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TP-6255 - Atlantis Marine Power

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2. ADV7384 1 ADC control 2 Select button 3 Generator set master switch Figure 4 4 ADC Control TP 6255 4 10 Fuel System Priming Procedure If the above priming procedure does not accomplish adequate fuel system priming use the following procedure Note Connectthe battery during the priming procedure to allow engine cranking Note If the ADC 2100 indicates an overcrank fault during this procedure disconnect the 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 arag handy during the bleeding procedure Wipe up all spilled diesel fuel after bleeding the system Wash hands after any contact with fuel oil Procedure to Bleed the Fuel System 8 9EOZD and 6 5 7EFOZD Models 13 32EOZD and 11 27EFOZD Models with Specs GM33035 GA1 GA2 GM33036 GA1 GA2 and GM33037 GA1 GA2 1 Loosen the fuel filter screw at position 1 See Figure 4 5 2 Initiate the auto start sequence until fuel free of air bubbles flows from the vent screw at position 1 Tighten the screw 3 Loosen the fuel filter screw at position 2 4 Initiate the auto start sequence until fuel free of air bubbles flows from the vent screw at position 2 Tighten the screw 5 Loosen the fuel injection pump screw at position 5 6 Initiate the auto start sequence until fuel
3. 65 8 2 Separate Excitation Sehr Ri REIR hated 65 8 3 Exciter Field 8 832EOZD 6 5 28EFOZD Models 67 8 4 Exciter Armature 8 32EOZD and 6 5 28EFOZD Models 68 8 5 Slip Rings GEOD 4 5EFOD Models 69 8 6 Brushes GEOD A 5EFOD 5 69 8 7 Rectifier Module B 32EOZD and 6 5 28EFOZD 70 8 8 Bolo Rede ER UR MA wanda ei RR ERU ER RA AERE 70 8 97 exta ned Meet t 71 810 Voltage Eee ter deze ees a rs ER 73 8 10 1 Voltage Regulation 73 8 10 2 Voltage 73 8 11 Four Lead Reconnection 75 8 11 1 100 120 Volt Configurations 75 8 11 2 100 120 200 240 Volt Configurations 75 8 11 3 200 240 Volt Configurations 76 8 12 Twelve Lead Reconnection 76 813 Fault Shutdown Tests 77 8 13 1 Controller Fault Shutdown Functions 77 8 13 2 Fault Shutdown 78
4. 18 1 5 Service Views is eri unre Abia vow e 19 1 6 Torque Specifications 20 Section 2 Scheduled Maintenance 21 2 1 General cech Loe Gace 21 2 2 Lubrication System oie Enn Ae RS 22 Section Intake and Exhaust 23 3 1 Air Intake Silencer Cleaner 23 3 2 Exhaust System Inspection 24 3 3 Servicing Mixing Elbow 25 3 4 Turbocharger Models 14 15 15 5 23 24EOZD and 11 5 13 20EFOZD 25 Section 4 Fuel System ee east ee ties ete ers 27 5 General EUR abes Mediae ders 27 4 2 E el Filter Re bp NC paid fied ki dotate 27 4 2 1 Priming the Fuel System 28 4 3 Fuel Pump 8 32EOZD and 6 5 28EFOZD Models 30 4 4 oie cen Se eis ios waite gin beta ave RUE nes da Raf ep RR 30 Section 5 Cooling System io len ILLIS makes Beak 31 51 Gieierala ut Ede tut 31 5 2 Water Cooled E
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7. To set the voltage frequency setting To step to the next parameter unit configuration Uc To set the unit configuration setting to UcOO if necessary To step to the next parameter engine type Ec To set the engine type if necessary To step to the next parameter advanced configuration mode or save mode selection e Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs battery voltage and communications Press To enter advanced configuration mode Go to Figure 7 10 To proceed to the save mode without AIV entering the advanced configuration mode Go to Figure 7 11 Note Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed x denotes any number from 0 to 9 Figure 7 9 Configuration Mode system voltage frequency unit configuration and engine type parameters 54 Section 7 Controller TP 6255 4 10 Pressing the up arrow key at the Adnc display See Figure 7 9 puts you into the Advanced Configuration Mode Press To set the engine data input type To enter battery voltage selection mode To toggle between 12 and 24 VDC 12 volt models 24 volt models To enter communications
8. 100 AYT3N HSV14 1 18 170 1304 id 100 NYI 1 14 1089 42 19 1VBA vZ LdM 34 3j MCN 1109 Av138 B31N3H OL TYNOIS 14 gt 05 1 0012 NOOD T3 sce Les 9a pereat cod SA aT 88 NVO WNHIX3 11 18 NYO 11 3 1 e ig eeu ot 2510 0 9 2580 1l 1Zd NOLO3NNOO 15 0 01 129 NOLO3NNOO 1502 ONnONO 6 124 TN L l d JN8 8 l d 9 1 NYA XAV s3sn 1Zd L dOIS 1MvIS 310W34 1 Z dOlS bNIS 5 1 4 GTAIHS 1 1 H NO NOLLO3NNOO 3OV M3INI N3A01Sn2 8 14 ogy 1 19 21 ADV7095A D Sheet 1 of 2 Figure 10 4 Schematic for Model 6EOD 4 5EFOD Section 10 Wiring Diagrams 91 TP 6255 4 10 oorzoav 13836 4430 Nna v12 ua1uvis Tan 1V8A AV 13H HSV 14 3ALLVO3N IOH1NOO Av T3H H31HVIS AV 13H LINV4 NOWAOO 9 AV T3H Xhv 13n3 6 Vid 8 L vld 9 vid S vid t vld vid e vid SNOILOSNNOO tid ON L1NV4 NOWWOO ON AV T3H NO
9. IVNH31X3 11 19 NEO NYO TWNHALXS 017 Ld BISA MAA RE ENG Q38 4 18 9 SMa lt 980 89 9 IOH1NOO HSV14 S t ld t 13 14 1n0 AV 3H HS Y 14 2 91 IOB1NOO 1 61 WOO Z Ld 4 19 LNO LINYA NONWOO IOH1NOO LHYLS 7 Ld NOLLOANNOO LSND 1 NOLLO3NNOO LSND 6 L2d 2 1zd vo 1V8 8 1 4 P 44 97128 LNANI LINY Xnv 124 1 4018 15 15 310W3H 124 2 9015 1 15 310N3H S d Q I3IHS NYO 2 1 1NVO H NOLLOSNNOO 3OV3H3NI 5 OIN 4d Z OL 103198 SNONNILNOD OL 2 1 29 23 3dON SNOILOANNOO 2 1 19 1 AV 3H 1303 1VGA vZ Ld dinoAvisHusiuvis ONDOHO 227194 N 21100 HIV OL TYNOIS gar 0012 a 2 00 zs gt 1 02088 130 Sheet 1 of 2 Figure 10 8 Schematic for Models 8 32EOZD and 6 5 27EFOZD Section 10 Wiring Diagrams 95
10. See Section 8 13 2 Fault Shutdown Switches Figure 8 31 Continuity Checks 80 Section 8 Component Testing and Adjustment TP 6255 4 10 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 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 Disassembly Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger if equipped 3 Disconnect the generator set engine starting battery negative lead first WARNING S Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery TP 6255 4 10 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 doo
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13. 8 vid N 2 19 LN 3NI9N3 NOL Figure 10 11 Wiring Diagram for Model 9EOZD 7EFOZD see Figure 10 2 for applicable specs TP 6255 4 10 98 Section 10 Wiring Diagrams 335 OLVW3HOS 403 9 335 WVHOVIO AHOSS3OOV 404 MOVIS 191 5 NilNVIS SS MOLON MibNIS NS d3TIOMINOO NOOMIS NOS QMVOB 3OVAMJINI AVI3M gid 193NNOO 9 YOLOANNOD 10 Sdo 3MfSS3Hd N3lVM YIS MOT HOLIMS 3BfSS3Md 10 401 5 O1 MOIVNH3EV 01 AYTAY MOIO3NNOO QNnONO NJTIOMINOO S M019 dION3IOS TANA 54 T3n4 3univ3dWaL ISnvHX3 513 52018 3NI9N3 98a M3ON3S INv1000 512 89 MOIVNH3ETV AMillvH AVT3 MilV3H NIV MHY zov wos uos 14 zo uos ZL 2 01 N NOLLO3NNOO 39V 3INI 5 via v9 7771 21 19 ZZZZA 9 12 vor 23 dd c 1 3 G 14 ZNOOD MOIVIS 5
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15. 4 2 4 Priming the Fuel System Prime the fuel system to bleed the air from the system 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 Priming 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 Press and hold the Select button located on the ADC See Figure 4 4 2 Move the generator set master switch to the RUN position to enter the programming mode 3 Continue to hold the Select button for 10 seconds The ADC will display Fuel and the fuel priming pump will start 4 Continue to hold the Select button for as long as you want the fuel priming pump to function typically 10 seconds 5 Release the Select button and move the Master switch to the OFF position 6 Place the Master switch to the RUN position to start the unit B i t Cee
16. 8 14 IHM L Nid SNOILOSNNOD Id _ KINO 0203 8 aw 28 25109 2540 gz id Le 49 1983 NS 083 comi 81 19 L 11 124 01 1 94 98 090 N 41 66d ANIONS GM30264 H TP 6255 4 10 Figure 10 7 Wiring Diagram for Models 8EOZD 10 32EOZD 6 5EFOZD and 8 5 27EFOZD 94 Section 10 Wiring Diagrams QNnOHO 3208 3NION3 HOLVIS LVLS GION310S 5 SS YOLOW H31HVIS WS Q3T10H1NOO NOONIS HOS 30Y443LNI alH 1O3NNOO NODD oma 3unsS3ud 10 540 HOLIMS SHNSS3Ud H31VM WAS HOLIMS 3Hh SS3Hd 110 H3TIOHLNOO O1 MNVHO 029 INSNI d9 XO8 H3TIOHLNOO NI T1Nd GION310S 1304 53 GION310S 1303 HS4 GION3I1OS 1919 54 and dd 3sna 4 SYNLVYAdWAL LSnvHX3 S13 3un1vH3dWa3L LNV1OO9 SLO 90 HOLVNH3 LYV WOE H31V3H HHY H31V3H HY aua3931 dd quia HOLVIS NIVW AAAA 33HH SZ85 AQv
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18. 8 Reconnect the engine wiring harness connector P1 plug 35 pin to the controller 60 Section 7 Controller 9 Reconnect the generator set engine starting battery negative lead last 10 Reconnect power to the battery charger if equipped 11 Place the generator set master switch in the AUTO position 1 Engine wiring harness connector plug P1 2 Continuous power mode jumper location P7 3 J15 connector 4 J16 connector 5 Generator set master switch Figure 7 15 ADC Controller back cover removed 7 9 Master Switch The generator set master switch is a three position RUN OFF RESET AUTO rocker switch The leads connecting to the master switch are labeled RUN VBAT and AUTO Check that the three pink connectors are connected to the terminals on the back of the switch as shown in Figure 7 15 Be careful not to reverse the RUN and AUTO leads TP 6255 4 10 7 10 Relay Interface Board RIB The standard relay interface board RIB contains the K2 crank K3 flash and K5 run relays Three LEDs indicate relay operation See Figure 7 16 Refer to the schematic diagram in Section 10 for the standard relay board connections The RIB is protected by a 10 amp fuse F2 located in the wiring harness Ifthe fuse blows repeatedly disconnect the board leads one at a time to identify the cause of the blown fuse e Lead 70A at the fuel solenoid e Lead 71A at the starter relay e Leads FP and FN at the rotor
19. Fuel line restriction Inspect fuel lines Air cleaner clogged Replace element Section 3 Blown controller fuse F3 Replace fuse Section 8 14 Blown auxiliary winding fuse F1 Replace fuse If fuse blows again test generator components Section 8 14 Blown relay interface board RIB fuse F2 Replace fuse Section 8 14 Engine overheated hot engine only Check air intake oil level air inlet outlet Sections 2 and 3 Low oil pressure LOP shutdown Attempt startup If the unit shuts down remove the lead from the LOP switch and reset the controller A successful restart attempt indicates a faulty LOP shutdown switch Note Check the engine oil pressure before performing the test and or replacing the LOP shutdown switch Section 8 13 Engine overloaded Reduce electrical load Generator Set I M Loss of generator output voltage to controller Check connections at P15 plug Check continuity of AC sensing leads 11 and 44 for 1 phase models or leads 7 8 and 9 for 3 phase models Section 10 Faulty K3 flash relay Check for Flash LED illumination Check RIB fuse Replace relay board Section 7 10 Section 6 Troubleshooting 39 Troubleshooting Chart continued Problem Generator set operates erratically Possible Cause Air cleaner clogged Corrective Action Replace element Reference Section 3 Governo
20. TP 6255 4 10 EN OON La 9 Dy e gt 2 Xi 1 1353 0 oorzoav 12 H31HVIS 6 vld GNNOYD 8 rid vo 2 14 1VBA 9 bld AVI3H S vid 3ALLVO3N v rid 7OHINOO AVT3H H31HVIS amp bid 7OHINOO AV 3H Ln v3 NOWWOO 2 bld NOY 1 4 SNOLLO3NNOO vld NOWWOD 9 ON AVTSY S Eld ONAVI3HN H b Eld LINVANOWWOD ld NOWWOO 17 74 NOWWOO 2 ld NOWWOO Av13H N H ld SNOILOANNOO 4 3OVJH3LNI AV THH pv 8A 1 Ov 6A 1 LULA 1 OV e sir 2 91 SNOILOSNNOO SIP 99 LndNI ONIGNIM 4 SNNIW 65 1 170 Av T3H HSW14 9 smd 9 91 9 91 91 9ld 2 91 1 914 SNOILO3NNOO 917 1097138 AGOW 4d 2 1 24 SNOLLO3NNOO 23 26259 cecsd 6 Sd 8 Sd L Sd 9 Sd S Sd v Sd Sd 2 1 84 SNOILO3NNOO Sd OX NO 1V8A JWNDIS HOSN3S 3HfiSS3Hd 3Ouh0S HOSN3S 55 HOIH HOSN3S HA SSOT T3A31 LNY 1000 Z dO1S 18V1S SLOWSY dOLS LUVLS SLOWSY
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22. 33HHl S 8G AOV 2335 SNOLLO3NNOO MOIVHJN39 M04 310N 1 81 LA v 3SvHd TIONIS G8S A0v 335 SNOLL 3NNOO MOIVH3N39 304 ALON 1 15 duas h 8 12 Wedd 3 ss ss CH fo 52 19 9 19 Zid 1 000 66 914 vr 1 812 207 405 99 1NOO0 99 wis SNOIIO3NNOO Sid MOlVIS Qvil wis 8A 5 6A vis 4 Mf Nid SNOIIO3NNOO Sid MOIVIS Q N Q N Q N 0 15 0 8 15 0 124 g iza S N amp IN Y 92 9 5 115 99 0 2 021 SNOLLO3NNOO 5 5 gag 001 n L NMOHS M3MOd 33S SNOLO3NNOO HANN Zd ALON Sid amp s izd GAIVINSNINN 95 zc S19 GALVINSNINN SS 12 dawvinsNNn ZS OZ v isdo O N 907 0 4 NOL SNOIIS3NNOO 14 GM 2 12 1 12 8 1815 v 1si9 TA
23. 8 14 FUSES ire Soe gs opp eite p pf oot crest 79 8 15 Continuity Checks ok od RE ae 79 Section 9 Generator Disassembly Reassembly 81 94 Disassembly teo dete EE ui eee ee ae 81 9 2 Collector Ring and Bearing Replacement 6EOD 4 5EFOD Model 85 9 3 Beassembly e e pater cim DLP AU Dat ts 85 Section 10 Wiring Diagrams 89 10 1 Wiring Diagram Reference 89 10 2 Manual Marine Ship to Shore 2 Wire and 3 Wire Transfer Switches 102 10 3 Manual Marine Ship to Shore 4 Wire Transfer Switch 108 Appendix A Abbreviations 105 Appendix B Common Hardware Application Guidelines 107 Appendix C General Torque 108 Appendix D Common Hardware Identification 109 Appendix E Common Hardware List 110 4 Table of Contents TP 6255 4 10 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and
24. KOHLER POWER SYSTEMS Service Marine Generator Sets la Models 6EOD 4 5EFOD 8 32 02 6 5 28EFOZD NATIONALLY REGISTERED TP 6255 4 10c 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 6255 4 10 Table of Contents Safety Precautions and Instructions 5 Introduction Qnae V ME RU CR oe ee 9 ASSISTANCE MM ot nein 9 Section 1 Specifications Der pi RI aS RR 11 Weds General 2 5 thi debt bg eger mtb ooi 11 1 2 iEnglnes o Ee neige LA E ees 12 T3 Generator 4 Lead sese A 17 1 4 Generator 12 Lead
25. M3MOd SNONNLLNOO perm QNnON9 1 29 100 Avi3H HSV M3dWnr 23 SNOLLO3NNOO Ld i id Ino ENA 1d 110 NONNOO 1 14 1no avum sapis 42 AVEAt vZ Ld 3 Hd HN 5 100 OL Z Id e cs 0012 Sav 21 6 rvid Nalivis 9 14 4 amp 244 8 14 N L vld n4 NOL TN A ra La l 90 r Hw 1 Ww voL 234 0 7 0 Zd ANNO m T Scr nir Tad 2 7 E Figure 10 13 Schematic for Model 9 32EOZD 7 28EFOZD Sheet 1 of 2 see Figure 10 2 for applicable specs 100 Section 10 Wiring Diagrams ADV7283A C 7 8 OV Ov 817 LL ZN 1ndNI OV 1 8 SNOII23NNOO Sif ble specs 001 viZ uanvis qNnouo Tan4 WEA JONINOO AVTSY HSY 3A1V93N JONINOO AVIAN M3lNVIS JOMINOO AYT3H NOWWOO 7OMINOO AVT3M NOY Xhv T3n4 6 vld 8 vld 12 71 9 1 9 1 t tld tld vYld 1 14 SNOIIO3NNOO 14 ON LINYA NOWWOO AVI3M NNA ON Avi
26. Slotted au T e e Hex Socket Washers Washer Styles Plain Split Lock or Spring Spring or Wave External Tooth Lock Internal Tooth Lock Internal External Tooth Lock Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company 1 4 20 x 1 Sample Dimensions American Standard Screws Bolts Studs and Nuts L Length In Inches Screws and Bolts Threads Per Inch Metric Screws Bolts Studs and Nuts 8 1 25 x 20 L Length In Millimeters Screws and Bolts Distance Between Threads In Millimeters Major Thread Diameter In Millimeters TP 6255 4 10 Major Thread Diameter In Fractional Inches Or Screw Number Size 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 EI Internal Dimension Appendix 109 Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Dimensions Part No Dimensions PartNo Dimensions Hex Head Bolts Grade 5 Hex Head Bolts cont Hex Nuts X 465 17 1 4 20 x 38 X 6238 14 3 8 24 75 X 6009 1 1 8 Standard X 465 6 1 4 20 x 50 X 6238 16 3 8 24 x 1 25 465 2 1 4 20 62 6238 21 3 8 24 4 00 X 6210 3 6 32 Whiz X 465 16 1 4 20 x 7
27. ADC 2100 Ohmmeter Exciter field Exciter armature Main field rotor Figure 8 4 Exciter Field Resistance Test TP 6255 4 10 Section 8 Component Testing and Adjustment 67 8 4 Exciter Armature 8 32EOZD and 6 5 28EFOZD 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 Disassemble 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 a shorted winding heat discoloration 4 Check the exciter armature winding for a short to ground condition Use a megohmmeter 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 read
28. Diesel ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Fuel shutoff solenoid Electric Fuel pump Electric rotary vane Fuel pump priming Electric Max recommended fuel pump lift m ft 1 2 4 Battery voltage 12 volts standard 24 volts optional Battery charging 40 amp alternator Battery recommendation minimum 650 CCA 100 amp hr 800 CCA 100 amp hr Starter motor 1 8 kW 2 3 kW 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 6 0 6 3 7 57 8 tank Thermostat C F 82 179 High exhaust temperature shutdown C F Low oil pressure shutdown kg cm 0 1 kg cm psi 102 215 5 0 5 7 1 3 4 NPT with sound shield 25 1 without sound shield 3 Seawater inlet water line hose ID 1 3 4 NPT with sound shield mm in 19 0 75 without sound shield 19 0 75 without sound shield for specs GM55348 GA1 to GA16 Water cooled exhaust outlet hose ID 76 3 with sound shield 76 3 with sound shield mm in 76 3 without sound shield 76 3 without sound shield 14 Section 1 Specifications TP 6255 4 10 20EOZD 17EFOZD 17 5EFOZD 1 and 3 Ph Generator Model 28EOZD 23EFOZD 27EFOZD 23EOZD 24EOZD 25EFOZD 28EFOZD 20EFOZD 20EFOZD 1 and3Ph 1 and 3 Ph 32 02 Fuel inlet size 3 8 NPT with s
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31. Section 7 Controller 47 Fault Description Check High battery voltage warning Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 2 seconds when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 2 seconds Check the battery rating and condition Low battery voltage warning Fault code is displayed if the engine starting battery voltage falls below 9 5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 2 seconds when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 2 seconds Figure 7 5 Fault Warnings 48 Section 7 Controller Check the battery rating and condition Charge or replace the battery TP 6255 4 10 7 5 Controller Configuration and Adjustment The first step in troubleshooting the controller is to verify that the controller is correctly configured for the generator set The controller s configuration modes allow setting of the engine type generator set configuration marine mobile or standby data input types and other parameters The controller configuration for each generator model
32. 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 an ohmmeter on the x 100 scale to check the resistance between all the rectifier diodes as shown in Figure 8 9 The ohmmeter should show low resistance in one direction and upon reversing the ohmmeter leads a high resistance in the other direction Replace the rectifier module if any of the diodes tests differently than described 1 Diode terminal 2 Diode terminal 3 Ohmmeter Figure 8 9 Rectifier Module Test 70 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 low reading indicates an internal short and a high rea
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34. ous 20 250 4 X 125 27 5 16 18 x 2 75 129 X259 6 X 125 28 5 16 18 x 3 00 X 129 51 1 2 20 x 75 X 25 48 188 438 049 48 125 22 5 16 18 4 50 129 45 1 2 20 1 25 X 25 36 219 500 049 10 Pee 2 T 129 52 1 2 20 1 50 25 40 281 625 065 1 4 X 125 86 5 16 18 6 00 X 6021 3 5 8 11 1 00 p X 125 40 5 16 18 x 6 50 X 6021 4 5 8 11 x 1 25 X534 469 92 065 7 16 X 6021 2 5 8 11 x 1 50 i X 125 43 5 16 24 x 1 75 50513 5 8 11 x 1 75 X 25 26 531 1 062 095 1 2 X 125 44 5 16 24 x 2 50 272049 5 8 11 x 2 00 25 15 656 1312 095 5 8 X 125 30 5 16 24 x 75 X 8021 5 58 11 x 225 X 25 29 812 1 469 134 3 4 X 125 39 5 16 24 x 2 00 X 6021 6 5 8 11 2 50 X 25 127 1 062 2 000 134 1 X 125 38 5 16 24 x 2 75 X 6021 7 5 8 11 x 2 75 Ur X 6021 12 5 8 11 3 75 923810 98 16 x 75 X6021 1 5 8 M x 4 50 X 6238 3 3 8 16 x 88 X 6021 10 5 8 11 x 6 00 X 6238 11 3 8 16 x 1 00 X 6021 9 5 8 18 x 2 50 X 6238 4 3 8 16 x 1 25 X 6238 5 3 8 16 x 1 50 X 6239 1 3 4 10 x 1 00 X 6238 1 3 8 16 x 1 75 X 6239 8 3 4 10 x 1 25 X 6238 6 3 8 16 x 2 00 X 6239 2 3 4 10 x 1 50 X 6238 17 3 8 16 x 2 25 X 6239 3 3 4 10 x 2 00 X 6238 7 3 8 16 x 2 50 X 6239 4 3 4 10 x 2 50 X 6238 8 3 8 16 x 2 75 X 6239 5 3 4 10 x 3 00 X 6238 9 3 8 16 x 3 00 X 6239 6 3 4 10 x 3 50 TON E ee 6238 20 3 8 16 3 75 792 5 1 8 3 00 6238 13 3 8 16 4 50 X 792 8 1 8 x 5 00 X 6238 18 3 8 16 x 5 50 X 623
35. speed turn the screw counterclockwise Tighten the locking nut when the correct setting is reached See Figure 4 7 1 Speed adjusting screw 2 Locking nut Figure 4 7 Governor Adjustment The generators use a 3 lead fuel solenoid This solenoid has a white lead P which energizes the pull in coil only during cranking During operation the red lead energizes the hold coil and the black lead is the common ground TP 6255 4 10 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 cooled exhaust manifold and an exhaust mixer See Figure 5 1 for cooling system components 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 Engine block Exhaust manifold Exhaust mixer elbow Outlet flapper Silencer Thermostat Figure 5 1 Cooling System Components TP 6255 4 10 Section 5 Cooling System 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 co
36. 8 1 Starting Sequence Master Switch Moved to RUN 45 7 8 2 Starting Sequence Remote Start 45 7 8 8 Running Sequence 46 7 3 4 Stopping Sequence Master Switch Moved to OFF RESET 46 TP 6255 4 10 Table of Contents 3 7 8 5 Stopping Sequence Remote Stop 46 TA FaultS iso bad be 46 7 4 1 Fault Sh tdowns ER ERG aes jensen Rue 46 74 2 Warnlhigs ics Ren AER RE 46 7 5 Controller Configuration and Adjustment 49 7 5 1 Controller Time 49 7 5 2 Controller Configuration 49 7 5 3 Voltage 49 7 6 Controller Application Program 57 7 7 Silicon Controlled Rectifier SCR Module 57 7 8 Continuous Power Mode Jumper if equipped 59 9 Master Switch dope e 60 7 10 Relay Interface Board RIB 61 7 11 Controller Replacement 62 Section 8 Component Testing and Adjustment 65 81 Theory of Operation
37. Adjust the voltage when necessary according to the following procedure The adjustment procedure requires a meter that can measure voltage and frequency Use the ADC to adjust the voltage gain and volts Hz Refer to Section 7 for instructions to adjust each parameter and save the changes using the controller keypad Note The ADC controller will time out and exit the adjustment mode after approximately 1 minute if no buttons are pressed Any unsaved changes are discarded if the controller times out before the settings are saved Refer to Section 7 5 for instructions to save your settings Voltage Adjustment Adjusts generator output between 100 and 130 volts Gain Stability Adjustment circuitry to reduce light flicker Fine tunes regulator Volis Hz Adjustment Determines frequency Hz at which generator output voltage begins to drop The ADC maintains generator output at the specified voltage under load until the generator engine speed drops to a preset level factory setting 57 5 Hz on 60 Hz models and 47 5 Hz on 50 Hz models Then the ADC allows the generator voltage and current to drop The voltage current drop enables the engine to pick up the load When the generator speed returns to normal 60 Hz or 50 Hz as load is accepted the generator output also returns to normal TP 6255 4 10 A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guard
38. F Figure 2 2 Engine Oil Selection for Models GEOD and 4 5EFOD Note Failure to observe the oil specifications may cause inadequate lubrication oil pressure and cold starting difficulties TP 6255 4 10 Section 3 Intake and Exhaust System 3 1 Air Intake Silencer Cleaner Atthe interval specified in the service schedule clean or replace the air intake silencer element Clean the silencer more frequently if the generator set operates in dirty dusty conditions Follow one of the procedures described below 6EOD 8 9 10EOZD 4 5EFOD and 6 5 7 9EFOZD Models A dry type air cleaner silences and filters the intake air The air intake silencer assembly connects to the intake manifold via a flexible hose Air Cleaner Service Replacement Procedure 1 Release the spring clips to open the housing and remove the air silencer element See Figure 3 1 2 Tap the element lightly against a flat surface to dislodge loose surface dirt Do not clean in any liquid or use compressed air as these will damage the filter element 3 Examine the element and housing for damage and wear Replace the element or housing if necessary 4 Wipe the cover and base with a clean rag to remove any dirt Make sure that the sealing surfaces fit correctly and reattach the spring clips Air Cleaner Element Element Figure 3 1 TP 6255 4 10 13 20 28 32 020 and 11 17 17 5 23 25
39. Figure 7 12 Output Voltage Adjustments 56 Section 7 Controller TP 6255 4 10 7 6 Controller Application Program The controller s application program version number is displayed on the LED screen during the key sequence to enter the configuration mode Hold the Select button and move the generator set master switch to the RUN position After about 5 seconds the application program version number will be displayed on the controller display For example u1 04 will be displayed for program version 1 04 Use the Program Loader Software and a personal computer to update the controller s application program to the latest version when necessary Check www kohlernet com Tech Tools Software for information on ADC 2100 application program updates and instructions to obtain the latest application code and Program Loader software Refer to TT 1285 Program Loader for instructions to load the application program onto the controller 7 7 Silicon Controlled Rectifier SCR Module The silicon controlled rectifier SCR module works with the ADC 2100 to regulate the output voltage The ADC 2100 monitors generator output voltage and adjusts the excitation current to the rotor through the SCR module The SCR module location is shown in Figure 7 1 The SCR module is powered through stator leads 55 and 66 connected to SCR terminals AC1 and AC2 Leads G connected to terminals G1 and G2 provide the controller signal Leads FP and FN connected to
40. Fuel feed pump Oil check Pressure cap Overflow tube Oil fill Lube oil filter High engine temperature sensor Fuel filter Oil fill Seawater pump water inlet GM30645D Oil drain valve and hose Strain relief for the load lead cable Cooling air inlet AC circuit breaker coverplate Anticorrosion zinc anode seawater drain all models except 13 24EOZD amp 11 20EFOZD models Belt guard V belts Coolant freshwater drain all models except 13 24EOZD 4 11 20EFOZD models Heat exchanger all models except 13 24EOZD amp 11 20EFOZD models Heat exchanger 13 24EOZD amp 11 20EFOZD models Seawater drain 13 24EOZD amp 11 20EFOZD models Coolant freshwater drain 13 24EOZD amp 11 20EFOZD models Figure 1 2 Service Views Typical 82020 Model Shown Unless Noted TP 6255 4 10 Section 1 Specifications 19 1 6 Torque Specifications Follow the general torque specification found in Appendix C of this manual unless noted below 6EOD Generator Model 4 5EFOD Overbolts 9 5 Nm 7 0 ft Ibs Back plate mtg bolts 15 Nm 11 ft Ibs Flywheel bolts 73 Nm 54 ft Ibs Drive disc 45 Nm 34 ft Ibs Fan to flywheel stud 23 Nm 17 ft Ibs Fan to flywheel nut 23 Nm 17 ft Ibs SCR to junction box 4 Nm 35 in Ibs 10EOZD 15EOZD 8EOZD 9EOZD 8 5EFOZD 13EOZD 14 02 15 5 02 Generator Model 6 5EFOZD 7EFOZD 9EFOZD 11EF
41. GALWINSNINN SS 8 510 690 GALWINSNINN 45 02 510 LHM v sdO 907 2 19 vee ON wi bid NOZ SNOLLO3NNOO id 3 456 1 02 SNOLLOANNOO YAWOLSND wie 983 ss ON Ta ON N voz vee NOL 08 02 dob 8 029 521 der tld voz 01 ss aer 2988 NOI o 1983 SNOLLO3NNOO ass SNOILO3NNOO WZd 6 14 z 67d LHM SNOILLOANNOO SNOILO3NNOO vtd 8 2 6 vid viz 98 j dor N VIL pe sa NOLLONAL g2 1d se H am 28 13 48 983 Nh O OvNOLLdO amp QvNOlLdO fal 5197 R 2 e 01 128 02 e983 z993 1993 bed S T 1 i i cg 02 N Figure 10 6 Wiring Diagram for Model 9EOZD 7EFOZD Section 10 Wiring Diagrams 93 TP 6255 4 10 9 335 OUVW3HOS MO4 9v8 W9 33S AMOSS3OOV 404 MOlVI
42. Ph 60 120 240 V 1 Ph 3 W a 13EFOZD 1 Ph 50 230 V 1 Ph 2 W N 115 230 V 1 Ph 3 W 6 240 V 1 Ph 2 W 13 12 or 24 0 No Can 10r 6 J1939 70r9 Smartcraft t Use voltage frequency parameters Uu07 Uu23 only with ADC application program version 1 20 or higher See Figure 7 7 for Ed settings with optional sender kits See Figure 7 8 for Cn settings with optional digital gauges gauges are available on selected models only Note Setting the Ec parameter automatically selects the Ed parameter for the standard data inputs for that engine If you change Ec check the Ed setting 50 Section 7 Controller TP 6255 4 10 Marine Diesel Model 14EOZD 8 Ph Voltage Phases 120 240 V 1 Ph SW Market Engine Type Battery Voltage CANbus Comm 120 208 V 3 Ph 4 W Wye 127 220 V 3 Ph 4 W Wye 120 240 V 3 Ph 4 W Delta 139 240 V Ph 4 W Wye 277 480 V Ph 4 W Wye Uc 15EOZD 1 Ph 120 240 V 1 Ph 3 15 5EOZD 1 Ph 120 240 V 1 Ph 3 W 17EFOZD 1 Ph 230 V 1 Ph 2W 115 230 V 1 Ph 3 W 240 V 1 Ph 2W 17 5EFOZD 8 Ph 115 230 V 1 Ph 3W 115 230 V 3 Ph 4 W Delta 110 190 V 3 Ph 4 W Wye 120 208 V 3 Ph 4 W Wye 220 380 V 3 Ph 4 W Wye 230 400 V Ph 4 W Wye 240 416 V Ph 4 W Wye 20EOZD 1 Ph 1
43. Repair or replace the component causing the blown fuse Iffuse continues to blow and disconnecting components did not identify the cause remove the leads from the P14 connector using a pin pusher part 241918 large or 241919 small If replacing the leads does not solve the problem replace the RIB The individual relays are not replaceable If one or more relays are faulty replace the entire RIB To replace the RIB 1 Disconnect P14 and the exciter leads FP and FN 2 Pull the board straight off the mounting stand offs 3 Snap the new board onto the stand offs and reconnect P14 and the exciter leads The generator set may be equipped with an optional RIB which contains the K4 auxiliary run relay and K1 common fault relay in addition to the standard relays The optional relay board kit includes a wiring harness for connection of customer equipment to the K1 and K4 relays See Figure 7 17 for optional relay connections TP 6255 4 10 GM29779 A K1 common fault relay optional K2 crank relay standard K8 flash relay standard K4 auxiliary run relay optional K5 run relay standard P14 engine harness connection standard P13 connection to optional relay harness optional Figure 7 16 Relay Board Harness Lead Connector Number Pin Number Connection Common fault normally open Common fault common Common fault normally closed Run relay normally open R
44. configuration mode Press the up arrow button when Adnc is displayed to enter the advanced configuration mode Engine data input types Ed This setting defines the type of senders used on the generator set engine Battery voltage Bt This setting toggles between 12 and 24 VDC for the engine starting battery voltage Communications setting Cn This setting allows the user to set the controller for communication with optional gauges which are available for marine and mobile units only 7 5 3 Voltage Adjustment The flowchart in Figure 7 12 outlines the procedures for using the ADC controller to adjust the output voltage Voltage adjustment may be required after controller replacement generator set reconnection or other service procedures The generator set must be running during this adjustment Use a multimeter to measure the generator set output voltage during adjustment Refer to Section 8 10 2 Voltage Adjustment for instructions to measure the output voltage Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Section 7 Controller 49 Marine Diesel Model 4 5EFOD 1 Ph Voltage Phases 230 V 1 Ph 2W Market Battery Voltage CANbus Comm 115 230 V 1 Ph 3 W 240 V 1 Ph 2W EF Uc 6EOD 1 Ph 120 240 V 1 Ph 3 120 V 1 Ph SW 120 V
45. 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 3 TP 6255 4 10 TP 5616 Drive shaft assembly Snap ring Pulley Brass washer Housing Seal Impeller Ceramic seat Gasket Rubber seat Cover plate Key impeller end Figure 5 3 Seawater Pump Typical 3 Remove the impeller 4 Inspect the impeller for damage including cracks broken or flattened vanes The impeller vanes should be straight and flexible See Figure 5 4 1 Flattened vane 2 Crack 3 Broken vane Figure 5 4 Worn Impeller 5 Lubricate the impeller with soapy water before installation 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 Section 5 Cooling System 33 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 for leaks 11 Stop the generator set and repair leaks or replace components as necessary 5 8 Belt Tension WARNING Hazardous voltage Moving parts Can cause
46. ld 9 14 5 14 1 old SNOILO3NNOO 1 H3TIOHINOO 0012 ADV7095B D Sheet 2 of 2 Figure 10 5 Schematic for Model 6EOD 4 5EFOD TP 6255 4 10 92 Section 10 Wiring Diagrams Sv89 AQV 33S OILLVW3HOS 9P8EEND 33S WVHOVIO AHOSS3OOV HOS HOLVIS 1V1S GION31OS H31HVIS SS HOLOW H31HVIS WS HaldlLO3H Q3TIOHLNOO NOOTIIS HOS QHVOB AV 13H 818 1O3NNOO 0 HOLO3NNOO 3unssaud 10 580 3unsSaud H31vM YIS HOLIMS 3HhSS3Hd 10 15 07 HOLVNH3LLTV 01 AV T3H 02 HOLO3NNOO INSNI H3TIOHLNOO 959 GION3 10S 1909 54 TAN SNOLLO3NNOO LIOA No azoa ze 01 NO d9 zdO 149 INOW SSVHd 9289 385 SNOLLO3NNOO 8A 5503 03 2A SYNLWHAdWAL LSnvHX3 S13 32018 3NION3 3aola 3univu3dW3L 519 uaxvaus LINDUIO 092 HO1VNH3LTV H31v3H lv HHY QN3931 99 wis ss 98 x 9 99 Ie E T Ov HOS oHO 99 SNS
47. not require changes unless the controller is replaced The controller s advanced configuration mode allows the user to set the data input type for engine senders toggle the battery voltage between 12 and 24 volts and change the controller communications setting for optional meters Check these settings after controller replacement and change them if necessary to match the settings shown in Figure 7 6 TP 6255 4 10 Follow the instructions in Figure 7 9 to enter the configuration mode while the engine is not running and then step through the following parameters Use the up and down v arrow buttons to select the appropriate setting for the application Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Voltage frequency setting Uu Select the system voltage and frequency from the table in Figure 7 6 Note This parameter sets the nominal system voltage and frequency To adjust the output measured voltage and frequency see Section 4 4 Section 7 5 3 and Figure 7 12 Unit configuration Uc This parameter sets the generator set type marine standby or mobile Engine configuration Ec The engine configuration must match the generator set engine type Advanced configuration mode Adnc The data input types battery voltage and communications setting can be changed in the advanced
48. of the generator Abrasive dust on the slip rings however shortens the life of the brushes Excessive arcing at the brushes could damage the SCR module and the controller Weak springs damaged slip rings sticking brushes a loose brush holder or poor brush contact causes arcing The brushes must be free to move within the holder and be held in contact with the slip rings by the springs When correctly positioned spring pressure on the brush surface causes the brush to wear evenly The entire brush must ride on the ring or arcing occurs and causes 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 on the 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 6255 4 10 Lo _ 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 69 8 7 Rectifier Module 8 32EOZD and 6 5 28EFOZD Models The rectifier module located between the exciter armature and the main field converts AC from the exciter
49. 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 square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier S sec second Sl Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s sq square sq square centimeter sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temp
50. plate Junction box Figure 9 4 Advanced Digital Control ADC 2100 12 Remove the junction box SCR module and relay board as necessary See Figure 9 4 TP 6255 4 10 13 14 Disconnect the FP and FN leads 8 32EOZD 6 5 28EFOZD Models Remove the four bolts to remove the exciter field Figure 9 5 See 1 Bolts 4 2 Exciter field Figure 9 5 Exciter Field Removal 15 16 17 8 32EOZD 6 5 28EFOZD Models Remove the three bolts and spacers from the rectifier board 8 32EOZD 6 5 28EFOZD Models Disconnect the main field rotor leads from the rectifier board positive negative terminals Remove the armature retaining bolt and washer See Figure 9 6 8 32EOZD 6 5 28EFOZD Models Remove the armature from the shaft guiding the rotor leads through the armature bores See Figure 9 6 1 Armature 2 Armature retaining bolt 3 Rotor leads 4 Rectifier board Figure 9 6 Armature Removal TP 6255 4 10 18 19 20 21 22 23 24 6EOD 4 5EFOD Model Remove the four screws to remove the brush holder cover and brush cover gasket 6EOD 4 5EFOD 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 6EOD 4 5EFOD Model Remove the brush holder and carefully pull the leads out of the stator housing Attach a hoist hook to the generator lifting eye See Figure 9 7 Note The hoist capac
51. pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that 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 6255 4 10 Accidental Starting A WARNING o 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 batte
52. selection mode To set the communications parameter mode o To enter SAVE mode Go to Figure 7 11 SIAIVIE o Note Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed x denotes any number from 0 to 9 Figure 7 10 Advanced Configuration Mode engine data input types battery voltage and engine communications There are 3 options when the display says SAVE Press To return to the first parameter system voltage frequency Uu to check or change settings before saving See Figure 7 9 or To save changes or To discard changes without saving no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours x Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position x in the runtime hours display above denotes any number from 0 to 9 Now move the master switch to OFF RESET Figure 7 11 Save Mode after configuring generator set parameters TP 6255 4 10 Section 7 Controller 55 Output Voltage Adjustment Mode Display Move the generator set master swit
53. severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Check the belt tensions at the interval specified in the service schedule If tensions are not within the specifications adjust as necessary using the following procedures 34 Section 5 Cooling System Engine driven water pump pulley Adjusting arm pivot screw Battery charging alternator pulley Alternator adjusting screw Alternator pivot screw Check the alternator belt tension here Crankshaft pulley Check the seawater pump belt tension here Seawater pump adjusting screw Seawater pump pulley Pivot screw 1 2 3 4 5 6 7 8 9 0 1 Figure 5 5 Belt Tension Typical 5 8 1 Seawater Pump Belt Tensioning Procedure 1 Remove the belt guard 2 Check the belt tension at the midpoint of the longest span of the belt using a belt tensioning tool set to 55 ft lbs See Figure 5 5 Recheck a new belt tension after 10 minutes of operation Note If the belt tension is not within specifications go to step 3 If the belt tension is within specifications go to step 7 3 Loosen the pivot and
54. the engine reaches the crank disconnect speed Note The high engine temperature shutdown functions only when the coolant level is in the operating range Check for a low engine coolant level Loss of coolant shutdown Shutdown occurs 5 seconds after a loss of coolant condition is detected This protection becomes active 10 seconds after the engine has reached its stated crank disconnect speed and remains active as long as the generator run command is active Check for a clogged seawater intake or sea strainer Check for a damaged seawater pump impeller Low oil pressure shutdown Shutdown occurs if a low oil pressure condition exists for more than 5 seconds This protection becomes active 30 seconds after the engine has reached crank disconnect speed 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Check for leaks in the lubrication system Check the oil level and add oil if the level is low Overcrank shutdown Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts 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 Overfrequency shutdown Shutdown occurs when the governed frequency exceeds 110 of the system s fre
55. the positive and negative SCR terminals provide excitation current to the rotor See Figure 7 13 and the wiring diagrams in Section 10 The SCR module is protected by a 10 amp fuse F1 in lead 55 in the wiring harness Check the fuse and replace it if blown In the case of output voltage problems check the controller configuration and settings Thentestthe SCR module using the following procedure TP 6255 4 10 SCR Module Test Procedure Required equipment e Ohmmeter e 12 volt test lamp or voltmeter e 12 volt DC power source e 100 500 ohm resistor e Jumper 1 Set the ohmmeter to the R X 1 scale 2 Connect the ohmmeter from 4 to on the SCR module You should read high resistance in one direction and low resistance in the other reverse the leads Figure 7 13 Silicon Controlled Rectifier SCR Module 3 Connect the ohmmeter from AC1 to on the SCR module You should read high resistance in both directions 4 Connectthe ohmmeter from AC1 to on the SCR module You should read high resistance in one direction and low resistance in the other 5 Repeat steps 3 and 4 for AC2 6 Connect the ohmmeter from G1 to on the SCR module You should read low resistance in both directions 7 Repeat step 6 for G2 You should read low resistance in both directions 8 See Figure 7 14 Connect the negative lead from the DC power sourc
56. 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 Generator set Fuel tank Dual dip tubes Fuel filter Fuel feed pump Water trap Figure 4 1 Fuel System Schematic Typical 4 2 FuelFilter 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 TP 6255 4 10 Section 4 Fuel System Fuel Filter Replacement Procedure 8 9EOZD and 6 5 7EFOZD Models 1 Place the generator set on off switch in the OFF position 2 Disconnect the generator set engine starting battery negative lead first 3 Close the fuel supply valve 4 Remove the retaining ring filter cup o ring fuel filter element and spring 5 Wipe off all parts with a clean rag all mating surfaces and threads for damage replace as necessary 6 Replace the fuel filter element and install as shown in Figure 4 2 7 Open the fuel supply valve 8 Reconnect the gene
57. too high Check the engine speed using tachometer or frequency meter Adjust governor as necessary Section 4 4 Loose voltage sensing connections Check connections stator leads 11 and 44 for 1 phase models or leads 7 8 and 9 for 3 phase models and P15 controller connection Section 8 9 SCR module Check the wiring and connections to the SCR module Check the auxiliary winding fuse F1 lead 55 Replace SCR module and test voltage Section 7 7 Controller Check fuses wiring and connections Before replacing the controller replace the SCR module and test voltage Section 7 5 Section 7 7 Section 7 11 No output voltage TP 6255 4 10 AC output circuit breaker open Check for AC voltage on the generator side of the circuit breaker If there is AC voltage on the generator side of the breaker then a problem in the load circuits is causing the line circuit breaker to trip Check for and correct short circuits or overloading on the load side before resetting the circuit breaker Alternator or control system Perform separate excitation procedure to isolate the problem to the alternator or the control system Then troubleshoot the alternator or control system components as follows Section 8 2 Aux winding fuse blown lead 55 Replace blown fuse If fuse blows again check stator Section 8 14 SCR module Check auxiliary winding fuse F1 lead 55 Repla
58. 0 8 13 Fault Shutdown Tests Verify the operation of the generator set overspeed overcrank 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 8 13 1 Controller Fault Shutdown Functions Check the operation of the fault functions programmed in the ADC 2100 by performing the following tests If the ADC 2100 does not operate as described check the ADC configuration settings see Section 7 5 2 Also check the ADC 2100 wiring and connections see Section 10 Overspeed Shutdown The overspeed setting is programmed into the ADC contr
59. 0 2844 2986 Intake exhaust valve clearance cold 0 15 0 25 0 006 0 0010 mm in Fuel pump static pressure psi 4 8 12 volt pump or 5 5 9 24 volt pump 97 14 Pressure cap rating kPa psi TP 6255 4 10 Section 1 Specifications 13 20EOZD 28EOZD 32 020 17EFOZD 23EFOZD 27EFOZD 17 5EFOZD 23EOZD 24EOZD 25EFOZD 28EFOZD Generator Model 1 and 3 Ph 20EFOZD 20EFOZD 1 and 3 Ph 1 and 3 Ph Number of cylinders 4 Type 4 cycle 4 cycle turbocharged 4 cycle naturally aspirated Cylinder block material Cast iron Cylinder head material Cast iron Crankshaft material Forged steel Piston rings 2 compression 1 oil Connecting rod material Forged carbon steel Governor Centrifugal mechanical Engine firing order 1 cylinder on flywheel side 1737472 Direction of rotation as viewed from flywheel Counterclockwise Combustion system Direct injection 88 x 90 84 x 90 98 x 110 3 46 x 3 54 3 31 x 3 54 3 86 x 4 33 Displacement L CID 2 189 133 58 1 995 121 74 3 319 202 5 Compression ratio 19 1 1 18 9 1 18 5 1 Max power at rated RPM 60 50 Hz 30 1 24 8 37 1 29 3 55 8 46 7 RPM 60 50 Hz 1800 1500 Lubrication system Pressure trochoid pump Lube oil capacity w filter L U S qts 5 8 6 1 10 2 10 78 Bore x stroke mm in Oil recommendation API CD or CF class Fuel recommendation API
60. 1 Ph 2W 6 5EFOZD 1 Ph 230 V 1 Ph 2W 115 230 V 1 Ph 3 W 240 V 1 Ph 2W 7EFOZD 1 Ph 230 V 1 Ph 2 W 115 230 V 1 Ph 3 240 V 1 Ph 2W 8EOZD 1 Ph 120 240 V 1 Ph 3 W 120 V 1 Ph 3 W 120 V 1 Ph 2W 8 5EFOZD 3 Ph 230 400 V Ph 4 W Wye Bt Cn 0 No Can 10r6 J1939 70r9 Smartcraft t 0 No Can 10r 6 71939 x 0 No Can 10r6 J1939 70r9 Smartcraft t 0 No Can 10r 6 71939 9EFOZD 1 Ph 230 V 1 Ph 2W 115 230 V 1 Ph 3 W 240 V 1 Ph 2W 9EOZD 1 Ph 120 240 V 1 Ph 3 W 120 V 1 Ph SW 120 V 1 Ph 2W 12 or 24 10EOZD 1 Ph 120 240 V 1 Ph 3 W 120 V 1 Ph SW 120 V 1 Ph 2W o 10EOZD Ph 120 240 V 3 Ph 4 W Delta E o 127 220 V 3 Ph 4 W Wye E 220 380 V Ph 4 W Wye E 240 416 V Ph 4 W Wye T1EFOZD 1 Ph 230 V 1 Ph 2W N 115 230 V 1 Ph 3 W 240 V 1 Ph 2 E 11 5EFOZD 3 Ph 115 230 V 1 Ph 3W 115 230 V 3 Ph 4 W Delta A BA 110 190 V 3 Ph 4 W Wye e N 120 208 V 3 Ph 4 W Wye E 220 380 V 3 Ph 4 W Wye N 230 400 V 3 Ph 4 W Wye 5 240 416 V Ph 4 W Wye 13 20 1
61. 2 1 75 x 60 M12 1 75 x 65 M12 1 75 x 80 M12 1 75 x 90 M12 1 75 x 100 M12 1 75 x 110 M16 2 00 x 90 M20 2 50 x 65 M20 2 50 x 120 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 Part No Dimensions Hex Head Bolts full thread M933 04006 60 M933 05050 60 M933 06010 60 M933 06014 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06040 60 M933 06050 60 M933 08016 60 M933 08020 60 M933 08025 60 M933 08030 60 M933 10012 60 M961 10020 60 M933 10020 60 M933 10025 60 M933 10030 60 M933 10030 82 M961 10035 60 M933 10035 60 M933 12016 60 M933 12020 60 M933 12025 60 M933 12025 82 M933 12030 60 M933 12040 60 M933 12040 82 M961 14025 60 M933 14025 60 M961 16025 60 M933 16025 60 M933 16030 82 M933 16035 60 M933 16040 60 M933 16050 60 M933 16050 82 M933 16060 60 M933 18050 60 M933 18060 60 M4 0 70 x 6 M5 0 80 x 50 M6 1 00 x 10 M6 1 00 x 14 M6 1 00 x 16 M6 1 00 x 20 M6 1 00 x 25 M6 1 00 x 40 M6 1 00 x 50 M8 1 25 x 16 M8 1 25 x 20 M8 1 25 x 25 M8 1 25 x 30 M10 1 50 x 12 M10 1 25 x 20 M10 1 50 x 20 M10 1 50 x 25 M10 1 50 x 30 M10 1 50 x 30 M10 1 25 x 35 M10 1 50 x 35 M12 1 75 x 16 M12 1 75 x 20 M12 1 75 x 25 M12 1 75 x 25 M12 1 75 x 30 M12 1 75 x 40 M12 1 75 x 40 M14 1 50 x 25 M14 2 00 x 25 M16 1 50 x 25 M16 2 00 x 25 M16 2 00 x 30 M16 2 00 x 35 M16 2 00 x 40 M16 2 00 x 50 M16 2 00 x 50 M16 2 00 x
62. 20 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 5 LO Neutral LO 9 Ground 2 GRD gt L2 Load side O O Two Pole Line Circuit Side Breaker Jumper lead Figure 8 19 100 120 Volt 3 Wire Configuration TP 6255 4 10 8 11 2 100 120 200 240 Volt Configurations The 100 120 200 240 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 19 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 LO Ground GRD Load Side Single Pole Circuit Breaker 4 3 2 1 Stator Leads 60 Hz 50 Hz LO L1 100 120 Volt 100 120 Volt LO L2 100 120 Volt 100 120 Volt Figure 8 20 100 120 Volt 2 Wire Configuration LO Neutral LO Ground 2 GRD L1 gt 2 Load Side O O Factory O Two Pole tine Circuit Side Breaker 100 120 200 240 Volt A dA om 33 3 Wire Stator Lead
63. 20 240 V 1 Ph 3 W 20EOZD 3 Ph 120 240 V 1 Ph 3 120 208 V 3 Ph 4 W Wye 127 220 V 3 Ph 4 W Wye 120 240 V 3 Ph 4 W Delta 139 240 V Ph 4 W Wye 277 480 V Ph 4 W Wye Ec 20EFOZD 1 Ph 230 V 1 Ph 2W 115 230 V 1 Ph 3W 240 V 1 Ph 2W 20EFOZD 3 Ph 115 230 V 1 Ph 3 W 115 230 V 3 Ph 4 W Delta 110 190 V 3 Ph 4 W Wye 120 208 V 3 Ph 4 W Wye 220 380 V 3 Ph 4 W Wye 230 400 V Ph 4 W Wye 240 416 V Ph 4 W Wye 23EOZD 1 Ph 120 240 V 1 Ph 3 24EOZD 3 Ph 120 240 V 1 Ph 3 120 208 V 3 Ph 4 W Wye 127 220 V 3 Ph 4 W Wye 120 240 V 3 Ph 4 W Delta 139 240 V Ph 4 W Wye 277 480 V Ph 4 W Wye 2 w o preheater or 9 w preheater 23EFOZD 1 Ph 230 V 1 Ph 2W 115 230 V 1 Ph 3 W 240 V 1 Ph 2W 25EFOZD 1 Ph 50 230 V 1 Ph 2W 115 230 V 1 Ph 3W 240 V 1 Ph 2W 18 Bt 12 or 24 Cn 0 No Can 10r 6 41939 70r9 Smartcraft t Use voltage frequency parameters Uu07 Uu23 only with ADC application program version 1 20 or higher See Figure 7 7 for Ed settings with optional sender kits See Figure 7 8 for Cn settings with optional digital gauges gauges are available on selected models only Note Setting the Ec parameter automatically selects the Ed pa
64. 27 28bEFOZD Models A dry type air cleaner silences and filters the intake air The air intake silencer assembly connects to the intake manifold via a flexible hose Refer to Figure 3 2 during this procedure 1 Cover 2 Spring clip s 3 Housing 4 Pressure tap 1 8 27 NPT 5 Primary element 6 Dust ejector Figure 3 2 Cleaner 1 Release the spring clips to open the housing and remove the air silencer element 2 Tap the element lightly against a flat surface to dislodge loose surface dirt Do not clean the element in any liquid or use compressed air as these will damage the filter element 3 Examine the element and housing for damage Replace the element or housing if necessary 4 Wipe the cover and housing with a clean rag to remove dirt Make sure the sealing surfaces fit correctly and reattach the spring clips Section 3 Intake and Exhaust System 23 14 15 15 5 23 24EOZD and 11 5 13 20EFOZD Models These models use round polyurethane sound absorbing type intake silencer to silence the intake air drawn into the cylinder head from the intake port Besides providing a silencing effect the silencer also acts as an air cleaner Clean the silencer more frequently if operating in dirty dusty conditions See Figure 3 3 and refer to the following procedure Air Intake Silencer Cleaning Procedure 1 Remove t
65. 3 Ph 4 W Wye 11 127 220 V 3 Ph 4 W Wye 16 120 240 V 3 Ph 4 W Delta 10 139 240 V 3 Ph 4 W Wye 10 277 480 V 3 Ph 4 W Wye 4 28EOZD 3 Ph 32EOZD 3 Ph Use voltage frequency parameters Uu07 Uu23 only with ADC application program version 1 20 or higher See Figure 7 7 for Ed settings with optional sender kits See Figure 7 8 for Cn settings with optional digital gauges gauges are available on selected models only Note Setting the Ec parameter automatically selects the Ed parameter for the standard data inputs for that engine If you change Ec check the Ed setting Figure 7 6 Controller Parameters Settings Marine Diesel Models 52 Section 7 Controller TP 6255 4 10 Optional Sender Kits and Ed Setting The installation of optional sender kits may require a change to the Ed engine data inputs setting See Figure 7 7 for the Ed settings with optional sender kits No Change means the installation of the kit does not require a change to the Ed setting Note The Ec setting can affect the Ed setting If you change the Ec setting check the Ed setting and change it if necessary to match the value shown in the tables for your unit Note Installation of an optional electronic governor kit with a magnetic pickup does not require a change to the E
66. 3EFOZD models are powered by a three cylinder water cooled turbocharged diesel engine with a heat exchanger The 20EOZDA7EFOZD 20EOZD 17 5EFOZD models are powered by a four cylinder water cooled four cycle diesel engine with a heat exchanger The 23EOZD 20EFOZD 24EOZD 20EFOZD models are powered by a four cylinder water cooled four cycle turbocharged diesel engine with a heat exchanger The 28EOZD 23 25EFOZD and 32EOZD 27 28bEFOZD models are powered by a four cylinder water cooled four cycle diesel engine with 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 Kohler marine generator set ratings using accepted reference conditions of 25 C 77 F and pressure of 29 2 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 2 for identification and location of components Section 1 Specifications 11 1 2 Engine Generator Model 10EOZD 8 5EFOZD 9EFOZD 15 02 15 5 02 13EFOZD 8EOZD 6 5EFOZD 9EOZD 7EFOZD 13 02 11EFOZD 14 02 11 5EFOZ
67. 5 X 6238 22 3 8 24 4 50 X 6210 4 8 32 Whiz X 465 18 1 4 20 x 88 X 6210 5 10 24 Whiz X 465 7 1 4 20 x 1 00 X 6024 5 7 16 14 x 75 X 6210 1 10 32 Whiz X 465 8 1 4 20 x 1 25 X 6024 2 7 16 14 x 1 00 X 6210 2 qa og X 465 9 1 4 20 x 1 50 X 6024 8 7 16 14 x 1 25 6210 4 piraloc X 465 10 1 4 20 x 1 75 X 6024 3 7 16 14 x 1 50 X 6210 6 1 4 28 Spiralock X 465 11 1 4 20 x 2 00 X 6024 4 7 16 14 x 2 00 X 6210 7 5 16 18 Spiralock X 465 12 1 4 20 x 2 25 X 6024 11 7 16 14 x 2 75 X 6210 8 5 16 24 Spiralock X 465 14 1 4 20 x 2 75 X 6024 12 7 16 14 x 6 50 X 6210 9 3 8 16 Spiralock X 465 21 1 4 20 x 5 00 X 6210 10 3 8 24 Spiralock X 465 25 1 4 28 x 38 X 129 15 1 2 13 x 75 X 6210 11 7 16 14 Spiralock D lt T O0 X 129 17 1 2 13 x 1 00 X 6210 12 1 2 13 Spiralock Ris 92B XA 129 18 1 2 13 1 25 6210 15 7 1620 X 125 83 5 16 18 50 129 19 1 2 13 1 50 X 6210 14 Spiralock X 125 23 5 16 18 x 62 X 129 20 12 13 x 1 75 X 125 3 5 16 18 x 75 X 129 21 1 2 13 x 2 00 X 85 3 5 8 11 Standard X 125 31 5 1 6 18 88 X 129 22 1 2 1 3x2 25 X 88 12 3 4 1 0 Standard X 125 5 5h 6 18 x 1 00 X 129 23 1 2 1 3x2 50 X 89 2 1 2 20 Standard X 125 24 5 16 18 x 1 25 X 129 24 1 2 13 x 2 75 X 125 34 5 16 18 x 1 50 X 129 25 1 2 13 x 3 00 Washers X 125 25 5 16 18 x 1 75 X 129 27 1 2 13 x 3 50 X 125 26 5 16 18 x 2 00 X 129 29 1 2 13 x 4 00 Bolt 230578 5 16 18 x 2 25 X 129 30 1 2 13 x 4 50 PartNo ID OD Thick Screw X 25 29 5 16 18 x 2 50
68. 51 0 601 0 045 0 601 0 045 Main field rotor resistance cold ohms 20 C 68 F 3 0 3 0 2 24 2 24 Stator output voltages with separately excited generator using 12 v olt battery 60 Hz only 1 2 3 4 volts 95 95 55 66 volts Cold stator resistance 1 2 3 4 ohms 55 66 ohms TP 6255 4 10 Section 1 Specifications 17 1 4 Generator 12 Lead Component Specification Hot exciter field voltage amperage readings at rated voltage 10EOZD 8 5EFOZD 14EOZD 11 5EFOZD 202020 17 5EFOZD 24 020 20EFOZD No load 63 Hz volts amps 4 0 9 Full load 60 Hz volts amps 12 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 4 2 5 8 6 7 10 8 11 9 12 volts 150 145 55 66 volts 170 165 Cold stator resistance 1 4 2 5 3 6 7 10 8 11 9 12 ohms 55 66 ohms Component Specification Hot exciter field voltage amperage readings at rated voltage 28EOZD 23EFOZD 25EFOZD 32 020 27EFOZD 28EFOZD No load 63 Hz volts amps 21 0 8 21 0 8 Full load 60 Hz volts amps 64 2 3 70 2 5 Exciter f
69. 6 14 8 14 1 14 9 14 89 14 14 2 4 2 14 b bd SNOILOANNOO Td TIONI OT 10 2 for appl igure Sheet 2 of 2 see Fi Figure 10 14 Schematic for Model 9 32EOZD 7 28EFOZD Section 10 Wiring Diagrams 101 TP 6255 4 10 10 2 Manual Marine Ship to Shore 2 Wire and 3 Wire Transfer Switches Electro Switch AANS Generator SEIS 3 Wire Generator Sets 1 lt O L1 2 1 3 4 To Generator To Shore Set Power L2 Ge To Generator 6 8 ToShore Set Power LO Y Y To Load To Load Kraus Naimler American Solenoid Early Rectangular Design 2 Wire Generator Sets 3 Wire Generator Sets To Generator 5 To Shore Set Power To Generator 7 ToShore Set Power Kraus Naimler American Solenoid Newer Round Design 2 Wire Generator Sets 3 Wire Generator Sets 1 0 X To Generator 4 1 To Shore Set Power To Generator 5 To Shore Set Power Lo lt O Y To Load To Load TP 5399 5 102 Section 10 Wiring Diagrams TP 6255 4 10 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 TP 6255 4 10 Section 10 Wiring Diagrams 103 Notes 104 Section 10 Wiring Diagrams TP 6255 4 10 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp AB
70. 60 M18 2 50 x 50 M18 2 50 x 60 Pan Head Machine Screws 7985 03010 20 7985 03012 20 7985 04020 20 7985 05010 20 7985 05012 20 0 50 x 10 0 50 x 12 M4 0 70 x 20 5 0 80 x 10 5 0 80 x 12 Flat Head Machine Screws M965A 05016 20 M5 0 80 x 16 Part No Hex Nuts M934 03 50 M934 04 50 M934 05 50 M982 05 80 M6923 06 80 M934 06 64 M982 06 80 M6923 08 80 M934 08 60 M982 08 80 M6923 10 80 M982 10 80 M6923 12 80 M982 12 80 M982 14 80 M6923 16 80 M982 16 80 M982 18 80 M934 20 80 M982 20 80 M934 22 80 M982 22 80 M934 24 80 M982 24 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 5 0 80 5 0 80 M6 1 00 M6 1 00 M6 1 00 M8 1 25 M8 1 25 8 1 25 10 1 50 10 1 50 12 1 75 12 1 75 14 2 00 16 2 00 16 2 00 18 2 50 20 2 50 20 2 50 22 2 50 22 2 50 24 3 00 24 3 00 ID 3 2 4 3 5 8 6 4 8 4 10 5 13 0 15 0 17 0 19 0 21 0 25 0 OD 7 0 9 0 10 0 12 0 16 0 20 0 24 0 28 0 30 0 34 0 37 0 44 0 Type Standard Standard Standard Elastic Stop Spiralock Std green Elastic Stop Spiralock Standard Elastic Stop Spiralock Elastic Stop Spiralock Elastic Stop Elastic Stop Spiralock Elastic Stop Elast
71. 8 25 3 8 16 x 6 50 110 Appendix TP 6255 4 10 Metric Hex head bolts are hardness grade 8 8 unless noted Part No Hex Head Bolts partial thread M931 06040 60 M931 06055 60 M931 06060 60 M931 06070 60 M931 06075 60 M931 06090 60 M931 08035 60 M931 08040 60 M931 08040 82 M931 08045 60 M931 08050 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 10040 60 M931 10045 60 M931 10050 60 M931 10055 60 M931 10060 60 M931 10065 60 M931 10070 60 M931 10080 60 M931 10090 60 M931 10100 60 M931 12045 60 M931 12050 60 M931 12055 60 M931 12060 60 M931 12065 60 M931 12080 60 M931 12090 60 M931 12100 60 M931 12110 60 M931 16090 60 M931 20065 60 M931 20120 60 M931 20160 60 M931 22090 60 M931 22120 60 M931 22160 60 M931 24090 60 M931 24120 60 M931 24160 60 This metric hex bolt s hardness is grade 10 9 TP 6255 4 10 Dimensions M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M8 1 25 x 35 M8 1 25 x 40 M8 1 25 x 40 M8 1 25 x 45 M8 1 25 x 50 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 M10 1 50 x 40 M10 1 50 x 45 M10 1 50 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 50 x 90 M10 1 50 x 100 M12 1 75 x 45 M12 1 75 x 50 M12 1 75 x 55 M1
72. 80 3366231 Fax 91 80 3315972 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 9 Notes 10 Service Assistance TP 6255 4 10 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 SED 120 240 120 8 9 10EOZD 120 240 220 380 ee 240 416 13 15 15 5 20 23 28 32 02 120 240 14 20 24 28 32EOZD 120 240 120 208 120 240 127 220 139 240 277 480 14 20 24 28 32EOZD 115 230 230 240 115 230 6 5 7 9 11 13 17 20 23 25 27 28EFOZD 230 240 8 5EFOZD 230 400 11 5 17 5 20 23 25 27 28EFOZD 115 230 110 190 115 230 120 208 220 380 230 400 240 416 11 5 17 5 20 23 25 27 28EFOZD Figure 1 1 Generator Model Coverage TP 6255 4 10 Section 1 Specifications The 6EOD 4 5EFOD models are powered by a three cylinder water cooled four cycle diesel engine with a heat exchanger The 8EOZD 6 5EFOZD 9EOZD 7EFOZD 10EOZD 9EFOZD 10EOZD 8 5EFOZD and 13EOZD 11EFOZD models are powered by a three cylinder water cooled four cycle diesel engine with a heat exchanger The 14EOZD 11 5EFOZD and 15 15 5EOZD 1
73. ADV 7095B D Figure 10 5 aceon GM46351 Figure 10 6 BEOZD ADV 6845A F Figure 10 8 2 328166 Figure 10 10 10 32EOZD ADV 6845B F Figure 10 9 6 5EFOZD GM30264 H Figure 10 7 8 5 27EFOZD Figure 10 1 Wiring Diagrams For All Specs Except If Listed in Figure 10 2 Wiring Accessory Model Specs Diagram Figure Schematic Figure Diagram Figure 9EOZD 7EFOZD GM55351 GA1 to GA2 GM50490 C Figure 10 11 GM55350 GA to GAB ADV 7283A C Figure 10 13 GM33846 C Figure 10 10 10 32EOZD GM55349 GA1 to GA12 EPIO ADV 7283B C Figure 10 14 9 8 5 28EFOZD GM55348 GA1 to GA16 7 garei GM55347 GA1 to GA16 Figure 10 2 Wiring Diagrams TP 6255 4 10 Section 10 Wiring Diagrams 89 60 33S OLVN3HOS 404 335 AHOSS3OOV 304 MOlVIS 1915 GION3IOS MilMVIS SS YOLON YaLYVIS WS C3TIOMINOO NOOMIS NOS 3OV4H3INI 193NNOO WIND MO0193NNOO 10 Sdo YIS HOLIMS 10 401 5 07 YOLVNYALTY 01 MOIO3NNOO P XNIIQISNI INSNI 3iTIOMINOO 9nd GION3IOS 1304 Sd 3504 dii ANNOYS ANIONS 583 INYI000 go 9NIONVHO AMillv8 VOR
74. D Number of cylinders Type 4 cycle turbocharged Cylinder block material Cast iron Cylinder head material Cast iron Crankshaft material Stamped forging Forged steel Piston rings 2 compression 1 oil Connecting rod material Forged carbon steel Governor Centrifugal mechanical Engine firing order 1 cylinder flywheel side 1 3 2 Direction of rotation as viewed from flywheel Counterclockwise Combustion system Special swirl pre combustion Indirect SES Direct injection injection chamber Bore x stroke mm in 74 x 78 2 91 x 3 07 76 x 82 3 0 x 3 2 82 x 84 3 23 x 3 30 88 x 90 3 46 x 3 54 84 x 90 3 31 x 3 54 Displacement L CID 1 01 61 39 1 115 68 1 33 81 14 1 642 100 2 1 5 91 3 Compression ratio 23 1 23 5 1 19 2 1 19 1 1 19 0 1 Max power at rated RPM 60 50 Hz 14 0 11 6 14 74 12 43 18 4 15 1 22 6 18 6 26 1 21 8 RPM 60 50 Hz 1800 1500 Lubrication system Pressure trochoid pump Lube oil capacity w filter L U S qts 3 6 3 8 4 7 5 0 Oil recommendation CD or CF class Fuel recommendation API Diesel ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Fuel shutoff solenoid Electric Fuel pump Electric rotary vane Fuel pump priming Electric Max recommended fuel pump lift
75. DC AC A D ADC adj ADV AHWT AISI ALOP alt ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BDC BHP blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cow CEC cfh cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British
76. ED display is powered by the generator set s battery Also the remote start stop command is supported via the ADC remote gauge Seethe wiring diagram and schematic drawing in Section 10 Controllers are shipped from the factory with the jumper connected Disconnecting the jumper allows the controller to power down 48 hours after the generator set shuts down and the remote start stop command is no longer supported A jumper across controller pins P7 1 and P7 2 maintains power to the controller at all times Controllers are shipped with the jumper connected for continuous power See Figure 7 15 If the generator set is not used for a long period of time without exercising the battery may drain The P7 connector has either 2 or 3 pins Disconnecting the jumper or moving the jumper to pins P7 2 and P7 3 allows the controller to power down automatically 48 hours after the generator set shuts down if the generator set master switch is in the AUTO position A remote start signal from a transfer switch or a remote start stop switch connected to controller leads 3 and 4 or moving the generator set master switch to the RUN position turns the controller back on Note For most applications it is not necessary to disconnect the continuous power mode jumper Use the following procedure to disconnect the jumper if desired Section 7 Controller 59 Procedure to disconnect the continuous power mode jumper optional Note The P7 jumper was av
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79. Nm 27 ft 165 45 Nm 34 ft Ibs 20 Section 1 Specifications TP 6255 4 10 2 1 General Schedule routine maintenance using the service schedule located in the generator set operation manual and the runtime hours shown on the ADC 2100 If the generator set will be subject to extreme operating conditions service the unit accordingly Note See the generator set operation manual for the service schedule and other service not included in this manual Note High mineral content seawater salt water can cause rapid destruction of metals Wipe up all salt water spillage on and around the generator set and keep metal surfaces free from accumulated salt deposits TP 6255 4 10 Section 2 Scheduled Maintenance WARNING Pa or 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 Move the generator set master switch to the OFF position 2 Disconnectthe 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
80. Note Check the generator set nameplate to verify the original voltage configuration Reconnect the P1 P15 and P16 connectors Connect the ground strap using bolt washer and lock washer install the lock washer against the ground strap Reinstall the ADC 2100 Reinstall the junction box louvered panel Reconnect all of the external connections the exhaust line to the mixing elbow the fuel line to the TP 6255 4 10 21 22 23 24 fuel pump filter inlet the water line to the seawater pump the remote interface connector the AC output leads and the battery cables to the battery negative lead last Verify that the generator set master switch is in the OFF position 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 87 Notes Section 9 Generator Disassembly Reassembly TP 6255 4 10 88 Section 10 Wiring Diagrams WARNING S Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equi
81. OZD 11 5EFOZD 13EFOZD Overbolts 34 Nm 25 ft Ibs Rotating diode board 38 Nm 28 ft Ibs Crankshaft pulley 36 6 Nm 27 ft Ibs 21 6 Nm 23 Nm Thermostat housing 192 in Ibs 17 ft Ibs Exhaust manifold 19 Nm 14 ft Ibs 38 41 Nm 37 Nm Seawater pump pulley 28 30 ft Ibs 27 ft Ibs Back plate to engine block 37 Nm 27 ft Ibs Rotor hub to flex disc 38 Nm 28 ft Ibs Flex disc to flywheel 19 Nm 14 ft Ibs 78 5 88 3 Nm Flywheel bolts 58 65 ft Ibs SCR to end bracket 4 Nm 35 in Ibs 21 6 Nm 192 in Ibs 38 41 Nm 28 30 ft Ibs 83 3 88 2 Nm 62 65 ft Ibs 202020 28EOZD 32bEOZD 17EFOZD 23EFOZD 27EFOZD 17 5EFOZD 23EOZD 24EOZD 25EFOZD 28EFOZD Generator Model 1 and 3 Ph 20EFOZD 20EFOZD 1 and 3 Ph 1 and 3 Ph Overbolts 34 Nm 25 ft Ibs Rotating diode board 38 Nm 28 ft Ibs Back plate to engine block 36 6 Nm 27 ft Ibs Rotor hub to flex disc 38 Nm 28 ft Ibs Flex disc to flywheel 19 Nm 14 ft Ibs Exhaust manifold 22 7 Nm 16 8 ft Ibs Thermostat housing 21 6 Nm 192 in Ibs Rotor fan to flywheel 45 Nm 34 ft Ibs Crankshaft pulley 36 6 Nm 27 ft Ibs Generator adapter rear 1 2 to front 1 2 N A 53 Nm 39 ft Ibs Generator adapter to flywheel housing backplate Seawater pump pulley 38 41 Nm 28 30 ft Ibs SCR to end bracket 4 Nm 35 Ibs 37
82. S LVIS GIONTIOS NilMVIS SS SOLON 33biVIS WS M3iJlLO34 C3TIOMINOO NOOIIIS MOS QuvOH 3OVJM3INI AVT34 LOANNOD f NODD M3QN3S 3snsS3Md 10 SdO 3HnSS3Hd YUYM YIS MOT HOLIMS 3NnsS3Md 10 901 0045 O1 MOIVNS3LIV 01 02 MOLO3NNOO fr 5 INSNI ANNONS N3TIOMINOO 99 GION3IOS 1303 83 dWnd 1304 dd 3sni 4 HOLMS 3Nhive3dW3l 513 983 ipa M3ON3S INYIOOO ngo 9NIDuVHO AM3llv8 NilV3H NIV Milv3H NN ZS SNOILOJNNOO LIOA t QNO 4203 Zem 01 TE SNOLLO3NNOO LIOA 21 Wmo azoa 01 d 149 d 3Ov4WalNI 5 O N s zsd0 c3 dd voz 21 19 OL 0 zz id 01 95 98 140 sc id O0 14 01 19 THA MOlvis dvd 3SVHd 33HHl S 8S Ady 1335 SNOLLO3NNOO MOIVH3N35 310N 1 15 z S1d 6A s1d BA 0 14 ZA BSVHd SIONIS 9289 MOlVIS CVT 335 SNOLLO3NNOO MOIVH3N39 N04 310N lvls e eid 1 91 ii j on
83. When set the generator as load is applied attempts to maintain normal output until the engine speed drops below the cut in frequency set in step 6 Setthe voltmeter to measure frequency Adjustthe engine speed to the operating frequency 50 or 60 Hz by adjusting the engine governor Readjust the voltage gain parameter 2P until the light flicker minimizes if necessary Check the voltage Readjust the voltage parameter 1P if necessary Save the settings Refer to Section 7 5 for instructions Note The ADC will revert to the previous settings at the next startup if the changes are not saved Stop the generator set Cut In Frequency 60 Hz 57 5 Hz 50 Hz 47 5 Hz Figure 8 18 Cut In Frequencies TP 6255 4 10 8 11 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 8111 100 120 Volt Configurations If the installation requires a factory two pole circuit breaker do not connect the load side terminals of the circuit breaker together see Figure 8 19 If the installation requires a 100 120 volt 2 wire system use a single pole circuit breaker See Figure 8
84. Y ON Av T3H NOH ON 17074 NONWOO NOWWOO 17003 NOWWOO NONWWOO AVT3H NOH 9 Eld G Eld b Eld Eld 1 14 SNOLLO3NNOO 18 QHVO8 30VJU3 NI AV T3H LndNIOV 6A 1 Ov LUZA 1 Ov e sir 2 91 1 91 SNOLLO3NNOO SIP 99 ON 4 07314 65 LNdNI ONIGNIM 170 Av T3H HSV 14 0 9 94 86 914 91 E 9ld 2 94 1 914 SNOILOSNNOO 91f 22258 25 SNOLLO3NNOO Sd 22254 NO 1V8A WNOIS HOSN3S HOSN3S 3HfiSS3Hd HOIH HOSN3S HA HOIH SSOY T3A31 1NY 1009 Z dOLS LUVLS SLOWSY dOLS LUVLS 310W3H WEA HOSN3S HOSN3S HA HOLIMS 5 TIO 170 HOVL 170 AVIA TAN NMOGLNHS 7 TWNYALXa H NWO 1VNH31X3 MO HOSN3S 1 1000 HOIH HOSN3S LNY 1009 82 HONH3AOD VL HONH3A05 91 HONH3AOO NOWWOO 2 1109 Av 138 H31V3H OL 5 NO 15 56 14 vE ld 88 14 6 14 18 14 06 14 62 1 82 1 212 1 92 56 14 ve ld c ld 12 1 02 81 14 21 14 91 14 Gl ld Zl ld 01 14 6 14 8 ld L
85. a ON LInvs NONNOO NOWWOO LInvs NONWOO NOWWOD AVT3H ND SNOIIO3NNOO Std avoa 3OV3H3INI AVTST 9 Eld 9 14 Eld ld 2 14 1 81 99 INANI XNY amp SANIN 27314 LNdNI ONIGNIM Xnv 110 AVI34 9 SMa qr 9 9ld 8 914 914 9ld 914 1 914 SNOIIO3NNOO 917 103135 33MOd 5 3 N 4d 2 4 1 24 5 24 9 N 3 N ANNONS 3 N 22258 22258 6 8 54 1 9 Sd Sd 1 99 QXL 22658 NO 1V8A WNOIS MOSN3S 553 3OMhOS MNOSN3S 3H SS3Md MOSN3S SSO1 T3A31 LNV1009 Z dOLS IMVIS 310W3M L dOIS INVIS 310N33 LWA HOSN3S 3HhSS3Hd 3OSN3S YA ANNONO HOLIMS JYNSSJYd 1no HOWL 1 0 7303 NMOGLNHS NYO NYO MOT NOSN3S dWil INY1OOD HOIH MOSN3S dW3l 1NY1009 82 MONH3AO09 VC YONYAAOD VL HONH3JAO9 8 YONYAAOD I1nv4 NONWOO 100 AvT33 N31V3H OL TYNOIS 100 Avia Milivis 98 14 14 geld 2 14 12 14 08 14 62 13 82 14 12 14 92 19 92 14 14 Z lId 22 14 1 14 02 14 61 14 81 14 11 14 91 14 91 14 91 14 l ld 21 14 11 189 01 14
86. ading is stable proceed to step 4 66 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 this test shows that the rotor and stator are in good condition check the wiring and fuses Check the SCR module See Section 7 7 Silicon Controlled Rectifier SCR Module Check the controller settings and connections See Section 7 Controller TP563274 9 8 7 SCR module FN lead disconnected from SCR FP lead disconnected from SCR 10 amp fuse DC ammeter 12V battery Exciter or brushes slip rings Rectifier module Main field rotor ONDA Figure 8 3 Separate Excitation Connections TP 6255 4 10 8 3 Exciter Field 5 Check the exciter field for a short to ground condition Use a megohmmeter to apply 500 volts 8 32EOZD 6 5 28EFOZD DC to the FN or FP lead and the exciter field frame Models See Figure 8 5 Follow the megohmmeter manufacturer s instructions for using the Direct current from the battery magnetizes the exciter megohmmeter A reading of approximately field When the exciter armature rotates within the 1 5 MOhms and higher indicates th
87. 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 TP 6255 4 10 5 8 2 Battery Charging Alternator Belt Tensioning Procedure 1 Remove the belt guard 2 Check the belt tension at the midpoint of the longest span of the belt by pressing with your finger See Figure 5 5 and Figure 5 6 Ifthe beltis not within the specifications go to step 3 If the belt is within the specifications go to step 7 Belt Type Deflection mm in New 8 12 0 3 0 5 Used 10 14 0 4 0 6 Figure 5 6 Belt Specifications 3 Loosen the adjusting arm pivot screw alternator pivot screw and alternator adjusting screw 4 While prying the alternator outward tighten the alternator adjusting screw 5 Tighten the adjusting arm pivot screw and alternator pivot screw 6 Recheck and adjust as necessary 7 Replace the belt guard 5 8 3 Anticorrosion Zinc Anode The heat exchanger on models 8 9 10EOZD 6 5 7 9EFOZD 28 32EOZD and 23 25 27 28EFOZD 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 Section 1 for the location and us
88. ailable on generator sets with serial numbers before 2051415 Note For most applications it is not necessary to disconnect the continuous power mode jumper 1 Prevent the generator set from starting a Move the generator set master switch to the OFF RESET position b Disconnect power to the battery charger if equipped c Disconnect the generator set engine starting battery negative lead first 2 Remove the controller from the generator set housing Disconnect the engine wiring harness connector P1 plug 35 pin from the controller Disconnect the J15 and J16 connectors See Figure 7 15 b Remove the controller from the generator set housing in order to access the back of the controller 3 Remove the controller s back cover to access the jumper a Notethe labels on the three leads connected to the generator set master switch for reconnection later Disconnect the leads at the pink connectors See Figure 7 15 b Remove the cover screws and remove the controller s back cover See Figure 7 15 4 Locate the P7 connector near the top of the controller See Figure 7 15 Remove the jumper from pins 1 and 2 of the P7 connector If the P7 connector has three pins connect the jumper across pins 2 and 3 for storage 5 Replace the controller s back cover and secure the cover screws 6 Reconnect the three pink connectors to the generator set master switch 7 Reconnect the J15 and J16 connectors
89. amage 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 TP 6255 4 10 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 If the 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 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
90. ator set If the unit shuts down disconnect lead 13 from the LOP switch and reset the controller Restart the generator set and verify that it does not shut down A successful restart indicates a bad LOP switch Replace the switch 4 D 2 m UC Te Se 4 1 Coolant Temperature Sensor Figure 8 24 Coolant Temperature Sensor Location BEOZD Model Shown Temperature C F Resistance Ohms 30 86 2106 2392 100 212 182 198 Figure 8 25 Coolant Temperature Sensor Resistance Readings All Models o 1 Oil pressure switch Figure 8 26 Oil Pressure Switch Location 24EOZD Model Shown Oil Pressure Range MPa kg cm 0 29 0 39 3 4 0 21 0 41 2 1 4 2 8 32 02 and 6 5 28EFOZD 6EOD and 4 5EFOD Figure 8 27 Oil Pressure Range TP 6255 4 10 8 14 Fuses The engine harness or junction box for 6 OD 4 5EFOD and 9EOZD 7EFOZD models contains three inline fuses See Figure 8 28 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 i
91. ator set cranks but does not start Possible Cause No fuel Corrective Action Check the fuel supply Reference Loose connection or open circuit Check for loose or open connections at the fuel solenoid lead 70A Check the controller engine wiring continuity Section 10 Air cleaner clogged Clean or replace Section 3 Incorrect controller configuration Check for correct controller configuration parameters unit configuration UC and engine configuration EC Section 7 5 No engine rotation sensed check for an overcrank fault shutdown Check for a locked rotor Section 8 8 Generator set starts hard Low battery voltage Check battery voltage power supply and operation Generator Set O M Air cleaner clogged Replace element Section 3 Worn piston rings valves Check compression Engine S M Generator set starts but shuts down Fault shutdown Check for a fault shutdown code on the Advance Digital Control s LED display Correct the fault and then move the generator set master switch to the OFF RESET position to reset the ADC Section 7 4 Generator set stops suddenly TP 6255 4 10 Fault shutdown Check for a fault shutdown code on the Advanced Digital Control s LED display Correct the fault and then move the generator set master switch to the OFF RESET position to reset the ADC Section 7 4 No fuel Check the fuel supply
92. ce SCR module and test voltage Section 8 14 Section 7 7 Controller Check controller settings Check wiring and connections Before replacing the controller replace the SCR module and test voltage Section 7 5 Section 7 7 Section 7 11 Section 6 Troubleshooting 41 Troubleshooting Chart continued Problem No output voltage continued Possible Cause Open wiring terminal or pin in buildup circuit or SCR module circuit Corrective Action Check continuity Reference Section 7 7 Rotor connections Check for open circuit in the rotor connection circuit leads FN and FP to the SCR and RIB Section 8 8 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 Flash relay K3 on relay interface board RIB Check flash LED on RIB Check fuse F2 and troubleshoot RIB Section 7 10 Generator set is noisy Exhaust system leaks Check and replace as necessary Engine not running smoothly See Generator set operates erratically this table See Generator set 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 not securely installed Inspect for loo
93. ch to the RUN position The generator set XIXIXIx engine starts and the controller display shows the engine runtime hours Hold Wait about 5 seconds until the display changes from runtime hours Or to the program version number x Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password The controller is now in the voltage coarse adjustment mode Press lt l To raise or lower the voltage in large increments approximately 5 7 volts per step To enter fine voltage adjustment mode To raise or lower the voltage in smaller increments approximately 0 5 0 7 volts per step lt To enter coarse voltage stability gain adjustment mode To raise or lower the voltage stability gain in large increments To enter fine voltage stability gain adjustment mode To raise or lower the voltage stability gain in smaller increments K Io To enter volts Hz adjustment mode To raise or lower the volts Hz 00 low 09 high lt 0 To save see Figure 7 11 Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model
94. cuments included with the product e Call toll free in the 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 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 TP 6255 4 10 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 atthe prescribed intervals Maintenance work must be performed by appropriately skiled 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
95. d setting Sender Kit None GM32112 KA1 and KP1 GM50552 KA1 GM47164 KP1 None 1 GM32112 KA1 and KP1 3 GM50552 KA1 OP and WT sender kits Oil pressure sender kits Electronic governor kit No Change No Change 8 32ECZD 6 5 28EFOZD No Change Figure 7 7 Settings with Optional Sender Kits Cn Communication Parameter See Figure 7 8 for communication parameter settings If your generator set is connected to a remote digital gauge refer to Figure 7 8 or the instruction sheet provided with the gauge to determine the communication parameter Cn setting Gauge Cn CAN Description Setting Description None GM32337 KP1 Remote Digital Gauge inch GM46035 KP1 Remote Digital Gauge inch GM50822 KP1 Remote Digital Gauge 2 inch Smartcraft Figure 7 8 Communication Parameter Cn Settings optional gauges are available on selected models only TP 6255 4 10 Power Modes Use Figure 7 8 to determine power down times With the generator set master switch in the AUTO position there are three possible controller power modes e 48 hour power down If the ADC 2100 communication parameter setting is Cn00 CnO7 the controller will power down after 48 hours of inactivity Ifthe generator set has been started the controller will power down 48 hours after the generator set stops Continuous power mode f the ADC 2100 c
96. dentical replacement parts Part Number Location Lead 55 358337 Auxiliary Winding 10 amps Relay Interface Board 223316 Lead PF2 10 amps Controller 10 amps 223316 Lead See Figure 8 29 for GEOD 4 5EFOD and 9EOZD 7EFOZD models fuse location Figure 8 28 Fuses 6EOD 4 5EFOD Model Ts Ds Bs Ds s Ps Ds Bs Diss PS Bs s Bs Bs Ps S Ds ADV6967 A 1 Fuses Figure 8 29 Fuse Location on 6EOD 4 5EFOD 9EOZD 7EFOZD Models TP 6255 4 10 8 15 Continuity Checks WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment To further check generator set components disconnect the battery and remove wiring harness plugs from the ADC circuit board U
97. ding indicates an open winding Repair or replace the main field if the ohmmeter readings indicate the main field is inoperative If the 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 condition 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 6255 4 10 TP 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 varnish
98. ds screens and covers before operating the generator set 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 standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn offthe 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 6255 4 10 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 repairs Remove all jewelry before servicing the equipm
99. dure to isolate problem to the alternator or the control System Section 8 2 SCR module Check wiring and connections to the SCR module Check the auxiliary winding fuse F1 lead 55 Replace SCR module and test voltage Section 7 5 Section 7 7 Controller Check the controller settings Check the controller fuse wiring and connections Before replacing the controller replace the SCR module and test voltage Section 7 5 Section 7 7 Section 7 11 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 Low engine speed causing voltage roll off 40 Section 6 Troubleshooting Check system voltage frequency UU and engine type EC parameters Adjust the engine governor speed Troubleshoot the engine Section 7 5 Section 4 4 Engine S M TP 6255 4 10 Troubleshooting Chart continued Problem Light flicker Possible Cause Voltage stability gain setting Corrective Action Check and adjust the voltage stability gain setting using the ADC 2100 Reference Section 7 5 3 High generator output voltage Incorrect controller configuration Check and adjust the controller configuration parameters Section 7 5 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 7 5 3 Engine speed
100. e field winding magnetized exciter field windings an electrical current is functional A reading of less than approximately develops within the exciter armature Test the exciter 1 5 MOhms indicates deterioration of the winding field according to the following procedure insulation and possible current flow to ground if so replace the exciter field Exciter Field Test Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect the generator set engine starting battery negative lead first 3 Disconnect the FN FP leads 4 Check the exciter field resistance by connecting an ohmmeter across exciter field FN and FP leads See Figure 8 4 See Section 1 Specifications for the resistance reading of a cold exciter field Alow reading indicates an internal short and a high reading indicates an open winding Repair or MS ADC 2100 replace the exciter field if the ohmmeter readings Megohmmeter indicate an inoperative exciter field refer to Frame connection Section 9 for removal If the resistance test is Exciter armature Exciter field Main field rotor inconclusive perform a megohmmeter test on the exciter field as described in the next step Figure 8 5 Megohmmeter Connections on the Exciter Field
101. e replacing other components e Incorrect controller settings Always check the controller configuration settings before replacing the controller Section 7 5 contains the instructions for checking and changing the controller configuration Some problems may be solved by updating the controller s application program Check www kohlernet com Tech Tools Software for information on ADC 2100 application program updates Refer to Section 7 6 for instructions to check the version number of the controller s application program and for more information on updating the application program TP 6255 4 10 Section 6 Troubleshooting 6 3 General Before beginning the troubleshooting procedures read all the safety precautions at the beginning of this manual 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 ris
102. e 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 TP 6255 4 10 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 7 and Figure 5 8 Anticorrosion Zinc Anode Replacement New Anode Dimensions mm in Replace When Percent of Zinc Remaining Is lt 50 of length diameter Models 8 9 10EOZD 6 5 7 9EFOZD 28 32EOZD 23 25 27 28EFOZD 9 0 34 x 43 1 7 lt 50 of 9 0 34 1949 29 length diameter Figure 5 7 Anticorrosion Zinc Anode Plug Measurements 1 Diameter 9 mm 0 34 in 2 Length 43 mm 1 7 in for 8 9 1 0EOZD 6 5 7 9EFOZD models or 19 mm 0 75 for 28 82EOZD 23 25 27 28EFOZD models Figure 5 8 Anticorrosion Zinc Anode Plug 4 Clean the threaded hole of the 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 pum
103. e to the positive 4 terminal on the SCR module Note The SCR module may be damaged if the power supply is connected incorrectly Be sure to connect the negative lead from the battery to the positive terminal on the SCR module Section 7 Controller 57 9 Connect the positive lead from the DC power source with the lamp in series to terminal AC1 on the SCR module The lamp should not glow 10 Connectthe jumper with the resistor in series from the positive lead ofthe DC power source to terminal G1 on the SCR module The lamp should glow 11 Repeat steps 9 and 10 with the positive lead and lamp connected to terminal AC2 on the SCR module and connecting the jumper with resistor to 5 terminal G2 12 If any of the above checks indicates a bad SCR module replace the module Note When replacing the SCR module be sure to e d apply thermal compound to the back of the A module to prevent overheating Thermal AC2 compound is provided with the SCR module d replacement kit 12VDC power source 12 VDC test lamp SCR module Jumper 100 500 ohm resistor Figure 7 14 SCR Test 58 Section 7 Controller TP 6255 4 10 7 8 Continuous Power Mode Jumper if equipped Note The P7 jumper was available on generator sets with serial numbers before 2051415 A WARNING S Accidental starting Can cause severe injury or death Disconnect the battery cables befo
104. ed 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 Testthe 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 performing 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 Checkthe generator output lead connections See Section 10 Wiring Diagrams TP 6255 4 10 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 1and2 1 and 11 2 and 11 3 and 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 Contin
105. engine The run relay energizes andthe run LED 1 turns on The crank and flash relays energize and the corresponding LEDs 2 and 3 turn on 0 5 seconds later The ADC display indicates the crank cycle 1 code CC 1 The ADC attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shuts down on an overcrank fault TP 6255 4 10 When the engine comes up to speed the low oil pressure switch contacts open Note The controller circuit board prevents fault shutdowns during startup until the crank disconnect relay energizes The cyclic cranking cycle is programmed into the ADC s application code and is not adjustable in the field The factory sets the cranking cycle for three cycles of 15 seconds on time and 15 seconds off time If the cranking cycle seems shorter than the factory setting check the engine starting battery 7 3 2 Starting Sequence Remote Start When the master switch is moved to the AUTO position the controller may remain OFF until the remote start switch or transfer switch engine start contacts close the first time if the power jumper is removed The start sequence proceeds as described in Section 7 3 1 Starting Sequence Master Switch Moved to RUN Section 7 Controller 45 7 39 8 Running Sequence When the engine speed reaches 750 rpm the crank relay deenergizes and the crank LED 3 turns o
106. ent Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building marina electrical system only through an approved device and after the building marina main switch is turned off Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a ship to shore transfer switch to prevent interconnection of the generator set power and shore power 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 andfollowthe instructions ofthe 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 6255 4 10 Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to rel
107. eration Remove the jumper wire from the LOP switch and ground Start the generator set and run it for at least 25 35 seconds to verify that the generator set does not shut down Overcrank Shutdown Disconnect the starter motor lead at the starter solenoid K20 terminal Move the controller master switch to the RUN position Observe that the generator set simulates cranking for 15 seconds and then rests for 15 seconds Check that the generator set shuts down after the third crank rest cycle High Engine Temperature Shutdown Connect a jumper wire across coolant temperature sensor CTS connections P1 8 and P1 9 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 77 8 13 2 Fault Shutdown Switches Check the low oil pressure and high engine temperature shutdown switches on the engine by performing the following tests If the sensor does not function as described replace it WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair cl
108. erator Disassembly Reassembly 2 Screws with spacers 4 3 Screws without spacers 4 1 Bolts 8 2 Rotor assembly 1 Drive disc 2 Rotor 3 Bolt Figure 9 11 Drive Disc TP 6255 4 10 9 2 Collector Ring and Bearing View A A PRESS COLLECTOR RINGS ONTO Replacement 6EOD 4 5EFOD ROTOR SHAFT SHOULDER IN THIS POSITION Model 90 1 Unsolder the collector ring leads from the collector ring terminals 2 Remove the collector rings with a three jaw puller CONNECTION END VIEW 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 13 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 1 Collector ring commutator stones Turn down the collector rings on the rotor shaft Figure 9 13 Rotor Assembly 7 Solder the leads onto the collector ring terminals The connection is not to exceed 9 65 mm 0 38 in 9 3 Reassembly beyond the eelleetor rings see Figure 9e 1 Clamp the rotor in a soft jaw vise Install a new drive disc on the rotor Tighten the eight bolts to 8 Test to ensure continuity at the collector rings i 38 Nm 28 ft Ibs See Figure 9 14 Min diameter mm in 57 15 2 250 Max f
109. erature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6255 4 10 Appendix Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clea
110. es with separately excited generator using 12 volt battery 60 Hz only 1 2 3 4 volts 55 66 volts Cold stator resistance 1 2 3 4 ohms 55 66 ohms Component Specification Hot exciter field voltage amperage readings at rated voltage 8 020 6 5EFOZD 9EOZD 7EFOZD 10EOZD 9EFOZD 13EOZD 11EFOZD 15EOZD 15 5EOZD 13EFOZD No load 63 Hz volts amps 4 0 9 4 0 9 Full load 60 Hz volts amps 9 1 5 9 1 5 Exciter field resistance cold ohms 20 C 68 F 4 8 4 8 Exciter armature resistance cold ohms line to line 1 18 1 18 Main field rotor resistance cold ohms 20 C 68 F 5 0 5 0 Stator output voltages with separately excited generator using 12 v olt battery 60 Hz only 1 2 3 4 volts 135 135 55 66 volts 180 180 Cold stator resistance 1 2 3 4 ohms 55 66 ohms Component Specification Hot exciter field voltage amperage readings at rated voltage 20 02 17EFOZD 23EOZD 20EFOZD 282020 23EFOZD 25EFOZD 32 02 27EFOZD 28EFOZD No load 63 Hz volts amps 6 1 0 6 1 0 18 0 7 18 0 7 Full load 60 Hz volts amps 14 2 1 16 2 4 42 1 6 45 1 7 Exciter field resistance cold ohms 20 C 68 F 5 8 5 8 22 7 2 8 22 7 2 8 Exciter armature resistance cold ohms line to line 0 51 0
111. ess than 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 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 Use a 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 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 d
112. ff When the output voltage on leads 11 and 44 for 1 phase models or leads 7 8 and 9 for 3 phase models reaches about 30 VAC the flash relay deenergizes and the flash LED 2 turns off 7 3 4 Stopping Sequence Master Switch Moved to OFF RESET Place the generator master switch in the OFF RESET position The run relay deenergizes and the run LED 1 turns off The generator set stops 7 39 5 Stopping Sequence Remote Stop If the generator set is running momentarily closing the remote start stop contacts deenergizes the run relay and the run LED 1 turns off but the controller does not power down The controller remains powered and displays the engine runtime hours Note Forunits with serial numbers before 2051415 Disconnecting the P7 jumper will allow the controller to power down 48 hours after generator set shutdown See Section 7 8 Continuous Power Mode Note For units with serial numbers 2051415 and later If the ADC 2100 is configured for a CAN gauge the controller will not power down if the master switch is in the AUTO position If the ADC 2100 is not configured for a CAN gauge the controller will power down after 48 hours if the master switch is in the AUTO position If the generator has been started the controller will power down 48 hours after the generator stops 46 Section 7 Controller 7 4 Faults 7 4 4 Fault Shutdowns Under the fault conditions listed in Figure 7 4 the ADC displays a faul
113. free of air bubbles flows from the vent screw at position 5 Tighten the screw 6EOD 10 32EOZD 4 5EFOD and 9 28bEFOZD Models 1 Loosen the fuel injection pump screw See Figure 4 5 2 Initiate the auto start sequence until fuel free of air bubbles flows from the injection pump screw 3 Tighten the fuel injection pump screw TP 6255 4 10 8 9EOZD and 6 5 7EFOZD Models ADV6843a a 13 32 020 amp 11 27EFOZD Models with Specs GM33035 GA1 GA2 GM33036 GA1 GA2 amp GM33037 GA1 GA2 Vent screw position 1 Vent screw position 2 Fuel filter Fuel injection pump Vent screw position 5 Fuel injection pump screw Figure 4 5 Fuel System Typical Section 4 Fuel System 29 4 3 Fuel Pump 8 32EOZD and 6 5 28EFOZD Models 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 6 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 p
114. haust manifold mounting threads for cracking and corrosion 3 4 Turbocharger Models 14 15 15 5 23 24EOZD and 11 5 13 20EFOZD Inspectthe compressor blower atthe specified interval for build up of carbon residue Perform all other turbocharger inspection and service as described in the service schedule of the engine service manuals See Figure 3 4 and Figure 3 5 to inspect the compressor Compressor Inspection 1 Remove the breather hose from the air intake silencer connector if equipped 2 Remove the air intake silencer 3 Inspect the compressor blower housing and the impeller blower wheel for buildup of carbon residue Use a Yanmar approved turbocharger cleaner if cleaning is required 4 Place the air intake silencer over the turbocharger compressor housing inlet and tighten the clamp 5 Attach the breather hose to the air intake silencer connector if equipped TP 6255 4 10 TP 6071 32 Compressor housing Rotor assembly turbo Housing assembly blower Plate assembly seal Circlips Housing assembly bearing Heat protector Figure 3 4 Turbocharger Inspection TP 6071 32 Turbocharger assembly Gaskets Exhaust elbow Exhaust manifold Petcock PT 1 8 Figure 3 5 Turbocharger Components Typical Section 3 Intake and Exhaust System 25 Notes 26 Section 3 Intake and Exhaust System TP 6255 4 10 4 1 General In most installations both the generator set and
115. he 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 inthe craft 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 check for tight exhaust system connections e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Checkfor 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 e Visually inspect the 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 6255 4 10 3 3 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 ex
116. he intake silencer cover 2 Remove the element from the cover and inspect it To clean the element continue to step 3 If the element is damaged or in poor condition replace the element skip step 3 and go to step 4 If the element is clean go to step 6 TP 6071 31 1 Air intake silencer cover 2 Air intake silencer element 3 Base 4 Clamp 5 Turbocharger Figure 3 3 Air Intake Silencer 3 Wash the element in mild detergent and water solution Rinse the element and allow it to air dry 4 Lightly coat the foam element with oil 5 Squeeze out any excess oil 6 Wipe the cover and base with a clean rag to remove any dirt Replace the base if it is damaged 7 Reassemble the element and cover assembly to the intake silencer base Make sure the sealing surfaces fit properly 8 Direct the air intake silencer duct down and away from engine 24 Section 3 Intake and Exhaust System 3 2 Exhaust System Inspection 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 t
117. ible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install 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 Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats and buildings 6 Safety Precautions and Instructions Fuel System WARNING 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 s
118. ic Stop Standard Elastic Stop Standard Elastic Stop Standard Elastic Stop Bolt Thick Screw 0 5 M3 0 8 M4 1 0 M5 1 6 M6 1 6 M8 2 0 M10 2 5 M12 2 5 M14 3 0 M16 3 0 M18 3 0 M20 4 0 M24 Appendix 111 112 TP 6255 4 10 TP 6255 4 10 113 114 TP 6255 4 10 TP 6255 4 10 115 TP 6255 4 10c 2004 2006 2007 and 2010 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
119. ic torque values The charts list values for new plated zinc phosphate or oiled threads Increase values by 1596 for nonplated threads All torque values are 0 10 American Standard Fasteners Torque Specifications Torque 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 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 2202 2 2 22 3333333 22222222222222 33333333333333 z 3 2222 2 2 3 33333 Assembled into Cast Iron or Steel Assembled into Assembled into Cast Iron or Steel Measurement Grade 2 Grade 5 Grade 8 209 25 293 458 513 818 1109 895 1214 Size mm 108 Appendix Grade 5 8 Grade 8 8 Aluminum Grade 2 or 5 Assembled into Aluminum Grade 10 9 Grade 5 8 or 8 8 TP 6255 4 10 Appendix D Common Hardware Identification Screw Bolts Studs Nut Styles Hex Head or Machine Head Pp Hex Head Grade 2 Hex Head or Machine Head with Washer D Lock or Elastic Grade 5 Flat Head FHM y Square Grade 8 Round Head RHM gym Cap or Acorn Grade 8 9 Hex Socket Head Pan Head Wing 2 al Hex Socket Head Allen Head Cap Hex Socket Head or Allen Head Shoulder Bolt i uy Sheet Metal Screw Stud Drive Styles Hex Hex and Slotted Phillips
120. ield resistance cold ohms 20 C 68 F 22 7 2 8 22 7 2 8 Exciter armature resistance cold ohms F1 F2 F1 F3 F2 F3 0 601 0 045 0 601 0 045 Main field rotor resistance cold ohms 20 C 68 F 2 24 2 24 Stator output voltages with separately excited generator using 12 volt battery 60 Hz only 1 4 2 5 8 6 7 10 8 11 9 12 volts 84 55 66 volts 150 Cold stator resistance 1 4 2 5 3 6 7 10 8 11 9 12 ohms 55 66 ohms 18 Section 1 Specifications TP 6255 4 10 1 5 Service Views BB BRB BSE SB 13 14 15 Lu ADV 6843 13 24EOZD 8 11 20EFOZD Models ____ Non Service Side View 27 wwwwwwwwwwwwwwwwv ADC 2100 Control Run Off Reset Auto switch Nameplate Mixing elbow water outlet exhaust outlet Air intake silencer Lifting eye Coolant overflow bottle location varies by model
121. ieve pressure Notice NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown or questionable NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Safety Precautions and Instructions 7 Notes 8 Safety Precautions and Instructions TP 6255 4 10 This manual provides troubleshooting and repair instructions for 6EOD 8 32EOZD 4 5EFOD and 6 5 28EFOZD 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 do
122. ing of approximately 1 5 MOhms and higher indicates the exciter armature is functional A reading of less than approximately 1 5 MoOhms indicates deterioration of the winding insulation and possible current flow to ground if so replace the exciter armature 68 Section 8 Component Testing and Adjustment Lad ANI 4 Ohmmeter 5 Armature 6 Exciter field 1 Main field rotor 2 Stator windings 3 Rectifier 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 6255 4 10 8 5 Slip Rings 6EOD 4 5EFOD Models Slip rings acquire a glossy brown finish in normal operation Do not attempt to maintain a bright newly machined appearance on the slip rings Cleaning with a dry lint free cloth is usually sufficient Use very fine sandpaper 00 and apply light pressure to remove roughness Do not use emery or carborundum paper or cloth Clean all carbon dust from the generator after sanding the slip rings If the rings are black or pitted remove the rotor and use a lathe to remove some of the slip ring surface material 8 6 Brushes 6EOD 4 5EFOD Models The brushes transfer current from the SCR module to the slip rings The brushes should last the life
123. inish 32 micro inches Max eccentricity mm in 0 08 0 003 Max out of round mm in 0 01 0 0002 Figure 9 12 Collector Ring Dimensions 1 Drive disc 2 Rotor 3 Bolt Figure 9 14 Drive Disc Installation TP 6255 4 10 Section 9 Generator Disassembly Reassembly 85 2 Install the rotor drive disc assembly on the engine flywheel using eight washers and bolts Tighten the bolts to 19 Nm 14 ft Ibs Align the fan to the rotor drive disc assembly using the mark created in the disassembly procedure Install the fan to the drive disc using eight screws four spacers washers and locknuts Note Install the fan with the flange side facing away from the flywheel 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 15 Figure 9 15 Stator Installation 5 Install the four overbolts the two long bolts in the lower holes Check that the alignment marks on the stator housing and locator plate match See Figure 9 16 Tighten the overbolts to 34 Nm 25 ft Ibs 1 Alignment marks Figure 9 16 Alignment Marks Section 9 Generator Disassembly Reassembly 10 11 12 13 14 6EOD 4 5EFOD Model 6EOD 4 5EFOD Model Use the hoist to raise the alternator end Remove the wood block from under the locator plate Lower the generator set and install a b
124. is set at the factory Generator set reconnection sender changes controller replacement or other changes may result in the need to change the controller configuration Use the instructions in the following section to check the controller settings and change them if necessary 7 5 1 Controller Time Out The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed Start the configuration procedure over again from the beginning if the controller exits the configuration mode before the settings have been saved Changes in voltage and speed adjustments are also lost if they are not saved before the generator set shuts down The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup Be sure to save your changes immediately after making adjustments 7 5 2 Controller Configuration The controller configuration is factory set and should not normally require changes in the field However the controller configuration may need to be changed after generator set reconnection or controller replacement The controller s configuration mode allows adjustment of the system parameters listed in this section Change the system voltage and frequency after reconnection or controller replacement The unit configuration and engine type are factory set for each type of generator set and engine and should
125. ity rating should be one half ton or greater Remove the two vibromount bolts See Figure 9 7 Raise the alternator end and place a wood block under the locator plate Lower the alternator until the wood block supports the backplate See Figure 9 7 Remove the four overbolts from the end bracket 1 Lifting eye 2 Backplate 3 Wood block 4 Vibromounts Figure 9 7 Supporting the Generator Typical Section 9 Generator Disassembly Reassembly 25 26 2T 28 29 30 31 32 Install a sling capable of handling the weight of the stator housing on the stator housing See Figure 9 8 Use a two jaw puller to pull the end bracket stator assembly from the bearing on the rotor shaft See Figure 9 8 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 four screws with spacers and the four Screws without spacers See Figure 9 9 Remove the fan and fan spacers See Figure 9 9 Remove the eight bolts and remove the drive disc rotor assembly from the engine flywheel See Figure 9 10 Clamp the rotor in a soft jaw vise Remove the eight bolts and remove the drive disc assembly from the rotor See Figure 9 11 X Za DY W 1 Sling 2 Fan guard 3 Two jaw puller Figure 9 8 Stator Assembly Removal 84 Section 9 Gen
126. ixer elbow 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 9 Siphon Break Plastic U Type 36 Section 5 Cooling System TP 6255 4 10 6 1 Introduction Corrective action and testing in many cases requires knowledge of electrical systems and electronic circuits Have an authorized service distributor dealer perform testing and service Refer to the engine service manual for engine service information If the troubleshooting procedures in this section identify a bad part refer to the parts catalog for 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 controller display Section 7 4 describes the warning and shutdown fault codes e Blown fuses Fuses in the wiring harness protect the controller SCR module and relay interface board Always check and replace the fuses befor
127. k 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 6 4 Troubleshooting Chart Use the following tables as reference 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 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 Set 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 8 15 Section 10 Blown fuse F3 controller Replace fuse if fuse blows again check circuit and components Section 8 14 Section 10 Blown fuse F2 relay interface board RIB Replace fuse Section 8 14 If fuse blows again disconnect the board leads one at a time t
128. le mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQ milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg mounting 106 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns OD OEM OF opt OS OSHA OV OZ pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly 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
129. ller Mounting Screws 11 Placethe new controller into position and install the four mounting screws 12 Reattach connectors P1 P15 and P16 to the new controller TP 6255 4 10 13 14 15 16 17 18 19 20 Verify that the generator set master switch is in the OFF position Reconnect the engine starting battery negative lead last Reconnect power to the battery charger if equipped Follow the instructions in Section 7 5 2 to change the new controller s configuration settings to match the generator set system voltage and frequency unit configuration engine type engine data input types battery voltage and communications settings Use a voltmeter to check the output voltage Follow the instructions in Sections 7 5 3 Voltage Adjustment and 8 10 2 Voltage Adjustment to adjust the output voltage and stability Check the output frequency Follow the instructions in Section 4 4 Governor to adjust the output frequency Place the generator set master switch in the AUTO position if an ATS or remote start stop switch is used Replace the sound shield roof and door s if equipped Section 7 Controller 63 Notes 64 Section 7 Controller TP 6255 4 10 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 master switch DC current from the battery magneti
130. m ft 1 2 4 Battery voltage 12 volts 12 volts standard 24 volts optional Battery charging 40 amp alternator Battery recommendation minimum 500 CCA 100 amp hr Starter motor 0 8 kW Bendix automotive type 1 8 kW Bendix gear reduction automotive type 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 9 4 12 2 46 2 6 4 4 4 6 Thermostat C F 82 179 High exhaust temperature shutdown C F 102 215 5 Low oil pressure shutdown kg cm x 0 1 kg cm psi 05 7 1 Seawater inlet water line hose ID mm in 12 Section 1 Specifications 1 2 NPT with sound shield 16 5 8 without sound shield 3 4 NPT with sound shield 25 1 without sound shield TP 6255 4 10 Generator Model 10EOZD 8EOZD 9EOZD 8 5EFOZD 6 5EFOZD 7EFOZD 9EFOZD 15EOZD 13EOZD 14EOZD 15 5EOZD 11EFOZD 11 5EFOZD 13EFOZD Water cooled exhaust outlet hose ID mm in 51 2 with sound shield 51 2 without sound shield 76 3 with sound shield 76 3 without sound shield 3 8 NPT with sound shield 1 4 NPT without sound shield 3 8 NPT with sound shield 1 4 NPT without sound shield Fuel inlet size Fuel return size 120 130 1706 1849 Fuel injection pressure kgf cm sq psi 120 1706 200 21
131. nnect power to the battery charger if equipped 3 Disconnect the generator set engine starting battery negative lead first WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Sound Shield Equipped Models For access to the generator set to perform regular maintenance remove the sound shield doors and roof 62 Section 7 Controller 4 Sound Shielded Models Open the service side door 5 Sound Shielded Models Release the two quarter turn fasteners located underneath the roof See Figure 7 18 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 Sound shield roof Quarter turn fastener Alternator end door Service side door Front rail Engine end door Figure 7 18 Sound Shield Roof Removal TP 6255 4 10 9 Disconnect wiring harness plugs P1 P15 and P16 from the ADC controller 10 Loosen and remove the four controller mounting screws at the front of the controller See Figure 7 19 Remove the controller 1 Controller mounting screws 4 ea Figure 7 19 Contro
132. nnection Figure 7 1 Advanced Digital Control ADC 2100 TP 6255 4 10 Section 7 Controller configuration covered in Section 7 5 and adjustment are A silicon controlled rectifier SCR module works with the controller to regulate the output voltage See Section 7 7 A relay interface board RIB is used with the ADC controller Section 7 10 describes the standard and optional RIBs GM29253 5 Generator set master switch 6 ADC 2100 7 Line circuit breaker plate 8 Junction box Section 7 Controller 43 7 2 Advanced Digital Control Display and Keypad The Advanced Digital Control has an LED display and a three button keypad See Figure 7 2 The LED display shows runtime hours fault codes application program version number or controller parameters during configuration and adjustment See Figure 7 3 The keypad is used to enter the controller s configuration and adjustment menus and to change the controller settings A password key sequence is required to enter the configuration and adjustment menus Section 7 5 contains the instructions to enter the configuration and adjustment menus and change the settings using the controller keypad ADVANCED DIGITAL CONTROL CODE DEFINITION Over Voltage Under Frequency Under Voltage OFF RESET 4 GM28707A C 1 LED display 2 Select button use for setup and adjustment only 3 Up and down arrow buttons use fo
133. nternational 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 kilo 1000 kelvin kiloampere kilobyte 219 bytes Appendix 105 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display Id shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male ms cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 229 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mi
134. o identify the cause of the blown fuse Lead 70A at the fuel solenoid Lead 71A at the crank relay Lead FP and FN at the rotor Repair or replace the component causing the blown fuse Section 10 If the fuse continues to blow and the previous step did not identify the cause remove the leads from the P14 connector using a pin pusher part 2241918 large or 241919 small If replacing the leads does not solve the problem replace the RIB Section 7 10 Section 10 Crank relay on relay interface board RIB Check connections to the RIB Check for 12VDC to the RIB between PF2 and 71N Check for a good ground connection lead N Check crank relay K2 operation LED3 Replace the RIB if the relay does not operate Section 7 10 Section 10 Section 7 10 Generator set master switch Check connections to the master switch on the ADC 2100 Test function of the switch Section 7 9 Section 8 15 Poor ground connection Clean and retighten Starter Check the starter connections Section 10 Rebuild or replace the starter Engine Service Manual S M Controller 38 Section 6 Troubleshooting Check the controller connections and operation Check for power to the controller Move the generator set master switch to the OFF RESET position and then to the RUN position Section 7 Section 10 TP 6255 4 10 Troubleshooting Chart continued Problem Gener
135. o minimize the risk of fire Catch fuels in an approved container Wipe up spilled fuels and engine oil Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation fire prevention procedures Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Safety Precautions and Instructions 5 Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin 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 e Light headedness dizziness e Physical fatigue weakness in joints and muscles e 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 poss
136. of the stator windings have been tested A reading of 1 5 MOhms and higher 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 72 Section 8 Component Testing and Adjustment 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 15 Megohmmeter Connections on 1 Phase 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 TP 6255 4 10 8 10 Voltage 8 10 1 Voltage Regulation Voltage regulation is performed by the Advanced Digital Control ADC and the SCR module The ADC monitors generator output voltage and adjusts the excitation current to the rotor through the SCR module 8 10 2 Voltage Adjustment The factory sets the voltage for correct generator operation under a variety of load conditions Usually the voltage needs no further adjustment
137. oled Check the coolant level at the tank if the generator set has a coolant recovery tank NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces lt Seawater lt Coolant antifreeze 607151 Heat exchanger Engine seawater pump Seawater strainer Seacock Intake strainer Engine driven water pump Section 5 Cooling System 31 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 housing Figure 5 2 Thermostat Location 10EOZD model shown 32 Section 5 Cooling System 5 3 Closed Heat Exchanger 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 ofthe exhaust outlet See Section 1 for coolant capacity thermostat and pressure cap ratings Note Coolant solution A coolant solution of 5096 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F Acoolant solution with l
138. oller and is not adjustable Verify that the following controller configuration parameters are set correctly for your unit See Section 7 5 2 for the settings e System voltage frequency parameter UU e Unit configuration parameter UC e Engine type parameter EC e Engine data input type parameter ED TP 6255 4 10 WARNING AS aa 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 Open the generator set output circuit breaker before beginning the test See Figure 8 17 for the circuit breaker location Connect a DVM to measure the output frequency Start the generator set and manually adjust the 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 OS If the overspeed shutdown does not operate the generator set should shut down on an overfrequency fault OF after approximately 5 seconds Low Oil Pressure LOP Shutdown Connect a jumper wire from the LOP switch lead 13 to the generator set ground Start the generator set Verify that the generator set shuts down after approximately 25 35 seconds of op
139. olt a large washer two small washers and a locknut on each vibromount Tighten the mounting bolts to 28 Nm 20 ft Ibs Apply antiseize 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 Check the keyway of the shaft and key of the 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 original screws Remove the brush retainer and check alignment See Section 8 6 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 6EOD 4 5EFOD Model Replace the brush cover gasket and install the brush holder cover Install the three spacers and bolts to mount the relay board Install the SCR module and junction box 8 23EOZD and 6 5 20EFOZD Models Position the field leads at the top Install the exciter field using four bolts and washers See Figure 9 17 1 Exciter field bolts 4 2 Exciter field Figure 9 17 Installing Exciter Field 8 28EOZD and 6 5 20EFOZD ModelsO TP 6255 4 10 15 16 17 18 19 20 Install tie wraps to secure the wires as necessary Reconnect the leads to the circuit breaker and neutral stud LO as marked during disassembly
140. ommunication parameter setting is the controller will not power down The controller remains powered at all times to maintain CAN communications allow remote start commands from the CAN gauge 1 hour power down If the ADC 2100 communication parameter setting is or 9 the controller will power down after 1 hour of inactivity In this mode a remote start stop switch or the generator set master switch must be used to activate the controller after it has powered down ADC 2100 application code version 1 21 or higher is required for the 1 hour power down option Note After controller power down a remote digital gauge will not have power and therefore will not be able to send a start signal to activate the controller Note Kohler s 2 inch digital gauge allows wake up of the controller remotely Section 7 Controller 53 Controller Configuration Mode Use Figure 7 6 with Controller Parameters Hold the Select button Display Move the generator set master switch to the RUN position The generator set engine will not start Wait about 5 seconds until the display shows the program version number The number may be different than the one shown here Press the down arrow key and then the up arrow key 3 times to enter the configuration mode This is the controller password Now release the Select button
141. othing 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 Temperature Sensor CTS The coolant temperature sensor CTS is used to monitor engine temperature for the high engine temperature fault shutdown HE See Figure 8 24 for the coolant temperature sensor location the generator set master switch to the OFF position and allow the generator setto cool Disconnectthe 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 25 If the resistance is very low indicated a short circuit or very high indicating an open circuit replace the CTS Low Oil Pressure LOP Switch See Figure 8 26 for the low oil pressure LOP switch location Remove the LOP switch and install an oil pressure gauge to verify that the engine oil pressure is within the range specified in Figure 8 27 before testing or 78 Section 8 Component Testing and Adjustment replacing the LOP switch test the LOP switch reinstall the switch and start the gener
142. ound shield 1 4 NPT without sound shield Fuel return size 3 8 NPT with sound shield 1 4 NPT without sound shield Fuel injection pressure kgf cm sq psi 200 210 2844 2986 220 230 3129 3271 Intake exhaust valve clearance cold mm in 0 15 0 25 0 006 0 0010 Fuel pump static pressure psi 4 8 12 volt pump or 5 5 9 24 volt pump Pressure cap rating kPa psi Generator Model 97 14 6EOD 4 5EFOD Number of cylinders 3 Type 4 cycle Cylinder block material Cast iron Cylinder head material Cast iron Crankshaft material Forged steel Piston rings 2 compression 1 oil Connecting rod material Cast iron Governor All speed mechanical Engine firing order 1 cylinder on flywheel side 1 2 3 Direction of rotation as viewed from flywheel Counterclockwise Combustion system Indirect injection Bore x stroke mm in 67 x 72 2 64 x 2 83 Displacement L CID 0 762 46 5 Compression ratio 23 5 1 Max power at rated RPM 60 50 Hz HP 10 19 8 18 RPM 60 50 Hz 1800 1500 Lubrication system Pressure trochoid pump Lube oil capacity w filter L U S qts 3 05 3 2 Oil recommendation API CD or CF class Fuel recommendation API Diesel ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Fuel shutoff solenoid Electric Fuel
143. ource 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 6255 4 10 L 44 va 7 5 Rectifier module 6 Main field rotor 7 Stator windings 8 Sensing leads 11 44 1 Fuse 2 Power lead 55 3 Excitation to rotor 4 Exciter or brushes slip rings Figure 8 1 Generator Schematic Single Phase Model Shown No Generator Output Separate Excitation Output within Specifications Check Wiring Fuses SCR Module and ADC 2100 Erratic or No Output Check Rotor Check Stator TP563273 Figure 8 2 General Troubleshooting Section 8 Component Testing and Adjustment 65 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 s
144. ources 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 Excitation Procedure Perform the following procedure to use an external voltage source to excite the main field rotor 1 Disconnect the black FN and FP leads from the alternator at the SCR module and terminals 2 Connect a DC ammeter 20 amp fuse and a 12 volt automotive battery to the positive FP and negative FN exciter 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 3 5 ohms rotor resistance 8 4 amps rotor current 3 Start the engine and check that the ammeter reading remains stable 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 re
145. p is operating if the cooling water flows from the exhaust outlet If water is not discharging at the exhaust outlet see the Operation Manual s Prestart Checklist Seawater Pump Priming Section 5 Cooling System 35 5 9 Siphon Break A siphon 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 cm 9 above the waterline of a fully loaded shut down craft Use the following procedure to inspect 4 Check that the reed valve opening is clear he 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 Install the retaining cap and finger tighten only Do assembly for inspection See Figure 5 9 DR Baty y 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 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 m
146. park producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in 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 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 guar
147. pment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe 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 10 1 Wiring Diagram Reference Figure 10 1 and Figure 10 2 lists the wiring diagram numbers and locations 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 Wiring Accessory Model Diagram Figure Schematic Figure Diagram Figure 6EOD ADV 7095A D Figure 10 4 4 5EFOD GM42202 F Figure 10 3
148. pump Mechanical Fuel pump priming N A Max recommended fuel pump lift m ft 0 9 3 0 Battery voltage 12 volts Battery charging 18 amp alternator Battery recommendation minimum 500 CCA 100 amp hr Starter motor 0 8 kW Bendix automotive type 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 2 0 2 1 Thermostat C F 82 179 High exhaust temperature shutdown C F TP 6255 4 10 N A Section 1 Specifications Low oil pressure shutdown kg cm 0 1 kg cm psi 0 5 7 1 1 2 NPT with sound shield 19 0 75 without sound shield 51 2 with sound shield 51 2 without sound shield 3 8 NPT with sound shield 8 0 31 without sound shield 1 4 NPT with sound shield 5 0 19 without sound shield Seawater inlet water line hose ID mm in Water cooled exhaust outlet hose ID mm in Fuel inlet size Fuel return size Fuel injection pressure kg cm psi 120 1707 Intake exhaust valve lash cold mm in 0 2 0 0078 Fuel pump static pressure kPa psi 34 5 Pressure cap rating kPa psi 96 14 16 Section 1 Specifications TP 6255 4 10 1 3 Generator 4 Lead Component Specification Main field rotor resistance cold ohms 20 C 68 F 6EOD 4 5EFOD Stator output voltag
149. quency setpoint for more than 5 seconds This protection becomes active 10 seconds after engine start 10 second inhibit Contact an authorized distributor dealer for service if problem continues Overspeed shutdown Shutdown occurs if the engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service if problem continues Overvoltage shutdown Shutdown occurs if the voltage exceeds 120 of the voltage regulator setpoint for more than 2 seconds Contact an authorized distributor dealer for service if problem continues Underfrequency shutdown Shutdown occurs when the governed frequency falls below 90 of the system s frequency setpoint for more than 5 seconds This protection becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Undervoltage shutdown Shutdown occurs if the voltage falls below 80 of the voltage regulator setpoint for more than 10 seconds Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Controller error TP 6255 4 10 Indicates a software or communication problem within the ADC 2100 Figure 7 4 Fault Shutdowns Contact an authorized distributor dealer for service if problem continues
150. r 5 Sound Shielded Models Release the two quarter turn fasteners located underneath the roof See Figure 9 1 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 Sound shield roof Quarter turn fastener Alternator end door Service side door Front rail Engine end door Figure 9 1 Sound Shield Roof Removal Section 9 Generator Disassembly Reassembly 81 9 Disconnect wiring harness plugs P1 P15 and P16 from the ADC 2100 10 Loosen and remove the four controller mounting screws at the front of the controller See Figure 9 2 Remove the controller tp6196 1 Controller mounting screws 4 ea Figure 9 2 ADC 2100 Mounting Screws 11 Remove the junction box louvered panel See Figure 9 3 and Figure 9 4 1 ADC 2100 2 Junction box louvered panel Figure 9 3 Covers Section 9 Generator Disassembly Reassembly 82 Junction box louvered panel SCR module mounted behind ADC 2100 on 6EOD 4 5EFOD models Relay board Engine harness to controller connection Generator set master switch ADC 2100 Line circuit breaker
151. r adjustment incorrect Adjust governor stability Section 4 4 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 Inspect valves and valve seats Engine S M Generator set lacks power Air intake restriction inadequate cooling Inspect air intakes and exhaust for obstructions Check the air cleaner Section 3 Generator overloaded Reduce load Generator Set I M Engine not running at rated rpm Check controller settings for unit configuration UC and engine type EC Adjust governor speed Section 7 5 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 governor Section 4 4 Generator set overheats Inadequate cooling Inspect cooling system for obstructions Air cleaner clogged Replace element Section 3 Low output or excessive drop in voltage Generator overloaded Reduce load Generator Set I M Incorrect controller configuration Check and adjust the controller configuration parameters Section 7 5 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 7 5 3 Alternator or control system Perform separate excitation proce
152. r setup and adjustment only 4 Generator set master switch Figure 7 2 Advanced Digital Control 44 Section 7 Controller Controller Display Item Crank indication Description Displays 1 CC 2 or CC Sto indicate the 1st 2nd or 3rd attempt to start the engine The last digit flashes during the crank cycle rest periods Runtime hours Displays total generator set runtime hours when no other code is displayed Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 7 4 System parameters Displays 2 letter codes or 4 digit alphanumeric codes during system configuration or adjustment See Section 7 5 Application program version number Displays the version number of the controller s application program before entering the configuration or adjustment mode See Section 7 6 Figure 7 3 Advanced Digital Control s LED Display TP 6255 4 10 7 3 Sequence of Operation The following sections describe the controller sequence of operation during generator start run stop and fault shutdown modes Use this as a starting point for controller and relay board fault identification Refer to the wiring diagrams in Section 10 to assist in the troubleshooting procedure 7 3 1 Starting Sequence Master Switch Moved to RUN When the master switch is moved to the RUN position there is a delay of about 1 second before the ADC attempts to start the
153. rameter for the standard data inputs for that engine If you change Ec check the Ed setting TP 6255 4 10 Section 7 Controller 51 Battery CANbus Marine Diesel Market Voltage Comm Model Voltage Phases Bt 115 230 V 1 Ph 115 230 V 3 Ph 4 W Delta 110 190 V 3 Ph 4 W Wye 23EFOZD 3 Ph 120 208 V 3 Ph 4 W Wye 220 380 V 3 Ph 4 W Wye 230 400 V 3 Ph 4 W Wye 240 416 V 3 Ph 4 W Wye 115 230 V 1 Ph 115 230 V 3 Ph 4 W Delta 110 190 V 3 Ph 4 W Wye 25EFOZD 3 Ph 120 208 V 3 Ph 4 W Wye 220 380 V 3 Ph 4 W Wye 230 400 V 3 Ph 4 W Wye 240 416 V Ph 4 Wye 230 V 1 Ph 2W 27EFOZD 1 Ph 115 230 V 1 Ph 240 V 1 Ph 2W 230 V 1 Ph 2W 28EFOZD 1 Ph 115 230 V 1 Ph 240 V 1 Ph 2W 115 230 V 1 Ph 115 230 V 3 Ph 4 W Delta 110 190 V 3 Ph 4 W Wye No Can 27EFOZD 3 Ph 120 208 V 3 Ph 4 W Wye NET ne a 220 380 V 3 Ph 4 W Wye 7 or 9 230 400 V Ph 4 W Wye Smartcraft 240 416 V 3 Ph 4 W Wye 115 230 V 1 Ph 115 230 V 3 Ph 4 W Delta 110 190 V 3 Ph 4 W Wye 28EFOZD 3 Ph 120 208 V 3 Ph 4 W Wye 220 380 V 3 Ph 4 W Wye 230 400 V 3 Ph 4 W Wye 240 416 V 3 Ph 4 W Wye 28EOZD 1 Ph 120 240 V 1 Ph 3W 120 240 V 1 Ph 3W 120 208 V 3 Ph 4 W Wye 127 220 V 3 Ph 4 W Wye 120 240 V 3 Ph 4 W Delta 139 240 V 3 Ph 4 W Wye 277 480 V 3 Ph 4 W Wye 32EOZD 1 Ph 120 240 V 1 Ph 3W 120 240 V 1 Ph 3W 120 208 V
154. rance 1 1 2 of bolt diameter 2 Minimum 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths TP 6255 4 10 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 the diagram below 3 Follow these SAE washer rules after determining exit hole type a Always use a washer between hardware and a 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 the diagram below which depicts the preceding hardware configuration possibilities 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 107 Appendix C General Torque Specifications Use the following torque specifications when service literature instructions give no specif
155. rator set engine starting battery negative lead last 9 Bleed the system See Section 4 2 1 Bleeding the Fuel System 1 Fuel strainer assembly 2 Body 3 Fuel element 4 Spring 5 O ring 6 Filter cup 7 Retaining ring TP 561633 Figure 4 2 Fuel Oil Filter Element Section 4 Fuel System 27 6EOD 10 32EOZD 4 5EFOD and 9 28EFOZD Models 1 Place the generator set on off switch in the OFF position 2 Disconnect the generator set engine starting battery negative lead first 3 Close the fuel supply valve 4 Loosenthe 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 5 Clean the contact surface of the fuel oil filter adapter 6 Lightly lubricate the gasket surface of the new fuel filter 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 7 Open the fuel supply valve 8 Reconnect the generator set engine starting battery negative lead last 9 Bleed the system See Section 4 2 1 Bleeding the Fuel System N T N 3 Tom NS Fuel filter adapter Fuel filter Removal counterclockwise Installation clockwise TP 606111 Figure 4 3 Spin On Fuel Oil Filter 28 Section 4 Fuel System
156. re 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 Move the generator set master switch to the OFF position 2 Disconnectthe 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 WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment TP 6255 4 10 Note The controller is powered by the generator set engine starting battery A jumper on connector P7 on the back of the controller causes the controller to remain powered at all times With the jumper connected the ADC s L
157. ronic 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 estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft ft Ibs ft min 9 ga gal gen genset GFI GND gov gph gpm gr GRD gr wt fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext IP ISO J JIS k K kA KB hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification I
158. ry Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Engine Backfire Flash Fire WARNING Gh 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 t
159. s 60 Hz 50 Hz LO L1 100 120 Volt 100 120 Volt LO L2 100 120 Volt 100 120 Volt L1 L2 200 240 Volt 200 240 Volt Figure 8 21 100 120 200 240 Volt 3 Wire Configuration Section 8 Component Testing and Adjustment 75 8 11 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 19 for location See Figure 8 22 LO Neutral 9 LO o Ground 2 GRD L1 Load Side O Line Single Pole Side Circuit 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 22 200 220 240 Volt 2 Wire Configuration for Models with ADC 2100 8 12 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 connection 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 se
160. s 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 power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Voltage Adjustment Procedure 1 Connect a digital voltmeter from one side of the circuit breaker to the LO terminal See Figure 8 17 for the LO terminal location Set the meter to measure voltage Note For 120 or 240 volt systems the voltage measured from one side of the breaker to LO should be approximately 120 VAC For 240 volt systems the voltage measured from one side of the circuit breaker to the other should be approximately 240 VAC 2 Start the generator set 3 Follow the ADC instructions in Section 7 5 to enter the adjustment mode and increase voltage or decrease
161. se 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 Back View Zero ohms continuity across RUN and VBAT terminals Master Switch in RUN Position z gt Back View Zero ohms continuity across VBAT and AUTO terminals Master Switch in AUTO Position Figure 8 30 Generator Master Switch Continuity Check Section 8 Component Testing and Adjustment 79 Component Generator set master switch Ohmmeter Connections RUN and VBAT See Figure 8 30 Ohmmeter Scale Generator Set Master Switch Position RUN Ohmmeter Readings for Operative Components Zero ohms continuity Any other reading indicates a bad switch OFF RESET No reading open circuit Any other reading indicates a bad switch AUTO and VBAT See Figure 8 30 AUTO Zero ohms continuity Any other reading indicates a bad switch OFF RESET No reading open circuit Any other reading indicates a bad switch P1
162. se parts and secure if necessary Excessive engine generator vibration Check rotor crankshaft bearing etc disassembly of engine and or alternator may be required Section 9 Disassembly Reassembly and Engine S M Emits black or gray smoke Air intake restriction Check air cleaner and intake Section 3 Emits black or gray smoke Oil level high Check oil level Section 2 and Generator Set O M Worn piston rings valves etc Check compression Engine S M High oil consumption External leakage defective gaskets Replace gaskets Engine S M Worn piston rings valves etc Check compression Engine S M Engine knocks Excessive load Reduce load Generator Set I M Low oil level 42 Section 6 Troubleshooting Check oil level and add oil if low Section 2 and Generator Set O M TP 6255 4 10 7 1 Introduction This section covers operation configuration adjustment and replacement of the ADC 2100 controller See Section 6 for troubleshooting procedures See Figure 7 1 for the locations of the controller and related components Section 7 2 describes the controller keypad and display Section 7 3 describes the sequence of operation and faults are described in Section 7 4 Controller 1 Junction box louvered panel 2 SCR module mounted behind ADC 2100 on 6EOD and 4 5EFOD models 3 Relay board 4 Engine harness to controller co
163. t 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 RESET position 2 Disconnect engine starting battery negative lead first Disconnect power to battery charger if equipped 3 Use Figure 8 23 to determine generator set voltage configuration Note the original voltage and reconnect the generator set as needed GENERATOR CONNECTIONS P 3 PHASE DELTA 12 WIRE Omo 23 WED 6 312 9 115 230VOLT 50 HZ 120 240 VOLT 60 HZ 3 PHASE WYE 12 WIRE 190 208 VOLT 50 HZ 208 240 VOLT 60 HZ 3 PHASE WYE 12 WIRE HIGH WYE 912 YN oy eo a 380 416 VOLT 50 HZ 416 480 VOLT 60 HZ SINGLE PHASE 3 WIRE SOME SETS NOT RATED FOR SINGLE PHASE SEE MANUALS NOT USED OT TIO Ef AAT 115 230 VOLT 50 HZ 120 240 VOLT 60 HZ CT3 NOT USED OAS Lo MET SINGLE PHASE 2 WIRE MARINE ONLY TAPE TO INSULATE 7 FROM GROUND 12 DN L 6 230 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 23 Generator Reconnection 76 Section 8 Component Testing and Adjustment TP 6255 4 1
164. t code and the generator set shuts down Always identify and correct the cause of a fault shutdown before restarting the generator set Refer to Section 6 Troubleshooting for instructions to identify and correct the cause of the fault To restart the generator set first move the generator set master switch to the OFF RESET position to reset the controller Note Forunits with serial numbers before 2051415 If the power jumper is removed and the controller powers down after a fault shutdown move the master switch to the OFF RESET position and then to the RUN position to display the fault code Moving the master switch to the OFF position again will clear the fault See Section 7 8 for more information on the continuous power mode jumper 7 4 2 Warnings The fault conditions listed in Figure 7 5 will cause the controller to display a fault code but will not shut down the generator set TP 6255 4 10 Auxiliary fault input shutdown Description Input from a customer supplied switch that closes when the fault is active Shutdown occurs 0 3 seconds after the fault is detected and will not start when the fault is active input is grounded This protection becomes active 3 seconds after crank disconnect Check the cause of the auxiliary fault High engine temperature shutdown Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This protection becomes active after
165. thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute TP 6255 4 10 CID CL CMOS cogen Com conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia elect
166. 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 itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Section 2 Scheduled Maintenance 21 2 2 Lubrication System Use oil that meets the American Petroleum Institute API classification of CD or CF Using an unsuitable oil or neglecting an oil change may result in damage and a shorter engine life Figure 2 1 and Figure 2 2 show the recommended Society of Automotive Engineers SAE viscosity designation for given operating temperature ranges Figure 2 1 Engine Selection for Models 8 32EOZD and 6 5 27EFOZD 22 Section 2 Scheduled Maintenance Engine Oil Viscosity SAE Ambient Temperature Service Grade Minimum Maximum 0W20 40 C 40 F 10 C 50 F 0W30 40 C 40 F 30 C 86 F ow40 40 C 40 F 40 C 104 F 5W30 30 C 22 F 30 C 86 F 5w40 30 C 22 F 40 C 104 F 10W30 20 C 4 F 40 C 104 F 15W40 10 C 14 F 50 C 122
167. uity Test Results on a Good Stator 1 Phase Section 8 Component Testing and Adjustment 71 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 5 Check the cold resistance of the stator windings by connecting the meter leads to the stator leads as shown in Figure 8 13 or Figure 8 14 See Section 1 Specifications for the stator resistance values If the 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 Note The stator resistance can vary directly with increased temperature If any of the stator readings vary during the previous checks replace the stator 6 Check the stator for a short to ground condition 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 using the megohmmeter Repeat the test on the other leads until all
168. ump Connect the negative terminal of the fuel pump to the negative terminal of the battery You should hear the 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 terminal 4 Fuel outlet Figure 4 6 Fuel Pump 30 Section 4 Fuel System 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 adjusts 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 57 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 47 53 Hz 1500 rpm under full load and 1590 rpm under 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
169. un relay common Run relay normally closed S TEN n 90 N 24 VAR F ARES 92 5 JUN A j 93 91 NS NL Figure 7 17 Optional Common Fault and Run Relay Board Harness Connections Section 7 Controller 61 7 11 Controller Replacement 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 For output voltage problems replace the SCR module and check the operation again before replacing the controller After replacing the controller verify that the new controller s configuration settings match the generator set system voltage and frequency unit configuration engine type engine data input types battery voltage and communications settings Refer to Section 7 5 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 If the output voltage or frequency needs adjustment use the voltage adjustment procedure in Section 8 10 2 and the governor adjustment instructions in Section 4 4 ADC 2100 Controller Replacement Procedure 1 Place the generator set master switch in the OFF position 2 Disco
170. vid VIL SS if SNOILO3NNOO 8d XO8 NOLLONAP Wie N Cid 14 NIL vee NOL NOLLO3NNOO YINOLSNO peri oe HY ANY DOR OD Nid SNOIIO3NNOO vid 2519 2580 zo83 4 1 21 194 0 2 19 01 95 92 140 sz id OL 1 14 01 01 19 01 13 SNOILO3NNOO 129 GM50490 C d 1 83 det 6 89 SZI 2 21 4 EVOL 2 14 VOL Z 9d Lez ZN d bod L NZL s az v0 ZN SNOLIO3NNOO Zld 80 1 0 cM f 1250 SNOILOANNOO 9d 1HM 9 08 19 0 19 61 19 v 002 1 e a GIONF10S Tans a 54 i 1519 CR SNOILOSNNOO VZd eas liri bna 5 0 18 7 2519 82 19 LE O ru sia 8 SN 91 19 1 11 129 01 1zd 24 va NZL or 6 19 8 14 IHM L SNOILOANNOOD VGd LNOL BN 1 99 9N SN 6 14
171. voltage parameter 1P until the output reaches the desired voltage 4 Follow the ADC instructions to step to the voltage gain adjustment menu Adjust the voltage gain parameter 2P until the light flicker minimizes Save the settings Section 8 Component Testing and Adjustment 73 5 6 4 4 LE LIN I 4 7 2 7 8 Service Side View 6EOD 4 5EFOD and 8 32EOZD Models Typical 10 11 Earlier Models 4 E Later Models Generator End View Service Side View Shown with louvered panel removed 12 6EOD 4 5EFOD and 8 24EOZD Models Top View Shown with junction box cover removed 28 32EOZD Models 1 Line circuit breaker 2 Circuit breaker mounting hardware 3 Circuit breaker cover plate 4 Load connection terminal LO 5 Ground connection terminal GRD Figure 8 17 Circuit Breaker and LO Terminal Location 74 Section 8 Component Testing and Adjustment Check and readjust the voltage if necessary Setthe voltmeter to measure frequency Adjustthe engine speed to the cut in frequency shown in Figure 8 18 by adjusting the governor as described in Section 4 4 Set the voltmeter to measure voltage Adjust the volts Hz parameter 3P until the voltage level measured by the voltmeter begins to drop
172. wiring harness P1 27 and ground OFF RESET Zero ohms continuity Any other reading indicates a poor ground connection P15 1 and P15 3 stator leads 11 and 44 for 1 phase models or P15 1 P15 2 and P15 3 stator leads 7 8 and 9 for 3 phase models OFF RESET Zero ohms continuity If no continuity check wiring P16 3 and P16 6 stator leads 55 and 66 OFF RESET Zero ohms continuity If no continuity check fuse F1 and wiring Controller fuse and wiring P1 24 and battery positive OFF RESET Zero ohms continuity If no continuity is found check fuse F3 and wiring Auxiliary winding fuse 10 amp fuse P16 3 and stator lead 55 OFF RESET Zero ohms continuity If no continuity is found check for an open circuit and or a blown fuse Low oil pressure LOP switch Lead 13 and ground engine block R x 100 OFF RESET Zero ohms continuity No continuity indicates a bad switch and or wiring Temperature sensor CTS P1 8 and P1 9 R x 1000 OFF RESET 180 2500 ohms depending on engine temperature Zero ohms or an open circuit indicates bad wiring or a bad switch Aux run relay K5 Terminals 85 and 86 OFF RESET 12 volt relay 85 5 ohms coil resistance 24 volt relay 305 15 ohms coil resistance Lower resistance indicates a shorted relay coil and or wiring High resistance indicates an open relay coil and or wiring
173. xhaust Manifold 32 5 3 Closed Heat Exchanger 32 5 4 Check and Fill 32 5 5 Flush and Clean Cooling System 33 5 6 Pressure oe Qe P aca exa Aas le aaa 33 5 7 Impeller Inspection and Replacement 33 5 8 Tension eter LR benigni Oh Pid 34 5 8 1 Seawater Pump Belt Tensioning Procedure 34 5 8 2 Battery Charging Alternator Belt Tensioning Procedure 35 5 8 8 Anticorrosion Zinc Anode 35 5 9 Siphon oc b x lec EPA ii thle deb 36 Section 6 Troubleshooting 37 6 1 Introd ctl n en hee nie eee better etn fa exe erster 37 9 2 Nta Checks i ob erbe veste emos 37 6 3 General det eR e e Lg iesus 37 6 4 Troubleshooting Chart 37 Section 7 Controler DI 43 Ti Introd ctlon re eee Pret decere dede eem ipie 43 7 2 Advanced Digital Control Display and Keypad 44 7 3 Sequence of Operation 45 7
174. zes 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 SCR module feeds rectified stator output current to the rotor through the exciter or brushes slip rings for model 6EOD A 5EFOD to increase the strength of the rotor field As the rotor field increases in strength generator output also increases The ADC 2100 monitors the generator 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 from the SCR module 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 ofthe test procedures include additional safety precautions Check the condition of the alternator fuse before performing the separate excitation procedure The inline fuse is located in lead 55 of the wiring harness See Figure 8 1 Ifthe fuse is not blown use the following procedure to separately excite the generator using an external voltage source a 12 volt automotive battery Separately exciting the generator can identify faulty voltage regulation by the ADC 2100 or reveal a running fault in the rotor and or stator An external power s

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