to Pin 6 TPS1 SIGNAL d pulis 3 0 Ohms Pin 1 DRIVER to Pin 4 DRIVER 30 Figure 5 23 TPS Electronic Throttle Sensor Resistance 58 Section 5 Component Testing and Adjustment 5 11 Fuses See Figure 5 24 for fuse ratings and part numbers Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Section 3 Troubleshooting for conditions that may indicate a blown fuse Replace blown fuses with identical replacement parts Schematic Diagram Fuse Reference Number Location Fuse Part Number 1 Fuse block position 1 Customer connection GM42337 F2 Fuse block position 4 Voltage regulator GM42339 F3 Fuse block position 5 Injector
83. ctronic Throttle Control ETC Spring Test Failed Upon initial engine startup the ADC II performs a safety test of the throttle return spring If this spring has become weak the throttle will fail this test and set the fault Perform a throttle spring test by cycling the ignition and rechecking the fault Note Do not service the throttle components Repair or replace the throttle body assembly ECT input lo Engine Coolant Temperature ECT Sensor Input Low The controller indicates an ECT Input High fault within 1 second of the condition being present and an ECT Input Low warning within 1 second of the condition being present Fault appears if the coolant sensor wire is shorted to ground or the sensor has failed Check the sensor connector and wiring for a short to GND ADC II pin 11 to ECT A ADC II pin 28 to ECT pin B O2 sens open Oxygen O2 Sensor Open Circuit The warning is displayed when the controller senses an open circuit Troubleshoot the P2 oxygen sensor connections O2 limit err O2 Limit Error Oxygen sensor voltage limits exceeded Replace the oxygen sensor Starter Starter Fault The starter does not engage Troubleshoot the starter circuit and starter motor Overload Power Limit Warning Figure 4 8 Fault Warnings 6593 10 13 An overload condition exists when the controller senses the generator is overloaded If sensed the controller will display an overlo
84. dily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Stator Continuity and Resistance Tests 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger if equipped 3 Disconnect the generator set engine starting battery negative lead first 4 Disconnect all stator leads before performing all stator tests 5 To check for stator continuity set the ohmmeter on Rx1 scale First set ohmmeter zero by holding the red and black meter leads together and setting the ohmmeter reading to zero Then check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 5 4 6593 10 13 Note For single phase models leads 1 4 are the generator output leads Leads 11 44 55 and 66 are the controller sensing and supply leads Refer to the schematic in Figure 5 5 when performing the following steps Note When taking an ohmmeter reading using lead 55 make the connection before the in line fuse 6 Contact the ohmmeter leads and readjust the ohmmeter to read zero ohms 7 Check the cold resistance of the stator windings by connecting the meter leads to the stator leads See Section 1 4 Alternator Specifications for stator winding resistances Note Most ohmmeters do not provide accurate readings below 1 ohm
85. e fuel injector Ifthe ADC receives a voltage signal above 500mV the air fuel mixture would be interpreted as too rich and the ADC II would decrease the duty cycle of the fuel injector TP 6593 10 13 Shutdown the generator set disconnect the battery negative lead first and allow the generator set to cool Disconnect the heated oxygen sensor and use an ohmmeter to measure the resistance across the sensor pins See Figure 5 20 Sensor Pin Resistance Check Pin C HEATER GND to Pin D HEATER PWR 0 4 Ohms Figure 5 20 Sensor Resistance Side View of Exhaust Manifold GM53065 B 1 Heated oxygen sensor Figure 5 21 Heated Oxygen Sensor Location Section 5 Component Testing and Adjustment 57 5 10 Electronic Throttle Assembly The electronic throttle body assembly ETC contains the throttle valve throttle valve actuator and throttle position sensor TPS1 The ADC calculates the correct throttle valve opening makes any adjustments and then generates an electrical signal to the throttle valve actuator The ADC calculates the correct throttle position based on RPM and MAP and compares this to the actual throttle position based on TPS1 The ADC II continuously checks and monitors all sensors and calculated data If no redundant signal is available or the calculated data cannot solve the malfunction the ADC II shuts the engine down storing the fault information in the ADC Ele
86. e generator set disconnect the battery negative lead first and allow the generator set to cool Disconnect the TMAP sensor and use an ohmmeter to measure the resistance across the sensor The sensor resistance varies with temperature and should be within the values shown in Figure 5 14 If the resistance is very low indicating a short circuit or very high indicating an open circuit replace the TMAP sensor GM58159 E GM39604 1 TMAP Sensor 2 Intake manifold assembly Figure 5 12 TMAP Sensor Location 6593 10 13 Thermal Characteristics Nominal Sensor Sensor Temperature Resistance Temperature Resistance C F Ohms C F Ohms 130 266 1 85 45 45 113 1 1008 6 125 257 1 96 68 40 104 1 1199 6 120 248 109 65 35 95 4 1431 8 1 124 66 1715 4 142 08 2062 9 105 2 162 35 2510 6 100 212 186 00 3074 9 1 Ei ES E i 95 203 213 68 3791 1 0 194 246 15 4706 9 185 284 06 3 5886 7 176 329 48 7419 0 167 382 89 9426 0 158 466 33 E 12078 149 521 91 4 15614 140 612 27 25 13 20376 d d 131 720 65 30 22 26855 5 0 5 0 5 0 5 0 122 851 10 35 31 35763
87. e internal circuit disconnect the coil connector and measure the resistance from pin to pin See Figure 5 19 EST 1 High Electronic Spark 1 Timing High An EST failure condition exists when the spark signal is pulled high or low The controller indicates EST1 fault within 1 second of the condition being present To Electronic Spark Timing EST is a current driver signal This fault appears if the signal from the ADC II is open or lost or the coil driver signal is high or overcurrent Check the coil driver wiring for an open circuit or disconnected connector ADC II pin 17 to COIL pin A Verify GND on COIL pin B Verify GND on COIL pin C Verify GND on COIL pin D Verify 12VDC on COIL pin E To check the internal circuit disconnect the coil connector and measure the resistance from pin to pin See Figure 5 19 Electronic Spark 2 Timing Low An EST failure condition exists when the spark signal is pulled high or low The controller indicates EST2 fault within 1 second of the condition being present The Electronic Spark Timing EST is a current driver signal and this fault appears if the signal from the ADC is shorted to ground or the coil driver signal is low or undercurrent Check the coil driver wiring and connector for shorts ADC II pin 18 to COIL pin A Verify GND on COIL pin B Verify GND on COIL pin C Verify GND on COIL pin D Verify 12VDC on COIL pin E To check the internal circuit disconnect the coil conne
88. e the O M No CO sensor fault Carbon monoxide sensor missing Shutdown occurs if communication is lost between the CO sensor and the ADC Pulsed signal No signal Check the connections to the CO sensor If connections are okay replace the CO sensor Contact an authorized distributor dealer for service Over voltage fault Overvoltage shutdown occurs if the voltage exceeds the default setting of the voltage regulator setpoint Alternator output Above setting 120926 of nominal Check AC voltage Check wiring and connections Contact an authorized distributor dealer for service if problem continues Under volt fault Undervoltage shutdown occurs if the voltage falls below the default setting of the voltage regulator setpoint Alternator output Below setting 80 of nominal Reduce the load and restart the generator set Check wiring and connections Check AC voltage and adjust if necessary Separately excite unit Check stator continuity Check the F5 fuse Contact an authorized distributor dealer for service if problem continues Over freq fault Overfrequency shutdown occurs when the governed frequency exceeds the default setting of the system s frequency setpoint 28 Section 4 Controller Alternator output Above setting 11096 of nominal Check engine governing system controlled by the engine ECM Contact an authorized d
89. embly dice we Svat ie ERA eee ad ds 61 6 2 Collector Ring and Bearing Replacement 64 6 3 Heassembly ze ee ee eee ER e eni ETE n 65 6 4 Exhaust Manifold Heat Exchanger Instructions 66 Section 7 Wiring Diagrams 67 Appendix A Abbreviations 71 Appendix Common Hardware Application Guidelines 73 Appendix General Torque Specifications 74 Appendix D Common Hardware Identification 75 Appendix E Common Hardware List 76 4 Table of Contents TP 6593 10 13 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that
90. et when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set TP 6593 10 13 Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution possible whenever electricity is present Ensure you comply with all applicable codes standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Short circuits Hazardous voltage current can cause severe injury or deat
91. extinguisher operation fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Safety Precautions and Instructions 5 Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas present in exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following Light headedness dizziness Physical fatigue weakness joints and muscles Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision 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 Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each
92. ginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service at the prescribed intervals Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service Tech Tools Access the TechTools site to find the following topics e Software used by generator set controllers including updates and documentation references e Network Communications provides basics to terms protocols standards wiring configurations and model e Engine Electronic Control Module ECM has information about electronic devices provided by the engine manufacturer to manage engine data TP 6593 10 13 Introduction List of Related Materials Separate manuals contain operation installation and parts information not provided in this manual Separate engine Operation and Service manuals are also available The following table lists the available manual part numbers Literature Type Part Number Installation Manual TP 6592 Operation Manual Generator TP 6591 Operation Manual Engine 66 590 02 Parts Catalog TP 6594 Service Manual Generator TP 6593 Service Manual Engine 66 690 01 One manual combines Generator and Engine information Figure 1 Generator Set Literature R
93. h Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building marina electrical system only through an approved device and after the building marina main switch is turned off Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a ship to shore transfer switch to prevent interconnection of the generator set power and shore power 6593 10 13 Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volt
94. hreads In Millimeters Major Thread Diameter In Millimeters TP 6593 10 13 Metric Number stamped on hardware 5 8 shown Plain Washers 9 32 x 5 8 x 1 16 L Thickness External Dimension Internal Dimension Lock Washers 5 8 Internal Dimension Appendix 75 Appendix Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Dimensions Part No Dimensions PartNo Dimensions Type Hex Head Bolts Grade 5 Hex Head Bolts cont Hex Nuts X 465 17 1 4 20 x 38 X 6238 14 3 8 24 x 75 6009 1 1 8 Standard X 465 6 1 4 20 x 50 X 6238 16 3 8 24 x 1 25 X 465 2 1 4 20 x 62 X 6238 21 3 8 24 x 4 00 X 6210 3 6 32 Whiz X 465 16 1 4 20 x 75 6238 22 3 8 24 4 50 6210 4 8 32 Whiz X 465 18 1 4 20 x 88 X 6210 5 10 24 Whiz 465 7 1 4 20 1 00 6024 5 7 16 14 75 DEAE 1032 hie X 6024 2 7 16 14 x 1 00 X 465 8 1 4 20 x 1 25 465 9 1 4 20 1 50 6024 8 7116 14 x 1 25 X 6210 2 1 4 20 Spiralock X 465 10 1 4 20 x 1 75 X 6024 3 7 16 14 x 1 50 X 6210 6 1 4 28 Spiralock X 465 11 1 4 20 x 2 00 2 ea x Bae X 6210 7 5 16 18 Spiralock X 465 12 1 4 20 x 2 25 ee 212 2 6210 8 5 16 24 Spiralock 465 14 1 4 20 2 75 i 1 QUU X 6210 9 3 8 16 Spiralock X 465 21 1 4 20 x 5 00 X 129 15 1 2 13 x 75 X 6210 10 3 8 24 Spiralock X 465 25 1 4 28 x 38 X 129 17 1 2 13 x 1 00 X 6210 11 7 16 14 Spiralock X 465 20 1 4 28 x 1
95. igital gauge for stopping instructions Note ADC Il powers down after 48 hours of inactivity If the generator has been started the controller will power down 48 hours after the generator stops Note A remote start stop switch connected to P21 connector leads 3 and 4 is not available when configured for SmartCraft 4 2 5 Fault Shutdowns and Warnings The generator set shuts down automatically under the fault conditions listed in Figure 4 5 and Figure 4 7 and the controller displays a fault code The generator set cannot be restarted until the fault condition is corrected andthe controller is reset See Section 4 2 6to resetthe controller after a fault shutdown The controller resets automatically after a battery voltage fault condition is corrected Shutdown switches on the generator set automatically reset when the problem is corrected The high engine temperature switch automatically resets when the generator set cools However the fault does not clear until the controller is reset The controller displays warning text but the generator set does not shut down under the conditions shown in Figure 4 6 and Figure 4 8 TP 6593 10 13 Fault Shutdowns Code and Description Sensing Mechanism Active State Inhibit Time Delay Time Default Setting Check Over crank fault Overcrank shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts of 7 seco
96. ing 55 66 0 16 1 70 0 16 1 70 0 07 0 35 Stator output voltage with separately excited rotor using 12 volt battery Main winding 1 2 3 4 volts Aux winding 55 66 volts minimum 150 190 150 190 130 170 Rotor field voltage current readings at rated output voltage hot No load volts amps Full load volts amps 11 2 4 35 7 11 2 4 47 9 13 2 4 55 8 Most ohmmeters do not give accurate readings when measuring less than 1 ohm The stator can be considered good if a low resistance reading continuity is obtained and there is no evidence of shorted windings discoloration Do not confuse a low resistance reading with a reading indicating a shorted winding 1 5 Alternator Specifications Continued 5 7 5 10EKD 4 6 8EFKD 60 50 Hz Brush type Digital Analog Class H 1 sealed Alternator Specification Frequency Hz Excitation method Voltage regulator type Winding material Bearing quantity and type Circuit protection Customer connection F1 10 amp fuse 25 amp fuse Voltage regulator F2 Injector CO sensor fuel pumps oxygen sensor and coils F3 Controller F4 Auxiliary winding F5 Brush length new 20 amp fuse 10 amp fuse 10 amp fuse 1 9 cm 0 75 in 12 Section 1 Specifications TP 6593 10 13 1 6 Torque Specifications Follow the general torque specification found in Appendix C of this manual unless noted
97. into Cast Iron or Steel Assembled into Measurement Grade 2 Aluminum Grade 2 or 5 10 24 10 32 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 See Note 3 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 1 8 1 12 Metric Fasteners Torque Specifications Measured in Nm ft Ib Assembled into Cast Iron or Steel Size mm x 1 00 Grade 5 8 Grade 8 8 9 5 7 Grade 10 9 M8 1 25 23 0 17 8 x 1 00 24 0 18 M10 x 1 50 45 0 34 M10 x 1 25 47 0 35 M12 x 1 75 80 0 59 M12 x 1 50 85 0 63 14 2 00 126 0 93 14 1 50 o 133 0 98 M16 x 2 00 194 0 143 M16 x 1 50 201 0 148 M18 2 50 273 0 201 M18 1 50 Notes 1 2 3 4 289 0 213 Do not use these values when the torque values are specified on the assembly drawing These values are based on new plates threads Increase values by 15 if non plated threads are used Hardware threaded into aluminum must have two diameters of thread engagement or may require 30 or more reduction in the torque Torques are calculated as equivalent stress loading to American hardware and approximately a preload of 90 of yield
98. ircuit engine controller Check loose connections Section 7 connections Check the wire harness continuity Blown fuse F4 controller Replace fuse if fuse blows again check circuit and Section 5 11 components Section 7 Crank relay Check for 12VDC on lead 71N Section 7 Check for a good ground connection lead N Section 7 Poor ground connection Clean and retighten Starter Check starter connections Section 7 Rebuild or replace starter Engine S M Controller Check controller connections and operation Check for Section 4 power to the controller Section 7 Blown F3 fuse Check the starter solenoid for a stuck solenoid Check Section 7 wiring for open grounds or loose connections Also check for pushed out pins Blown F4 fuse Check the controller wiring Check wiring for open Section 7 grounds or loose connections Also check for pushed out pins Engine harnessing to throttle Check the generator set harnessing to the throttle body Section 7 body not connected and TMAP sensors Check wiring for open grounds or loose connections Also check for pushed out pins Cranks but fuel Check the fuel supply Check the fuel filters for does not blockage start Spark plugs or spark plug Check spark plug wires and connections Replace or O M connections clean and regap spark plugs Loose connection or open circuit Check for loose or open connections at the fuel p
99. istributor dealer for service if problem continues TP 6593 10 13 Fault Shutdowns Code and Description Sensing Mechanism Active State Inhibit Time Default Setting Check Under freq fault Underfrequency shutdown occurs when the governed frequency falls below the default setting of the system s frequency setpoint Alternator output Below setting 10 sec 90 of nominal Reduce the load and restart the generator set Check P2 AC sensing connection at the controller Contact an authorized distributor dealer for service if problem continues HVR Comm Err fault Hybrid Voltage Regulator HVR Communications Loss Remote CAN communication loss shutdown Communications loss between the voltage regulator and controller circuits Loss of communication Figure 4 5 Advanced Digital Control Il Fault Shutdown TP 6593 10 13 Check the remote digital gauge and connection Replace the controller Section 4 Controller 29 Warnings Code and Description Sensing Mechanism Active State Inhibit Time Default Setting Check High battery High battery voltage warning This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits Analog input Above setting 0 sec 16 volts for 12 volt system Check the battery rating and condition
100. ity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Section 7 Wiring Diagrams 67 M3TIOHINOO MA OL sz v8d Ie 6z vad 62 01 82 91 84 6 1 4 92 1 18 Sc 11 v8d 44 0 02 9 124 6l r v8d 9 vim 91 ci vi 2 4 e Si ved ol z ved LIZ 6 v 1 81a 19 2 oZ vid 5 14 GM90655A 1998 335 5 404 5 SIONIS 86 335 SNOLIO3NNOO MOIVH3N39 803 310N 2 di 1 Ni Y lvls 90 O8 s zd 88 8 24 LL Led 14006 s 92 14 203 v O N 2 92 19 193 1 is DAL 6M ZIN v vis SNOIIO3NNOO 129 023 8 L 9 2 vis 88 z l 01
101. n open circuit ADC Il pin 11 to ECT A ADC II pin 28 to ECT pin B TP 6593 10 13 Fault Shutdowns Text Displayed Description Check 02 input hi Oxygen Sensor Input High The controller indicates an O2 Input High Low fault within 1 second of the condition being present Fault appears if the 02 sensor ADC II driver signal is shorted to power Check if the 02 sensor is shorted to 5VDC or battery 02 SIGNAL pin to ADC II pin 22 Verify operation of O2 sensor heater circuit by measuring circuit resistance of 2 1 ohms 0 4 ohms O2 pin C HEATER GND to pin D HEATER PWR O2 input lo Oxygen Sensor Input Low The controller indicates an O2 Input High Low fault within 1 second of the condition being present Fault appears if the oxygen sensor input is low Check the O2 sensor connector and wiring for a short to ground ADC II pin 22 to O2 sensor pin B ADC II pin 28 to O2 sensor pin A O2 adapt O2 Adapt Limit Fault Fault appears when the O2 sensor can no longer switch or be driven above or below 500mv by the ADC O2 sensor is not switching across the reference AFR voltage Check for an open coil by disconnecting the connector and measuring the resistance approx 26 ohms 2 ohms Pin A SIGNAL to pin B PWR CAN loss CAN Receive Message Fault Replace the controller Overload Power Limit Shutdown An overload condition exists when the controller senses the generator
102. nal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6593 10 13 Appendix Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See Appendix C General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance
103. nds cranking and 15 seconds rest The generator set shuts down on an overcrank fault if no engine rotation is sensed Fail to start Excessive crank cycles 0 sec 7 sec on 15 sec off 3 crank cycles Check the fuel supply and battery Also check for loose connections Check spark plug Check for a locked rotor Contact an authorized distributor dealer for service if problem continues Locked rotor fault Overcrank locked rotor shutdown A locked rotor condition indicates that there is no engine rotation when the starter is engaged The controller indicates the fault after an engine speed of 0 5 rpm is detected for a max of 3 seconds Fail to crank Excessive locked rotor cycles Contact an authorized distributor dealer for service if problem continues Low oil pres fault Low oil pressure shutdown occurs if a low oil pressure condition exists Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine The controller displays a low oil pressure shutdown fault 35 seconds from engine start when the low oil pressure switch is activated to below 7 psi The controller inhibits the fault for at least 30 seconds after crank disconnect speed is reached After the 30 second inhibit period there is a 5 second delay after activation of the low oil pressure signal before the shutdown occurs ADC II data Below setting grounded
104. nection circuit leads FN and FP Section 7 Rotor slip rings dirty or corroded Check slip ring condition Section 5 4 Rotor open grounded or shorted windings Check voltage and continuity Section 5 4 Stator open grounded or shorted windings 20 Section Troubleshooting Check voltage and continuity Section 5 3 TP 6593 10 13 Possible Cause Corrective Action Reference Noisy Exhaust system leaks Check and replace as necessary operation Engine not running smoothly See Generator set operates erratically this table Broken or damaged Check and replace as necessary vibromount s Loose or vibrating sheet Retighten screws replace rivets metal housing Exhaust piping or air Inspect for loose parts and secure if necessary inlets outlets not securely installed Excessive engine generator Check rotor crankshaft bearing etc disassembly of Engine S M vibration engine and or alternator may be required TP 6593 10 3 Section 3 Troubleshooting 21 Notes 22 Section 3 Troubleshooting TP 6593 10 13 4 1 This section describes operation and replacement the ADC controller Controller configuration and adjustment are explained in Section 4 7 See Section 3 for troubleshooting procedures Introduction Top View III
105. nmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exh ext fglass FHM fl oz flex freq FS ft Ibs ft min ga gal gen genset GFI GND gov gph gpm gr GRD gr wt HxWxD HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg 165 Inc ind int int ext 150 JIS exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temperature high engine temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water in
106. nnect speed is reached After the 30 second inhibit period there is no delay after reaching 210 F before the warning is indicated ADC II data Above setting 30 sec Check for a low engine coolant level Check seawater system for reduced flow NOTE Allow the generator set to cool down before checking Maint req Maintenance required Figure 4 6 Advanced Digital Control Warnings TP 6593 10 13 Section 4 Controller 31 In addition to the fault shutdowns and warnings included Figure 4 5 Figure 4 6 other fault shutdowns and warnings may occur see Figure 4 7 and Figure 4 8 Fault Shutdowns Text Displayed Description Check Check engine Check engine A check engine fault occurs when the ECM sends a signal for the generator set controller to shut down because the engine has stalled An engine stall could be related to the loss of fuel or other engine peripheral Check the following Fuel supply High fuel restrictions Air leak in the supply side of the fuel system Inoperative low or high pressure fuel pump Fuel vaporization in higher than maximum temperature operation specifications ECM voltage No or low voltage to the ECM Check if the 10 amp F1 fuse is blown or missing Check if lead 70 circuit is open between plug P1 4 and the battery during cranking attempts Check for low voltage on lead 70 Low voltage could be caused by the following Poor conne
107. o ADC II pin 27 OPS transducer GND Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP pin 1 GND to pin 4 PRESSURE SIGNAL KPA of 2 4 8 2 kOhms TMAP pin 3 PWR to pin 4 PRESSURE SIGNAL KPA of 3 4 8 2 kOhms Trans hi Transducer voltage XDRP Sensor Input High Fault appears if the sensor power from the ADC II increases above 5 9 VDC Measure the transducer power at the TMAP connector with multimeter TMAP pin 3 5VDC to TMAP pin 1 XDCR GND Verify transducer power at the ADC with a multimeter ADC II pin 29 5VDC to ADC pin 28 XDCR GND Verify transducer power at ETC with a multimeter ETC pin 3 XDCR PWR to ETC pin 2 XDCR GND Trans lo Transducer voltage XDRP Sensor Input Low Fault appears if the sensor power from the ADC drops below 4 8 VDC TPS range lo TPS input lo and MAP input lo are expected faults when the transducer power is lost Measure the transducer power at the TMAP connector with a multimeter TMAP pin 3 5VDC to TMAP pin 1 XDCR GND Verify transducer power at the ADC with a multimeter ADC II pin 29 5VDC to ADC pin 28 GND Verify transducer power at ETC with a multimeter ETC pin 3 XDCR PWR to ETC pin 2 XDCR GND input hi Intake Air Temperature IAT Input Sensor High The controller indicates an Input High Low fault within 1 second of the condition being present Fault appears if the TMAP temperature signal
108. od condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Ignition protected equipment Explosive fuel vapors can cause severe injury or death Gasoline vapors can cause an explosion USCG Regulation 33CFR183 requires that all electrical devices ship to shore transfer switch remote start panel etc must be ignition protected when used in a gasoline and gaseous fueled environment Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Hazardous Voltage Moving Parts WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator s
109. onnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch start stop switch or engine start command from a remote computer Engine Backfire Flash Fire WARNING 2 Gh Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the backfire flame arrester A sudden backfire can cause severe injury or death Do not operate the generator set with the backfire flame arrester removed Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Combustible materials A sudden flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the generator set Keep the compartment and the generator set clean and free of debris to minimize the risk of fire Catch fuels in an approved container Wipe up spilled fuels and engine oil Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires as recommended by the local fire code or an authorized agency Train all personnel fire
110. ontact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment TP 6593 10 13 Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Voltage Adjustment Procedure 1 With the generator set off connect a digital voltmeter to the output leads or an electrical outlet onthe load side ofthe generator set Setthe meter to measure voltage 2 Start the generator set by pressing the Start Stop Button 3 Use the Advanced Digital Control to adjust the voltage until the output voltage reaches the desired value 4 Adjust the voltage stability gain to minimize light flicker One rotation of the control knob is 1 volt 5 Readjust the voltage if necessary Volts per Hertz Hz Adjustments The cut in frequency is preset for 58 Hz 60 Hz system or 48 Hz 50 Hz system When the frequency falls below the cut in output voltage is reduced to relieve the engine The amount ofthe voltage
111. outine Service Parts The following table contains part numbers for recommended spare parts Contact your Kohler generator distributor dealer for a complete list of service parts for your generator set or for models or spec numbers not listed Part Description Part Number Backfire flame arrestor GM24212 267987 Fuel filter Fuse F1 10 amp Customer connection Fuse F2 25 amp Voltage regulator Fuse F3 20 amp Injector CO sensor fuel pumps oxygen sensor and coils Fuse F4 10 amp Controller Fuse F5 10 amp Auxiliary winding Oil filter GM42337 GM42339 GM47427 GM42337 358337 52 050 02 S 359978 GM53040 66 203 01 S 25 132 16 S GM48126 260085 Seawater pump impeller kit Seawater pump belt Engine cooling pump belt Spark plug Spray paint Matterhorn white Zinc anode Figure 2 Maintenance and Service Parts Introduction 9 Service Assistance For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KOHLERPower com Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada
112. output voltage If the output voltage needs adjustment use the Voltage Adjustment Procedure in Section 4 7 ADC II Controller Replacement Procedure 1 Push the generator set power button OFF 2 Disconnect power to the battery charger if equipped 3 Disconnect the generator set engine starting battery negative lead first 4 Remove four mounting screws from the front of the controller 5 Carefully pull the controller forward 6 Disconnect plugs P1 and P2 See Figure 4 15 40 Section 4 Controller 7 Attach plugs P1 and P2 to the new controller 8 Place the new controller into position and install the four mounting screws 9 Reconnect the engine starting battery negative lead last 10 Reconnect power to the battery charger if equipped 11 Follow the instructions in Section 4 7 to change the new controller s configuration settings to match the generator set system voltage and frequency unit configuration engine data input types battery voltage and communications settings 12 Useavoltmeterto checkthe output voltage Follow the instructions in Section 4 7 to adjust the output voltage and stability Nonservice Side of ADC Il GM58225 C 1 P2 8 pin connector 2 P1 35 pin connector Figure 4 15 Controller Connections TP 6593 10 13 47 Controller Configuration and Adjustment This section contains instructions for using the controller
113. r when performing this test Note A reading of approximately 500 kOhms 1 2 megohm or higher indicates a good rotor c Repair or replace the rotor if the reading is less than approximately 500 kOhms A reading of less than 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground d Following the test remove the retainer wire from the brush holder and check the brush positions on the slip rings See Section 5 6 Brushes e Reinstall the brush cover on the end bracket Section 5 Component Testing and Adjustment 51 5 5 Slip Rings Slip rings acquire a glossy brown finish in normal operation Do not attempt to maintain bright newly machined appearance onthe slip rings Cleaning with a dry lint free cloth is usually sufficient Use very fine sandpaper 00 and apply light pressure to remove roughness Do not use emery or carborundum paper or cloth Clean all carbon dust from the generator after sanding the slip rings If the rings are black or pitted remove the rotor and use a lathe to remove some of the slip ring surface material 5 6 Brushes The brushes transfer current from the ADC II to the slip rings The brushes should last the life of the generator Abrasive dust on the slip rings however shortens the life of the brushes Excessive arcing at the brushes could damage the ADC II and the controller Weak springs damaged slip rings sticking brushes a loose brush holder or
114. reduced is set by the V Hz slope adjustment Monitor engine speed and output voltage as loads are applied e fthere is excessive droop in engine speed little droop in voltage increase the V Hz slope e f there is little engine speed droop but excessive voltage droop decrease the V Hz slope One rotation of the control knob is 1 Hz 1 Readjust the voltage stability gain if necessary 2 Readjust the voltage if necessary 3 Stop the generator set Section 4 Controller 41 Main Menu Flow Power Button Pressed Rotate Knob Kohler Power Systems CONFIRM CLR CONFIRM CLR FAULT NO FAULT YES If Faulted Push Push to Push Start Stop clear fault Knob Rotate Knob If system voltage is 240 VAC 120 11 12 240 Cranking Warning Fault Priming Freq 60 Hz Freq 60 Hz Cranking 351 2 hr Fault 351 1 Priming 30 Low battery Locked rotor PUSH TO STOP Rotate Knob Rotate Knob L1 N 121 L2 N 119 eT With analog oil Whenever a Kohler USB stick ng is connected to Advanced 011 pres NA Digital Control Eng 129 F igital Contro 011 65 PSI Rotate Knob USB Stick Present Batt 10 1 See Figure 4 19 RPM 3610 Rotate Knob Push Knob Next maint 34 7 hr Push _ RESET MAINT Rotate RESET MAINT Knob TIMER NO Knob TIMER YES Rotate Knob
115. s and under Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Notice NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown or questionable NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Safety Precautions and Instructions 7 Notes 8 Safety Precautions and Instructions TP 6593 10 13 This manual provides troubleshooting instructions for the generator set models listed on the front cover For engine service procedures not covered in this manual refer to the Engine Service Manual listed below Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the be
116. strength and friction coefficient of 0 125 74 Appendix Assembled into Aluminum Grade 5 8 or 8 8 See Note 3 TP 6593 10 13 Screw Bolts Studs Head Styles Hex Head or Machine Head Pp Nut Styles Hex Head Cy Appendix D Common Hardware Identification Hardness Grades American Standard Grade 2 Hex Head or Machine Head with Washer Lock Elastic Grade 5 Flat Head FHM y Square Grade 8 Round Head RHM gp Cap or Acorn Grade 8 9 Hex Socket Head Pan Head Wing Hex Socket Head Cap or Allen Head Cap Hex Socket Head or Allen Head Shoulder Bolt Sheet Metal Screw gt Stud x Drive Styles Hex Hex and Slotted Phillips Slotted e e Hex Socket Washers Washer Styles Plain Split Lock or Spring Spring or Wave External Tooth Lock Internal Tooth Lock Internal External Tooth Lock Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company 1 4 20x 1 Sample Dimensions American Standard Screws Bolts Studs and Nuts Length In Inches Screws and Bolts Threads Per Inch Major Thread Diameter In Fractional Inches Or Screw Number Size Metric Screws Bolts Studs and Nuts 8 1 25 x 20 Length In Millimeters Screws and Bolts Distance Between T
117. switch 30 sec Check for leaks in the lubrication system Check the oil level and add oil if the level is low Check the low oil pressure switch connections and operation Check the oil pump and lubrication system Over speed fault Overspeed shutdown occurs if the engine speed exceeds the default setting ADC II data Above setting Check engine governing system controlled by the engine ECM Contact an authorized distributor dealer for service if problem continues Coolant loss fault Loss of coolant shutdown occurs after a loss of seawater pressure condition is detected Digital input Grounded Check for a clogged seawater intake or sea strainer Check for a damaged seawater pump impeller Check for a clogged or dirty seawater flow switch Check for damaged water lines Check for proper installation Check for inlet restriction exceeding the seawater pump s maximum inlet restriction Hi eng temp fault High engine temperature shutdown occurs if the engine coolant temperature exceeds the default setting Note The high engine temp shutdown functions only when the coolant level is in the operating range TP 6593 10 13 ADC II analog data Above setting 30 sec Check for a low engine coolant level Check seawater pump impeller strainers and seacock Section 4 Controller 27 Fault Shutdowns Code and Description Sensing Mechanism
118. t material Hardened steel Crankshaft bearings type Inserts Governor type Electronic Lubrication system Pressure Oil capacity w filter L qt 1 9 2 0 Oil pressure kPa psi 276 40 Oil recommendation API SJ or higher Fuel system type Throttle body fuel injected Battery charging alternator 25 amps Battery voltage 12 VDC Battery ground Negative Battery recommendation minimum 250 CCA Spark plug gap mm in 0 76 0 030 Ignition system Inductive Starter motor Bendix automotive type Cooling system Water cooled Section 1 Specifications 13 1 8 Service View Service Side 20 19 18 Nonservice Side Nameplate top Advanced Digital Control Generator set start stop button AC circuit breaker Optional lifting eye tool Pressure cap coolant fill location after draining coolant Overflow tube Heat exchanger Anticorrosion zinc anode seawater drain Coolant drain Spark plug also one located on the nonservice side Air intake silencer backfire flame arrestor Coolant overflow bottle daily coolant check fill location Oil fill check V belt Seawater pump Seawater inlet Oil drain valve Lube oil filter Figure 1 2 Service Views 14 Section 1 Specifications 20 21 22 23 24 25 26 27 28
119. t start stop to the STOP position 38 Section 4 Controller 4 2 7 USB Connection The Advanced Digital Control includes USB connection for updating software and configuring parameters See Figure 1 2 for location Note Have software downloads setup adjustments of the Advanced Digital Control performed only by an authorized Kohler distributor dealer Click on the TechTools button to find the following topics e Software used by generator set controllers including updates and documentation references e Network Communications provides basics to terms protocols standards wiring configurations and model e Engine Electronic Control Module ECM has information about electronic devices provided by the engine manufacturer to manage engine data 4 3 Circuit Protection Ifthe generator set circuit breaker trips or the fuses blow repeatedly see Section 3 for possible causes 4 3 1 Line Circuit Breaker A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load The line circuit breaker location is shown in Figure 1 2 Ifthe circuit breaker trips reduce the load and switch the breaker back to the ON position TP 6593 10 13 4 3 2 Fuses The junction box contains five fuses See Figure 1 2 for the fuse locations Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Section 4 for conditions that m
120. tate J1939 Knob J1939 J1939 Smartcraft NMEA 2000 Rotate Knob SAVE CHANGES Push CONFIRM lt Rotate CONFIRM Push parameters Kno SAVE NO Kno SAVE YES Knob saved Rotate Knob DISCARD Push CONFIRM lt Rotate CONFIRM Push Changes CHANGES Knob DISCARD Knob DISCARD Yes Knob discarded Rotate Knob RESTORE Push CONFIRM Rotate CONFIRM Push Parameters MFG SETTINGS Knob RESTORE NO Knob RESTORE YES Knob restored Figure 4 17 Advanced Digital Control Non Runtime System Parameter 5 7 5 10EKD and 4 6 8EFKD Models TP 6593 10 13 Section 4 Controller 43 Runtime Adjustment Parameter Go to B volt adjust Push gt volt adjust Rotate 240 v Knob 240 v 1V Rotate Knob V Hz 51 ope Push V Hz Slope Rotate 4 Knob 14 ae Rotate Knob Push gt Voltage Rotate Knob Gain 50 Rotate Knob Calibrate Push gt Calibrate Rotate 11 12 241 Knob 11 12 241 1V Rotate Knob Calibrate Push Calibrate Rotate 11 121 Knob 11 121 1V Rotate Knob SAVE CHANGES Push CONFIRM Rotate CONFIRM Push parameters Knob SAVE NO Knob SAVE YES Knob saved Rotate Knob PUSH TO Push Knob RETURN Figure 4 18 Advanced Digital Control Runtime Adjustment Parameter 5 7 5 10EKD and 4 6 8EFKD Models 44 Section 4 Controller TP 6593 10 13 USB Flow USB Stick
121. tdown Tests Verify the operation of the generator set shutdowns by performing the following tests If these tests are inconclusive test individual shutdown circuit components wiring harness switch etc as described elsewhere in this section WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Overcrank Shutdown Temporarily remove power to both the low pressure and high pressure pumps Press the power button to turn the controller on Press the start stop button to start the generator set Observe that the generator set simulates cranking for 7 seconds and then rests for 15 seconds Check that the generator set shuts down after the third crank rest cycle TP 6593 10 13 High Engine Temperature Shutdown Remove the connector from the cool
122. the TPS Input High condition is indicated The range error is dynamically determined and may or may not occur before reaching 5 VDC In some cases both may occur simultaneously The ADC II protective monitor will react to only one shutdown condition therefore whichever of these faults is detected first will be indicated as the reason for the shutdown Fault appears if the sensor potentiometer has malfunctioned Check for dirt or oxidation on the sensor traces Check the throttle connector and pins for corrosion To check disconnect the throttle connector and measure the resistance of 1 25 kOhms 30 from TPS pin 2 GND to pin 6 TPSI SIGNAL TPS pin 3 PWR to pin 6 TPSI SIGNAL Note Do not service this sensor Repair by replacing the throttle body assembly Note Available on software version 1 3 0 or higher On software version 1 2 0 and below this condition was displayed as Out of fuel Note Available on software version 1 3 0 or higher On software version 1 2 0 and below this condition was displayed as Low battery fault 32 Section 4 Controller TP 6593 10 13 Fault Shutdowns Text Displayed Description Check TPS range lo Throttle Position Sensor Range Low The TPS Range Low and TPS Input Low conditions are closely related If the input reaches 0 VDC the TPS Input Low condition is indicated The range error is dynamically determined and may or may not occur before reaching 0 VDC In some
123. ts down on an overcrank fault Local Starting 1 Press the Power Button to turn the controller on The LED Status Indicator appears green and begins flashing 2 Press the Start Stop Button to start the generator set The Advanced Digital Control II attempts to start the generator set in three crank cycles crank cycle time is pre programmed When the engine comes up to speed the low oil pressure switch contacts open Note The controller circuit board prevents fault shutdowns during startup until the crank disconnect relay energizes The cyclic cranking cycle is programmed into the controller s application code and is not adjustable in the field The factory sets the cranking cycle for three cycles of 7 seconds on time and 15 seconds Ifthe cranking cycle seems shorter than the factory setting check the engine starting battery Section 4 Controller 25 Remote Starting Aremote start stop switch connected to P21 connector leads 3 and 4 or a remote digital gauge connected to P21 connector pins 1 2 and 5 via CAN can be connected to the customer interface connection See the wiring diagram in Section 7 Note A remote start stop switch connected to P21 connector leads 3 and 4 is not available when configured for SmartCraft Press the Power Button to turn the controller on Consult the instruction sheet supplied with the remote start stop switch or remote digital gauge for starting instructions
124. umps Section 7 and at the engine control module Check controller engine wiring continuity Backfire flame arrestor clogged Clean or replace O M Incorrect controller configuration Check for correct controller configuration settings Section 4 7 Ignition system spark control or Test and or replace components Engine S M ignition coil No engine rotation sensed check Check for locked rotor Section 5 4 for an overcrank fault shutdown Starts hard Low battery voltage Check battery voltage O M Backfire flame arrestor clogged Clean or replace O M Spark plug s Replace or regap spark plug s O M Spark plug wire s Check spark plug wires and connections Replace Engine S M spark plug wires Ignition components ignition Test replace ignition components Check the harnessing Engine S M coils to these components for continuity Worn piston rings valves Check compression Engine S M Blown F2 fuse Check voltage regulator wiring Section 7 Starts but Fault shutdown Check for a fault shutdown code on the controller s Section 4 2 5 shuts display Correct the fault and then reset the controller Section 5 9 down 18 Section 3 Troubleshooting TP 6593 10 13 Stops suddenly Possible Cause Fault shutdown Corrective Action Check for a fault shutdown code on the controller s display Correct the fault and then reset the controller Reference Section 4 2
125. w Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference round head RHM round head machine screw rly relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier S Sec second SI Systeme international International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s sq square 54 square centimeter sq in square inch 55 stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term termi
126. wiring Section 7 Operates erratically Backfire flame arrestor clogged Clean or replace O M Spark plug s Replace and regap plugs O M Spark plug wire s Replace spark plug wires Engine S M Fuel line restriction Check fuel lines filters and pumps Ignition system Test and or replace components Engine S M Inadequate cooling hot engine only Inspect air inlet and outlet Carbon buildup in engine Clean cylinder head Engine S M Engine valves not seating correctly Check cylinder pressures with leakdown test Inspect valves and valve seats Engine S M Air intake restriction inadequate cooling Inspect air intakes and exhaust for obstructions Check air cleaner Generator overloaded Reduce load Spark plug s Replace and regap plug s O M Spark plug wire s Replace spark plug wires Engine S M Engine not running at rated rpm Check controller configuration setting Section 4 7 Engine power loss Refer to the Engine Service Manual for troubleshooting and repair instructions Engine S M Ignition system Test and or replace Check ignition coil wiring Engine S M Overheats 6593 10 13 Inadequate cooling Inspect cooling system for air intake obstructions Check the engine coolant system for blockage and clean as necessary Backfire flame arrestor clogged Clean or repla

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