Kohler 40EFOZ, 33EFOZ, 40EOZ, 50EOZ, 55EFOZ Operation Manual

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Page 1

Operation

Marine Generator Sets

Models:

33EFOZ/40EOZ 40EFOZ/50EOZ 55EFOZ/65EOZ 70EFOZ/80EOZ

80EFOZ/99EOZ 100EFOZ/125EOZ 125EFOZ/150EOZ

TP-6109 6/03c

Page 2

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

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

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

x:in:007:001

Page 3

Table of Contents

Product Information inside front cover.........................................................

Safety Precautions and Instructions I........................................................

Introduction 1...............................................................................

Service Assistance 1........................................................................

Maintenance and Service Parts/Related Literature 2............................................

Section 1 Specifications 3...................................................................

1.1 Introduction 3..........................................................

1.2 Specifications 3.........................................................

1.3 Service Views 4........................................................

1.4 Remote Annunciator Kit 5................................................

1.5 Safeguard Breaker 5....................................................

1.6 Line Circuit Breaker 5...................................................

1.7 Run Relay Kit 5.........................................................

Section 2 Operation 7.......................................................................

2.1 Prestart Checklist 7.....................................................

2.2 Marine Inspection 7.....................................................

2.3 Angular Operation 7.....................................................

2.4 Operation in European Union Member Countries 7..........................

2.5 Exercising the Generator Set 8...........................................

2.6 Decision-Maker

2.6.1 Controls and Indicators 9........................................

2.6.2 Fuses and Terminal Strips 10......................................

2.6.3 Auxiliary Fault Lamp Conditions 11.................................

2.6.4 Starting the Generator Set 12......................................

2.6.5 Stopping the Generator Set 12.....................................

2.6.6 Prime Power Mode Operation 13...................................

2.6.7 Fault Shutdowns 13..............................................

2.6.8 Controller Resetting Procedure 14..................................

2.6.9 Resetting the Emergency Stop Switch 14............................

2.7 Expanded Decision-Maker

2.7.1 Controls and Indicators 15........................................

2.7.2 Starting the Generator Set 16......................................

2.7.3 Stopping the Generator Set 16.....................................

2.7.4 Fault Shutdowns 16..............................................

2.7.5 Controller Resetting Procedure 16.................................

2.8 Standard Decision-Makert 1 Controller Operation 17........................

2.8.1 Controls and Indicators 17........................................

2.8.2 Starting the Generator Set 17......................................

2.8.3 Stopping the Generator Set 17.....................................

2.8.4 Fault Shutdowns 18..............................................

2.8.5 Controller Resetting Procedure 18.................................

Section 3 Scheduled Maintenance 19..........................................................

3.1 General Maintenance 19..................................................

3.2 Generator Set Service Schedule 20........................................

3.3 Cooling System 21.......................................................

3.3.1 Siphon Break 21.................................................

3.3.2 Impeller Inspection and Replacement Procedure 22..................

3.4 Exhaust System 23......................................................

3.5 Storage Procedure 24....................................................

3.5.1 Lubricating System 24............................................

3.5.2 Cooling System 24...............................................

3.5.3 Fuel System 24..................................................

t 3+, 16-Light Microprocessor Controller Operation 8.........

t 1 Controller Operation 15........................

Table of ContentsTP-6109 6/03

Page 4

3.5.4 Exterior 24......................................................

3.5.5 Battery 24.......................................................

Section 4 General Troubleshooting 25.........................................................

Section 5 Wiring Diagrams 31................................................................

Appendix A Abbreviations A-1..................................................................

Appendix B Operating Hour Service Log A-3.....................................................

TP-6109 6/03Table of Contents

Page 5

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,orsubstantial 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.

Battery

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid

can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a containerwith4L(1gal.)ofwaterand mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

Battery gases. Explosion can cause severe injury or death. Battery gases

can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

TP-6109 6/03 ISafety Precautions and Instructions

Page 6

Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash Fire

WARNING

Fire. Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the fuel system. A flash fire can cause severe injury or death.

Do not smoke or permit flames or sparks near the carburetor, 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 carburetor.

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 fuel system. Keep the compartment and the generator set clean and free of debris to minimize the risk of fire. 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.

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

monoxide is a poisonous gas present in exhaust gases. 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.

Copper tubing exhaust systems. Carbon monoxide can cause severe nausea, fainting, or death. Do not

use copper tubing in diesel exhaust systems. Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in exhaust/water leakage.

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. Consult the boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.

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

is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Use the following precautions when installing and operating the generator set. Do not install the exhaust outlet where exhaust can be drawn in through portholes, vents, or air conditioners. If the generator set exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow of exhaust. Never operate the generator set without a functioning carbon monoxide detector. 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. Avoid overloading the craft.

TP-6109 6/03II Safety Precautions and Instructions

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Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly

explosive. Use extreme care when handling and storing fuels. Store fuels inawell-ventilatedareaawayfrom 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.

Installing the fuel system. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an

explosion. Do not modify the tank or the propulsion engine fuel system. Equip the craft with a tank that allows one of the two pickup arrangements described in the installation section. The tank and installation must conform to USCG Regulations.

Pipe sealant. Explosive fuel vapors can cause severe injury or death.

Fuel leakage can cause an explosion. Use pipe sealant on all threaded fittings to prevent fuel leakage. Use pipe sealant that resists gasoline, grease, lubrication oil, common bilge solvents, salt deposits, and water.

Ignition-protected equipment. Explosive fuel vapors can cause severe injury or death. Gasoline

vapors can cause an explosion. USCG Regulation 33CFR183 requires that all electrical devices (ship-to-shore transfer switch, remote start panel, etc.) must be ignition protected when used in a gasoline and gaseous-fueled environment. The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous-fueled environment such as an engine room or near fuel tanks. Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash.

Hazardous Noise

CAUTION

Hazardous noise. Can cause hearing loss.

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

Engine noise. Hazardous noise can cause hearing loss. Generator sets

not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/ Electrical Shock

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

CAUTION

Welding the generator set. Can cause severe electrical equipment damage.

Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution

is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Moving rotor.

TP-6109 6/03 IIISafety Precautions and Instructions

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Disconnecting the electrical load. Hazardous voltage can cause severe injury or death. Disconnect

the generator set from the load by opening 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.

Welding the generator set. Can cause severe electrical equipment damage. Before welding the generator

set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine batterycharging alternator connections. (5) Attach the weld ground connection close to the weld location.

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.

Testing the voltage regulator. Hazardous voltage can cause severe injury or death. High voltage

is present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator.

(PowerBoostt, PowerBoostt III, and PowerBoostt V voltage regulator models only)

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 opened. 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. Can cause severe injury or death.

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

WARNING

Hot engine and exhaust system. Can cause severe injury or death.

Do not work on the generator set until it cools.

Checking the coolant level. Hot coolant can cause severe injury or death. 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.

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.

Moving Parts

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

WARNING

Moving rotor.

Rotating parts. Can cause severe injury or death.

Operate the generator set only when all guards, screens, and covers are in place.

TP-6109 6/03IV Safety Precautions and Instructions

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WARNING

Airborne particles. Can cause severe injury or blindness.

Wear protective goggles and clothing when using power tools, hand tools, or compressed air.

Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause

the hardware or pulley to release from the generator set engine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.

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.

Sound shield removal. Exposed moving parts can cause severe injury or death. The generator set

must be operating in order to perform some scheduled maintenance procedures. Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

(Sound-shield-equipped models only)

Notice

NOTICE

This generator set has been rewired from its nameplate voltage to

246242

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.

NOTICE

Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are

available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE

Electrostatic discharge damage.

Electrostatic discharge (ESD) damages electronic circuit boards. Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short,to ground.

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-6109 6/03 VSafety Precautions and Instructions

Page 10

Notes

TP-6109 6/03VI Safety Precautions and Instructions

Page 11

Introduction

This manual provides operation instructions for 40/50/65/80/99/125/150EOZ and 33/40/55/70/80/100/ 125EFOZ model generator sets equipped with the following controllers:

D Decision-Makert 3+ 16-Light D Decision-Makert 1 Expanded D Decision-Makert 1 Standard

x:in:001:001

This manual may be used for models not listed on the front cover.

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

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Obtain service from an authorized service distributor/dealer to keep equipment in top condition.

Before installing a marine generator set, obtain the most current installation manual from your local distributor/dealer. Only qualified persons should install the generator set.

x:in:001:002:a

Service Assistance

For professional advice on generator 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

KohlerPowerSystems.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

Africa, Europe, Middle East

London Regional Office Langley, Slough, England Phone: (44) 1753-580-771 Fax: (44) 1753-580-036

Asia Pacific

Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 264-6422 Fax: (65) 264-6455

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

X:in:008:001a

TP-6109 6/03 1Introduction

Page 12

Maintenance and Service Parts/Related Literature

Maintenance and Service Parts

Figure 1 identifies maintenance and service parts for your generator set. Obtain a complete list of maintenance and service parts from your authorized generator distributor/dealer.

Models

40EOZ/

Part Description

Air Filter Element GM15397 GM15397 GM15397 GM15398 GM15398 324134 324134

Belt (Alternator and Seawater Pump)

Dec I Standard Controller:

Input Fuse (10 amp)

Dec I Expanded Controller:

Input Fuse (10 amp)

Dec 3+ Controller:

Remote Annunciator Fuse (3 amp) Controller Fuse (3 amp) Engine & Accessory Fuse (15 amp)

Fuel Filter Element GM15399 GM15399 GM15399 GM15399 GM15399 GM18808 GM18808

Oil Filter GM15400 GM15400 GM15400 GM15400 GM15400 223673 223673

Seawater Pump Impeller Kit GM15401 GM15401 GM15401 GM15401 GM15401 GM18793 GM18793

Spray Paint (White) 221335 221335 221335 221335 221335 221335 221335

Touch-Up Paint (White) GM19490 GM19490 GM19490 GM19490 GM19490 GM19490 GM19490

Zinc Anode GM15403 GM15403 GM15403 GM15404 GM15404 GM15404 GM15404

33EFOZ

GM15402 GM15402 GM15402 GM15402 GM15402 GM18704 GM18704

223316 223316 223316 223316 223316 223316 223316

243273 243273 243273 243273 243273 243273 243273

283645 283645 283645 283645 283645 283645 283645

50EOZ/

40EFOZ

65EOZ/

55EFOZ

80EOZ/

70EFOZ

99EOZ/

80EFOZ

125EOZ/

100EFOZ

150EOZ/

125EFOZ

Figure 1 Maintenance and Service Parts

Related Literature

Figure 2 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set.

Models

40EOZ/

Literature Type

Installation Manual TP-6069 TP-6069 TP-6069 TP-6069 TP-6069 TP-6069 TP-6069

Parts Catalog* TP-5738 TP-5738 TP-5738 TP-5738 TP-5738 TP-5738 TP-5738

Operation & Service Manual (Engine)

Service Manual (Generator) TP-5737 TP-5737 TP-5737 TP-5737 TP-5737 TP-5737 TP-5737

* Includes the generator and engine information.

33EFOZ

TP-6084 TP-6084 TP-6084 TP-6084 TP-6084 N/A N/A

Figure 2 Generator Set Literature

50EOZ/

40EFOZ

65EOZ/

55EFOZ

80EOZ/

70EFOZ

99EOZ/

80EFOZ

125EOZ/

100EFOZ

150EOZ/

125EFOZ

x:in:001:005

TP-6109 6/032 Maintenance and Service Parts/Related Literature

Page 13

Section 1 Specifications

1.1 Introduction

The specification sheets for each generator set provide specific generator and engine information. Refer to the respective specification sheet for data not supplied in this manual. Consult the generator set service manual, installation manual, engine operation manual, and engine service manual for additional specifications.

1.2 Specifications

The alternator is a 4-pole, rotating-field unit with a brushless, permanent-magnet-generator (PMG) excitation system. The generator set excitation system uses a permanent-magnet exciter with a silicon-controlled rectifier (SCR) assembly that controls the amount of DC current supplied to the generator field. The voltage regulator sends a signal to the SCR assembly through an optical coupling. The voltage regulator bases the signal on engine speed and generator output voltage. The signal turns a stationary light-emitting diode (LED) on or off. The LED is mounted on the end bracket opposite a photo transistor board that rotates on the shaft. The photo transistor receives the signal from the LED and signals the SCR assembly to turn on or off. See Figure 1-1.

PMG, Fast-Responset II generator sets offer the following advantages:

and 200--300% for the duration of the short circuit. The SCR assembly sends full exciter power to the main field and the generator sustains up to 300% of rated current. The sustained high current causes the correspondingly rated load circuit fuses/breakers to trip. The safeguard breaker kit collapses the generator set’s main field during a sustained heavy overload or short circuit.

D The voltage recovery period of this type of generator

is several times faster than the conventional PMG generators because the generator set does not have

to contend with the inductance of the 2

D Better recovery characteristics than static-excited

exciter field.

generators because the system doesn’t draw excitation power from the generator output voltage.

D The inherent ability to support short-circuit current

and allow system coordination for tripping downstream branch circuit breakers.

The PMG exciter system changes the level of exciter current to the main field within 0.05 seconds of a load change.

For the duration of a short circuit in the load circuit(s), the output voltage drops and the amperage momentarily rises to 200--300% of the generator set’s rated current,

1. Field

2. Main generator/alternator

3. SCR assembly

4. Exciter generator/alternator

5. Exciter field magnets

6. Exciter armature

7. Optical coupling

8. Starting battery

9. Safegaurd breaker (optional)

10. AC voltage regulator

11. LED board

12. Photo transistor board

13. Stator

Figure 1-1 Alternator Schematic

TP-5353-1

TP-6109 6/03 3Section 1 Specifications

Page 14

1.3 Service Views

2345 8

6 107

11 12 13 14 15 16 17

1. Nameplate

2. Controller (Decision-Makert I expanded controller shown)

3. Generator set master switch

4. Hourmeter

5. Air cleaner

6. Exhaust outlet (nonservice side)

7. Fuel return

8. Lifting eye

9. Fuel filter

10. Fuel inlet

11. Fuel pump

12. Seawater pump

13. Oil fill

14. Coolant overflow bottle

Figure 1-2 Service Views (Typical)

15. Pressure cap

16. Overflow tube

17. Heat exchanger

18. Anticorrosion zinc anode

19. Fuel injection pump

20. Oil drain (optional location)

21. Seawater inlet (drain)

22. Coolant drain

23. Belt guard

24. Oil dipstick (check)

25. Oil filter

26. Oil drain valve and hose

27. Cooling air inlets (generator)

212324252627

ADV-6581A-

TP-6109 6/034 Section 1 Specifications

Page 15

1.4 Remote Annunciator Kit

A remote annunciator provides convenient monitoring of the generator set’s condition from a remote location. See Figure 1-3. The remote annunciator includes an alarm horn, alarm silence switch, lamp test, and the same lamp indicators (except air damper and auxiliary prealarm) as the microprocessor controller, plus the following lamps:

Line Power lamp illuminates to indicate that the commercial utility is the power source.

X-796

Figure 1-4 Safeguard Breaker

1.6 Line Circuit Breaker

Generator Power lamp illuminates to indicate that the generator set is the power source.

Remote Annunciator

42A 2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10K11 K13K14K12

CONTACTRATINGS: 10A@120VAC RES. LOAD

INPUT

NO C CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14

42B

FBA--1

.01A@28VDC MIN. 10A@28VDC MAX.

10 AMP

PCB ASSY A--320639

LOT NO.

A-258782

The line circuit breaker interrupts generator output if an overload or short circuit occurs. Use the line circuit breaker to manually disconnect the generator set from the load during generator set service. See Figure 1-5.

TP-5352-1

Figure 1-5 Line Circuit Breaker

1.7 Run Relay Kit

The run relay kit includes three sets of contacts that energize only during generator set operation. The run relay kit can control air intake louvers, radiator louvers, alarms, and other signaling devices. See Figure 1-6.

14-Relay Dry Contact Box

Figure 1-3 Remote Annunciator with 14-Relay Dry

Contact Box

1.5 Safeguard Breaker

The safeguard breaker senses output current on each generator phase and shuts off the AC voltage regulator if a sustained overload or short circuit occurs. It is not a line circuit breaker and does not disconnect the generator set from the load. See Figure 1-4.

TP-6109 6/03 5Section 1 Specifications

A-293983

273705

Figure 1-6 Run Relay Kit

Page 16

Notes

TP-6109 6/036 Section 1 Specifications

Page 17

Section 2 Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.

Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine.

Air Inlets. Check for clean and unobstructed air inlets.

Air Shrouding. Check for securely installed and

positioned air shrouding.

Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.

Coolant Level. Check the coolant level according to the cooling system maintenance information.

Drive Belts. Check the belt condition and tension of the water pump and battery charging alternator belt.

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

Inspect the exhaust system components (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and exhaust outlet) for cracks, leaks, and corrosion.

Fuel Level. Check the fuel level and keep the tank(s) full to ensure adequate fuel supply.

Lamp Test. Press the lamp test button, if equipped to verify that all controller LEDs illuminate.

Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.

Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.

Seawater Pump Priming. Prime the seawater pump before initial startup. To prime the pump: (1) close the seacock, (2) remove the hose from the water-filter outlet, (3) fill the hose and seawater pump with clean water, (4) reconnect the hose to the water filter outlet, and (5) open the seacock. Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet.

2.2 Marine Inspection

Kohler Co. recommends that all boat owners have their vessels—especially the exhaust system attached to the generator set—inspected at the start of each boating season by the local Coast Guard Auxiliary. If there is no Coast Guard Auxiliary in the area, contact an authorized Kohler distributor/dealer for the inspection.

2.3 Angular Operation

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 as needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect 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.

D Ensure that the carbon monoxide detector(s) is (1) in

the craft, (2) functional, and (3) energized whenever the generator set operates.

Note: Never operate the generator set without a

functioning carbon monoxide detector.

TP-6109 6/03 7Section 2 Operation

See Figure 2-1 for angular operation limits for units covered in this manual.

Continuous

25_ 30_

Maximum value for all directions

Figure 2-1 Angular Operation

Intermittent—

3 minutes or less

m:op:001:004

2.4 Operation in European Union Member Countries

This generator set is specifically intended and approved for operation below the deck in the engine compartment. Operation above the deck and/or outdoors would constitute a violation of European Union Directive 2000/14/EC noise emission standard.

Page 18

2.5 Exercising the Generator Set

Operate the generator set under load once each week for one hour with an operator present.

2.6 Decision-Maker 3+, 16-Light Microprocessor Controller Operation

The operator should perform all of the prestart checks before starting the exercise procedure. Start the generator set according to the starting procedure in the controller section of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks.

x:op:001:005

12 34 5 6

The Decision-Makert 3+, 16-light microprocessor controller has a prime power mode of operation. See Section 2.6.6 for prime power mode operation. Figure 2-2 identifies the relay controller’s indicators and controls and their functions.

1. Fuses (inside controller)

2. Frequency meter

3. AC voltmeter

4. Controller TB1 and TB2 terminal strips (on circuit board)

5. AC ammeter

6. Scale lamps (upper/lower)

7. Selector switch

8. Annunciator panel lamps

9. Alarm silence switch

10. Lamp test

11. Generator set master switch

12. Alarm horn

13. DC voltmeter

14. Emergency stop switch (if equipped)

15. Water temperature gauge

16. Voltage adjustment

17. Oil pressure gauge

18. Hourmeter

Figure 2-2 Decision-Makert 3+, 16-Light Microprocessor Controller

1011121314151617

ADV-5849 P1

TP-6109 6/038 Section 2 Operation

Page 19

2.6.1 Controls and Indicators

The following table describes the controls and indicators located on the controller.

Name Description

AC ammeter Meter displays the AC output

AC voltmeter Meter displays the AC output

DC voltmeter Meter displays the voltage of the

Alarm horn Horn sounds if any fault or

Alarm silence switch Switch disconnects the alarm

Auxiliary fault lamp Lamp flashes or lights when the

Frequency meter Meter displays the frequency (Hz)

Generator set master switch

High engine temperature lamp

Hourmeter Hourmeter records the generator

amperage. Use the selector switch to choose the phase current.

voltage. Use the selector switch to choose the output lead circuits.

starting battery(ies).

anticipatory condition exists. Place the generator set master switch in the AUTO position before silencing the horn. See the Controller Resetting Procedure later in this section.

during service (place the generator set master switch in the AUTO position before silencing the alarm horn). Restore the alarm horn switches at all locations (controller, remote annunciator, and audio/visual alarm) to normal positions after correcting the fault shutdown to avoid reactivating the alarm horn. See the Controller Resetting Procedure later in this section.

controller detects a fault. See the lamp conditions section following.

of the generator set output voltage.

Switch functions as the controller reset and generator set operation switch.

Lamp illuminates if the generator set shuts down because of high engine temperature. Shutdown occurs 5 seconds after the engine reaches temperature shutdown range.

set total operating hours for reference in maintenance scheduling.

Lamp test switch Switch tests the controller indicator

Low oil pressure lamp

Overcrank lamp Lamp illuminates and cranking

Overspeed lamp Lamp illuminates if the generator

Water temperature gauge

Oil pressure gauge Gauge displays the engine oil

Scale lamps (upper/lower)

Selector switch Switch selects which generator set

Voltage adjustment potentiometer

lamps.

Lamp illuminates if the generator set shuts down because of low oil pressure. Shutdown occurs 5 seconds after the engine reaches oil pressure shutdown range.

stops if the engine does not start after 45 seconds of continuous cranking or 75 seconds of cyclic cranking.

Cranking stops and overcrank lamp lights after 15 seconds if the starter or engine does not turn (locked rotor).

Overcrank lamp flashes if speed sensor signal is absent longer than one second.

NOTE: The generator set controller’s automatic restart function attempts to restart the generator set if the engine speed drops below 13 Hz (390 rpm). Continued decreased engine speed causes an overcrank condition.

set shuts down because governed frequency on 50 and 60 Hz models exceeds 70 Hz.

Gauge displays the engine coolant temperature.

pressure.

Lamps indicate which AC voltmeter and/or ammeter scales to read.

output circuits to measure. When switched to a position with two circuit labels, measures amperage on the lead shown in the upper label and measures voltage between the two leads shown in the lower label. The AC ammeter and voltmeter function only with the switch in the ON position.

Potentiometer fine-tunes (±5%) the generator set output voltage. Fine adjustment (5%) of generator output voltage level.

TP-6109 6/03 9Section 2 Operation

Page 20

Name Description

Auxiliary prealarm lamp

Lamp illuminates when customer-provided sensing devices activate the pump.

Emergency stop lamp

Lamp illuminates and the generator set shuts down when the operator energizes the optional emergency stop switch. The lamp needs the optional emergency stop switch to function.

Generator switch not in auto lamp

Lamp illuminates when the generator set master switch is in the RUN or OFF/RESET position.

Low fuel lamp Lamp illuminates when the fuel

level in the tank approaches empty. The lamp needs a low fuel sensor in the fuel tank to function.

High water temperature lamp

Lamp illuminates when the water temperature approaches shutdown range. The lamp needs an optional prealarm sender kit to function.

Prealarm high engine temperature lamp

Lamp illuminates when the engine coolant temperature approaches shutdown range. The lamp needs an optional prealarm sender kit to function.

Prealarm low oil pressure lamp

Lamp illuminates when the engine oil pressure approaches shutdown range. The lamp needs an optional prealarm sender kit to function.

System ready lamp Lamp illuminates when the

generator set master switch is in AUTO position and the system senses no faults.

Emergency stop switch

Switch, if activated, instantly shuts down the generator set in emergency situations. Use the emergency stop switch for emergency shutdowns only. Use the generator set master switch for normal shutdowns.

2.6.2 Fuses and Terminal Strips

The following table describes the controller circuit board fuses and controller terminal strips.

Name Description

3-amp remote annunciator fuse

3-amp controller fuse Fuse protects the controller circuit

15-amp engine and accessories fuse

Controller TB1 terminal strip

Controller TB2 terminal strip

Fuse protects the remote annunciator circuit, A/V alarm, and isolated alarm kit, if equipped.

board, speed sensor, and lamp circuit board.

Fuse protects the engine/starting circuitry and accessories.

Terminal strip provides connection points for customer-supplied sensing devices and generator set accessories such as the emergency stop switch, remote start stop/switch, audio/visual alarms, etc., to the controller. Figure 2-3 shows the location of the TB1 terminal strip on the controller circuit board. Refer to the wiring diagrams for information on connecting accessories to the TB1 terminal strip.

Terminal strip provides connection points for crank mode selection (cyclic or continuous) and remote start/stop switch inputs of operation. Figure 2-3 shows the location of the TB2 terminal strip on the controller circuit board. Refer to the wiring diagrams for connection information.

R41

LED4

1. TB1 terminal strip

2. TB2 terminal strip

3. Fuses

Figure 2-3 TB1 and TB2 Terminal Strips on

Decision-Makert 3+ Controller Circuit Board

TP-6109 6/0310 Section 2 Operation

A-336415-A

Page 21

2.6.3 Auxiliary Fault Lamp Conditions

The following descriptions define the possible auxiliary fault lamp conditions.

Flashing Lamp Conditions

Emergency Stop Switch Reset. Resetting the optional emergency stop switch while the generator set master switch is in the AUTO or RUN position causes the auxiliary lamp to light. Place the generator set master switch in the OFF/RESET position to clear the auxiliary lamp ON condition.

No AC Output. The auxiliary lamp flashes immediately if the controller senses no AC output while the generator set runs (except during the first 10 seconds after startup). The flashing stops and the light goes out when the controller senses AC output. The controller requires no manual reset.

Low Battery Voltage. The auxiliary lamp flashes if the battery power was reconnected or was low and then restored while the generator set master switch was in the RUN or AUTO position. A possible cause is a temporary low battery condition when the battery is weak or undersized for the application. To clear the low battery voltage condition, place the generator set master switch in the OFF/RESET position.

Continuous-On Lamp Conditions

Emergency Stop Switch Energized. Upon activation of the emergency stop switch, if equipped, the auxiliary lamp lights and the generator set shuts down immediately.

Note: Auxiliary Delay Shutdown. The auxiliary lamp

lights and the engine shuts down 5 seconds after the high oil temperature (P1-13) or auxiliary delay shutdown (P1-15) fault, if equipped, occurs. Auxiliary Delay Shutdown is inhibited during the first 30 seconds after crank disconnect.

Note: Overvoltage Shutdown. If a generator set is

equipped with this kit, the auxiliary lamp lights and the engine shuts down immediately when an overvoltage condition occurs.

Note: Auxiliary Immediate Shutdown. The auxiliary

lamp lights and the engine shuts down immediately when any customer-supplied sensing devices connected to auxiliary immediate shutdown ports (P1-17 and P1-18) activate them.

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TP-6109 6/03 11Section 2 Operation

Page 22

2.6.4 Starting the Generator Set

2.6.5 Stopping the Generator Set

The following procedures describe starting the generator set.

Local Starting (Nonautomatic). Move the generator set master switch to the RUN position to start the generator set at the controller.

Automatic (Auto) Starting. Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or remote start/stop switch (connected to controller terminals TB1-3 and TB1-4).

Note: The alarm horn sounds whenever the generator

set master switch is not in the AUTO position.

Note: The transient start/stop function of the

Decision-Makert3+ controller prevents accidental cranking of the rotating engine. When the generator set master switch is momentarily placed in the OFF/RESET position, then quickly returned to RUN, the generator set slows to 249 rpm and then recranks before returning to its rated speed.

Note: The Decision-Makert 3+ controller’s automatic

restart function attempts to restart the generator set if the engine speed drops below 390 rpm (generator output frequency of 13 Hz). Continued decreased engine speed causes an overcrank fault condition.

The following procedures describe stopping the generator set.

Normal Stopping

1. Cooldown. Run the generator set at no load for 5 minutes to ensure adequate engine cooldown.

2. Stopping. Move the generator set master switch to the OFF/RESET position. The engine stops.

Note: The generator set continues running during

a 5-minute cooldown cycle if a remote switch or automatic transfer switch signals the engine to stop.

Emergency Stopping

Move the generator set master switch to the OFF/RESET position or activate the remote emergency stop, if equipped, for immediate shutdown. The controller AUXILIARY lamp lights and the generator set shuts down on activation of the emergency stop switch. The remote annunciator and/or A/V alarms, if equipped, signal an emergency stop.

Crank Mode Selection

The Decision-Makert3+ controller cranks continuously for up to 45 seconds or cyclically for up to 75 seconds (crank 15 seconds, rest 15 seconds, crank 15 seconds, etc.) before overcrank shutdown. Select the crank mode (cyclic or continuous) on the controller circuit board terminal strip. For cyclic cranking, leave circuit board terminal TB2-9 open. For continuous cranking, attach a jumper between circuit board terminal TB2-9A (ground) and terminal TB2-9.

TP-6109 6/0312 Section 2 Operation

Page 23

2.6.6 Prime Power Mode Operation

2.6.7 Fault Shutdowns

The Decision-Makert 3+ controller operates in either the normal mode or the prime power mode. In prime power mode, the controller draws less current, minimizing the battery drain. Consider using the prime power mode for installations that do not have a battery charger.

Moving the generator set master switch to the OFF/RESET position disables all controller functions. Moving the generator set master switch to the AUTO position restores controller functions.

Enabling and Disabling the Prime Power Mode.

Enable the prime power mode by connecting jumpers across the following terminals on terminal strip TB2 on the controller circuit board:

D TB2-1P and TB2-2P

D TB2-3P and TB2-4P

D TB2-3 and TB2-4

See Figure 2-3. Remove the jumpers listed above to disable the prime power mode.

Prime Power Starting. The prime power mode provides local starting only at the controller. When the generator set master switch is in the OFF/RESET position, the controller functions are inoperative. Move the generator set master switch to the AUTO position to start the generator set. Do not start the generator set with the master switch in the RUN position because the alarm horn will sound.

Note: Move the generator set master switch to the

AUTO position to return controller functions to normal.

Prime Power Stopping. Move the generator set master switch to the OFF/RESET position to stop the generator set and power down the controller.

Note: The controller functions are inoperative when the

generator set master switch is in the OFF/RESET position.

The generator set shuts down automatically under the following fault conditions and cannot be restarted until the fault condition is corrected. The system automatically resets when the problem is corrected or the generator set cools (if high engine temperature was the fault).

Name Description

High engine temperature

High exhaust temperature

Low coolant level (water-cooled engines only)

Low oil pressure Shutdown occurs 5 seconds after

Overcrank Shutdown occurs after 45 seconds

Overspeed Shutdown occurs immediately

Overvoltage (optional)

Shutdown occurs 5 seconds after the fault. The high engine temperature shutdown does not function during the first 5 seconds after startup.

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

Shutdown occurs 5 seconds after the fault. The high exhaust temperature shutdown does not function during the first 5 seconds after startup.

Shutdown occurs 5 seconds after fault. The low coolant level shutdown does not function during the first 5 seconds after startup.

the fault. The low oil pressure shutdown does not function during the first 5 seconds after startup.

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

of continuous cranking or 75 seconds of cyclic cranking (crank 15 seconds, rest 15 seconds, crank 15 seconds, etc.).

when the governed frequency on 50 and 60 Hz models exceeds 70 Hz.

The generator set shuts down and the auxiliary lamp lights when voltage is 15% or more over the nominal voltage for 2 seconds or longer.

NOTE: Overvoltage can damage sensitive equipment in less than one second. Install separate overvoltage protection on on-line equipment requiring faster shutdown.

x:op:005:007

TP-6109 6/03 13Section 2 Operation

Page 24

2.6.8 Controller Resetting Procedure (Following Fault Shutdown)

2.6.9 Resetting the Emergency Stop Switch

Use the following procedure to restart the generator set after a fault shutdown. Refer to Resetting the Emergency Stop Switch in this section to reset the generator set after an emergency stop.

1. Place the controller alarm horn silence switch in the SILENCE position to activate the A/V annunciator alarm horn and lamp, if equipped. Place the A/V annunciator alarm switch in the SILENCE position to stop the alarm horn. The A/V annunciator lamp stays lit. (The A/V alarm uses one lamp to indicate a fault shutdown; the respective fault lamp on the remote annunciator lights to indicate a fault condition.)

2. Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch.

3. Correct the cause of the fault shutdown. See the Safety Precautions at the beginning of this section before proceeding.

4. Place the generator set master switch in the OFF/RESET position and then in the RUN position to start the generator set. The A/V annunciator alarm horn sounds and the lamp, if equipped, darkens.

Use the following procedure to restart the generator set after an emergency stop switch shutdown. Refer to the Controller Resetting Procedure in this section to restart the generator set following a fault shutdown. The generator set does not crank until the operator completes the resetting procedure.

Note: The controller auxiliary lamp lights when the

generator set master switch is in the RUN or AUTO position during the resetting procedure.

Procedure to Restart the Generator Set After an Emergency Stop Shutdown:

1. Determine the cause of the emergency stop and correct the problem(s).

2. Reset the controller emergency stop switch by rotating the switch clockwise until the switch springs back to the original position.

3. Toggle the generator set master switch to OFF/RESET and then to RUN or AUTO to restart the generator set.

5. Test operate the generator set to verify that the cause of the shutdown has been corrected.

6. Reconnect the generator set to the load via the line circuit breaker or automatic transfer switch.

7. Place the generator set master switch in the AUTO position for startup by a remote transfer switch or remote start/stop switch. Place the A/V annunciator alarm switch, if equipped, in the NORMAL position.

8. Place the generator set master switch in the AUTO position before silencing the alarm horn.

x:op:005:008

TP-6109 6/0314 Section 2 Operation

Page 25

2.7 Expanded Decision-Makert 1 Controller Operation

For identification of the expanded controller’s indicators and controls and their functions, refer to Figure 2-4.

1. Frequency meter

2. AC voltmeter

3. AC ammeter

4. Scale lamps (upper/lower)

5. Selector switch

6. Hourmeter

7. Generator set master switch

Figure 2-4 Expanded Decision-Makert 1 Controller

8. Voltage adjustment potentiometer

9. Fault lamp

10. 10-amp controller fuse

11. DC voltmeter

12. Water temperature gauge

13. Oil pressure gauge

ADV-5849E-B

2.7.1 Controls and Indicators

The following table describes the controls and indicators located on the controller.

Name Description

AC voltmeter Meter displays the AC output voltage.

Use the selector switch to choose the output lead circuits.

AC ammeter Meter displays the AC output

amperage. Use the selector switch to choose the phase currents.

DC voltmeter Meter displays the voltage of the

starting battery(ies).

Fault lamp Lamp illuminates during engine

shutdown if the engine shuts down because of one of the following faults: high engine temperature, low water level, low oil pressure, overcrank, or overspeed. See Section 2.7.4, Fault Shutdowns, for additional shutdown information.

Frequency meter Meter displays the frequency (Hz) of

the generator set output.

x:op:002:001

Generator set master switch

Switch functions as the controller reset and generator set operation switch.

Hourmeter Hourmeter records the generator set

total operating hours for reference in maintenance scheduling.

Oil pressure gauge

Scale lamps (upper/lower)

Gauge displays the engine oil pressure.

Lamps indicate which AC voltmeter and/or ammeter scales to read.

Selector switch Switch selects the generator set

output circuits to measure. When switched to a position with two circuit labels, measure amperage on the lead shown in the upper label and measure voltage between the two leads shown in the lower label. The AC ammeter and voltmeter function only with the switch in the ON position.

Voltage adjustment

Potentiometer fine-tunes (±5%) the generator set output voltage.

potentiometer

Water temperature

Gauge displays the engine coolant temperature.

gauge

10-amp controller fuse

Fuse protects the controller circuitry from short circuits and overloads.

x:op:002:002

TP-6109 6/03 15Section 2 Operation

Page 26

2.7.2 Starting the Generator Set

The following procedures describe starting the generator set.

Local Starting. Move the generator set to the RUN position to immediately start the generator set.

Auto (Automatic) Starting. Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or the remote start/stop switch (connected to controller terminals TB1-3 and TB1-4).

Note: The controller provides up to 30 seconds of

continuous cranking before overcrank shutdown occurs.

2.7.3 Stopping the Generator Set

The following procedure describe how to stop the generator set.

Normal Stopping

1. Cooldown. Run the generator set at no load for 5 minutes to ensure adequate engine cooldown.

2. Stopping. Move the generator set master switch to the OFF/RESET position. The engine stops.

x:op:002:004

2.7.4 Fault Shutdowns

Fault Description

High engine temperature

High exhaust temperature

Low coolant level Shutdown occurs 5 seconds after the

Low oil pressure Shutdown occurs 5 seconds after the

Overcrank Shutdown occurs after 30 seconds of

Overspeed Shutdown occurs immediately when

Shutdown occurs 5 seconds after the fault. The high engine temperature shutdown does not function during the first 5 seconds after startup.

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

Shutdown occurs 5 seconds after the fault. The high exhaust temperature shutdown does not function during the first 5 seconds after startup.

fault. The low coolant level shutdown does not function during the first 5 seconds after startup.

fault. The low oil pressure shutdown does not function during the first 5 seconds after startup.

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

continuous cranking. Shutdown occurs after 30 seconds if the engine or starter does not turn (locked rotor).

the governed frequency on the 50 and 60 Hz models exceeds 70 Hz.

x:op:002:005

2.7.5 Controller Resetting Procedure (Following Fault Shutdown)

The fault lamp does not stay lit after the generator set shuts down on a fault condition.

Use the following procedure to restart the generator set after a fault shutdown.

1. Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch. See the Safety Precautions at the beginning of this section before proceeding.

2. Correct the cause of the fault shutdown. See the Safety Precautions at the beginning of this section before proceeding.

3. Start the generator set by moving the generator set master switch to RESET/OFF and then to RUN.

4. Verify that the cause of the shutdown has been corrected by test operating the generator set.

5. Reconnect the generator set to the load using the line circuit breaker or automatic transfer switch.

6. Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start/stop switch.

x:op:002:006

TP-6109 6/0316 Section 2 Operation

Page 27

2.8 Standard Decision-Makert 1 Controller Operation

For identification of the standard basic controller’s indicators and controls and their functions, refer to Figure 2-5.

345

1. Hourmeter

2. Voltage adjustment

3. 10-amp controller fuse

4. Fault lamp

5. Generator set master switch

Figure 2-5 Decision-Makert 1 Controller

2.8.1 Controls and Indicators

A-227600

x:op:004:001

2.8.2 Starting the Generator Set

The following procedures describe starting the generator set.

Local Starting. Move the generator set master switch to the RUN position to immediately start the generator set.

Automatic (Auto) Starting. Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or the remote start/stop switch (connected to controller terminals TB1-3 and TB1-4).

Note: The controller provides up to 30 seconds of

continuous cranking before the overcrank shutdown occurs.

2.8.3 Stopping the Generator Set

The following procedure describe how to stop the generator set.

Normal Stopping

1. Cooldown. Run the generator set at no load for 5 minutes to ensure adequate engine cooldown.

2. Stopping. Move the generator set master switch to the OFF/RESET position. The engine stops.

x:op:004:004

The following table describes the controls and indicators located on the controller.

Name Description

Fault lamp Lamp illuminates during engine

Generator set master switch

Hourmeter Hourmeter records the generator

Voltage adjust potentiometer

10-amp controller fuse

shutdown if the engine shuts down because of one of the following faults: high engine temperature, low water level, low oil pressure, overcrank, or overspeed. See Section 2.8.4, Fault Shutdowns, for additional shutdown information.

Switch functions as the controller reset and generator operation switch.

set total operating hours for reference in maintenance scheduling.

Potentiometer fine-tunes (±5%) generator output voltage.

Fuse protects the controller circuitry from short circuits and overloads.

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TP-6109 6/03 17Section 2 Operation

Page 28

2.8.4 Fault Shutdowns

Fault Description

High engine temperature

High exhaust temperature

Low coolant level Shutdown occurs 5 seconds after

Low oil pressure Shutdown occurs 5 seconds after

Overcrank Shutdown occurs after 30 seconds

Overspeed Shutdown occurs immediately

Shutdown occurs 5 seconds after the fault. The high engine temperature shutdown does not function during the first 5 seconds after startup.

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

Shutdown occurs 5 seconds after the fault. The high exhaust temperature shutdown does not function during the first 5 seconds after startup.

the fault. Low coolant level shutdown does not function during the first 5 seconds after startup.

the fault. Low oil pressure shutdown does not function during the first 5 seconds after startup.

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

of continuous cranking. Shutdown occurs after 30 seconds if the engine or starter does not turn (locked rotor).

when the governed frequency on 50 and 60 Hz models exceeds 70 Hz.

x:op:004:005

2.8.5 Controller Resetting Procedure (Following Fault Shutdown)

Use the following procedure to restart the generator set after a fault shutdown.

1. Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch. See the Safety Precautions at the beginning of this section before proceeding.

2. Correct the cause of the fault shutdown. See the Safety Precautions at the beginning of this section before proceeding.

3. Start the generator set by moving the generator set master switch to RESET/OFF and then to RUN.

4. Verify that the cause of the shutdown has been corrected by test operating the generator set.

5. Reconnect the generator set to the load using the line circuit breaker or automatic transfer switch.

6. Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start/stop switch.

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TP-6109 6/0318 Section 2 Operation

Page 29

Section 3 Scheduled Maintenance

3.1 General Maintenance

WARNING

Accidental starting. Can cause severe injury or death.

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.

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.

WARNING

Rotating parts. Can cause severe injury or death.

Operate the generator set only when all guards, screens, and covers 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.

Sound shield removal. Exposed moving parts can cause severe injury or death. The generator set must be operating

in order to perform some scheduled maintenance procedures. Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

(Sound-shield-equipped models only)

WARNING

Hot engine and exhaust system. Can cause severe injury or death.

Do not work on the generator set until it cools.

NOTICE

Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE

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

TP-6109 6/03 19Section 3 Scheduled Maintenance

Page 30

See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized distributor/dealer perform generator set service.

Engine Service. Perform generator set engine service at the intervals specified by the engine operation manual.

Generator Set Service. Perform generator set service at the intervals specified by the generator set operation manual.

If the generator set operates under dusty or dirty conditions, use dry compressed air to blow dust out of the alternator. With the generator set running, direct the stream of air in through the cooling slots at the alternator end.

3.2 Generator Set Service Schedule

Routine Maintenance. Refer to the following generator set service schedule, the engine service schedule, and the hourmeter located on the generator set controller to determine when to schedule routine maintenance. Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions.

Service Log. Use the Operating Hour Service Log located in the back of this manual to document performed services.

Service Schedule. Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set. For example, an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months, 300 hours or 9 months, and so on.

x:sm:004:001

Every

Perform Service at Intervals

Indicated (X)

COOLING SYSTEM

Check the seawater outlet and clean as necessary 3.4 X Check the function of the siphon break, if equipped 3.3.1 X

Check/replace the seawater pump impeller *[

EXHAUST SYSTEM

Inspect the exhaust system components *[

Check the exhaust gas condition. If the exhaust is blue or black, contact your local distributor/dealer

Clean the exhaust/water mixing elbow *[ Inspect the complete exhaust system w 2.2 X

ENGINE AND MOUNTING

Check for water, fuel, coolant, and oil leakage *[]

Check the mounting bolts/vibromounts and tighten if necessary *

GENERATOR

Test run the generator set 2.5

Blow dust out of the generator *[

* Requires removal of the sound shield, if installed

[ Consult your local distributor/dealer for service ] Read the WARNING found at the beginning of the manual regarding moving parts w Should be performed by your local distributor/dealer

Reference

Section

3.3.2

3.4

3.4 X

3.1 X

Daily

(Before

operation)

(During

operation)

(After

operation)

50 Hrs.

or 1

Month

(Weekly)

Every

200 Hrs.

or 3

Months

Every

400 Hrs.

or 6

Months

(Check)X(Replace)

1000 Hrs.

or Yearly

Every

TP-6109 6/0320 Section 3 Scheduled Maintenance

Page 31

3.3 Cooling System

WARNING

Hot coolant and steam. Can cause severe injury or death.

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

Siphon Break Inspection

1. Stop the generator set.

2. Remove the retaining cap and remove the reed valve for inspection. See Figure 3-1.

3. Use a mild detergent to remove residue and oxidation from the reed valve.

4. Clear blockage from the reed valve opening.

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

Checking the coolant level. Hot coolant can cause severe injury or death. 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.

3.3.1 Siphon Break

A siphon break prevents seawater entry into the generator set’s engine when the engine exhaust manifold outlet is less than 230 mm (9 in.) above the waterline of a fully loaded, docked or stationary craft. The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater. Use the following procedure to inspect the siphon break at the intervals listed in the service schedule.

6. Install the reed valve into the mounting base with the valve downward. See Figure 3-1, item 3.

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

1. Mounting base

2. Retaining cap

3. Reed valve

TP-5856-3

Figure 3-1 Siphon Break

m:sm:003:007

TP-6109 6/03 21Section 3 Scheduled Maintenance

Page 32

3.3.2 Impeller Inspection and Replacement Procedure

The gear driven seawater pump is located on the service side of the generator set. Check and change the seawater pump impeller at the interval specified in the service schedule. Follow the instructions included with the impeller kit. If the instructions are not included with the kit, use the following procedure:

Impeller Inspection and Replacement Procedure:

1. Close the seacock.

2. Remove the seawater pump coverplate. See Figure 3-2.

1. Seawater pump

2. Coverplate

3. Gasket

4. Impeller

5. Bearing

6. Housing

7. Pulley

8. Drive shaft

9. Washer

10. Nut

TP-6053

1. Flattened vane

TP-6053

2. Crack

3. Broken vane

Figure 3-3 Worn Impeller

5. Lubricate the impeller with soapy water before installation.

6. Install the impeller.

Note: During installation push and rotate the

impeller in the same direction as the engine rotation until it is thoroughly seated in the impeller housing.

7. Inspect the coverplate and gasket for corrosion and/or damage. Replace components as necessary.

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

9. Open the seacock.

Figure 3-2 Seawater Pump, Typical

3. Remove the impeller.

4. Inspect the impeller for damaged, cracked, broken, missing or flattened vanes. The impeller vanes should be straight and flexible. See Figure 3-3. Replace the impeller if it is damaged.

10. Start the generator set and check for leaks.

11. Stop the generator set and repair leaks or replace damaged or worn components.

m:sm:003:008

TP-6109 6/0322 Section 3 Scheduled Maintenance

Page 33

3.4 Exhaust System

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. Consult the boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.

At the interval specified in the service schedule, inspect the exhaust system. See Section 1 for the exhaust outlet location.

Inspection Points

Inspect the the exhaust system components (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and outlet flapper) for cracks, leaks, and corrosion.

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 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.

D Ensure that the carbon monoxide detector is (1) in the

craft, (2) functional, and (3) energized whenever the generator set operates.

x:op:001:002

TP-6109 6/03 23Section 3 Scheduled Maintenance

Page 34

3.5 Storage Procedure

3.5.3 Fuel System

Perform the following storage procedure before taking a generator set out of service for three months or longer. Follow the engine manufacturer’s recommendations, if available, for fuel system and internal engine component storage.

x:sm:002:001

3.5.1 Lubricating System

Prepare the engine lubricating system for storage as follows:

1. Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature.

2. Stop the generator set.

3. With the engine still warm, drain the oil from the crankcase.

4. Remove and replace the oil filter.

5. Refill the crankcase with oil suited to the climate.

6. Run the generator set for two minutes to distribute the clean oil.

Prepare the fuel system for storage as follows:

Diesel-Fueled Engines

1. Fill the fuel tank with #2 diesel fuel.

2. Condition the fuel system with compatible additives to control microbial growth.

3. Change the fuel filter/separator and bleed the fuel system. See the service manual.

3.5.4 Exterior

Prepare the exterior for storage as follows:

1. Clean the exterior surface of the generator set.

2. Seal all engine openings except for the air intake with nonabsorbent adhesive tape.

3. To prevent impurities from entering the air intake and to allow moisture to escape from the engine, secure a cloth over the air intake.

4. Mask electrical connections.

7. Stop the generator set.

8. Check the oil level and adjust, if needed.

x:sm:002:002

3.5.2 Cooling System

Prepare the cooling system for storage as follows:

1. Check the coolant freeze protection using a coolant tester.

2. Add or replace coolant as necessary to ensure adequate freezing protection. Use the guidelines included in the engine operation manual.

3. Run the generator set for 30 minutes to redistribute added coolant.

x:sm:002:003

5. Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion.

x:sm:002:006a

3.5.5 Battery

Perform battery storage after all other storage procedures.

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

2. Disconnect the battery(ies), negative (--) lead first.

3. Clean the battery. Refer to the battery manufacturer’s instructions for the battery cleaning procedure.

4. Place the battery in a cool, dry location.

5. Connect the battery to a float/equalize battery charger or charge it monthly with a trickle battery charger. Refer to the battery charger manufacturer’s recommendations.

6. Maintain a full charge to extend battery life.

TP-6109 6/0324 Section 3 Scheduled Maintenance

Page 35

Section 4 Troubleshooting

This section contains generator set troubleshooting, diagnostic, and repair information.

Use the following chart as a quick troubleshooting reference. The table groups generator set faults and suggests likely causes and remedies. The table also refers you to more detailed information including sections of this manual, the generator set service manual (S/M), the generator set installation manual (I/M), and the engine service manual (Engine S/M) to correct the indicated problem.

Corrective action and testing often require knowledge of electrical and electronic circuits. To avoid additional problems caused by incorrect repairs, have an authorized service distributor/dealer perform service.

NOTICE

Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/dealer. Use the record to help describe the problem and repairs or adjustments made to the equipment.

x:gt:001:002a:

TP-6109 6/03 25Section 4 Troubleshooting

Page 36

Section or

Reference*

Publication

Gen. S/M

Eng. O/M

Trouble Symptoms

Move the controller master switch to the RUN or AUTO position. Section 2

Probable Causes Recommended Actions

Controller master switch in the

abnormal noise Excessive or

consumption High fuel

pressure Low oil

Overheats

Lacks power

suddenly Stops

output voltage No or low

OFF/RESET position

Controller fuse blown Replace the blown controller fuse. If the fuse blows again,

troubleshoot the controller.[

Reset the emergency stop switch. Section 2

Emergency stop switch activated, if

equipped

Replace the controller master or start/stop switch. —

Troubleshoot the controller.[

Controller master or start/stop switch

inoperative

x Controller fault

x x Air openings clogged Clean the air openings. —

system.

Restore the coolant to normal operating level. Eng. O/M

High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling

Low coolant level shutdown, if

equipped

x Impeller inoperative Replace the impeller Section 3

x x Seawater strainer clogged or restricted Clean the strainer. Section 3

x Coolant level low Restore the coolant to normal operating level. Eng. O/M

x Thermostat inoperative Replace the thermostat. Eng. S/M

x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M

Starts hard

does not start Cranks but

crank Does not

26 Section 4 Troubleshooting

Controller

x x x

x x

x x Controller circuit board(s) inoperative Replace the controller circuit board. Gen. S/M

Cooling System

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

TP-6109 6/03

Page 37

Section or

Reference*

Publication

Recommended ActionsProbable Causes

Eng. O/M, S/S

W/D

I/M

Section 3, I/M

Gen. S/M

Eng. O/M

Trouble Symptoms

Verify that the battery connections are correct, clean, and tight. —

Battery connections loose, corroded,

abnormal noise Excessive or

consumption High fuel

pressure Low oil

Overheats

Lacks power

suddenly Stops

output voltage No or low

or incorrect

Battery weak or dead Recharge or replace the battery. The spec sheet provides

recommended battery CCA rating.

Disconnect the engine harness connector(s) then reconnect it to

Engine harness connector(s) not

the controller.

locked tight

TP-6109 6/03

x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2

Replace the inoperative switch. Gen. S/M or W/D

High exhaust temperature switch

inoperative

Clean or replace the filter element. Eng. O/M

Air cleaner/backfire flame arrestor

clogged

manual for wattage specifications.

system components.[

Engine overload Reduce the electrical load. See the generator set installation

Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust

x x x x x

components.[

Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system

Adjust the governor.[

Adjust the valves.[

x Vibration excessive Tighten all loose hardware. —

x x Valve clearance incorrect

Starts hard

does not start Cranks but

crank Does not

x x

Electrical System (DC circuits)

x x

x x x x Governor inoperative

x x x x

x x

x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M

Engine

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

27Section 4 TroubleshootingTP-6109 6/03

Page 38

Section or

Reference*

Publication

Recommended ActionsProbable Causes

Eng. S/M

Clean, test, and/or replace the inoperative fuel injector.[

Eng. S/M

Adjust the fuel injection timing.[

Eng. S/M

Rebuild or replace the injection pump.[

—

Gen. S/M

—

Gen. S/M

Section 2

side of the circuit breaker.

Move the transfer switch test switch to the AUTO position. —

Check for continuity. Gen. S/M, W/D

Test and/or replace the rotor.[

Test and/or replace the stator.[

Tighten loose components.[

troubleshoot the voltage regulator.

distributor/dealer.

abnormal noise Excessive or

consumption High fuel

pressure Low oil

Overheats

Lacks power

suddenly Stops

output voltage

Trouble Symptoms

28 Section 4 Troubleshooting

No or low

Starts hard

does not start Cranks but

crank Does not

x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —

Fuel System

x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M

Fuel or fuel injectors dirty or faulty

(diesel only)

x x x

Fuel injection timing out of adjustment

(diesel only)

Fuel feed or injection pump inoperative

(diesel only)

x x x x

x x x

AC output circuit breaker open Reset the breaker and check for AC voltage at the generator

Generator

Transfer switch test switch in the OFF

position

Wiring, terminals, or pin in the exciter

field open

Main field (rotor) inoperative (open or

grounded)

x Vibration excessive

x Stator inoperative (open or grounded)

x x Voltage regulator out of adjustment Adjust the voltage regulator. Gen. S/M

Voltage regulator fuse blown Replace the voltage regulator fuse, If the fuse blows again,

x x

Overspeed shutdown Reset the controller. If the unit shuts down again, contact the

Overcrank shutdown Reset the controller. If the unit shuts down again, contact the

x x x

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

TP-6109 6/03

Page 39

Section or

Reference*

Publication

Recommended ActionsProbable Causes

Eng. O/M

Change the oil. Use oil with a viscosity suitable for the operating

climate.

Trouble Symptoms

abnormal noise Excessive or

consumption High fuel

pressure Low oil

Overheats

x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M

Lacks power

suddenly Stops

output voltage No or low

Starts hard

does not start Cranks but

crank Does not

Lube System

x Low oil pressure shutdown Check the oil level. Eng. O/M

Crankcase oil type incorrect for

ambient temperature

TP-6109 6/03

x x x x

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

29Section 4 TroubleshootingTP-6109 6/03

Page 40

Notes

TP-6109 6/0330 Troubleshooting

Page 41

Section 5 Wiring Diagrams

WARNING

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible

whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

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

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

Moving rotor.

TP-6109 6/03 31Section 5 Wiring Diagrams

Page 42

Figure 5-1 Wiring Diagram, Decision-Makert 1 Standard Controller (Sheet 1 of 3)

GM24452A-A

TP-6109 6/0332 Section 5 Wiring Diagrams

Page 43

Figure 5-2 Wiring Diagram, Decision-Makert 1 Standard Controller, Remote Panel Options (Sheet 2 of 3)

TP-6109 6/03 33Section 5 Wiring Diagrams

GM24452B-A

Page 44

Figure 5-3 Wiring Diagram, Decision-Makert 1 Standard Controller, Remote Panel Options (Sheet 3 of 3)

GM24452C-A

TP-6109 6/0334 Section 5 Wiring Diagrams

Page 45

Figure 5-4 Wiring Diagram—Schematic, Decision-Makert 1 Standard Controller (Sheet 1 of 1)

TP-6109 6/03 35Section 5 Wiring Diagrams

ADV6740-A

Page 46

Figure 5-5 Wiring Diagram, Decision-Makert 1 Expanded Controller (Sheet 1 of 6)

GM24453A-A

TP-6109 6/0336 Section 5 Wiring Diagrams

Page 47

Figure 5-6 Wiring Diagram, Decision-Makert 1 Expanded Controller (Sheet 2 of 6)

TP-6109 6/03 37Section 5 Wiring Diagrams

GM24453B-A

Page 48

Figure 5-7 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 3 of 6)

GM24453C-A

TP-6109 6/0338 Section 5 Wiring Diagrams

Page 49

Figure 5-8 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 4 of 6)

TP-6109 6/03 39Section 5 Wiring Diagrams

GM24453D-A

Page 50

Figure 5-9 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 5 of 6)

GM24453E-A

TP-6109 6/0340 Section 5 Wiring Diagrams

Page 51

Figure 5-10 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 6 of 6)

TP-6109 6/03 41Section 5 Wiring Diagrams

GM24453F-A

Page 52

Figure 5-11 Wiring Diagram—Schematic, Decision-Makert 1 Expanded Controller (Sheet 1 of 1)

ADV6741-A

TP-6109 6/0342 Section 5 Wiring Diagrams

Page 53

Figure 5-12 Wiring Diagram, Decision-Makert 3+ Controller (Sheet 1 of 7)

TP-6109 6/03 43Section 5 Wiring Diagrams

GM24454A-B

Page 54

Figure 5-13 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 2 of 7)

GM24454B-B

TP-6109 6/0344 Section 5 Wiring Diagrams

Page 55

Figure 5-14 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 3 of 7)

TP-6109 6/03 45Section 5 Wiring Diagrams

GM24454C-B

Page 56

Figure 5-15 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 4 of 7)

GM24454D-B

TP-6109 6/0346 Section 5 Wiring Diagrams

Page 57

Figure 5-16 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel/Annunciator Options (Sheet 5 of 7)

TP-6109 6/03 47Section 5 Wiring Diagrams

GM24454E-B

Page 58

Figure 5-17 Wiring Diagram, Decision-Makert 3+ Controller, Remote Annunciator Options (Sheet 6 of 7)

GM24454F-B

TP-6109 6/0348 Section 5 Wiring Diagrams

Page 59

Figure 5-18 Wiring Diagram, Decision-Makert 3+ Controller, Remote Annunciator Options (Sheet 7 of 7)

TP-6109 6/03 49Section 5 Wiring Diagrams

GM24454G-B

Page 60

Figure 5-19 Wiring Diagram—Schematic, Decision-Makert 3+ Controller (Sheet 1 of 1)

ADV6742-A

TP-6109 6/0350 Section 5 Wiring Diagrams

Page 61

Terminal Purpose

1 Ground—emergency stop relay (K4)—connect

emergency stop across terminals TB1-1 and 1A *

1A Emergency stop relay (K4) coil; negative

side—connect emergency stop across terminals TB1-1 and 1A *

2 Ground terminal

Overcrank (OC) indicator [

Auxiliary (AUX) indicator [

32 Common fault/prealarm line 1—A/V alarm or

common fault relay activated by OC, 12; AUX, 26; LWT, 35; HET, 36; LOP, 38; OS, 39; PHET, 40; PLOP, 41; and LF, 63 faults

32A Common fault/prealarm line 2—A/V alarm or

common fault relay activated by AUX, 26; HET, 36; LOP, 38; OS, 39; and E-Stop, 48 faults

35 Low water temperature (LWT) indicator

High engine temperature (HET) indicator [

Low oil pressure (LOP) indicator [

Overspeed (OS) indicator [

40 Prealarm high engine temperature (PHET)

indicator [

41 Prealarm low oil pressure (PLOP)

indicator [

42A Battery voltage (fuse #1 protected)—

accessory power supply; customer may also provide separate accessory power source

Emergency stop (ES) indicator [

56 Air damper (AD) indicator, if equipped;

standard on all 200--2000 kW Detroit Diesel-powered models

System ready indicator [

61 Battery charger fault—connect battery charger

alarm contact to TB1-61 to activate fault lamp (active low) (if used)

62 Low battery volts—connect battery charger

alarm contact to TB1-62 to activate fault lamp (active low) (if used)

63 Low fuel (LF) fault—connect fuel level sensor

to TB1-63 to activate fault lamp (active low) (if used)

70C Generator in cool down mode signal

70R Generator in running mode signal

* Connect jumper across terminals 1 and 1A if emergency stop

switch is not used.

[ Use a remote annunciator and/or A/V alarm kit as an indicator

with a dry contact kit connected to controller terminal strip TB1.

Note: Not all terminals are used for all generator sets (see appropriate wiring diagrams for specific generator set model).

Not in auto indicator [

Terminal Purpose

1P Prime power operation

2P Prime power operation

Remote start ground—connect transfer

switchorremotestartswitchtoTB2--3and TB2--4

3P Prime power operation

Remote start—connect transfer switch or remote start switch to TB2--3 and TB2--4

4P Prime power operation

Crank mode selection (open: cyclic crank, ground: continuous crank); connect TB2--9

to TB2--9A for continuous cranking; leave TB2--9 open cyclic cranking; see starting instructions in Section 2, Operation.

9A Crank mode ground

Note: To use prime power mode—place jumpers across TB2-1P to TB2-2P, TB2-3P to TB2-4P, and TB2-3 to TB2-4. To deactivate prime power mode—remove jumpers across TB2-1P to TB2-2P, TB2-3P to TB2-4P, and TB2-3 to TB2-4.

Figure 5-21 Controller TB2 Terminal Strip

(Decision-Makert 3+ Controller)

Figure 5-20 Controller TB1 Terminal Strip

(Decision-Makert 3+ Controller)

TP-6109 6/03 51Section 5 Wiring Diagrams

Page 62

Notes

TP-6109 6/0352 Section 5 Wiring Diagrams

Page 63

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimensional

AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards

AO anticipatory only API American Petroleum Institute approx. approximate, approximately AR as required, as requested AS as supplied, as stated, as

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary A/V audiovisual avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery

BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block

blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CARB California Air Resources Board CB circuit breaker cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide

cogen. cogeneration Com communications (port) conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards

CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., ° degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung

DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection

EPS emergency power system ER emergency relay ES engineering special,

ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust ext. external F Fahrenheit, female

substrate (semiconductor)

Association

e. V. (also Deutsche Industrie Normenausschuss)

Association

Agency

engineered special

fglass. fiberglass FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lbs. foot pounds (torque) ft./min. feet per minute ggram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter

GND, gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temperature hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air

HWT high water temperature Hz hertz (cycles per second) IC integrated circuit ID inside diameter, identification IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting in. inch in. H in. Hg inches of mercury in. lbs. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe ISO International Organization for

J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (2

ground

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

bytes)

TP-6109 6/03 Appendix A-1

Page 64

kg kilogram

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound, pounds

lbm/ft

pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side L

sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (10

units), male

cubic meter

/min. cubic meters per minute

when used with SI

mA milliampere man. manual max. maximum MB megabyte (2

bytes) MCM one thousand circular mils MCCB molded-case circuit breaker meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, mΩ

milliohm

MOhm, MΩ

megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second MTBF mean time between failure MTBO mean time between overhauls mtg. mounting

MW megawatt mW milliwatt µF microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical

Manufacturers Association

NFPA National Fire Protection

Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe

thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment

manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health

Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor

ph.,

∅ phase

PHC Phillips head crimptite (screw) PHH Phillips hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent-magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only

memory psi pounds per square inch pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart qty. quantity R replacement (emergency)

power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote RFI radio frequency interference RH round head RHM round head machine (screw) rly. relay

rms root mean square rnd. round ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive

Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites,

International System of Units SI/EO side in/end out sil. silencer SN serial number SPDT single --pole, double--throw SPST single--pole, single--throw spec, specs

specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to

normal TDES time delay engine start TDNE time delay normal to

emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple

locations) UF underfrequency UHF ultrahigh frequency UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer

TP-6109 6/03A-2 Appendix

Page 65

Appendix B Operating Hour Service Log

Use the log below to keep a cumulative record of operating hours on your generator set and the dates

OPERATING HOURS SERVICE RECORD

DATE

RUN

HOURS

RUN

TOTAL

HOURS

SERVICE

DATE

required services were performed. Enter hours to the nearest quarter hour.

SERVICE

TP-6109 6/03 Appendix A-3

Page 66

Page 67

Page 68

TP-6109 6/03c

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 KohlerPowerSystems.com

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455

Kohler 40EFOZ, 33EFOZ, 40EOZ, 50EOZ, 55EFOZ Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual