Kohler 6 EOD, 8 32EOZD, 4.5 EFOD, 6.5 28EFOZD Marine Generator Set Service Manual

Service

Marine Generator Sets

Models:

6EOD

4.5EFOD

8--32EOZD

6.5--28EFOZD

TP-6255 4/10c

Product Identification Information

Product identification numbers determine service parts.

Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.

Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

Record the product identification numbers from the generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

x:in:007:001

2 TP-6255 4/10

Table of Contents

Safety Precautions and Instructions

Introduction

Service Assistance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Generator, 4 Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4

Generator, 12 Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

18

19

20

11

11

12

Section 2 Scheduled Maintenance

2.1

General

3.1

3.4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Lubrication System

Section 3 Intake and Exhaust System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Intake Silencer/Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Exhaust System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Servicing Mixing Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger (Models: 14/15/15.5/23/24EOZD and 11.5/13/20EFOZD) . . . . . .

Section 4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1

Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Fuel Pump (8--32EOZD and 6.5--28EFOZD Models) . . . . . . . . . . . . . . . . . . . . . . .

4.4

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

27

27

28

30

30

23

23

24

25

25

21

21

22

Section 5 Cooling System

5.1

General

5.2

Water-Cooled Exhaust Manifold

5.3

Closed Heat Exchanger

5.4

Check and Fill Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5

Flush and Clean Cooling System

5.6

Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7

Impeller Inspection and Replacement

5.8

Belt Tension

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9

Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

Introduction

6.2

Initial Checks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 7 Controller

7.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.1

Seawater Pump Belt Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . .

5.8.2

Battery Charging Alternator Belt Tensioning Procedure . . . . . . . . . . . . .

5.8.3

Anticorrosion Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2

Advanced Digital Control Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1

Starting Sequence, Master Switch Moved to RUN

7.3.2

Starting Sequence, Remote Start

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.3

Running Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.4

Stopping Sequence, Master Switch Moved to OFF/RESET . . . . . . . . . .

37

37

37

37

37

43

43

44

45

45

45

46

46

31

31

32

32

32

33

33

33

34

34

35

35

36

5

9

9

TP-6255 4/10 Table of Contents 3

7.3.5

Stopping Sequence, Remote Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4.1

Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4.2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5

Controller Configuration and Adjustment

7.5.1

Controller Time Out

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5.2

Controller Configuration

7.5.3

Voltage Adjustment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6

Controller Application Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7

Silicon Controlled Rectifier (SCR) Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8

Continuous Power Mode Jumper, if equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9

Master Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.10 Relay Interface Board (RIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

49

49

49

57

57

59

46

46

46

46

60

61

62

Section 8 Component Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2

Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3

Exciter Field (8--32EOZD/6.5--28EFOZD Models) . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4

Exciter Armature (8--32EOZD and 6.5--28EFOZD Models)

8.5

Slip Rings (6EOD/4.5EFOD Models)

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6

Brushes (6EOD/4.5EFOD Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7

Rectifier Module (8--32EOZD and 6.5--28EFOZD Models) . . . . . . . . . . . . . . . . . . .

8.8

Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9

Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.10 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.10.1

Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.10.2

Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.11 Four-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.11.1

100--120-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.11.2

100--120/200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.11.3

200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.12 Twelve-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.13 Fault Shutdown Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.13.1

Controller Fault Shutdown Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.13.2

Fault Shutdown Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.14 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.15 Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73

73

73

75

75

75

76

76

77

77

78

79

79

69

70

70

71

65

65

65

67

68

69

Section 9 Generator Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2

Collector Ring and Bearing Replacement (6EOD/4.5EFOD Model) . . . . . . . . . . .

9.3

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 10 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 Wiring Diagram Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89

89

10.2 Manual Marine (Ship-to-Shore) 2 Wire and 3 Wire Transfer Switches

10.3 Manual Marine (Ship-to-Shore) 4 Wire Transfer Switch

. . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

102

103

81

81

85

85

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105

Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

108

Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109

Appendix E Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110

4 Table of Contents TP-6255 4/10

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.

Read and follow all safety precautions and instructions.

SAVE

THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions: Danger,

Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

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.

Accidental Starting

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 cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Engine Backfire/Flash

Fire

WARNING

Fire.


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.

Equip the compartment or nearby area with a fully charged fire extinguisher.

Select a fire extinguisher rated ABC or

BC for electrical fires or as recommended by the local fire code or an authorized agency.

Train all personnel on fire extinguisher operation and fire prevention procedures.

Exhaust System

WARNING

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

TP-6255 4/10 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:

D Light-headedness, dizziness

D Physical fatigue, weakness in joints and muscles

D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea

If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.

Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

Inspecting the exhaust system.

Carbon monoxide can cause severe nausea, fainting, or death.

For the safety of the craft’s occupants, install a carbon monoxide detector.

Never operate the generator set without a functioning carbon monoxide detector.

Inspect the detector before each generator set use.

Operating the generator set. Carbon monoxide can cause severe nausea, fainting, or death.

Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate. If operating the generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always be aware of others, making sure your exhaust is directed away from other boats and buildings.

Fuel System

WARNING

Explosive fuel vapors.


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 good condition. Do not replace flexible fuel lines with rigid lines.

Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.

Repair fuel systems before resuming generator set operation.

Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.

Hazardous Noise

CAUTION

Hazardous Voltage/

Moving Parts

WARNING

Hazardous voltage.

Moving parts.


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 related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Disconnecting the electrical load.

Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads.

High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load.

Hazardous noise.

Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

6 Safety Precautions and Instructions TP-6255 4/10

Short circuits.

Hazardous voltage/current can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage.

Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

Remove all jewelry before servicing the equipment.

Electrical backfeed to the utility.

Hazardous backfeed voltage can cause severe injury or death.

Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is turned off. Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near the work area.

Some states and localities prohibit unauthorized connection to the utility electrical system.

Install a ship-to-shore transfer switch to prevent interconnection of the generator set power and shore power.

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)

Hot Parts

WARNING

Hot coolant and steam.


Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

Notice

NOTICE

Fuse replacement.

Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic).

Do not substitute clear glass-type fuses for ceramic fuses.

Refer to the wiring diagram when the ampere rating is unknown or questionable.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

TP-6255 4/10 Safety Precautions and Instructions 7

Notes

8 Safety Precautions and Instructions TP-6255 4/10

This manual provides troubleshooting and repair instructions for 6EOD, 8-32EOZD, 4.5EFOD and

6.5-28EFOZD model generator sets (4-lead and

12-lead), Advanced Digital Control, and accessories.

Refer to the engine service manual for generator set engine service information.

x:in:001:001

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

Introduction

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the

Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals.

Maintenance work must be performed by appropriately skilled and suitably-trained maintenance personnel familiar with generator set operation and service.

x:in:001:003

Service Assistance

For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric

D Visit the Kohler Power Systems website at

KohlerPower.com

D Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product

D Call toll free in the US and Canada 1-800-544-2444

D Outside the US and Canada, call the nearest regional office

Headquarters Europe, Middle East, Africa

(EMEA)

Kohler Power Systems

3 rue de Brennus

93200 Saint Denis

France

Phone: (33) 1 49 178300

Fax: (33) 1 49 178301

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 6264-6422

Fax: (65) 6264-6455

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131

TP-6255 4/10 Introduction 9

Notes

10 Service Assistance TP-6255 4/10

Section 1 Specifications

1.1 General

This manual covers maintenance, troubleshooting, and repair of the alternating current marine generator sets listed in Figure 1-1. Consult the generator set nameplate for specific generator set ratings.

6EOD

8/9/10EOZD

10EOZD

Models

13/15/15.5/20/23/28/32EOZD

14/20/24/28/32EOZD

14/20/24/28/32EOZD

4.5EFOD

6.5/7/9/11/13/17/20/23/25/27/28EFOZD

8.5EFOZD

11.5/17.5/20/23/25/27/28EFOZD

11.5/17.5/20/23/25/27/28EFOZD

Voltage Hz Ph

120

120/240

60 1

120

120/240

220/380

240/416

60

60

1

3

120/240 60 1

120/240 60 1

120/208

120/240

127/220

139/240

277/480

60 3

115/230

230

240

115/230

230

240

50

50

1

1

230/400 50 3

115/230 50 1

110/190

115/230

120/208

220/380

230/400

240/416

50 3

Figure 1-1 Generator Model Coverage

The 6EOD/4.5EFOD models are powered by a three-cylinder, water-cooled, four-cycle diesel engine with a heat exchanger.

The 8EOZD/6.5EFOZD, 9EOZD/7EFOZD, 10EOZD/

9EFOZD, 10EOZD/8.5EFOZD, and 13EOZD/11EFOZD models are powered by a three-cylinder, water-cooled, four-cycle diesel engine with a heat exchanger.

The 14EOZD/11.5EFOZD and 15/15.5EOZD/13EFOZD models are powered by a three-cylinder, water-cooled, turbocharged diesel engine with a heat exchanger.

The 20EOZD/17EFOZD and 20EOZD/17.5EFOZD

models are powered by a four-cylinder, water-cooled, four-cycle diesel engine with a heat exchanger.

The 23EOZD/20EFOZD and 24EOZD/20EFOZD models are powered by a four-cylinder, water-cooled, four-cycle, turbocharged diesel engine with a heat exchanger.

The 28EOZD/23/25EFOZD and 32EOZD/27/28EFOZD models are powered by a four cylinder, water cooled, four cycle diesel engine with heat exchanger.

Heat exchanger cooling consists of a heat exchanger with a coolant recovery tank, thermostat, rubber impeller seawater pump, centrifugal type engine circulating pump, water-cooled exhaust manifold, and an exhaust mixer.

Kohler Co. develops all Kohler r marine generator set ratings using accepted reference conditions of 25

_C

(77

_F) and pressure of 29.2 in. Hg dry barometer. ISO

3046 and ISO 8528-1 include reference conditions and output calculations. Obtain the technical information bulletin on ratings guidelines (TIB-101) for complete ratings definitions.

Read this manual, then carefully follow all service recommendations. See Figure 1-2 for identification and location of components.

TP-6255 4/10 Section 1 Specifications 11

1.2 Engine

Generator Model

Number of cylinders

Type

Cylinder block material

Cylinder head material

8EOZD/

6.5EFOZD

9EOZD/

7EFOZD

10EOZD/

8.5EFOZD/

9EFOZD

3

13EOZD/

11EFOZD

4 cycle

Cast iron

Cast iron

14EOZD/

11.5EFOZD

15EOZD/

15.5EOZD/

13EFOZD

4 cycle, turbocharged

Crankshaft material

Stamped forging

Forged steel

Piston rings

Connecting rod material

Governor

Engine firing order (#1 cylinder on flywheel side)

Direction of rotation (as viewed from flywheel)

2 compression/1 oil

Forged carbon steel

Centrifugal, mechanical

1--3--2

Counterclockwise

Combustion system

Bore x stroke, mm (in.)

Displacement L (CID)

Compression ratio

Max. power at rated RPM, 60/50 Hz

RPM 60/50 Hz

Lubrication system

Lube oil capacity, w/filter L (U.S. qts.)

Oil recommendation (API)

Fuel recommendation (API)

Fuel shutoff solenoid

Fuel pump

Fuel pump priming

Max. recommended fuel pump lift, m (ft.)

Battery voltage

Battery charging

Battery recommendation (minimum)

Starter motor

Special swirl precombustion chamber

74 x 78

(2.91 x 3.07)

1.01 (61.39)

23:1

14.0/11.6

Indirect injection

Direct injection

76 x 82

(3.0 x 3.2)

82 x 84

(3.23 x 3.30)

88 x 90

(3.46 x 3.54)

1.115 (68) 1.33 (81.14) 1.642 (100.2)

23.5:1

14.74/12.43

19.2:1

18.4/15.1

1800/1500

19.1:1

22.6/18.6

84 x 90

(3.31 x 3.54)

1.5 (91.3)

19.0:1

26.1/21.8

2.3 (2.4)

Pressure, trochoid pump

3.6 (3.8) 4.7 (5.0)

CD or CF class

Diesel--ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.)

Electric

12 volts

Electric, rotary vane

Electric

1.2 (4)

12 volts (standard) 24 volts (optional)

40-amp alternator

500 CCA, 100 amp hr.

0.8 kW Bendix automotive type

1.8 kW Bendix, gear-reduction automotive type

50% ethylene glycol; 50% clean, softened water Recommended coolant

Coolant capacity, approx. L (U.S. qts.) add 0.24 L (8 oz.) for coolant recovery tank

Thermostat,

_C (_F)

High exhaust temperature shutdown,

_C (_F)

Low oil pressure shutdown, kg/cm

@ ± 0.1 kg/cm@ (psi)

Seawater inlet water line hose ID, mm (in.)

3.9 (4.12) 2.46 (2.6)

1/2 NPT with sound shield

16 (5/8) without sound shield

82 (179)

102 (215)

0.5

±5

(7.1)

4.4 (4.6)


25 (1) without sound shield

12 Section 1 Specifications TP-6255 4/10

Generator Model

Water cooled exhaust outlet hose ID, mm (in.)

Fuel inlet size

Fuel return size

Fuel injection pressure, kgf/cm sq. (psi)

Intake/exhaust valve clearance (cold), mm (in.)

Fuel pump static pressure, psi

Pressure cap rating, kPa (psi)

8EOZD/

6.5EFOZD

9EOZD/

7EFOZD

10EOZD/

8.5EFOZD

9EFOZD

13EOZD/

11EFOZD

14EOZD/

11.5EFOZD

15EOZD

15.5EOZD/

13EFOZD

51 (2) with sound shield





1/4 NPT without sound shield



120 (1706)

120--130

(1706--1849)

200--210 (2844--2986)

0.15--0.25 (0.006--0.0010)

4--8 (12-volt pump) or 5.5--9 (24-volt pump)

97 (14)


Generator Model

Number of cylinders

Type



Crankshaft material

Piston rings


Governor

Engine firing order

(#1 cylinder on flywheel side)


Combustion system

20EOZD/

17EFOZD/

17.5EFOZD

(1 and 3 Ph.)

4 cycle

23EOZD/

20EFOZD

24EOZD/

20EFOZD

28EOZD/

23EFOZD/

25EFOZD

(1 and 3 Ph.)

32EOZD/

27EFOZD/

28EFOZD

(1 and 3 Ph.)

4

4 cycle, turbocharged

Cast iron

Cast iron

Forged steel

2 compression/1 oil

Forged carbon steel

Centrifugal, mechanical

4 cycle, naturally aspirated

1--3--4--2

Counterclockwise



Compression ratio

Max. power at rated RPM, 60/50 Hz

RPM 60/50 Hz

Lubrication system





Fuel pump

Fuel pump priming


Battery voltage

Battery charging


Starter motor

Recommended coolant


Thermostat,

_C (_F)


_C (_F)


@ ± 0.1 kg/cm@ (psi)

88 x 90

(3.46 x 3.54)

Direct injection

84 x 90

(3.31 x 3.54)

98 x 110

(3.86 x 4.33)

2.189 (133.58)

19.1:1

30.1/24.8

1.995 (121.74)

18.9:1

37.1/29.3

1800/1500


3.319 (202.5)

18.5:1

55.8/46.7

5.8 (6.1) 10.2 (10.78)

CD or CF class

Diesel--ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.)

Electric

Electric, rotary vane

Electric

1.2 (4)

12 volts (standard) 24 volts (optional)

40-amp alternator


1.8 kW


2.3 kW

50% ethylene glycol; 50% clean, softened water

6.0 (6.3)

82 (179)

102 (215)

±5

0.5 (7.1)

7.57 (8)




25 (1) without sound shield or

19 (0.75) without sound shield for specs GM55348--GA1 to --GA16




19 (0.75) without sound shield




Generator Model

Fuel inlet size

Fuel return size

Fuel injection pressure, kgf/cm sq. (psi)

Intake/exhaust valve clearance (cold), mm (in.)

Fuel pump static pressure, psi


20EOZD/

17EFOZD/

17.5EFOZD

(1 and 3 Ph.)

23EOZD/

20EFOZD

24EOZD/

20EFOZD

28EOZD/

23EFOZD/

25EFOZD

(1 and 3 Ph.)



32EOZD/

27EFOZD/

28EFOZD

(1 and 3 Ph.)



200--210 (2844--2986) 220--230 (3129--3271)

0.15--0.25 (0.006--0.0010)

4--8 (12-volt pump) or 5.5--9 (24-volt pump)

97 (14)

Generator Model

Number of cylinders

Type



Crankshaft material

Piston rings


Governor

Engine firing order (#1 cylinder on flywheel side)


Combustion system



Compression ratio

Max. power at rated RPM, 60/50 Hz, HP

RPM 60/50 Hz

Lubrication system





Fuel pump

Fuel pump priming


Battery voltage

Battery charging


Starter motor

Recommended coolant


Thermostat,

_C (_F)


_C (_F)

6EOD/

4.5EFOD

3

4 cycle

Cast iron

Cast iron

Forged steel

2 compression/1 oil

Cast iron

All speed, mechanical

1--2--3

Counterclockwise

Indirect injection

67 x 72 (2.64 x 2.83)

0.762 (46.5)

23.5:1

10.19/8.18

1800/1500


3.05 (3.2)

CD or CF class

Diesel--ISO 8217 DMA, BS 2869 A1 or A2

(Cetane No. 45 min.)

Electric

Mechanical

N/A

0.9 (3.0)

12 volts

18-amp alternator


0.8 kW Bendix automotive type

50% ethylene glycol; 50% clean, softened water

2.0 (2.1)

82 (179)

N/A



@ ± 0.1 kg/cm@

(psi)



Fuel inlet size

Fuel return size

Fuel injection pressure, kg/cm

@ (psi)

Intake/exhaust valve lash (cold), mm (in.)

Fuel pump static pressure, kPa psi


0.5

(7.1)









120 (1707)

0.2 (0.0078)

34 (5)

96 (14)


1.3 Generator, 4 Lead

Component Specification

Main field (rotor) resistance (cold)—ohms @ 20

_C (68_F)

Stator output voltages with separately excited generator, using 12-volt battery (60 Hz only)

1--2, 3--4—volts

55--66—volts

Cold stator resistance

1--2, 3--4—ohms

55--66—ohms

6EOD

4.5EFOD

4.4--5.0

130

155

0.19

2.7


Hot exciter field voltage/amperage readings at rated voltage

8EOZD/

6.5EFOZD

9EOZD/

7EFOZD

No load (63 Hz)—volts/amps 4/0.9

4/0.9

Full load (60 Hz)—volts/amps

Exciter field resistance (cold)—ohms @ 20 _C (68_F)

Exciter armature resistance (cold)—ohms (line-to-line)


_C (68_F)

9/1.5

4.8

1.18

5.0

9/1.5

4.8

1.18

5.0


1--2, 3--4—volts

55--66—volts

135

180

135

180


1--2, 3--4—ohms

55--66—ohms

0.26

2.11

0.26

2.11

10EOZD/

9EFOZD

13EOZD/

11EFOZD

15EOZD/

15.5EOZD/

13EFOZD

4/0.8

12/2.2

4.8

1.18

5.7

135

180

0.19

1.89

4/0.7

12/1.8

5.8

0.51

4.3

135

180

0.12

1.46

4/0.7

14/2.3

5.8

0.51

2.9

135

180

0.12

1.46



No load (63 Hz)—volts/amps

20EOZD/

17EFOZD

23EOZD/

20EFOZD

6/1.0

6/1.0


Exciter field resistance (cold)—ohms @ 20 _C (68_F)

14/2.1

5.8

16/2.4

5.8



_C (68_F)

0.51

3.0

0.51

3.0


1--2, 3--4—volts

55--66—volts


1--2, 3--4—ohms

55--66—ohms

95

125

0.07

1.26

95

125

0.07

1.26

28EOZD/

23EFOZD/

25EFOZD

32EOZD/

27EFOZD/

28EFOZD

18/0.7

18/0.7

42/1.6

45/1.7

22.7

±2.3

22.7

±2.3

0.601

±0.045 0.601 ±0.045

2.24

2.24

84

148

0.040

1.70

84

148

0.040

1.70


1.4 Generator, 12 Lead



10EOZD/

8.5EFOZD

14EOZD/

11.5EFOZD


6/0.9


Exciter field resistance (cold)—ohms @ 20

_C (68_F)



_C (68_F)

12/2.2

4.8

1.18

5.7


17/2.6

5.8

0.51

2.9

1--4, 2--5, 3--6, 7--10, 8--11, 9--12—volts 150 145

170 165 55--66—volts


1--4, 2--5, 3--6, 7--10, 8--11, 9--12—ohms

55--66—ohms

0.09

2.5

0.06

1.5

20EOZD/

17.5EFOZD

8/1.4

14/2.1

5.8

0.51

3.0

140

158

0.04

1.3

24EOZD/

20EFOZD

8/1.4

16/2.4

5.8

0.51

3.0

140

158

0.04

1.3

28EOZD/

23EFOZD/

25EFOZD

32EOZD/

27EFOZD/

28EFOZD Component Specification



21/0.8


Exciter field resistance (cold)—ohms @ 20

_C (68_F)

Exciter armature resistance (cold)—ohms (F1--F2, F1--F3, F2--F3)

Main field (rotor) resistance (cold)—ohms @ 20 _C (68_F)

64/2.3


70/2.5

22.7

±2.3

22.7

±2.3

0.601

±0.045

0.601

±0.045

2.24

2.24

1--4, 2--5, 3--6, 7--10, 8--11, 9--12—volts

55--66—volts

84

150

84

150


1--4, 2--5, 3--6, 7--10, 8--11, 9--12—ohms

55--66—ohms

0.094

2.1

0.094

2.1


1.5 Service Views

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

16

17

18

19 20 21 22 23 24

13--24EOZD & 11--20EFOZD Models

Non Service-Side View

27

25 26

28 29

ADV-6843-

1. ADC 2100 Control

2. Run-Off/Reset-Auto switch

3. Nameplate

4. Mixing elbow (water outlet/exhaust outlet)

5. Air intake silencer

6. Lifting eye

7. Coolant overflow bottle (location varies by model)

8. Fuel feed pump

9. Oil check

10. Pressure cap

11. Overflow tube

12. Oil fill

13. Lube oil filter

14. High engine temperature sensor

15. Fuel filter

16. Oil fill

17. Seawater pump (water inlet)

GM30645D-

18. Oil drain valve and hose

19. Strain relief for the load lead cable

20. Cooling air inlet

21. AC circuit breaker coverplate

22. Anticorrosion zinc anode (seawater drain) (all models except

13--24EOZD & 11--20EFOZD models)

23. Belt guard

24. V-belts

25. Coolant (freshwater) drain (all models except 13--24EOZD &

11--20EFOZD models)

26. Heat exchanger (all models except 13--24EOZD &

11--20EFOZD models)

27. Heat exchanger (13--24EOZD & 11--20EFOZD models)

28. Seawater drain (13--24EOZD & 11--20EFOZD models)

29. Coolant (freshwater) drain (13--24EOZD & 11--20EFOZD models)

Figure 1-2 Service Views—Typical (8EOZD Model Shown Unless Noted)


1.6 Torque Specifications

Follow the general torque specification found in

Appendix C of this manual unless noted below.

Generator Model

Overbolts

Back plate mtg. bolts

Flywheel bolts

Drive disc

Fan to flywheel stud

Fan to flywheel nut

SCR to junction box

6EOD/

4.5EFOD

9.5 Nm (7.0 ft. lbs.)

15 Nm (11 ft. lbs.)

73 Nm (54 ft. lbs.)

45 Nm (34 ft. lbs.)

23 Nm (17 ft. lbs.)

23 Nm (17 ft. lbs.)

4 Nm (35 in. lbs.)

Generator Model

Overbolts

Rotating diode board

Crankshaft pulley

Thermostat housing

Exhaust manifold

Seawater pump pulley

Back plate to engine block

Rotor hub to flex. disc

Flex disc to flywheel

Flywheel bolts

SCR to end bracket

Generator Model

Overbolts

Rotating diode board

Back plate to engine block

Rotor hub to flex. disc

Flex disc to flywheel

Exhaust manifold

Thermostat housing

Rotor fan to flywheel

Crankshaft pulley

Generator adapter (rear 1/2 to front 1/2)

Generator adapter to flywheel housing/backplate

Seawater pump pulley

SCR to end bracket

8EOZD/

6.5EFOZD

9EOZD/

7EFOZD

10EOZD/

8.5EFOZD

9EFOZD

13EOZD/

11EFOZD

34 Nm (25 ft. lbs.)

38 Nm (28 ft. lbs.)

36.6 Nm (27 ft. lbs.)

14EOZD/

11.5EFOZD

21.6 Nm

(192 in. lbs.)

23 Nm

(17 ft. lbs.)

21.6 Nm (192 in. lbs.)

19 Nm (14 ft. lbs.)

38--41 Nm

(28--30 ft. lbs.)

37 Nm

(27 ft. lbs.)

38--41 Nm (28--30 ft. lbs.)

37 Nm (27 ft. lbs.)

38 Nm (28 ft. lbs.)

19 Nm (14 ft. lbs.)

78.5--88.3 Nm

(58--65 ft. lbs.)

83.3--88.2 Nm (62--65 ft. lbs.)

4 Nm (35 in. lbs.)

20EOZD/

17EFOZD/

17.5EFOZD

(1 and 3 Ph.)

23EOZD/

20EFOZD

34 Nm (25 ft. lbs.)

24EOZD/

20EFOZD

38 Nm (28 ft. lbs.)

36.6 Nm (27 ft. lbs.)

38 Nm (28 ft. lbs.)

19 Nm (14 ft. lbs.)

22.7 Nm (16.8 ft. lbs.)

21.6 Nm (192 in. lbs.)

28EOZD/

23EFOZD/

25EFOZD

(1 and 3 Ph.)

32EOZD/

27EFOZD/

28EFOZD

(1 and 3 Ph.)

45 Nm (34 ft. lbs.)

36.6 Nm (27 ft. lbs.)

15EOZD/

15.5EOZD/

13EFOZD

N/A

37 Nm (27 ft. lbs.)

38--41 Nm (28--30 ft. lbs.)

4 Nm (35 in. lbs.)

53 Nm (39 ft. lbs.)

45 Nm (34 ft. lbs.)


Section 2 Scheduled Maintenance

2.1 General

Schedule routine maintenance using the service schedule located in the generator set operation manual and the runtime hours shown on the ADC 2100. If the generator set will be subject to extreme operating conditions, service the unit accordingly.

Note: See the generator set operation manual for the service schedule and other service not included in this manual.

Note: High-mineral content seawater (salt water) can cause rapid destruction of metals. Wipe up all salt water spillage on and around the generator set and keep metal surfaces free from accumulated salt deposits.

WARNING








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.


WARNING

Hazardous voltage.

Moving parts.



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-6255 4/10 Section 2 Scheduled Maintenance 21

2.2 Lubrication System

Use oil that meets the American Petroleum Institute

(API) classification of CD or CF. Using an unsuitable oil or neglecting an oil change may result in damage and a shorter engine life. Figure 2-1 and Figure 2-2 show the recommended Society of Automotive Engineers (SAE) viscosity designation for given operating temperature ranges.

SAE

Service

Grade

10W

20W

10W30

15W40

#20

#30

°C --30 --20 --10 0

#40

20W50

10 20 30 40 50 °C

°F 0 20 40 60

Operating Temperature

80 100 122 °F

TP-5856-1

Figure 2-1 Engine Oil Selection for Models

8--32EOZD and 6.5--27EFOZD

SAE

Service Grade

0W20

0W30

0W40

5W30

5W40

10W30

15W40

Engine Oil Viscosity

Ambient Temperature

Minimum

--40 _C (--40_F)

--40 _C (--40_F)

--40 _C (--40_F)

--30 _C (--22_F)

--30

_C (--22_F)

--20 _C (--4_F)

--10 _C (14_F)

Maximum

10 _C (50_F)

30 _C (86_F)

40 _C (104_F)

30 _C (86_F)

40

_C (104_F)

40 _C (104_F)

50 _C (122_F)

Figure 2-2 Engine Oil Selection for Models 6EOD and 4.5EFOD

Note: Failure to observe the oil specifications may cause inadequate lubrication/oil pressure and cold-starting difficulties.

22 Section 2 Scheduled Maintenance TP-6255 4/10

Section 3 Intake and Exhaust System

3.1 Air Intake Silencer/Cleaner

At the interval specified in the service schedule, clean or replace the air intake silencer element.

Clean the silencer more frequently if the generator set operates in dirty, dusty conditions. Follow one of the procedures described below.

6EOD, 8/9/10EOZD, 4.5EFOD, and 6.5/7/9EFOZD

Models:

A dry-type air cleaner silences and filters the intake air.

The air intake silencer assembly connects to the intake manifold via a flexible hose.

Air Cleaner Service/Replacement Procedure:

1. Release the spring clips to open the housing and remove the air silencer element. See Figure 3-1.

2. Tap the element lightly against a flat surface to dislodge loose surface dirt. Do not clean in any liquid or use compressed air as these will damage the filter element.

3. Examine the element and housing for damage and wear. Replace the element or housing if necessary.

4. Wipe the cover and base with a clean rag to remove any dirt. Make sure that the sealing surfaces fit correctly, and reattach the spring clips.

13/20/28/32EOZD and 11/17/17.5/23/25/27/28EFOZD

Models:

A dry-type air cleaner silences and filters the intake air.

The air intake silencer assembly connects to the intake manifold via a flexible hose. Refer to Figure 3-2 during this procedure.

2 3 4

1

GM21379

6

1. Cover

2. Spring clip(s)

3. Housing

4. Pressure tap (1/8-27 NPT)

5

5. Primary element

6. Dust ejector

Figure 3-2 Air Cleaner

1. Release the spring clips to open the housing and remove the air silencer element.

2. Tap the element lightly against a flat surface to dislodge loose surface dirt.

Do not clean the element in any liquid or use compressed air as these will damage the filter element.

3. Examine the element and housing for damage.

Replace the element or housing if necessary.

4. Wipe the cover and housing with a clean rag to remove dirt. Make sure the sealing surfaces fit correctly and reattach the spring clips.

Figure 3-1 Air Cleaner Element Element

TP-6255 4/10 Section 3 Intake and Exhaust System 23

14/15/15.5/23/24EOZD and

11.5/13/20EFOZD Models:

These models use a round, polyurethane, sound-absorbing-type intake silencer to silence the intake air drawn into the cylinder head from the intake port. Besides providing a silencing effect, the silencer also acts as an air cleaner. Clean the silencer more frequently if operating in dirty, dusty conditions. See

Figure 3-3 and refer to the following procedure.

Air Intake Silencer Cleaning Procedure:

1. Remove the intake silencer cover.

2. Remove the element from the cover and inspect it.

To clean the element, continue to step 3. If the element is damaged or in poor condition, replace the element; skip step 3 and go to step 4. If the element is clean go to step 6.

3

4

1

2

5

TP-6071-31

1. Air intake silencer cover

2. Air intake silencer element

3. Base

4. Clamp

5. Turbocharger

Figure 3-3 Air Intake Silencer

3. Wash the element in mild detergent and water solution. Rinse the element and allow it to air dry.

4. Lightly coat the foam element with oil.

5. Squeeze out any excess oil.

6. Wipe the cover and base with a clean rag to remove any dirt. Replace the base if it is damaged.

7. Reassemble the element and cover assembly to the intake silencer base. Make sure the sealing surfaces fit properly.

8. Direct the air intake silencer duct down and away from engine.

3.2 Exhaust System Inspection

WARNING

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of the craft’s occupants, install a carbon monoxide detector.

Never operate the generator set without a functioning carbon monoxide detector.

Inspect the detector before each generator set use.

At the interval specified in the service schedule, inspect the exhaust system components (exhaust manifold, mixing elbow, exhaust hose, hose clamps, silencer, and outlet flapper) for cracks, leaks, and corrosion.

Ensure that the carbon monoxide detector(s) is (1) in the craft, (2) functional, and (3) energized whenever the generator set operates.

For your safety: Never operate the generator set without a functioning carbon monoxide detector(s) for your safety and the safety of others on your vessel.

Exhaust System Inspection Points

Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections.

D Check the hoses for softness, cracks, leaks, or dents.

Replace the hoses as needed.

D Check for corroded or broken metal parts and replace them as needed.

D Check for loose, corroded, or missing clamps.

Tighten or replace the hose clamps and/or hangers as needed.

D Check that the exhaust outlet is unobstructed.

D 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.

24 Section 3 Intake and Exhaust System TP-6255 4/10

3.3 Servicing Mixing Elbow

The mixing elbow combines high-temperature exhaust with cooling seawater. See the operation manual for mixing elbow scheduled maintenance.

1. Check the mixing elbow for carbon buildup and corrosion inside the pipe.

2. Clean or replace the mixing elbow as necessary.

3. Inspect the exhaust manifold mounting threads for cracking and corrosion.

3.4 Turbocharger (Models:

14/15/15.5/23/24EOZD and

11.5/13/20EFOZD)

Inspect the compressor (blower) at the specified interval for build-up of carbon residue. Perform all other turbocharger inspection and service as described in the service schedule of the engine service manuals. See

Figure 3-4 and Figure 3-5 to inspect the compressor.

Compressor Inspection:

1. Remove the breather hose from the air intake silencer connector, if equipped.

2. Remove the air intake silencer.

3. Inspect the compressor (blower) housing and the impeller (blower wheel) for buildup of carbon residue. Use a Yanmar approved turbocharger cleaner, if cleaning is required.

4. Place the air intake silencer over the turbocharger compressor housing inlet and tighten the clamp.

5. Attach the breather hose to the air intake silencer connector, if equipped.

1

1

5

2

2

7

6

3

5

1. Compressor housing

2. Rotor assembly (turbo)

3. Housing assembly (blower)

4. Plate assembly (seal)

5. Circlips

6. Housing assembly (bearing)

7. Heat protector

Figure 3-4 Turbocharger Inspection

4

4

3

TP-6071-32

TP-6071-32

1. Turbocharger assembly

2. Gaskets

3. Exhaust elbow

4. Exhaust manifold

5. Petcock PT 1/8

Figure 3-5 Turbocharger Components, Typical

TP-6255 4/10 Section 3 Intake and Exhaust System 25

Notes

26 Section 3 Intake and Exhaust System TP-6255 4/10

Section 4 Fuel System

4.1 General

In most installations, both the generator set and the propulsion engine operate from a common fuel tank with a dual dip tube arrangement. The generator set’s dip tube is shorter than the propulsion engine’s dip tube.

With this arrangement fuel may not be available to the generator set when the fuel supply is low.

See

Figure 4-1 for a fuel system schematic.

Propulsion engine

2 3

4

To fuel injectors

Generator set

5

1

1. Fuel tank

2. Dual dip tubes

3. Fuel filter

4. Fuel feed pump

5. Water trap

Figure 4-1 Fuel System Schematic, Typical

607141

4.2 Fuel Filter

Clean the fuel filter with fresh fuel oil and compressed air. The filter’s useful life will be determined largely by the quality and condition of the fuel used. Under normal conditions, replace the fuel filter element at the specified interval in the generator set’s operation manual. Use the following procedure to replace the fuel filter.

Fuel Filter Replacement Procedure

8/9EOZD and 6.5/7EFOZD Models:

1. Place the generator set on/off switch in the OFF position.

2. Disconnect the generator set engine starting battery, negative (--) lead first.

3. Close the fuel supply valve.

4. Remove the retaining ring, filter cup, o-ring, fuel filter element and spring.

5. Wipe off all parts with a clean rag.

Inspect all mating surfaces and threads for damage; replace as necessary.

6. Replace the fuel filter element and install as shown in Figure 4-2.

7. Open the fuel supply valve.

8. Reconnect the generator set engine starting battery, negative (--) lead last.

9. Bleed the system. See Section 4.2.1, Bleeding the

Fuel System.

1

2

3

4

5

6

TP-6255 4/10

7

1. Fuel strainer assembly

2. Body

3. Fuel element

4. Spring

5. O-ring

6. Filter cup

7. Retaining ring

TP-561633

Figure 4-2 Fuel Oil Filter Element

Section 4 Fuel System 27

6EOD, 10--32EOZD, 4.5EFOD, and 9--28EFOZD

Models:

1. Place the generator set on/off switch in the OFF position.


3. Close the fuel supply valve.

4. Loosen the fuel filter by turning it counterclockwise.

Remove the fuel filter and use rags to clean up spilled fuel oil. Dispose of the fuel filter and rags in an approved manner.

5. Clean the contact surface of the fuel oil filter adapter.

6. Lightly lubricate the gasket surface of the new fuel filter with fresh fuel oil. Thread the filter on the adapter until the gasket makes contact; hand-tighten the filter an additional one-half turn.

Wash hands after any contact with fuel oil.

7. Open the fuel supply valve.


9. Bleed the system. See Section 4.2.1, Bleeding the

Fuel System.

1

2

4.2.1

Priming the Fuel System

Prime the fuel system to bleed the air from the system.

Trapped air in the fuel system can cause difficult starting and erratic engine operation.

Prime the fuel system under the following conditions:

D Before starting the engine for the first time.

D After running out of fuel and adding fuel to the tank.

D After fuel system maintenance such as changing the fuel filter, draining the fuel/water separator, or replacing a fuel system component.

Fuel System Priming Procedure (Preferred)

Note: To prevent damage to the starter motor, do not crank the engine to prime the fuel system. Use the following procedure.

1. Press and hold the Select button located on the

ADC. See Figure 4-4.

2. Move the generator set master switch to the RUN position to enter the programming mode.

3. Continue to hold the Select button for 10 seconds.

The ADC will display “Fuel” and the fuel priming pump will start.

4. Continue to hold the Select button for as long as you want the fuel priming pump to function

(typically 10 seconds).

5. Release the Select button and move the Master switch to the OFF position.

6. Place the Master switch to the RUN position to start the unit.

1

2

3

4

<

<

<

<

1. Fuel filter adapter

2. Fuel filter

3. Removal (counterclockwise)

4. Installation (clockwise)

Figure 4-3 Spin-On Fuel Oil Filter

TP-606111

3

ADV7384-

1. ADC control

2. Select button

3. Generator set master switch

Figure 4-4 ADC Control

28 Section 4 Fuel System TP-6255 4/10

Fuel System Priming Procedure

If the above priming procedure does not accomplish adequate fuel system priming, use the following procedure.

Note: Connect the battery during the priming procedure to allow engine cranking.

Note: If the ADC 2100 indicates an overcrank fault during this procedure, disconnect the negative wire from the fuel solenoid (allowing the fuel injection pump to fill with fuel) and repeat this procedure after allowing the starter motor to cool down.

Note: Have a rag handy during the bleeding procedure.

Wipe up all spilled diesel fuel after bleeding the system. Wash hands after any contact with fuel oil.

Procedure to Bleed the Fuel System

8/9EOZD and 6.5/7EFOZD Models and

13--32EOZD and 11--27EFOZD Models with Specs:

GM33035-GA1/GA2, GM33036-GA1/GA2, and

GM33037-GA1/GA2

1. Loosen the fuel filter screw at position 1.

See

Figure 4-5.

2. Initiate the auto/start sequence until fuel, free of air bubbles, flows from the vent screw at position 1.

Tighten the screw.

3. Loosen the fuel filter screw at position 2.


Tighten the screw.

5. Loosen the fuel injection pump screw at position 5.


Tighten the screw.

6EOD, 10--32EOZD, 4.5EFOD, and 9--28EFOZD

Models

1. Loosen the fuel injection pump screw.

See

Figure 4-5.

2. Initiate the auto/start sequence until fuel, free of air bubbles, flows from the injection pump screw.

3. Tighten the fuel injection pump screw.

8/9EOZD and 6.5/7EFOZD Models

5 4 1 2

ADV6843a-a

13--32EOZD & 11--27EFOZD Models with Specs:

GM33035-GA1/GA2, GM33036-GA1/GA2, &

GM33037-GA1/GA2

1 2

5 4

TP-5592-3

6EOD, 10--32EOZD, 4.5EFOD, and 9--28EFOZD Models

3 6

1. Vent screw, position 1


3. Fuel filter

4. Fuel injection pump


6. Fuel injection pump screw

Figure 4-5 Fuel System (Typical)

3

3

TP-6255 4/10 Section 4 Fuel System 29

4.3 Fuel Pump (8--32EOZD and

6.5--28EFOZD Models)

The fuel pump transfers fuel from a source to the injection pump.

Fuel Pump Test Procedure:

1. Remove the two leads at the bottom of the fuel pump. The pump terminals are labeled (--) and (+).

See Figure 4-6.

2. Connect the inlet side of the pump to a fuel source.

Disconnect the outlet hose from the fuel filter and place the hose end in a container to catch the fuel.

3. Connect the positive (+) terminal of a 12-volt battery to the positive terminal of the fuel pump.

Connect the negative terminal of the fuel pump to the negative (--) terminal of the battery. You should hear the pump operate and see fuel discharge from the pump outlet. Replace the pump if it does not operate.

4. Connect a pressure gauge to the outlet side of the fuel pump. Repeat step 3 .

See Section 1 for the specified fuel pump pressure ratings.

4.4 Governor

The centrifugal, mechanical governor keeps the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. The governor requires no regular service. The factory adjusts the governor during run-in, and further adjustment should not be needed unless greatly varying load conditions are encountered or if poor governor control develops after extended usage.

60 Hz generator sets are designed to operate in the range of 57-63 Hz (1800 rpm under full load and

1890 rpm under no load).

50 Hz generator sets are designed to operate in the range of 47-53 Hz (1500 rpm under full load and 1590 rpm under no load).

To check the engine speed, use a frequency meter connected to the load leads or use a hand tachometer. If adjustment is needed, loosen the locking nut on the speed adjusting screw. Turn the screw clockwise to increase the speed (and frequency). To decrease the speed, turn the screw counterclockwise. Tighten the locking nut when the correct setting is reached. See

Figure 4-7.

1

2

1

2

1. Fuel inlet

2. Negative (--) terminal

3. Positive (+) terminal

4. Fuel outlet

Figure 4-6 Fuel Pump

3

4

30 Section 4 Fuel System

I-940

607146

1. Speed adjusting screw

2. Locking nut

Figure 4-7 Governor Adjustment

The generators use a 3-lead fuel solenoid.

This solenoid has a white lead (P) which energizes the pull-in coil only during cranking. During operation, the red lead energizes the hold coil and the black lead is the common ground.

TP-6255 4/10

Section 5 Cooling System

5.1 General

Heat exchanger cooling consists of a heat exchanger with coolant recovery tank, thermostat, rubber impeller seawater pump, centrifugal-type engine circulating pump, water-cooled exhaust manifold, and an exhaust mixer. See Figure 5-1 for cooling system components.

WARNING

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.

Hot coolant and steam.


Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

1

2

3

4

5

6

12

8

7

9

10

1. Engine block

2. Exhaust manifold

3. Exhaust mixer elbow

4. Outlet flapper

5. Silencer

6. Thermostat

Figure 5-1 Cooling System Components

11

TP-6255 4/10

Seawater

Coolant/antifreeze

7. Heat exchanger

8. Engine seawater pump

9. Seawater strainer

10. Seacock

11. Intake strainer

12. Engine-driven water pump

607151

Section 5 Cooling System 31

5.2 Water-Cooled Exhaust

Manifold

Each marine generator set has a water-cooled exhaust manifold. The coolant solution circulates through the manifold, reducing the amount of heat radiated from the exhaust into the surrounding area.

The engine thermostat is located in the water-cooled exhaust manifold. See Figure 5-2. See Section 1 for the water-cooled exhaust manifold torque spec.

3

6

1

2

5

4 1

1. Thermostat housing

Figure 5-2 Thermostat Location (10EOZD model shown)

5.3 Closed Heat Exchanger

In a closed cooling system, seawater circulates through separate chambers within the heat exchanger to cool the engine coolant.

The seawater then mixes with engine exhaust and ejects out of the exhaust outlet. See

Section 1 for coolant capacity, thermostat and pressure cap ratings.

Note: Coolant solution. A coolant solution of 50% ethylene glycol provides freezing protection to

--37 °C (--34°F) and overheating protection to

129 °C (265°F). A coolant 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.

5.4 Check and Fill Coolant

Note: Do not add coolant to a hot engine.

Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until the engine has cooled.

Maintain the coolant level in the coolant recovery tank at approximately 1/4 full. Before filling the cooling system, close all petcocks and tighten all hose clamps. Use a solution of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion and prevent freezing. Add coolant, as necessary, to the coolant recovery tank.

Periodically check the coolant level on closed systems by removing the pressure cap. Do not rely solely on the level in the coolant recovery tank. Add fresh coolant until level is just below the overflow tube opening.

Note: Coolant solution. A coolant solution of 50% ethylene glycol provides freezing protection to

--37 _C (--34_F) and overheating protection to

129 °C (265°F). A coolant 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.

32 Section 5 Cooling System TP-6255 4/10

5.5 Flush and Clean Cooling

System

For optimum protection, drain, flush, and refill the cooling system at the interval listed in the service schedule.

Pay special attention to the coolant level. When refilling the cooling system, allow time for complete refill of the engine water jacket.

Check the coolant level as described in Section 5.4.

Flush and Clean Procedure:

1. Remove the water drain pipe plug located at the heat exchanger and completely drain the system.

2. Remove the pressure cap to make draining easier.

3. Drain, clean, and flush the cooling system and the coolant recovery tank with clean water.

4. Replace the water drain pipe plug.

5. Fill the cooling system with recommended coolant.

6. Replace the pressure cap.

5.6 Pressure Cap

Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant, enabling proper operating temperatures. If the cap leaks, replace it with a cap of the same rating. See Section 1, Specifications.

The pressure cap typically has the pressure rating stamped on the cap body.

5.7 Impeller Inspection and

Replacement

The belt-driven seawater pump is located on the service side of the generator set.

Check and change the seawater pump impeller at the interval specified in the service schedule. Follow the instructions included with the impeller kit. If the instructions are not included with the kit, use the following procedure.

Impeller Inspection and Replacement Procedure:

1. Close the seacock.

2. Remove the seawater pump coverplate.

See

Figure 5-3.

7

8

9

10

11

12

6

4

5

3

1

2

1. Drive shaft assembly

2. Pulley

3. Housing

4. Impeller

5. Gasket

6. Cover plate

TP-5616

7. Snap ring

8. Brass washer

9. Seal

10. Ceramic seat

11. Rubber seat

12. Key (impeller end)

Figure 5-3 Seawater Pump, Typical

3. Remove the impeller.

4. Inspect the impeller for damage, including cracks, broken or flattened vanes.

The impeller vanes should be straight and flexible. See Figure 5-4.

1

2

3

607153

1. Flattened vane

2. Crack

3. Broken vane

Figure 5-4 Worn Impeller

5. Lubricate the impeller with soapy water before installation.

6. While installing the impeller, always rotate the drive shaft and the impeller together in the same direction as the engine rotation.

7. Inspect the coverplate and gasket for corrosion and/or damage.

Replace components as necessary.

TP-6255 4/10 Section 5 Cooling System 33

8. Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing.

9. Open the seacock.

10. Start the generator set and check for leaks.

11. Stop the generator set and repair leaks or replace components as necessary.

5.8 Belt Tension

WARNING

10

11

1

2

3

6

4

5

Hazardous voltage.

Moving parts.





Check the belt tensions at the interval specified in the service schedule. If tensions are not within the specifications, adjust as necessary using the following procedures.

9 8

1. Engine-driven water pump pulley

2. Adjusting arm pivot screw

3. Battery charging alternator pulley

4. Alternator adjusting screw

5. Alternator pivot screw

6. Check the alternator belt tension here

7. Crankshaft pulley

8. Check the seawater pump belt tension here

9. Seawater pump adjusting screw

10. Seawater pump pulley

11. Pivot screw

Figure 5-5 Belt Tension (Typical)

7

TP-5586-3

5.8.1

Seawater Pump Belt Tensioning

Procedure

1. Remove the belt guard.

2. Check the belt tension at the midpoint of the longest span of the belt using a belt-tensioning tool set to 55 ft. lbs. See Figure 5-5. Recheck a new belt tension after 10 minutes of operation.

Note: If the belt tension is not within specifications, go to step 3. If the belt tension is within specifications, go to step 7.

3. Loosen the pivot and 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.


5.8.2

Battery Charging Alternator Belt

Tensioning Procedure

1. Remove the belt guard.

2. Check the belt tension at the midpoint of the longest span of the belt by pressing with your finger. See Figure 5-5 and Figure 5-6. If the belt is not within the specifications, go to step 3. If the belt is within the specifications, go to step 7.

Belt Type

New

Used

Deflection mm (in.)

8--12 (0.3--0.5)

10--14 (0.4--0.6)

Figure 5-6 Belt Specifications

3. Loosen the adjusting arm pivot screw, alternator pivot screw, and alternator adjusting screw.

4. While prying the alternator outward, tighten the alternator adjusting screw.

5. Tighten the adjusting arm pivot screw and alternator pivot screw.

6. Recheck and adjust as necessary.

7. Replace the belt guard.

5.8.3

Anticorrosion Zinc Anode

The heat exchanger on models 8/9/10EOZD,

6.5/7/9EFOZD, 28/32EOZD, and 23/25/27/28EFOZD contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion by seawater.

Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule.

Depending upon operating conditions and seawater properties, the anticorrosion zinc anode may require more frequent replacement.

See Section 1 for the location and use the following procedure.

Anticorrosion Zinc Anode Replacement

1. With the generator set cooled, close the seacock, open the petcock on the engine, and drain the coolant into a suitable container.

2. Remove the anticorrosion zinc anode (plug) from the heat exchanger.

3. Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode. Replace the anode according to Figure 5-7 and Figure 5-8.

Anticorrosion Zinc Anode Replacement

Models

8/9/10EOZD

6.5/7/9EFOZD

New Anode

Dimensions mm (in.)

9 (0.34) x 43 (1.7)

28/32EOZD

23/25/27/28EFOZD

9 (0.34) x 19 (0.75)

Replace When

Percent of Zinc

Remaining Is:

<50% of length/diameter

<50% of length/diameter

Figure 5-7 Anticorrosion Zinc Anode (Plug)

Measurements

1

2

TP-5586-3

1. Diameter: 9 mm (0.34 in.)

2. Length:

43 mm (1.7 in.) for 8/9/10EOZD, 6.5/7/9EFOZD models or

19 mm (0.75 in.) for 28/32EOZD, 23/25/27/28EFOZD models

Figure 5-8 Anticorrosion Zinc Anode (Plug)

4. Clean the threaded hole of the heat exchanger and coat the threads of the anticorrosion zinc anode

(plug) with pipe sealant suitable for marine applications.

Cut the anticorrosion zinc to the correct length. Install the anticorrosion zinc anode into the heat exchanger.

5. Close the petcock on the engine and open the seacock. Refill the cooling system.

6. Start the generator set and check for leaks at the anticorrosion zinc anode location. The pump is operating if the cooling water flows from the exhaust outlet. If water is not discharging at the exhaust outlet, see the Operation Manual’s

Prestart Checklist—Seawater Pump Priming.

TP-6255 4/10 Section 5 Cooling System 35

5.9 Siphon Break

A siphon break prevents seawater entry into the engine when the engine exhaust manifold outlet is less than

23 cm (9 in.) above the waterline of a fully-loaded, shut-down craft. Use the following procedure to inspect the siphon break.

Siphon Break Inspection Procedure:

1. Stop the generator set.

2. Remove the retaining cap and lift out the reed valve assembly for inspection. See Figure 5-9.

3. Use a light detergent to clean the reed valve to remove residue and oxidation.

4. Check that the reed valve opening is clear.

5. Replace the siphon break if it is cracked or if the reed valve material has hardened or deteriorated.

6. Install the reed valve into the mounting base with the valve downward.

7. Install the retaining cap and finger-tighten only. Do not overtighten.

2

3

7

8

9

20

1

6

5

18

4

Waterline

19

14

10

17

13

15

11

16

12

TP-5586-3

1. Mounting base

2. Retaining cap

3. Reed valve assembly

4. Silencer vertical lift 1.2 m (4 ft.) max.

5. Exhaust mixer elbow distance above waterline; if less than

23 cm (9 in.), siphon break is required

6. Siphon break distance above waterline 30.5 cm (1 ft.) min.

7. Siphon break

8. Exhaust mixer elbow

9. Heat exchanger (locations vary by model)

10. Seawater strainer

11. Seacock

12. Intake strainer

13. Engine-driven seawater pump

14. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in./ft.) min.

15. Water lock (optional)

16. Silencer distance from exhaust mixer elbow 3 m (10 ft.) max.

17. Silencer (customer-supplied)

18. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in./ft.) min.

19. Exhaust outlet distance above waterline 10 cm (4 in.) min.

20. Seawater outlet

NOTE: Consult the installation manual for complete explanation of dimensions and other installation considerations.

Figure 5-9 Siphon Break (Plastic “U” Type)


6.1 Introduction

Corrective action and testing in many cases requires knowledge of electrical systems and electronic circuits.

Have an authorized service distributor/dealer perform testing and service.

Refer to the engine service manual for engine service information.

If the troubleshooting procedures in this section identify a bad part, refer to the parts catalog for replacement part numbers.

6.2 Initial Checks

When troubleshooting, always check for simple problems first.

Check for the following common problems before replacing parts:

D Loose connections or damaged wiring.

D Dead battery.

D Fault shutdown.

Check for a fault code on the controller display. Section 7.4 describes the warning and shutdown fault codes.

D Blown fuses. Fuses in the wiring harness protect the controller, SCR module, and relay interface board.

Always check and replace the fuses before replacing other components.

D Incorrect controller settings. Always check the controller configuration settings before replacing the controller. Section 7.5 contains the instructions for checking and changing the controller configuration.

Some problems may be solved by updating the controller’s application program.

Check www.kohlernet.com, Tech Tools, Software, for information on ADC 2100 application program updates.

Refer to Section 7.6 for instructions to check the version number of the controller’s application program and for more information on updating the application program.

Section 6 Troubleshooting

6.3 General

Before beginning the troubleshooting procedures, read all the safety precautions at the beginning of this manual.

WARNING

Hazardous voltage.

Moving parts.



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.


Short circuits.

Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage.

Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

6.4 Troubleshooting Chart

Use the following tables as a reference in troubleshooting individual problems.

Generator set faults are listed in groups and include likely causes and remedies. The simplest and most likely causes of the problem are listed first; follow the recommendations in the order shown.

The reference column provides additional sources of information in this and related manuals regarding the problem and solution.

TP-6255 4/10 Section 6 Troubleshooting 37

Troubleshooting Chart

Problem

Generator set does not crank

Possible Cause

Weak or dead battery

Battery connections

Open circuit in engine/controller connections

Blown fuse F3, controller

Blown fuse F2, relay interface board (RIB)

Crank relay on relay interface board (RIB)

Generator set master switch

Poor ground (--) connection

Starter

Controller

Corrective Action

Recharge or replace battery.

Check for reversed or poor battery connections.

Check for loose connections.

Check the wire harness continuity.

Replace fuse; if fuse blows again, check circuit and components.

Reference

Generator Set O/M

—

Section 8.15

Section 10

Section 8.14

Section 10

Section 8.14

Section 10

Replace fuse.

If fuse blows again, disconnect the board leads one at a time to identify the cause of the blown fuse:

Lead 70A at the fuel solenoid

Lead 71A at the crank relay

Lead FP and FN at the rotor

Repair or replace the component causing the blown fuse.

If the fuse continues to blow and the previous step did not identify the cause, remove the leads from the P14 connector using a pin pusher, part #241918 (large) or

241919 (small). If replacing the leads does not solve the problem, replace the RIB.

Check connections to the RIB.

Check for 12VDC to the RIB between PF2 and 71N.

Check for a good ground connection (lead N)

Check crank relay K2 operation

(LED3). Replace the RIB if the relay does not operate.

Check connections to the master switch on the ADC 2100.

Test function of the switch.

Clean and retighten.

Check the starter connections.

Rebuild or replace the starter.

Check the controller connections and operation. Check for power to the controller. Move the generator set master switch to the

OFF/RESET position and then to the RUN position.

Section 7.10

Section 10

Section 7.10

Section 10

Section 7.10

Section 7.9

Section 8.15

—

Section 10

Engine Service Manual (S/M)

Section 7

Section 10

38 Section 6 Troubleshooting TP-6255 4/10

Troubleshooting Chart, continued

Problem

Generator set cranks but does not start

Generator set starts hard

Generator set starts but shuts down

Generator set stops suddenly

Possible Cause Corrective Action

No fuel Check the fuel supply.

Loose connection or open circuit Check for loose or open connections at the fuel solenoid

(lead 70A). Check the controller/engine wiring continuity.

Air cleaner clogged Clean or replace.

Incorrect controller configuration Check for correct controller configuration parameters: unit configuration (UC) and engine configuration (EC).

No engine rotation sensed (check for an overcrank fault shutdown)

Low battery voltage

Check for a locked rotor.

Check battery voltage, power supply, and operation.

Air cleaner clogged

Worn piston rings, valves

Fault shutdown

Fault shutdown

Replace element.

Check compression.

Check for a fault shutdown code on the Advance Digital Control’s

LED display. Correct the fault and then move the generator set master switch to the OFF/RESET position to reset the ADC.

Check for a fault shutdown code on the Advanced Digital Control’s

LED display. Correct the fault and then move the generator set master switch to the OFF/RESET position to reset the ADC.

Check the fuel supply.

No fuel

Fuel line restriction

Air cleaner clogged

Inspect fuel lines.

Replace element.

Blown controller fuse (F3) Replace fuse.

Blown auxiliary winding fuse (F1) Replace fuse. If fuse blows again, test generator components.

Blown relay interface board (RIB) fuse (F2)

Engine overheated (hot engine only)

Replace fuse.

Check air intake, oil level, air inlet/outlet.

Low oil pressure (LOP) shutdown Attempt startup. If the unit shuts down, remove the lead from the

LOP switch and reset the controller. A successful restart attempt indicates a faulty LOP shutdown switch.

Note: Check the engine oil pressure before performing the test and/or replacing the LOP shutdown switch.

Engine overloaded

Loss of generator output voltage to controller

Faulty K3 (flash) relay

Reduce electrical load.

Check connections at P15 plug.

Check continuity of AC sensing leads 11 and 44 (for 1-phase models) or leads 7, 8, and 9 (for

3-phase models).

Check for Flash LED illumination.

Check RIB fuse. Replace relay board.

Reference

Section 10

Section 3

Section 7.5

Section 8.8

Section 3

Engine S/M

Section 7.4

Section 7.4

Section 3

Section 8.14

Section 8.14

Section 8.14

Sections 2 and 3

Section 8.13

—

Generator Set O/M

—

—

Generator Set I/M

Section 10

Section 7.10



Problem

Generator set operates erratically

Generator set lacks power

Generator set overheats

Low output or excessive drop in voltage

Possible Cause

Air cleaner clogged

Governor adjustment incorrect

Inadequate cooling (hot engine only)

Carbon buildup in engine

Engine valves not seating correctly

Air intake restriction, inadequate cooling

Corrective Action

Replace element.

Adjust governor stability.

Inspect air inlet and outlet.

Clean cylinder head.

Inspect valves and valve seats.

Generator overloaded

Engine not running at rated rpm

Engine power loss

Inspect air intakes and exhaust for obstructions.

Check the air cleaner.

Reduce load.

Check controller settings for unit configuration (UC) and engine type (EC).

Adjust governor speed.

Refer to the Engine Service

Manual for troubleshooting and repair instructions.

Test/readjust governor.

Governor malfunction or misadjustment

Inadequate cooling Inspect cooling system for obstructions.

Replace element.

Air cleaner clogged

Generator overloaded Reduce load.

Incorrect controller configuration Check and adjust the controller configuration parameters.

Reference

Section 3

Section 4.4

Engine S/M

Engine S/M

Section 4.4

Engine S/M

Section 4.4

Section 3

Generator Set I/M

Section 7.5

—

Section 3

Generator Set I/M

Section 7.5

—

Incorrect controller voltage settings

Check and adjust the controller voltage settings.

Section 7.5.3

Alternator or control system Perform separate excitation procedure to isolate problem to the alternator or the control system.

Section 8.2

SCR module

Controller

Rotor (open, grounded, or shorted windings)

Stator (open, grounded, or shorted windings)

Low engine speed causing voltage roll-off

Check wiring and connections to the SCR module.

Check the auxiliary winding fuse

F1 (lead 55).

Replace SCR module and test voltage.

Check the controller settings.

Check the controller fuse, wiring and connections.

Before replacing the controller, replace the SCR module and test voltage.

Test and/or replace.

Test and/or replace.

Check system voltage/frequency

(UU) and engine type (EC) parameters.

Section 7.5

Section 7.7

Section 7.5

Section 7.7

Section 7.11

Section 8.8

Section 8.9

Section 7.5

Adjust the engine governor speed.

Section 4.4

Troubleshoot the engine.

Engine S/M



Problem

Light flicker

Possible Cause

Voltage stability (gain) setting

Corrective Action

Check and adjust the voltage stability (gain) setting using the

ADC 2100.

High generator output voltage

Incorrect controller configuration Check and adjust the controller configuration parameters.

Incorrect controller voltage settings

Check and adjust the controller voltage settings.

No output voltage

Reference

Section 7.5.3

Section 7.5

Section 7.5.3

Engine speed too high

Loose voltage sensing connections

Check the engine speed using tachometer or frequency meter.

Adjust governor as necessary.

Check connections: stator leads

11 and 44 (for 1-phase models) or leads 7, 8, and 9 (for 3-phase models) and P15 controller connection.

Section 4.4

Section 8.9

SCR module Check the wiring and connections to the SCR module.

Check the auxiliary winding fuse

F1 (lead 55).


Controller Check fuses, wiring, and connections. Before replacing the controller, replace the SCR module and test voltage.

AC output circuit breaker open Check for AC voltage on the generator side of the circuit breaker. If there is AC voltage on the generator side of the breaker, then a problem in the load circuits is causing the line circuit breaker to trip. Check for and correct short circuits or overloading on the load side before resetting the circuit breaker.

Alternator or control system Perform separate excitation procedure to isolate the problem to the alternator or the control system. Then troubleshoot the alternator or control system components as follows.

Aux. winding fuse blown (lead 55) Replace blown fuse. If fuse blows again, check stator.

SCR module Check auxiliary winding fuse F1

(lead 55).


Section 7.7

Section 7.5

Section 7.7

Section 7.11

Section 8.2

Section 8.14

Section 8.14

Section 7.7

Controller Check controller settings. Check wiring and connections. Before replacing the controller, replace the SCR module and test voltage.

Section 7.5

Section 7.7

Section 7.11

—



Problem

No output voltage

(continued)

Possible Cause

Open wiring, terminal, or pin in buildup circuit or SCR module circuit

Rotor connections

Corrective Action

Check continuity.

Reference

Section 7.7

Check for open circuit in the rotor connection circuit (leads FN and

FP to the SCR and RIB).

Check voltage and continuity.

Section 8.8

Rotor (open, grounded, or shorted windings)

Stator (open, grounded, or shorted windings)

Check voltage and continuity.

Section 8.8

Section 8.9

Flash relay (K3) on relay interface board (RIB)

Check flash LED on RIB.

Check fuse F2 and troubleshoot

RIB.

Section 7.10

Generator set is noisy

Exhaust system leaks

Engine not running smoothly

Check and replace as necessary.

See “Generator set operates erratically,” this table.

—

See “Generator set operates erratically,” this table

— Broken or damaged vibromount(s) Check and replace as necessary.

Loose or vibrating sheet metal/housing

Retighten screws, replace rivets.

Exhaust piping or air inlets/outlets not securely installed

Excessive engine/generator vibration

Air intake restriction

Inspect for loose parts and secure if necessary.

Check, rotor, crankshaft, bearing, etc. (disassembly of engine and/or alternator may be required).

Check air cleaner and intake.

Emits black or gray smoke

Emits black or gray smoke

High oil consumption

Oil level high

Worn piston rings, valves, etc.

External leakage/defective gaskets

Worn piston rings, valves, etc.

Engine knocks Excessive load

Low oil level

Check oil level.

Check compression.

Replace gaskets.

Check compression.

Reduce load

Section 9, Disassembly/

Reassembly and Engine S/M

Section 3

Section 2 and Generator Set O/M

Engine S/M

Engine S/M

Engine S/M

—

—

Generator Set I/M

Check oil level and add oil if low Section 2 and Generator Set O/M


Section 7 Controller

7.1 Introduction

This section covers operation, configuration, adjustment, and replacement of the ADC 2100 controller.

procedures.

See Section 6 for troubleshooting

See Figure 7-1 for the locations of the controller and related components.

Section 7.2 describes the controller keypad and display.

Section 7.3 describes the sequence of operation, and faults are described in Section 7.4.

Controller configuration and adjustment are covered in

Section 7.5.

A silicon controlled rectifier (SCR) module works with the controller to regulate the output voltage.

See

Section 7.7.

A relay interface board (RIB) is used with the ADC controller.

Section 7.10 describes the standard and optional RIBs.

3

1

2

8

7

6

4

5

GM29253

1. Junction box louvered panel

2. SCR module (mounted behind ADC 2100 on 6EOD and

4.5EFOD models)

3. Relay board

4. Engine harness-to-controller connection

Figure 7-1 Advanced Digital Control (ADC 2100)


6. ADC 2100

7. Line circuit breaker plate

8. Junction box

TP-6255 4/10 Section 7 Controller 43

7.2 Advanced Digital Control

Display and Keypad

The Advanced Digital Control has an LED display and a three-button keypad. See Figure 7-2. The LED display shows runtime hours, fault codes, application program version number, or controller parameters during configuration and adjustment. See Figure 7-3. The keypad is used to enter the controller’s configuration and adjustment menus, and to change the controller settings.

A password key sequence is required to enter the configuration and adjustment menus.

Section 7.5

contains the instructions to enter the configuration and adjustment menus and change the settings using the controller keypad.

1

3

2

Controller Display

Item Description

Crank indication Displays CC_1, CC_2, or CC_3 to indicate the 1st, 2nd or 3rd attempt to start the engine. The last digit flashes during the crank cycle rest periods.

Runtime hours Displays total generator set runtime hours when no other code is displayed.

Fault codes

System parameters

Application program version number

Flashes a 2- or 3-letter fault code to indicate various fault conditions. See Section 7.4.

Displays 2-letter codes or 4-digit alphanumeric codes during system configuration or adjustment. See Section

7.5.

Displays the version number of the controller’s application program before entering the configuration or adjustment mode. See Section 7.6.

Figure 7-3 Advanced Digital Control’s LED Display

1. LED display

4

2. Select button (use for setup and adjustment only)

GM28707A-C

3. Up and down arrow buttons (use for setup and adjustment only)


Figure 7-2 Advanced Digital Control

44 Section 7 Controller TP-6255 4/10

7.3 Sequence of Operation

The following sections describe the controller sequence of operation during generator start, run, stop, and fault shutdown modes.

Use this as a starting point for controller and relay board fault identification. Refer to the wiring diagrams in Section 10 to assist in the troubleshooting procedure.

7.3.1

Starting Sequence, Master Switch

Moved to RUN

When the master switch is moved to the RUN position, there is a delay of about 1 second before the ADC attempts to start the engine. The run relay energizes and the run LED (1) turns on. The crank and flash relays energize and the corresponding LEDs (2 and 3) turn on

0.5 seconds later. The ADC display indicates the crank cycle 1 code, CC 1.

The ADC attempts to start the generator set three times

(three crank cycles, 15 seconds crank and 15 seconds off). If the generator set does not start in three attempts, the system shuts down on an overcrank fault.

When the engine comes up to speed, the low oil pressure switch contacts open.

Note: The controller circuit board prevents fault shutdowns during startup until the crank disconnect relay energizes.

The cyclic cranking cycle is programmed into the ADC’s application code and is not adjustable in the field.

The factory sets the cranking cycle for three cycles of

15 seconds on time and 15 seconds off time. If the cranking cycle seems shorter than the factory setting, check the engine starting battery.

7.3.2

Starting Sequence, Remote Start

When the master switch is moved to the AUTO position, the controller may remain OFF until the remote start switch or transfer switch engine start contacts close the first time, if the power jumper is removed.

The start sequence proceeds as described in

Section 7.3.1, Starting Sequence, Master Switch

Moved to RUN.


7.3.3

Running Sequence

When the engine speed reaches 750 rpm, the crank relay deenergizes and the crank LED (3) turns off.

When the output voltage on leads 11 and 44 (for 1-phase models) or leads 7, 8, and 9 (for 3-phase models) reaches about 30 VAC, the flash relay deenergizes and the flash LED (2) turns off.

7.3.4

Stopping Sequence, Master

Switch Moved to OFF/RESET

Place the generator master switch in the OFF/RESET position. The run relay deenergizes and the run LED (1) turns off. The generator set stops.

7.3.5

Stopping Sequence, Remote Stop

If the generator set is running, momentarily closing the remote start/stop contacts deenergizes the run relay and the run LED (1) turns off, but the controller does not power down.

The controller remains powered and displays the engine runtime hours.

Note: For units with serial numbers before 2051415:

Disconnecting the P7 jumper will allow the controller to power down 48 hours after generator set shutdown.

See Section 7.8, Continuous

Power Mode.

Note: For units with serial numbers 2051415 and later:

If the ADC 2100 is configured for a CAN gauge, the controller will not power down (if the master switch is in the AUTO position).

If the ADC 2100 is not configured for a CAN gauge, the controller will power down after

48 hours (if the master switch is in the AUTO position). If the generator has been started, the controller will power down 48 hours after the generator stops.

7.4 Faults

7.4.1

Fault Shutdowns

Under the fault conditions listed in Figure 7-4, the ADC displays a fault code and the generator set shuts down.

Always identify and correct the cause of a fault shutdown before restarting the generator set. Refer to

Section 6, Troubleshooting, for instructions to identify and correct the cause of the fault.

To restart the generator set, first move the generator set master switch to the OFF/RESET position to reset the controller.

Note: For units with serial numbers before 2051415:

If the power jumper is removed and the controller powers down after a fault shutdown, move the master switch to the OFF/RESET position and then to the RUN position to display the fault code.

Moving the master switch to the OFF position again will clear the fault. See Section 7.8 for more information on the continuous power mode jumper.

7.4.2

Warnings

The fault conditions listed in Figure 7-5 will cause the controller to display a fault code but will not shut down the generator set.


Code Fault

AF Auxiliary fault input shutdown

HE

LOP

OC

OF

OS

OU

UF

UU

High engine temperature shutdown

LOC Loss of coolant shutdown

Low oil pressure shutdown

Overcrank shutdown

Overfrequency shutdown

Overspeed shutdown

Overvoltage shutdown

Underfrequency shutdown

Undervoltage shutdown

SCF0 Controller error

Description

Input from a customer-supplied switch that closes when the fault is active. Shutdown occurs

0.3 seconds after the fault is detected and will not start when the fault is active (input is grounded). This protection becomes active 3-seconds after crank disconnect.

Check

Check the cause of the auxiliary fault.

Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than

5 seconds. This protection becomes active after the engine reaches the crank disconnect speed.

Note: The high engine temperature shutdown functions only when the coolant level is in the operating range.

Shutdown occurs 5 seconds after a loss of coolant condition is detected. This protection becomes active

10 seconds after the engine has reached its stated crank disconnect speed and remains active as long as the generator run command is active.

Shutdown occurs if a low oil pressure condition exists for more than 5 seconds. This protection becomes active 30 seconds after the engine has reached crank disconnect speed (30 second inhibit).

Note: The low oil pressure shutdown does not protect against low oil level. Check the oil level at the engine.

Shutdown occurs after 3 unsuccessful starting attempts. The crank cycle is set for three starting attempts.

Shutdown occurs when the governed frequency exceeds 110% of the system’s frequency setpoint for more than 5 seconds. This protection becomes active

10 seconds after engine start (10 second inhibit).

Check for a low engine coolant level.

Check for a clogged seawater intake or sea strainer.

Check for a damaged seawater pump impeller.

Check for leaks in the lubrication system.

Check the oil level and add oil if the level is low.

Check the fuel supply and battery.

If there is no output voltage, check the line circuit breaker. Also check for loose connections.

Contact an authorized distributor/dealer for service if problem continues.


Shutdown occurs if the engine speed exceeds 115% of the normal running speed for more than 0.3 seconds.

Shutdown occurs if the voltage exceeds 120% of the voltage regulator setpoint for more than 2 seconds.



Shutdown occurs when the governed frequency falls below 90% of the system’s frequency setpoint for more than 5 seconds. This protection becomes active

10 seconds after engine start (10-second inhibit).

Shutdown occurs if the voltage falls below 80% of the voltage regulator setpoint for more than 10 seconds.

Indicates a software or communication problem within the ADC 2100.

Reduce the load and restart the generator set.


Reduce the load and restart the generator set.



Figure 7-4 Fault Shutdowns


Code Fault

HB High battery voltage warning

LB Low battery voltage warning

Description

Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than

2 seconds when the engine is not running. This fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to a voltage within the limits for more than

2 seconds.

Fault code is displayed if the engine starting battery voltage falls below 9.5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than

2 seconds when the engine is not running. This fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to a voltage within the limits for more than

2 seconds.

Figure 7-5 Fault Warnings

Check

Check the battery rating and condition.

Check the battery rating and condition.

Charge or replace the battery.


7.5 Controller Configuration and

Adjustment

The first step in troubleshooting the controller is to verify that the controller is correctly configured for the generator set.

The controller’s configuration modes allow setting of the engine type, generator set configuration (marine, mobile, or standby), data input types, and other parameters.

The controller configuration for each generator model is set at the factory. Generator set reconnection, sender changes, controller replacement, or other changes may result in the need to change the controller configuration.

Use the instructions in the following section to check the controller settings and change them, if necessary.

7.5.1

Controller Time Out

The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed.

Start the configuration procedure over again from the beginning if the controller exits the configuration mode before the settings have been saved.

Changes in voltage and speed adjustments are also lost if they are not saved before the generator set shuts down. The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup. Be sure to save your changes immediately after making adjustments.

7.5.2

Controller Configuration

The controller configuration is factory-set and should not normally require changes in the field. However, the controller configuration may need to be changed after generator set reconnection or controller replacement.

The controller’s configuration mode allows adjustment of the system parameters listed in this section. Change the system voltage and frequency after reconnection or controller replacement.

The unit configuration and engine type are factory-set for each type of generator set and engine and should not require changes unless the controller is replaced.

The controller’s advanced configuration mode allows the user to set the data input type for engine senders, toggle the battery voltage between 12 and 24 volts, and change the controller communications setting for optional meters. Check these settings after controller replacement and change them, if necessary, to match the settings shown in Figure 7-6.

TP-6255 4/10

Follow the instructions in Figure 7-9 to enter the configuration mode while the engine is not running and then step through the following parameters. Use the up (

∧

) and down (

∨

) arrow buttons to select the appropriate setting for the application.

Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position.

Voltage/frequency setting (Uu). Select the system voltage and frequency from the table in Figure 7-6.

Note: This parameter sets the nominal system voltage and frequency. To adjust the output (measured) voltage and frequency, see Section 4.4,

Section 7.5.3, and Figure 7-12.

Unit configuration (Uc).

This parameter sets the generator set type: marine, standby, or mobile.

Engine configuration (Ec). The engine configuration must match the generator set engine type.

Advanced configuration mode (Adnc).

The data input types, battery voltage, and communications setting can be changed in the advanced configuration mode.

Press the up arrow button when Adnc is displayed to enter the advanced configuration mode.

Engine data input types (Ed). This setting defines the type of senders used on the generator set engine.

Battery voltage (Bt). This setting toggles between 12 and 24 VDC for the engine starting battery voltage.

Communications setting (Cn). This setting allows the user to set the controller for communication with optional gauges, which are available for marine and mobile units only.

7.5.3

Voltage Adjustment

The flowchart in Figure 7-12 outlines the procedures for using the ADC controller to adjust the output voltage.

Voltage adjustment may be required after controller replacement, generator set reconnection, or other service procedures. The generator set must be running during this adjustment. Use a multimeter to measure the generator set output voltage during adjustment. Refer to Section 8.10.2, Voltage Adjustment for instructions to measure the output voltage.


Section 7 Controller 49

Marine Diesel

Model

4.5EFOD (1 Ph)

6EOD (1 Ph)

Freq.

Hz

50

60

Voltage, Phases

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

120/240 V, 1 Ph, 3 W

120 V, 1 Ph, 3 W

120 V, 1 Ph, 2 W

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

Volts,

Hz Market

Uc Uu*

2

6

13

1

0

0

2

0

0

Engine

Type

Ec

Data

Inputs

Ed [

Battery

Voltage

Bt

CANbus

Comm.

Cn

0

]

(No Can)

1 or 6

(J1939)

7 or 9

(Smartcraft)

]

6.5EFOZD (1 Ph)

7EFOZD (1 Ph)

8EOZD (1 Ph)

8.5EFOZD (3 Ph)

9EFOZD (1 Ph)

9EOZD (1 Ph)

10EOZD (1 Ph)

10EOZD (3 Ph)

11EFOZD (1 Ph)

11.5EFOZD

(3 Ph)

13EOZD (1 Ph)

13EFOZD (1 Ph)

50

50

60

50

50

60

60

60

50

50

60

50

240 V, 1 Ph, 2 W

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

120/240 V, 1 Ph, 3 W

120 V, 1 Ph, 3 W

120 V, 1 Ph, 2 W

230/400 V, 3 Ph, 4 W, Wye

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

120/240 V, 1 Ph, 3 W

120 V, 1 Ph, 3 W

120 V, 1 Ph, 2 W

120/240 V, 1 Ph, 3 W

120 V, 1 Ph, 3 W

120 V, 1 Ph, 2 W

120/240 V, 3 Ph, 4 W, Delta

127/220 V, 3 Ph, 4 W, Wye

220/380 V, 3 Ph, 4 W, Wye

240/416 V, 3 Ph, 4 W, Wye

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

115/230 V, 3 Ph, 4 W, Delta

110/190 V, 3 Ph, 4 W, Wye

120/208 V, 3 Ph, 4 W, Wye

220/380 V, 3 Ph, 4 W, Wye

230/400 V, 3 Ph, 4 W, Wye

240/416 V, 3 Ph, 4 W, Wye

120/240 V, 1 Ph, 3 W

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

6

13

2

6

13

1

0

0

3

2

6

13

1

0

0

1

0

0

10

16

19

20

2

6

13

6

14

17

18

21

3

22

1

2

6

13

0

0

0

0

0

0

0

0

0

0

0

0

1

2

1

2

1 (std.) or

3 (opt.

ops)

12

12 or 24

12

12 or 24

0

(No Can)

1 or 6

(J1939)

]

0

(No Can)

1 or 6

(J1939)

7 or 9

(Smartcraft)

]

0

(No Can)

1 or 6

(J1939)

]

0

(No Can)

1 or 6

(J1939)

7 or 9

(Smartcraft)

]

* Use voltage/frequency parameters Uu07--Uu23 only with ADC application program version 1.20 or higher.

[ See Figure 7-7 for Ed settings with optional sender kits.

] See Figure 7-8 for Cn settings with optional digital gauges (gauges are available on selected models only).

Note: Setting the Ec parameter automatically selects the Ed parameter for the standard data inputs for that engine. If you change Ec, check the Ed setting.


Volts,

Hz Market

Uc

Engine

Type

Data

Inputs

Ed [

Battery

Voltage

CANbus

Comm.

Cn ]

14EOZD (3 Ph)

15EOZD (1 Ph)

15.5EOZD (1 Ph)

17EFOZD (1 Ph)

17.5EFOZD

(3 Ph)

20EOZD (1 Ph)

20EOZD (3 Ph)

20EFOZD (1 Ph)

20EFOZD (3 Ph)

23EOZD (1 Ph)

24EOZD (3 Ph)

23EFOZD (1 Ph)

25EFOZD (1 Ph)

60

60

60

50

50

60

60

50

50

60

60

50

50

120/240 V, 1 Ph, 3 W

120/208 V, 3 Ph, 4 W, Wye

127/220 V, 3 Ph, 4 W, Wye

120/240 V, 3 Ph, 4 W, Delta

139/240 V, 3 Ph, 4 W, Wye

277/480 V, 3 Ph, 4 W, Wye

120/240 V, 1 Ph, 3 W

120/240 V, 1 Ph, 3 W

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

115/230 V, 3 Ph, 4 W, Delta

110/190 V, 3 Ph, 4 W, Wye

120/208 V, 3 Ph, 4 W, Wye

220/380 V, 3 Ph, 4 W, Wye

230/400 V, 3 Ph, 4 W, Wye

240/416 V, 3 Ph, 4 W, Wye

120/240 V, 1 Ph, 3 W

120/240 V, 1 Ph, 3 W

120/208 V, 3 Ph, 4 W, Wye

127/220 V, 3 Ph, 4 W, Wye

120/240 V, 3 Ph, 4 W, Delta

139/240 V, 3 Ph, 4 W, Wye

277/480 V, 3 Ph, 4 W, Wye

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

115/230 V, 3 Ph, 4 W, Delta

110/190 V, 3 Ph, 4 W, Wye

120/208 V, 3 Ph, 4 W, Wye

220/380 V, 3 Ph, 4 W, Wye

230/400 V, 3 Ph, 4 W, Wye

240/416 V, 3 Ph, 4 W, Wye

120/240 V, 1 Ph, 3 W

120/240 V, 1 Ph, 3 W

120/208 V, 3 Ph, 4 W, Wye

127/220 V, 3 Ph, 4 W, Wye

120/240 V, 3 Ph, 4 W, Delta

139/240 V, 3 Ph, 4 W, Wye

277/480 V, 3 Ph, 4 W, Wye

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

Uu*

1

11

16

10

10

4

1

1

2

6

13

6

14

17

18

21

3

22

1

1

11

16

10

10

4

2

6

13

6

14

17

18

21

3

22

1

1

11

16

10

10

4

2

6

13

2

6

13

0

0

0

0

0

0

0

0

0

0

0

0

0

Ec

2

2 (w.o.

preheater) or

9 (w/ preheater)

7

1 (std.) or

3 (opt.

ops)

Bt

12 or 24

0

(No Can)

1 or 6

(J1939)

7 or 9

(Smartcraft)

]






Volts,

Hz Market

Uc

0

0

Engine

Type

Data

Inputs

Ed [

Battery

Voltage

CANbus

Comm.

Cn ]

23EFOZD (3 Ph)

25EFOZD (3 Ph)

27EFOZD (1 Ph)

28EFOZD (1 Ph)

27EFOZD (3 Ph)

28EFOZD (3 Ph)

28EOZD (1 Ph)

28EOZD (3 Ph)

32EOZD (1 Ph)

32EOZD (3 Ph)

50

50

50

50

50

50

60

60

60

60

115/230 V, 1 Ph, 3 W

115/230 V, 3 Ph, 4 W, Delta

110/190 V, 3 Ph, 4 W, Wye

120/208 V, 3 Ph, 4 W, Wye

220/380 V, 3 Ph, 4 W, Wye

230/400 V, 3 Ph, 4 W, Wye

240/416 V, 3 Ph, 4 W, Wye

115/230 V, 1 Ph, 3 W

115/230 V, 3 Ph, 4 W, Delta

110/190 V, 3 Ph, 4 W, Wye

120/208 V, 3 Ph, 4 W, Wye

220/380 V, 3 Ph, 4 W, Wye

230/400 V, 3 Ph, 4 W, Wye

240/416 V, 3 Ph, 4 W, Wye

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

230 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

240 V, 1 Ph, 2 W

115/230 V, 1 Ph, 3 W

115/230 V, 3 Ph, 4 W, Delta

110/190 V, 3 Ph, 4 W, Wye

120/208 V, 3 Ph, 4 W, Wye

220/380 V, 3 Ph, 4 W, Wye

230/400 V, 3 Ph, 4 W, Wye

240/416 V, 3 Ph, 4 W, Wye

115/230 V, 1 Ph, 3 W

115/230 V, 3 Ph, 4 W, Delta

110/190 V, 3 Ph, 4 W, Wye

120/208 V, 3 Ph, 4 W, Wye

220/380 V, 3 Ph, 4 W, Wye

230/400 V, 3 Ph, 4 W, Wye

240/416 V, 3 Ph, 4 W, Wye

120/240 V, 1 Ph, 3 W

120/240 V, 1 Ph, 3 W

120/208 V, 3 Ph, 4 W, Wye

127/220 V, 3 Ph, 4 W, Wye

120/240 V, 3 Ph, 4 W, Delta

139/240 V, 3 Ph, 4 W, Wye

277/480 V, 3 Ph, 4 W, Wye

120/240 V, 1 Ph, 3 W

120/240 V, 1 Ph, 3 W

120/208 V, 3 Ph, 4 W, Wye

127/220 V, 3 Ph, 4 W, Wye

120/240 V, 3 Ph, 4 W, Delta

139/240 V, 3 Ph, 4 W, Wye

277/480 V, 3 Ph, 4 W, Wye

Uu*

6

14

17

18

21

3

22

6

14

17

18

21

3

22

2

6

13

2

6

13

6

14

17

18

21

3

22

6

14

17

18

21

3

22

1

1

11

16

10

10

4

1

1

11

16

10

10

4

0

0

0

0

0

0

0

0

0

0

Ec

7

1 (std.) or

3 (opt.

ops)

Bt

12 or 24

0

(No Can)

1 or 6

(J1939)

7 or 9

(Smartcraft)

]





Figure 7-6 Controller Parameters Settings, Marine Diesel Models


Optional Sender Kits and Ed Setting

The installation of optional sender kits may require a change to the Ed (engine data inputs) setting. See

Figure 7-7 for the Ed settings with optional sender kits.

“No Change” means the installation of the kit does not require a change to the Ed setting.

Note: The Ec setting can affect the Ed setting. If you change the Ec setting, check the Ed setting and change it if necessary to match the value shown in the tables for your unit.

Note: Installation of an optional electronic governor kit with a magnetic pickup does not require a change to the Ed setting.

Model Sender Kit

None

6EOD

4.5EFOD

GM32112-KA1 and -KP1 *

GM50552-KA1

[

GM47164-KP1

]

None

8--32EOZD

6.5--28EFOZD

GM32112-KA1 and -KP1 *

GM50552-KA1 [

* OP and WT sender kits

[ Oil pressure sender kits

] Electronic governor kit

Ed

1

3

No Change

No Change

1

3

No Change

Figure 7-7 Ed Settings with Optional Sender Kits

Cn Communication Parameter

See Figure 7-8 for communication parameter settings.

If your generator set is connected to a remote digital gauge, refer to Figure 7-8 or the instruction sheet provided with the gauge to determine the communication parameter Cn setting.

Power Modes

Use Figure 7-8 to determine power down times.

With the generator set master switch in the AUTO position, there are three possible controller power modes:

D 48-hour power down.

If the ADC 2100 communication parameter setting is Cn00 or Cn07, the controller will power down after 48 hours of inactivity. If the generator set has been started, the controller will power down 48 hours after the generator set stops.

D Continuous power mode.

If the ADC 2100 communication parameter setting is Cn01, the controller will not power down.

The controller remains powered at all times to maintain CAN communications and allow remote start commands from the CAN gauge.

D 1-hour power down.

If the ADC 2100 communication parameter setting is Cn06 or Cn09, the controller will power down after 1 hour of inactivity. In this mode, a remote start/stop switch or the generator set master switch must be used to activate the controller after it has powered down.

ADC 2100 application code version 1.21 or higher is required for the 1-hour power down option.

Note: After controller power down, a remote digital gauge will not have power and therefore will not be able to send a start signal to activate the controller.

Note: Kohler’s 2-inch digital gauge allows “wake-up” of the controller remotely.

Gauge Kit

None

Gauge

Description

—

GM32337-KP1 Remote

Digital Gauge

(3 inch)

Cn

Setting

Cn00

Power

Down

Time

48

Hours

Cn01 Never/

None

Cn06 1 Hour

Cn07 48

Hours

CAN

Description

No CAN

J1939

GM46035-KP1 Remote

Digital Gauge

(3 inch)

GM50822-KP1 Remote

Digital Gauge

(2 inch)

Cn09 1 Hour

Smartcraft

Figure 7-8 Communication Parameter Cn Settings

(optional gauges are available on selected models only)


Controller Configuration Mode: (Use Figure 7-6 with Controller Parameters.)

Hold the Select button:

Move the generator set master switch to the RUN position. (The generator set engine will not start.)

Display:

.

0

Wait about 5 seconds until the display shows the program version number. (The number may be different than the one shown here.)

Press the down arrow key and then the up arrow key 3 times to enter the configuration mode.

(This is the controller “password.”) u 1 0 4

U u 0 x

Now release the Select button.

Press: or

To set the voltage/frequency setting.

or

To step to the next parameter, unit configuration

Uc.

To set the unit configuration setting to Uc00, if necessary.

To step to the next parameter, engine type Ec.

U u 0 x

U c 0 0 or

To set the engine type, if necessary.

To step to the next parameter, advanced configuration mode or save mode selection.

E c 0 x

A d n c

Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs, battery voltage, and communications.

Press:

To enter advanced configuration mode.

Go to Figure 7-10.

or or To proceed to the save mode without entering the advanced configuration mode.

Go to Figure 7-11.

E d 0 x

S A V E

Note: Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed. “x” denotes any number from 0 to 9.

Figure 7-9 Configuration Mode (system voltage/frequency, unit configuration, and engine type parameters)


Pressing the up arrow key at the Adnc display (See Figure 7-9) puts you into the Advanced Configuration Mode.

Press: or To set the engine data input type.

E d 0 x

To enter battery voltage selection mode.

or To toggle between 12 and 24 VDC.

12-volt models

24-volt models

B t 1 2

B t 2 4

To enter communications selection mode.

or

To set the communications parameter mode.

C n 0 0

To enter SAVE mode. Go to Figure 7-11.

S A V E

Note: Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed. “x” denotes any number from 0 to 9.

Figure 7-10 Advanced Configuration Mode (engine data input types, battery voltage, and engine communications)

There are 3 options when the display says SAVE:

Press:

To return to the first parameter, system voltage/frequency Uu, to check or change settings before saving. See Figure 7-9.

or

To save changes.

or

To discard changes without saving.

S A V E

U u 0 x

Y E S n o

“Yes”or “no” flashes when the up or down arrow is pressed and then the controller exits the configuration mode. The display returns to the runtime hours.

x x x x


* x in the runtime hours display above denotes any number from 0 to 9.

Now move the master switch to OFF/RESET.

Figure 7-11 Save Mode (after configuring generator set parameters)


Output Voltage Adjustment Mode:

Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours.

Hold:

Wait about 5 seconds until the display changes from runtime hours to the program version number.

Display :* x x x x x.

x x

Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode. (This is the controller “password.”)

1 P x x

The controller is now in the voltage coarse adjustment mode.

Press: or

To raise or lower the voltage in large increments

(approximately 5--7 volts per step).

or or

To enter fine voltage adjustment mode.

To raise or lower the voltage in smaller increments

(approximately 0.5--0.7 volts per step).

To enter coarse voltage stability (gain) adjustment mode.

To raise or lower the voltage stability (gain) in large increments.

or

To enter fine voltage stability (gain) adjustment mode.

To raise or lower the voltage stability (gain) in smaller increments.

1 P

1 P

2 P

2 P x x x x x x x x

To enter volts/Hz adjustment mode.

To raise or lower the volts/Hz: 00=low; 09= high

3 P 0 x or

To save, see Figure 7-11.

* Shaded boxes show which character in the controller display changes for each adjustment. X in the examples above denotes any number from 0 to 9. The actual values may vary from model-to-model.

Figure 7-12 Output Voltage Adjustments

TP6196


7.6 Controller Application

Program

The controller’s application program version number is displayed on the LED screen during the key sequence to enter the configuration mode. Hold the Select button and move the generator set master switch to the RUN position.

After about 5 seconds, the application program version number will be displayed on the controller display. For example, u1.04 will be displayed for program version 1.04.

Use the Program Loader Software and a personal computer to update the controller’s application program to the latest version, when necessary.

Check www.kohlernet.com, Tech Tools, Software, for information on ADC 2100 application program updates and instructions to obtain the latest application code and

Program Loader software. Refer to TT-1285, Program

Loader, for instructions to load the application program onto the controller.

7.7 Silicon Controlled Rectifier

(SCR) Module

The silicon controlled rectifier (SCR) module works with the ADC 2100 to regulate the output voltage.

The

ADC 2100 monitors generator output voltage and adjusts the excitation current to the rotor through the

SCR module. The SCR module location is shown in

Figure 7-1.

The SCR module is powered through stator leads 55 and 66 connected to SCR terminals AC1 and AC2.

Leads G connected to terminals G1 and G2 provide the controller signal. Leads FP and FN connected to the positive (+) and negative (--) SCR terminals provide excitation current to the rotor. See Figure 7-13 and the wiring diagrams in Section 10.

The SCR module is protected by a 10-amp fuse (F1) in lead 55 in the wiring harness.

Check the fuse and replace it, if blown.

In the case of output voltage problems, check the controller configuration and settings. Then test the SCR module using the following procedure.

SCR Module Test Procedure

Required equipment:

D

D

D

D

D

Ohmmeter

12-volt test lamp (or voltmeter)

12-volt DC power source

100--500 ohm resistor

Jumper

1. Set the ohmmeter to the R X 1 scale.

2. Connect the ohmmeter from (+) to (--) on the SCR module. You should read high resistance in one direction and low resistance in the other (reverse the leads).

AC1 G1 --

AC2 G2 +

GM28483

Figure 7-13 Silicon Controlled Rectifier (SCR)

Module

3. Connect the ohmmeter from AC1 to (+) on the SCR module. You should read high resistance in both directions.

4. Connect the ohmmeter from AC1 to (--) on the SCR module. You should read high resistance in one direction and low resistance in the other.

5. Repeat steps 3 and 4 for AC2.

6. Connect the ohmmeter from G1 to (+) on the SCR module. You should read low resistance in both directions.

7. Repeat step 6 for G2.

You should read low resistance in both directions.

8. See Figure 7-14. Connect the negative (--) lead from the DC power source to the positive (+) terminal on the SCR module.

Note: The SCR module may be damaged if the power supply is connected incorrectly. Be sure to connect the negative lead from the battery to the positive terminal on the SCR module.


1

(--)

4

(+)

G1

(+)

G2

1. 12VDC power source

2. 12 VDC test lamp

3. SCR module

4. Jumper

5. 100--500 ohm resistor

Figure 7-14 SCR Test

AC1

AC2

5

2

3

(--) tp6196

9. Connect the positive (+) lead from the DC power source, with the lamp in series, to terminal AC1 on the SCR module. The lamp should not glow.

10. Connect the jumper, with the resistor in series, from the positive lead of the DC power source to terminal

G1 on the SCR module. The lamp should glow.

11. Repeat steps 9 and 10, with the positive (+) lead and lamp connected to terminal AC2 on the SCR module, and connecting the jumper with resistor to terminal G2.

12. If any of the above checks indicates a bad SCR module, replace the module.

Note: When replacing the SCR module, be sure to apply thermal compound to the back of the module to prevent overheating.

Thermal compound is provided with the SCR module replacement kit.


7.8 Continuous Power Mode

Jumper, if equipped

Note: The P7 jumper was available on generator sets with serial numbers before 2051415.

WARNING












WARNING

Note: The controller is powered by the generator set engine starting battery.

A jumper on connector P7 on the back of the controller causes the controller to remain powered at all times.

With the jumper connected, the ADC’s LED display is powered by the generator set’s battery. Also, the remote start/stop command is supported via the ADC remote gauge. See the wiring diagram and schematic drawing in Section 10. Controllers are shipped from the factory with the jumper connected. Disconnecting the jumper allows the controller to power down 48 hours after the generator set shuts down and the remote start/stop command is no longer supported.

A jumper across controller pins P7-1 and P7-2 maintains power to the controller at all times.

Controllers are shipped with the jumper connected for continuous power. See Figure 7-15.

If the generator set is not used for a long period of time, without exercising, the battery may drain.

The P7 connector has either 2 or 3 pins. Disconnecting the jumper or moving the jumper to pins P7-2 and P7-3 allows the controller to power down automatically

48 hours after the generator set shuts down if the generator set master switch is in the AUTO position. A remote start signal (from a transfer switch or a remote start/stop switch connected to controller leads 3 and 4) or moving the generator set master switch to the RUN position turns the controller back on.

Note: For most applications, it is not necessary to disconnect the continuous power mode jumper.

Use the following procedure to disconnect the jumper, if desired.

Hazardous voltage.

Moving parts.



Short circuits.




Procedure to disconnect the continuous power mode jumper (optional).

Note: The P7 jumper was available on generator sets with serial numbers before 2051415.

Note: For most applications, it is not necessary to disconnect the continuous power mode jumper.

1. Prevent the generator set from starting.

a. Move the generator set master switch to the

OFF/RESET position.

b. Disconnect power to the battery charger, if equipped c. Disconnect the generator set engine starting battery, negative (--) lead first.

2. Remove the controller from the generator set housing.

a. Disconnect the engine wiring harness connector P1 plug (35-pin) from the controller.

Disconnect the J15 and J16 connectors. See

Figure 7-15.

b. Remove the controller from the generator set housing in order to access the back of the controller.

3. Remove the controller’s back cover to access the jumper.

a. Note the labels on the three leads connected to the generator set master switch for reconnection later. Disconnect the leads at the pink connectors. See Figure 7-15.

b. Remove the cover screws and remove the controller’s back cover. See Figure 7-15.

4. Locate the P7 connector near the top of the controller. See Figure 7-15. Remove the jumper from pins 1 and 2 of the P7 connector. If the P7 connector has three pins, connect the jumper across pins 2 and 3 for storage.

5. Replace the controller’s back cover and secure the cover screws.

6. Reconnect the three pink connectors to the generator set master switch.

7. Reconnect the J15 and J16 connectors.

8. Reconnect the engine wiring harness connector

P1 plug (35-pin) to the controller.


10. Reconnect power to the battery charger, if equipped.

11. Place the generator set master switch in the AUTO position.

1

5 4

2

3 tp6196

1. Engine wiring harness connector plug (P1)

2. Continuous power mode jumper location (P7)

3. J15 connector

4. J16 connector


Figure 7-15 ADC Controller (back cover removed)

7.9 Master Switch

The generator set master switch is a three-position

(RUN\OFF/RESET\AUTO) rocker switch.

The leads connecting to the master switch are labeled RUN, VBAT, and AUTO. Check that the three pink connectors are connected to the terminals on the back of the switch as shown in Figure 7-15. Be careful not to reverse the RUN and AUTO leads.


7.10 Relay Interface Board (RIB)

The standard relay interface board (RIB) contains the

K2 crank, K3 flash, and K5 run relays. Three LEDs indicate relay operation. See Figure 7-16.

Refer to the schematic diagram in Section 10 for the standard relay board connections.

The RIB is protected by a 10 amp fuse (F2) located in the wiring harness. If the fuse blows repeatedly, disconnect the board leads one at a time to identify the cause of the blown fuse:

D

D

D

Lead 70A at the fuel solenoid

Lead 71A at the starter relay

Leads FP and FN at the rotor

Repair or replace the component causing the blown fuse.

If fuse continues to blow and disconnecting components did not identify the cause, remove the leads from the

P14 connector using a pin pusher, part #241918 (large) or 241919 (small). If replacing the leads does not solve the problem, replace the RIB.

The individual relays are not replaceable. If one or more relays are faulty, replace the entire RIB.

To replace the RIB:

1. Disconnect P14 and the exciter leads FP and FN.

2. Pull the board straight off the mounting stand-offs.

3. Snap the new board onto the stand-offs and reconnect P14 and the exciter leads.

The generator set may be equipped with an optional

RIB, which contains the K4 auxiliary run relay and K1 common fault relay in addition to the standard relays.

The optional relay board kit includes a wiring harness for connection of customer equipment to the K1 and K4 relays. See Figure 7-17 for optional relay connections.

1

2

3

K1

7

3 1

9

3

6

P13

4

P14

1

7

K4

4

5

VBAT R

K3 FLASH

R

R

6

1. K1 common fault relay (optional)

2. K2 crank relay (standard)

3. K3 flash relay (standard)

4. K4 auxiliary run relay (optional)

5. K5 run relay (standard)

6. P14, engine harness connection (standard)

7. P13, connection to optional relay harness (optional)

GM29779-A

Figure 7-16 Relay Board

Harness

Lead

Number

88

89

90

91

92

93

Connector

Pin Number

6

2

3

4

1

5

Connection

Common fault normally open

Common fault common

Common fault normally closed

Run relay normally open

Run relay common

Run relay normally closed

Figure 7-17 Optional Common Fault and Run Relay

Board Harness Connections


7.11 Controller Replacement

If the troubleshooting procedures in Section 6 identify a faulty controller, use the procedure in this section for controller replacement.

Always check the controller configuration, fuse, wiring, and connections before replacing the controller. For output voltage problems, replace the SCR module and check the operation again before replacing the controller.

After replacing the controller, verify that the new controller’s configuration settings match the generator set system voltage and frequency, unit configuration, engine type, engine data input types, battery voltage, and communications settings. Refer to Section 7.5 for instructions to check the controller configuration and to change the settings, if necessary.

After the controller configuration has been checked and set to match the generator set, use a voltmeter to check the generator set output voltage. If the output voltage or frequency needs adjustment, use the voltage adjustment procedure in Section 8.10.2 and the governor adjustment instructions in Section 4.4.

ADC 2100 Controller Replacement Procedure

1. Place the generator set master switch in the OFF position.

2. Disconnect power to the battery charger, if equipped.


WARNING

4. Sound-Shielded Models: Open the service-side door.

5. Sound-Shielded Models: Release the two quarter-turn fasteners located underneath the roof.

See Figure 7-18.

6. Sound-Shielded Models: Lift up the roof.

7. Sound-Shielded Models: Slide the roof towards the service side of the unit for removal.

8. Sound-Shielded Models: Open the front, rear, and non-service side doors as needed.

3

2






Sound Shield Equipped Models: For access to the generator set to perform regular maintenance, remove the sound shield doors and roof.

4

1. Sound shield roof

2. Quarter-turn fastener

3. Alternator-end door

4. Service-side door

5. Front rail

6. Engine-end door

5

Figure 7-18 Sound Shield Roof Removal

1

6

2


9. Disconnect wiring harness plugs P1, P15, and P16 from the ADC controller.

10. Loosen and remove the four controller mounting screws at the front of the controller.

See

Figure 7-19. Remove the controller.

1 tp6196

1. Controller mounting screws (4 ea.)

Figure 7-19 Controller Mounting Screws

11. Place the new controller into position and install the four mounting screws.

12. Reattach connectors P1, P15, and P16 to the new controller.

13. Verify that the generator set master switch is in the

OFF position.

14. Reconnect the engine starting battery, negative (--) lead last.


16. Follow the instructions in Section 7.5.2 to change the new controller’s configuration settings to match the generator set system voltage and frequency, unit configuration, engine type, engine data input types, battery voltage, and communications settings.

17. Use a voltmeter to check the output voltage. Follow the instructions in Sections 7.5.3, Voltage

Adjustment and 8.10.2, Voltage Adjustment, to adjust the output voltage and stability.

18. Check the output frequency.

Follow the instructions in Section 4.4, Governor, to adjust the output frequency.

19. Place the generator set master switch in the AUTO position if an ATS or remote start/stop switch is used.

20. Replace the sound shield roof and door(s), if equipped.


Notes


Section 8 Component Testing and Adjustment

8.1 Theory of Operation

These generator sets utilize a rotating-field alternator to produce AC voltage. Upon activation of the generator master switch, DC current from the battery magnetizes the rotor (field). When the magnetized rotor rotates within the stator windings, an electrical voltage develops within the stator. As engine speed and generator output increase, the SCR module feeds rectified stator output current to the rotor through the exciter (or brushes/slip rings for model 6EOD/4.5EFOD) to increase the strength of the rotor field. As the rotor field increases in strength, generator output also increases.

The

ADC 2100 monitors the generator output voltage through leads 11 and 44 (for 1-phase models) or leads

V7, V8, and V9 (for 3-phase models) and adjusts the DC current from the SCR module to the rotor to meet load requirements. See Figure 8-1.

8.2 Separate Excitation

To determine the cause of no- or low-AC output, refer to the troubleshooting flowchart in Figure 8-2.

Before beginning the test procedures, read all of the safety precautions at the beginning of this manual. Many of the test procedures include additional safety precautions.

Check the condition of the alternator fuse before performing the separate excitation procedure.

The inline fuse is located in lead 55 of the wiring harness.

See Figure 8-1. If the fuse is not blown, use the following procedure to separately excite the generator using an external voltage source (a 12-volt automotive battery).

Separately exciting the generator can identify faulty voltage regulation by the ADC 2100 or reveal a running fault in the rotor and/or stator. An external power source duplicates the role of the voltage regulator and excites the generator field (rotor). A generator component that appears to be in good condition while stationary may exhibit a running open or short circuit while moving.

Short circuits can be caused by centrifugal forces acting on the windings during rotation or insulation breakdown as temperatures increase.

1

55

ADC

2100

55

66

G

F+

FP

66

AC1

AC2

G1

G2

(+)

(--)

FN

SCR

2

3

11

44

44

4 3 2 1 11

55 66

FN

FP

8

7 F +

F --

AC

AC

AC

6

1. Fuse

2. Power lead (55)

3. Excitation to rotor

4. Exciter (or brushes/slip rings)

5

4

5. Rectifier module

6. Main field (rotor)

7. Stator windings

8. Sensing leads (11--44)

Figure 8-1 Generator Schematic

(Single-Phase Model Shown)

No Generator Output

Separate Excitation

Output within

Specifications

Erratic or No Output

Check Rotor

Check Wiring, Fuses,

SCR Module and

ADC 2100

Check Stator

TP563273

Figure 8-2 General Troubleshooting

TP-6255 4/10 Section 8 Component Testing and Adjustment 65



Short circuits.



Separate Excitation Procedure:

Perform the following procedure to use an external voltage source to excite the main field (rotor).

1. Disconnect the black FN and FP leads from the alternator at the SCR module (+) and (--) terminals.

2. Connect a DC ammeter, 20-amp fuse, and a

12-volt automotive battery to the positive (FP) and negative (FN) exciter leads as shown in Figure 8-3.

Note and record the ammeter reading.

Note: The approximate ammeter reading should be the battery voltage divided by the specified rotor resistance. See Section 1, Specifications, for the specified rotor resistance values.

Example :

12 volts (battery voltage)

3.5 ohms (rotor resistance)

= 3.4 amps (rotor current)

3. Start the engine and check that the ammeter reading remains stable.

An increasing meter reading indicates a shorted rotor. A decreasing meter reading to zero or an unstable reading suggests a running open. Refer to Section 8.8,

Rotor, to test the rotor. If the ammeter reading is stable, proceed to step 4.

4. Check for AC output across the stator leads; see

Section 8.9, Stator. Compare the readings to the

1

AC output values shown in Section 1,

Specifications. If the readings vary considerably, a faulty stator is likely. Refer to Section 8.9, Stator, for further information.

5. If this test shows that the rotor and stator are in good condition, check the wiring and fuses. Check the SCR module.

See Section 7.7, Silicon

Controlled Rectifier (SCR) Module.

Check the controller settings

Section 7, Controller.

and

2 3 connections.

4

5

See

FN FP

+ -

6

+

F +

F --

AC

AC

AC

9 8 7

1. SCR module

2. FN lead disconnected from SCR

3. FP lead disconnected from SCR

4. 10-amp fuse

5. DC ammeter

6. 12V battery

7. Exciter (or brushes/slip rings)

8. Rectifier module


Figure 8-3 Separate Excitation Connections

TP563274

66 Section 8 Component Testing and Adjustment TP-6255 4/10

8.3 Exciter Field

(8--32EOZD/6.5--28EFOZD

Models)

Direct current from the battery magnetizes the exciter field.

When the exciter armature rotates within the magnetized exciter field windings, an electrical current develops within the exciter armature. Test the exciter field according to the following procedure.

Exciter Field Test Procedure:



3. Disconnect the FN/FP leads.

4. Check the exciter field resistance by connecting an ohmmeter across exciter field FN and FP leads.

See Figure 8-4. See Section 1, Specifications for the resistance reading of a cold exciter field. A low reading indicates an internal short and a high reading indicates an open winding.

Repair or replace the exciter field if the ohmmeter readings indicate an inoperative exciter field (refer to

Section 9 for removal). If the resistance test is inconclusive, perform a megohmmeter test on the exciter field as described in the next step.

5. Check the exciter field for a short-to-ground condition. Use a megohmmeter to apply 500 volts

DC to the FN or FP lead and the exciter field frame.

See Figure 8-5.

Follow the megohmmeter manufacturer’s instructions for using the megohmmeter.

A reading of approximately

1.5 MOhms and higher indicates the field winding is functional. A reading of less than approximately

1.5 MOhms indicates deterioration of the winding insulation and possible current flow to ground; if so, replace the exciter field.

1

2

5

FN FP

3

6 4

1. ADC 2100

2. Megohmmeter

3. Frame connection

4. Exciter armature

5. Exciter field


Figure 8-5 Megohmmeter Connections on the

Exciter Field

TP-5983-7

2

1

FN FP 3

4

5

1. ADC 2100

2. Ohmmeter

3. Exciter field

4. Exciter armature


Figure 8-4 Exciter Field Resistance Test

TP-5983-7


8.4 Exciter Armature (8--32EOZD and 6.5--28EFOZD Models)

The exciter armature supplies excitation current to the generator main field through the rectifier module. Test the exciter armature as described in the following steps.

Exciter Armature Test Procedure:

1. Disassemble the alternator. Refer to Section 9.

2. With the alternator disassembled, disconnect the armature leads from the rectifier module AC terminals. Refer to Section 10.

3. With an ohmmeter on the R x 1 scale, check the resistance across the exciter armature leads. See

Figure 8-6. See Section 1, Specifications for the armature resistance. No continuity indicates an open armature winding. If the resistance test is inconclusive, perform a megohmmeter test on the exciter armature as described in the next step.

Note: Most ohmmeters will not accurately measure less than one ohm. Consider the exciter armature functional if the resistance reading (continuity) is low and there is no evidence of a shorted winding (heat discoloration).

4. Check the exciter armature winding for a short-to-ground condition. Use a megohmmeter to apply 500 volts DC to either armature lead and the armature frame.

Follow the megohmmeter manufacturer’s instructions for using the megohmmeter.

See Figure 8-7.

A reading of approximately 1.5 MOhms and higher indicates the exciter armature is functional. A reading of less than approximately 1.5

MOhms indicates deterioration of the winding insulation and possible current flow to ground; if so, replace the exciter armature.

6

5

4

3

1

AC

AC

AC

F+

F--

2


2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Armature

6. Exciter field

Figure 8-6 Exciter Armature Ohmmeter Test

TP-5983-7

7

6

1

AC

AC

AC

F+

F--

3

2

4

5

1. Main field rotor

2. Stator windings

3. Rectifier module

4. Megohmmeter

5. Shaft connection

6. Armature

7. Exciter field

Figure 8-7 Megohmmeter Connections on

Exciter Armature

TP-5983-7


8.5 Slip Rings (6EOD/4.5EFOD

Models)

Slip rings acquire a glossy brown finish in normal operation.

Do not attempt to maintain a bright, newly-machined appearance on the slip rings. Cleaning with a dry, lint-free cloth is usually sufficient. Use very fine sandpaper (#00) and apply light pressure to remove roughness. Do not use emery or carborundum paper or cloth. Clean all carbon dust from the generator after sanding the slip rings. If the rings are black or pitted, remove the rotor and use a lathe to remove some of the slip ring surface material.

8.6 Brushes (6EOD/4.5EFOD

Models)

The brushes transfer current from the SCR module to the slip rings. The brushes should last the life of the generator. Abrasive dust on the slip rings, however, shortens the life of the brushes. Excessive arcing at the brushes could damage the SCR module and the controller. Weak springs, damaged slip rings, sticking brushes, a loose brush holder, or poor brush contact causes arcing.

The brushes must be free to move within the holder and be held in contact with the slip rings by the springs.

When correctly positioned, spring pressure on the brush surface causes the brush to wear evenly. The entire brush must ride on the ring or arcing occurs and causes burned rings or voltage regulator failure. Figure 8-8 shows the correct positioning of the brushes. Add or remove shims as necessary to center the brushes on the slip rings. Replace the brushes if they show uneven wear or are worn to one half their original length.

Check the resistance through the brushes. Resistance through the brushes should be low, 0.1--0.2 ohms without meter lead resistance.

1

Front View

4

2

7 5

6

3

New 1.9 cm (0.75 in.)

2

8

Side View

9

2

3

1. Brush holders (2)

2. Slip ring

3. Brush

4. Retainer wire

5. Shim

6. Spring

Figure 8-8 Brush Assembly

TP5867

7. Brush holder

8. Correctly positioned brush

9. Incorrectly positioned brush


8.7 Rectifier Module (8--32EOZD and 6.5--28EFOZD Models)

The rectifier module located between the exciter armature and the main field converts AC from the exciter armature to DC, which magnetizes the generator main field.

Test the rectifier module as described in the following steps.

Rectifier Module Test Procedure:

1. Disconnect the exciter armature and the main field leads from the rectifier module.

2. Use an ohmmeter on the R x 100 scale to check the resistance between all the rectifier diodes as shown in Figure 8-9. The ohmmeter should show a low resistance in one direction and, upon reversing the ohmmeter leads, a high resistance in the other direction. Replace the rectifier module if any of the diodes tests differently than described.

A

8.8 Rotor

The generator rotor (magnetized by DC from the rectifier module) rotating within the stator windings induces AC in the stator windings. Test the generator rotor (main field) as described in the following steps. Disassemble the generator prior to performing this test.

See

Section 9.

Generator Main Field (Rotor) Test Procedure:

1. With the generator disassembled, disconnect the generator main field windings at the rectifier module terminals F+ and F--.

2. Check the main field resistance by connecting an ohmmeter across the main field F+ and F-- leads.

See Figure 8-10. See Section 1, Specifications for the resistance reading. A low reading indicates an internal short and a high reading indicates an open winding. Repair or replace the main field if the ohmmeter readings indicate the main field is inoperative. If the resistance test is inconclusive, perform a megohmmeter test on the main field as described in the next step.

1 B

--

+

6

5

AC

AC

AC

F+

F--

3

1

3

C

2

(AC)

(AC)

A1

B1

C1

B

--

C (AC)

1. Diode terminal

2. Diode terminal

3. Ohmmeter

Figure 8-9 Rectifier Module Test

+

TP-5983-7

4

2

TP-5983-7


2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Armature

6. Exciter field

Figure 8-10 Ohmmeter Connections on

Main Field

3. Check the main field for a short-to-ground condition by using a megohmmeter.

Apply

500 volts DC to either field lead and the main field frame. Follow the megohmmeter manufacturers instructions for using the megohmmeter.

See

Figure 8-11. A reading of 1.5 MOhms and higher indicates the main field is functional. A reading of less than 1.5 MOhms indicates deterioration of the winding insulation and possible current flow to ground; if so, replace the main field.


8

7

AC

F+

AC

AC

F--

1

5

2

3

6

4


2. Stator windings

3. Frame connection

4. Shaft connection

5. Rectifier module

6. Megohmmeter

7. Armature

8. Exciter field

TP-5983-7

Figure 8-11 Megohmmeter Connections on

Main Field

8.9 Stator

The stator consists of a series of coils of wire laid in a laminated steel frame. The stator leads supply voltage to the AC load and exciter regulator.

Before testing the stator, inspect it for heat discoloration and visible damage to the housing lead wires and exposed and varnished areas of the frame laminations.

Be sure the stator is securely fastened in the stator housing.

The stator produces electrical output (AC) as the magnetized main field rotates within the stator windings.

Test the condition of the stator according to the following procedure.

Leads 1, 2, 3, and 4 are the generator output leads.

Leads 55 and 66 are the voltage regulator supply and sensing leads. Refer to the schematic in Figure 8-12 when performing the following tests.

Stator Test Procedure:

1. Place the generator master switch in the OFF position.


3. Check the generator output lead connections. See

Section 10, Wiring Diagrams.

4

3

44

66

55

2

1

11

6196

Figure 8-12 Alternator Stator Leads

4. Disconnect all the stator leads to isolate the windings. To check the stator continuity, set the ohmmeter on the R x 1 scale. Check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 8-12.

See

Figure 8-13 for single-phase and Figure 8-14 for three-phase values. Perform the stator tests on all the stator windings.

Leads

1 and 2

1 and 11

2 and 11

3 and 4

3 and 44

4 and 44

55 and 66

1 and 3, 4, 44, 55, or 66

2 and 3, 4, 44, 55, or 66

3 and 1, 2, 11, 55, or 66

4 and 1, 2, 11, 55, or 66

Any stator lead and ground on stator housing or frame laminations

Continuity

Yes

No

Figure 8-13 Stator Continuity Test Results on a Good

Stator (1-Phase)


Leads

1 and 4

2 and 5

3 and 6

7 and 10

8 and 11

9 and 12

55 and 66

1 and 2, 3, 7, 8, or 9

1 and 55

Any stator lead and ground

Continuity

Yes

No

Figure 8-14 Stator Continuity Test Results on a Good

Stator (3-Phase)

5. Check the cold resistance of the stator windings by connecting the meter leads to the stator leads as shown in Figure 8-13 or Figure 8-14.

See

Section 1, Specifications for the stator resistance values. If the stator resistance test is inconclusive, perform a megohmmeter test on the stator as described in the next step.

Note: Consider the stator functional if the resistance reading (continuity) is low and there is no evidence of shorted windings

(heat discoloration).

Note: When taking an ohmmeter reading using lead 55, make the connection before the in-line fuse.

Note: The stator resistance can vary directly with increased temperature.

If any of the stator readings vary during the previous checks, replace the stator.

6. Check the stator for a short-to-ground condition using a megohmmeter.

See Figure 8-15 for a single-phase megohmmeter connections and

Figure 8-16 for three-phase megohmmeter connections. Apply 500 volts DC to any stator lead from each winding and the stator frame. Follow the megohmmeter manufacturer’s instructions for using the megohmmeter. Repeat the test on the other leads until all of the stator windings have been tested. A reading of 1.5 MOhms and higher indicates the stator is functional. A reading of less than 1.5 MOhms indicates deterioration of the winding insulation and possible current flow to ground; if so, repair or replace the stator.

F1 F2

9

8

AC

AC

AC

F+

F--

5

1

66 55 3 4

2

4 3

1 2

7

6

TP-5983-7

1. ADC’s voltage regulator power supply leads

2. Sensing leads (208--240 volts nominal)

3. Stator windings


5. Rectifier module

6. Frame connection

7. Megohmmeter

8. Armature

9. Exciter field

Figure 8-15 Megohmmeter Connections on 1-Phase

Stator

1

2

F1 F2 9

3

5

8

7

6

4

TP-5983-7

1. ADC’s voltage regulator power supply leads

2. Sensing leads (208--240 volts nominal)

3. Stator windings


5. Rectifier module

6. Frame connection

7. Megohmmeter

8. Armature

9. Exciter field

Figure 8-16 Megohmmeter Connections on 3-Phase

Stator


8.10 Voltage

8.10.1 Voltage Regulation

Voltage regulation is performed by the Advanced Digital

Control (ADC) and the SCR module. The ADC monitors generator output voltage and adjusts the excitation current to the rotor through the SCR module.

8.10.2 Voltage Adjustment

The factory sets the voltage for correct generator operation under a variety of load conditions. Usually, the voltage needs no further adjustment. Adjust the voltage when necessary according to the following procedure.

The adjustment procedure requires a meter that can measure voltage and frequency.

Use the ADC to adjust the voltage, gain, and volts/Hz.

Refer to Section 7 for instructions to adjust each parameter and save the changes using the controller keypad.

Note: The ADC controller will time out and exit the adjustment mode after approximately 1 minute if no buttons are pressed. Any unsaved changes are discarded if the controller times out before the settings are saved.

Refer to Section 7.5 for instructions to save your settings.

Voltage Adjustment.

Adjusts generator output between 100 and 130 volts.

Gain (Stability) Adjustment.

Fine tunes regulator circuitry to reduce light flicker.

Volts/Hz Adjustment. Determines frequency (Hz) at which generator output voltage begins to drop.

The ADC maintains generator output at the specified voltage under load until the generator engine speed drops to a preset level (factory setting 57.5 Hz on 60 Hz models and 47.5 Hz on 50 Hz models). Then the ADC allows the generator voltage and current to drop. The voltage/current drop enables the engine to pick up the load.

When the generator speed returns to normal

(60 Hz or 50 Hz) as load is accepted, the generator output also returns to normal.

WARNING

Hazardous voltage.

Moving parts.



Short circuits.





Voltage Adjustment Procedure

1. Connect a digital voltmeter from one side of the circuit breaker to the L0 terminal. See Figure 8-17 for the L0 terminal location.

Set the meter to measure voltage.

Note: For 120- or 240-volt systems the voltage measured from one side of the breaker to L0 should be approximately 120 VAC.

For

240-volt systems, the voltage measured from one side of the circuit breaker to the other should be approximately 240 VAC.

2. Start the generator set.

3. Follow the ADC instructions in Section 7.5 to enter the adjustment mode and increase voltage or decrease voltage (parameter 1P) until the output reaches the desired voltage.

4. Follow the ADC instructions to step to the voltage gain adjustment menu. Adjust the voltage gain

(parameter 2P) until the light flicker minimizes.

Save the settings.


5

4

1

2

3

Service-Side View

6EOD/4.5EFOD and 8--32EOZD Models, Typical

Earlier Models

Generator-End View

4, 5

(Shown with louvered panel removed)

Later Models

Service-Side View

6EOD/4.5EFOD and 8--24EOZD Models

5. Check and readjust the voltage if necessary.

6. Set the voltmeter to measure frequency. Adjust the engine speed to the cut-in frequency shown in

Figure 8-18 by adjusting the governor as described in Section 4.4.

7. Set the voltmeter to measure voltage. Adjust the volts/Hz (parameter 3P) until the voltage level measured by the voltmeter begins to drop. When set, the generator (as load is applied) attempts to maintain normal output until the engine speed drops below the cut-in frequency set in step 6.

8. Set the voltmeter to measure frequency. Adjust the engine speed to the operating frequency (50 or

60 Hz) by adjusting the engine governor.

9. Readjust the voltage gain (parameter 2P) until the light flicker minimizes, if necessary.

10. Check the voltage.

Readjust the voltage

(parameter 1P), if necessary.

11. Save the settings.

Refer to Section 7.5 for instructions.

Note: The ADC will revert to the previous settings at the next startup if the changes are not saved.

12. Stop the generator set.

Frequency

60 Hz

50 Hz

Cut-In Frequency

57.5 Hz

47.5 Hz

Figure 8-18 Cut-In Frequencies

5

4

Top View

(Shown with junction box cover removed)

28/32EOZD Models

1. Line circuit breaker

2. Circuit breaker mounting hardware

3. Circuit breaker cover plate

4. Load connection terminal L0

5. Ground connection terminal GRD

Figure 8-17 Circuit Breaker and L0 Terminal Location


8.11 Four-Lead Reconnection

The following information illustrates the reconnection of four-lead generator sets. In all cases, conform to the

National Electrical Code (NEC).

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.

8.11.1 100--120-Volt Configurations

If the installation requires a factory two-pole circuit breaker, do not connect the load-side terminals of the circuit breaker together; see Figure 8-19.

If the installation requires a 100--120-volt, 2-wire system, use a single-pole circuit breaker. See Figure 8-20. When connecting stator phase leads together, size the output lead (L1) to handle the amperage. Use a jumper lead on the line side of the circuit breaker to balance the load of the generator set.

8.11.2 100--120/200--240-Volt

Configurations

The 100--120/200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight

100--120 volt, 3-wire, remove the jumper lead (see

Figure 8-19 for location).

Select a two-pole circuit breaker. Application of two single-pole circuit breakers does not conform to NEC requirements for supplying a

200--240-volt load, even if the breakers are mechanically attached together. Leads L1 and L2 are for different phases; never connect them together.

L0 (Neutral)

Ground

Load

Side

Single-Pole

Circuit

Breaker

Line

Side

L0

GRD.

L1

Load

Side

Line

Side

L0 (Neutral)

Ground

L0

GRD.

L1

L2

Two-Pole

Circuit

Breaker

Jumper lead

4 3 2 1

Figure 8-19 100--120-Volt, 3-Wire Configuration

TP-6255 4/10

4 3 2 1

Stator Leads

60 Hz

L0--L1 100--120 Volt

L0--L2 100--120 Volt

50 Hz

100--120 Volt

100--120 Volt

Figure 8-20 100--120-Volt, 2-Wire Configuration

L0 (Neutral)

Ground

L0

GRD.

L1

L2

Load

Side

Line

Side

Factory

Two-Pole

Circuit

Breaker

4 3 2 1

Stator Leads

100--120/200--240-Volt,

3-Wire

60 Hz

L0--L1 100--120 Volt

L0--L2 100--120 Volt

L1--L2 200--240 Volt

50 Hz

100--120 Volt

100--120 Volt

200--240 Volt

Figure 8-21 100--120/200--240-Volt, 3-Wire

Configuration

Section 8 Component Testing and Adjustment 75

8.11.3 200--240-Volt Configurations

The 200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 100--120 volt, 3-wire, remove the jumper lead (see Figure 8-19 for location). See Figure 8-22.

L0 (Neutral)

Load

Side

Ground

Line

Side

L0

GRD.

L1

Single-Pole

Circuit

Breaker

Tape to insulate from ground

4 1 3

Stator Leads

2

200--220--240 Volt

2 Wire

L0--L1

60 Hz 50 Hz

200-240 Volt 200--220--240 Volt

Figure 8-22 200--220--240-Volt, 2-Wire Configuration for Models with ADC 2100

8.12 Twelve-Lead Reconnection

The reconnection procedure following details voltage reconnections only.

If the generator set requires frequency changes, adjust the governor.

The following information illustrates the reconnection of

12-lead generator sets. In all cases, follow the National

Electrical Code (NEC) guidelines.

Reconnect the stator leads of the generator set to change output phase or voltage. Refer to the following procedure and connection schematics. Follow all safety precautions at the front of this manual and in the text during reconnection procedure.

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.

Twelve-Lead Reconnection Procedure

1. Move generator set master switch to OFF/RESET position.

2. Disconnect engine starting battery, negative (--) lead first. Disconnect power to battery charger, if equipped.

3. Use Figure 8-23 to determine generator set voltage configuration.

Note the original voltage and reconnect the generator set as needed.

115/230

115/230

230

Note: Current Transformers (CTs) are not used on all sets. CT dot or “HI” toward generator.

Figure 8-23 Generator Reconnection

76 Section 8 Component Testing and Adjustment

EM-250000

TP-6255 4/10

8.13 Fault Shutdown Tests

Verify the operation of the generator set overspeed, overcrank, and low oil pressure shutdowns by performing the following tests.

If these tests are inconclusive, test individual shutdown circuit components (wiring harness, switch, etc.) as described elsewhere in this section.

WARNING

Hazardous voltage.

Moving parts.





Short circuits.



8.13.1 Controller Fault Shutdown

Functions

Check the operation of the fault functions programmed in the ADC 2100 by performing the following tests. If the

ADC 2100 does not operate as described, check the

ADC configuration settings; see Section 7.5.2. Also check the ADC 2100 wiring and connections; see

Section 10.

Overspeed Shutdown

The overspeed setting is programmed into the ADC controller and is not adjustable. Verify that the following controller configuration parameters are set correctly for your unit. See Section 7.5.2 for the settings.

D System voltage/frequency parameter (UU)

D Unit configuration parameter (UC)

D Engine type parameter (EC)

D Engine data input type parameter (ED)

WARNING

Hot engine and exhaust system.


Do not work on the generator set until it cools.

Servicing the exhaust system.

Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.

Open the generator set output circuit breaker before beginning the test.

(See Figure 8-17 for the circuit breaker location.)

Connect a DVM to measure the output frequency. Start the generator set and manually adjust the engine speed.

See Section 4.4.

Increase the engine speed to at least 115% of the rated engine speed, 69 Hz on 60 Hz models or 58 Hz on 50 Hz models. Verify that the generator set shuts down on an overspeed fault (OS). If the overspeed shutdown does not operate, the generator set should shut down on an overfrequency fault (OF) after approximately 5 seconds.

Low Oil Pressure (LOP) Shutdown

Connect a jumper wire from the LOP switch (lead 13) to the generator set ground. Start the generator set. Verify that the generator set shuts down after approximately

25--35 seconds of operation. Remove the jumper wire from the LOP switch and ground. Start the generator set and run it for at least 25--35 seconds to verify that the generator set does not shut down.

Overcrank Shutdown

Disconnect the starter motor lead at the starter solenoid

(K20) terminal. Move the controller master switch to the

RUN position. Observe that the generator set simulates cranking for 15 seconds and then rests for 15 seconds.

Check that the generator set shuts down after the third crank/rest cycle.

High Engine Temperature Shutdown

Connect a jumper wire across coolant temperature sensor (CTS) connections P1-8 and P1-9. Start the generator set. Verify that the generator set shuts down approximately 5 seconds after the generator set comes up to speed.

Remove the jumper wire.

Start the generator set and run it for at least 30 seconds to verify that the generator set does not shut down.


8.13.2 Fault Shutdown Switches

Check the low oil pressure and high engine temperature shutdown switches on the engine by performing the following tests.

If the sensor does not function as described, replace it.

WARNING

replacing the LOP switch.

To test the LOP switch, reinstall the switch and start the generator set. If the unit shuts down, disconnect lead 13 from the LOP switch and reset the controller. Restart the generator set and verify that it does not shut down. A successful restart indicates a bad LOP switch. Replace the switch.

1

Hazardous voltage.

Moving parts.





Short circuits.



Temperature Sensor (CTS)

The coolant temperature sensor (CTS) is used to monitor engine temperature for the high engine temperature fault shutdown (HE). See Figure 8-24 for the coolant temperature sensor location.

Set the generator set master switch to the OFF position and allow the generator set to cool. Disconnect the CTS and use an ohmmeter to measure the resistance across the sensor. The sensor resistance varies with temperature and should be within the values shown in Figure 8-25. If the resistance is very low (indicated a short circuit) or very high (indicating an open circuit) replace the CTS.

Low Oil Pressure (LOP) Switch

See Figure 8-26 for the low oil pressure (LOP) switch location.

Remove the LOP switch and install an oil pressure gauge to verify that the engine oil pressure is within the range specified in Figure 8-27 before testing or

1. Coolant Temperature Sensor

Figure 8-24 Coolant Temperature Sensor Location

(8EOZD Model Shown)

Temperature, _C (_F)

30 (86)

100 (212)

Resistance, Ohms

2106--2392

182--198

Figure 8-25 Coolant Temperature Sensor Resistance

Readings (All Models)

1

1. Oil pressure switch

Figure 8-26 Oil Pressure Switch Location

(24EOZD Model Shown)

Model

8--32EOZD and 6.5--28EFOZD

6EOD and 4.5EFOD

Figure 8-27 Oil Pressure Range

Oil Pressure Range

MPa (kg/cm

2

)

0.29--0.39 (3--4)

0.21--0.41 (2.1--4.2)


8.14 Fuses

The engine harness (or junction box for 6EOD/4.5EFOD

and 9EOZD/7EFOZD models) contains three inline fuses. See Figure 8-28.

Always identify and correct the cause of a blown fuse before restarting the generator set. Refer to Section 6,

Troubleshooting, for conditions that may indicate a blown fuse.

Replace blown fuses with identical replacement parts.

Fuse

Auxiliary Winding,

10 amps

Relay Interface Board,

10 amps

Controller, 10 amps

Label

F1

F2

F3

Part

Number Location

358337 Lead 55

223316 Lead PF2

223316 Lead PF3

* See Figure 8-29 for 6EOD/4.5EFOD and 9EOZD/7EFOZD models fuse location.

Figure 8-28 Fuses

6EOD/4.5EFOD Model

1

9EOZD/7EFOZD Model

ADV7093A-A

8.15 Continuity Checks

WARNING

Hazardous voltage.

Moving parts.



Short circuits.



To further check generator set components, disconnect the battery and remove wiring harness plugs from the

ADC circuit board.

Use an ohmmeter to check the continuity of the components listed in Figure 8-31. Also see Section 10, Wiring Diagrams.

Figure 8-31 gives resistance readings for functional components. A zero reading on the ohmmeter indicates continuity. No ohmmeter reading indicates very high resistance or an open circuit.

A measurement that varies significantly from the value shown in the table indicates a faulty component; replace faulty components.

Note: Disconnect the generator set battery before performing continuity checks to prevent damage to the ohmmeter.

Back View

Zero ohms (continuity) across RUN and VBAT terminals

3 2 1

Master Switch in

RUN Position

Back View

Zero ohms (continuity) across

VBAT and AUTO terminals

3 2 1

ADV6967-A

1

1. Fuses

Figure 8-29 Fuse Location on 6EOD/4.5EFOD and

9EOZD/7EFOZD Models

TP-6255 4/10

Master Switch in

AUTO Position

Figure 8-30 Generator Master Switch Continuity Check

Section 8 Component Testing and Adjustment 79

Component

Generator set master switch

P1 wiring harness

Controller fuse and wiring

Auxiliary winding fuse

10 amp fuse

Low oil pressure (LOP) switch *

Temperature sensor

(CTS) *

Aux. run relay (K5)

Ohmmeter

Connections

RUN and VBAT

(See Figure 8-30)

AUTO and VBAT

(See Figure 8-30)

P1-27 and ground

P15-1 and P15-3

(stator leads 11 and 44 for

1-phase models) or

P15-1, P15-2, and P15-3

(stator leads 7, 8, and 9 for

3-phase models)

P16-3 and P16-6 (stator leads 55 and 66)

P1-24 and battery positive

(+)

P16-3 and stator lead 55

Lead 13 and ground

(engine block)

P1-8 and P1-9

Terminals 85 and 86

Ohmmeter

Scale

R x 100

R x 100

R x 1

R x 1

Generator Set

Master Switch

Position

RUN

OFF/RESET

AUTO

OFF/RESET

OFF/RESET

OFF/RESET

Ohmmeter Readings for Operative

Components*

Zero ohms (continuity). Any other reading indicates a bad switch.

No reading (open circuit). Any other reading indicates a bad switch.

Zero ohms (continuity). Any other reading indicates a bad switch.

No reading (open circuit). Any other reading indicates a bad switch.

Zero ohms (continuity)

Any other reading indicates a poor ground connection.

Zero ohms (continuity). If no continuity, check wiring.

R x 1

R x 100

R x 100

R x 100

R x 1000

R x 1

OFF/RESET

OFF/RESET

OFF/RESET

OFF/RESET

OFF/RESET

OFF/RESET

Zero ohms (continuity). If no continuity, check fuse F1 and wiring.

Zero ohms (continuity). If no continuity is found, check fuse F3 and wiring.

Zero ohms (continuity). If no continuity is found, check for an open circuit and/or a blown fuse.

Zero ohms (continuity). No continuity indicates a bad switch and/or wiring.

180--2500 ohms, depending on engine temperature. Zero ohms or an open circuit indicates bad wiring or a bad switch.

12-volt relay: 85

±5 ohms coil resistance

24-volt relay: 305 ±15 ohms coil resistance

Lower resistance indicates a shorted relay coil and/or wiring. High resistance indicates an open relay coil and/or wiring.

* See Section 8.13.2, Fault Shutdown Switches

Figure 8-31 Continuity Checks


Section 9 Generator Disassembly/Reassembly

9.1 Disassembly

Disconnect all of the external connections—battery cables at the battery (negative (--) lead first), AC-output leads, remote interface connector, water line at the seawater pump, fuel line at the fuel pump filter inlet, and exhaust line at the mixing elbow. Observe all of the safety precautions listed at the beginning of this manual during the disassembly/reassembly procedures.

Note: Because this manual covers several models, the procedure for disassembly may vary because of product updates and the assembly variations.

Disassembly Procedure:


2. Disconnect power to the battery charger, if equipped.


WARNING

Sound Shield Equipped Models: For access to the generator set to perform regular maintenance, remove the sound shield doors and roof.

4. Sound-Shielded Models: Open the service-side door.

5. Sound-Shielded Models: Release the two quarter-turn fasteners located underneath the roof.

See Figure 9-1.

6. Sound-Shielded Models: Lift up the roof.

7. Sound-Shielded Models: Slide the roof towards the service side of the unit for removal.

8. Sound-Shielded Models: Open the front, rear, and non-service side doors as needed.

2

1

2






3

4

1. Sound shield roof

2. Quarter-turn fastener

3. Alternator-end door

4. Service-side door

5. Front rail

6. Engine-end door

5

Figure 9-1 Sound Shield Roof Removal

6

TP-6255 4/10 Section 9 Generator Disassembly/Reassembly

81

9. Disconnect wiring harness plugs P1, P15, and P16 from the ADC 2100.

10. Loosen and remove the four controller mounting screws at the front of the controller.

See

Figure 9-2. Remove the controller.

3

1

2

1

4

6

5

8

7 tp6196

1. Controller mounting screws (4 ea.)

Figure 9-2 ADC 2100 Mounting Screws

11. Remove the junction box louvered panel.

See

Figure 9-3 and Figure 9-4.

1

2


2. SCR module (mounted behind ADC 2100 on

6EOD/4.5EFOD models)

3. Relay board

4. Engine harness-to-controller connection


6. ADC 2100

7. Line circuit breaker plate

8. Junction box

Figure 9-4 Advanced Digital Control (ADC 2100)

12. Remove the junction box, SCR module, and relay board as necessary. See Figure 9-4.

1. ADC 2100


Figure 9-3 Covers

82

Section 9 Generator Disassembly/Reassembly TP-6255 4/10

13. Disconnect the FP and FN leads.

14. 8--32EOZD/6.5--28EFOZD Models: Remove the four bolts to remove the exciter field.

See

Figure 9-5.

1

2

558864

1. Bolts (4)

2. Exciter field

Figure 9-5 Exciter Field Removal

15. 8--32EOZD/6.5--28EFOZD Models: Remove the three bolts and spacers from the rectifier board.

16. 8--32EOZD/6.5--28EFOZD Models: Disconnect the main field rotor leads from the rectifier board positive/negative terminals. Remove the armature retaining bolt and washer. See Figure 9-6.

17. 8--32EOZD/6.5--28EFOZD Models: Remove the armature from the shaft, guiding the rotor leads through the armature bores. See Figure 9-6.

18. 6EOD/4.5EFOD Model: Remove the four screws to remove the brush holder cover and brush cover gasket.

19. 6EOD/4.5EFOD Model: Push the brushes into the holder. Secure the brushes into position by sliding a retainer into the brush keeping holder.

See

Section 8.6.

20. 6EOD/4.5EFOD Model: Remove the brush holder and carefully pull the leads out of the stator housing.

21. Attach a hoist hook to the generator lifting eye. See

Figure 9-7.

Note: The hoist capacity rating should be one-half ton or greater.

22. Remove the two vibromount bolts. See Figure 9-7.

23. Raise the alternator end and place a wood block under the locator plate. Lower the alternator until the wood block supports the backplate.

See

Figure 9-7.

24. Remove the four overbolts from the end bracket.

1

2

3

4

3

2

1. Lifting eye

2. Backplate

3. Wood block

4. Vibromounts

Figure 9-7 Supporting the Generator, Typical

558866

1

4

1. Armature

2. Armature retaining bolt

3. Rotor leads

4. Rectifier board

Figure 9-6 Armature Removal

558865


83

25. Install a sling capable of handling the weight of the stator housing on the stator housing.

See

Figure 9-8.

26. Use a two-jaw puller to pull the end bracket/stator assembly from the bearing on the rotor shaft. See

Figure 9-8.

27. Remove the stator assembly from the rotor.

Remove or rotate the fan guard, if necessary, to clear the vibromounts.

28. Mark the fan’s position on the rotor/drive disc assembly with a permanent marker.

29. Remove the four screws with spacers and the four screws without spacers. See Figure 9-9.

30. Remove the fan and fan spacers. See Figure 9-9.

31. Remove the eight bolts and remove the drive disc/rotor assembly from the engine flywheel. See

Figure 9-10.

32. Clamp the rotor in a soft-jaw vise. Remove the eight bolts and remove the drive disc assembly from the rotor. See Figure 9-11.

1

1. Fan

2. Screws with spacers (4)

3. Screws without spacers (4)

Figure 9-9 Fan Removal

1

2

2

3

558868

1

2

3

1. Sling

2. Fan guard

3. Two-jaw puller

Figure 9-8 Stator Assembly Removal

558867

1. Bolts (8)

2. Rotor assembly

Figure 9-10 Disc/Rotor Assembly

1

2

558869

3

5588610

1. Drive disc

2. Rotor

3. Bolt

Figure 9-11 Drive Disc

84


9.2 Collector Ring and Bearing

Replacement (6EOD/4.5EFOD

Model)

1. Unsolder the collector ring leads from the collector ring terminals.

2. Remove the collector rings with a three-jaw puller.

3. Remove the bearing with a three-jaw puller.

4. Press the new bearing onto the rotor shaft.

5. Align the collector ring keyway with the keyway on the rotor shaft. See Figure 9-13.

6. Press the new collector rings onto the rotor shaft.

Note: The new collector rings must be turned down to a finish of 32 micro inches using a lathe and commutator stones.

Turn down the collector rings on the rotor shaft.

7. Solder the leads onto the collector ring terminals.

The connection is not to exceed 9.65 mm (0.38 in.) beyond the collector rings. See Figure 9-13.

8. Test to ensure continuity at the collector rings.

Min. diameter mm (in.)

Max. finish

Max. eccentricity mm (in.)

Max. out-of-round mm (in.)

57.15 (2.250)

32 micro inches

0.08 (0.003)

0.01 (0.0002)

Figure 9-12 Collector Ring Dimensions

View A-A

A

A

1

2

598695

1. Collector ring

Figure 9-13 Rotor Assembly

9.3 Reassembly

1. Clamp the rotor in a soft-jaw vise. Install a new drive disc on the rotor. Tighten the eight bolts to

38 Nm (28 ft. lbs.) See Figure 9-14.

1

3

1. Drive disc

2. Rotor

3. Bolt

Figure 9-14 Drive Disc Installation

5588611


85

2. Install the rotor/drive disc assembly on the engine flywheel using eight washers and bolts. Tighten the bolts to 19 Nm (14 ft. lbs.)

3. Align the fan to the rotor/drive disc assembly using the mark created in the disassembly procedure.

Install the fan to the drive disc using eight screws, four spacers, washers, and locknuts.

Note: Install the fan with the flange side facing away from the flywheel.

4. Replace the O-ring in the end bracket bearing bore.

Use a sling to support the stator assembly while installing the stator over the rotor. Do not damage the rotor. See Figure 9-15.

1. O-ring

1

Figure 9-15 Stator Installation

5. Install the four overbolts (the two long bolts in the lower holes). Check that the alignment marks on the stator housing and locator plate match. See

Figure 9-16.

Tighten the overbolts to 34 Nm

(25 ft. lbs.).

1

5588612

6. Use the hoist to raise the alternator end. Remove the wood block from under the locator plate. Lower the generator set and install a bolt, a large washer, two small washers, and a locknut on each vibromount. Tighten the mounting bolts to 28 Nm

(20 ft. lbs.).

7. Apply antiseize compound to the keyed end of the rotor shaft. Bring the rotor leads through the bores in the armature while installing the armature on the shaft. Check the keyway of the shaft and key of the armature for damage.

Install the armature retaining bolt and washer.

8. 6EOD/4.5EFOD Model: Feed the brush leads inside the stator housing up through the opening.

Secure the brush holder using the original screws.

9. 6EOD/4.5EFOD Model: Remove the brush retainer and check alignment. See Section 8.6.

10. Use screws and lock washers to install the rotor leads to the rectifier board at the positive (+) and negative (--) terminals.

Note: Position the lock washers against the rectifier board.

11. 6EOD/4.5EFOD Model: Replace the brush cover gasket and install the brush holder cover.

12. Install the three spacers and bolts to mount the relay board.

13. Install the SCR module and junction box.

14. 8--23EOZD and 6.5--20EFOZD Models: Position the field leads at the top. Install the exciter field using four bolts and washers. See Figure 9-17.

1

2

1. Alignment marks

Figure 9-16 Alignment Marks

86

Section 9 Generator Disassembly/Reassembly

5588613

5588614

1. Exciter field bolts (4)

2. Exciter field

Figure 9-17 Installing Exciter Field (8--23EOZD and

6.5--20EFOZD Models0

TP-6255 4/10

15. Install tie wraps to secure the wires as necessary.

16. Reconnect the leads to the circuit breaker and neutral stud (LO) as marked during disassembly.

Note: Check the generator set nameplate to verify the original voltage configuration.

17. Reconnect the P1, P15, and P16 connectors.

Connect the ground strap using bolt, washer, and lock washer (install the lock washer against the ground strap).

18. Reinstall the ADC 2100.

19. Reinstall the junction box louvered panel.

20. Reconnect all of the external connections—the exhaust line to the mixing elbow, the fuel line to the fuel pump filter inlet, the water line to the seawater pump, the remote interface connector, the AC output leads, and the battery cables to the battery

(negative (--) lead last).

21. Verify that the generator set master switch is in the

OFF position.

22. Reconnect the engine starting battery, negative (--) lead last.


24. Replace the sound shield roof and door(s), if equipped.


87

Notes

88


Section 10 Wiring Diagrams

WARNING WARNING












10.1 Wiring Diagram Reference

Figure 10-1 and Figure 10-2 lists the wiring diagram numbers and locations.

Hazardous voltage.

Moving parts.





Model

6EOD

4.5EFOD

9EOZD

7EFOZD

8EOZD,

10--32EOZD,

6.5EFOZD,

8.5--27EFOZD

Wiring

Diagram

GM46351

Figure

GM42202-F Figure 10-3

Figure 10-6

GM30264-H Figure 10-7

Schematic

ADV-7095A-D

ADV-7095B-D

Figure

Figure 10-4

Figure 10-5

ADV-6845A-F

ADV-6845B-F

Figure 10-8

Figure 10-9

Accessory

Diagram Figure

GM33846-C Figure 10-10

Figure 10-1 Wiring Diagrams For All Specs Except If Listed in Figure 10-2

Model

9EOZD

7EFOZD

Specs

GM55351-GA1 to --GA2

10--32EOZD,

8.5--28EFOZD

GM55350--GA1 to -GA8

GM55349-GA1 to -GA12



Figure 10-2 Wiring Diagrams

Wiring

Diagram Figure Schematic Figure

Accessory

Diagram Figure



ADV-7283A-C

ADV-7283B-C

Figure 10-13

Figure 10-14


TP-6255 4/10 Section 10 Wiring Diagrams 89

Figure 10-3 Wiring Diagram for Model 6EOD/4.5EFOD

90 Section 10 Wiring Diagrams

GM42202-F

TP-6255 4/10

Figure 10-4 Schematic for Model 6EOD/4.5EFOD; Sheet 1 of 2

TP-6255 4/10

ADV7095A-D

Section 10 Wiring Diagrams 91

Figure 10-5 Schematic for Model 6EOD/4.5EFOD; Sheet 2 of 2


ADV7095B-D

TP-6255 4/10

Figure 10-6 Wiring Diagram for Model 9EOZD/7EFOZD

TP-6255 4/10

GM46351-


Figure 10-7 Wiring Diagram for Models 8EOZD, 10--32EOZD, 6.5EFOZD, and 8.5--27EFOZD


GM30264-H

TP-6255 4/10

ADV6845A-F

Figure 10-8 Schematic for Models 8--32EOZD and 6.5--27EFOZD; Sheet 1 of 2


Figure 10-9 Schematic for Models 8--32EOZD and 6.5--27EFOZD; Sheet 2 of 2


ADV6845B-F

TP-6255 4/10

Figure 10-10 Accessory Diagram

TP-6255 4/10

GM33846-C


GM50490-C

Figure 10-11 Wiring Diagram for Model 9EOZD/7EFOZD (see Figure 10-2 for applicable specs)

98 Section 10 Wiring Diagrams TP-6255 4/10

GM50488-C

Figure 10-12 Wiring Diagram for Model 10--32EOZD/8.5--28EFOZD (see Figure 10-2 for applicable specs)


ADV7283A-C

Figure 10-13 Schematic for Model 9--32EOZD/7--28EFOZD; Sheet 1 of 2 (see Figure 10-2 for applicable specs)


ADV7283A-C

Figure 10-14 Schematic for Model 9--32EOZD/7--28EFOZD; Sheet 2 of 2 (see Figure 10-2 for applicable specs)


10.2 Manual Marine (Ship-to-Shore) 2 Wire and 3 Wire Transfer Switches

Electro Switch

2-Wire Generator Sets

L1

To Generator

Set

L2

2

6

1

5 7

To Load

3 4

To Shore

Power

8

L1

2

L2

To Generator

Set

L0

6

10


1 3 4

5 7

9 11

To Load

8 To Shore

Power

12

Kraus Naimler/American Solenoid

(Early Rectangular Design)

2-Wire Generator Sets 3-Wire Generator Sets

L1

To Generator

Set

L2

1

3

2

4 8

6 5

To Shore

Power

7

L1

1

L2

To Generator

Set

L0

3

9

2

4 8

10 14

6 5

7 To Shore

Power

13

To Load

To Load

L1

To Generator

Set

L2

3

7


Kraus Naimler/American Solenoid

(Newer Round Design)


L1

2 4 1

To Shore

Power

3 2 4

6 8 5

L2

To Generator

Set

L0

7

11

6

10 12

8

To Load

To Load

1

5

To Shore

Power

9

TP-5399-5


10.3 Manual Marine (Ship-to-Shore) 4 Wire Transfer Switch

To Generator

Set

L1

Kraus Naimer/American Solenoid

4-Wire, three phase

Generator Sets

3 2 4 1

L2

7 6 8 5

L3

11 10 12 9

L0

15 14 16 13

L1

L2

To Shore

Power

L3

L0

L1 L2 L3 L0

To Load

I-940


Notes


Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere

ABDC after bottom dead center

AC

A/D alternating current analog to digital

ADC adj.

ADV

AHWT analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature

AISI

ALOP alt.

Al

ANSI

AO

API approx.

approximate, approximately

AR

AS as required, as requested as supplied, as stated, as suggested

ASE

ASME assy.

ASTM

American Society of Engineers

American Society of

Mechanical Engineers assembly

ATDC

ATS auto.

aux.

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

American Society for Testing

Materials after top dead center automatic transfer switch automatic auxiliary

A / V avg.

AVR

AWG

AWM bat.

BBDC

BC audiovisual average automatic voltage regulator

American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging

BCA

BCI

BDC

BHP battery charging alternator

Battery Council International before dead center brake horsepower blk.

black (paint color), block

(engine) blk. htr.

block heater

CARB

CB cc

CCA ccw.

CEC cfh cfm

BMEP bps br.

BTDC brake mean effective pressure bits per second brass before top dead center

Btu British thermal unit

Btu/min.

British thermal units per minute

C cal.

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

CT

Cu cu. in.

cw.

CWC cyl.

D/A

DAC dB dBA

DC

DCR deg.,

° dept.

dia.

DI/EO

DIN

CG

CID

CL cm

CMOS cogen.

Com conn.

cont.

CPVC crit.

CRT

CSA 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)

DIP

DPDT

DPST

DS dual inline package double-pole, double-throw double-pole, single-throw disconnect switch

DVR digital voltage regulator

E, emer.

emergency (power source)

EDI

EFR electronic data interchange emergency frequency relay e.g.

EG

EGSA

EIA for example (exempli gratia) electronic governor

Electrical Generating Systems

Association

Electronic Industries

Association

EI/EO

EMI emiss.

eng.

EPA

EPS

ER

ES

ESD est.

E-Stop etc.

exh.

ext.

F 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

TP-6255 4/10 fglass.

FHM fl. oz.

flex.

freq.

FS ft.

ft. lbs.

ft./min.

g ga.

gal.

gen.

genset

GFI 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

HD

HET hex

Hg

HH

HHC

HP hr.

HS hsg.

HVAC

GND, gov.

gph gpm gr.

GRD ground governor gallons per hour gallons per minute grade, gross equipment ground gr. wt.

gross weight

H x W x D height by width by depth

HC

HCHT 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

J

JIS k

K kA

KB

HWT

Hz

IC

ID

IEC

IEEE

IMS in.

improved motor starting inch in. H 2 in. Hg

O inches of water inches of mercury in. lbs.

inch pounds

Inc.

ind.

incorporated industrial int.

internal int./ext.

internal/external

I/O

IP

ISO high water temperature hertz (cycles per second) integrated circuit inside diameter, identification

International Electrotechnical

Commission

Institute of Electrical and

Electronics Engineers input/output iron pipe

International Organization for

Standardization joule

Japanese Industry Standard kilo (1000) kelvin kiloampere kilobyte (2

10 bytes)

Appendix 105

kg kg/cm

2 kilogram kilograms per square centimeter kgm kg/m

3 kHz kJ kilogram-meter kilograms per cubic meter kilohertz kilojoule km kilometer kOhm, k

Ω kilo-ohm kPa kilopascal kph kilometers per hour kV kVA kVAR kW kWh kWm

L

LAN kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical liter local area network

L x W x H length by width by height lb.

lbm/ft

3 pound, pounds pounds mass per cubic feet

LCB

LCD line circuit breaker liquid crystal display ld. shd.

load shed

LED light emitting diode

Lph

Lpm

LOP

LP liters per hour liters per minute low oil pressure liquefied petroleum

LPG

LS liquefied petroleum gas left side

L wa

LWL

LWT sound power level, A weighted low water level low water temperature m

M meter, milli (1/1000) mega (10

6 when used with SI m

3 m

3 units), male cubic meter

/min.

cubic meters per minute mA milliampere

MOV

MPa mpg mph

MS m/sec.

MTBF

MTBO mtg.

man.

max.

MB

MCM

MCCB manual maximum megabyte (2

20 bytes) one thousand circular mils molded-case circuit breaker meggar megohmmeter

MHz mi.

megahertz mile mil min.

misc.

MJ one one-thousandth of an inch minimum, minute miscellaneous megajoule mJ millijoule mm millimeter mOhm, m

Ω milliohm

MOhm, M

Ω megohm metal oxide varistor megapascal miles per gallon miles per hour military standard meters per second mean time between failure mean time between overhauls mounting

MW megawatt mW

μF milliwatt microfarad

N, norm.

normal (power source)

NA not available, not applicable nat. gas natural gas

NBS

NC

National Bureau of Standards normally closed

NEC

NEMA

National Electrical Code

National Electrical

Manufacturers Association

NFPA National Fire Protection

Association newton meter Nm

NO normally open no., nos.

number, numbers

NPS

NPSC

NPT

National Pipe, Straight

National Pipe, Straight-coupling

National Standard taper pipe thread per general use

NPTF

NR ns

OC

OD

OEM

OF opt.

OS

OSHA

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

OV oz.

p., pp.

PC

PCB pF overvoltage ounce page, pages personal computer printed circuit board picofarad psi pt.

PTC

PTO

PVC qt.

qty.

R rad.

RAM

RDO ref.

rem.

RFI

RH

RHM rly.

PF ph., power factor

∅ phase

PHC

PHH

Phillips head crimptite (screw)

Phillips hex head (screw)

PHM

PLC

PMG pot ppm

PROM pan head machine (screw) programmable logic control permanent-magnet generator potentiometer, potential parts per million programmable read-only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement (emergency) power source radiator, radius random access memory relay driver output reference remote radio frequency interference round head round head machine (screw) relay

VAC

VAR

VDC

VFD

VGA

VHF

W

WCR w/ w/o wt.

xfmr rms rnd.

ROM rot.

rpm

RS

RTV

SAE scfm

SCR s, sec.

SI root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization

Society of Automotive

Engineers standard cubic feet per minute silicon controlled rectifier second

Systeme international d’unites,

International System of Units

UF

UHF

UL

UNC

UNF univ.

US

UV

V

TDOE

TDON temp.

term.

TIF

TIR tol.

turbo.

typ.

SI/EO sil.

SN

SPDT side in/end out silencer serial number single--pole, double--throw

SPST single--pole, single--throw spec, specs specification(s) sq.

sq. cm sq. in.

SS std.

stl.

tach.

TD

TDC

TDEC

TDEN

TDES

TDNE square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency

Underwriter’s Laboratories, Inc.

unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer

106 Appendix TP-6255 4/10

Appendix B Common Hardware Application Guidelines

Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made.

Bolt/Screw Length: When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method.

Washers and Nuts: Use split lock washers as a bolt locking device where specified. Use SAE flat washers with whiz nuts, spiralock nuts, or standard nuts and preloading (torque) of the bolt in all other applications.

See General Torque Specifications and other torque specifications in the service literature.

Preferred Nut/Bolt Clearance

1 2

Steps for common hardware application

1. Determine entry hole type: round or slotted.

2. Determine exit hole type: fixed female thread (weld nut), round, or slotted.

For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter, or

1/2 inch in diameter or less.

Hardware that is greater than 1/2 inch in diameter takes a standard nut and SAE washer. Hardware 1/2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut. See the diagram below.

3. Follow these SAE washer rules after determining exit hole type: a. Always use a washer between hardware and a slot.

b. Always use a washer under a nut (see 2 above for exception).

c. Use a washer under a bolt when the female thread is fixed (weld nut).

4. Refer to the diagram below, which depicts the preceding hardware configuration possibilities.

Unacceptable Nut/Bolt Clearance

3

1

2

3

G-585

1. 1/2 of bolt diameter

2. Minimum 1 full thread beyond top of nut

3. Below top of nut

Figure 1 Acceptable Bolt Lengths

5

6

4

1. Cap screw

2. Entry hole types

3. Standard nut and SAE washer

4. Whiz nut or spiralock: up to 1/2 in. dia. hardware

5. Weld nuts: above 1/2 in. dia. hardware

6. Exit hole types

Figure 2 Acceptable Hardware Combinations

G-585

TP-6255 4/10 Appendix 107

Appendix C General Torque Specifications

Use the following torque specifications when service literature instructions give no specific torque values.

The charts list values for new plated, zinc phosphate, or oiled threads. Increase values by 15% for nonplated threads. All torque values are +0%/--10%.

American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel

Size

Torque

Measurement

7/16-14

7/16-20

1/2-13

1/2-20

9/16-12

9/16-18

5/8-11

5/8-18

3/4-10

3/4-16

1-8

1-12

8-32

10-24

10-32

1/4-20 in. lbs. (Nm) in. lbs. (Nm) in. lbs. (Nm) in. lbs. (Nm)

1/4-28 in. lbs. (Nm)

5/16-18 in. lbs. (Nm)

5/16-24 in. lbs. (Nm)

3/8-16 ft. lbs. (Nm)

3/8-24 ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm) ft. lbs. (Nm)

Grade 2 Grade 5 Grade 8

16 (1.8) 20 (2.3)

26 (2.9) 32 (3.6)

—

—

26 (2.9) 32 (3.6) —

60 (6.8) 96 (10.8) 132 (14.9)

72 (8.1) 108 (12.2) 144 (16.3)

120 (13.6) 192 (21.7) 264 (29.8)

132 (14.9) 204 (23.1) 288 (32.5)

18 (24) 28 (38) 39 (53)

20 (27) 31 (42) 44 (60)

29 (39) 44 (60) 63 (85)

32 (43) 50 (68) 70 (95)

44 (60) 68 (92) 96 (130)

49 (66) 76 (103) 108 (146)

60 (81) 98 (133) 138 (187)

67 (91) 109 (148) 154 (209)

83 (113) 135 (183) 191 (259)

94 (128) 153 (208) 216 (293)

147 (199) 240 (325) 338 (458)

164 (222) 268 (363) 378 (513)

191 (259) 532 (721) 818 (1109)

209 (283) 582 (789) 895 (1214)

Assembled into

Aluminum

Grade 2 or 5

—

—

—

—

—

—

—

—

—

—

—

—

16 (1.8)

26 (2.9)

26 (2.9)

60 (6.8)

72 (8.1)

120 (13.6)

132 (14.9)

18 (24)

20 (27)

Metric Fasteners Torque Specifications, Measured in ft. lbs. (Nm)

Assembled into Cast Iron or Steel

Size (mm) Grade 5.8

Grade 8.8

Grade 10.9

M6 x 1.00

M8 x 1.25

4 (5.6) 7 (9.9) 10 (14)

10 (13.6) 18 (25) 26 (35)

M8 x 1.00

16 (21) 18 (25) 26 (35)

M10 x 1.50

20 (27) 35 (49) 50 (68)

M10 x 1.25

29 (39) 35 (49) 50 (68)

M12 x 1.75

35 (47) 61 (83) 86 (117)

M12 x 1.50

48 (65) 65 (88) 92 (125)

M14 x 2.00

55 (74) 97 (132) 136 (185)

M14 x 1.50

74 (100) 103 (140) 142 (192)

M16 x 2.00

85 (115) 148 (200) 210 (285)

M16 x 1.50

104 (141) 155 (210) 218 (295)

M18 x 2.50

114 (155) 203 (275) 288 (390)

M18 x 1.50

145 (196) 225 (305) 315 (425)

Assembled into

Aluminum

Grade 5.8 or 8.8

—

—

—

—

—

—

4 (5.6)

10 (13.6)

16 (21)

20 (27)

29 (39)

—

—


Appendix D Common Hardware Identification

Screw/Bolts/Studs

Head Styles

Hex Head or Machine Head

Hex Head or Machine Head with Washer

Flat Head (FHM)

Round Head (RHM)

Nuts

Nut Styles

Hex Head

Lock or Elastic

Square

Cap or Acorn

Pan Head

Hex Socket Head Cap or

Allen t Head Cap

Hex Socket Head or Allen t

Head Shoulder Bolt

Sheet Metal Screw

Stud

Drive Styles

Hex

Wing

Washers

Washer Styles

Plain

Split Lock or Spring

Spring or Wave

External Tooth Lock

Internal Tooth Lock

Hex and Slotted

Phillips r

Slotted

Internal-External Tooth Lock

Hex Socket

Allen t head screw is a trademark of Holo-Krome Co.

Phillips r screw is a registered trademark of Phillips Screw Company.

Sample Dimensions

American Standard (Screws, Bolts, Studs, and Nuts)

1/4-20 x 1

Length In Inches (Screws and Bolts)

Threads Per Inch

Major Thread Diameter In Fractional Inches Or Screw Number Size

Metric (Screws, Bolts, Studs, and Nuts)

M8-1.25 x 20

Length In Millimeters (Screws and Bolts)

Distance Between Threads In Millimeters

Major Thread Diameter In Millimeters

Hardness Grades

American Standard

Grade 2

Grade 5

Grade 8

Grade 8/9 (Hex Socket

Head)

Metric

Number stamped on hardware; 5.8 shown

5.8

Plain Washers

9/32 x 5/8 x 1/16

Thickness

External Dimension

Internal Dimension

Lock Washers

5/8

Internal Dimension


Appendix E Common Hardware List

The Common Hardware List lists part numbers and dimensions for common hardware items.

American Standard

Part No.

Dimensions

Hex Head Bolts (Grade 5)

X-125-33

X-125-23

X-125-3

X-125-31

X-125-5

X-125-24

X-125-34

X-125-25

X-125-26

230578

X-125-29

X-125-27

X-125-28

X-125-22

X-125-32

X-125-35

X-125-36

X-125-40

X-465-17

X-465-6

X-465-2

X-465-16

X-465-18

X-465-7

X-465-8

X-465-9

X-465-10

X-465-11

X-465-12

X-465-14

X-465-21

X-465-25

X-465-20

X-125-43

X-125-44

X-125-30

X-125-39

X-125-38

X-6238-2

X-6238-10

X-6238-3

X-6238-11

X-6238-4

X-6238-5

X-6238-1

X-6238-6

X-6238-17

X-6238-7

X-6238-8

X-6238-9

X-6238-19

X-6238-12

X-6238-20

X-6238-13

X-6238-18

X-6238-25

1/4-20 x .38

1/4-20 x .50

1/4-20 x .62

1/4-20 x .75

1/4-20 x .88

1/4-20 x 1.00

1/4-20 x 1.25

1/4-20 x 1.50

1/4-20 x 1.75

1/4-20 x 2.00

1/4-20 x 2.25

1/4-20 x 2.75

1/4-20 x 5.00

1/4-28 x .38

1/4-28 x 1.00

5/16-18 x .50

5/16-18 x .62

5/16-18 x .75

5/16-18 x .88

5/16-18 x 1.00

5/16-18 x 1.25

5/16-18 x 1.50

5/16-18 x 1.75

5/16-18 x 2.00

5/16-18 x 2.25

5/16-18 x 2.50

5/16-18 x 2.75

5/16-18 x 3.00

5/16-18 x 4.50

5/16-18 x 5.00

5/16-18 x 5.50

5/16-18 x 6.00

5/16-18 x 6.50

5/16-24 x 1.75

5/16-24 x 2.50

5/16-24 x .75

5/16-24 x 2.00

5/16-24 x 2.75

3/8-16 x .62

3/8-16 x .75

3/8-16 x .88

3/8-16 x 1.00

3/8-16 x 1.25

3/8-16 x 1.50

3/8-16 x 1.75

3/8-16 x 2.00

3/8-16 x 2.25

3/8-16 x 2.50

3/8-16 x 2.75

3/8-16 x 3.00

3/8-16 x 3.25

3/8-16 x 3.50

3/8-16 x 3.75

3/8-16 x 4.50

3/8-16 x 5.50

3/8-16 x 6.50

Part No.

Dimensions

Hex Head Bolts, cont.

X-6238-14

X-6238-16

X-6238-21

X-6238-22

X-6024-5

X-6024-2

X-6024-8

X-6024-3

X-6024-4

X-6024-11

X-6024-12

X-129-15

X-129-17

X-129-18

X-129-19

X-129-20

X-129-21

X-129-22

X-129-23

X-129-24

X-129-25

X-129-27

X-129-29

X-129-30

X-463-9

X-129-44

X-129-51

X-129-45

X-129-52

X-6021-3

X-6021-4

X-6021-2

X-6021-1

273049

X-6021-5

X-6021-6

X-6021-7

X-6021-12

X-6021-11

X-6021-10

X-6021-9

X-6239-1

X-6239-8

X-6239-2

X-6239-3

X-6239-4

X-6239-5

X-6239-6

X-792-1

X-792-5

X-792-8

3/8-24 x .75

3/8-24 x 1.25

3/8-24 x 4.00

3/8-24 x 4.50

7/16-14 x .75

7/16-14 x 1.00

7/16-14 x 1.25

7/16-14 x 1.50

7/16-14 x 2.00

7/16-14 x 2.75

7/16-14 x 6.50

1/2-13 x .75

1/2-13 x 1.00

1/2-13 x 1.25

1/2-13 x 1.50

1/2-13 x 1.75

1/2-13 x 2.00

1/2-13 x 2.25

1/2-13 x 2.50

1/2-13 x 2.75

1/2-13 x 3.00

1/2-13 x 3.50

1/2-13 x 4.00

1/2-13 x 4.50

1/2-13 x 5.50

1/2-13 x 6.00

1/2-20 x .75

1/2-20 x 1.25

1/2-20 x 1.50

5/8-11 x 1.00

5/8-11 x 1.25

5/8-11 x 1.50

5/8-11 x 1.75

5/8-11 x 2.00

5/8-11 x 2.25

5/8-11 x 2.50

5/8-11 x 2.75

5/8-11 x 3.75

5/8-11 x 4.50

5/8-11 x 6.00

5/8-18 x 2.50

3/4-10 x 1.00

3/4-10 x 1.25

3/4-10 x 1.50

3/4-10 x 2.00

3/4-10 x 2.50

3/4-10 x 3.00

3/4-10 x 3.50

1-8 x 2.25

1-8 x 3.00

1-8 x 5.00

Part No.

Dimensions Type

Hex Nuts

X-6009-1

X-6210-3

X-6210-4

X-6210-5

X-6210-1

X-6210-2

X-6210-6

X-6210-7

X-6210-8

X-6210-9

X-6210-10

X-6210-11

X-6210-12

X-6210-15

X-6210-14

X-85-3

X-88-12

X-89-2

1-8

6-32

8-32

10-24

10-32

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

1/2-13

7/16-20

5/8-11

3/4-10

1/2-20

Standard

Whiz

Whiz

Whiz

Whiz

Spiralock

Spiralock

Spiralock

Spiralock

Spiralock

Spiralock

Spiralock

Spiralock

Spiralock

Spiralock

Standard

Standard

Standard

Washers

Part No.

ID

Bolt/

OD Thick. Screw

X-25-46 .125

X-25-9 .156

X-25-48 .188

X-25-36 .219

X-25-40 .281

X-25-85 .344

X-25-37 .406

X-25-34 .469

X-25-26 .531

1.062

X-25-15 .656

1.312

X-25-29 .812

1.469

X-25-127 1.062

2.000

.250

.375

.438

.500

.625

.687

.812

.922

.022

.049

.049

.049

.065

.065

.065

.065

.095

.095

.134

.134

#4

#6

#8

#10

1/4

5/16

3/8

7/16

1/2

5/8

3/4

1


Metric

Hex head bolts are hardness grade 8.8 unless noted.

Part No.

Dimensions

Hex Head Bolts (partial thread)

M931-06040-60

M931-06055-60

M931-06060-60

M931-06070-60

M931-06075-60

M931-06090-60

M931-08035-60

M931-08040-60

M931-08040-82

M931-08045-60

M931-08050-60

M931-08055-82

M931-08060-60

M931-08070-60

M931-08070-82

M931-08075-60

M931-08080-60

M931-08090-60

M931-08095-60

M931-08100-60

M931-10040-60

M931-10045-60

M931-10050-60

M931-10055-60

M931-10060-60

M931-10065-60

M931-10070-60

M931-10080-60

M931-10090-60

M931-10100-60

M931-12045-60

M931-12050-60

M931-12055-60

M931-12060-60

M931-12065-60

M931-12080-60

M931-12090-60

M931-12100-60

M931-12110-60

M931-16090-60

M931-20065-60

M931-20120-60

M931-20160-60

M931-22090-60

M931-22120-60

M931-22160-60

M931-24090-60

M931-24120-60

M931-24160-60

M6-1.00 x 40

M6-1.00 x 55

M6-1.00 x 60

M6-1.00 x 70

M6-1.00 x 75

M6-1.00 x 90

M8-1.25 x 35

M8-1.25 x 40

M8-1.25 x 40*

M8-1.25 x 45

M8-1.25 x 50

M8-1.25 x 55*

M8-1.25 x 60

M8-1.25 x 70

M8-1.25 x 70*

M8-1.25 x 75

M8-1.25 x 80

M8-1.25 x 90

M8-1.25 x 95

M8-1.25 x 100

M10-1.50 x 40

M10-1.50 x 45

M10-1.50 x 50

M10-1.50 x 55

M10-1.50 x 60

M10-1.50 x 65

M10-1.50 x 70

M10-1.50 x 80

M10-1.50 x 90

M10-1.50 x 100

M12-1.75 x 45

M12-1.75 x 50

M12-1.75 x 55

M12-1.75 x 60

M12-1.75 x 65

M12-1.75 x 80

M12-1.75 x 90

M12-1.75 x 100

M12-1.75 x 110

M16-2.00 x 90

M20-2.50 x 65

M20-2.50 x 120

M20-2.50 x 160

M22-2.50 x 90

M22-2.50 x 120

M22-2.50 x 160

M24-3.00 x 90

M24-3.00 x 120

M24-3.00 x 160

Part No.

Dimensions

Hex Head Bolts (full thread)

M933-04006-60

M933-05050-60

M933-06010-60

M933-06014-60

M933-06016-60

M933-06020-60

M933-06025-60

M933-06040-60

M933-06050-60

M933-08016-60

M933-08020-60

M933-08025-60

M933-08030-60

M933-10012-60

M961-10020-60

M933-10020-60

M933-10025-60

M933-10030-60

M933-10030-82

M961-10035-60

M933-10035-60

M933-12016-60

M933-12020-60

M933-12025-60

M933-12025-82

M933-12030-60

M933-12040-60

M933-12040-82

M961-14025-60

M933-14025-60

M961-16025-60

M933-16025-60

M933-16030-82

M933-16035-60

M933-16040-60

M933-16050-60

M933-16050-82

M933-16060-60

M933-18050-60

M933-18060-60

M4-0.70 x 6

M5-0.80 x 50

M6-1.00 x 10

M6-1.00 x 14

M6-1.00 x 16

M6-1.00 x 20

M6-1.00 x 25

M6-1.00 x 40

M6-1.00 x 50

M8-1.25 x 16

M8-1.25 x 20

M8-1.25 x 25

M8-1.25 x 30

M10-1.50 x 12

M10-1.25 x 20

M10-1.50 x 20

M10-1.50 x 25

M10-1.50 x 30

M10-1.50 x 30*

M10-1.25 x 35

M10-1.50 x 35

M12-1.75 x 16

M12-1.75 x 20

M12-1.75 x 25

M12-1.75 x 25*

M12-1.75 x 30

M12-1.75 x 40

M12-1.75 x 40*

M14-1.50 x 25

M14-2.00 x 25

M16-1.50 x 25

M16-2.00 x 25

M16-2.00 x 30*

M16-2.00 x 35

M16-2.00 x 40

M16-2.00 x 50

M16-2.00 x 50*

M16-2.00 x 60

M18-2.50 x 50

M18-2.50 x 60

Pan Head Machine Screws

M7985A-03010-20 M3-0.50 x 10

M7985A-03012-20 M3-0.50 x 12

M7985A-04020-20 M4-0.70 x 20

M7985A-05010-20 M5-0.80 x 10

M7985A-05012-20 M5-0.80 x 12

Flat Head Machine Screws

M965A-05016-20 M5-0.80 x 16

* This metric hex bolt’s hardness is grade 10.9.

Part No.

Dimensions

Hex Nuts

M934-03-50

M934-04-50

M3-0.50

M4-0.70

M934-05-50

M982-05-80

M5-0.80

M5-0.80

M6923-06-80 M6-1.00

M934-06-64

M982-06-80

M6-1.00

M6-1.00

M6923-08-80 M8-1.25

M934-08-60 M8-1.25

M982-08-80 M8-1.25

M6923-10-80 M10-1.50

M982-10-80 M10-1.50

M6923-12-80 M12-1.75

M982-12-80 M12-1.75

M982-14-80 M14-2.00

M6923-16-80 M16-2.00

M982-16-80 M16-2.00

M982-18-80 M18-2.50

M934-20-80

M982-20-80

M20-2.50

M20-2.50

M934-22-80

M982-22-80

M934-24-80

M982-24-80

M22-2.50

M22-2.50

M24-3.00

M24-3.00

Type

Standard

Standard

Standard

Elastic Stop

Spiralock

Std. (green)

Elastic Stop

Spiralock

Standard

Elastic Stop

Spiralock

Elastic Stop

Spiralock

Elastic Stop

Elastic Stop

Spiralock

Elastic Stop

Elastic Stop

Standard

Elastic Stop

Standard

Elastic Stop

Standard

Elastic Stop

Washers

Part No.

Bolt/

ID OD Thick. Screw

M125A-03-80 3.2

7.0

M125A-04-80 4.3

9.0

M125A-05-80 5.3

10.0

M125A-06-80 6.4

12.0

M125A-08-80 8.4

16.0

M125A-10-80 10.5

20.0

M125A-12-80 13.0

24.0

M125A-14-80 15.0

28.0

M125A-16-80 17.0

30.0

M125A-18-80 19.0

34.0

M125A-20-80 21.0

37.0

M125A-24-80 25.0

44.0

2.5

2.5

3.0

3.0

3.0

4.0

0.5

0.8

1.0

1.6

1.6

2.0

M12

M14

M16

M18

M20

M24

M3

M4

M5

M6

M8

M10


112 TP-6255 4/10

TP-6255 4/10 113

114 TP-6255 4/10

TP-6255 4/10 115

TP-6255 4/10c

E 2004, 2006, 2007 and 2010 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044

Phone 920-565-3381, Fax 920-459-1646

For the nearest sales/service outlet in the

US and Canada, phone 1-800-544-2444

KohlerPower.com

Kohler Power Systems

Asia Pacific Headquarters

7 Jurong Pier Road

Singapore 619159

Phone (65) 6264-6422, Fax (65) 6264-6455

Kohler 6 EOD, 8 32EOZD, 4.5 EFOD, 6.5 28EFOZD Marine Generator Set Service Manual

Assistant Bot

Marine Generator Sets

TP-6255 4/10c

Product Identification Information

Product identification numbers determine service parts.

Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.

Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

Record the product identification numbers from the generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

Table of Contents

Safety Precautions and Instructions

WARNING

WARNING

WARNING

WARNING

CAUTION

WARNING

WARNING

Notes

Introduction

Service Assistance

Notes

Section 1 Specifications

Section 2 Scheduled Maintenance

WARNING

WARNING

Section 3 Intake and Exhaust System

WARNING

Notes

Section 4 Fuel System

4.2.1

Priming the Fuel System

Section 5 Cooling System

WARNING

WARNING

5.8.1

Seawater Pump Belt Tensioning

Procedure

5.8.2

Battery Charging Alternator Belt

Tensioning Procedure

5.8.3

Anticorrosion Zinc Anode

Section 6 Troubleshooting

WARNING

Section 7 Controller

7.3.1

Starting Sequence, Master Switch

Moved to RUN

7.3.2

Starting Sequence, Remote Start

7.3.3

Running Sequence

7.3.4

Stopping Sequence, Master

Switch Moved to OFF/RESET

7.3.5

Stopping Sequence, Remote Stop

7.4.1

Fault Shutdowns

7.4.2

Warnings

7.5.1

Controller Time Out

7.5.2

Controller Configuration

∧

∨

7.5.3

Voltage Adjustment