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TP-6772

1. 43 31 General Maintenance 55222522222222222222222222 2 2222 2 2292 43 2 Service Schedule 6 11EKOD EKOZD amp 5 9EFKOD EFKOZD Models 44 3 3 Lubrication System eee ed Se d IX Bienes 46 3 3 1 Oil Specifications es ie prete ne er bea a KP ERA R 46 3 92 OIL Check sa a a s Pas dex d ur ET UR 46 3 9 3 Oil Change iore GaSe iad be Sad RITU ae RET tee 47 TP 6772 2 14b Table of Contents 3 odii Alene 48 3 4 1 Fuel Specifications 66666664 4 48 3 4 2 Fuel Filth tei E eae 48 3 4 3 Fuel System 5 5 5555522222222222222222222 2 49 9 5 Exhaust System castus nd ais eure nia es da RR had EE Render 50 3 6 Cooling System luce Apu sree ek ae a pa gba d RP YA 1 cde 51 3 6 1 Closed Heat Exchanger 51 3 6 0 Checking and Filling Coolant 0 cece eee eee eee eee 51 3 6 3 Flushing and Cleaning eect eee ee eee eee eee 51 9 6 4 Pressure Cap csse ek eh d ma ad pede 52 3 6 05 Seawater Pump 22222 22 2 kk kk ks 52 3 6 6 1 Siphon Break aaa CREE 53 3 6 7 A Anticorrosion Zinc Anode 666066466 55 Belt Tension a an eset og LIN VDLULIeEMURRUE
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3. Zid iHd z 170A 21 8 T 9NIONnONO Isolated Ground Wiring Diagram Schematic Figure 5 6 Section 5 Wiring Diagrams TP 6772 2 14b AL START ST EMOTE R y y 8 AZANINA ey 2YEN ZAZ A A A Qa BO CUSTC INTERFACE JR NERAT OG GENI n SEE CE CONNECTION INTERF R JSTOME FULL DOO AAAA G SAA DAOC AZAL Z r 8 e d s MEAM FEN Z N FEN Ws AKU REIL RATO AGRAM GENE GENE TO oie Figure 5 7 Accessory Interconnection Drawing 68 Section 5 Wiring Diagrams CTIO CONNE AL Y OPTIO o N QURMETE 4 E SAZI 1 DAAE OOO Aaa A e 2 S 2 3 2 SI e MEA KEI SEI M DAOA GENERAT ONNECTIONS STOP START STOP START 7 DIGITAIL GAUGE EXTENSION PIGTAIL AND REMOTE CONTROL PANEL OPTIONS OP NEL RT P TA S OTE GM33846 D TP 6772 2 14b Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj
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5. 8 919 rev 52619 9 6 1 3snivWav 83 2383 5 64 5 64 2 7812 Lh 1 14 Hd z sid 6A c sid 8 825 N4 4 80S di 2 N 513 22 9 2 018 v 6d c M IN IM 54 ZM SNOILO3NNOO Td 1 r za 99 1 2 99 per eu Qin gii zm N IN lsm mn x 5 avis 6 lvls vis 2 N vis 99 4 vis Avis 1 Nid SNOILOSNNOO 24 Q 8 64 4 of LHM 01 14 IHM 3 62 14 03 8 82 14 Y B v Nid SNOILOANNOO 014 24 zHd 64 6 ass pna MOlvIS 083 5 9 G 540 Old 2 9 225 d 20 45 29 5 214 004 iS 2 14 80 m doz om 9 14 28 1 4 SS zd f Nid SNOILOINNOO 214 v 94 voz 6d 904 52 Sz 342 T L 28 023 OLN
6. SAE 10W 30 SAE 10W 40 SAE 10W 60 SAE 15W 40 SAE 15W 40 SAE 20W 60 SAE 5W 30 Mineral base Semi synthetic base Synthetic base SAE Grade Figure 3 1 Engine Oil Selection 46 Section 3 Scheduled Maintenance 3 3 2 Oil Check Check the oil level in the crankcase daily or before each startup to ensure that the level is in the safe range To checkthe oil level remove the dipstick and wipe the end clean reinsert as far as possible and remove Maintain the oil level between the Min and Max marks on the dipstick as shown in Figure 3 2 See Section 1 for dipstick location 1 Min mark 2 Max mark Figure 3 2 Oil Level Check Marks TP 5586 3 Note Do not operate the set if the oil level is below the Min mark or above the Max mark 6772 2 14b 3 3 3 Oil Change Change the oil more frequently ifthe generator operates under dirty dusty conditions See Figure 3 3 for oil capacities Model L Qts 6EKOD and 5EFKOD 25 2 6 9EKOZD and 7EFKOZD 2 5 2 6 11EKOZD and 9EFKOZD 1 Phase 34 3 6 11EKOZD and 9EFKOZD 3 Phase 3 4 3 6 Figure 3 3 Oil Capacities Oil Change Procedure Whenever possible drain the oil while it is still warm 1 Drain the oil a Place the generator set master switch in the OFF position Disconnect the power to the battery charger
7. e e r I M o X o ADC IId controller USB port Nameplate on top of controller Fuses F1 F2 and F3 AC circuit breaker panel Battery positive 4 connection Coolant fill coolant overflow tube Seawater inlet Fuel solenoid Fuel filter Seawater pump Oil check dipstick Fuel return Coolant overflow bottle Oil drain valve Oil fill OO A a Figure 1 1 Service Views Typical Fuel feed pump Fuel inlet Oil filter Customer load lead connection Alternator cooling air inlet V belt Belt guard Battery negative connection Seawater drain Engine coolant drain Heat exchanger internal to exhaust manifold Lifting eye Mixing elbow water outlet exhaust outlet Customer interface Anticorrosion zinc anode Air outlet ADV7942 A Note Consult installation drawings in the spec sheet or installation manual for more details on fuel and battery connection points Consult an authorized distributor dealer or the service manual for items not shown TP 6772 2 14b Section 1 Service Views 13 Sound Shield Equipped Models For access to the generator set to perform regular maintenance remove A WARNING Accidental starting
8. 8 8 5 9015 15 310W3H 8 14 NMOGLNHS 61 14 14 Of 4 9 6d NANI 4 2 14 la v13 MNYHO 22 14 l S15 QNnONO 6 6 1 64 1 2 64 amp NH5 64 c JN8A 8 64 23 7303 64 30 xnv 835 3OV3N3INI M3NO SDO 202 31 15 Q3lodlONd NOLLNOL IVNOILdO S 6d amp 1HK ADV7995 C AMALLVE 170A 21 IC Schemat iagram D iring Figure 5 4 65 Section 5 Wiring Diagrams TP 6772 2 14b GM79009 E 31 051 MH3T1041N02 3NINVW M 11 9 8 Wis vis LL 9 2 8 9 e z l sm vis 99 14 36 VIS 43 04 vis 4 if Nid Ola SNOILOANNOO Zd 966 335 804 8 01 3SVHd TIONIS 85 33S SNOILO3NNOO D 310N 2 2 1 Zd N4 4 15 0134 21 008 214 33 801 15 0931 ZL 31n00N 8314 339 801 15 OYJ v 3SvHd 319NIS 85 73438 SNOILO3NNOO X04 310N 1815 3SVHd 1 G 8G6 AQv 335 SNOILO3NNOO MOLVH3N3O 804 310 v sd qar
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10. Yes Battery Powered Auto No USB Powered Auto Yes Battery Powered Auto No USB Powered Auto Battery Powered Auto Running Stopped Black Green Red Yes N A Stopped Black Red Yes Yes NOTE Under unique conditions the controller may not operate normally If this happens the controller uses the red LED to represent the status code To show the status code the controller holds the red LED for 5 seconds followed by a sequence of flashes that represents the status code 1 flash forced into bootloader 2 flashes no application software 3 flashes application code is invalid 4 flashes RAM check failure 5 flashes reformatting flash See an authorized Kohler distributor dealer Figure 2 4 Possible LED Status Indicator Displays A WARNING 2 6 2 Starting the Generator Set The following procedures describe the actions required to start the generator set Note Opening seacock Before starting the generator set open the seacock to allow cooling water passage Failure to do so could damage the seawater pump impeller and cause serious engine overheating damage Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Note Transfer switch Check that the marine ship to shore transfer switch if equipped is in the ship position Operating the generator set Carbon monoxide can cause severe nausea
11. Note Connectthe battery duringthe priming procedure to allow engine cranking Note If the ADC Ild indicates an overcrank fault during this procedure disconnectthe negative wire from the fuel solenoid allowing the fuel injection pump to fill with fuel and repeat this procedure after allowing the starter motor to cool down Note Have a rag handy during this procedure Wipe up any spilled diesel fuel Wash hands after any contact with fuel Dispose of fuel in an environmentally safe manner Fuel System Bleed Procedure 1 Loosen the fuel filters air vent screw See Figure 3 5 2 Initiate the auto start sequence until fuel free of air bubbles flows from the vent screw at the fuel filter 3 Tighten the fuel filter s air vent screw GM74543 B Fuel filter s air vent screw location Figure 3 5 Fuel Filter s Air Vent Screw Section 3 Scheduled Maintenance 49 3 5 Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use Atthe interval specified in the service schedule inspect the exhaust system components exhaus
12. Section 2 Operation 23 System Events Display Message List Warning Shutdown Status Relay Description Display Message Function Function Notice Output Engine Functions Engine over speed Eng Speed High Shutdwn x x Engine start aid active Preheat N x Engine under speed Eng Speed Low Shutdwn x x High battery voltage Battery High Warning x x High coolant temperature Coolnt Temp High Warning x x High coolant temperature Coolnt Temp High Shutdwn x x High exhaust temperature Exh Temp High Shutdwn x x Low battery voltage Battery Low Warning x x Low seawater pressure Sea Pressure Low Shutdwn X x Low cranking voltage Lo Crank VIt Warning X X Low oil pressure Oil Pres Low Warning X X Low oil pressure Oil Pres Low Shutdwn X x Overcrank Over Crank Shutdwn x X General Functions Aux inputs 0 5 VDC 1 analog Aux Input Shutdwn X x Backup parameters loaded Backup Pars Status S No Engine start delay active Start Delay Notice N x Engine started Engine Start Status S X Engine stopped Engine Stop Status S X Generator running Gen Running Notice N X Remote start Remote Start Status S X System ready System Ready Status S X System timer failed Timer Error Notice N x Generator Functions AC sensing loss AC Sens Loss Warning X X AC sensing loss AC Sens Loss Low Shutdwn x x Locked rotor failed to crank Locked Rotor Shutdwn x x Overfrequency Frequ
13. 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 the sound shield doors and roof Sound Shield Roof and Door Removal 1 2 Open the service side door Release the two wing nuts located underneath the roof See Figure 1 2 Lift up the roof Slide the roof towards the service side of the unit for removal Open the front rear and non service side doors as needed 14 Section 1 Service Views Sound shield roof Wing nut Alternator end door Service side door Front rail Engine end door ORON Figure 1 2 Sound Shield Roof Removal TP 6772 2 14b 2 1 Prestart Checklist A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Operating the generator set Carbon monoxide can cause severe nausea fainting or death Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats a
14. 2 9 Monitoring and Programming Setup The user programmer can access the controller data with the controller digital display or a personal computer PC with optional SiteTech software to monitor and or program Access the controller system with a PC using a USB cable with a standard type A and a standard type B USB plug Refer to the Introduction List of Related Materials for related software literature While this manual focuses on data access through the controller pushbutton rotary selector dial and display some data entries require input using a PC for initial setup The PC entries typically include alpha characters such as digital input descriptions 2 9 1 PC Communications Communicate between a PC and the generator set controller logic using USB communication protocol The PC connections require optional SiteTech software Contact your authorized distributor dealer for assistance Local Single Connection A PC connects to the USB port of the generator set controller using a standard type B USB connector See Figure 2 17 and Section 2 10 12 Generator Set Controller USB Cable Personal Computer Figure 2 17 Local Single Connection 2 10 Reviewing Menu Displays Use this section to review a summary of the generator set controller data See Figure 2 18 for which menus provide data monitoring data adjustments or SiteTech software to make data adjustments Use the pushbutton rotary select
15. Reset Calibration User can reset individual volt values or reset all values GenSet Information Menu e Generator Set Model No Generator Set Serial No e Controller Serial No GenSet Run Time Menu e Engine Run Time e Engine Starts e Next Maintenance GenSet System Menu e System Frequency e Battery DC Voltage 9 CANA J1939 SmartCraft NMEA 2000 e Measurement System Metric or English e Contrast display Voltage Regulator Menu e Voltage Regulator Voltage Adjust Volt Hz Adjust Gain Adjust Stability Adjust Reset Voltage Regulator Settings o Reset Voltage Regulator Event Log Menu See Section 2 6 6 for a list of items that can appear in Event Log Prime Menu See Section 2 10 10 Volt Select Menu Volt Select o 120 240 V 1 Ph 120 208 V 3 Ph 139 240 V 3 Ph 277 480 V 3 Ph 120 240 V 3 Ph 115 230 V 1 Ph 120V1 Ph 230V 1 Ph 240 V 1 Ph 110 190 V 3 Ph 127 220 V 3 Ph 115 230 V 3 Ph 230 400 V 3 Ph 240 416 V 3 Ph ONO 3 O0 09 900 o o USB Menu 9 See Section 2 10 12 for USB flowchart information User Defined Changeable Menu Displays NOTE Some changes require activating the calibration or adjustment mode Some displays may only appear when in the calibration or adjustment mode Refer to Section 2 10 Reviewing Menu Displays to activate the calibration or adjustment mode 34 Section 2 Operation TP 6772 2 14b
16. The unit will start cranking after the time delay times out The local display shows Preheat Engine Started This status indicates that the generator set start circuitis closed allowing the engine to crank and run The local display shows Engine Start Status Engine Stopped This status indicates that the generator set start circuit is open causing the engine to shutdown The local display shows Engine Stop Status Generator Running This notice indicates that the generator set has started and is running The local display shows Gen Running Notice 6772 2 14b Generator Set Calibration User Defined This selectable display is in the GenSet Metering Menu allowing the user to calibrate the controller and generator set Usethe Pushbutton Rotary Selector Dial to navigate and select this feature Changesto this display must be done with the generator setrunning The local display shows Enter calib No or Yes Select No to make no change Select Yes to calibrate the following values e Volts L1 L2 x x V e Volts L2 L3 x x V e Volts L3 L1 x x V e Volts L1 N x x V e Volts L2 N x x V e Volts L3 N x x V The user can individually calibrate the values above or resetall ofthem Thelocal display Resetall calib No or Yes Select No to make no changes and exit GenSet Calibration Select Yes to reset all of the values When calibrating voltage the metered value and the number being entered as the calibrated value must be wit
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18. the load on the generator set is reduced This can be shown 72 Appendix mathematically by Ohm s law which states that power is equal to the voltage squared divided by the impedance As the voltage is reduced the power delivered by the alternator decreases by a squared relationship Since it is the power in the alternator that translates into engine torque the engine load is also reduced By changing various parameters of this compensation technique the controlling system can be tailored to match the performance capabilities of most engine and alternator combinations The point at which the unloading begins to act or how much unloading occurs can be adjusted to impact maximum voltage droop maximum speed droop or time to recover Some applications may not need unloading and in these cases set the unloading parameter to disable the function These parameters are further described below An example is provided to help clarify the relationship between these parameters Underfrequency Unload Slope Underfrequency unload slope is the term used to describe the amount that the voltage is reduced per cycle per second or per hertz Hz when in an underfrequency condition The slope or schedule is sometimes called the volts per hertz slope When the electrical frequency drops below the cut in point see below the excitation control system temporarily reducesthe regulated voltage to reduce the subsequent torque on the engine The amount
19. 086 43018 3NISN3 983 YOSNS dW3L 1NV1009 510 CERERI 89 8 QE c 4 Su DM Sd C SN 8 62 14 18 vf Nid SNOILO3NNOO Sd 8 2 61 14 0 9 91 18 s 8 1 im 95 54 N33H9 NYO 2 54 59 MOTA 734 L Nid SNOLLO3NNOO 6d NOLLO3NNOO 30v3831NI 6d Isolated Ground Wiring Diagram Point to Point Figure 5 5 66 Section 5 Wiring Diagrams ANNOYS d31V10SI W3T1081NOO 20 3 MX 11 9 ADV7996 D 67 XINO 83008 Hsnua Q ES 1 d 43 N 1915 0134 NIVW SL8S AQV 3338 SNOLLO3NNOO M VM3N39 N04 S3LON WOlvIS 3 21 831114 Z yd 0 88 4 indi 454 b bd 0 M353VHO 1 8 quu 831283 013 5 Qv31 v 0134 NIV 518 03177051 801 15 1716 GION310S 83 818 SS SOLON M3LMV S WS 103NNOO XIND 5 AVTaY Lv3H 3Hd Hd ond 5 6 3NhsS3Nd TIO 540 HOLIMS 38 55384 N3lYM YIS MO 5 4 MOTD 65 GIONX10S Tin 53 dWnd Tan 43 35 4 4 HOLIMS dWil 1SnvHX3 513 AN
20. 2011 2012 and 2014 by Kohler Co All rights reserved KOHLER Power Systems KOHLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KOHLERPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
21. 6 11EKOD EKOZD amp 5 9EFKOD EFKOZD Models continued Perform Service at Intervals Indicated X Reference Section Every 250 Hrs or3 Months Every 500 Hrs or 6 Months Every 1000 Hrs or Yearly INTAKE EXHAUST SYSTEM Inspect the exhaust system components X Before operation Check the exhaust gas condition If the exhaust is blue or black contact your local distributor dealer X During operation Clean the exhaust water mixing elbow Inspect the crankcase breather system f X 1500 hrs Check the breather pipe for obstructions Inspect the complete exhaust system X ELECTRICAL SYSTEM Keep the battery charged and in good condition X Before operation Check and tighten the electrical connections Clean the battery cables X Check the starter motor t 5000 hrs ENGINE AND MOUNTING Check for water fuel coolant and oil leakage 72 X After operation Retighten any loose nuts and bolts X Before operation Check the mounting bolts vibromounts and tighten if necessary Adjust the intake exhaust valve clearance Check the compartment condition fuel oil or water leaks X Before operation Replace the timing belt X 4000 hrs Partial engine overhaul X 5000 hrs Total engine overhaul t 10000 hrs REMOTE START PANEL Check
22. ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cc CCA CCW 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 thermal unit British thermal uni
23. Crankshaft pulley Pivot screw Belt guard Figure 3 13 Belt Tension 56 Section 3 Scheduled Maintenance 3 7 4 Seawater Pump Belt Tensioning Procedure 1 Remove the belt guard See Figure 3 13 2 Check the belt tension at the midpoint of the longest span of the belt by pressing with your finger approx 10 kg 22 Ibs of force See Figure 3 14 for belt deflection Recheck anew belttension after 10 minutes of operation Deflection mm in 10 0 4 Figure 3 14 Belt Specification Note If the belt tension is not within specification go to step 3 If the belt tension is within specifications go to step 7 3 Loosen the pivot and adjusting screws 4 While prying the seawater pump outward tighten the adjusting screw 5 Tighten the pivot screw 6 Recheck and adjust as necessary 7 Replace the belt guard TP 6772 2 14b 3 8 Battery Consult the battery manufacturer s instructions regarding battery care and maintenance 3 9 Generator Storage Procedure Keep the craft afloat for generator operation during the storage procedure Follow the procedure below when storing your generator set for 3 months or more Generator Set Storage Procedure 1 Start and run the generator set until it reaches operating temperature or about 15 minutes Stop the generator set Change the oil and oil filter See Section 3 3 3 Close the seacock and remove the hose at the seacock Place the hose
24. Figure 6EKOD 5EFKOD 9EKOZD 7EFKOZD GM79009 E Figure 5 5 ADV 7996 D Figure 5 61 GM33846 D Figure 5 7 11EKOZD 9EFKOZD Figure 5 2 Wiring Diagrams for Units with Isolated Ground TP 6772 2 14b Section 5 Wiring Diagrams 63 M3T1041N02 3N MYR 30 1 9 666 335 OllVN3HOS 0134 01 15 0931 ZL 3SVHd 1 G 8G6 AQv 335 SNOILO3NNOO MOLVH3N39 NO z sid 6A 6 914 8 eos Ln 801 15 OYJ v 3SvHd 319NIS 85 7338 SNOILO3NNOO X04 310N 1815 31n00N 214 33 anaon 3 oL Qr 896 IYNLVNYY 83 2383 91 yr 221 sg y zd 99 sald 81 Gri gil S 3 x M3bMVIS 0213310081 NOLINOI Nolldo 983 T Z yd N 6 69 8N 6N 8 99 SN 2 214 ZIN sm viz SS 8 ss vid phe d ss zad uM 3 cad 22223 ZZZZA 1d OTIM 2005 DM MONIS lvis GIONSIOS 1 5 SS MOLON 831 15 NS 103NNOO XIND 035 AWRY 1yaHadd Hd OIO3NNOO d 30 35 3unss3Nd 0 540 HOLIMS 3WnSS3Nd YaLVMVaS MOT d l Qnis 01 3 NYNO OZ 508 ANNONS GaLVIOS 891 9nd 019 f d9 GIONS10S 1303
25. cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Engine Backfire Flash Fire A WARNING Lh Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the fuel injection system fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner silencer removed Combustible materials A sudden flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the generator set Keep the compartment and the generator set clean and free of debris to minimize the risk of fire Catch fuels in an approved container 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 Equ
26. exhaust outlet See Figure 3 6 for coolant capacities include coolant recovery tank capacity of 0 24 L 8 oz Model L Qts 6EKOD and 5EFKOD 9EKOZD and 7EFKOZD 11EKOZD and 9EFKOZD 1 Phase 11EKOZD and 9EFKOZD 3 Phase Figure 3 6 Engine Coolant Capacities 3 6 2 Checking and Filling Coolant A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces TP 6772 2 14b 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 preventfreezing Add additional coolant solution as necessary to the coolant rec
27. 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 Note If the generator set does not start after 3 crank attempts an overcrank fault occurs 1 Close the seacock 2 Completely drain the water from the exhaust system at the silencer s drain plug 3 Do not attempt generator set restart 4 Contact an authorized Kohler distributor dealer A water filled exhaust piping and silencer may further hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valves Water ingested into the engine may cause major engine damage that the Kohler Co warranty does not cover 18 Section 2 Operation 6772 2 14b The controller attempts to start the generator set three times If the generator set does not start in three attempts the system shuts down on an overcrank fault Local Starting 1 Press the Power Button to turn the controller on The LED Status Indicator appears green and begins flashing 2 Press the Start Stop Button to start the generator set The Advanced Digital Control attempts to start the generator set in three crank cycles crank cycle time is pre p
28. for the time delay period The local display shows Volts L1 L2 L2 L3 or L3 L1 Low Shutdwn See Figure 2 16 for undervoltage specifications Undervoltage Inhibit Time Delay Time Default Setting 80 of nominal at 10 sec 10 sec 10 sec Figure 2 16 Undervoltage Specs 32 Section 2 Operation 2 7 7 Status and Notice Digital Displays Warnings and shutdown faults appear on the digital display and become part of the event history Beyond the warnings and shutdowns there are several events which also appear on the digital display Status is an event that is not an alert but is part of the event history Notice is an alert that is not part of the event history The controller allows a selected number of changes by the user for setting up the controller application which are covered in this section Note Text shown in italics in this section of the manual represents digital display messages Backup Parameters Loaded This status message indicates that backup parameter firmware is now loaded on the controller The local display shows Backup Pars Status Engine Start Aid Active This notice message indicates that the start aid is active and will energize an engine equipped preheat or ether system during the crank cycle The local display shows Preheat Engine Start Delay Active This notice message indicates that the delay for engine start is active where the generator set will not start right after the RUN button is pressed
29. if equipped Disconnect the generator set engine starting battery negative lead first Remove the oil drain hose from its retaining clip Remove the cap from the oil drain hose and lower the hose into an oil collection container Electric Oil Drain Oil Fill Pump Procedure Connect the pump to the end of the oil drain hose Place the outlet of the pump into an oil collection container Remove the oil fill cap s Open the oil drain valve on the engine Allow time for the engine oil to drain completely Electric Oil Drain Oil Fill Pump Procedure Activate the pump until all of the oil is removed Go to step 2 TP 6772 2 14b g h a b Close the oil drain valve Replace the cap on the oil drain hose Replace the oil drain hose in its retaining clip 2 Replace the oil filter Remove the oil filter by rotating it counterclockwise with an oil filter wrench Apply a light coat of clean oil to the rubber seal of the new oil filter Install the new oil filter following the instructions provided with the filter Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner Fill with oil Add new oil of the weight grade and quantity specified in Section 3 3 Electric Oil Drain Oil Fill Pump Procedure Disconnect the pump Close the oil drain valve Replace the cap on the oil drain hose a Check for leaks Checkthat the generator set master swi
30. local display VR Volt Adj xxx x V 2 8 Menu Displays Use the Menu Summary List section after reading and understanding the features of the pushbutton rotary selector dial See Section 2 6 5 Digital Display The Menu Summary List provides a quick reference to the digital display data Some digital display data may not be identical to your display due to generator set application differences The closed bullet items represent main level data and the open bullet items are sub level data The Menu Summary List indicates items that are user selectable Use SiteTech software for changing programmable information Section 2 10 Reviewing the Menu Displays provides a digital display menu overview and explains the navigation using the pushbutton rotary selector dial Section 2 Operation 33 Menu Summary List Legend e First level submenu second level submenu Overview Menu Available as scrolling or fixed display text Active Shutdowns if present Active Warnings if present e Genset State Average Volts Line to Line Frequency Coolant Temperature Oil Pressure Battery DC Voltage Engine Run Time Next Maintenance Software Version v Engine Metering Menu e Engine Speed Tachometer e Oil Pressure 9 Coolant Temperature e Battery DC Voltage Generator Metering Menu Volts L1 L2 Volts L2 L3 Volts L3 L1 Volts L1 N Volts L2 N Volts L3 N Frequency
31. output voltage for more than 3 seconds after crank disconnect The controller displays AC Sens Loss Low Shutdwn Auxiliary Input Shutdown The fault lamp flashes red and the unit shuts down when an auxiliary inputs signals the controller Use SiteTech software to define inputs as shutdowns The local display shows Aux Input Shutdwn Engine Over Speed The fault lamp flashes red and the unit shuts down immediately when the governed frequency on 50 and 60 Hz models exceeds the over speed setting The local display shows Eng Speed High Shutdwn Engine Under Speed The fault lamp flashes red the alarm horn sounds and the unit shuts down immediately when the governed frequency on 50 and 60 Hz models drop below the underspeed setting The local display shows Eng Speed Low Shutdwn High Coolant Temperature The fault lamp flashes red and the unit shuts down because of high engine coolant temperature The high coolant temperature shutdown does not function during the preset inhibit time delay period after startup The local display shows Coolnt Temp High Shutdwn Note The high engine temperature shutdown function and the low seawater pressure shutdown function are independent A low seawater pressure condition may not activate the high engine temperature switch High Exhaust Temperature The fault lamp flashes red and the unit shuts down because of high exhaust temperature The local display shows Exh Temp High Shutdwn TP 6772
32. stays hot enough to prevent water vapor from condensing At low load situations wet stacking can occur The operator should perform all of the prestart checks Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks TP 6772 2 14b 2 6 Advanced Digital Control 10 Operation Figure 2 3 illustrates the user interface on the Advanced Digital Control The controller is factory set and should not require configuration or adjustment under normal operating conditions f the generator set is reconnected to a different voltage and or frequency refer to an authorized Kohler distributor dealer for system configuration and adjustment instructions Note Have setup and adjustments of the Advanced Digital Control performed only by an authorized Kohler distributor dealer TAR STOP R DIGITAL CONTROL Il GM58225A LCD digital display Pushbutton rotary selector dial Engine start stop button Power button LED status indicator Figure 2 3 Advanced Digital Control Ild 2 6 1 Controls and Indicators LCD Digital Display The LCD digital display is backlit any time the generator set is running or for at least 5 minutes after a user manipul
33. that the control system reduces voltage is defined as the product or multiplication of the slope and the amount of frequency or speed below the cut in point For every Hz below the cut in point the control system reduces the line to line voltage by an amount equal to the slope Because each engine responds differently to the various loads encountered the slope may be adjusted to improve the system response If when large loads are applied to the generator set the engine speed drops below the acceptable limit as determined by the particular loads applied the slope may need to be increased Increasingthe slope will cause the voltage to droop more during load applications consequently reducing the load torque on the engine and allowing the speed to increase If however the voltage drops below an acceptable lower limit as determined by the particular loads connected to the generator set a lower slope may work better The underfrequency unloading function may be disabled by setting the slope to zero 6772 2 14b Frequency Setpoint or Cut In Point The point at which the underfrequency unloading begins to take effect is adjustable allowing the system to be tailored for each application Because the characteristics of the engine have the largest effect on the system s performance the engine s response should determine the unloading point The unloading setpoint is the frequency below which the excitation control will reduce
34. the side of the junction box See Figure 2 8 e 10 Amp F1 fuse protects the auxiliary winding e 20 Amp F2 fuse protects the controller circuits fuel pump and fuel shutoff solenoid e 5 Amp F3 fuse protects the customer connections 1 Fuses qty 3 Figure 2 8 Fuses on the Side of the Junction Box 2 7 Controller Logic Specifications Refer to Figure 2 9 for inhibit and time delays on fault shutdowns Refer to Figure 2 10 for inhibit and time delays on warnings Inhibit Time Delay The inhibit time delay is the time period following crank disconnect during which the generator set stabilizes and the controller does not detect a fault or status event The inhibit time delay is not adjustable Time Delay Shutdown or Warning The time delay follows the inhibit time delay The time delay is the time period between when the controller first detects a fault or status event and the controller warning or shutdown lamp illuminates The time delay is not adjustable 2 7 1 Fault Shutdown and Warning Specifications The following list contains fault shutdown and warning specifications with time delays Section 2 Operation 25 Fault Shutdowns Sensing State s Inhibit Code Description Mechanism Detected Time Trip Point Check AC Sens The loss of AC Frequency Post starting 10 sec AC voltage Contact an authorized Loss Low voltage shutdown over aid running reached AC distributor dealer for servi
35. the voltage so that the engine may begin to recover The cut in point or frequency setpoint should be set 0 5 3 0 Hz lower than the normal steady state band of operation If the engine normally operates within a very narrow range of speeds close to the nominal a setpoint of 0 5 to 1 0 Hz below nominal should be suitable If the engine normally operates over a wide range of speeds the setpoint may need to be 2 0 3 0 Hz from the nominal The underfrequency unloading function can be eliminated by setting the cut in point below the minimum expected operating frequency Three Phase Sensing Three phase sensing describes how the excitation control or voltage regulator determines the condition of the alternator output voltage Early types of regulators sensed the voltage on just one phase of the alternator Single phase sensing is not uncommon today as most alternators are designed to produce balanced equal voltage on all three phases If the loads applied to the generator set including no load are equal and balanced the output voltage on each phase will be nearly equal However in some applications individual phases may have unequal or unbalanced loads In these cases the output voltages will not be equal on each phase In general the phase with the greatest load will have the lowest voltage while the phase with the least load will have the highest voltage This is true regardless of the type of sensing used in the regulator system A
36. 2 14b Locked Rotor failed to crank If none of the speed sensing inputs show engine rotation within the preset time delay of initiating engine cranking the ignition and crank circuits turn off for the preset period and the cycle repeats The fault lamp flashes red and the unit shuts down after the second cycle of the preset period of cranking The local display shows Locked Rotor Shutdown Low Seawater Pressure The fault lamp flashes red and the unit shuts down because of low seawater pressure Shutdown occurs 5 seconds after low seawater pressure is detected Local display shows Sea Pressure Low Shutdwn Low Oil Pressure The fault lamp flashes red and the unit shuts down because of low oil pressure The shutdown occurs 10 seconds after the low pressure condition is detected The low oil pressure shutdown does not function during the first 15 seconds after startup The local display shows Oil Press Low Shutdwn Overcrank The fault lamp flashes red and cranking stops when the unit does not start within the defined cranking period The local display shows Over Crank Shutdwn See Section 2 6 2 Starting the Generator Set and Section 2 7 1 Status Event and Fault Specifications for cyclic crank specifications Note The controller is equipped with an automatic restart function When speed drops below 25 Hz 750 rpm while the engine is running the unit attempts to recrank The unit then follows the cyclic cranking cycle and when th
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38. 8 dd em 0 5 0 0 M3iMVIS 0231331084 283 Q 9M 40 28 514 8 614 em 302 vM YN L Nid ZM zHd SNOUSaNNOO yar B Z SS td SNOUO3NNOO Zd 0 212 SNOILO3NNOO 24 89 ZIN 55 ya 1 Nid SNOIIO3NNOO 414 8 84 8 94 N 4 CYLINDER ONLY add Zd9 d9 sala EM voL vf Nid gt D S M ZN id S Wf Nid SNOILO3NNOO 8d SNOILOJNNOO 94 Ep A N 27 o 4 if Nid S4 9d SNOTO3NNO td 8M 581 014 vd 1 d 44 gm 1814 s zid d9 8M 55 28 2 222 te te e e siz vis 8v 31114 quw oos DM avis 815 xolvis 715 0 0 3105 5 SS MOLON 3 5 WS 103NNOO XIND 035 AVY 1v3H3ud is M L 3NN02 d 358 3 AMAL VE 1 yd d ss ed Zad n 4 cad LM TP 6772 2 14b 30 35 3unss3Nd 0 580 HOLMS 3HnSS3Nd N3lvMv3S MOT dMI Qnis 01 2 NYYD OZ 518 ANNONS 1051 891 0114 019 f d9 GIONS10S 1304 53 1303 da 3snj 4 HOLIMS dW3L 19 513
39. LLNUL STLINSA TES 56 3 7 1 Seawater Pump Belt Tensioning Procedure 56 3 8 Battery s s ae e AE RIS cag RR Rr Gr 57 3 9 Generator Storage Procedure 22 2222 57 Section 4 Troubleshooting ee 4 44 4448 xr 0 8 RA Ra YR 6 688 464880 59 41 EaultGodes Tassie eee cei L k blade ee bid ete b etta Late dal 59 Section 5 Wiring Diagrams oo nnn nnn hn hh 63 5 1 Wiring Diagram Reference 63 Appendix A ADDreviatilolis os tipsi DE LEE TIRE Ue E GE IQ ERG luce y ed aes 69 Appendix B Operating Hour Service Log V yoo aya Raya aaa aaa yaaa aaa 71 Appendix C Voltage Regulator Definitions and Adjustments 2 22 72 4 Table of Contents TP 6772 2 14b Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Cautio
40. MOLVH3N39 104 SALON ONIONIM ONIONIM XV ONIGNIM 07313 15 831114 zd M00 ANNONO 414 1041 2 V 1 lid 1 yd 358 3 1 8 013 NP 8 ONIGNIM 0134 Wolvis Qv31 v 0134 N YA 018 ANIONA YOLVLS 1915 ONTOS NilMVIS SS NilNVIS WS 193NNOO yolno 138 Lv3H 3Md ond HOL MS 5 39 55344 TO 540 HOLMS 38 5538 1 YIS MOT ond 019 66 0 3105 Tan 53 Tan da 35 4 4 HOLIMS dWil 1SnvHX3 513 5 3snivi3dWiL 1NV1002 SLO N3531 ATNO S3NIDN3 NO 035 vdO ALON NN yab 14 IW3H 3ud id 088 44 NY 3HnsS3Nd NilVM MOT 62 14 086 91 14 IHM NYO TVNM31X3 Y1 14 NM NWO VNM31X3 91 14 m 734 MOSN3S dWil 5 21 Ld 6 6 38 55384 TWO 5 14 513 dN31 1NV1002 11 1 eS 89
41. NOYS 310018 ANIONS 983 2000 f a 30 35 LNY1009 510 QON3931 IN 9 4 ta AVI38 9NIONnONS ATNO S3N N3 NO G3SN LON E T yab 42 ld GNNOYD 01 ld TVNO S M SN3S 38 5384 65 19 304 05 MOSN3S 38 553 82 14 0 6 MOSN3S 39155394 8 Zd LNdNI 3 1 24 1ndNI 2 v 9 28 1NdNI O v Zd 4 ONIGNIM y Zd 1141 ONIGNIM XNY 1 Zd 9NIONIM 0134 Z d 9NIONIM 0134 ld IV3H 3Nd ld 088 ld NAY GNNOND 91 1d NYO TVNM31X3 1 865 H NYO MNN3DG 91 56 38 55384 NilVM MO 2 ld MOSN3S dWil 15 51 49 dN3l 1NV1000 11 14 015 15 310 28 8 14 NMOGLNHS 61 1 NSAF 2 1 p HA BA 94 8 Sd SN 267 Sd e s v 8d 8 8d 2N S19 8d QNnONO 6 6 1 64 1 2 64 S 6d amp 1HM Jv8A 8 64 ani 6d 0 9 64 INANI INYA 835 3OV3H3INI MANO SDO 6d 20 2m 202 983 pi M3IMVIS 0213210924 NOLL NOL TVNOLLd0 ale YINVEO 814
42. Operation Marine Generator Sets Models 6EKOD 9 11EKOZD 5EFKOD 7 9EFKOZD 9001 mut POVVER SYSTEMS KOHLER wee Power Systems TP 6772 2 14b California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts 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 6772 2 14b Table of Contents Product Identification Information e nh mnn 2 Safety Precautions and Instructions n nnn nnn 5 Introduction pr Uer a Y COR UNE RR NR EE EE Wr 9 Service Assistance v s ue usa eed veda YAR wa RR 8 8 RR a ERA ER 8888 10 Maintenance and Servi
43. ad 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 SI 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 50 cm 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 temperature 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 Labora
44. ate Knob Push Push Knob Knob USB LOAD Filename Loading Load SOFTWARE PUSH TO LOAD Complete Rotate Knob Note Before inserting a mass storage device USB host connector power off and then power on the controller See Figure 2 19 for tested approved manufacturer s USB flash drive types that work with the ADC Ild controller CustomUSB Kohler Power Systems 2 GB spin full size Part Number KW A202 Imation 4 GB full size Lexar 4 GB full size PNY 4 GB full size and micro Verbatin 4 GB full size and micro Figure 2 19 ADC USB Identification TP 6772 2 14b Section 2 Operation 41 Notes 42 Section 2 Operation TP 6772 2 14b 3 1 General Maintenance A WARNING aS 2 Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting t
45. ates a button or the pushbutton rotary selector dial The LCD displays generator status run time hours fault shutdowns and fault warnings Pushbutton Rotary Selector Dial This control provides access to the menus for monitoring Pressthe selector dial to activate the digital display and to select choices shown on the display Rotate the dial to navigate through the menus TP 6772 2 14b The pushbutton rotary selector dial has several features and functions e Momentarily press the dial to activate the digital display if dark e Rotate the dial to navigate through the main menus turn clockwise to go forward down and counterclockwise to go back up The menus do not wrap to the beginning e Press the dial at a given main menu to access the submenus within the selected main menu e When in the submenu rotate the dial to navigate through the submenu clockwise to go forward down and counterclockwise to go back up The menus do not wrap to the beginning e Momentarily press the dial when in the submenu to make a user selection choice if available or to go back to the respective main menu e After about 5 minutes of no user input pushbutton rotary selector dial or buttons the menu resets to the top of the main menus and auto paging activates for the Overview submenus Engine Start Stop Button The Engine Start Stop button toggles the running state ofthe engine Whenthe controller is off it has no effect When t
46. ay be desirable to keep one phase ata particular value Modify the voltage adjust setting higher or lower accordingly for any unique requirements for the particular application Adjustment and Setting Specifications Voltage Adjust The voltage adjust is entered as the rated or otherwise desired line to line voltage The average of the line to line voltages is then regulated to the corresponding value as previously described The setting may be as fine as tenths of volts The voltage adjust defaults to the rated system voltage whenever the system voltage is changed The voltage adjust may be set to any value within 10 of the system voltage The upper limit is 10 above the system voltage and the lower limit is 10 below the system voltage Appendix 73 As a reference the present voltage adjust setting is displayed as well as the average value of the line to line voltages The individual line to line voltages are also displayed on the subsequent menu screens This allows the user to monitor any individual phase if desired The voltage adjust setting may be changed by means other than the menu including user defined digital input or remote communications If voltage adjustment occurs the new value will be displayed accordingly in the voltage adjust menu Underfrequency Unload Enable The underfrequency unload enable menu is used to turn the underfrequency unload on or off A YES entry will turn the feature on and the display wi
47. been corrected 7 Shut the generator off by pressing the generator set start stop to the STOP position 8 Reconnect the generator set to the load 2 7 8 Voltage Regulator and Calibration Specifications The controller has a voltage regulation function that is internal to the processor This means that no external voltage regulator is necessary The voltage regulation of the controller uses root mean square rms sensing for fast response to changes in indicated and regulated voltages resulting in excellent regulation accuracy 2 7 4 Voltage Regulator Adjustments The descriptions of the voltage regulator adjustments andfeatures follow See Appendix C Voltage Regulator Definitions and Adjustments for additional information and to customize adjustments for specific applications TP 6772 2 14b Voltage Adjustment The voltage adjustment allows the user to enter the desired generator set output level This regulated level setting is the average of the three line to line voltages in three phase configurations or L1 to L2 in single phase configurations Submenus display the individual line to line voltages These voltages are for reference only and are relevant in unbalanced load conditions The voltage adjust setpoint can be changed to accommodate an important phase in an unbalanced system Underfrequency Unload Frequency Setpoint This adjustmentaffects the voltage droop volts per Hz when load is applied and underfrequency o
48. c Anode ED0090802150 S ED0090802150 S ED0090802150 S ED0090802150 S Figure 1 Maintenance and Service Parts x in 001 004 List of Related Literature Figure 2 identifies related literature available for the generator sets covered in this manual Only trained and qualified personnel should install or service the generator set Literature Type Models GEKOD and 5EFKOD 1 Phase 9EKOZD and TEFKOZD 1 Phase 11EKOZD and 9EFKOZD 1 Phase 11EKOZD and 9EFKOZD 3 Phase Specification Sheet G2 147 G2 148 G2 149 G2 150 Installation Manual TP 6773 Operation Manual TP 6772 Parts Catalog TP 6775 Service Manual Engine TP 6776 Service Manual Generator TP 6774 SiteTech Software Operation Manual Includes generator and engine information Figure 2 Generator Set Literature TP 6772 2 14b TP 6701 x in 001 005 Introduction 11 Notes 12 Introduction TP 6772 2 14b Section 1 Service Views m s 19 18 17 16 27 N N 15 14 Non Service Side View 28
49. ccurs The underfrequency unload setting defines the setpoint where underfrequency starts Any frequency below the setpoint causes the voltage to drop thus reducing the load allowing the engine speed to recover according to the underfrequency unload slope setting Engine speed recovery depends upon characteristics such as engine make fuel type load types and operating conditions The underfrequency unload setting should match the engine speed recovery characteristics for the application Underfrequency Unload Slope This setting determines how much the voltage drops during an underfrequency condition Typically applying a large electrical load causes a dip in engine speed and frequency The voltage regulator reduces voltage allowing engine speed recovery The volts per Hz setting determines the amount of voltage drop Regulator Gain Regulator gain refers to the gain ofthe control system Generally the higher the gain the faster the system responds to changes and the lower the gain the more stable the system If the voltage is slow to recover when loads are applied or removed increase the regulator gain Ifthe voltage is unstable decrease the regulator gain Section 2 Operation 29 2 7 5 System Fault Warning Lamp with Digital Displays The system FAULT lamp blinks green then red indicating a warning fault but does not shut down the generator set When the system warning lamp is on and no message displays rotate the se
50. ce Shutdwn occurs when the voltage cooldown system controller does voltage and not detect the then drops nominal generator below 5 AC output voltage of the trip for more than 3 point for seconds after low AC crank disconnect voltage fault shutdown Aux Input Auxiliary fault Digital input Auto fault Switch Check the cause of the auxiliary Shutdwn input shutdown start delay closes fault Note Input from a ECM start shorted to customer supplied starting aid ground switch that closes cranking when the fault is crank pause active post starting aid running cooldown Coolant High coolant Analog input Post starting Coolant Check for a low engine coolant Temp High temperature aid running temperature level Shutdwn shutdown occurs if cooldown at or above the engine coolant 110 C temperature 230 F exceeds the default setting Note The high engine temp shutdown functions only when the coolant level is in the operating range Check seawater pump impeller strainers and seacock Eng Speed High engine Frequency Post starting Engine Contact an authorized High speed shutdown over AC aid running speed distributor dealer for service if Shutdwn occurs if the voltage cooldown exceeds problem continues engine speed 11596 of the exceeds the rated speed default setting Eng Speed Low engine speed Frequency Post starting Engine Contact an authorized Low shutdown occurs over AC aid r
51. ce Parts Related Literature 11 Section 1 Service VieWS e adn UE x EAR dA Ra Oa Ere e 13 Section 2 Operation eos I AUG REX eee eee REF LEE TENURE EE REFER EA 15 2 1 Prestart Checklist 2 o docens er dod ode e ope eed quA bes Bas ed 15 2 2 Marine Inspection ne ELE LED ea RI ER ERN WEE a 16 2 3 AngularOperati n 2 sce rer ERI ERR ERE Rem Ea 16 2 4 Operation in European Union Member Countries 16 2 5 Eoad Profle osse IPIE nde Xp d r TERES 16 2 6 Advanced Digital Control Operation 222222222222222222 17 2 6 1 Controls and Indicators 17 2 6 2 Starting the Generator Set 00 cece eects 18 2 6 3 Stopping the Generator Set 8 8 8 8 88 880 19 2 6 4 Fault Shutdowns and Warnings 19 2 6 5 Digital Display en beac aes REP res 21 2 6 6 Controller Fault Diagnostics 2 2222222222222222222 2 23 2 6 7 Communication Port 0 cece eee eee n 25 2 6 8 FUSES ci d 1778 pax 25 2 7 Controller Logic 2 2222 2222 222 222222 2228 25 2 7 1 Fault Shutdown and Warning Specifications 25 2 7 2 Controller Resetting Following System Fault Shutdown 29 2 7 3 Voltage Regulat
52. d d 149 240 d9 599 4 CYLINDER ONLY vM N 8 EM voL vf Nid SNOILOJNNOO 94 QS 53 9d s zid d9 go c3 4 em 60 44 Og 91 14 3 x 71 14 N33H9 NYO 0160528862 si id MOTI3A 734 Vf Nid 3oygsiN 3 015 2 SNOUO3NNOO 6d L zHa 214 583 2 zHd z zid 80115 083 614 Ld gm 0 2 rM N 1 SM 012 SNOLLO3NNOO Zd O N z6 14 083 ZIN SS ya 1 Nid SNOIIOJNNOO 214 N UM d SNOILOJNN Uf Nid 03 vd v sd 9 64 s 6d 1 6d z 6d 513 v 8d 9 64 sao em vm Lm zw SNOTO3NNO 14 14 2 N 2 N 0 N 2 8 2 N 2 N of HA 734 NY9 O N 4 2 N O N 2 IN Hd 31114 vis 8v O 6d W3ONVHO 311 8 is 81 GM79008 C int Po Figure 5 3 Wiring Diagram Point to TP 6772 2 14b 64 Section 5 Wiring Diagrams YaTIOWLNOD AINO 9 3008 5 8 4 15 0134 NIVN 20 29 SL8S AQV 3338 SNOILO3NNOO
53. d equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load TP 6772 2 14b Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardous backfeed 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 personne
54. e engine fails to start will shut down on an overcrank fault condition Overfrequency The fault lamp flashes red and the unit shuts down when the frequency is above the overfrequency setting The local display shows Freq High Shutdwn See Figure 2 13 Overfrequency Overfrequency EPI Range Time Delay Default Setting 10296 14096 10296 14095 of nominal nominal 11096 of nominal Figure 2 13 Overfrequency Specs Section 2 Operation 31 Overvoltage Each Phase The fault lamp flashes red and the unit shuts down when the voltage exceeds the overvoltage setting for the preset time delay period The local display shows Volts L1 L2 L2 L3 orL3 L1 High Shutdwn See Figure 2 14 for overvoltage specifications Note Overvoltage can damage sensitive equipment in less than one second nstall separate overvoltage protection on online equipment requiring faster than 2 second shutdovvn Overvoltage Default nhibit Time Delay Time Setting Figure 2 14 Overvoltage Specs Underfrequency The fault lamp flashes red and the unit shuts down when the frequency drops below the underfrequency setting The local display shows Frequency Low Shutdwn See Figure 2 15 for underfrequency specifications Underfrequency Time Delay Time Default Setting 0s6e 90 of nominal Figure 2 15 Underfrequency Specs Undervoltage The fault lamp flashes red and the unit shuts down when the voltage drops below the undervoltage setting
55. ency High Shutdwn X X Overvoltage each phase Volts xx xx High Shutdwn x x Underfrequency Frequency Low Shutdwn x x Undervoltage each phase Volts xx xx Low Shutdwn x x Some functions require optional input sensors or are engine ECM dependent on some generator set models 24 Section 2 Operation TP 6772 2 14b 2 6 7 Communication Port The main logic circuit board contains a standard type B USB communication port for PC connections and a USB host connector for a mass storage device connection See Figure 2 6 and Figure 2 7 See Section 2 10 12 for USB flowchart information Refer to the List of Related Materials in the Introduction for corresponding SiteTech software and or communication installation information Note Before inserting a mass storage device USB host connector power off and then power on the controller See Figure 2 5 for tested approved manufacturer s USB flash drive types that work with the ADC 184 controller CustomUSB Kohler Power Systems Part Number KW A202 Imation 2 GB spin full size 4 GB full size 4 GB full size 4 GB full size and micro Lexar PNY Verbatim 4 GB full size and micro Figure 2 5 USB Types Tested Approved for ADC lld START STOP 1 USB device connector connects to SiteTech 2 USB host connector connects to mass storage device Figure 2 7 ADC USB Identification TP 6772 2 14b 2 6 8 Fuses Fuses are located on
56. enu Volts displays the alternator output AC voltages The display shows all line to line and line to neutral voltage combinations for three phase or single phase configurations Frequency Hz value displays for the output AC voltage This value also shows in the Overview Menu Reset Calibration provides the means to reset the configuration values The calibration values are reviewable at all times and provide the calibration of the voltage sensing logic Changing the system voltage or replacing the circuit board requires a calibration adjustment To enable calibration start the generator set and select the Volts L1 L2 display Then push and hold the pushbutton rotary selector dial until the Calibration Enabled popup appears Calibration of each display is now available The display will show the following values for three phase generator sets Single phase generator sets will only display items marked Volts L1 L2 Volts L2 L3 Volts L3 L1 Volts L1 N Volts L2 N Volts L3 N The user can change individual values or can select Reset Calib Yes to reset all values The Reset Calib display will only show if calibration is enabled Refer to the requirements shown with Generator Set Calibration in 2 7 7 Status and Notice Digital Displays To disable calibration Rotate the pushbutton rotary selector dial until the Return popup appears Momentarily press the pushbutton rotary selector dial Stop the generator set if n
57. er Button to turn the controller off Remote Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 The generator set stops when the remote start stop switch contacts close momentarily or when the remote digital gauge sends a stop command Consult the instruction sheet supplied with the remote start stop switch or remote digital gauge for stopping instructions Note ADC powers down after 48 hours of inactivity If the generator has been started the controller will power down 48 hours after the generator stops 2 6 4 Fault Shutdowns and Warnings The generator set shuts down automatically under the fault conditions listed in Figure 2 9 and the controller displays a fault code The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 7 2 to reset the controller after a fault shutdown The controller resets automatically after a battery voltage fault condition is corrected Shutdown conditions on the generator set automatically reset when the problem is corrected The high engine temperature condition automatically resets when the generator set cools However the fault shutdowns do not clear until the controller is reset The controller displays warning text but the generator set does not shut down under the conditions shown in Figure 2 10 Section 2 Operation 19 System Warning Fault Lamp Green Red lam
58. eric display provides generator set and engine data system status and fault information See Figure 2 3 The digital display shows abbreviations in some instances refer to Section 2 7 1 Status Event and Fault Specifications for the abbreviations and their full descriptions Note US Metric Unit Display is selectable in Generator Set System Note After about 5 minutes of no user input pushbutton rotary selector dial or buttons the menu resets to the top of the main menus and auto paging activates for the Overview submenus The main menus are listed below Within each main menu are multiple submenus with descriptions following Overview Engine Metering Generator Metering GenSet Information GenSet Run Time GenSet System Voltage Regulation Digital Inputs not applicable for units with ADC lld Digital Outputs not applicable for units with ADC Analog Inputs not applicable for units with ADC Ild Event Log Prime Volt Select Overview Menu When a new shutdown or warning fault occurs the auto paging display feature activates Active Shutdowns display if any are present This alerts the user to single or multiple shutdown fault conditions See Section 2 7 6 System Shutdown Fault Lamp with Digital Displays for a list of possible shutdown faults Active Warnings display if any are present This alerts the user to single or multiple warning fault conditions See Section 2 7 5 System Warning Fault Lamp with D
59. ernators are designed to operate at limited voltage frequency or phase connections and as a result some settings may have limited parameters Display for Measurement System is user selectable as English or Metric Contrast display is user adjustable to help improve digital display visibility in dimly lit rooms or in direct sunlight Note The contrast feature is a controller hardware change and may not be available on older units even if the firmware is updated GenSet System GenSet gt System System Freq User Selectable gt 60 Hz or 50 Hz Battery V V CAN A Usor Selectable se J1939 SmartCraft or NMEA 2000 Meas System User Selectable gt English or Metric Contrast User Selectable gt Note After changing the CAN A communication setting power off and then power on the controller TP 6772 2 14b 2 10 8 Voltage Regulator Displays the voltage regulator adjustment volt Hz gain and stability adjustment values The voltage regulator value is reviewable at all times and provides the ability to fine adjust voltage Changing the system voltage or replacing the circuit board typically requires a voltage adjustment To enable calibration start the generator set and select the VR Volt Adj Volt Hz Gain or Stability display Then Voltage Regulator push and hold the pushbutton rota
60. hard starting Replace the fuel filter Fuel water separator draining Fuel water separator cleaning Inspect clean and test the fuel injectors T3 Inspect the fuel injection nozzle pressure T3 LUBRICATION SYSTEM Check the crankcase oil level and add oil as necessary X Before operation Replace the oil in the crankcase X Break in period Replace the lube oil filter element X Break in period COOLING SYSTEM Check the coolant level and fill as necessary X Before operation Check the seawater outlet and clean as necessary 3 5 X Check adjust the seawater pump belt tension 3 7 1 X Break in period Check the function of the siphon break if equipped 3 6 6 Check replace the seawater pump impeller 3 6 5 X Replace Replace the coolant T 3 6 3 Check replace the heat exchanger anticorrosion zinc anode if equipped 3 6 7 X Replace Clean the heat exchanger tube Gen S M Check replace the coolant hoses Requires removal of the sound shield door if installed Consult your local distributor dealer for service CO ME 44 Section 3 Scheduled Maintenance Read the WARNING found at the beginning of the manual regarding moving parts Consult the operating instructions supplied with the craft X Replace 6772 2 14b Service Schedule
61. he battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set TP 6772 2 14b Section 3 Scheduled Maintenance NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces NOTICE The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized distributor dealer perform generator set service Engine Service Perform generator set engine service at the intervals specified by the engine operation manual Generator Set Service Perform generator set service at the intervals specified by the generator set o
62. he battery Oil Pres Low Warning Low engine oil pressure warning Post starting aid running cooldown Figure 2 10 Advanced Digital Control 14 Warnings 28 Section 2 Operation At or below 138 kPa Check for leaks in the lubrication system Check the oil level and add oil if the level is low 6772 2 14b 2 7 2 Controller Resetting Following System Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Use the following procedure to reset the generator set controller after a fault shutdown 1 Disconnect the generator set from the load See the safety precautions at the beginning of this manual before proceeding 2 Identify and correct the cause of the fault shutdown See the safety precautions at the beginning of this manual before proceeding Refer to Section 4 Troubleshooting 3 Use the Advanced Digital Control s pushbutton rotary selector dial to select the Overview page 4 When the Overview page appears press the pushbutton rotary selector dial to view the active fault Press the pushbutton rotary selector dial again and then use the pushbutton rotary selector dial to CONFIRM CLR FAULT YES to clear the fault 5 Push the pushbutton rotary selector dial 6 Start the generator set by pressing the generator set start stop button to START Test operate the generator set to verify that the cause of the shutdown has
63. he controller is in a low power mode the Engine Start Stop button starts the engine When the controller is in a low power mode the button may need to be pressed twice to start the engine Power Button The Power button toggles the controller between on and off When the controller is off it does not respond to any input except the Power button Note After about 5 minutes of no user input pushbutton rotary selector dial or buttons the menu is reset to the top of the main menus and auto paging activates for the Overview submenus Note Measurements display in metric or English units Use the Generator Set System menu to change the measurement display LED Status Indicator The LED provides asummary of the generator state Figure 2 4 shows the possible LED displays When two or more colors are shown the LED blinks between the two colors in 2 second intervals The 2nd and 3rd if any colors are shown for 100 ms each and the 1st color appears for the remainder of the time Section 2 Operation 17 Controller Power Warning Engine LED Color s Display Operational Backlight Functional Mode N A None Yes N A Stopped Black Black Green Black Green Red Black Red Off Low Power Auto Low Power Auto Low Power Auto No USB Powered Auto Battery Powered Auto Stopped Black Green None Yes Green Yes Green Red Running Battery Powered Auto
64. hin 1096 of the system operating voltage Measurement Units User Defined This selectable display is in the GenSet System Menu allowing the user to choose between Metric and English displays Usethe Pushbutton Rotary Selector Dial to navigate and select this feature Changes to this display can be done with the generator set running or stopped The local display shows Meas Units Metric or Meas Units English Remote Start This status indicates that the generator set start circuit was closed from a remote location allowing the engine to crank and run The remote location is typically a set of contacts on a transfer switch or remote start switch The local display shows Remote Start Status TP 6772 2 14b System Ready This status indicates thatthe generator setisinthe AUTO mode and available to start ifthe start circuit is closed The local display shows System Ready System Timer Failed This notice indicates that the controller timer logic has failed to time out a designated function The local display shows Timer Error Notice Voltage Regulator Adjustment User Defined This feature is in the Voltage Regulator Menu allowing the user to fine adjust the output voltage Use the Pushbutton Rotary Selector Dial to navigate and select this feature Changes to this display must be done with the generator set running The local display shows Enter volt reg No or Yes Select No to exit the voltage regulator menu Select Yes to change the
65. igital Displays for a list of possible warning faults TP 6772 2 14b Generator Set State displays the generator set status e Off e Standby e Running e Cooldown e Stopping When the unit is cranking the attempt number is displayed When the unit is priming the time remaining is displayed Average Volts Line to Line value displays For three phase configurations the average line to line voltage of L1 L2 and L3 is displayed Single phase configurations show the L1 L2 voltage Frequency Hz value displays for the output AC voltage Coolant Temperature diplays for the engine coolant temperature Oil Pressure displays the engine oil pressure Battery displays the DC voltage of the engine starting battery ies Engine Run Time displays the total run time hours Next Maintenance displaysthe next maintenance timer in hours Software Version displays in the Overview menu Use the version number to determine if an upgrade is needed and or when troubleshooting the controller Engine Metering Menu Engine Speed Tachometer displays the engine speed in RPM Oil Pressure displays the engine oil pressure This value also shows in the Overview Menu Coolant Temperature displays the engine coolant temperature This value also shows in the Overview Menu Battery displays the DC voltage of the engine starting battery ies This value also shows in the Overview Menu Section 2 Operation 21 Generator Metering M
66. in a container having approximately 3 7 7 5 L 1 2 U S gallons of coolant antifreeze Kohler Co recommends using an environmentally friendly potable antifreeze such as Peak RV marine propylene glycol water mix or equivalent Disconnect the lead 87 to the low seawater pressure LWP switch With a suitable container at the exhaust outlet run the generator set until coolant discharges at the exhaust outlet or until the coolant mixture is depleted Do not allow coolant mixture to flow into waterways TP 6772 2 14b 10 11 12 13 14 Reconnect the lead 87 to the low seawater pressure LWP switch Stop the generator set Connectahosetothe seacock Leavethe seacock closed Check the coolant level of the heat exchanger and add coolant if necessary Note Use antifreeze capable of withstanding the lowest possible temperatures Cleanthe exterior ofthe generator set and spreada light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion Disconnect and remove the battery Place the battery in a warm dry location for the storage period Recharge the battery once a month to maintain a full charge Select a well ventilated not humid or dusty location to store the generator Cover the entire unit with a dust cover Note Run the generator set once a month whenever possible Section 3 Scheduled Maintenance 57 Notes 58 Section 3 Schedu
67. inc Anode Plug 4 Cleanthethreaded hole ofthe heat exchanger and coat the threads of the anticorrosion zinc anode plug with pipe sealant suitable for marine applications Cut the anticorrosion zinc to the correct length Install the anticorrosion zinc anode into the heat exchanger 5 Close the petcock on the engine and open the seacock Refill the cooling system 6 Start the generator set and check for leaks at the anticorrosion zinc anode location The pump is operating if the cooling water flows from the exhaust outlet If water is not discharging at the exhaust outlet see Section 2 1 Prestart Checklist Seawater Pump Priming Section 3 Scheduled Maintenance 55 3 7 Belt Tension A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when 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 tension at the interval specified in the service schedule If tension is not within the specification adjust as necessary using the following procedure Seawater pump adjusting screw Seawater pump pulley Check the seawater pump belt deflection tension here
68. ing 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 HHC hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext VO IP ISO J JIS k K kA KB fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal exte
69. ion 3 Scheduled Maintenance Note Do not run the generator set out of fuel because the fuel lines will draw in air and necessitate bleeding the fuel system before restarting the unit 3 4 2 FuelFilter The quality and condition of the fuel largely determine the filter s useful life Replace the fuel filter element as listed in the service schedule Section 1 shows the typical location of a fuel filter Use the applicable procedure below to replace the fuel filter Fuel Filter Cleaning Replacement Procedure 1 Close the fuel supply valve 2 Loosen the fuel filter by turning it counterclockwise Remove the fuel filter and use rags to clean up spilled fuel oil Dispose of the fuel filter in an approved manner 3 Clean the contact surface of the fuel oil filter adapter 4 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 5 Open the fuel supply valve 6 Bleed the system See Section 3 4 3 Fuel System Bleed TP 6772 2 14b 3 4 3 Fuel System Bleed Bleed air from the fuel system in order to reduce rough running or vapor lock Trapped air in the fuel system can cause difficult starting and erratic engine operation Prime the fuel system under the following conditions e Before starting the engine for the first time e After run
70. ion from the reed valve 4 Clear blockage from the reed valve opening 5 Replace the siphon break if the reed valve is cracked or if the reed valve material has hardened or deteriorated TP 6772 2 14b 6 Install the reed valve into the mounting base with the valve downward See Figure 3 9 item 2 7 Install and only finger tighten the retaining cap Do not overtighten it Note Ensure that the siphon break s cap is tight before operating the generator set 1 Cap 2 Reed valve 3 Mounting base Figure 3 9 Siphon Break m sm 003 007 Section 3 Scheduled Maintenance 53 1 Silencer vertical lift 1 2 m 4 ft max Exhaust mixer elbow distance above waterline If less than 23 cm 9 in a siphon break is required Siphon break distance above waterline 30 5 cm 1 ft min Siphon break Exhaust mixer elbow Heat exchanger locations vary by model Coolant recovery tank Seawater strainer Seacock Figure 3 10 Siphon Break Plastic U Type Installation Note Consult the installation manual for complete explanation of dimensions and other installation considerations 54 Section 3 Scheduled Maintenance Intake strainer Engine driven seawater pump Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Water lock optional Silencer distance from exhaust mixer elbow 3 m 10 ft max Maximum distance between silencer and exhaust
71. ip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Safety Precautions and Instructions 5 Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas present in exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie 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
72. jo 1no Buruy uonoefur jen 4 4 40joefui any eAnegedour y eoejdei 40 489 uee o Ajuo jeseip o Ap sJojoefui jen 40 jenJ Ulejs s jeseip eui 918 jeseip uieis s any Ul Jv 4 jan eui 100use qnoJ 4900 10 8 69 jen4 JOY ni v 905 084 10 ULD uonoHs l lil ON Uonisod NO 24 O Jen y e ouu pue l n ppv HO 1nus jen 10 Ajdwe yug l n i 93 8948 98 0883 4 40 08395 5 0 3 pepueuiuoo2eH 895 53 9149 044 esiou jewuouge 40 AISS OXZ1 uonduinsuoo uBiH eunsseud SYE UH AQ Jewod sxyoe1 Ajueppns 90018 1ndino MO JO ON peu sueis peys jou seop 114 swojdwAs TP 6772 2 14b 62 Section 4 Troubleshooting Section 5 Wiring Diagrams A WARNING D KS Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set
73. l 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 and follow the instructions of the test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under TP 6772 2 14b Hot Parts A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Notice NOTICE Fuse replacement Replace 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 Saltwate
74. leaks as needed e Ensure that the carbon monoxide detector s is 1 in the 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 Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set Seawater Pump Priming Prime the seawater pump before initial startup To prime the pump 1 close the seacock 2 remove the hose from the seawater filter outlet 3 fill the hose and seawater pump with clean water 4 reconnect the hose to the water filter outlet and 5 open the seacock Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet Section 2 Operation 15 2 2 Marine Inspection Kohler Co recommends that all boat owners have their vessels inspected at the start of each boating season by the US Coast Guard the local Coast Guard Auxiliary or local state agency Kohler Co also recommends having the generator s exhaust system inspected at the start of each boating season by an authorized Kohler distributo
75. lector dial to view messages When the system warning continues it may lead to a fault and cause a system shutdown Note Text shown in italics in this section of the manual represents digital display messages AC Sensing Loss The fault lamp illuminates green then red when the controller does not detect the nominal generator set AC output voltage after crank disconnect The controller displays AC Sens Loss Warning High Battery Voltage The fault lamp illuminates green then red maybe black when the battery voltage rises above the preset level for more than 10 seconds The local display shows Battery High Warning Figure 2 11 shows high battery voltage specifications The high battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes Engine Electrical High Battery High Battery Voltage System Voltage Voltage Range Default Setting Figure 2 11 High Battery Voltage Specs High Coolant Temperature The fault lamp illuminates green then red maybe black when the engine coolant temperature approaches the shutdown range The high coolant temperature warning does not function during the preset inhibit time delay period after startup The local display shows Coolnt Temp High Warning 30 Section 2 Operation Low Battery Voltage The fault lamp illuminates green then red maybe black when the battery voltage drops below a preset level for more than 90 seconds The local displa
76. led Maintenance TP 6772 2 14b This section contains generator set troubleshooting diagnostic and repair information Use the following charts as a quick troubleshooting reference The table groups generator set faults and suggests likely causes and remedies The table also refers you to more detailed information including sections of this manual the generator set service manual S M the generator set installation manual I M and the engine service manual Engine S M to correct the indicated problem Corrective action and testing often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service distributor dealer perform service 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 TP 6772 2 14b Section 4 Troubleshooting Maintain a record of repairs and adjustments performed on the equipment If the procedures in this manual do not explain how to correct the problem contact an authorized distributor dealer Use the record to help describe the problem and repairs or adjustments made to the equipment x gt 001 002a 4 1 Fault Codes The Advanced Digital Control 14 displays fault codes to aid in troubleshooting Fault codes descriptio
77. ll show ENABLED YES A NO entry will turn the feature off and the display will show ENABLED NO The underfrequency unload defaults to an enabled ON condition 74 Appendix Frequency Setpoint The frequency setpoint is the cut in point for underfrequency unloading At any operating frequency below the frequency setpoint the output voltage will be reduced The frequency may be entered with resolution to tenths of aHz The range of acceptable entries is 30 to 70 Hz The default value is one cycle per second or two for non ECM engines below the normal system frequency The frequency setpoint changes to the default value ifthe system frequency changes Asetting of 30 Hz essentially disables the underfrequency unload feature because most engines do not normally drop to speeds this low even during load applications Underfrequency Unload Slope The slope determines how much voltage is reduced during an unloading condition The line to line voltage is regulated to a value less than the voltage adjust setting by this amount for every cycle below the frequency setpoint The voltage may be entered with resolution as fine as one tenth of one volt The default value is 2 0 volts per cycle per second A zero entry for the slope in effect turns the underfrequency unload feature off 6772 2 14b Notes TP 6772 2 14b Appendix 75 76 TP 6772 2 14b TP 6772 2 14b 77 78 TP 6772 2 14b TP 6772 2 14b 79 TP 6772 2 145
78. 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 5 1 Wiring Diagram Reference A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Model Point to Point Figure Schematic Figure Accessory Figure 6EKOD 5EFKOD 9EKOZD 7EFKOZD GM79008 C Figure 5 3 ADV 7995 C Figure 5 4 GM33846 D Figure 5 7 11EKOZD 9EFKOZD Figure 5 1 Wiring Diagrams for Units without Isolated Ground Model Point to Point Figure Schematic Figure Accessory
79. n 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 6772 2 14b Accidental Starting A 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 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
80. nd buildings To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Inlets Check for clean and unobstructed air inlets Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Drive Belt Check the belt condition and tension of the water pump belt Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections TP 6772 2 14b Section 2 Operation Inspect the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper for cracks leaks and corrosion e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replacethe hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal
81. ne 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka ndia Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 dapan Korea North Asia Regional Office Tokyo dapan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 TP 6772 2 14b Maintenance and Service Parts Related Literature Maintenance and Service Parts Figure 1 identifies maintenance and service parts for your generator set Obtain a complete list of maintenance and service parts from your authorized generator distributor dealer Part Description Models 6EKOD and 5EFKOD 1 Phase 9EKOZD and 7EFKOZD 1 Phase 11EKOZD and 9EFKOZD 1 Phase 11EKOZD and 9EFKOZD 3 Phase Fuse Auxiliary Winding F1 10 Amp 358337 358337 358337 358337 Fuse Controller Fuel Pump and Fuel Shutoff Solenoid F2 20 Amp GM39266 GM39266 GM39266 GM39266 Fuse Customer Connection F3 5 Amp 239298 239298 239298 239298 Fuel Filter Element ED0021752880 S 00021752880 5 00021752880 5 00021752880 5 Oil Filter ED0021752850 S ED0021752850 S 00021752850 5 00021752850 5 Seawater Pump Impeller Kit 229826 229826 229826 229826 V Belt Seawater Pump 229125 229125 229125 229125 Zin
82. ning out of fuel and adding fuel to the tank e After fuel system maintenance such as changing the fuel filter draining the fuel water separator or replacing a fuel system component Fuel System Bleed Procedure Preferred Note To prevent damage to the starter motor do not crank the engine to prime the fuel system Use the following procedure 1 Push the power button on the Advanced Digital Control Ild to the ON position 2 Whenthe run time hours appear on the LCD digital display rotate the pushbutton rotary selector dial until PUSH TO PRIME appears on the LCD digital display 3 Push the pushbutton rotary selector dial 4 Rotate the pushbutton rotary selector dial to CONFIRM PRIME Yes 5 Push the pushbutton rotary selector dial to begin the fuel priming procedure A 30 second priming sequence begins automatically If necessary push the control knob to stop the priming procedure before the 30 seconds are up PUSH TO PRIME O KO R Ro DVANCED DIGITAL CONTROL 114 NS 1 LCD digital display 2 Pushbutton rotary selector dial 3 Power button GM58225A Figure 3 4 Advanced Digital Control Il TP 6772 2 14b Typically running the Prime function on the ADC Ild is all that is required If rough operation continues use the following procedure to open the air bleed valve on the fuel filter
83. ns and recommended actions are listed in Section 2 7 1 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 7 2 Section 4 Troubleshooting 59 W S 40 W O duind eui soejday eui eoejdeJ 40 ue1uDi eAnejedoui dund sayem 1 00 92 68 SIY uuoped jepeep 1oinquisip 831 4958 pezuouine ue e eH 4 weibeig 99 8 oeds s s enuen 1 enuen uone ed 9 4N O enuen uomejeisu N I 295 101eeuec ues euiBu3 Buy youms 48 8 41 oneuiogny S v enuew siu jo uonoes pejequinu uonoeg 2egS x w s jejsouueu eui eoejdey jejsouue8u L uonoeg lJe e Bunejedo jeuuou oj 1ue ooo eui eJoiseH NO JG 9 JUB OOD W O Buz g s s ulejs s Bulloo eui 100usejqnoa 9 1 umop 1002 01 eurBue eui MO V uMopinus eJnje1eduue uonoeg eDeurep 10 Jejjeduui duund jeyewees y 4041215 eui ULAJ 40 peDBojo jeurens Jejewees uonoeg 49 99 v eoe deu 54910 1 4ej eduu sBuiuedo 1e eui sBuiuedo 4 Uonisod ejouleJ BU SLY JO 8 e UJO4J 994 pueululoo dois 548 W S ueo 4
84. nt operation Inspect the parts often and perform required service atthe prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition Before installing a marine generator set obtain the most current installation manual from your local distributor dealer Only qualified persons should install the generator set Introduction 9 Service Assistance For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KOHLERPower com e Look atthelabels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outsidethe US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Netherlands B V Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 331631 Asia Pacific Povver Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 10 Introduction 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 Pho
85. o change from auto scrolling to fixed display press the rotary dial and the main menu will appear Press the rotary dial again to select the first menu item Overview Turn the rotary dial to select the desired fixed view Overview Auto Scrolling Display Active Shutdowns if present Overview gt gt gt 44 hr Y Active Warnings if present Genset State ill Avg VL L Y Frequency Hz Coolnt Temp HH F Oil Pressure PSI Battery Eng Runtime Next maint h SW Version 1 02 36 Section 2 Operation Overview Fixed Display Overview V Hz hr 1 English Display HHPF HHH Measurements gt HHH PSI ee Y Metric Display HHP C Measurements gt kPa HHAV 2 10 3 Engine Metering Displays engine operating data as measured by the engine and other sensors Engine Metering Engine Metering gt Eng Speed R min Oil Pres PSI Coolnt Temp Battery TP 6772 2 14b 2 10 4 Generator Metering and Calibration Displays generator output data including line to line and line to neutral voltages and frequency The menu displays three phase voltage readings when applicable All menu displays apply to both single phase o
86. ood 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 guards 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 and standards Electrically ground the generator set transfer switch and relate
87. or and Calibration Specifications 29 2 7 4 Voltage Regulator Adjustments 0 0 cece eee eee 29 2 7 5 System Fault Warning Lamp with Digital Displays 30 2 7 68 System Fault Shutdown Lamp With Digital Displays 31 2 7 7 Status and Notice Digital Displays 32 2 8 Menu Displays eo ease dr nated DED YAR ws 33 2 9 Monitoring and Programming 2 eens 35 2 9 1 PC Communications ieena EE E A EE a a 35 2 10 Reviewing Menu Displays 9 ooo eee eens 35 2 101 Eror 85 5 oed Per G Y a 35 2102 Overview eoru rd rie ER deeb E EAE YES 36 2 10 8 Engine Metering sien he Pana RR rane E 36 2 10 4 Generator Metering and Calibration 37 2 10 5 GenSet Information 225252222222222222222222222 2222 38 2 10 6 GenSet Run Time 8 8 8 8 88 888 38 2 10 7 GenSet System iun wee ee Aya Baa Ride EUER 38 2 10 8 Voltage Regulator 39 210 9 Event Loge eo sr EE wae a bt ene AERE ERE 39 2 10 10 Prime M nu c r ARX esi aad Sade dae eee ide 40 2 10 11 Volt Select cond REL decd nad siete edo 40 2 10 12 USB Flowchart ine gii RR te debere PN a 41 Section 3 Scheduled Maintenance
88. or dial to navigate to the respective menus TP 6772 2 14b Menus displaying the symbol represent one of the following data types e System calculated data e System measured data e User entered data Note The examples given on the following pages represent digital displays with the Measurement Units set to English 2 10 1 Error Messages Certain entries or attempted entries may cause the controller to display an error message Cannot Calibrate appears when attempting to calibrate the voltage values in the Generator Metering menu with the unit stopped The unit must be running in order to make adjustments Cannot Edit When Stopped appears in the Voltage Regulator menu when attempting to change the VR Volt Adj value when the unit is not running Controller SiteTech Adjustable Adjustable Controller Menu Name Viewable Overview Engine Metering Generator Metering GenSet Information GenSet Run Time GenSet System Voltage Regulation Event Log XIX X X X X X XxX Prime x Volt Select n SiteTech the voltage and phase get set individually Figure 2 18 Menu Displays for Viewing and Adjusting Section 2 Operation 35 2 10 2 Overview Displays basic and commonly sought after information about the generator set This information scrolls automatically after about 5 minutes of no user input pushbutton rotary selector dial or button activity T
89. ot already done Generator Set Information Menu GenSet M N displays the generator set model number GenSet S N displays the generator set serial number Controller S N displays the controller serial number 22 Section 2 Operation Generator Set Run Time Menu Engine Run Time displays the total run time hours This value also shows in the Overview Menu Engine Starts displays the total number of generator set startup events Next Maintenance displays the next maintenance timer The maintenance interval for the ADC lld is 250 hours Generator Set System Menu The values in these menus are user entered for the generator set configuration and are NOT measured values of the generator set System Frequency displays the programmer entered L1 L2 L3 output voltage frequency for three phase or the L1 L2 output voltage frequency for single phase Battery Voltage displays the engine electrical system 12 or 24 volts CAN A displays the remote communication s protocol in use J1939 SmartCraft or NMEA 2000 Note After changing the CAN A communication setting power off and then power on the controller Measure Units displays the user selected unit of measure as Metric or English Contrast displays user selected resolution values to improve digital display clarity Voltage Regulator Menu The voltage regulator value is reviewable at all times and provides the ability to fine adjust voltage Changing the system voltage o
90. outlet of 1 5 m 5 ft Silencer customer supplied Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Exhaust outlet distance above the waterline 10 cm 4 in min TP 6772 2 14b 3 6 7 Anticorrosion Zinc Anode The heat exchanger contains an anticorrosion zinc anode plug to prevent electrolytic corrosion by seawater Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule Depending upon operating conditions and seawater properties the anticorrosion zinc anode may require more frequent replacement See Section 1 for the location and use the following procedure Anticorrosion Zinc Anode Replacement 1 With the generator set cooled close the seacock open the petcock on the engine and drain the coolant into a suitable container 2 Remove the anticorrosion zinc anode plug from the heat exchanger 3 Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode Replace the anode according to Figure 3 11 and Figure 3 12 Anticorrosion Zinc Anode Replacement Replace When Percent of Zinc Remaining Is New Anode Models Dimensions mm in 6EKOD 5EFKOD 9EKOZD 7EFKOZD lt 50 of 635 0 25 x 20 0 78 tength diameter 11EKOZD 9EFKOZD Figure 3 11 Anticorrosion Zinc Anode Plug Measurements TP 6772 2 14b 1 Diameter 6 35 mm 0 25 in 2 Length 20 mm 0 78 in Figure 3 12 Anticorrosion Z
91. overy 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 the level is just below the overflow tube opening Note A coolant solution of 5096 ethylene glycol is required This mix 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 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 Note Do not add coolant to an overheated engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled Note Pay special attention to the coolant level After the coolant drains allow time when refilling the coolant for a complete refill of the engine water jacket Check the coolant level as prescribed in the Prestart Checklist 3 6 3 Flushing and Cleaning For optimum protection drain flush and refill the cooling system at the interval listed in the service schedule Flushing and Cleaning Procedure 1 Open the pressure cap and open petcocks located at the heat exchanger engine block and cooling
92. p identifies an existing fault condition that does not shut down the generator set A continuing system warning fault condition may cause a system shutdown Correct all system warnings as soon as practical See Section 2 7 5 System Fault Warning Lamp with Digital Displays for definitions of the items listed The following conditions cause a system warning AC sensing loss High battery voltage High coolant temperature Low battery voltage Low cranking voltage Low oil pressure 20 Section 2 Operation System Shutdown Fault Lamp Red lamp indicates that the generator set has shut down because of a fault condition The unit will not start without resetting the controller see Section 2 7 2 Controller Resetting procedure See Section 2 7 6 System Fault Shutdown Lamp with Digital Displays for definitions of the items listed The following conditions cause a system shutdown AC sensing loss Auxiliary input analog or digital Engine over speed Engine under speed High coolant temperature High exhaust temperature Locked rotor failed to crank Low seawater pressure Low oil pressure Overcrank Overfrequency Overvoltage each phase Underfrequency Undervoltage each phase TP 6772 2 14b 2 6 5 Digital Display The generator set must be running for some displays to indicate values If the generator set is not running some values will display zero or N A not available The 12 character 2 line backlit alpha num
93. per hour MS military standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg mounting 70 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns OC OD OEM OF opt OS OSHA OV oz p pp PC PCB pF PF ph 2 PHC PHH PHM PLC PMG pot ppm PROM psi pt PTC 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 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 re
94. peration manual If the generator set operates under dusty or dirty conditions use dry compressed air to blow dust out of the alternator With the generator set running directthe stream of air in through the cooling slots atthe alternator end Routine Maintenance Refertothefollowing generator set service schedule the engine service schedule and the runtime hours shown on the ADC IId to determine when to schedule routine maintenance Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions Service Log Use the Operating Hour Service Log located in the back of this manual to document performed services Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set For example an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months 300 hours or 9 months and so on Section 3 Scheduled Maintenance 43 3 2 Service Schedule 6 11EKOD EKOZD 8 5 9EFKOD EFKOZD Models Perform Service at Intervals Indicated X Check the fuel level and fill as necessary Reference Section Before operation Every 250 Hrs or3 Months Every 500 Hrs or6 Months Every 1000 Hrs or Yearly Check for any unusual noise X During operation Remove the sediment from the fuel tank and drain the fuel tank T Bleed the fuel system if encountering
95. pes of applications should understand these terms This appendix contains references to other sections of this manual Please refer to these sections for further information and explanation Paralleling generator sets can be a complicated and dangerous exercise Application programming must be performed by appropriately skilled and suitably trained personnel Definitions Underfrequency Unloading Underfrequency unloading is a function used in the alternator excitation control system to improve the overall generator set system engine and alternator response n particular underfrequency unloading relates to large block load applications When applied to engine driven alternators large block loads cause a subsequent transient torque load on the engine This torque load can reduce the engine s speed below the normal operating point Typically the engine speed controller or governor will compensate for this by commanding an increase in fuel If however the fuel system is inadequate to recover from a relatively large load the speed may never recover In these instances other measures must be taken This is where the underfrequency unloading occurs When the excitation control system detects a drop in the speed or electrical frequency below some predetermined point the control system enters an unloading condition This can be described as moving to a lower voltage regulation point By reducing the output voltage of the alternator
96. r dealer Repair any problems identified before operating the generator set A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected 2 3 Angular Operation See Figure 2 1 for angular operation limits Instant Operation Intermittent Operation up to 1 min up to 30 min Figure 2 1 Angular Operation 2 4 Operation in European Union Member Countries This generator set is specifically intended and approved for operation belowthe deck inthe engine compartment Operation above the deck and or outdoors would constitute a violation of European Union Directive 2000 14 EC noise emission standard 16 Section 2 Operation 2 5 Load Profile Whenever operating the generator set Kohler Co recommends maintaining the minimum load profile indicated in Figure 2 1 Maintaining the load profile prevents corrosion formation on internal engine components when they re exposed to the breakdown of exhaust gases Extended light loading may result in engine wet stacking Minimum Ideal Load Requirement Load Requirement 3096 load 70 load or more Figure 2 2 Load Profile Wet Stacking occurs when water vapor condenses in the exhaust system At normal combustion temperatures water stays vaporized but at low combustion temperatures it condenses backto a liquid When running the generator set under normal loads 30 load or more diesel exhaust
97. r 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 6772 2 14b This manual provides operation instructions for 6EKOD 9 11EKOZD and 5EFKOD 7 9EFKOZD model generator sets Refer to the engine operation manual for generator set engine scheduled maintenance information Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference TP 6772 2 14b Introduction The generator set specification sheets provide specific generator and engine information Refer to the spec sheet for data not supplied in this manual Consult the generator set service manual engine operation manual and engine service manual for additional specifications Obtain copies of the latest spec sheets manuals diagrams and drawings from your local distributor dealer The equipment service requirements are very important to safe and efficie
98. r replacing the circuit board typically requires a voltage adjustment To enable calibration start the generator set and select the VR Volt Adi Voli Hz Gain or Stabil display Then push and hold the pushbutton rotary selector dial until the Editing Enabled popup appears Editing of the Voltage Adjustment Volts Hz Gain and Stability is now available The user can change the individual value or can select Reset VR Yes to reset to the default value The Reset VR Settings display will only show if editing is enabled To disable calibration rotate the pushbutton rotary selector dial until the Return popup appears Momentarily press the pushbutton rotary selector dial Stop the generator set if not already done TP 6772 2 14b Event Log Menu This menu allows the user to review upto 1000 entries of system events including shutdown faults warning faults and status events See 2 6 6 Controller Fault Diagnostics for a list of the items that appear on the Event Log Prime Menu This menu if confirmed allows the user to initiate the electric fuel pump to prime the fuel system Volt Select Menu Note The generator set must be stopped before changing the voltage selection This menu allows the user to readily change controller voltage settings Note The generator set output leads require voltage reconnection See the installation manual for voltage reconnection information With the generator set stopped go to
99. r three phase voltages on the menu overview The phase designation does not appear in the controller menu displays Some displays will show 0 values when single phase connections are shown Display also provides access to the calibration factors for metering volts Changing the system voltage or replacing the main logic control circuit board requires calibration adjustment Connect a meter with a minimum accuracy of 1 to the generator set output leads to calibrate the voltage sensing logic To enable calibration start the generator set and select the Volts L1 L2 display Then push and hold the pushbutton rotary selector dial until the Calibration Enabled popup appears Calibration of each display is now available The display will show the following values for three phase generator sets Single phase generator sets will only display items marked Volts L1 L2 Volts L2 L3 Volts L3 L1 Volts L1 N Volts L2 N Volts L3 N The user can change individual values or can select Reset Calib Yes to reset all voltage values The Reset Calib display will only show if calibration is enabled When calibrating voltage the metered value and the number being entered as the calibrated value must be within 10 of the system operating voltage To disable calibration Rotate the pushbutton rotary selector dial until the Return popup appears Momentarily press the pushbutton rotary selector dial Stop the generator set if not alread
100. rator set output leads require voltage reconnection See the installation manual for voltage reconnection information With the generator set stopped go to the Volt Select menu Then push and hold the pushbutton rotary selector dial until the voltage selection starts to flash Volt selection is now available Scroll to the desired voltage and momentarily press the pushbutton rotary selector dial to confirm the voltage selection 40 Section 2 Operation Volt Select Volt Select gt lil V Ph 120 240 V 1 Ph Y 120 208 V 3 Ph Y 139 240 V 3 Ph Y 277 480 V 3 Ph Y 120 240 V 3 Ph Y 115 230 V 1 Ph 120 V 1 Ph 230 V 1 Ph Y 240 V 1 Ph Y 110 190 V 3 Ph Y 127 220 V 3 Ph Y 115 230 V 3 Ph Y 230 400 V 3 Ph Y 240 416 V 3 Ph 6772 2 14b 2 10 12 USB Flowchart USB Stick i Present Note Ignored until generator set stops running Push Rotate Push Y Knob Knob Knob USB SAVE gt CONFIRM gt CONFIRM gt Saving gt Save e PARAMS amp LOG SAVE NO SAVE YES complete Rotate Knob Skipped if Genset is Running Push Push Knob Knob USB LOAD Filename Loading Load PARAMS PUSH TO LOAD Complete Rot
101. rnal input output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 21 bytes Appendix 69 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm KQ 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 d 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 108 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 270 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQ milliohm MOhm MO megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles
102. rogrammed Remote Starting A remote start stop switch connected to P9 connector leads 3 and 4 or a remote digital gauge connected to P9 connector pins 1 2 and 5 via CAN can be connected to the customer interface connection See the wiring diagram in Section 5 Note A remote start stop switch connected to P9 connector leads 3 and 4 is not available when configured for SmartCraft 1 Press the Power Button to turn the controller on Consult the instruction sheet supplied with the remote start stop switch or remote digital gauge for starting instructions Note The ADC llid allows three 7 second crank cycle attempts before the overcrank shutdown occurs Remote communications require an active powered up controller Be advised that the Advanced Digital Control enters a low power state with an average current drain of approximately 100 uA The ADC will power down mA draw after 48 hours of inactivity Press the start switch button once for the remote start stop switch or twice for the remote digital gauge to wake up the ADC and start the generator set TP 6772 2 14b 2 6 3 Stopping the Generator Set The following procedures describe the actions required to stop the generator set Local Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 Press the Start Stop button to stop the generator set The engine stops 3 Press the Pow
103. ry selector dial until the Editing Enabled popup appears Editing of the voltage adjustment is now available The user can change the individual value or can select Reset VR Yes to reset to the default value The Reset VR Settings display will only show if editing is enabled To disable calibration Rotate the pushbutton rotary selector dial until the Return popup appears Momentarily press the pushbutton rotary selector dial Stop the generator set if not already done Voltage gt VR Volt Adj Regulator XXX X VR Volt Hz XXX X VR Gain XXX X VR Stabil XXX X R VR d Reset VR eset gt ese User Selectable gt Settings No OR Reset VR Yes 2 10 9 Event Log Displays up to 1000 stored status warning and shutdown events After the first 1000 events each additional new event replaces the oldest event See 2 6 6 Controller Fault Diagnostics for a list of possible events Event Log Event Log gt lil Message Text Scroll through up to 1000 max stored events TP 6772 2 14b Section 2 Operation 39 2 10 10 Prime Menu This menu if confirmed allows the user to initiate the electric fuel pump to prime the fuel system Prime the Fuel System Push To Prime gt Confirm Prime Yes OR Confirm Prime No 2 10 11 Volt Select This menu allows the user to readily change controller voltage settings Note The gene
104. s shorted to ground Check for a clogged seawater intake or sea strainer Check for a damaged seawater pump impeller Volts xx xx High Shutdwn Overvoltage shutdown occurs if the voltage exceeds the default setting of the voltage regulator setpoint Alternator output Post starting aid running cooldown xx xx AC voltage exceeds 120 of the AC system voltage Contact an authorized distributor dealer for service if problem continues Volts xx xx Low Shutdwn Undervoltage shutdown occurs if the voltage falls below the default setting of the voltage regulator setpoint Figure 2 9 TP 6772 2 14b Alternator output Post starting aid running cooldown Advanced Digital Control Fault Shutdown xx xx AC voltage below 80 of the AC system voltage Reduce the load and restart the generator set Check the F1 fuse Contact an authorized distributor dealer for service if problem continues Section 2 Operation 27 Warnings Code Description Sensing Mechanism State s Detected Inhibit Time Trip Point Check AC Sens Loss Warning Loss of AC voltage warning occurs when the controller does not detect the nominal generator set AC output voltage after crank disconnect Frequency over AC voltage Post starting aid running cooldown 10 sec AC voltage is below 5 of the trip point for low AC voltage fault shu
105. 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 A WARNING W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never 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 g
106. single phase sensing excitation controller will keep the voltage of the sensed phase at the voltage adjustment value A three phase sensing system will average the three phases and hold the average to the adjustment setting The average is the sum of the voltages of three phases divided by 3 TP 6772 2 14b As stated above three phase sensing does not eliminate the unequal voltage phenomenon Three phase sensing balances the inequality of voltage between the phases to the desired value In other words if a system with unbalanced loads uses a single phase control feedback the voltage on the sensed phase would be at the setpoint while the other two phases would vary by their proportional loads For example if the sensed phase had rated load while the two other phases were only loaded at half the rated value those two phases would have higher than rated voltage which may be undesirable If a three phase sensing feedback were utilized the phase with rated load would be regulated to a voltage slightly below the rated voltage while the other two phases would be slightly above the rated voltage but lower than in the previous case The sum of the three divided by 3 would be equal to the regulation setpoint In a single phase system line to line voltage is held equal to the line to line voltage adjust setting Ina three phase system the average ofthe three line to line voltage is regulated to the voltage adjust setting In some cases it m
107. start the generator set Contact an authorized distributor dealer for service if problem continues Locked Rotor Shutdwn Overcrank locked rotor shutdown Frequency over AC voltage Cranking 3 sec Engine speed is below 10 rpm and the oil pressure is below crank oil pressure 69 kPa Contact an authorized distributor dealer for service if problem continues Oil Pres Low Shutdwn Low oil pressure shutdown occurs if a low oil pressure condition exists Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Analog or digital input Post starting aid running cooldown At or below 117 kPa Check for leaks in the lubrication system Check the oil level and add oil if the level is low Overcrank shutdown occurs after 3 unsuccessful starting attempts Over Crank Shutdwn Fail to start ECM start starting aid cranking crank pause 7 sec on 15 sec off 3 crank cycles Controller goes into the cranking state 3 consecutive times without going into post starting aid Check the fuel supply and battery Also check for loose connections Contact an authorized distributor dealer for service if problem continues Low seawater pressure shutdown occurs after a loss of seawater pressure is detected Sea Pressur Low Shutdwn Digital input Post starting aid running cooldown Switch close
108. system andletthe system drain completely Some models may have petcocks located behind the belt guard Remove the pressure cap to simplify draining 2 Drain clean and flush the coolant recovery tank 3 Flush the system with clean water 4 Fill the system with recommended coolant Section 3 Scheduled Maintenance 51 3 6 4 Pressure Cap Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the engine coolant enabling proper operating temperatures If the cap leaks replace it with a cap of the same rating The pressure cap typically has the pressure rating stamped on the cap body 3 6 5 Seawater Pump The belt driven seawater pump is located on the service side of the generator set Check and change the seawater pump impeller at the interval specified in the service schedule Follow the instructions included with the impeller kit If the instructions are not included with the kit use the following procedure Impeller Inspection and Replacement Procedure 1 Close the seacock 2 Remove the seawater pump coverplate See Figure 3 7 3 Remove the impeller 4 Inspect the impeller for damaged cracked broken missing or flattened vanes The impeller vanes should be straight and flexible See Figure 3 8 Replace the impeller if it is damaged Seawater pump Coverplate Gasket Impeller Bearing 6 Housing 7 Pulley 8 Mechanical seal if equipped Figure 3 7 Seawater P
109. t manifold mixing elbow exhaust hose hose clamps silencer and outlet flapper for cracks leaks and corrosion See Section 1 for the exhaust outlet location Ensure that the carbon monoxide detector s is 1 in the craft 2 functional and 3 energized whenever the generator set operates 50 Section 3 Scheduled Maintenance 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 Check the hoses for softness cracks leaks or dents Replace the hoses as needed e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed 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 6772 2 14b 3 6 Cooling System 3 6 1 Closed Heat Exchanger In a closed cooling system the seawater circulates through separate chambers within the heat exchanger or manifold to cool the engine coolant The seawater then mixes with the engine exhaust and ejects out of the
110. tch is in the OFF position Reconnect the generator set engine starting battery negative lead last Reconnect the power to the battery charger if equipped Start the generator set and check for leaks around the oil filter Stop the generator set and tighten the oil filter to stop any leaks x sm 001 003 Section 3 Scheduled Maintenance 47 3 4 Fuel System 3 4 4 Fuel Specifications Use a clean good quality diesel fuel oil with a cetane number of 51 or greater Clean fuel prevents the diesel fuel injectors and pumps from clogging Diesel Fuel Specifications Cetane number minimum 51 Viscosity 2 0 4 5 centistokes at 40 C Density 0 835 0 855 kg litre Distillation 85 at 350 Sulphur maximum 0 05 of the weight Diesel Fuel Recommendations Fuel with low sulphur content API CF4 CG4 API CF CD CE Fuel with high sulphur content The countries in which diesel normally has alow sulphur content are Europe North America and Australia Note Never store diesel fuel in galvanized containers diesel fuel and the galvanized coating react chemically to produce flaking that quickly clogs filters or causes fuel pump or injector failure Note Avoid storing fuel for more than one month Take special precautions to keep all dirt water and other contaminants out of fuel to prevent the growth of microbes Microbes form slime that clogs the fuel filter and lines 48 Sect
111. tdown Contact an authorized distributor dealer for service Battery High Warning High battery voltage warning The fault condition clears when the battery voltage returns to a voltage within the limits Analog input Auto fault start delay ECM start starting aid cranking crank pause post starting aid running cooldown Battery voltage exceeds 125 of the nominal system voltage 12 V Check the battery rating and condition Battery Low Warning Low battery voltage warning The fault condition clears when the battery voltage returns to a voltage within the limits Analog input Auto fault start delay ECM start starting aid cranking crank pause post starting aid running cooldown Battery voltage is at or below 100 of the nominal system voltage 12 V Check the battery rating and condition Charge or replace the battery Coolnt Temp High Warning High coolant temperature warning Post starting aid running cooldown Coolant temperature at or above 105 C 221 F Check for a low engine coolant level Check seawater system for reduced flow NOTE Allow the generator set to cool down before checking Low Crank Vit Warning Low cranking voltage warning Analog input Cranking Battery voltage drops below 60 of the nominal system voltage 12 V Check the battery rating and condition Charge or replace t
112. the Volt Select menu Then push and hold the pushbutton rotary selector dial until the voltage selection starts to flash Volt selection is now available Scroll to the desired voltage and momentarily press the pushbutton rotary selector dial to confirm the voltage selection The displays for Volt Select appear as shown in the following list e 120 240 V 1 Ph 3 wire e 120 208 V 3 Ph 4 wire Wye e 139 240 V 3 Ph Wye e 277 480 V 3 Ph Wye e 120 240 V 3 Ph Delta e 115 230 V 1 Ph 3 wire e 120 V 1 Ph 2 wire e 230 V 1 Ph 2 wire e 240 V 1 Ph 2 wire e 110 190 V 3 Ph Wye e 127 220 V 3 Ph Wye e 115 230 V 3 Ph Delta e 230 400 V 3 Ph Wye e 240 416 V 3 Ph Wye TP 6772 2 14b 2 6 6 Controller Fault Diagnostics This table provides descriptions of the system events and their types warning shutdown status and notice Warnings show green red fault lamp and signal an impending problem Shutdowns show red fault lamp and stop the generator set Status is an event that is not an alert but is part of the event history Notice is an alert that is NOT part of the event history System events are available as a Relay Output as shown Throughout this manual there are examples of the display text In some cases the message words and phrases are abbreviated or shortened to accommodate the number of characters in the 12 x 2 digital display See the following table for a full description ofthe system event display messages
113. the remote start panel operation if equipped X Break in period X GENERATOR X Test run the generator set Blow dust out of the generator 3 1 6EKOD 5EFKOD Models Clean the slip rings and inspect the brushes Requires removal of the sound shield door if installed Consult your local distributor dealer for service CO He Consult the battery manufacturer s instructions TP 6772 2 14b Gen S M Read the WARNING found at the beginning of the manual regarding moving parts Section 3 Scheduled Maintenance 45 3 3 Lubrication System See the Scheduled Maintenance section for oil change and oil filter replacementintervals See Section 1 forthe oil drain oil check oil fill and oil filter locations x sm 001 002 3 3 4 Oil Specifications 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 3 1 showsthe recommended Society of Automotive Engineers SAE viscosity designation for given operating temperature ranges Note Failure to observe the oil specifications may cause inadequate lubrication oil pressure and cold starting difficulties KA od t 40 35 30 25 20 1510 5 0 5 10 1520 25 30 35 40 45 50 SAE 10W SAE 20W SAE 30 SAE 40
114. tories 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 watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6772 2 14b Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed Enter hours to the operating hours on your generator set and the dates nearest quarter hour OPERATING HOURS SERVICE RECORD DATE TOTAL SERVICE RUN HOURS DATE SERVICE TP 6772 2 14b Appendix 71 Appendix C Voltage Regulator Definitions and Adjustments The following definitions and adjustment setting specifications are intended for users planning to adjust the voltage regulator beyond the default settings in order to customize the alternator for a specific application This information is not intended to be a comprehensive explanation of all the terms mentioned There are numerous documents available that define these terms more completely than described herein Any user planning to change the generator set controller adjustment settings or to apply the generator set to these ty
115. ts 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 6772 2 14b CG CID CL cm 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 electronic governor Electrical Generat
116. ump Typical 52 Section 3 Scheduled Maintenance 1 Figure 3 8 5 Flattened vane 2 Crack 3 Broken vane Worn Impeller Lubricate the impeller with soapy water before installation Install the impeller Note During installation push and rotate the impeller in the same direction as the engine rotation until it is thoroughly seated in the impeller housing Inspect the coverplate and gasket for corrosion and or damage necessary Replace components as Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing Open the seacock Start the generator set and check for leaks Stop the generator set and repair leaks or replace damaged or worn components m sm 003 008 TP 6772 2 14b 3 6 6 Siphon Break A siphon break prevents seawater entry into the generator set s engine when the engine exhaust manifold outlet is less than 230 mm 9 in above the waterline of a fully loaded docked or stationary craft See Figure 3 10 The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater Use the following procedure to inspect the siphon break at the intervals listed in the service schedule Siphon Break Inspection 1 Stop the generator set 2 Remove the retaining cap and remove the reed valve for inspection See Figure 3 9 3 Use a mild detergent to remove residue and oxidat
117. unning speed falls distributor dealer for service Shutdwn if the engine voltage cooldown below 8596 speed falls below of the rated the default setting speed Exh Temp High exhaust Digital input Auto fault Switch Check the wiring to the sensor High temperature start ECM closes Check for a clogged seawater Shutdown shutdown occurs if start starting shorted to intake or sea strainer the engine exhaust aid cranking ground Check for a damaged seawater temperature crank pause pump impeller exceeds the post starting Check the exhaust system see default setting aid running Section 3 5 cooldown Frequency Overfrequency Alternator Post starting AC Contact an authorized High shutdown occurs output aid running frequency distributor dealer for service if Shutdwn when the cooldown exceeds problem continues governed 11096 of the frequency exceeds systems the default setting frequency of the system s frequency setpoint 26 Section 2 Operation TP 6772 2 14b Fault Shutdowns Code Description Sensing Mechanism State s Detected Inhibit Time Trip Point Check Frequency Low Shutdown Underfrequency shutdown occurs when the governed frequency falls below the default setting of the system s frequency setpoint Alternator output Post starting aid running cooldown 10 sec AC frequency below 90 of the systems frequency Reduce the load and re
118. y done TP 6772 2 14b Generator Metering Generating gt Metering Volts L1 L2 HV Volts L2 L3 Volts L3 L1 Volts L1 N Volts L2 N Volts L3 N 1 Frequency Hz Reset Calibration Reset Calib No OR Reset Calib Yes Section 2 Operation 37 2 10 5 GenSet Information Displays generator set and controller information Displayed data is factory entered GenSet Information GenSet gt Genset M N Information Y GenSet S N HH Cntrllr S N 2 10 6 GenSet Run Time Displays the generator set s operating record including total run time loaded and unloaded number of starts and total energy kW hours GenSet Run Time GenSet gt Eng Runtime Run Time Eng Starts Next Maint Hg h Since Maint Starts 38 Section 2 Operation 2 10 7 GenSet System Display shows the generator set system data Use the values entered in this menu to help determine shutdown values and time delays The programming user defines the data shown in the GenSet System menu is NOT data measured by the controller and associated sensing devices The programming user defines these values for purposes of calibrating the control Some alt
119. y shows Battery Low Warning See Figure 2 12 for low battery voltage specifications Engine Electrical Low Battery Low Battery Voltage System Voltage Voltage Range Default Setting 9 6 126 Figure 2 12 Low Battery Voltage Specs The low battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes The controller logic inhibits the low battery voltage warning during the crank cycle Low Cranking Voltage The fault lamp illuminates green then red when the battery voltage drops below 60 of the nominal voltage 12 VDC for more than 6 seconds during the crank cycle The local display shows Lo Crank VIt Warning Low Oil Pressure The fault lamp illuminates green then red when the engine oil pressure approaches the shutdown range Thelow oil pressure warning does not function during the first 11 seconds after startup The local display shows Oil Press Low Warning 6772 2 14b 2 7 6 System Fault Shutdown Lamp With Digital Displays The system FAULT lamp flashes red and the unit shuts down to indicate a fault shutdown under the following conditions See Section 2 7 2 Controller Resetting procedure for information on resetting a system shutdown Note Text shown in italics in this section of the manual represents digital display messages AC Sensing Loss The fault lamp flashes red and the unit shuts down when the controller does not detect the nominal generator set AC

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