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TP-6774 - Atlantis Marine Power

1. 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 6774 2 14a 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 anda slot b Always use a washer under a nut See 2 above for exception c Use a washer under a bolt when the female thread is fixed weld nut 4 Refer to Figure 2 which depicts the preceding hardware configuration possibilities D 4 9 0 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 111 Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into To
2. 47 7 5 1 Controls and Indicators 47 7 5 2 Starting the Generator Set 48 7 5 8 Stopping the Generator Set 49 7 5 4 Fault Shutdowns and Warnings 49 7 5 5 Digital Display eser Ea Meee bea 51 TP 6774 2 14a Table of Contents 3 7 5 6 Controller Fault Diagnostics 53 7 6 Communication Port 55 f CEUSeS hate eom ae rd ieu Sls 55 7 8 Preheat Relay i 3A Sa Pe us 55 7 9 Battery Charging Module 56 7 10 Controller Logic 5 56 7 10 1 Fault Shutdown and Warning Specifications 56 7 10 2 Controller Resetting Following System Fault Shutdown 60 7 10 3 Voltage Regulator and Calibration Specifications 60 7 10 4 Voltage Regulator Adjustments 60 7 10 5 System Fault Warning Lamp with Digital Displays 61 7 10 6 System Fault Shutdown Lamp With Digital Displays 62 7 10 7 Status and Notice Digital Displays 63 FAV Menu Displays i e Ope ocd bo oogonia E RE PH
3. 15 1 5 Service VIEWS cce xD Yu a Pee Eau 16 1 6 Torque Specifications 17 Section 2 Scheduled Maintenance 19 24 General 222222 e ebbe t dna tbe bttebt ba Lev 19 2 2 Lubrication System residet 20 section 3 Exhaust System oec oi rented sea how vee EE REPRE be ERE tne ee ee 21 3 4 Exhaust System Inspection 21 3 2 Servicing Mixing cece eee eee eee eee 21 Section 4 Fuel System 23 43 General 2 ER MOD AP eR e MOT ee 23 4 2 Fuel Filter ac ike RI prt I I ded eee MEE 23 4 2 1 Fuel System Bleed 24 43 Fuel P MP eriei add e ER e Wem ERE ee a 25 LI MMC LER 25 4 5 Euel Solenoid 3 not s o pts 6 25 Section 5 Cooling System 27 5 1 General 2 REDE arena HIE be eae ERE ERIT 27 5 2 Water Cooled Exhaust Manifold 28 5 3 Coolant Replacement Including Heat Exchanger 28 54 Check and Fill
4. M00 ANNONO 6 114 1fldNI 2 V 1 114 1 MW3ONVHO 1v8 07314 NP ONIGNIM 0134 Wolvis Qv31 v 0134 GNNOYS Y90718 ANIONA YOLVLS 1915 ONTOS NilMVIS SS MOLON NilNVIS WS 193NNOO f NQo0 Lv3H 3Md ond HOLMS S3ON3S 3MhsS3Nd 10 540 HOLMS 38055384 N3lVM YIS MO MI ond 99 0 2105 1304 S3 TANI 3sni 4 HOLIMS dWil 1SnvHX3 513 YIANIS 3snivi3dWiL LNVIOOD SLO QON3931 53 NO 0350 vdO ALON ANN 49 bd IV3H 3Nd id ANNOY 14 3HnsS3Nd NilVM MOT 62 14 GNNOND 91 14 1 7 NYO 3 91 149 9 NWO NNN3DG 51 14 13 MOSN3S dWil ISnVHX3 21 14 12 0 3Hnss3Hd 10 5 14 513 INV1000 11 195 8 84 2 4015 1815 310W3H 8 14 NMOGLNHS 61 1414 00 4 9 6d NANI INVA 2 14 la v13 26 1414 411 519 8d 6 64 L1 1 69 h 134 Z 6d amp NH5 JN8A 24 1 649 202 1 xnv 5 3O
5. Fuse 7 Stator windings Power lead 55 8 Sensing leads Excitation to rotor 11 and 44 for Exciter or brushes slip 1 phase models or rings V7 V8 and V9 for Rectifier module 3 phase models Main field rotor Figure 8 1 Generator Schematic Single Phase Model Shown No Generator Output Separate Excitation Output within Specifications Check Wiring Fuses and ADC Erratic or No Output Check Rotor Check Stator TP563273 Figure 8 2 General Troubleshooting Section 8 Component Testing and Adjustment 73 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 all jewelry before servicing the equipment Separate Excit
6. Loading Load PARAMS PUSH TO LOAD Complete Rotate Knob Push Push Knob Knob USB LOAD Filename Loading Load SOFTWARE PUSH TO LOAD Complete Rotate Knob Note Before inserting a mass storage device USB CustomUSB host connector power off and then power on the Kohler Power Systems _ 2 GB spin full size controller Part Number KW A202 Imation 4 GB full size Lexar 4 GB full size PNY 4 GB full size and micro See Figure 7 24 for tested approved manufacturer s USB flash drive types that work with the ADC controller Verbatin 4 GB full size and micro Figure 7 24 ADC lld USB Identification 72 Section 7 Controller TP 6774 2 14a Section 8 Component Testing and Adjustment 8 1 Theory of Operation These 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 lld feeds rectified stator output current to the rotor through the exciter or brushes slip rings for model 6EKOD 5EFKOD to increase the strength of the rotor field As the rotor field increases in strength generator output also increases The ADC monitors the gener
7. Install the retaining cap and finger tighten only Do assembly for inspection See Figure 5 25 not overtighten Waterline 16 Mounting base 11 Seacock Retaining cap 12 Intake strainer Reed valve assembly 13 Engine driven seawater pump Silencer vertical lift 1 2 m 4 ft max 14 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in ft min Exhaust mixer elbow distance above waterline if less than 15 Water lock optional 23 cm 9 siphon break is required 16 Silencer distance from exhaust mixer elbow 3 m 10 ft max Siphon break distance above waterline 30 5 cm 1 ft min 17 Silencer customer supplied Siphon break 18 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in ft min Exhaust mixer elbow 19 Exhaust outlet distance above waterline 10 cm 4 in min Heat exchanger locations vary by model 20 Seawater outlet Seawater strainer NOTE Consult the installation manual for complete explanation of dimensions and other installation considerations Figure 5 25 Siphon Break Plastic U Type TP 6774 2 14a Section 5 Cooling System 35 5 36 Section 5 Cooling System TP 6774 2 14a 6 1 Introduction Corrective action and testing in 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 TP
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9. CD or CF class Fuel recommendation API Cetane No 51 min Fuel with low sulphur content CF4 CG4 or Fuel with high sulphur content API CF CD CE Fuel shutoff solenoid Electric Fuel pump Electric Max recommended fuel pump lift m ft Battery voltage 12 volts Battery charging module 10 amp Battery recommendation minimum 650 CCA 0 F Starter motor 2 5 kW 12 volt Recommended coolant 50 ethylene glycol 50 clean softened water Coolant capacity approx L U S qts add 0 24 L 8 oz for coolant recovery tank 3 3 2 4 3 4 5 Thermostat opening temp C F 83 87 181 188 High exhaust temperature shutdown C F 1022 8 215 5 Seawater inlet water line hose ID mm in 19 0 75 with or without sound shield Water cooled exhaust outlet hose ID mm in 51 2 with or without sound shield Fuel inlet size 1 4 NPT with or without sound shield Fuel return size 1 4 NPT with or without sound shield Fuel injection pressure bar 128 137 Intake exhaust valve clearance cold mm in 0 20 0 008 Fuel pump static pressure psi 4 8 12 volt pump Pressure cap s overpressure valve opening pressure bar 14 Section 1 Specifications 0 7 TP 6774 2 14 1 3 Generator 4 Lead 6EKOD Component Specification 5EFKOD Main field rotor resistance cold
10. Note If the generator set does not start after 3 crank attempts an overcrank fault occurs 1 Close the seacock 2 Completely drain the water from the exhaust system at the silencer s drain plug 3 Do not attempt generator set restart 4 Contact an authorized Kohler distributor dealer A water filled exhaust piping and silencer may further 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 TP 6774 2 14a The controller attempts to start the generator set three times If the generator set does not start in three attempts the system shuts 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 attempts to start the generator set in three crank cycles crank cycle time is pre programmed Remote Starting A remote start stop switch connected to P9 connector leads 3 and 4 or a remote digital gauge connected to P9 connector pins 1 2 and 5 via CAN can be connected to the customer interface connection See the wiring diagram in Section 10 Note A remote start stop switch connected to P9 connector leads 3 and 4 is not available when configured for SmartCraft 1
11. Battery HEN Eng Runtime Hn Next maint High SW Version 1 02 TP 6774 2 14a Overview Fixed Display Overview 4 Hz hr Y English Display HHH Measurements HHH PSI Y Metric Display 96 Measurements 8 8 HHAV 7 13 3 Engine Metering Displays engine operating data as measured by the engine and other sensors Engine Metering Engine Metering gt Eng Speed R min Oil Pres PSI Coolnt Temp THEE Battery Hg Section 7 Controller 67 7 13 4 Generator Metering and Calibration Displays generator output data including line to line and line to neutral voltages and frequency The menu displays three phase voltage readings when applicable All menu displays apply to both single phase or three phase voltages on the menu overview The phase designation does not appear in the controller menu displays Some displays will show 0 values when single phase connections are shown Display also provides access to the calibration factors for metering volts Changing the system voltage or replacing the main logic control circuit board requires calibration adjustment Connect a meter with a minimum accuracy of 1 to the generator set output leads to calibrate the voltage sensing logic To enable calibration start the ge
12. 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 Note The ADC allows three 7 second crank cycle attempts before the overcrank shutdown occurs Remote communications require an active powered up controller Be advised that the Advanced Digital Control enters a low power state with an average current drain of approximately 100 uA The ADC llid 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 Ild and start the generator set TP 6774 2 14a 7 5 3 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 setstops when the remote start stop switch contacts close momentarily or when the remote digital gauge sends a stop command Consult the instruction sheet supplied with the remote start stop switch or remote digital gauge for stopping in
13. Service Marine Generator Sets Models 6EKOD 5EFKOD 9 11EKOZD 7 9EFKOZD 9001 POWER SYSTEMS KOHLER we Power Systems TP 6774 2 14a Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number x in 007 001 TP 6774 2 14a Table of Contents Safety Precautions and Instructions 7 Intr duction 11 Service no np RI E RA tele Rie CURE EROR RR RR PUR SR 11 Section 1 Specifications o ov 13 14 General 2 ate a deve 13 152 Engine ARR bei ep Wala ne 14 1 3 Generator 4 Lead m eredi EE 15 T 4 Generator 12 Lead e tre
14. Zero ohms continuity If no continuity check fuse F1 and wiring Controller fuse and P1 2 and battery positive wiring Zero ohms continuity If no continuity is found check fuse F2 and wiring Auxiliary winding fuse 2 3 and stator lead 55 10 amp fuse Zero ohms continuity If no continuity is found check for an open circuit and or a blown fuse R x 100 Low oil pressure LOP sender Lead 7 and ground engine block Zero ohms continuity No continuity indicates a bad switch and or wiring Temperature sensor P8 1 and P8 2 CTS R x 1000 180 2500 ohms depending on engine temperature Zero ohms or an open circuit indicates bad wiring or a bad switch Preheat relay Terminals 85 and 86 PH1 and PH2 12 volt relay 90 10 ohms coil resistance Lower resistance indicates a shorted relay coil and or wiring High resistance indicates an open relay coil and or wiring See Section 8 14 2 Fault Shutdown Senders Figure 8 31 Continuity Checks 90 Section 8 Component Testing and Adjustment TP 6774 2 14a Section 9 Generator Disassembly Reassembly 9 1 Disassembly Disconnect all of the external connections battery cables at the battery negative lead first AC output leads remote interface connector water line at the seawater pump fuel line at the fuel pump filter inlet and exhaust line at the mixing elbow Remove the sound shield enclosure if e
15. crank pause 7 sec on 15 sec off 3 crank cycles Controller goes into the cranking state 3 consecutive times without going into post starting aid Check the fuel supply and battery If there is no output voltage check the line circuit breaker Also check for loose connections Contact an authorized distributor dealer for service if problem continues Sea Pressur Low Shutdwn Low seawater pressure shutdown occurs after a loss of seawater pressure is detected Digital input Post starting aid running cooldown Switch closes shorted to ground Check for a clogged seawater intake or sea strainer Check for a damaged seawater pump impeller Volts xx xx High Shutdwn Overvoltage shutdown occurs if the voltage exceeds the default setting of the voltage regulator setpoint Alternator output Post starting aid running cooldown xx xx voltage exceeds 120 of the AC system voltage Check AC voltage Check wiring and connections Contact an authorized distributor dealer for service if problem continues Volts xx xx Low Shutdwn Undervoltage shutdown occurs if the voltage falls below the default setting of the voltage regulator setpoint Alternator output Post starting aid running cooldown Figure 7 14 Advanced Digital Control Ild Fault Shutdown 58 Section 7 Controller xx xx voltage below 80 of the AC system volt
16. 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 Engine Backfire Flash Fire A WARNING Lh 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the fuel injection system fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner silencer 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
17. shutdown occurs when the governed frequency falls below the default setting of the system s frequency setpoint Alternator output Post starting aid running cooldown 10 sec AC frequency below 90 of the systems frequency 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 Locked Rotor Shutdwn Overcrank locked rotor shutdown A locked rotor condition indicates that there is no engine rotation when the starter is engaged Frequency over AC voltage Cranking 3 sec Engine speed is below 10 rpm and the oil pressure is below crank oil pressure 69 kPa Check for a locked rotor Contact an authorized distributor dealer for service if problem continues Oil Pres Low Shutdwn 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 Analog or digital input Post starting aid running cooldown At or below 117 kPa Check for leaks in the lubrication system Check the oil level and add oil if the level is low Check the oil pressure sender connections and operation Over Crank Shutdwn Overcrank shutdown occurs after 3 unsuccessful starting attempts Fail to start ECM start starting aid cranking
18. 1 50 20 M10 1 50 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 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 M7985A 0301 0 20 M7985A 0301 2 20 M7985A 04010 20 M7985A 04016 20 M798
19. 10 Ground 2 GRD L1 22 10 Load Side Factory Two Pole lame Side reaker 100 120 200 240 Volt 1 4 3 2 Stator Leads 60 Hz 50 Hz LO L1 100 120 Volt LO L2 100 120 Volt L1 L2 200 240 Volt 100 120 Volt 100 120 Volt 200 240 Volt Figure 8 20 100 120 200 240 Volt 3 Wire Configuration Section 8 Component Testing and Adjustment 85 8 12 3 200 240 Volt Configurations The 200 240 volt configuration does not use a jumper lead If the unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 8 18 for location See Figure 8 21 LO Neutral LO Ground GRD Load Side Line Single Pole Side Circuit LO Breaker Tape to insulate from ground 4 1 3 Stator Leads 200 220 240 Volt 2 Wire 60 Hz 50 Hz LO L1 200 240 Volt 200 220 240 Volt Figure 8 21 200 220 240 Volt 2 Wire Configuration for Models with ADC 8 13 Twelve Lead Reconnection The reconnection procedure following details voltage reconnections only If the generator set requires frequency changes adjust the governor The following information illustrates the reconnection of 12 lead generator sets In all cases follow the National Electrical Code NEC guidelines Reconnect the stator leads of the generator set to change output phase or voltage Refer to the following procedure and connectio
20. 139 240 V 3 Ph Wye e 277 480 V 3 Ph Wye e 120 240 V 3 Ph Delta e 115 230 V 1 Ph 3 wire e 120 V 1 Ph 2 wire e 230 V 1 Ph 2 wire e 240 V 1 Ph 2 wire e 110 190 V 3 Ph Wye e 127 220 V 3 Ph Wye e 115 230 V 3 Ph Delta e 230 400 V 3 Ph Wye e 240 416 V 3 Ph Wye TP 6774 2 14a 7 5 6 Controller Fault Diagnostics This table provides descriptions of the system events andtheir types warning shutdown status and notice Warnings show green red fault lamp and signal an impending problem Shutdowns show red fault lamp and stop the generator set Status is an eventthat is not an alert but is part of the event history Notice is an alert that is NOT part ofthe event history System events are available as a Relay Output as shown Throughout this manual there are examples of the display text In some cases the message words and phrases are abbreviated or shortened to accommodate the number of characters in the 12 x 2 digital display See the following table for a full description ofthe system event display messages Section 7 Controller 53 System Events Display Message List Warning Shutdown Status Relay Description Display Message Function Function Notice Output Engine Functions Engine over speed Eng Speed High Shutdwn x x Engine start aid active Preheat N Engine under speed Eng Speed Low S
21. 15 Section 10 Crank relay Check for 12VDC on lead 71N Section 10 Check for a good ground connection lead N Section 10 Poor ground connection Clean and retighten Starter Check starter connections Section 10 Rebuild or replace starter Engine S M Controller Check controller connections and operation Check for power to the controller Section 7 Section 10 Cranks but does not start No fuel Check the fuel supply Check the fuel filters for blockage Loose connection or open circuit Check for loose or open connections at the fuel pump or fuel solenoid Check the controller engine wiring continuity Section 10 Incorrect controller configuration Check for correct controller configuration settings Section 7 13 No engine rotation sensed check for an overcrank fault shutdown Check for locked rotor Section 8 8 Starts hard Low battery voltage Check battery voltage power supply and operation O M Worn piston rings valves Check compression Engine S M Glow plug s Verify that battery voltage is present at each glow plug control wire to ground while cranking To check glow plug condition remove each glow plug and measure the resistance from the control wire connection point to the tip of the glow plug If the resistance is approx 1 ohm the glow plug is good OR Remove each glow plug ground the threaded p
22. 2 14a Section 9 Generator Disassembly Reassembly 95 21 9 11EKOZD and 7 9EFKOZD Models Remove the four screws to remove the exciter field See Figure 9 7 GM73474 A 1 Screws 4 2 Exciter field Figure 9 7 Exciter Field Removal 22 23 24 9 11EKOZD and 7 9EFKOZD Models Remove the three screws and spacers from the rectifier board 9 11EKOZD and 7 9EFKOZD Models Disconnect the main field rotor leads from the rectifier board positive negative terminals Remove the armature retaining bolt and washer See Figure 9 8 9 11EKOZD and 7 9EFKOZD Models Remove the armature from the shaft guiding the rotor leads through the armature bores See Figure 9 8 1 Armature 2 Armature retaining bolt 3 Rotor leads 4 Rectifier board Figure 9 8 Armature Removal 96 Section 9 Generator Disassembly Reassembly 25 26 27 28 29 30 31 6EKOD 5EFKOD Model Remove the four screws to remove the brush holder cover and brush cover gasket 6EKOD 5EFKOD Model Push the brushes into the holder Secure the brushes into position by sliding a retainer into the brush keeping holder See Section 8 6 6EKOD 5EFKOD Model Remove the brush holder and carefully pull the leads out of the stator housing Attach a hoist hookto the generator lifting eye See Figure 9 9 Note The hoist capacity rating should be one half ton or greater Remove the two vibromount bolts See Figure 9 9 Raise t
23. 35 mm 0 25 in 2 Length 20 mm 0 78 in Figure 5 24 Anticorrosion Zinc Anode Plug 4 Cleanthethreaded hole ofthe heat exchanger and coat the threads of the anticorrosion zinc anode plug with pipe sealant suitable for marine applications Cut the anticorrosion zinc to the correct length Install the anticorrosion zinc anode into the heat exchanger 5 Close the petcock on the engine and open the seacock Refill the cooling system 6 Start the generator set and check for leaks at the anticorrosion zinc anode location The pump is operating if the cooling water flows from the exhaust outlet If water is not discharging at the exhaust outlet see Prestart Checklist Seawater Pump Priming in the operation manual TP 6774 2 14a 5 10 5 Asiphon break prevents seawater entry into the engine 3 Use a light detergent to clean the reed valve to when the engine exhaust manifold outlet is less than remove residue and oxidation 23 9 above the waterline of a fully loaded 15 shut down craft Use the following procedure to inspect 4 Check that the reed valve opening is clear ine siphon break 5 Replace the siphon break if it is cracked or if the reed valve material has hardened or deteriorated Siphon Break Inspection Procedure 6 Install the reed valve into the mounting base with 1 Stop the generator set the valve downward 2 Remove the retaining cap and lift out the reed valve 7
24. 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Consult the engine manufacturer s operation manual for engine coolant specifications Section 5 Cooling System 31 5 5 Flush and Clean Cooling System For optimum protection drain flush and refill the cooling system at the interval listed in the service schedule Pay special attention to the coolant level When refilling the cooling system allow time for complete refill of the engine water jacket Check the coolant level as described in Section 5 4 Flush and Clean Procedure 1 Remove the water drain pipe plug located at the heat exchanger and completely drain the system 2 Remove the pressure cap to make draining easier 3 Drain clean and flush the cooling system and the coolant recovery tank with clean water 4 Replace the water drain pipe plug 5 Fill the cooling system with recommended coolant 6 Replace the pressure cap 5 6 Pressure Cap Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant enabling proper operating temperatures Ifthe cap leaks replace it with a cap of the same rating See Section 1 Specifications The pressure cap typically has the pressure rating stamped on the cap body 1 Pressure ca
25. Controller 7 10 Controller Logic Specifications Refer to Figure 7 14 for inhibit and time delays on fault shutdowns Refer to Figure 7 15 for inhibit and time delays on warnings Inhibit Time Delay The inhibit time delay is the time period following crank disconnect during which the generator set stabilizes and the controller does not detect a fault or status event The inhibit time delay is not adjustable Time Delay Shutdown or Warning The time delay follows the inhibit time delay The time delay is the time period between when the controller first detects a fault or status event and the controller warning or shutdown lamp illuminates The time delay is not adjustable 7 10 1 Fault Shutdown and Warning Specifications The following list contains fault shutdown and warning specifications with time delays TP 6774 2 14a Fault Shutdowns Code Description Sensing Mechanism State s Detected Inhibit Time Trip Point Check AC Sens Loss Low Shutdwn The loss of AC voltage shutdown occurs when the controller does not detect the nominal generator AC output voltage for more than 3 seconds after crank disconnect Frequency over AC voltage Post starting aid running cooldown 10 sec AC voltage reached AC system voltage and then drops below 5 of the trip point for low AC voltage fault shutdown Check for loose connections Check all AC leads connected to the controller
26. Coolant 31 5 5 Flush and Clean Cooling System 32 5 6 Pressure c EE REA 32 5 7 Impeller Inspection and Replacement 32 5 8 socer 0e Pu Ad 33 5 8 1 Seawater Pump Belt Tensioning Procedure 338 5 9 Anticorrosion Zinc Anode 34 5 10 SiphomBreak or bt Erbe Ue ME 35 Section 6 Troubleshooting 37 6 1 Iritroduction sz eoe Ds PY hene nb T e Pass eee ecu E 37 6 2 Initial GHECKS 1 0 3 4 ooo e E pe pe repr MR eU eens ad 37 6 3 Troubleshooting 37 Section 7 Controller 43 lr troduction c cce pete n ER E ERA AME ey Tg 43 7 2 General Repair Information 44 7 3 SiteTech 45 7 4 Controller Service Replacement Kit GM83745 45 7 5 Advanced Digital Control Operation
27. Machine Head with Washer Lock or 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 o Stud d Drive Styles Hex Hex and Slotted Phillips Slotted 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 L 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 Threads In Millimeters Major Thread Diameter In Millimeters TP 6774 2 14a 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 113 Appendix Common Hardware List
28. O v 1 24 1ndNI 9 1 O v Zd ONIGNIM INANI ONIGNIM XNY 1 9NIONIM 0134 Z d 9NIONIM 0134 ld IV3H 3Nd 14 1 91 14 7 1 3 91 149 9 H NYO MNN3DG 81 14 38055384 NilVM 62 14 MOSN3S dWil ISnVHX3 21 14 dN3l INVIOOO 11 19 9018 1415 1 8 14 NMOGLNHS 61 14 IWAA 2 14 p ADV7996 D BA jeze 54 8 Sd GN Sd v 8d 8 8d 2N 519 QNnONO 6 64 LI 1 69 h 134 6d amp Nu5 5 64 amp 1HM 6d p s Jv8A 8 64 Nd 6d 02 4 9 6d INANI INYA xnv N3sn 3OV3H3INI H3AOlSnO 6d 231 4 20 2m 202 E 583 M3IMVIS 031031094 TY NOILdO YINVEO Eld do ANSILVB 170A 1 9NIONnONO Figure 10 6 Isolated Ground Wiring Diagram Schematic Section 10 Wiring Diagrams 105 TP 6774 2 14a AL START ST EMOTE p R CTION y y ANSA 7 CONNE ACE INTERF R DY ASARAS NENETS ILAE JSTOME FULL FEAT CUSTC INTERFACE JR
29. Point 104 Section 10 Wiring Diagrams XINO ua IOH Hsnua Q ES 1 d di 1915 01315 03171051 YaTNIOYLNOD 1190Y 11 g SL8S AQV 3338 5 BOLVMH3N39 S3LON WOlvIS 931 Z yd M00 QNnoHO 6 114 O 1 14 b bd 20 MW3ONVHO 1v8 quu Maloxa 0734 Qv31 v 0134 NIV 508 ANNOYS G3lv7os F MOlVlS 1915 GION310S MilNVIS SS SOLON N3lNVIS WS 103NNOO XIND NODD 3NhsS3Nd 10 540 HOLIMS 34055384 N3lYM YIS MOT 01 99 0 2105 1304 54 1303 3sni 4 HOLIMS dWil 1SnvHX3 513 ANNOYS 983 LNY1009 512 QON3931 IN 9 10 9NIONnONS S3NIDN3 H3ONTAO NO 0360 99 LON E T 18 14 GNNOYD 01 14 WN9IS YOSNIS 34055384 62 14 06 MOSN3S 38066384 82 14 YOSNIS 34nSS3Hd 8 24
30. 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 6238 14 3 8 24 75 6009 1 18 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 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 x 4 50 X 6210 4 8 32 Whiz X 465 18 1 4 20 x 88 X 6210 5 10 24 Whiz X 465 7 1 4 20 x 1 00 X 6024 5 7 16 14 x 75 x40 1535 6024 2 7 16 14 1 00 465 8 1 4 20 1 25 465 9 1 4 20 1 50 6024 8 7 16 14 1 25 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 6024 4 7N E rt X 6210 7 5 16 18 Spiralock X 465 12 1 4 20 x 2 25 See a s e 6210 8 5 16 24 Spiralock X 465 14 1 4 20 x 2 75 SITAME X 6210 9 3 8 16 Spiralock X 465 21 1 4 20 x 5 00 X 129 15 1 2 13 x 75 X 6210 10 3 8 24 Spiralock X 465 25 1 4 28 x 38 X 129 17 1 2 13 x 1 00 X 6210 11 7 16 14 Spiralock X 465 20 1 4 28 x 1 00 X 129 18 1 2 13 x 1 25 X 6210 12 1 2 13 Spiralock PER 129 19 1 2 13 1 50 6210 15 7 16 20 Spiralock oe 18 50 X 129 20 1 2 13 x 1 75 X 6210 14 1 2 20 Spiralock X 125 23 5 16 18 x 62 125 3 5 16 18 x 75 129 21 1 2 13 2 00 129 22 1 2 13 x 2 25 X 85 3 5 8 11 Standard x 25 31 21 id 8x Y X 129 23 1 2 13
31. Thermostat assembly Heat exchanger internal to exhaust manifold Lifting eye Oil pressure sender High exhaust temperature switch Mixing elbow water outlet exhaust outlet Customer interface Anticorrosion zinc anode Air outlet TP 6774 2 14a 1 6 Torque Specifications Follow the general torque specification found in Appendix C of this manual unless noted below Generator Model 6EKOD 5EFKOD 1 Phase Overbolts 23 Nm 17 ft Ibs Drive discs to rotor hub 45 Nm 84 ft Ibs Rotor fan to flywheel 23 Nm 17 ft Ibs Back plate to engine block 23 Nm 17 ft Ibs Locator plate to engine block 23 Nm 17 ft Ibs Flywheel mounting bolts 80 Nm 59 ft Ibs Brush holder to brush holder brack et 4 Nm 35 in Ibs Brush bracket to end bracket 6 5 Nm 50 in Ibs Thermostat housing 23 Nm 17 in Ibs Exhaust manifold 25 Nm 18 in Ibs Cylinder head Follow the numerical order shown in the diagram and tighten the bolts in 3 phases 18 phase 50 Nm 37 ft Ibs 2nd phase Rotate the wrench clockwise 90 3 9 phase Rotate the wrench again clockwise 90 Generator Model 9EKOZD 7EFKOZD 1 Phase 11EKOZD 9EFKOZD 1 Phase 11EKOZD 9EFKOZD 3 Phase Overbolts 23 Nm 17 ft Ibs Drive discs to rotor hub 45 Nm 34 ft Ibs Rotor fan to flywheel 23 Nm 17 ft Ibs Back plate to eng
32. 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 or as recommended by the local fire code or an authorized agency Train all personnel fire extinguisher operation and 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 7 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 e Physical fatigue weakness in joints and muscles Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e 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 do
33. a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer Note Equipment damage Verify that the voltage ratings of the transfer switch line circuit breakers and other accessories match the selected line voltage A WARNING KS 55 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 setas follows 1 Movethe 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 6774 2 14a 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 Grounding electrical equipment Hazar
34. d 64 7 12 Monitoring and Programming Setup 66 7 12 1 PC Communications 66 7 13 Reviewing Menu 66 7 43 1 Error Messages 2 ne ld ER Mee bbe nb pede Lad 66 13 2 QVeIVIOW te ei pr ee ead RE abe E orar Uc EUR att mF 67 718 3 Engine Meteng ssec eter wee ee Pa RT 67 7 13 4 Generator Metering and Calibration 68 7 13 5 GenSet Information 69 7 13 6 GenSet Rum Time 1 2 date elbowed ede eee ot 69 GenSetSystem dise ote dane eet RI EP ot 69 7 13 8 Voltage ee eee e e ee mae 70 419 9 Event LOG oot ee ate dad a bees Ea eee ee 70 41 13 10 Prime rare eroe NEP TECUM seh ean 71 7 19 11 Volt Select REP Rn ds 71 7 13 12 USB Flowchart err dec awe ER ee eae Ta RAD Yn 72 Section 8 Component Testing and 78 8 1 Theory 73 8 2 Separate Excitation Eun UE E bat hed 73 83 Exciter Field 9 11EKOZD 7 9EFKOZD Models 75 8 4 Exciter Armature 9 11EKOZD and 7 9EFKOZD 7
35. 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 9 5 10 Safety Precautions and Instructions TP 6774 2 14a This manual provides troubleshooting and repair instructions for GEKOD 9 11EKOZD 5EFKOD and 7 9EFKOZD model generator sets 4 lead and 12 lead Advanced Digital Control and accessories Refer to the engine service manual for generator set engine service information x in 001 001 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 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 e 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 th
36. not securely installed Inspect for loose parts and secure if necessary Excessive engine generator vibration Check the rotor crankshaft bearing etc disassembly of engine and or alternator may be required Engine S M Emits black or gray smoke Oil level high Check the oil level Generator set O M Worn piston rings valves etc Check compression Engine S M High oil use External leakage defective gaskets Replace gaskets Engine S M Worn piston rings valves etc Check compression Engine S M Engine knocks TP 6774 2 14a Excessive load Reduce load Generator set I M Low oil level Check the oil level and add oil if low Section 6 Troubleshooting 41 Generator set O M 5 42 Section6 Troubleshooting TP 6774 2 14a Section 7 Controller 7 1 Introduction See Figure 7 1 for the locations of the controller and related components This section covers operation configuration adjustment and replacement of the ADC controller See Section 6 for troubleshooting procedures Junction box Bushing GM76137 Preheat relays qty 2 located inside junction box Vibromounts qty 4 F1 F2 and F3 fuses qty 3 Junction box controller panel Fuse holders qty 3 Screws and washers qty 4 Line circuit break
37. ohms 20 C 68 F 4 4 5 0 Stator output voltages with separately excited generator using 12 volt battery 60 Hz only 1 2 3 4 volts 130 55 66 volts 155 Cold stator resistance 1 2 3 4 ohms 55 66 ohms 9EKOZD 11 20 Component Specification 7EFKOZD 9EFKOZD Hot exciter field voltage amperage readings at rated voltage No load 63 Hz volts amps 12 0 8 Full load 60 Hz volts amps 33 2 2 Exciter field resistance cold ohms 20 C 68 F 4 8 Exciter armature resistance cold ohms line to line 1 18 Main field rotor resistance cold ohms 20 C 68 F 5 7 Stator output voltages with separately excited generator using 12 volt battery 60 Hz only 1 2 3 4 volts 115 55 66 volts 155 Cold stator resistance 1 2 3 4 ohms 55 66 ohms 1 4 Generator 12 Lead 11EKOZD Component Specification 9EFKOZD Hot exciter field voltage amperage readings at rated voltage No load 63 Hz volts amps 7 1 3 Full load 60 Hz volts amps 20 3 3 Exciter field resistance cold ohms 20 C 68 F 4 8 Exciter armature resistance cold ohms line to line 1 18 Main field rotor resistance cold ohms 20 C 68 F 5 7 Stator output voltages with separately excited generator using 12 volt battery 60 Hz only 1 4 2 5 3 6 7 10 8 11 9 12 volts 160 55 66 volts 192 Cold stator r
38. relays that power the engine glow plugs See Figure 7 1 for location The programmed glow plug circuit is for cold starting See Figure 7 12 86 87A 85 30 SCHEMATIC SINGLE POLE DOUBLE 1 12 VDC 133 mA 90 10 ohms Rated Voltage Operating Current Coil Resistance Pull In Voltage lt 8V Release Voltage 1 2V Max Operating Voltage 14 4 V GM49746 P Figure 7 12 Preheat Relay Specs Section 7 Controller 55 7 9 Battery Charging Module The junction box contains a battery charging module to maintain the engine starting battery The battery charging module monitors the battery voltage and provides 10 amps to charge the battery and up to 14 2 2 VDC when the generator set is running Note The battery charging module is reverse polarity protected Before testing the battery charging module ensure that no other DC loads are on the generator set At startup after approx 1 min check for a change in voltage If voltage increases the battery charging module is functioning If voltage decreases the battery charging module is inoperative GM82844 D 1 LED1 red reverse battery 2 LED2 green power Figure 7 13 Battery Charging Module 56 Section 7
39. rotary selector dial or buttons the menu resets to the top of the main menus and auto paging activates for the Overview submenus The main menus are listed below Within each main menu are multiple submenus with descriptions following Overview Engine Metering Generator Metering GenSet Information GenSet Run Time GenSet System Voltage Regulation Digital Inputs not applicable for units with ADC Digital Outputs not applicable for units with ADC Analog Inputs not applicable for units with ADC Ild Event Log Prime Volt Select Overview Menu When a new shutdown or warning fault occurs the auto paging display feature activates Active Shutdowns display if any are present This alerts the user to single or multiple shutdown fault conditions See Section 7 10 6 System Shutdown Fault Lamp with Digital Displays for a list of possible shutdown faults Active Warnings display if any are present This alerts the user to single or multiple warning fault conditions See Section 7 10 5 System Warning Fault Lamp with Digital Displays for a list of possible warning faults TP 6774 2 14a Generator Set State displays the generator set status e Off e Standby e Running e Cooldown e Stopping When the unit is cranking the attempt number is displayed When the unit is priming the time remaining is displayed Average Volts Line to Line value displays For three phase configurations the average line to l
40. standard type B USB communication port for PC connections and a USB host connector for a mass storage device connection See Figure 7 9 and Figure 7 10 See Section 7 13 12 for USB flowchart information Refer to the List of Related Materials in the Introduction for corresponding SiteTech software and or communication installation information Note Before inserting a mass storage device USB host connector power off and then power on the controller See Figure 7 8 for tested approved manufacturer s USB flash drive types that work with the ADC controller CustomUSB Kohler Power Systems Part Number KW A202 Imation 2 GB spin full size 4 GB full size 4 GB full size 4 GB full size and micro Lexar PNY Verbatin 4 GB full size and micro Figure 7 8 USB Types Tested Approved for ADC lld START STOP 1 USB device connector connects to SiteTech 2 USB host connector connects to mass storage device Figure 7 10 ADC Ild USB Identification TP 6774 2 14a 7 7 Fuses Fuses are located on the side of the junction box See Figure 7 11 e 10 Amp F1 fuse protects the auxiliary winding 20 Amp F2 fuse protects the controller circuits fuel pump and fuel shutoff solenoid e 5 Amp F3 fuse protects the customer connections 1 Fuses qty 3 Figure 7 11 Fuses on the Side of the Junction Box 7 8 Preheat Relay The junction box contains two preheat
41. to the mixing elbow 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 is stopped and the power button is off Reconnect the engine starting battery negative lead last Reconnect power to the battery charger if equipped Replace the sound shield roof and door s if equipped Section 9 Generator Disassembly Reassembly 99 5 100 Section 9 Generator Disassembly Reassembly TP 6774 2 14 Section 10 Wiring Diagrams A WARNING aS x 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 st
42. value or can select Reset VR Yesto reset to the default value The Reset VR Settings display will only show if editing is enabled To disable calibration Rotate the pushbutton rotary selector dial until the popup appears Momentarily press the pushbutton rotary selector dial Stop the generator set if not already done TP 6774 2 14a Event Log Menu This menu allows the user to review upto 1000 entries of system events including shutdown faults warning faults and status events See 7 5 6 Controller Fault Diagnostics for a list of the items that appear on the Event Log Prime Menu This menu if confirmed allows the user to initiate the electric fuel pump to prime the fuel system Volt Select Menu Note The generator set must be stopped before changing the voltage selection This menu allows the user to readily change controller voltage settings Note The generator set output leads require voltage reconnection See Section 8 11 for voltage reconnection information With the generator set stopped go to the Volt Select menu Then push and hold the pushbutton rotary selector dial until the voltage selection starts to flash Volt selection is now available Scroll to the desired voltage and momentarily press the pushbutton rotary selector dial to confirm the voltage selection The displays for Volt Select appear as shown in the following list e 120 240 V 1 Ph 3 wire e 120 208 V 3 Ph 4 wire Wye e
43. x 2 50 X 88 12 3 4 10 Standard 125 5 516418 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 50 125 25 5 16 18 1 75 X 129 27 1 2 13 3 50 129 29 1 2 13 4 00 Washers X 125 26 5 16 18 x 2 00 X 129 30 1 2 13 x 4 50 230578 5 16 18 x 2 25 X 463 9 12 13 x 5 50 Bolt 12529 5 1618 2 50 PartNo ID OD Thick Screw 125 27 5 16 18x 2 75 129 44 1 2 13x 6 00 X 125 28 5 16 18 x 3 00 X 129 51 1 2 20 x 75 X 25 46 125 250 022 4 X 125 22 5 16 18 x 4 50 X 129 45 1 2 20 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 8 125 35 5 16 18 5 50 25 36 219 500 049 10 X 125 36 5 16 18 x 6 00 X 6021 3 5 8 11 x 1 00 X 25 40 281 625 065 1 4 X 125 40 5 16 18 x 6 50 150 25 85 344 687 065 5 16 6021 11 1 25 37 406 812 065 3 8 125 43 5 16 24 1 75 6021 1 5 8 11 1 75 5 23 25 34 469 922 065 7 16 X 125 44 5 16 24 x 2 50 273049 5 8 11 x 2 00 USE 25 26 531 1 062 095 1 2 X 125 30 5 16 24 x 75 X 6021 5 5 8 11 x 2 25 25 15 656 1 312 095 5 8 X 125 39 5 16 24 x 2 00 X 6021 6 5 8 11 x 2 50 X 25 29 812 1469 134 3 4 X 125 38 5 16 24 x 2 75 X 6021 7 5 8 11 x 2 75 1 X 25 127 1 062 2 000 134 1 X 6021 12 5 8 11 x 3 75 X 6238 2 3 8 16 x 62 X 6021 11 5 8 11 x 4 50 X 6238 10 3 8 16 75 6238 3 3 8 16 x 88 BUE 6238 11 3 8
44. 0 M931 16100 82 M931 16120 60 M931 16150 60 M931 20065 60 M931 20090 60 M931 20100 60 M931 20120 60 M931 20140 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 60 M933 10035 82 M961 10040 60 M4 0 70 6 M5 0 80 30 5 0 80 x 35 5 0 80 x 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 8 1 25 x 20 M8 1 25 x 25 8 1 25 x 30 8 1 25 305 10 1 50 12 10 1 25 20 10
45. 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 5 3 10 0 6 4 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 M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 NNN AES 0001 oooo This metric hex nut s hardness is grade 8 116 Appendix TP 6774 2 14a 6774 2 14 117 118 6774 2 14 6774 2 14 119 6774 2 14 2012 and 2014 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 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
46. 140 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 6774 2 14a 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 8 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 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 6
47. 16 1 00 6021 9 5 8 18 2 50 6238 4 3 8 16 x 1 25 X 6238 5 3 8 16 x 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 8 8 16 2 00 6239 2 3 4 10 1 50 X 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 X 6239 6 3 4 10 x 3 50 X 6238 19 3 8 16 x 3 25 X 792 1 1 8x 2 25 X 6238 20 3 8 16 3 75 792 8 1 8 x 5 00 X 6238 13 3 8 16 x 4 50 X 6238 18 3 8 16 x 5 50 X 6238 25 3 8 16 x 6 50 114 Appendix TP 6774 2 14a 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 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 10
48. 4 zHd 214 SNOILOANNOD pd 6d MOlvIS e 09 Ld 804 2 rM SNOLLO3NNOO NZ d i Nd O N O N O N O N 1 0 O N 42 9 cz O N vz 48 cz 7 22 7 O N 02 9 6d 06 amp OO N 8 s 6d 91 1 64 13A 81 2 69 vi OO N si 4e u OL 6 1 18 ZA fag QE 77 ah N 64 8 DON 9 840 6 2 2 L 2 89 z zid 6 64 04 vM M SNOIIO3NNOO Td 614 914 ze 1d 14 983 SS td if SNOIIOJNNOO Std O W3ONVHO AYALLVE vis 8v is att GM79008 C int Po Figure 10 3 Wiring Diagram Point to TP 6774 2 14a 102 Section 10 Wiring Diagrams YaTIOWLNOD 3NRIVNA AINO Y3010H 1 15 lloav 5219 SL8S AQV 3338 SNOILO3NNOO MOLVH3N39 SALON ONIONIM ONIONIM ONIGNIM 01313 WOlVIS Qvil
49. 4 N 4 CYLINDER ONLY 249 249 d9 49 EM voL vf D S M ZN id S Wf Nid SNOILO3NNOO 8d SNOILOJNNOO 94 Ep N 07 64 94 SNOIIOJNNOO td 2812 fld vd 1 8 14 gm 1800 s zid 8M 55 te 6 vis 8v OJO TIM oos DM avis 811 xolvis 1415 0 4105 831815 SS MOLON 8315415 WS 103NNOO 3000 1v3H3ud YOLOENNOD 34085388 10 540 HOLIMS 34055384 GMS 01 MOLYNM3LY 01 AVIJM 02 W3oNVHO AYALLVE 01 94 ss ed SSS 244 n 4 LM 89 QE c ei Su DM Sd 61 19 Og 6774 2 14 508 ANNONS 0311051 9 1049 GIONS10S 1304 54 1303 3snj 4 HOLIMS dW3L 513 ANNOYS 8 983 YOSNS 14610002 510 89 8 62 14 18 vf Nid SNOILO3NNOO Sd 8 19 81 14 N33H9 NYO 91 14 MOTA Nid SNOLLO3NNOO 6d 8 2 9 0 14 2 l NOILOJNNO9 30v3831NI YIWOLSNO 6d Figure 10 5 Isolated Ground Wiring Diagram Point to
50. 4 quu 301415 OYI v MUI E ASVHd 319NIS LS8S AOY 1335 SNOILO3NNOO MOIVH3N39 ALON 1715 WOIVIS 3SVHd 338Hl 86 335 SNOILO3NNOO MOLVH3N3O N04 310 anaon oL Qr 899 3univWav 514 vv 2 4 6 814 8 6 99 per Gri si 21 19 1710190 M3iMVIS 031931059 993 1 z vd N 6 64 8N 6N SN z id SM 202241 viz 55 882 ss vid 24 23 1 9 d ss SSH uM 14 91 OTIM oos DM MONIS 191 0 3105 NilVIS SS MOLON 83138415 NS 103NNOO 3000 OIO3NNOO 34055384 10 590 HOLIMS 34055384 5 Qnis O1 01 NYNO OZ 508 ANNONS 03141051 891 9nd 1049 GIONS10S Tans 54 1303 3snj 4 HOLIMS dW3L 513 ANNOYS 2018 983 MOSNiS dW3L 1 1000 SLO 1 5 4 80S di 5 3SVHd 319 5 8 33S SNOILO3NNOO MOIVH3N39 310 z zd di 1 1 15 rov 122 9 24 1 Gi
51. 46 Section 7 Controller TP 6774 2 14a 7 5 Advanced Digital Control 114 Operation Figure 7 6 illustrates the user interface on the Advanced Digital Control 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 refer to an authorized Kohler distributor dealer for system configuration and adjustment instructions Note Have setup and adjustments of the Advanced Digital Control performed only by an authorized Kohler distributor dealer R DIG GM58225A LCD digital display Pushbutton rotary selector dial Engine start stop button Power button LED status indicator Figure 7 6 Advanced Digital Control Ild 7 5 1 Controls and Indicators LCD Digital Display The LCD digital display is backlit any time the generator set is running or for at least 5 minutes after a user manipulates a button or the pushbutton rotary selector dial The LCD displays generator status run time hours fault shutdowns and fault warnings Pushbutton Rotary Selector Dial This control provides access to the menus for monitoring Pressthe selector dial to activate the digital display and to select choices shown on the display Rotate the dial to navigate through the menus TP 6774 2 14a The pushbut
52. 5A 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 12 5 0 80 16 5 0 80 20 5 0 80 25 5 0 80 30 5 0 80 80 5 0 80 100 6 1 00 100 Flat Head Machine Screws M965A 04012 SS M965A 05012 SS M965A 05016 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 115 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 M125A 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
53. 6 8 5 Slip Rings GEKOD 5EFKOD Models 77 8 6 Brushes GEKOD 5EFKOD Models 77 8 7 Rectifier Module 9 11EKOZD and 7 9EFKOZD Models 78 86 8 ROM turus IR SENS 78 8 9 Staton secet REIS IE Publ Quan E PTT RE 79 8 10 Voltage Regulator th erate ede cere arcu Eden 81 8 10 1 Voltage Regulator and Calibration Specifications 81 8 10 2 Voltage Regulator Adjustments 81 8 10 3 Voltage Regulator iiai aidoma a a eee 82 8 11 Voltage Reconnection 83 8 12 Four Lead Reconnection 85 8 12 1 100 120 Volt Configurations 85 8 12 2 100 120 200 240 Volt Configurations 85 8 12 3 200 240 Volt Configurations 86 8 13 Twelve Lead Reconnection 86 8 14 Fault Shutdown Tests 87 8 14 1 Controller Fault Shutdown Functions 87 8 14 2 Fault Shutdown Senders Switches 88 8 15 EuseScc essai e cR rne 89 8 16 Continuity Checks 90 Section 9 Generato
54. 6774 2 14a 8 14 Fault Shutdown Tests Verify the operation of the generator set overspeed overcrank high engine temperature and low oil pressure 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 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 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 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 A WARNING rer e Did Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation 8 14 1 Controller Fa
55. 6776 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 Operation Manual explains how to check and change the controller configuration If the troubleshooting procedures in this section identify abad part refertothe parts catalogfor replacement part numbers 6 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 display Section 7 10 1 describes the warning and shutdown fault codes TP 6774 2 14a Section 6 Troubleshooting e Blown fuses See Figure 6 1 for fuse identification Always check and replace the fuses before replacing other components See the operation manual or parts catalog for fuse part numbers Fuse Auxiliary winding Controller fuel pump and fuel shutoff solenoid Customer connection Figure 6 1 Fuse Identification e Incorrect controller settings A ways check the controller configuration settings before replacing the controller Section 7 13 explains how to check and change the controller settings Some problems may be solved by updating the controller s application program Check Tech Tools Software for information on ADC Ild applicati
56. Engine S M Engine overloaded Reduce electrical load I M Loss of generator output voltage to controller Check connections at P2 plug Check continuity of AC sensing leads 11 and 44 for 1 phase models or leads V7 V8 and V9 for 3 phase models Section 10 Section 8 9 Intermittent wiring connections Inspect fuel pump wiring to ensure good connections Blown F1 fuse Troubleshoot rotor and stator assembly and wiring Section 8 8 Section 8 9 Section 10 Operates erratically Governor adjustment incorrect Adjust the governor stability Section 4 4 Fuel line restriction Check fuel lines filter and pump 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 Generator overloaded Reduce load Engine not running at rated rpm Check controller configuration setting Adjust the governor speed Section 4 4 Engine power loss Refer to the Engine Service Manual for troubleshooting and repair instructions Engine S M Governor malfunction or misadjustment Test readjust the governor Section 4 4 Overheats TP 6774 2 14a Inadequa
57. HT HD HET hex HH HHC HP hr HS hsg HVA HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext ISO J JIS estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol 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 temp high engine temp 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 inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard Appendix 109 KB KBus kg kg cm kgm kg m3 kHz kJ km kOhm kQ kPa kph kV kVA kVAR kW k
58. Kohler marine generator set ratings using accepted reference conditions of 25 C 77 F and pressure of 29 2 in Hg dry barometer ISO 3046 and ISO 8528 1 include reference conditions and output calculations Obtain the technical information bulletin on ratings guidelines TIB 101 for complete ratings definitions Read this manual then carefully follow all service recommendations See Figure 1 2for identification and location of components Section 1 Specifications 13 12 Engine Generator Model 6EKOD 5EFKOD 1 Phase 9EKOZD 7EFKOZD 1 Phase 11EKOZD 9EFKOZD 1 Phase 11EKOZD 9EFKOZD 3 Phase Number of cylinders Type 4 cycle naturally aspirated Engine block material Cast iron with re borable integral liners Cylinder head material Aluminum Governor Centrifugal mechanical Engine firing order 1 cylinder on flywheel end or alternator end Direction of rotation as viewed from flywheel Counterclockwise Combustion system Indirect injection Bore x stroke mm in 75 77 6 2 95 x 3 05 Displacement L CID 1 028 62 7 1 372 83 7 Compression ratio 24 5 1 Max power at rated rpm HP 60 50 Hz 10 1 8 4 14 5 11 9 19 6 15 4 RPM 60 50 Hz 1800 1500 Lubrication system Pressurized oil system with oil pump Lube oil capacity w filter L U S qts 2 5 2 6 3 4 3 6 Oil recommendation API
59. NERAT OG GENI n SEE 2000 SAN ANA A MAMMA ZUR 4 e d s MEAM FEN FN FEN AKU REIL RATO AGRAM GENE uua Figure 10 7 Accessory Interconnection Drawing 106 Section 10 Wiring Diagrams CTIO CONNE AL Y OPTIO lH N QURMETE 4 E DAAE OOO KINAN Y e 7 8 2 Ao SI e MEA KEI SEI M A DAOA Ha YaN GENERAT ONNECTIONS STOP STOP START 7 DIGITAIL GAUGE EXTENSION PIGTAIL AND REMOTE CONTROL PANEL OPTIONS OP NEL RT 5 OTE GM33846 D TP 6774 2 14a 10 2 Manual Marine Ship to Shore 2 Wire and 3 Wire Transfer Switches Electro Switch Generator Sets 3 Wire Generator Sets O Qu L1 2 1 3 4 To Generator To Shore Set Power gao e Generator 6 8 Shore Set Power lt lt Lo Y Y 10 To Load To Load Kraus Naimler American Solenoid Early Rectangular Design 2 Wire Generator Sets 3 Wire Generator Sets Li NE 2 6 To Generator 1 5 To Shore 1 Set Power 12 7 To Shore Set Power Y Y T
60. Push the pushbutton rotary selector dial 4 Rotate the pushbutton rotary selector dial to CONFIRM PRIME Yes 5 Push the pushbutton rotary selector dial to begin the fuel priming procedure A 30 second priming sequence begins automatically If necessary push the control knob to stop the priming procedure before the 30 seconds are up PUSH TO R DVA 016 TAL CONTROL GM58225A 1 LCD digital display 2 Pushbutton rotary selector dial 3 Power button Figure 4 3 Advanced Digital Control Ild 24 Section 4 Fuel System Typically running the Prime function on the ADC Ild is all that is required If rough operation continues use the following procedure to open the air bleed valve on the fuel filter Note Connectthe battery duringthe priming procedure to allow engine cranking Note If the ADC indicates an overcrank fault during this procedure disconnectthe negative wire from the fuel solenoid allowing the fuel injection pump to fill with fuel and repeat this procedure after allowing the starter motor to cool down Note Have rag handy during this procedure Wipe up any spilled diesel fuel Wash hands after any contact with fuel Dispose of fuel in an environmentally safe manner Fuel System Bleed Procedure 1 Loosen the fuel filters air vent screw See Figure 4 4 2 Initiate the auto start seq
61. Shutdwn Engine Under Speed The fault lamp flashes red the alarm horn sounds and the unit shuts down immediately when the governed frequency on 50 and 60 Hz models drop below the underspeed setting The local display shows Eng Speed Low Shutdwn High Coolant Temperature The fault lamp flashes red and the unit shuts down because of high engine coolant temperature The high coolant temperature shutdown does not function during the preset inhibit time delay period after startup The local display shows Cooint Temp High Shutdwn Note The high engine temperature shutdown function and the low seawater pressure shutdown function are independent A low seawater pressure condition may not activate the high engine temperature switch High Exhaust Temperature The fault lamp flashes red and the unit shuts down because of high exhaust temperature The local display shows Exh Temp High Shutdwn 62 Section 7 Controller Locked Rotor failed to crank If none of the speed sensing inputs show engine rotation within the preset time delay of initiating engine cranking the ignition and crank circuits turn off for the preset period and the cycle repeats The fault lamp flashes red and the unit shuts down after the second cycle of the preset period of cranking The local display shows Locked Rotor Shutdown Low Seawater Pressure The fault lamp flashes red and the unit shuts down because of low seawater pressure Shutdown occurs 5 seconds after
62. V3N3INI N3NOLSNO 6d 202 YALYVLS Q3lodlONd IVNOILdO 8 64 amp 1HK ADV7995 C AMALLVE 170A 21 Figure 10 4 Wiring Diagram Schematic Section 10 Wiring Diagrams 103 TP 6774 2 14a GM79009 E 9 03171081 Wu3TIOMINOO 3NINVW M 11 9 8 5 vis 9 8 e z l sm vis 99 14 456 VIS 1 vis if Nid 014 SNOILOANNOO 966 33S 5 8 019 319 5 SZ8S AGV 33S SNOILO3NNOO D 3OIVH3N39 310 z zd di 1 1715 qa Malox3 31000 01915 VAT ZL 31n00N WOlVIS OYJ v 3SvHd 319NIS 8 1335 SNOILO3NNOO MOIVH3N3O 04 310N 1915 3SVHd 338Hl 86 335 SNOILO3NNOO MOLVH3N3O M04 310 Qr 899 6 814 vv rev 122 9 64 1 3snivWav 5 64 1 64 2 64 1 81 18 1 19 2 4 6A 814 8 05 4 80S di 513 le 84 0 01 6 OL IM vzi ZM SNOILO3NNOO Td
63. Wh kWth L LAN LxWxH Ib Ibm ft3 LCB LCD Id shd LED Lph Lpm LOP LP LPG LS Lwa LWL LWT m M m3 m hr m min mA man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilo 1000 kelvin kiloampere kilobyte 210 bytes Kohler communication protocol kilogram kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display load shed light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature meter milli 1 1000 mega 108 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm mQmilliohm MOhm MQmegohm MOV MPa mpg mph MS ms m sec MTBF metal oxide varistor megapascal miles per gallon miles
64. age 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 F1 fuse Contact an authorized distributor dealer for service if problem continues TP 6774 2 14 Warnings Code Description Sensing Mechanism State s Detected Inhibit Time Trip Point Check AC Sens Loss Warning Loss of AC voltage warning occurs when the controller does not detect the nominal generator set AC output voltage after crank disconnect Frequency over AC voltage Post starting aid running cooldown 10 sec AC voltage is below 5 of the trip point for low AC voltage fault shutdown Check for loose connections Check all AC leads connected to the controller for continuity Alternator excitation failure Inspect the brushes GEKOD 5EFKOD and check the FN and FP connections Contact an authorized distributor dealer for service Battery High Warning High battery voltage warning The fault condition clears when the battery voltage returns to a voltage within the limits Analog input Auto fault start delay start starting aid cranking crank pause post starting aid running cooldown Battery voltage exceeds 12596 of the nominal system voltage 12 V Check the battery rating and condition Check the battery charger o
65. age 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 Ohmmeter Component Connections Scale Ohmmeter To further check generator set components disconnect the battery and remove wiring harness plugs from the ADC circuit board Use an ohmmeter to check the continuity of the components listed in Figure 8 31 Also see Section 10 Wiring Diagrams Figure 8 31 gives resistance readings for functional components A zero reading on the ohmmeter indicates continuity No ohmmeter reading indicates very high resistance or an open circuit A measurement that varies significantly from the value shown in the table indicates a faulty component replace faulty components Note Disconnect the generator set battery before performing continuity checks to prevent damage to the ohmmeter Generator Set Master Switch Position Ohmmeter Readings for Operative Components P1 wiring harness P1 3 and ground Rx1 OFF Zero ohms continuity Any other reading indicates a poor ground connection P2 6 and P2 7 stator leads 11 and 44 for 1 phase models or P2 6 P2 7 and P2 8 stator leads 7 8 and 9 for 3 phase models OFF Zero ohms continuity If no continuity check wiring P2 3 and P2 4 stator leads 55 and 66
66. als Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces 5 2 Water Cooled Exhaust Manifold Each marine generator set has a water cooled exhaust manifold The coolant solution circulates through the manifold reducing the amount of heat radiated from the exhaust into the surrounding area The engine thermostat is located in the water cooled exhaust manifold See Figure 5 2 See Section 1 forthe water cooled exhaust manifold torque spec 1 Thermostat assembly 2 Thermostat located inside thermostat housing Figure 5 2 Thermostat Location 28 Section 5 Cooling System 5 3 Coolant Replacement Including Heat Exchanger Service At the interval specified in the Service Schedule clean the heat exchanger tube In a closed cooling system seawater circulates through separate chambers within the heat exchanger to cool the engine coolant The seawater then mixes with engine exhaust and ejects out of the exhaust mixer s outlet See Section 1 for coolant capacity thermostat and pressure cap ratings 1 Open the heat exchanger outlet to drain the coolant See Figure 5 3 14 Figure 5 3 Heat Exchanger Outlet 2 Close the heat exchanger outlet 3 Remove the engine plug to drain the engine coolant See Figure 5 4 Figure 5 4 Engine Drain Plug 4 Replace the engine plug TP 6774 2 14a 5 Remove the exhaust 6 mounting nuts See Figure 5 5 Figure 5 7 Therm
67. an 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 Introduction 11 5 12 Service Assistance TP 6774 2 14a 1 1 General This manual covers maintenance troubleshooting and repair of the alternating current marine generator sets listed in Figure 1 1 Consult the generator set nameplate for specific generator set ratings Models Voltage 120 EKOD PERO 120 240 120 9 11EKOZD 120 240 220 380 240 416 120 240 127 220 11EKOZD 115 230 230 240 115 230 7 9EFKOZD 230 240 9EFKOZD 230 400 Figure 1 1 Generator Model Coverage TP 6774 2 14a Section 1 Specifications The 6EKOD 5EFKOD single phase models are powered by a three cylinder water cooled four cycle diesel engine with a heat exchanger The 9EKOZD 7EFKOZD single phase models are powered by a three cylinder water cooled four cycle diesel engine with a heat exchanger The 11EKOZD 9EFKOZD single and three phase models are powered by a four cylinder water cooled four cycle diesel engine with a heat exchanger Heat exchanger cooling consists of a heat exchanger with a coolant recovery tank thermostat rubber impeller seawater pump centrifugal type engine circulating pump water cooled exhaust manifold and an exhaust mixer Kohler Co develops all
68. anagement District 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 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 controller area network California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6774 2 14a cfm CG CID CL cm CMOS cogen com Coml Rec conn cont CPVC crit CRT CSA CT Cu cUL CUL cu in cw CWC cyl D A DAC dB dB A DC DCR deg dept DFMEA dia DI EO DIN DIP DPDT DPST DS DVR E emer ECM EDI EFR e g EGSA EIA EI EO EMI emiss eng EPA EPS ES ESD cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrat
69. are rms sensing for fast response to changes in indicated and regulated voltages resulting in excellent regulation accuracy 60 Section 7 Controller 7 10 4 Voltage Regulator Adjustments The descriptions of the voltage regulator adjustments and features follow Voltage Adjustment The voltage adjustment allows the user to enter the desired generator set output level This regulated level setting is the average of the three line to line voltages in three phase configurations or L1 to L2 in single phase configurations Submenus display the individual line to line voltages These voltages are for reference only and are relevant in unbalanced load conditions The voltage adjust setpoint can be changed to accommodate an important phase in an unbalanced system Underfrequency Unload Frequency Setpoint This adjustment affects the voltage droop volts per Hz when load is applied and underfrequency occurs The underfrequency unload setting defines the setpoint where underfrequency starts Any frequency below the setpoint causes the voltage to drop thus reducing the load allowing the engine speed to recover according to the underfrequency unload slope setting Engine speed recovery depends upon characteristics such as engine make fuel type load types and operating conditions The underfrequency unload setting should match the engine speed recovery characteristics for the application Underfrequency Unload Slope This setting de
70. art command from a remote computer 10 1 Wiring Diagram Reference 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 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 Model Point to Point Figure Schematic Figure Accessory Figure 6EKOD 5EFKOD 9EKOZD 7EFKOZD GM79008 C Figure 10 3 ADV 7995 C Figure 10 4 GM33846 D Figure 10 7 11EKOZD 9EFKOZD Figure 10 1 Wiring Diagrams for Units without Isolated Ground Model Point to Point Figure Schematic Figure Accessory Figure 6EKOD 5EFKOD 9EKOZD 7EFKOZD GM79009 E 10 5 ADV 7996 D Figure 10 6 GM33846 D Figure 10 7 11EKOZD 9EFKOZD Figure 10 2 Wiring Diagrams for Units with Isolated Ground TP 6774 2 14a Section 10 Wiring Diagrams 101 YATIONLNOO 11 9 66 33S 5 0
71. ated inside junction box F1 F2 and F3 fuses qty 3 Fuse holders qty 3 Line circuit breaker cover plate GRD lead connection LO lead connection Cable connector ONDARON 76137 Bushing Vibromounts qty 4 Junction box controller panel Screws and washers qty 4 Advanced Digital Control Ild Battery charging module shown removed from inside of the junction box Figure 9 4 Advanced Digital Control 1 4 ADC 11 and Junction Box Detail TP 6774 2 14a Section 9 Generator Disassembly Reassembly 93 GM73473 A 1 Overbolts Torque to 23 Nm 17 ft 106 End bracket 2 Washers O ring 3 Screws Rotor assembly 4 Brush holder cover Stator assembly During disassembly push the brushes into the holder Secure the brushes into position by sliding a retainer into the brush keeping holder Remove the brush holder and carefully pull the leads out of the stator housing During reassembly 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 alignment See Section 8 6 Alternator air outlet guard and screw Lead screw lock washer and plain washer Alternator fan Drive disk Washers Screws Torque to 45 Nm 34 ft Ibs Nuts Studs Torque to 23 Nm 17 ft Ibs 5 Gas
72. ation 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 at the ADC Iid and terminals 2 Connect a DC ammeter 10 amp fuse and a 12 volt automotive battery to the positive FP and negative FN exciter leads or brush leads as shown in Figure 8 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 the specified rotor resistance values Example 12 volts battery voltage Dee 3 5 ohms rotor resistance 3 4 amps rotor current 3 Start the engine and check that the ammeter reading remains stable An increasing meter reading indicates a shorted rotor A decreasing meter reading to zero or an unstable reading suggests a running open Refer to Section 8 8 Rotor to test the rotor If the ammeter reading is stable proceed to step 4 74 Section 8 Component Testing and Adjustment 4 Check for AC output across the stator leads see Section 8 9 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 8 9 Stator for further information 5 If this test shows that the rotor and stator are in good condition check the wiri
73. ator output voltage through leads 11 and 44 for 1 phase models or leads V7 V8 and V9 for 3 phase models and adjusts the DC current to the rotor to meet load requirements See Figure 8 1 8 2 Separate Excitation To determine the cause of no or low AC output refer to the troubleshooting flowchart in Figure 8 2 Before beginning the test procedures read all of the safety precautions atthe beginning of this manual Many of the test procedures include additional safety precautions Check the condition of the alternator fuse F1 before performing the separate excitation procedure See Figure 8 1 See Figure 1 2 for the fuse location If the 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 lld 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 Short circuits can be caused by centrifugal forces acting on the windings during rotation or insulation breakdown as temperatures increase TP 6774 2 14a ADC Ild
74. cifications go to step 7 3 Loosen the pivot and adjusting screws 4 While prying the seawater pump outward tighten the adjusting screw 5 Tighten the pivot screw 6 Recheck and adjust as necessary 7 Replace the belt guard Section 5 Cooling System 33 5 9 Anticorrosion Zinc Anode The heat exchanger contains an anticorrosion zinc anode plug to prevent electrolytic corrosion by seawater Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule Depending upon operating conditions and seawater properties the anticorrosion zinc anode may require more frequent replacement See Figure 1 2 for the location and use the following procedure Anticorrosion Zinc Anode Replacement 1 With the generator set cooled close the seacock open the petcock on the engine and drain the coolant into a suitable container 2 Remove the anticorrosion zinc anode plug from the heat exchanger 3 Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode Replace the anode according to Figure 5 23 and Figure 5 24 Anticorrosion Zinc Anode Replacement Replace When Percent of Zinc Remaining Is New Anode Models Dimensions mm in 6EKOD 5EFKOD 9EKOZD 7EFKOZD lt 50 of 6 35 0 25 x 20 0 78 tength diameter 11EKOZD 9EFKOZD Figure 5 23 Anticorrosion Zinc Anode Plug Measurements 34 Section 5 Cooling System 1 Diameter 6
75. crank and run The remote location is typically a set of contacts on a transfer switch or remote start switch The local display shows Remote Start Status 64 Section 7 Controller System Ready This status indicates thatthe generator setisinthe AUTO mode and available to start ifthe start circuit is closed The local display shows System Ready System Timer Failed This notice indicates that the controller timer logic has failed to time out a designated function The local display shows Timer Error Notice Voltage Regulator Adjustment User Defined This feature is in the Voltage Regulator Menu allowing the user to fine adjust the output voltage Use the pushbutton rotary selector dial to navigate and select this feature Changes to this display must be done with the generator set running The local display shows Enter volt reg No or Yes Select No to exit the voltage regulator menu Select Yes to change the local display VR Volt Adj xxx x V 7 11 Menu Displays Use the Menu Summary List section after reading and understanding the features of the pushbutton rotary selector dial See Section 7 5 5 Digital Display The Menu Summary List provides a quick reference to the digital display data Some digital display data may not be identical to your display due to generator set application differences The closed bullet items represent main level data and the open bullet items are sub level data The Menu Summary List indicates items
76. d around the generator set and keep metal surfaces free from accumulated salt deposits Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Movethe 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 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 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 TP 6774 2 14a Section 2 Scheduled Maintenance 19 2 2 Lubrication System Note Failure to observe the oil specifications may cause inadequate lubrication oil pressure and Use oil that meets the American Petroleum Institute cold starting difficulties API classification of CD or CF Using an unsuitable oil or neglecti
77. d 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 good 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 Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Hazardous Noise A 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 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 Gr
78. de doors as needed AB 9 Sound shield roof Wing nut Alternator end door Service side door Front rail Engine end door OORUN Figure 9 1 Sound Shield Roof Removal Section 9 Generator Disassembly Reassembly 91 10 Loosen and remove the four controller mounting 12 Refer to Figure 9 4 while performing steps 13 screws securing the controller and carefully lift the to 20 controller See Figure 9 2 13 Remove the controller Note Be careful of the leads and harness connected to the controller 14 Remove the junction box controller panel 15 Disconnect the generator output leads from the circuit breakers 16 Disconnect the LO and GRD lead connections 17 Disconnect the leads to the fuses 18 Disconnect the connectors to the preheat relays 19 Disconnect the AC lead connections and the P4 connector to the battery charging module 20 Remove the junction box from the four vibromounts 1 Controller mounting screws 4 ea Figure 9 2 ADC Mounting Screws 11 Note the connections on the back of the controller and then disconnect wiring harness plugs P1 35 plug and P2 8 pin plug from the ADC Ild See Figure 9 3 GM79009 A Figure 9 3 Controller Connections 92 Section 9 Generator Disassembly Reassembly TP 6774 2 14 Junction box Preheat relays qty 2 loc
79. djusts the governor during run in and further adjustment should not be needed unless greatly varying load conditions are encountered or if poor governor control develops after extended usage 60 Hz generator sets are designed to operate in the range of 59 63 Hz 1800 rpm under full load and 1890 rpm under no load 50 Hz generator sets are designed to operate in the range of 49 53 Hz 1500 rpm under full load and 1590 rpm under no load To check the engine speed use a frequency meter connected to the load leads or use a hand tachometer If adjustment is needed loosen the locking nut on the speed adjusting screw Turn the screw clockwise to increase the speed and frequency To decrease the speed turn the screw counterclockwise Tighten the locking nut when the correct setting is reached See Figure 4 6 1 Speed adjusting screw 2 Locking nut 3 Adjusting arm Figure 4 6 Governor Adjustment 4 5 Fuel Solenoid The generator set uses a 2 lead fuel solenoid See Section 1 Service Views for location This solenoid has lead 70A which energizes the coil during cranking opening fuel flow to the engine Lead N is the common ground Section 4 Fuel System 25 5 26 Section 4 Fuel System TP 6774 2 14a Section 5 Cooling System 5 1 General Heat exchanger cooling consists of a heat exchanger with coolant recovery tank thermostat rubber impeller seawater pump centrifugal type engine circulating pump water co
80. do not connect the load side terminals of the circuit breaker together see Figure 8 18 If the installation requires a 100 120 volt 2 wire system use a single pole circuit breaker See Figure 8 19 When connecting stator phase leads together size the output lead L1 to handle the amperage Use a jumper lead on the ine side of the circuit breaker to balance the load of the generator set 6 LO Neutral 10 Ground 2 SR 12 Load Side O O Two Pole Line Circuit Side Breaker Q Figure 8 18 100 120 Volt 3 Wire Configuration TP 6774 2 14a 8 12 2 100 120 200 240 Volt Configurations The 100 120 200 240 volt configuration does not use a jumper lead Ifthe unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 8 18 for location Select a two pole circuit breaker Application of two single pole circuit breakers does not conform to NEC requirements for supplying a 200 240 volt load even if the breakers are mechanically attached together Leads L1 and L2 are for different phases never connect them together LO Neutral 9 10 2 gt GRD Ground cE 41 Load Side O Single Pole Circuit Breaker 4 3 2 1 Stator Leads 60 Hz 50 Hz 10 11 100 120 Volt 100 120 Volt LO L2 100 120 Volt 100 120 Volt Figure 8 19 100 120 Volt 2 Wire Configuration LO Neutral
81. dous 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 all jewelry before servicing the equipment Section 8 Component Testing and Adjustment 83 Voltage Reconnection Procedure 1 Stop the generator set 2 Turn the controller pushbutton rotary selector dial until it stops at the Volt Select menu See Figure 8 17 Volt Select gt a 120 240 V 1 Ph V Ph Y 115 230 V 1 Ph Y 120 V 1 Ph 240 V 1 Ph Y 230 V 1 Ph Y 120 208 V 3 Ph Y 120 240 V 3 Ph Y 127 220 V 3 Ph Y 139 240 V 3 Ph Y 277 480 V 3 Ph Y 110 190 V 3 Ph Y 230 400 V 3 Ph Y 240 416 V 3 Ph Figure 8 17 Volt Select Menu 3 Press the selecto
82. e semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories 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 Design Failure Mode and Effects Analysis 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 control module engine control module 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 Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge est E Stop etc exh ext fglass FHM fl oz flex freq FS ft Ib ft min ga gal gen genset GFI GND gov gph gpm gr GR gr wt HxWxD HC
83. e 9 15 GM73473 A 1 Rotor 2 Drive disc 3 Bolt Figure 9 15 Drive Disc Installation 2 Install the rotor drive disc assembly on the engine flywheel using six studs and nuts torqued to 28 Nm 17 ft Ibs 3 Align the fan to the rotor drive disc assembly using the mark created in the disassembly procedure Note Install the fan with the flange side facing away from the flywheel 4 Replace the O ring in the end bracket bearing bore Use a sling to support the stator assembly while installing the stator over the rotor Do not damage the rotor See Figure 9 16 Figure 9 16 Stator Installation TP 6774 2 14a 10 11 12 6 5 Model 6EKOD 5EFKOD Model Install the four overbolts Check that the indent marks on the top of the stator housing match the locator plate and the end bracket Tighten the overbolts to 23 Nm 17 ft 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 and washer on each vibromount Apply anti seize compound to the keyed end of the rotor shaft Bring the rotor leads through the bores in the armature while installing the armature on the shaft Checkthe keyway ofthe shaft and key ofthe armature for damage Install the armature retaining bolt and washer Feed the brush leads inside the stator housing up through the opening Secure the brush holder using the ori
84. e US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Netherlands B V 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 TP 6774 2 14a Introduction 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 beginning 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 x in 001 003 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 803315972 Jap
85. e 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 ship to shore transfer switch to prevent interconnection of the generator set power and shore power 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 volts and under TP 6774 2 14a Hot Parts A 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
86. e delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor total indicator reading tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer TP 6774 2 14a Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method 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
87. eeds the overvoltage setting for the preset time delay period The local display shows Volts L1 L2 L2 L3 orL3 L1 High Shutdwn See Figure 7 19 for overvoltage specifications Note Overvoltage can damage sensitive equipment in less than second Install separate overvoltage protection on online equipment requiring faster than 2 second shutdown Overvoltage Default Inhibit Time Delay Time Setting Figure 7 19 Overvoltage Specs Underfrequency The fault lamp flashes red and the unit shuts down when the frequency drops below the underfrequency setting The local display shows Frequency Low Shutdwn See Figure 7 20 for underfrequency specifications Underfrequency e Time Delay Time Default Setting 90 of nominal Figure 7 20 Underfrequency Specs Undervoltage The fault lamp flashes red and the unit shuts down when the voltage drops below the undervoltage setting for the time delay period The local display shows Volts L1 L2 L2 L3 or L3 L1 Low Shutdwn See Figure 7 21 for undervoltage specifications Undervoltage Inhibit Time Delay Time Default Setting 8096 of nominal at 10 sec 10 sec 10 sec Figure 7 21 Undervoltage Specs TP 6774 2 14a 7 10 7 Status and Notice Digital Displays Warnings and shutdown faults appear on the digital display and become part of the event history Beyond the warnings and shutdowns there are several events which also appear on the digital display Status i
88. entered GenSet Information GenSet gt Genset M N Information HH Y GenSet S N HH S N 7 13 6 GenSet Run Time Displays the generator set s operating record including total run time loaded and unloaded number of starts and total energy kW hours GenSet Run Time GenSet gt gt Eng Runtime Run Time h Eng Starts Next Maint Hg h Since Maint Starts 7 13 7 GenSet System Display shows the generator set system data Use the values entered in this menu to help determine shutdown values and time delays The programming user defines the data shown in the GenSet System menu It is NOT data measured by the controller and associated sensing devices The programming user defines these values for purposes of calibrating the control Some alternators are designed to operate at limited voltage frequency or phase connections and asa result some settings may have limited parameters TP 6774 2 14a Display for Measurement System is user selectable as English or Metric Contrast display is user adjustable to help improve digital display visibility in dimly lit rooms or in direct sunlight Note The contrast feature is a controller hardware change and may not be available on older units even if the firmware is updated To enable editing of GenSet System parameters 1 At the GenSet System menu pre
89. er cover plate Advanced Digital Control Ild GRD lead connection Battery charging module shown removed from inside of the LO lead connection junction box Cable connector Figure 7 1 Advanced Digital Control 1 4 ADC Ild and Junction Box Detail TP 6774 2 14a Section 7 Controller 43 7 2 General Repair Information This section contains ADC lld controller repair information Service replacement of the controller is limited to the items shown in Figure 7 2 Refer to the respective parts catalog for service part numbers No other replacement service parts are available Before replacing the controller remove all external accessories and other electrical connections to verify that these items are not the cause of the controller problems Verify that the accessories and connections Decal Adjustment knob Controller bezel Protective boot Plastic tapping screw qty 6 Circuit board control Plastic tapping screw qty 6 Figure 7 2 Advanced Digital Control 14 ADC 11 44 Section 7 Controller are functioning correctly before reconnecting them to the new controller Go to the Overview Menu and verify that the Software SW Version is correct for the generator set model and alternator voltage See Section 7 13 2 or the respective operation manual for details regarding accessing the Overview Menu Use SiteTech software for updating the control
90. esistance 1 4 2 5 3 6 7 10 8 11 9 12 ohms 55 66 ohms TP 6774 2 14a Section 1 Specifications 15 1 5 Service Views p oi 24 23 22 21 20 19 18 32 Non Service Side View 30 33 34 gs o m 9 Battery charging module ADC Ild controller USB port Nameplate on top of controller Fuses F1 F2 and AC circuit breaker panel Closed breather Battery positive connection Seawater pressure switch Coolant fill coolant overflow tube Seawater inlet Fuel solenoid Fuel filter Seawater pump Oil check dipstick Fuel return Coolant overflow bottle Oil drain valve Oil fill Fuel feed Figure 1 2 Service Views Typical 8 16 Section 1 Specifications ADV7942 A Fuel inlet Oil filter Customer load lead connection Alternator cooling air inlet V belt Belt guard Battery negative connection Seawater drain Engine coolant drain Coolant temperature sensor
91. for continuity Alternator excitation failure Inspect the brushes 6EKOD 5EFKOD and check the FN and FP connections Contact an authorized distributor dealer for service Aux Input Shutdwn Auxiliary fault input shutdown Note Input from a customer supplied switch that closes when the fault is active Digital input Auto fault start delay ECM start starting aid cranking crank pause post starting aid running cooldown Switch closes shorted to ground Check the cause of the auxiliary fault Check the condition and operation of the customer supplied equipment connected to the auxiliary fault input Coolant Temp High Shutdwn High coolant 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 Analog input Post starting aid running cooldown Coolant temperature at or above 110 C 230 F Check for a low engine coolant level Check seawater pump impeller strainers and seacock Eng Speed High Shutdwn High engine speed shutdown occurs if the engine speed exceeds the default setting Frequency over AC voltage Post starting aid running cooldown Engine speed exceeds 115 of the rated speed Check the engine governing system Contact an authorized distributor dealer for service if problem conti
92. for leaks 11 Stop the generator set and repair leaks or replace components as necessary 5 8 Belt Tension 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 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 Check the belt tension at the interval specified in the service schedule If tension is not within the specification adjust as necessary using the following procedure TP 6774 2 14a Seawater pump adjusting screw Seawater pump pulley Check the seawater pump belt deflection tension here Crankshaft pulley Pivot screw Belt guard Figure 5 21 Belt Tension 5 81 Seawater Pump Belt Tensioning Procedure 1 Remove the belt guard See Figure 5 21 2 Check the belt tension at the midpoint of the longest span of the belt by pressing with your finger approx 10 kg 22 Ibs of force See Figure 5 22 for belt deflection Recheck a new belt tension after 10 minutes of operation Deflection mm in 10 0 4 Figure 5 22 Belt Specification Note If the belt tension is not within specification go to step 3 If the belt tension is within spe
93. ginal screws Remove the brush retainer and check alignment See Section 8 6 6EKOD 5EFKOD Model Replace the brush cover gasket and install the brush holder cover 9 11EKOZD and 7 9EFKOZD Models Use screws and lock washers to install the rotor leads to the rectifier board at the positive and negative terminals Note Position the lock washers against the rectifier board 9 11EKOZD and 7 9EFKOZD Models Position the field leads at the top Install the exciter field using four bolts and washers See Figure 9 17 Note Use cable tie s to restrain loose harness leads from entangling in rotor GM73474 A 1 Screws 4 2 Exciter field Figure 9 17 Installing Exciter Field TP 6774 2 14a 14 15 16 17 18 19 20 21 22 23 24 25 26 Remountthe junction box on the four vibromounts Reconnect the AC lead connections and the P4 connector to the battery charging module Reconnect the connectors to the preheat relays Reconnect the leads to the fuses Reconnect the LO and GRD lead connections Reconnect the generator output leads to the circuit breakers Note Checkthe generator set nameplate to verify the original voltage configuration Replace the junction box controller panel Reconnect the P1 35 pin and P2 8 pin connectors to the ADC 11 controller Reinstall the ADC 11 controller Reconnect all of the external connections the exhaust line
94. he alternator end and place a wood block under the locator plate Lower the alternator until the wood block supports the backplate See Figure 9 9 Remove the four overbolts from the end bracket 1 Lifting eye 2 Backplate 3 Wood block 4 Vibromounts Figure 9 9 Supporting the Generator Typical TP 6774 2 14a 32 Install a sling capable of handling the weight of the stator housing on the stator housing See Figure 9 10 1 Sling 2 Fan guard 3 Two jaw puller Figure 9 10 Stator Assembly Removal 33 34 35 36 37 Use a two jaw puller to pull the end bracket stator assembly from the bearing on the rotor shaft See Figure 9 10 Remove the stator assembly from the rotor Remove or rotate the fan guard if necessary to clear the vibromounts Mark the fan s position on the rotor drive disc assembly with a permanent marker Remove the rotor fan assembly from the engine flywheel by removing the six nuts and stud See Figure 9 11 Clamp the rotor in a soft jaw vise Remove the six bolts and remove the drive disc assembly from the rotor See Figure 9 12 TP 6774 2 14a GM73473 A 1 Bolts 6 2 Rotor assembly Figure 9 11 Rotor Fan Assembly GM73473 A 1 Rotor 2 Drive disc 3 Bolt Figure 9 12 Drive Disc Section 9 Generator Disassembly Reassembly 97 9 2 Collector Ring and Bearing Replacement GEKOD 5EFKOD Model 1 Unsolder the collect
95. he controller holds the red LED for 5 seconds followed by a sequence of flashes that represents the status code 1 flash forced into bootloader 2 flashes no application software 3 flashes application code is invalid 4 flashes RAM check failure 5 flashes reformatting flash See an authorized Kohler distributor dealer Figure 7 7 Possible LED Status Indicator Displays A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected 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 48 Section 7 Controller 7 5 2 Starting the Generator Set The following procedures describe the actions required to start the generator set 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
96. he nominal voltage 12 VDC for more than 6 seconds during the crank cycle The local display shows Lo Crank Vit Warning Low Oil Pressure The fault lamp illuminates green then red when the engine oil pressure approaches the shutdown range The low oil pressure warning does not function during the first 11 seconds after startup The local display shows Press Low Warning Section 7 Controller 61 7 10 6 System Fault Shutdown Lamp With Digital Displays The system FAULT lamp flashes red and the unit shuts down to indicate a fault shutdown under the following conditions See Section 7 10 2 Controller Resetting procedure for information on resetting a system shutdown Note Text shown in italics in this section of the manual represents digital display messages AC Sensing Loss The fault lamp flashes red and the unit shuts down when the controller does not detect the nominal generator set AC output voltage for more than seconds after crank disconnect The controller displays AC Sens Loss Low Shutdwn Auxiliary Input Shutdown The fault lamp flashes red and the unit shuts down when an auxiliary inputs signals the controller Use SiteTech software to define inputs as shutdowns The local display shows Aux Input Shutdwn Engine Over Speed The fault lamp flashes red and the unit shuts down immediately when the governed frequency on 50 and 60 Hz models exceeds the over speed setting The local display shows Eng Speed High
97. hmmeter 5 Check the exciter field resistance by connecting an Frame connection ohmmeter across exciter field FN and FP leads Exciter armature See Figure 8 4 See Section 1 Specifications for vd us the resistance reading of a cold exciter field A low Main field roton reading indicates an internal short and a high Figure 8 5 Megohmmeter Connections on the reading indicates an open winding Repair or Exciter Field replace the exciter field if the ohmmeter readings indicate an inoperative exciter field refer to Section 9 for removal If the resistance test is inconclusive perform a megohmmeter test on the exciter field as described in the next step ADC Ild Ohmmeter Exciter field Exciter armature Main field rotor Figure 8 4 Exciter Field Resistance Test 6 Check the exciter field for a short to ground condition Use a megohmmeter to apply 500 volts DC to the FN or FP lead and the exciter field frame See Figure 8 5 Follow the megohmmeter manufacturer s instructions for using the TP 6774 2 14a Section 8 Component Testing and Adjustment 75 8 4 Exciter Armature 9 11 20 and 7 9EFKOZD Models The exciter armature supplies excitation current to the generator main field through the rectifier module Test the exciter armature as described in the following steps Exciter Armature Test Procedure 1 Di
98. hutdwn x x High battery voltage Battery High Warning x x High coolant temperature Coolnt Temp High Warning x x High coolant temperature Coolnt Temp High Shutdwn x x High exhaust temperature Exh Temp High Shutdwn x x Low battery voltage Battery Low Warning x x Low seawater pressure Sea Pressure Low Shutdwn Low cranking voltage Lo Crank VIt Warning X X Low oil pressure Oil Pres Low Warning X X Low oil pressure Oil Pres Low Shutdwn Overcrank Over Crank Shutdwn x X General Functions Aux inputs 0 5 VDC 1 analog Aux Input Shutdwn X Backup parameters loaded Backup Pars Status 5 Engine start delay active Start Delay Notice N Engine started Engine Start Status 5 x Engine stopped Engine Stop Status 5 Generator running Gen Running Notice N x Remote start Remote Start Status 5 System ready System Ready Status 5 System timer failed Timer Error Notice N x Generator Functions AC sensing loss AC Sens Loss Warning X X AC sensing loss AC Sens Loss Low Shutdwn Locked rotor failed to crank Locked Rotor Shutdwn x x Overfrequency Frequency High Shutdwn X X Overvoltage each phase Volts xx xx High Shutdwn Underfrequency Frequency Low Shutdwn x x Undervoltage each phase Volts xx xx Low Shutdwn x x Some functions require optional input sensors or are engine ECM dependent on some generator set models 54 Section 7 Controller TP 6774 2 14 7 6 Communication Port The main logic circuit board contains a
99. ier module Figure 8 6 Exciter Armature Ohmmeter Test TP 5983 7 5 Shaft connection 6 Armature 7 Exciter field 1 Main field rotor 2 Stator windings 3 Rectifier module 4 Megohmmeter Figure 8 7 Megohmmeter Connections on Exciter Armature TP 6774 2 14a 8 5 Slip Rings GEKOD 5EFKOD Models Slip rings acquire a glossy brown finish in normal operation Do not attempt to maintain a 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 notuse 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 ofthe slip ring surface material 8 6 Brushes 6EKOD 5EFKOD Models The brushes transfer current from the ADC Ild 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 controller Weak springs damaged slip rings sticking brushes a loose brush holder or poor brush contact causes arcing The brushes must be free to move within the holder and be held in contact with the slip rings by the springs When correctly positioned spring pressure on the brush surface causes the brush t
100. ilter with fresh fuel oil Thread the filter on the adapter until the gasket makes contact hand tighten the filter an additional one half turn Wash hands after any contact with fuel oil 8 Open the fuel supply valve 9 Reconnect the generator set engine starting battery negative lead last 10 Bleed the system See Section 4 2 1 Fuel System Bleed GM74543 B Fuel filter adapter Fuel filter Removal counterclockwise Installation clockwise Figure 4 2 Spin On Fuel Oil Filter Section 4 Fuel System 23 4 2 41 Fuel System Bleed Bleed air from the fuel system in order to reduce rough running or vapor lock Trapped air in the fuel system can cause difficult starting and erratic engine operation Prime the fuel system under the following conditions e Before starting the engine for the first time e After running out of fuel and adding fuel to the tank e After fuel system maintenance such as changing the fuel filter draining the fuel water separator or replacing a fuel system component Fuel System Bleed Procedure Preferred Note To prevent damage to the starter motor do not crank the engine to prime the fuel system Use the following procedure 1 Push the power button on the Advanced Digital Control Ild to the ON position 2 Whenthe run time hours appear on the LCD digital display rotate the pushbutton rotary selector dial until PUSH TO PRIME appears on the LCD digital display 3
101. ine voltage of L1 L2 and L3 is displayed Single phase configurations show the L1 L2 voltage Frequency Hz value displays for the output AC voltage Coolant Temperature diplays for the engine coolant temperature Oil Pressure displays the engine oil pressure Battery displays the DC voltage of the engine starting battery ies Engine Run Time displays the total run time hours Next Maintenance displaysthe next maintenance timer in hours Software Version displays in the Overview menu Use the version number to determine if an upgrade is needed and or when troubleshooting the controller Engine Metering Menu Engine Speed Tachometer displays the engine speed in RPM Oil Pressure displays the engine oil pressure This value also shows in the Overview Menu Coolant Temperature displays the engine coolant temperature This value also shows in the Overview Menu Battery displays the DC voltage of the engine starting battery ies This value also shows in the Overview Menu Section 7 Controller 51 Generator Metering Menu Volts displays the alternator output AC voltages The display shows all line to line and line to neutral voltage combinations for three phase or single phase configurations Frequency Hz value displays for the output AC voltage This value also shows in the Overview Menu Reset Calibration provides the means to reset the configuration values The calibration values are reviewable at al
102. ine block 23 Nm 17 ft Ibs Locator plate to engine block 23 Nm 17 ft Ibs Flywheel mounting bolts 80 Nm 59 ft Ibs Exciter armature to rotor shaft 38 Nm 28 ft Ibs Thermostat housing Exhaust manifold 25 Nm 18 ft Ibs Cylinder head Follow the numerical order shown in the diagram and tighten the bolts in 3 phases 18 phase 50 Nm 37 ft Ibs 2nd phase Rotate the wrench clockwise 90 3 9 phase Rotate the wrench again clockwise 90 TP 6774 2 14a 23 Nm 17 ft Ibs 9 Section 1 Specifications 17 5 18 Section 1 Specifications TP 6774 2 14a Section 2 Scheduled Maintenance 2 1 General WARNING Schedule routine maintenance using the service schedule located in the generator set operation manual and the runtime hours shown on the ADC llid If the generator set will be subject to extreme operating conditions service the unit accordingly Accidental starting Can cause severe injury or death Note See the generator set operation manual for the service schedule and other service not included Disconnect the battery cables before in this manual working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Note High mineral content seawater salt water can cause rapid destruction of metals Wipe up all salt water spillage on an
103. ing the following tests Stator Test Procedure 1 Place the generator master switch in the OFF position 2 Disconnect the generator set engine starting battery negative lead first 3 Check the generator outputlead connections See Section 10 Wiring Diagrams TP 6774 2 14a Figure 8 12 Alternator Stator Leads 4 Disconnect all the stator leads to isolate the windings To check the stator continuity set the ohmmeter on the R x 1 scale Check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 8 12 See Figure 8 13 for single phase and Figure 8 14 for three phase values Perform the stator tests on all the stator windings Continuity 1 and 2 1 and 11 2 and 11 4 3 and 44 4 and 44 55 and 66 1 and 3 4 44 55 or 66 2 and 3 4 44 55 or 66 3 and 1 2 11 55 or 66 4 and 1 2 11 55 or 66 Any stator lead and ground on stator housing or frame laminations Figure 8 13 Stator Continuity Test Results on a Good Stator 1 Phase Continuity 1and4 2and5 3 and 6 7 and 10 8 and 11 9 and 12 55 and 66 1and2 3 7 8 0r9 1 and 55 Any stator lead and ground Figure 8 14 Stator Continuity Test Results on a Good Stator 3 Phase Section 8 Component Testing and Adjustment 79 5 Check the cold resistance of the stator windings by connecting the meter leads to the stator leads as shown i
104. ing 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 Low Oil Pressure LOP Sender Disconnect the low oil pressure sender and use an ohmmeter to measure the resistance ofthe sender The sender resistances varies with pressures and should be within the values shown in Figure 8 24 Ifthe resistance is very low or very high replace the low oil pressure sender Non Service Side View 1 A T ADV7941B A o e e 1 Oil pressure sender Figure 8 23 Oil Pressure Sender Location 88 Section 8 Component Testing and Adjustment Resistance Ohms 0 240 42 5 10 5 100 33 5 10 5 7 5 NOMINAL RESISTANCE vs PRESSURE 138 20 275 40 413 60 552 80 689 100 51 343473 Figure 8 24 Oil Pressure Sensor Resistance Readings Seawater Pressure Switch See Figure 8 25 for the seawater pressure switch location Remove the seawater pressure switch and install a pressure gauge to verify tha
105. is menu allows the user to readily change controller voltage settings Note The generator set output leads require voltage reconnection See Section 8 11 for voltage reconnection With the generator set stopped go to the Volt Select menu Then push and hold the pushbutton rotary selector dial until the voltage selection starts to flash Volt selection is now available Scroll to the desired voltage and momentarily press the pushbutton rotary selector dial to confirm the voltage selection TP 6774 2 14a Volt Select Volt Select gt N Ph 120 240 V 1 Ph Y 120 208 V 3 Ph Y 139 240 V 3 Ph Y 277 480 V 3 Ph Y 120 240 V 3 Ph Y 115 230 V 1 Ph 120 V 1 Ph 230 V 1 Ph 240 V 1 Ph Y 110 190 V 3 Ph Y 127 220 V 3 Ph Y 115 230 V 3 Ph Y 230 400 V 3 Ph Y 240 416 V 3 Ph Section 7 Controller 71 7 13 12 USB Flowchart USB Stick Present Note Ignored until generator set stops running Push Rotate Push Y Knob Knob Knob USB SAVE gt CONFIRM gt CONFIRM Saving gt Save e PARAMS amp LOG SAVE NO SAVE YES complete Rotate Knob Skipped if Genset is Running Push Push Knob Knob USB LOAD Filename
106. ket Figure 9 5 6EKOD 5EFKOD Alternator Assembly Disassembly Reassembly Follow the general torque specification found in Appendix C of this manual unless noted above or in Section 1 6 Torque Specifications 94 Section 9 Generator Disassembly Reassembly TP 6774 2 14 ES 17 Note Use cable ties to restrain loose harness 15 leads from entangling in rotor 1 e 2 14 i eee CT 12 n SN 13 xe 10 GM73474 A Screws and washers Lock washer End bracket panel Washer Overbolts Torque to 23 Nm 17 ft Ibs Exciter armature Note Apply a thin coat of anti seize Washers compound to shaft surface before attaching exciter armature Screws Rotor assembly Exciter field assembly Stator assembly O ring Assemble O ring into groove in bearing insert Alternator air outlet guard and screw End bracket Lead screw lock washer and plain washer End bracket air inlet guard and screw Alternator fan 10 Screws Drive disk 11 Screws and lock washers Washers 12 Terminals Screws Torque to 45 Nm 34 ft Ibs 13 Rotating diode board Nuts 14 Spacers Studs Torque to 23 Nm 17 ft Ibs 15 Bolt Torque to 38 Nm 28 ft Ibs o o01 cm Figure 9 6 9 11EKOZD 7 9EFKOZD Alternator Assembly Disassembly Reassembly Follow the general torque specification found in Appendix C of this manual unless noted above or in Section 1 6 Torque Specifications TP 6774
107. l times and provide the calibration of the voltage sensing logic Changing the system voltage or replacing the circuit board requires a calibration adjustment To enable calibration start the generator set and select the Volts L1 L2 display Then push and hold the pushbutton rotary selector dial until the Calibration Enabled popup appears Calibration of each display is now available The display will show the following values for three phase generator sets Single phase generator sets will only display items marked Volts L1 L2 Volts L2 L3 Volts L3 L1 Volts L1 N Volts L2 N Volts L3 N The user can change individual values or can select Reset Calib Yes to reset all values The Reset Calib display will only show if calibration is enabled Refer to the requirements shown with Generator Set Calibration in 7 10 7 Status and Notice Digital Displays To disable calibration Rotate the pushbutton rotary selector dial until the popup appears Momentarily press the pushbutton rotary selector dial Stop the generator set if not already done Generator Set Information Menu GenSet M N displays the generator set model number GenSet S N displays the generator set serial number Controller S N displays the controller serial number 52 Section 7 Controller Generator Set Run Time Menu Engine Run Time displays the total run time hours This value also shows in the Overview Menu Engine Starts displays the t
108. ler application code GM82832 D Circuit board power Insulator Controller heatsink Plastic tapping screw qty 3 Pin header connector USB gasket USB plug TP 6774 2 14a 7 3 SiteTech Software The following items are necessary PC requirements for using the SiteTech software e SiteTech Software Version 3 0 or higher by accessing TechTools to download on your PC hard drive or disk if not already installed on your PC e TP 6701 SiteTech Software Operation Manual available by accessing TechTools e USB Cable with a male USB A connector on the PC side and a male standard B connector on the controller side 7 4 Controller Service Replacement Kit GM83745 If the troubleshooting procedures in Section 6 identify a faulty 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 battery voltage and communications settings Refer to Section 7 13 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 output voltage Ifthe output voltage or frequency needs adjus
109. level for more than 10 seconds The local display shows Battery High Warning Figure 7 16 shows high battery voltage specifications The high battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes Engine Electrical High Battery High Battery Voltage System Voltage Voltage Range Default Setting Figure 7 16 High Battery Voltage Specs High Coolant Temperature The fault lamp illuminates green then red maybe black when the engine coolant temperature approaches the shutdown range The high coolant temperature warning does not function during the preset inhibit time delay period after startup The local display shows Coolnt Temp High Warning TP 6774 2 14a Low Battery Voltage The fault lamp illuminates green then red maybe black when the battery voltage drops below a preset level for more than 90 seconds The local display shows Battery Low Warning See Figure 7 17 for low battery voltage specifications Engine Electrical Low Battery Low Battery Voltage System Voltage Voltage Range Default Setting 96 126 Figure 7 17 Low Battery Voltage Specs The low battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes The controller logic inhibits the low battery voltage warning during the crank cycle Low Cranking Voltage The fault lamp illuminates green then red when the battery voltage drops below 60 of t
110. low seawater pressure is detected Local display shows Sea Pressure Low Shutdwn Low Oil Pressure The fault lamp flashes red and the unit shuts down because of low oil pressure The shutdown occurs 10 seconds after the low pressure condition is detected The low oil pressure shutdown does not function during the first 15 seconds after startup The local display shows Oil Press Low Shutdwn Overcrank The fault lamp flashes red and cranking stops when the unit does not start within the defined cranking period The local display shows Over Crank Shutdwn See Section 7 5 2 Starting the Generator Set and Section 7 10 1 Status Event and Fault Specifications for cyclic crank specifications Note The controller is equipped with an automatic restart function When speed drops below 25 Hz 750 rpm while the engine is running the unit attempts to recrank The unit then follows the cyclic cranking cycle and when the engine fails to start will shut down on an overcrank fault condition Overfrequency The fault lamp flashes red and the unit shuts down when the frequency is above the overfrequency setting The local display shows Freq High Shutdwn See Figure 7 18 Overfrequency Overfrequency Ler Range Time Delay Default Setting 102 140 102 140 of nominal nominal 110 of nominal Figure 7 18 Overfrequency Specs TP 6774 2 14 Overvoltage Each Phase The fault lamp flashes red and the unit shuts down when the voltage exc
111. m 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 8 2 Aux winding F1 fuse blown Replace blown fuse If fuse blows again check stator Section 8 15 Section 8 9 Controller Check controller settings Check wiring and connections Section 7 13 Section 10 Open wiring terminal or pin in buildup circuit Check continuity Section 8 16 Section 10 Brushes GEKOD 5EFKOD models Inspect brushes and replace if worn Section 8 6 Check for brushes sticking in brush holder or broken brush spring Section 8 6 Rotor connections Check for open circuit in rotor connection circuit leads FN and FP Section 8 8 Section 10 Rotor slip rings dirty or corroded BGEKOD 5EFKOD models Check slip ring condition Section 8 5 Rotor open grounded or shorted windings Check voltage and continuity Section 8 8 Stator open grounded or shorted windings Check voltage and continuity Section 8 9 Noisy operation Exhaust system leaks Check and replace as necessary O M Engine not running smoothly See Operates erratically this table Broken or damaged vibromount s Check and replace as necessary Loose or vibrating sheet metal housing Retighten screws replace rivets Exhaust piping or air inlets outlets
112. n Figure 8 13 or Figure 8 14 See Section 1 Specifications for the stator resistance values Ifthe stator resistance test is inconclusive perform a megohmmeter test on the stator as described in the next step Note Consider the stator functional if the resistance reading continuity is low and there is no evidence of shorted windings heat discoloration Note When taking an ohmmeter reading using lead 55 make the connection before the in line fuse ADC s voltage regulator power supply leads Sensing leads 208 240 volts nominal Stator windings Main field rotor Rectifier module Frame connection Megohmmeter Armature Exciter field Note The stator resistance can vary directly with increased temperature If any of the stator readings vary during the previous checks replace the stator Figure 8 15 Megohmmeter Connections on 1 Phase 6 Check the stator for a short to ground condition Stator using a megohmmeter See Figure 8 15 for a single phase megohmmeter connections and Figure 8 16 for three phase megohmmeter connections Apply 500 volts DC to any stator lead from each winding and the stator frame Follow the megohmmeter manufacturer s instructions for Po using the megohmmeter Repeat the test on the 9 5 other leads until all of the stator windings have been tested A reading of 1 5 MOhms and highe
113. n rotary selector dial or buttons the menu is reset to the top of the main menus and auto paging activates for the Overview submenus Note Measurements display in metric or English units Use the Generator Set System menu to change the measurement display LED Status Indicator The LED provides asummary of the generator state Figure 7 7 shows the possible LED displays When two or more colors are shown the LED blinks between the two colors in 2 second intervals The 2nd and 3rd if any colors are shown for 100 ms each and the 1st color appears for the remainder of the time Section 7 Controller 47 LED Warning Engine Color s Controller Power Display Backlight Functional Operational Mode N A Black Off None Black Green Low Power Auto t Yes Stopped Black Green Red Low Power Auto N A Black Red Low Power Auto Stopped None EP Black Green No USB Powered Auto Yes Battery Powered Auto Running Green Yes Battery Powered Auto Running Green Red Yes Battery Powered Auto Stopped Black Green Red No USB Powered Auto Yes Battery Powered Auto Yes N A Stopped Black Red No USB Powered Auto Yes Battery Powered Auto Yes NOTE Under unique conditions the controller may not operate normally If this happens the controller uses the red LED to represent the status code To show the status code t
114. n schematics Follow all safety precautions at the front of this manual and in the text during reconnection procedure NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer Twelve Lead Reconnection Procedure 1 Move generator set master switch to OFF position 2 Disconnect engine starting battery negative lead first Disconnect power to battery charger if equipped 3 Use Figure 8 22 to determine generator set voltage configuration Note the original voltage and reconnect the generator set as needed GENERATOR CONNECTIONS 3 PHASE DELTA 12 WIRE 115 230 VOLT 50 HZ 120 240 VOLT 60 HZ 3 PHASE WYE 12 WIRE LOW WYE 190 208 VOLT 50 HZ 208 240 VOLT 60 HZ 3 PHASE WYE 12 WIRE HIGHWYE 0 380 416 VOLT 50 HZ 416 480 VOLT 60 HZ SINGLE PHASE 3 WIRE SOME SETS NOT RATED FOR SINGLE PHASE SEE MANUALS CT3 NOT USED C 115 230 VOLT 50 HZ 120 240 VOLT 60 HZ NOT USED iN SINGLE PHASE 2 WIRE MARINE ONLY TAPE INSULATE 7 FROM GROUND 230 VOLT 50 HZ 240 VOLT 60 HZ EM 250000 Note Current Transformers CTs are not used on all sets CT dot or toward generator Figure 8 22 Generator Reconnection 86 Section 8 Component Testing and Adjustment TP
115. ncy starts Any frequency below the setpoint causes the voltage to drop thus reducing the load allowing the engine speed to recover according to the underfrequency unload slope setting Engine speed recovery depends upon characteristics such as engine make fuel type load types and operating conditions underfrequency unload setting should match the engine speed recovery characteristics for the application Underfrequency Unload Slope This setting determines how much the voltage drops during an underfrequency condition Typically applying a large electrical load causes a dip in engine speed and frequency The voltage regulator reduces voltage allowing engine speed recovery The volts per Hz setting determines the amount of voltage drop Regulator Gain Regulator gain refers to the gain ofthe control system Generally the higher the gain the faster the system responds to changes and the lower the gain the more stable the system If the voltage is slow to recover when loads are applied or removed increase the regulator gain Ifthe voltage is unstable decrease the regulator gain Section 8 Component Testing and Adjustment 81 8 10 3 Voltage Regulator Displays the voltage regulator adjustment volt Hz gain and stability adjustment values The voltage regulator value is reviewable at all times and provides the ability to fine adjust voltage Changing the system voltage or replacing the circuit board typically req
116. nerator set and select the Volts L1 L2 display Then push and hold the pushbutton rotary selector dial until the Calibration Enabled popup appears Calibration of each display is now available The display will show the following values for three phase generator sets Single phase generator sets will only display items marked e Volts L1 L2 e Volts L2 L3 Volts L3 L1 Volts L1 N Volts L2 N Volts L3 N The user can change individual values or can select Reset Calib Yes to reset all voltage values The Reset Calib display will only show if calibration is enabled When calibrating voltage the metered value and the number being entered as the calibrated value must be within 1096 of the system operating voltage To disable calibration Rotate the pushbutton rotary selector dial until the popup appears 68 Section 7 Controller Momentarily press the pushbutton rotary selector dial Stop the generator set if not already done Generator Metering Generating gt Volts 11 12 gt Metering V Volts L2 L3 V Volts L3 L1 V Volts L1 N Volts L2 N Volts L3 N Frequency HH Hz Reset Calibration Reset Calib No OR Reset Calib Yes TP 6774 2 14a 7 13 5 GenSet Information Displays generator set and controller information Displayed data is factory
117. ng an oil change may result in damage anda shorter engine life Figure 2 1 shows the recommended Society of Automotive Engineers SAE viscosity designation for given operating temperature ranges 40 35 3025 201510 5 0 5 101520 25 30 35 40 45 50 SAE 10W SAE 20W SAE 30 SAE 40 SAE 10W 30 SAE 10W 40 SAE 10W 60 SAE 15W 40 SAE15W 40 SAE 20W 60 SAE 5W 30 Mineral base SAE Grade Semi synthetic base Synthetic base Figure 2 1 Engine Oil Selection 20 Section 2 Scheduled Maintenance TP 6774 2 14 3 1 Exhaust System Inspection A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use At the interval specified in the service schedule inspect the exhaust system components exhaust manifold mixing elbow exhaust hose hose clamps silencer and outlet flapper for cracks leaks and corrosion Ensure that the carbon monoxide detector s is 1 in the c
118. ng and fuses Check the controller settings and connections See Section 7 Controller TP563274 8 7 6 FN lead disconnected in step 1 FP lead disconnected in step 1 10 amp fuse DC ammeter 12V battery Exciter or brushes slip rings Rectifier module Main field rotor ONOaRWND Figure 8 3 Separate Excitation Connections TP 6774 2 14a 8 3 Exciter Field megohmmeter reading of approximately 1 5 MOhms and higher indicates the field winding 9 11EKOZD 7 9EFKOZD is functional A reading of less than approximately Models 1 5 MOhms indicates deterioration of the winding insulation and possible current flow to ground if so Direct current from the battery magnetizes the exciter replace the exciter field field When the exciter armature rotates within the magnetized exciter field windings an electrical current develops within the exciter armature Test the exciter field according to the following procedure Exciter Field Test Procedure 1 Press the start stop button to stop the generator set 2 Press the power button to turn the controller off 3 Disconnect the generator set engine starting battery negative lead first 4 Disconnect the FN FP leads ADC Iid Mego
119. nues Eng Speed Low Shutdwn Low engine speed shutdown occurs if the engine speed falls below the default setting Frequency over AC voltage Post starting aid running cooldown Engine speed falls below 85 of the rated speed Reduce the load Contact an authorized distributor dealer for service Exh Temp High Shutdown High exhaust temperature shutdown occurs if the engine exhaust temperature exceeds the default setting Digital input Auto fault start ECM start starting aid cranking crank pause post starting aid running cooldown Switch closes shorted to ground Check the wiring to the sensor Check for a clogged seawater intake or sea strainer Check for a damaged seawater pump impeller Check the exhaust system see the operation manual Frequency High Shutdwn Overfrequency shutdown occurs when the governed frequency exceeds the default setting of the system s frequency setpoint TP 6774 2 14a Alternator output Post starting aid running cooldown AC frequency exceeds 110 of the systems frequency Check the engine governing system Contact an authorized distributor dealer for service if problem continues Section 7 Controller 57 Fault Shutdowns Code Description Sensing Mechanism State s Detected Inhibit Time Trip Point Check Frequency Low Shutdown Underfrequency
120. o Load To Load Kraus Naimler American Solenoid Newer Round Design 2 Wire Generator Sets 3 Wire Generator Sets LI Generator 5 3 1 To Shore Set Power To Generator 5 To Shore Set Power Y Y aT To Load To Load TP 5399 5 TP 6774 2 14a Section 10 Wiring Diagrams 107 10 3 Manual Marine Ship to Shore 4 Wire Transfer Switch Kraus Naimer American Solenoid 4 Wire three phase Generator Sets To Generator To Shore Set Power L1 L2 L3 LO To Load 108 Section 10 Wiring Diagrams TP 6774 2 14a Appendix A Abbreviations The following list contains abbreviations that may appear in this publication approx AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CAN CARB CB cc CCA CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour 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 Air Pollution Control District American Petroleum Institute approximate approximately Air Quality M
121. o wear evenly The entire brush must ride on the ring or arcing occurs and causes burned rings or voltage regulator failure Figure 8 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 TP 6774 2 14a T LJ Front View Side View TP5867 Brush holders 2 Brush holder Slip ring Correctly positioned Brush brush Retainer wire Incorrectly positioned Shim brush Spring Figure 8 8 Brush Assembly Section 8 Component Testing and Adjustment 77 8 7 Rectifier Module 9 11 20 and 7 9EFKOZD Models The rectifier module located between the exciter armature and the main field converts AC from the exciter armature to DC which magnetizes the generator main field Test the rectifier module as described in the following steps Rectifier Module Test Procedure 1 Disconnect the exciter armature and the main field leads from the rectifier module 2 Use anohmmeter on the R x 100 scale to check the resistance between all the rectifier diodes as shown in Figure 8 9 The ohmmeter should showa low resistance in one direction and upon reversing the ohmmeter leads a high resis
122. oled exhaust manifold and an exhaust mixer See Figure 5 1 for cooling system components lt Seawater lt Freshwater Coolant Antifreeze Engine block Intake strainer customer supplied Thermostat inside thermostat assembly Water cooled manifold Engine driven water pump Exhaust mixer elbow Engine driven seawater pump Heat exchanger located inside manifold Seawater strainer customer supplied Silencer customer supplied Seacock customer supplied Exhaust outlet customer supplied Figure 5 1 Cooling System Components TP 6774 2 14a Section 5 Cooling System 27 A 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 Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank NOTICE Saltwater damage Saltwater quickly deteriorates met
123. on program updates See Section 7 13 2 for instructions to check the version number of the controller s application program and for more information on updating the application program 6 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 1 refers to the Installation Manual and S M refers to the Service Manual Section 6 Troubleshooting 37 Troubleshooting Chart Problem Generator set does not crank Possible Cause Weak or dead battery Corrective Action Recharge or replace battery Reference Generator O M Battery connections Check for reversed or poor battery connections Open circuit in engine controller connections Check for loose connections Check the wire harness continuity Section 10 Blown F2 fuse Replace fuse if fuse blows again check circuit and components Check the controller wiring Check the starter solenoid for a stuck solenoid Check wiring for open grounds or loose connections Also check for pushed out pins Section 8
124. ondition by using a megohmmeter Apply 500 volts DC to either field lead and the main field frame Follow the megohmmeter manufacturers instructions for using the megohmmeter See Figure 8 11 A reading of 1 5 MOhms and higher indicates the main field is functional A reading of less than 1 5 MOhms indicates deterioration of the winding insulation and possible current flow to ground if so replace the main field TP 6774 2 14a 5983 7 5 Rectifier module 6 Megohmmeter 7 Armature 8 Exciter field 1 Main field rotor 2 Stator windings 3 Frame connection 4 Shaft connection Figure 8 11 Megohmmeter Connections on Main Field 8 9 Stator The stator consists of a series of coils of wire laid in a laminated steel frame The stator leads supply voltage to the AC load and exciter regulator Before testing the stator inspect it for heat discoloration and visible damage to the housing lead wires and exposed and varnished areas of the frame laminations Be sure the stator is securely fastened in the stator housing The stator produces electrical output AC as the magnetized main field rotates within the stator windings Test the condition of the stator according to the following procedure Leads 1 2 3 and 4 are the generator output leads Leads 55 and 66 are the voltage regulator supply and sensing leads Refer to the schematic in Figure 8 12 when perform
125. oolant temperature Low battery voltage Low cranking voltage Low oil pressure 50 Section 7 Controller System Shutdown Fault Lamp Red lamp indicates that the generator set has shut down because of a fault condition The unit will not start without resetting the controller see Section 7 10 2 Controller Resetting procedure See Section 7 10 6 System Fault Shutdown Lamp with Digital Displays for definitions of the items listed The following conditions cause a system shutdown AC sensing loss Auxiliary input analog or digital Engine over speed Engine under speed High coolant temperature High exhaust temperature Locked rotor failed to crank Low seawater pressure Low oil pressure Overcrank Overfrequency Overvoltage each phase Underfrequency Undervoltage each phase TP 6774 2 14a 7 5 5 Digital Display The generator set must be running for some displays to indicate values If the generator set is not running some values will display zero or N A not available The 12 character 2 line backlit alpha numeric display provides generator set and engine data system status and fault information See Figure 7 6 The digital display shows abbreviations in some instances refer to Section 7 10 1 Status Event and Fault Specifications for the abbreviations and their full descriptions Note US Metric Unit Display is selectable in Generator Set System Note After about 5 minutes of no user input pushbutton
126. or push and hold the pushbutton rotary selector dial until the Editing Enabled popup appears Editing of the voltage adjustment is now available The user can change the individual value or can select Reset VR Yes to reset to the default value The Reset Settings display will only show if editing is enabled To disable calibration Rotate the pushbutton rotary selector dial until the Return popup appears Momentarily press the pushbutton rotary selector dial Stop the generator set if not already done Voltage VR Volt Adj Regulator XXX X VR Volt Hz XXX X VR Gain XXX X VR Stabil XXX X R VR d Reset VR eset ese 7 User Selectable gt Settings No OR Reset VR Yes 7 13 9 Event Log Displays up to 1000 stored status warning and shutdown events After the first 1000 events each additional new event replaces the oldest event See 7 5 6 Controller Fault Diagnostics for a list of possible events 70 Section 7 Controller Event Log Event Log gt HHHHH Message Text Scroll through up to 1000 max stored events TP 6774 2 14 7 13 10 Prime Menu This menu if confirmed allows the user to initiate the electric fuel pump to prime the fuel system Prime the Fuel System Push To Prime gt Confirm Prime Yes Y OR Confirm Prime No 7 13 11 Volt Select Th
127. or ring leads from the collector ring terminals 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 5 Align the collector ring keyway with the keyway on the rotor shaft See Figure 9 14 6 Press the new collector rings onto the rotor shaft Note The new collector rings must be turned down to a finish of 32 micro inches using a lathe and commutator stones Turn down the collector rings on the rotor shaft 7 Solder the leads onto the collector ring terminals Bend over terminal and insulate with heat shrink tubing Terminal and insulator not to extend more than 6 4 mm 0 25 in beyond collector ring See Figure 9 14 8 Test to ensure continuity at the collector rings 32 micro inches 0 08 0 003 0 01 0 0002 Mex finish Max eccentricity mm in Max out of round mm in Figure 9 13 Collector Ring Dimensions PRESS COLLECTOR RINGS ONTO ROTOR SHAFT SHOULDER IN 5 POSITION COLLECTOR RING TERMINALS CHIDDEN LINES CONNECTION END VIEW RN MAXIMUM ALLOWABLE GAP BETWEEN FAN HUB BEARING amp SHAFT SHOULDER IS 0 25 0 0101 GM71834 A 1 Collector ring Figure 9 14 Rotor Assembly 98 Section 9 Generator Disassembly Reassembly 9 3 Reassembly 1 Clamp the rotor in a soft jaw vise Install a new drive disc and fan on the rotor Tighten the six bolts to 45 Nm 34 ft Ibs See Figur
128. ortion of the glow plug and crank the unit If the tip of the glow plug glows the glow plug is good Starts but shuts down Fault shutdown 38 Section 6 Troubleshooting Check for a fault shutdown code on the controller s display Correct the fault and then reset the controller Section 7 10 1 Section 7 10 2 Section 8 14 TP 6774 2 14a Problem 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 7 10 1 Section 7 10 2 Section 8 14 No fuel Check the fuel supply Fuel line restriction Inspect fuel lines and fuel filter for blockage Blown controller fuse F2 Replace fuse Check wiring to the controller Section 8 15 Section 10 Blown auxiliary winding fuse F1 Replace fuse If fuse blows again test generator components Section 8 15 Section 10 Engine overheated hot engine only Check air intake fuel oil level air inlet outlet O M and 1 Low oil pressure LOP sender Attempt startup Shutdown should say Oil Pres Low Shutdwn if unit shuts down remove the lead from the LOP sender and reset the controller A successful restart attempt indicates a faulty LOP shutdown sender Note Check the engine oil pressure before performing the test and or replacing the LOP shutdown sender Section 8 14 2
129. ostat Assembly 11 Loosen the rear cover screws See Figure 5 8 Figure 5 5 Exhaust Mixer s Mounting Nuts 6 Loosen any hose clamps 7 Remove the exhaust mixer 8 Loosen the front cover screws See Figure 5 6 Figure 5 8 Rear Cover of Heat Exchanger 12 Remove the heat exchanger tube See Figure 5 9 Figure 5 6 Front Cover of Heat Exchanger 9 Remove the front cover and O ring 10 Loosen the thermostat assembly s mounting screws and remove the thermostat assembly See Figure 5 7 Figure 5 9 Heat Exchanger Tube TP 6774 2 14a Section 5 Cooling System 29 13 Dip the heat exchanger tube into a solution of 16 Reassemble the O ring and front cover and tighten 90 water and 10 hydrochloric acid Use gloves the screws See Figure 5 12 and Figure 5 13 and goggles 14 Rinse the heat exchanger tube in clean water See Figure 5 10 Figure 5 10 Rinse Heat Exchanger Tube Note Replace any damaged O rings seals and or thermostat valve seals 15 Reinstall the heat exchanger tube and O rings See Figure 5 11 Figure 5 13 Tighten the Front Cover Screws 17 Fit the circlip and flange back into position See Figure 5 14 Figure 5 11 Reinstall Heat Exchanger Figure 5 14 Heat Exchanger s Circlip 30 Section 5 Cooling System TP 6774 2 14 18 Reassemble the O ring and rear cover and tighten the screws See Figure 5 15 Figure 5 15 Rear Cover of Heat Exchanger 19 Replace the the
130. otal number of generator set startup events Next Maintenance displays the next maintenance timer The maintenance interval for the ADC lld is 250 hours Generator Set System Menu The values in this menus are user entered for the generator set configuration and are NOT measured values of the generator set System Frequency displays the programmer entered L1 L2 L3 output voltage frequency for three phase or the L1 L2 output voltage frequency for single phase Battery Voltage displays the engine electrical system 12 or 24 volts CAN A displays the remote communication s protocol in use J1939 SmartCraft or NMEA 2000 Note After changing the CAN A communication setting power off and then power on the controller Measure Units displays the user selected unit of measure as Metric or English Contrast displays user selected resolution values to improve digital display clarity Voltage Regulator Menu The voltage regulator value is reviewable at all times and provides the ability to fine adjust voltage Changing the system voltage or replacing the circuit board typically requires a voltage adjustment To enable calibration start the generator set and select the VR Volt Adj Volt Hz Gain or Stabil display Then push and hold the pushbutton rotary selector dial until the Editing Enabled popup appears Editing of the Voltage Adjustment Volts Hz Gain and Stability is now available The user can change the individual
131. otice Section 7 Controller 63 Generator Set Calibration User Defined This selectable display is in the GenSet Metering Menu allowing the user to calibrate the controller and generator set Use the pushbutton rotary selector dialto navigate and select this feature Changesto this display must be done with the generator setrunning The local display shows Enter calib No or Yes Select No to make no change Select Yes to calibrate the following values e Volts L1 L2 x x V e Volts L2 L3 x x V e Volts L3 L1 x x V e Volts L1 N x x V e Volts L2 N x x V e Volts L3 N x x V The user can individually calibrate the values above or resetall ofthem Thelocal display Resetall calib No or Yes Select No to make no changes and exit GenSet Calibration Select Yes to reset all of the values When calibrating voltage the metered value and the number being entered as the calibrated value must be within 1096 of the system operating voltage Measurement Units User Defined This selectable display is in the GenSet System Menu allowing the user to choose between Metric and English displays Usethe pushbutton rotary selector dial to navigate and select this feature Changes to this display can be done with the generator set running or stopped The local display shows Meas Units Metric or Meas Units English Remote Start This status indicates that the generator set start circuit was closed from a remote location allowing the engine to
132. ounding 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 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 TP 6774 2 14a 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 Electrical backfeed to the utility Hazardous backfeed voltag
133. own 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 from the load See the safety precautions at the beginning of this manual before proceeding 2 Identify and correct the cause of the fault shutdown See the safety precautions at the beginning of this manual before proceeding Refer to Section 6 Troubleshooting 3 Use the Advanced Digital Control s pushbutton rotary selector dial to select the Overview Page 4 When the Overview page appears press the pushbutton rotary selector dial to view the active fault Press the pushbutton rotary selector dial again and then use the pushbutton rotary selector dial to CONFIRM CLR FAULT YES to clear the fault 5 Push the pushbutton rotary selector dial 6 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 7 Shut the generator off by pressing the generator set start stop to the STOP position 8 Reconnect the generator set to the load 7 10 3 Voltage Regulator and Calibration Specifications The controller has a voltage regulation function that is internal to the processor This means that no external voltage regulator is necessary The voltage regulation of the controller uses root mean squ
134. p Figure 5 18 Pressure Cap Location 32 Section 5 Cooling System 5 7 Impeller Inspection and Replacement The belt driven seawater pump is located on the service side of the generator set Check and change the seawater pump impeller at the interval specified in the service schedule Follow the instructions included with the impeller kit If the instructions are not included with the kit use the following procedure Impeller Inspection and Replacement Procedure 1 Close the seacock 2 Remove the seawater pump coverplate See Figure 5 19 Seawater pump 6 Impeller Pulley 7 Gasket Ball bearing 8 Cover plate Seal 9 Key Ceramic seat Figure 5 19 Seawater Pump Typical 3 Remove the impeller 4 Inspect the impeller for damage including cracks broken or flattened vanes See Figure 5 20 The impeller vanes should be straight and flexible 1 Flattened vane 2 Crack 3 Broken vane Figure 5 20 Worn Impeller 5 Lubricate the impeller with soapy water before installation TP 6774 2 14a 6 While installing the impeller always rotate the drive shaft and the impeller together in the same direction as the engine rotation 7 Inspect the coverplate and gasket for corrosion and or damage Replace components as necessary 8 Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing 9 Open the seacock 10 Start the generator set and check
135. per hour military standard millisecond meters per second mean time between failure 110 Appendix MTBO mtg MTU MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA 02 pF PF ph 2 PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH RHM rly mean time between overhauls mounting Motoren und Turbinen Union 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 screw 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 squa
136. peration Battery Low Warning Low battery voltage warning The fault condition clears when the battery voltage returns to a voltage within the limits Analog input Auto fault start delay start starting aid cranking crank pause post starting aid running cooldown Battery voltage is at or below 10096 of the nominal system voltage 12 V Check the battery rating and condition Charge or replace the battery Check the battery charger operation Coolnt Temp High Warning High coolant temperature warning Post starting aid running cooldown Coolant temperature at or above 105 C 221 F Check for a low engine coolant level Check seawater system for reduced flow NOTE Allow the generator set to cool down before checking Low Crank Vit Warning Low cranking voltage warning Analog input Cranking Battery voltage drops below 60 of the nominal system voltage 12 V Check the battery rating and condition Charge or replace the battery Oil Pres Low Warning Low engine oil pressure warning Post starting aid running cooldown Figure 7 15 Advanced Digital Control Warnings TP 6774 2 14a At or below 138 kPa Check for leaks in the lubrication system Check the oil level and add oil if the level is low Section 7 Controller 59 7 10 2 Controller Resetting Following System Fault Shutd
137. quency settings Adjust the engine governor speed Troubleshoot the engine Section 8 10 Section 4 4 Engine S M Light flicker Voltage stability gain setting Check and adjust the voltage stability gain setting using the ADC Section 8 10 High output voltage Incorrect controller configuration Check and adjust the controller configuration settings Section 7 13 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 8 10 Engine speed too high Check the engine speed using tachometer or frequency meter Adjust the governor as necessary Section 4 4 Loose voltage sensing connections Check connections stator leads 11 and 44 for 1 phase models or leads V7 V8 and V9 for 3 phase models and P2 controller connection Section 8 9 Section 10 Controller 40 Section6 Troubleshooting Check fuses wiring and connections Section 7 Section 10 TP 6774 2 14a Problem No output voltage Possible Cause AC output circuit breaker open Corrective Action 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 Reference Alternator or control system Perfor
138. quipped 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 10 during reassembly Disassembly Procedure 1 Press the start stop button to stop the generator set 2 Press the power button to turn the controller off 3 Disconnect power to the battery charger if equipped 4 Disconnect the generator set engine starting battery negative lead first A WARNING aS 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 TP 6774 2 14a Sound Shield Equipped Models For access to the generator set to perform regular maintenance remove the sound shield doors and roof 5 Sound Shielded Models Open the service side door 6 Sound Shielded Models Release the two wing nuts located underneath the roof See Figure 9 1 7 Sound Shielded Models Lift up the roof 8 Sound Shielded Models Slide the roof towards the service side of the unit for removal 9 Sound Shielded Models Open the front rear and non service si
139. r avv 2 24 vv 14 24 99 ANO vis vis 99 14 366 VIS vis 1f SNOILOdJNNOO Zd 8 L 9 8 2 l 8 1115 vis vis 1119 1115 vis 5 L 6A 1 M 99 di NJ 1 8 64 4 SNOILOSNNOO Gd 6 64 304 6 214 dod 2 802 14 02 v 9d voz 4 64 201 12225 M 149 149 cM 304 ZM 65 Id L 8 89 8 99 N M ZN 14 S Wf Nid SNOILOSNNOO 8d 1227 22 29 89 SN 8 62 14 48 V Nid SNOILO3NNOO Sd SNOILO3NNOO d 449 249 d9 49 4549 edo doz 55 zd f SNOIIOJNNOO Zld 1 Lit Nid 4 CYLINDER ONLY 8 voL vf SNOILOJNNOO 94 QS 64 9d s zid go c3 i em 61 19 91 19 8 14 im 81 14 N33H9 NY9 91 19 MOTI3A TBA 1 Nid 83101500 SNOUO3NNOO 6
140. r indicates the stator is functional A reading of less than 1 5 MOhms indicates deterioration of the winding insulation and possible current flow to ground if so repair or replace the stator ADC s voltage regulator power supply leads Sensing leads 208 240 volts nominal Stator windings Main field rotor Rectifier module Frame connection Megohmmeter Armature Exciter field Figure 8 16 Megohmmeter Connections on 3 Phase Stator 80 Section 8 Component Testing and Adjustment TP 6774 2 14a 8 10 Voltage Regulator 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 contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment 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 po
141. r Disassembly Reassembly 91 9 1 DisassemDly eere Dese RAE Od UR 91 9 2 Collector Ring and Bearing Replacement GEKOD 5EFKOD Model 98 9 3 Reassembly ii Rb E Ru ERR ERE Ma EX 98 4 Table of Contents TP 6774 2 14a Section 10 Wiring Diagrams hide weds eh pee 101 10 1 Wiring Diagram Reference 101 10 2 Manual Marine Ship to Shore 2 Wire and 3 Wire Transfer Switches 107 10 3 Manual Marine Ship to Shore 4 Wire Transfer Switch 108 Appendix A Abbreviations etre pete ud XR prete eee ee RU a s 109 Appendix Common Hardware Application Guidelines 111 Appendix C General Torque Specifications 112 Appendix Common Hardware 113 Appendix E Common Hardware 5 114 TP 6774 2 14a Table of Contents 5 5 6 Table of Contents TP 6774 2 14a 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 opera
142. r assembly 3 Alternator end door 3 oh ae door 13 Mount the new controller assembly onto the 6 Engine end door junction box using the four 4 screws removed in step 9 Figure 7 3 Sound Shield Roof Removal 14 Reconnect the engine starting battery negative 9 Loosen and remove the four controller mounting lead last screws securing the controller and carefully lift the controller 15 Reconnect power to the battery charger if equipped Note Be careful of the leads and harness connected to the controller 16 Follow the instructions in Section 7 13 to change the new controller s configuration settings to match the generator set system voltage and frequency battery voltage and communications settings 17 Use avoltmeter to check the output voltage Follow the instructions in Sections 7 10 4 and 7 13 8 to adjust the output voltage and stability 18 Check the output frequency Follow the instructions in Section 4 4 Governor to adjust the output frequency 19 Place the generator set master switch in the AUTO position if an ATS or remote start stop switch is used 1 Controller mounting screws 4 ea 20 Replace the sound shield roof and door s if Figure 7 4 Controller Mounting Screws equipped 10 Note the connections on the back of the controller and then disconnect wiring harness plugs P1 35 pin plug and P2 8 pin plug from the ADC lld See Figure 7 5
143. r dial and the voltage selection option second line on the display will start to flash 84 Section 8 Component Testing and Adjustment 10 Turn the selector dial clockwise counterclockwise until the desired voltage selection option appears Press the selector dial The second line on the display will stop flashing and the new voltage will appear Disconnect the generator set engine starting battery negative lead first Disconnect power to the battery charger if equipped Use Figure 8 18 Figure 8 19 Figure 8 20 Figure 8 21 or Figure 8 22 to determine the generator set voltage configuration Note the original voltage and reconnect as needed Reconnect the battery negative lead last Start the generator set Check the digital display for correct voltages using Section 7 13 4 Generator Metering Stop the generator set after completing the voltage adjustments TP 6774 2 14a 8 12 Four Lead Reconnection The following information illustrates the reconnection of four lead generator sets In all cases conform to the National Electrical Code NEC NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer 8 12 1 100 120 Volt Configurations If the installation requires a factory two pole circuit breaker
144. raft 2 functional and 3 energized whenever the generator set operates For your safety Never operate the generator set without a functioning carbon monoxide detector s for your safety and the safety of others on your vessel Exhaust System Inspection Points Check for exhaust leaks and blockages Check the silencer and piping condition and checkfor tight exhaust system connections e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed Visually inspectthe exhaust system for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed TP 6774 2 14a Section 3 Exhaust System 3 2 Servicing Mixing Elbow The mixing elbow combines high temperature exhaust with cooling seawater See the operation manual for mixing elbow scheduled maintenance 1 Check the mixing elbow for carbon buildup and corrosion inside the pipe 2 Clean or replace the mixing elbow as necessary 3 Inspect the exhaust manifold mounting threads for cracking and corrosion Section 3 Exhaust System 21 5 22 Section 3 Exhaust System TP 6774 2 14a 4 1 General In most installation
145. re inch pounds per square inch gauge 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 round head machine screw relay rms rnd ROM rot rpm RTU RTV SAE scfm SCR S Sec SI SI EO sil SNMP SPDT SPST spec specs sq sq cm sq in SS std stl tach TDC TDEC TDEN TDES TDNE TDOE TDON temp term THD TIF TIR tol turbo typ UF UHF UNC UNF univ UV VAC VAR VDC VFD VGA VHF WCR w w o xfmr root mean square round read only memory rotate rotating revolutions per minute right side remote terminal unit room temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency tim
146. rmostat assembly and tighten the screws See Figure 5 16 Figure 5 16 Thermostat Assembly 20 Reassemble the O ring and exhaust mixer 21 Tighten the exhaust mixer s mounting nuts 22 Tighten the hose clamps for seawater inlet and outlet 23 Remove the pressure cap and refill the coolant See Section 5 4 for details on coolant check and fill instructions The level should be approx 2 cm 0 75 in below the filling hole TP 6774 2 14a Figure 5 17 Pressure Cap 24 Replace the pressure cap 5 4 Check and Fill Coolant Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled Maintain the coolant level in the coolant recovery tank at approximately 1 4 full Before filling the cooling system close all petcocks and tighten all hose clamps Usea solution of 50 ethylene glycol and 50 clean softened water to inhibit rust corrosion and prevent freezing Add coolant as necessary to the coolant recovery tank Periodically check the coolant level on closed systems by removing the pressure cap Do not rely solely on the level in the coolant recovery tank Add fresh coolant until level is just below the overflow tube opening Note Coolant solution A coolant solution of 50 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F Acoolant solution with less than
147. rque Aluminum Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5 8 32 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 Ib 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 Aluminum Assembled into Cast Iron or Steel Size mm Grade 5 8 Grade 8 8 Grade 10 9 Grade 5 8 or 8 8 See Note 3 Notes 1 The torque values above are general guidelines Always use the torque values specified in the service manuals and or assembly drawings when they differ from the above torque values 2 The torque values above are based on new plated threads Increase torque values by 15 if non plated threads are used 3 Hardware threaded into aluminum must have either two diameters of thread engagement or a 30 or more reduction in the torque to prevent stripped threads 4 Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90 of the yield strength and a friction coefficient of 0 125 112 Appendix TP 6774 2 14a 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
148. s both the generator set and the propulsion engine operate from a common fuel tank with a dual dip tube arrangement The generator set s dip tube is shorter than the propulsion engine s dip tube With this arrangement fuel may not be available to the generator set when the fuel supply is low See Figure 4 1 for a fuel system schematic To fuel Propulsion engine Generator set Fuel tank Dual dip tubes Fuel filter Fuel feed pump Water trap Figure 4 1 Fuel System Schematic Typical 4 2 Fuel Filter Clean the fuel filter with fresh fuel oil and compressed air The filter s useful life will be determined largely by the quality and condition of the fuel used Under normal conditions replace the fuel filter element at the specified interval in the generator set s operation manual Use the following procedure to replace the fuel filter 1 Press the start stop button to stop the generator set 2 Press the power button to turn the controller off TP 6774 2 14a Section 4 Fuel System 3 Disconnect the generator set engine starting battery negative lead first 4 Close the fuel supply valve 5 Loosen the fuel filter by turning it counterclockwise Remove the fuel filter and use rags to clean up spilled fuel oil Dispose of the fuel filter and rags in an approved manner 6 Clean the contact surface of the fuel oil filter adapter 7 Lightly lubricate the gasket surface of the new fuel f
149. s an event that is not an alert but is part of the event history Notice is an alert that is not part of the event history The controller allows a selected number of changes by the user for setting up the controller application which are covered in this section Note Text shown in italics in this section of the manual represents digital display messages Backup Parameters Loaded This status message indicates that backup parameter firmware is now loaded on the controller The local display shows Backup Pars Status Engine Start Aid Active This notice message indicates that the start aid is active and will energize an engine equipped preheat or ether system during the crank cycle The local display shows Preheat Engine Start Delay Active This notice message indicates that the delay for engine start is active where the generator set will not start right after the RUN button is pressed The unit will start cranking after the time delay times out The local display shows Preheat Engine Started This status indicates that the generator set start circuitis closed allowing the engine to crank and run The local display shows Engine Start Status Engine Stopped This status indicates that the generator set start circuit is open causing the engine to shutdown local display shows Engine Stop Status Generator Running This notice indicates that the generator set has started and is running The local display shows Gen Running N
150. sassemble the alternator Refer to Section 9 2 With the alternator disassembled disconnect the armature leads from the rectifier module AC terminals Refer to Section 10 3 With an ohmmeter on the R x 1 scale check the resistance across the exciter armature leads See Figure 8 6 See Section 1 Specifications for the armature resistance No continuity indicates an open armature winding If the resistance test is inconclusive perform a megohmmeter test on the exciter armature as described in the next step Note Most ohmmeters will not accurately measure less than one ohm Consider the exciter armature functional if the resistance reading continuity is low and there is no evidence of shorted winding heat discoloration 4 Check the exciter armature winding for a short to ground condition Use amegohmmeter to apply 500 volts DC to either armature lead and the armature frame Follow the megohmmeter manufacturer s instructions for using the megohmmeter See Figure 8 7 A reading of approximately 1 5 MOhms and higher indicates the exciter armature is functional A reading of less than approximately 1 5 MOhms indicates deterioration of the winding insulation and possible current flow to ground if so replace the exciter armature 76 Section 8 Component Testing and Adjustment MALUM 4 Ohmmeter 5 Armature 6 Exciter field 1 Main field rotor 2 Stator windings 3 Rectif
151. ss the selector dial and rotate until System Freq appears 2 Press and hold the selector dial until Editing Enabled appears 3 Scroll through the parameters and press the selector dial at the parameter that requires changing The parameter blinks to indicate that it is editable 4 Press the selector dial to change the parameter Note Parameters automatically scroll and keep blinking until the desired selection is made by pressing the selector dial 5 Select Return to return to the GenSet System menu Note After changing the CAN A communication setting power off and then power on the controller GenSet System GenSet gt System System Freq User Selectable 60 Hz or 50 Hz Battery V HEN Y CAN A J1939 SmartCraft or NMEA 2000 User Selectable Meas System English or Metric User Selectable gt Contrast User Selectable gt Section 7 Controller 69 7 13 8 Voltage Regulator Displays the voltage regulator adjustment volt Hz gain and stability adjustment values The voltage regulator value is reviewable at all times and provides the ability to fine adjust voltage Changing the system voltage or replacing the circuit board typically requires a voltage adjustment To enable calibration start the generator set and select the VR Volt Adj Volt Hz Gain or Stability display Then Voltage Regulat
152. st 25 35 seconds to verify that the generator set does not shut down Overcrank Shutdown Disconnect the fuel supply line 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 15 seconds and then rests for 15 seconds Check that the generator set shuts down after the third crank rest cycle High Engine Temperature Shutdown Connect a jumper wire across coolant temperature sensor CTS connections P8 1 and P8 2 Start the generator set Verify that the generator set shuts down approximately 5 seconds after the generator set comes up to speed Remove the jumper wire Start the generator set and run it for at least 30 seconds to verify that the generator set does not shut down Section 8 Component Testing and Adjustment 87 8 14 2 Fault Shutdown Senders Switches Check the senders 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 operat
153. structions Note ADC Ild powers down after 48 hours of inactivity If the generator has been started the controller will power down 48 hours after the generator stops 7 5 4 Fault Shutdowns and Warnings The generator set shuts down automatically under the fault conditions listed in Figure 7 14 and the controller displays a fault code The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 7 10 2 to reset the controller after a fault shutdown The controller resets automatically after a battery voltage fault condition is corrected Shutdown conditions on the generator set automatically reset when the problem is corrected The high engine temperature condition automatically resets when the generator set cools However the fault shutdowns do 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 7 15 Section 7 Controller 49 System Warning Fault Lamp Green Red lamp identifies an existing fault condition that does not shut down the generator set A continuing system warning fault condition may cause a system shutdown Correct all system warnings as soon as practical See Section 7 10 5 System Fault Warning Lamp with Digital Displays for definitions of the items listed The following conditions cause a system warning AC sensing loss High battery voltage High c
154. t 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 seawater pressure switch if the calibration pressure or opening adjustment range is not 0 5 0 2 psi GM75706 A 1 Seawater pressure switch Figure 8 25 Seawater Pressure Switch Location TP 6774 2 14a Coolant Temperature Sensor CTS The coolant temperature sensor CTS is used to monitor engine temperature for the high engine temperature fault shutdown See Figure 8 26 for the coolant temperature sensor location Power down the generator set 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 8 27 Ifthe resistance is very low indicated a short circuit or very high indicating an open circuit replace the CTS 1 Coolant temperature sensor Figure 8 26 Coolant Temperature Sensor Location Resistance Ohms 2106 2392 182 198 Temperature C F 30 86 100 212 Figure 8 27 Coolant Temperature Sensor Resis
155. tance Readings All Models High Exhaust Temperature HET Switch In the event of a shutdown because of high exhaust temperature the ADC 11 controller will display fault code Exh Temp High Shutdown See Figure 8 28 for the high exhaust temperature switch location High exhaust temperature of 215 5 F 102 2 8 C will cause the unit to shut down TP 6774 2 14a 1 High exhaust temperature switch Figure 8 28 High Exhaust Temperature Switch Location 8 15 Fuses Fuses are located on the side of the junction box See Figure 8 29 Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Section 6 Troubleshooting for conditions that may indicate a blown fuse Replace blown fuses with identical replacement parts e 10 Amp F1 fuse protects the auxiliary winding 20 Amp F2 fuse protects the controller circuits fuel pump and fuel shutoff solenoid e 5 Amp F3 fuse protects the customer connections 1 Fuses aty 3 Part No Auxiliary Winding 358337 Controller Fuel Pump and Fuel Shutoff Solenoid Customer Connection GM39266 239298 Figure 8 30 Fuses Section 8 Component Testing and Adjustment 89 8 16 Continuity Checks 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 volt
156. tance in the other direction Replace the rectifier module if any ofthe diodes tests differently than described 1 Diode terminal 2 Diode terminal 3 Ohmmeter Figure 8 9 Rectifier Module Test 78 Section 8 Component Testing and Adjustment 8 8 Rotor The generator rotor magnetized by DC from the rectifier module rotating within the stator windings induces AC in the stator windings Test the generator rotor main field as described in the following steps Disassemble the generator prior to performing this test See Section 9 Generator Main Field Rotor Test Procedure 1 With the generator disassembled disconnect the generator main field windings at the rectifier module terminals F and F 2 Check the main field resistance by connecting an ohmmeter across the main field F and F leads See Figure 8 10 See Section 1 Specifications for the resistance reading Alow reading indicates an internal short and a high reading indicates an open winding Repair or replace the main field if the ohmmeter readings indicate the main field is inoperative Ifthe resistance test is inconclusive perform a megohmmeter test on the main field as described in the next step 4 Ohmmeter 5 Armature 6 Exciter field 1 Main field rotor 2 Stator windings 3 Rectifier module Figure 8 10 Ohmmeter Connections on Main Field 3 Check the main field for a short to ground c
157. te cooling Inspect cooling system for air intake obstructions Check the engine coolant system for blockage and clean as necessary Section 6 Troubleshooting 39 Problem 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 7 13 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 8 10 Alternator or control system Perform separate excitation procedure to isolate problem to the alternator or the control system Section 8 2 Intermittent wiring connection or lack of compression Check the harness connections Check the P2 plug and F1 fuse connections Section 8 15 Section 10 Controller Check the controller settings Check the controller fuse wiring and connections Section 7 13 Section 10 Rotor open grounded or shorted windings Test and or replace Section 8 8 Stator open grounded or shorted windings Test and or replace Section 8 9 Brush connection 6EKOD 5EFKOD models 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 8 6 Low engine speed causing voltage roll off Check the system voltage fre
158. ted 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 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 6774 2 14a Accidental Starting A WARNING 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
159. termines how much the voltage drops during an underfrequency condition Typically applying a large electrical load causes a dip in engine speed and frequency The voltage regulator reduces voltage allowing engine speed recovery The volts per Hz setting determines the amount of voltage drop Regulator Gain Regulator gain refers to the gain ofthe control system Generally the higher the gain the faster the system responds to changes and the lower the gain the more stable the system If the voltage is slow to recover when loads are applied or removed increase the regulator gain Ifthe voltage is unstable decrease the regulator gain TP 6774 2 14a 7 10 5 System Fault Warning Lamp with Digital Displays The system FAULT lamp blinks green then red indicating a warning fault but does not shut down the generator set When the system warning lamp is on and no message displays rotate the selector dial to view messages When the system warning continues it may lead to a fault and cause a system shutdown Note Text shown in italics in this section of the manual represents digital display messages AC Sensing Loss The fault lamp illuminates green then red when the controller does not detect the nominal generator set AC output voltage after crank disconnect The controller displays AC Sens Loss Warning High Battery Voltage The fault lamp illuminates green then red maybe black when the battery voltage rises above the preset
160. that are user selectable Use SiteTech software for changing programmable information Section 7 13 Reviewing the Menu Displays provides a digital display menu overview and explains the navigation using the pushbutton rotary selector dial TP 6774 2 14a Menu Summary List Legend First level submenu second level submenu Overview Menu Available as scrolling or fixed display text Active Shutdowns if present Active Warnings if present Genset State Average Volts Line to Line Frequency Coolant Temperature Oil Pressure Battery DC Voltage Engine Run Time Next Maintenance Software Version Engine Metering Menu Engine Speed Tachometer Oil Pressure Coolant Temperature e Battery DC Voltage Generator Metering Menu Volts L1 L2 Volts L2 L3 Volts L3 L1 Volts L1 N Volts L2 N Volts L3 N Frequency Reset Calibration User can reset individual volt values or reset all values GenSet Information Menu Generator Set Model No Generator Set Serial No e Controller Serial No GenSet Run Time Menu e Engine Run Time e Engine Starts e Next Maintenance GenSet System Menu e System Frequency e Battery DC Voltage J1939 SmartCraft NMEA 2000 Measurement System Metric or English e Contrast display Voltage Regulator Menu Voltage Regulator Voltage Adjust Volt Hz Adjust Gain Adj
161. tment use the voltage adjustment procedure in Section 7 10 4 and 7 13 8 and the governor adjustment instructions in Section 4 4 TP 6774 2 14a ADC 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 A WARNING KS 55 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 Sound Shield Equipped Models For access to the generator set to perform regular maintenance remove the sound shield doors and roof 4 Sound Shielded Models Open the service side door 5 Sound Shielded Models Release the two wing nuts located underneath the roof See Figure 7 3 6 Sound Shielded Models Lift up the roof 7 Sound Shielded Models Slide the roof towards the service side of the unit for removal 8 Sound Shielded Models Open the front rear and non service side doors as needed Section 7 Controller 45 2 3 GM79009 A 4 Figure 7 5 Controller Connections 5 6 11 Remove the old controller 1 Sound shield roof 12 Reconnect P1 35 pin plug and P2 8 pin plug to 2 Wing nut the new controlle
162. ton rotary selector dial has several features and functions e Momentarily press the dial to activate the digital display if dark e Rotate the dial to navigate through the main menus turn clockwise to go forward down and counterclockwise to go back up The menus do not wrap to the beginning e Press the dial at a given main menu to access the submenus within the selected main menu e When in the submenu rotate the dial to navigate through the submenu clockwise to go forward down and counterclockwise to go back up The menus do not wrap to the beginning e Momentarily press the dial when in the submenu to make a user selection choice if available or to go back to the respective main menu e After about 5 minutes of no user input pushbutton rotary selector dial or buttons the menu resets to the top of the main menus and auto paging activates for the Overview submenus Engine Start Stop Button The engine start stop button toggles the running state ofthe 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 When the controller is in a low power mode the button may need to be pressed twice to start the engine Power Button The power button toggles the controller between on and off When the controller is off it does not respond to any input except the power button Note After about 5 minutes of no user input pushbutto
163. uence until fuel free of air bubbles flows from the vent screw at the fuel filter 3 Tighten the fuel filter s air vent screw GM74543 B 1 Fuel filter s air vent screw location Figure 4 4 Fuel Filter s Air Vent Screw TP 6774 2 14a 4 3 Fuel Pump The fuel pump transfers fuel from a source to the injection pump Fuel Pump Test Procedure 1 Remove the two leads at the bottom of the fuel pump The pump terminals are labeled and See Figure 4 5 2 Connectthe inlet side of the pump to a fuel source Disconnect the outlet hose from the fuel filter and place the hose end in a container to catch the fuel 3 Connect the positive terminal of a 12 volt battery to the positive terminal of the fuel pump Connect the negative terminal of the fuel pump to the negative terminal of the battery You should hearthe pump operate and see fuel discharge from the pump outlet Replace the pump if it does not operate 4 Connect a pressure gauge to the outlet side of the fuel pump Repeat step 3 See Section 1 for the specified fuel pump pressure ratings 1 Fuel inlet 2 Negative terminal 3 Positive 4 terminal 4 Fuel outlet Figure 4 5 Fuel Pump TP 6774 2 14a 4 4 Governor The centrifugal mechanical governor keeps the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in theload The governor requires no regular service The factory a
164. uire input using a PC for initial setup The PC entries typically include alpha characters such as digital input descriptions 7 12 1 PC Communications Communicate between a PC and the generator set controller logic using USB communication protocol The PC connections require optional SiteTech software Contact your authorized distributor dealer for assistance Local Single Connection A PC connects to the USB port of the generator set controller using a standard type B USB connector See Figure 7 22 Figure 7 10 and Section 7 13 12 Generator Set Controller USB Cable Personal Computer Figure 7 22 Local Single Connection 7 13 Reviewing Menu Displays Use this section to review a summary of the generator set controller data See Figure 7 23 for which menus provide data monitoring data adjustments or SiteTech software to make data adjustments Use the pushbutton rotary selector dial to navigate to the respective menus 66 Section 7 Controller Menus displaying the symbol represent one of the following data types System calculated data System measured data User entered data Note The examples given on the following pages represent digital displays with the Measurement Units set to English 7 13 1 Error Messages Certain entries or attempted entries may cause the controller to display an error message Cannot Calibrate appears when attempting to calibrate the voltage
165. uires a voltage adjustment To enable calibration start the generator set and select the VR Volt Adj Volt Hz Gain or Stability display Then Voltage Regulator push and hold the pushbutton rotary selector dial until the Editing Enabled popup appears Editing of the voltage adjustment is now available The user can change the individual value or can select Reset VR Yes to reset to the default value The Reset Settings display will only show if editing is enabled To disable calibration Rotate the pushbutton rotary selector dial until the Return popup appears Momentarily press the pushbutton rotary selector dial Stop the generator set if not already done Voltage gt VR Volt Adj Regulator VR Volt Hz XXX X VR Gain XXX X VR Stabil XXX X User Selectable gt Reset VA gt Reset VR Settings No OR Reset VR Yes 82 Section 8 Component Testing and Adjustment TP 6774 2 14a 8 11 Voltage Reconnection Use the following voltage reconnection procedure to change the voltage of 4 and 12 lead generator sets Frequency changes require voltage regulator and governor adjustments Refer to the following procedure and the connection schematics Follow the safety precautions at the front of this manual and in the procedure text and observe National Electrical Code NEC guidelines NOTICE Voltage reconnection Affix
166. ult Shutdown Functions Checkthe operation ofthe fault functions programmed in the ADC by performing the following tests If the ADC lld does not operate as described check the ADC configuration settings see Section 7 13 Also check the ADC wiring and connections see Section 10 TP 6774 2 14a Overspeed Shutdown The overspeed setting is programmed into the ADC controller and is not adjustable Verify that the following controller configuration is set correctly for your unit Open the generator set output circuit breaker before beginning the test See 1 Service Views for the circuit breaker location Connect a DVM to measure the output frequency Start the generator set and manually adjustthe engine speed See Section 4 4 Increase the engine speed to at least 115 of the rated engine speed 69 Hz on 60 Hz models or 58 Hz on 50 Hz models Verify that the generator set shuts down on an overspeed fault Eng Speed High Shutdwn If the overspeed shutdown does not operate the generator set should shut down on an overfrequency fault Frequency High Shutdwn after approximately 5 seconds Low Oil Pressure LOP Shutdown Connect a jumper wire from the LOP sender lead 7 to the generator set ground Startthe generator set Verify that the generator set shuts down after approximately 25 35 seconds of operation Remove the jumper wire from the LOP sender and ground Start the generator set and run it for at lea
167. ust Stability Adjust Reset Voltage Regulator Settings Reset Voltage Regulator Event Log Menu See Section 7 5 6 for a list of items that can appear in Event Log Prime Menu See Section 7 13 10 Volt Select Menu Volt Select o 120 240 V 1 Ph 120 208 V 3 Ph 139 240 V 3 Ph 277 480 V 3 Ph 120 240 V 3 Ph 115 230 V 1 Ph 120 V 1 Ph 230 V 1 Ph 240 V 1 Ph 110 190 V 3 Ph 127 220 V 3 Ph 115 230 V 3 Ph 230 400 V 3 Ph 240 416 V 3 Ph Q 9Q O 00 50 05 0 Qi 6 0 0 USB Menu See Section 7 13 12 for USB flowchart information User Defined Changeable Menu Displays NOTE Some changes require activating the calibration or adjustment mode Some displays may only appear when in the calibration or adjustment mode Refer to Section 7 13 Reviewing Menu Displays to activate the calibration or adjustment mode TP 6774 2 14a Section 7 Controller 65 7 12 Monitoring and Programming Setup The user programmer can access the controller data with the controller digital display or a personal computer PC with optional SiteTech software to monitor and or program Access the controller system with a PC using a USB cable with a standard type A and a standard type B USB plug Refer to the Introduction List of Related Materials for related software literature While this manual focuses on data access through the controller pushbutton rotary selector dial and display some data entries req
168. values in the Generator Metering menu with the unit stopped The unit must be running in order to make adjustments Cannot Edit When Stopped appears in the Voltage Regulator menu when attempting to change the VR Volt Adj value when the unit is not running Controller SiteTech Adjustable Adjustable Controller Menu Name Viewable Overview Engine Metering Generator Metering GenSet Information GenSet Run Time GenSet System Voltage Regulation Event Log LK Prime Volt Select In SiteTech the voltage and phase get set individually Figure 7 23 Menu Displays for Viewing and Adjusting TP 6774 2 14a 7 13 2 Overview Displays basic and commonly sought after information about the generator set This information scrolls automatically after about 5 minutes of no user input pushbutton rotary selector dial or button activity To change from auto scrolling to fixed display press the rotary dial and the main menu will appear Press the rotary dial again to select the first menu item Overview Turn the rotary dial to select the desired fixed view Overview Auto Scrolling Display Active Shutdowns if present Overview 44 hr Y Active Warnings if present Genset State THHHHHE Avg V L L HEN Y Frequency Hz Coolnt Temp HH F Oil Pressure PSI
169. wer 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 8 10 1 Voltage Regulator and Calibration Specifications The Advanced Digital Control Ild ADC has a voltage regulation function that is internalto the processor This means that no external voltage regulator is necessary The voltage regulation of the controller uses root mean square rms sensing for fast response to changes in indicated and regulated voltages resulting in excellent regulation accuracy TP 6774 2 14a 8 10 2 Voltage Regulator Adjustments The descriptions of the voltage regulator adjustments and features follow Voltage Adjustment The voltage adjustment allows the user to enter the desired generator set output level This regulated level setting is the average of the three line to line voltages in three phase configurations or L1 to L2 in single phase configurations Submenus display the individual line to line voltages These voltages are for reference only and are relevant in unbalanced load conditions The voltage adjust setpoint can be changed to accommodate an important phase in an unbalanced system Underfrequency Unload Frequency Setpoint This adjustmentaffects the voltage droop volts per Hz when load is applied and underfrequency occurs The underfrequency unload setting defines the setpoint where underfreque
170. wn 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 a carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use Operating the generator set Carbon monoxide can cause severe nausea fainting or death especially careful if operating the generator set when moored or anchored under calm conditions because gases 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 8 Safety Precautions and Instructions Fuel System A WARNING 4 W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels 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 ad

TP-6774 - Atlantis Marine Power

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