Kohler 8-32EOZD, 6.5-27EFOZD Service Manual

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Page 1

Service

Marine Generator Sets

Models:

8--32EOZD

6.5--27EFOZD

TP-6255 7/06a

Page 2

Product Identification Information

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

Generator Set Identification Numbers

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

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

x:in:007:001

TP-6255 7/062

Page 3

Table of Contents

Product Identification Information 2............................................................

Safety Precautions and Instructions 5........................................................

Introduction 11...............................................................................

Service Assistance 11........................................................................

Section 1 Specifications 13...................................................................

1.1 General 13..............................................................

1.2 Engine 14...............................................................

1.3 Generator, 4 Lead 18.....................................................

1.4 Generator, 12 Lead 19....................................................

1.5 Service Views 20........................................................

1.6 Torque Specifications 21..................................................

Section 2 Scheduled Maintenance 23..........................................................

2.1 General 23..............................................................

2.2 Lubrication System 24....................................................

Section 3 Intake and Exhaust System 25.......................................................

3.1 Air Intake Silencer/Cleaner 25.............................................

3.2 Exhaust System Inspection 26.............................................

3.3 Servicing Mixing Elbow 26................................................

3.4 Turbocharger (Models: 14/15.5/23/24EOZD and 11.5/13/20EFOZD) 26..........

Section 4 Fuel System 29.....................................................................

4.1 General 29..............................................................

4.2 Fuel Filter 29............................................................

4.2.1 Bleeding the Fuel System 31......................................

4.3 Fuel Pump 32...........................................................

4.4 Governor 32.............................................................

Section 5 Cooling System 33.................................................................

5.1 General 33..............................................................

5.2 Water-Cooled Exhaust Manifold 34.........................................

5.3 Closed Heat Exchanger 34................................................

5.4 Check and Fill Coolant 34.................................................

5.5 Flush and Clean Cooling System 35........................................

5.6 Pressure Cap 35.........................................................

5.7 Impeller Inspection and Replacement 35....................................

5.8 Belt Tension 36..........................................................

5.8.1 Seawater Pump Belt Tensioning Procedure 36.......................

5.8.2 Battery Charging Alternator Belt Tensioning Procedure 37.............

5.8.3 Anticorrosion Zinc Anode 37.......................................

5.9 Siphon Break 38.........................................................

Section 6 Troubleshooting 39.................................................................

6.1 Introduction 39..........................................................

6.2 Initial Checks 39.........................................................

6.3 General 39..............................................................

6.4 Troubleshooting Chart 39.................................................

Section 7 Controller 45.......................................................................

7.1 Introduction 45..........................................................

7.2 Advanced Digital Control Display and Keypad 46.............................

7.3 Sequence of Operation 47................................................

7.3.1 Starting Sequence, Master Switch Moved to RUN 47.................

7.3.2 Starting Sequence, Remote Start 47................................

7.3.3 Running Sequence 48............................................

TP-6255 7/06 Table of Contents 3

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7.3.4 Stopping Sequence, Master Switch Moved to OFF/RESET 48..........

7.3.5 Stopping Sequence, Remote Stop 48...............................

7.4 Faults 48...............................................................

7.4.1 Fault Shutdowns 48..............................................

7.4.2 Warnings 48.....................................................

7.5 Controller Configuration and Adjustment 50.................................

7.5.1 Controller Time Out 50............................................

7.5.2 Controller Configuration 50........................................

7.5.3 Voltage Adjustment 50............................................

7.6 Controller Application Program 55..........................................

7.7 Silicon Controlled Rectifier (SCR) Module 55................................

7.8 Continuous Power Mode Jumper, if equipped 57.............................

7.9 Master Switch 58........................................................

7.10 Relay Interface Board (RIB) 59............................................

7.11 Controller Replacement 60................................................

Section 8 Component Testing and Adjustment 63..............................................

8.1 Theory of Operation 63...................................................

8.2 Separate Excitation 63....................................................

8.3 Exciter Field 65..........................................................

8.4 Exciter Armature 66......................................................

8.5 Rectifier Module 67......................................................

8.6 Rotor 67................................................................

8.7 Stator 68................................................................

8.8 Voltage 70..............................................................

8.8.1 Voltage Regulation 70............................................

8.8.2 Voltage Adjustment 70............................................

8.9 Four-Lead Reconnection 72...............................................

8.9.1 100--120-Volt Configurations 72....................................

8.9.2 100--120/200--240-Volt Configurations 72............................

8.9.3 200--240-Volt Configurations 73....................................

8.10 Twelve-Lead Reconnection 73.............................................

8.11 Fault Shutdown Tests 74..................................................

8.11.1 Controller Fault Shutdown Functions 74.............................

8.11.2 Fault Shutdown Switches 75.......................................

8.12 Fuses 76...............................................................

8.13 Continuity Checks 76.....................................................

Section 9 Generator Disassembly/Reassembly 79..............................................

9.1 Disassembly 79..........................................................

9.2 Reassembly 83..........................................................

Section 10 Wiring Diagrams 85...............................................................

10.1 Manual Marine (Ship-to-Shore) 2 Wire and 3 Wire Transfer Switches 90.........

10.2 Manual Marine (Ship-to-Shore) 4 Wire Transfer Switch 91.....................

Appendix A Abbreviations 93..................................................................

Appendix B Common Hardware Application Guidelines 95........................................

Appendix C General Torque Specifications 96...................................................

Appendix D Common Hardware Identification 97.................................................

Appendix E Common Hardware List 98.........................................................

TP-6255 7/06Table of Contents4

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Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment, including generator sets, transfer switches, switchgear,andaccessories, 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,orsubstantial 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 froma 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 thecase 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-6255 7/06 5Safety Precautions and Instructions

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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 air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator

set with the air cleaner/silencer removed.

Combustible materials. A sudden flash fire can cause severe injury or death. Do not smoke or permit flames

or sparks near the generator set. Keep the compartment and the generator set clean and free of debris to minimize the risk of fire. Catch fuels in an approved container. Wipe up spilled fuels and engine oil.

Combustible materials. A fire can cause severe injury or death.

Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.

Engine Fluids and Chemical Products

WARNING

Handling caustic engine fluids and chemical products. Can cause severe chemical burns, nausea, fainting, or death.

Most chemicals such as used engine oil, antifreeze/coolant, rustproofing agent, inhibiting oil, degreasing agent, spray paint, and adhesivesare hazardous to health. Read and follow the user information found on the packaging. Avoid inhalation and skin contact. Use only in well-ventilated areas and use a protective mask when spraying. Store engine fluids and chemical products in a locked cabinet. Contact your local recycling center for disposal information and locations.

WARNING

Flammable engine solvents and cleaners. Can cause severe injury or death.

Do not smoke or permit flames or sparks near flammable engine solvents and cleaners. Read and follow the user information found on the packaging. Use only in wellventilated areas. Never use gasoline or low flash-point solvents as cleaning agents.

Leaking or accumulated engine fluids. A fire cancause severe injury or death. Clean up engine fluids

including fuel, oil, grease, and coolant. Determine the source of engine leaks and correct before starting the generator set. Keep the generator set area clean and remove combustible materials.

Used engine oil. Contact with used engine oil may cause severe skin irritation. Repeated and prolonged skin exposure may have other health risks. Used engine oil is a

suspected carcinogen. Avoid contact with skin. Thoroughly wash your hands and nails with soap and water shortly after handling used engine oil. Wash or dispose of clothing or rags containing used engine oil. Dispose of used engine oil in a responsible manner. Contact your local recycling center for disposal information and locations.

Fire-damaged or burned O-rings may cause the formation of hydrofluoric acid. Contact with hydrofluoric acid may cause severe skin irritation and chemical burns.

O-rings and other fluoroelastomer seals exposed to fire or temperatures above 316_C (600_F) (i.e., during welding) may decompose forming hydrofluoric acid. Avoid inhalation or skin contact. Do not incinerate O-rings. Dispose of O-ring waste material in a responsible manner.

TP-6255 7/066 Safety Precautions and Instructions

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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 deathif inhaled for even a short time. Use the following precautions when installing and operating the generator set. Do not install the exhaustoutletwhereexhaust can be drawn in through portholes, vents, or air conditioners. Avoid overloading the craft. 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.

Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

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

WARNING

Avoid high pressure fluids. Can cause severe injury or death.

Do not work on high pressure fuel or hydraulic systems without protective equipment to protect hands, eyes, and body. Avoid the hazard by relieving pressure before disconnecting fuel injection pressure lines. Search for leaks using a piece of cardboard. Always protect hands, eyes, and body from high pressure fluids. If an accident occurs, seek medical attention immediately.

TP-6255 7/06 7Safety Precautions and Instructions

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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 catchfuel 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 roomor 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. Wear hearing

protection when near an operating generator set Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss.

Hazardous Voltage

WARNING

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

is possible whenever electricity is present. Turn off 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 applicablecodes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

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

the generator set from the load by 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.

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.

Hazardous voltage. Can cause severe injury or death.

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

Moving rotor.

TP-6255 7/068 Safety Precautions and Instructions

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

Do not work on the generator set until it cools.

WARNING

Hot engine oil. Can cause severe injury or death.

Avoid skin contact with hot oil. Do not start or operate the generator set with the engine oil filler cap removed, as hot oil can spray out. Ensure that the lubrication system is not under pressure when servicing. 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 ifthe generator set has a coolant recovery tank.

Moving Parts

WARNING

Hazardous voltage. Can cause severe injury or death.

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

WARNING

Rotating parts. Can cause severe injury or death.

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

WARNING

Airborne particles. Can cause severe injury or blindness.

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

Moving rotor.

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.

TP-6255 7/06 9Safety Precautions and Instructions

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.

Page 10

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

the hardware or pulley to release from the generator setengineandcancause 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

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.

Notice

NOTICE

This generator set has been rewired from its nameplate voltage to

246242

TP-6255 7/0610 Safety Precautions and Instructions

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Introduction

This manual provides troubleshooting and repair instructions for 8-32EOZD and 6.5-27EFOZD model generator sets (4-lead and 12-lead), Advanced Digital Control, and accessories.

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

x:in:001:001

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

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

D Consult the Yellow Pages under the heading

Generators—Electric

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

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Maintenance work must be performed by appropriately skilled and suitably-trained maintenance personnel familiar with generator set operation and service.

x:in:001:003

Service Assistance

China

North China Regional Office, Beijing Phone: (86) 10 6518 7950

(86) 10 6518 7951 (86) 10 6518 7952

Fax: (86) 10 6518 7955

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

Headquarters Europe, Middle East, Africa (EMEA)

Kohler Power Systems ZI Senia 122 12, rue des Hauts Flouviers 94517 Thiais Cedex France Phone: (33) 1 41 735500 Fax: (33) 1 41 735501

Asia Pacific

Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264-6422 Fax: (65) 6264-6455

East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office Bangalore, India Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727

Latin America

Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131

TP-6255 7/06 11Introduction

Page 12

Notes

TP-6255 7/0612 Service Assistance

Page 13

Section 1 Specifications

1.1 General

This manual covers maintenance, troubleshooting, and repair of the alternating current marine generator sets listedinFigure1-1.

Models Voltage Hz Phase

8/9/10EOZD

10EOZD

13/15.5/20/23/28/32EOZD 120/240 60 1

14/20/24/28/32EOZD 120/240 60 1

14/20/24/28/32EOZD

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

8.5EFOZD 230/400 50 3

11.5/17.5/20/23/27EFOZD 1 15/230 50 1

1 1.5/17.5/20/23/27EFOZD

Figure 1-1 Generator Model Coverage

120

120/240

220/380

240/416

120/208

120/240

127/220

139/240

277/480

1 15/230

230

240

1 10/190

1 15/230

120/208

230/400

240/416

60 1

60 3

50 1

50 3

The 8EOZD/6.5EFOZD, 9EOZD/7EFOZD, 10EOZD/ 9EFOZD, and 13EOZD/11EFOZD models are powered by a three-cylinder, water-cooled, four-cycle diesel engine with a heat exchanger.

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

The 20EOZD/17EFOZD and 20EOZD/17.5EFOZD models are powered by a four-cylinder, water-cooled, four-cycle diesel engine with a heat exchanger.

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

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

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

Kohler Co. develops all Kohlerr marine generator set ratings using accepted reference conditions of 25_C (77_F) and pressure of 29.2 in. Hg dry barometer. ISO 3046 and ISO 8528-1 include reference conditions and output calculations. Obtain the technical information bulletin on ratings guidelines (TIB-101) for complete ratings definitions.

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

TP-6255 7/06 13Section 1 Specifications

Page 14

1.2 Engine

Generator Model

Number of cylinders

Type

Cylinder block material

Cylinder head material

Crankshaft material

Piston rings

Connecting rod material

Governor

Engine firing order (#1 cylinder on flywheel side)

Direction of rotation (as viewed from flywheel)

Combustion system

Bore x stroke, mm (in.)

Displacement L (CID)

Compression ratio

Max. power at rated RPM, 60/50 Hz

RPM 60/50 Hz

Lubrication system

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

Oil recommendation (API)

Fuel recommendation (API)

Fuel shutoff solenoid

Fuel pump

Fuel pump priming

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

Battery voltage

Battery charging

Battery recommendation (minimum)

Starter motor

Recommended coolant

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

Thermostat, _C(_F)

High exhaust temperature shutdown, _C(_F)

Low oil pressure shutdown, kg/cm@ ± 0.1 kg/cm@ (psi)

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

10EOZD/

8EOZD/

6.5EFOZD

Stamped

forging

Special swirl

pre-

combustion

chamber

74 x 78

(2.91 x 3.07)

1.01 (61.39) 1.115 (68) 1.33 (81.14) 1.642 (100.2) 1.5 (91.3)

23:1 23.5:1 19.2:1 19.1:1 19.0:1

14.0/11.6 14.74/12.43 18.4/15.1 22.6/18.6 26.1/21.8

2.3 (2.4) 3.6 (3.8) 4.7 (5.0)

0.8 kW Bendix automotive

3.9 (4.12) 2.46 (2.6) 4.4 (4.6)

1/2 NPT with sound shield

16 (5/8) without sound shield

9EOZD/

7EFOZD

Indirect

injection

76 x 82

(3.0 x 3.2)

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

12 volts 12 volts (standard) 24 volts (optional)

type

50% ethylene glycol; 50% clean, softened water

8.5EFOZD/ 9EFOZD

4 cycle 4 cycle, turbocharged

2 compression/1 oil

Forged carbon steel

Centrifugal, mechanical

Counterclockwise

82 x 84

(3.23 x 3.30)

Pressure, trochoid pump

CD or CF class

Electric, rotary vane

40-amp alternator

500 CCA, 100 amp hr.

1.8 kW Bendix, gear-reduction automotive type

102 (215)±5

13EOZD/

11EFOZ D

Cast iron

Forged steel

1--3--2

(3.46 x 3.54)

1800/1500

Electric

1.2 (4)

82 (179)

0.5 (7.1)

14EOZD/

11.5EFOZD

Direct injection

88 x 90

3/4 NPT with sound shield

25 (1) without sound shield

15.5EOZD/ 13EFOZD

84 x 90

(3.31 x 3.54)

TP-6255 7/0614 Section 1 Specifications

Page 15

10EOZD/

8EOZD/

Generator Model

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

Fuel inlet size

Fuel return size

Fuel injection pressure, kgf/cm sq. (psi) 120 (1706)

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

Fuel pump static pressure, psi 4--8 (12-volt pump) or 5.5--9 (24-volt pump)

Pressure cap rating, kPa (psi) 97 (14)

6.5EFOZD

51 (2) without sound shield

9EOZD/

7EFOZD

51 (2) with sound shield

120--130

(1706--1849)

8.5EFOZD 9EFOZD

3/8 NPT with sound shield

1/4 NPT without sound shield

3/8 NPT with sound shield

1/4 NPT without sound shield

0.15--0.25 (0.006--0.0010)

13EOZD/

11EFOZ D

76 (3) with sound shield

76 (3) without sound shield

200--210 (2844--2986)

14EOZD/

11.5EFOZD

15.5EOZD/ 13EFOZD

TP-6255 7/06 15Section 1 Specifications

Page 16

20EOZD/

17EFOZD/

17.5EFOZD

Generator Model

Number of cylinders

Type

Cylinder block material

Cylinder head material

Crankshaft material

Piston rings

Connecting rod material

Governor

Engine firing order (#1 cylinder on flywheel side)

Direction of rotation (as viewed from flywheel)

Combustion system

Bore x stroke, mm (in.)

Displacement L (CID)

Compression ratio

Max. power at rated RPM, 60/50 Hz

RPM 60/50 Hz

Lubrication system

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

Oil recommendation (API)

Fuel recommendation (API)

Fuel shutoff solenoid Electric

Fuel pump Electric, rotary vane

Fuel pump priming Electric

Max. recommended fuel pump lift, m (ft.) 1.2 (4)

Battery voltage

Battery charging

Battery recommendation (minimum)

Starter motor

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

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

Thermostat, _C(_F)

High exhaust temperature shutdown, _C(_F)

Low oil pressure shutdown, kg/cm@ ± 0.1 kg/cm@ (psi)

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

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

(1 and 3 Ph.)

4 cycle 4 cycle, turbocharged 4 cycle, naturally aspirated

88 x 90

(3.46 x 3.54)

2.189 (133.58) 1.995 (121.74) 3.319 (202.5)

19.1:1 18.9:1 18.5:1

30.1/24.8 37.1/29.3 55.8/46.7

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

6.0 (6.3) 7.57 (8)

23EOZD/

20EFOZD

(3.31 x 3.54)

5.8 (6.1) 10.2 (10.78)

12 volts (standard) 24 volts (optional)

500 CCA, 100 amp hr. 800 CCA, 100 amp hr.

1.8 kW 2.3 kW

3/4 NPT with sound shield

25 (1) without sound shield

76 (3) with sound shield

76 (3) without sound shield

24EOZD/

20EFOZD

Cast iron

Forged steel

2 compression/1 oil

Forged carbon steel

Centrifugal, mechanical

1--3--4--2

Counterclockwise

Direct injection

84 x 90

1800/1500

Pressure, trochoid pump

CD or CF class

40-amp alternator

82 (179)

102 (215)±5

0.5 (7.1)

28EOZD/

23EFOZD

(1 and 3 Ph.)

98 x 110

(3.86 x 4.33)

3/4 NPT with sound shield

19 (0.75) without sound shield

76 (3) with sound shield

76 (3) without sound shield

32EOZD/

27EFOZD

(1 and 3 Ph.)

TP-6255 7/0616 Section 1 Specifications

Page 17

20EOZD/

17EFOZD/

17.5EFOZD

Generator Model

Fuel inlet size

Fuel return size

Fuel injection pressure, kgf/cm sq. (psi) 200--210 (2844--2986) 220--230 (3129--3271)

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

Fuel pump static pressure, psi 4--8 (12-volt pump) or 5.5--9 (24-volt pump)

Pressure cap rating, kPa (psi) 97 (14)

(1 and 3 Ph.)

23EOZD/

20EFOZD

1/4 NPT without sound shield

24EOZD/

20EFOZD

3/8 NPT with sound shield

0.15--0.25 (0.006--0.0010)

28EOZD/

23EFOZD

(1 and 3 Ph.)

32EOZD/

27EFOZD

(1 and 3 Ph.)

TP-6255 7/06 17Section 1 Specifications

Page 18

1.3 Generator, 4 Lead

8EOZD/

Component Specification

Hot exciter field voltage/amperage readings at rated voltage

No load (63 Hz)—volts/amps 4/0.9 4/0.9 4/0.8 4/0.7 4/0.7

Full load (60 Hz)—volts/amps 9/1.5 9/1.5 12/2.2 12/1.8 14/2.3

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

Exciter armature resistance (cold)—ohms (line-to-line) 1.18 1.18 1.18 0.51 0.51

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

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

1--2, 3--4—volts 135 135 135 135 135

55--66—volts 180 180 180 180 180

Cold stator resistance

1--2, 3--4—ohms 0.26 0.26 0.19 0.12 0.12

55--66—ohms 2.11 2.11 1.89 1.46 1.46

6.5EFOZD

4.8 4.8 4.8 5.8 5.8

5.0 5.0 5.7 4.3 2.9

20EOZD/

Component Specification

Hot exciter field voltage/amperage readings at rated voltage

No load (63 Hz)—volts/amps 6/1.0 6/1.0 18/0.7 18/0.7

Full load (60 Hz)—volts/amps 14/2.1 16/2.4 42/1.6 45/1.7

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

Exciter armature resistance (cold)—ohms (line-to-line) 0.51 0.51 0.601 ±0.045 0.601 ±0.045

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

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

1--2, 3--4—volts 95 95 84 84

55--66—volts 125 125 148 148

Cold stator resistance

1--2, 3--4—ohms 0.12 0.07 0.040 0.040

55--66—ohms 1.46 1.26 1.70 1.70

17EFOZD

5.8 5.8 22.7 ±2.3 22.7 ±2.3

4.3 3.0 2.24 2.24

9EOZD/

7EFOZD

23EOZD/

20EFOZD

10EOZD/

9EFOZD

28EOZD/

23EFOZD

13EOZD/

11EFOZ D

32EOZD/

27EFOZD

15.5EOZD/ 13EFOZD

TP-6255 7/0618 Section 1 Specifications

Page 19

1.4 Generator, 12 Lead

10EOZD/

Component Specification

Hot exciter field voltage/amperage readings at rated voltage

No load (63 Hz)—volts/amps 4/0.9 6/0.9 8/1.4 8/1.4

Full load (60 Hz)—volts/amps 12/2.2 17/2.6 14/2.1 16/2.4

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

Exciter armature resistance (cold)—ohms (line-to-line) 1.18 0.51 0.51 0.51

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

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

1--4, 2--5, 3--6, 7--10, 8--11, 9--12—volts 150 145 140 140

55--66—volts 170 165 158 158

Cold stator resistance

1--4, 2--5, 3--6, 7--10, 8--11, 9--12—ohms 0.09 0.06 0.04 0.04

55--66—ohms 2.5 1.5 1.3 1.3

8.5EFOZD

4.8 5.8 5.8 5.8

5.7 2.9 3.0 3.0

28EOZD/

Component Specification

Hot exciter field voltage/amperage readings at rated voltage

No load (63 Hz)—volts/amps 21/0.8 21/0.8

Full load (60 Hz)—volts/amps 64/2.3 70/2.5

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

Exciter armature resistance (cold)—ohms (F1--F2, F1--F3, F2--F3) 0.601 ±0.045 0.601 ±0.045

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

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

1--4, 2--5, 3--6, 7--10, 8--11, 9--12—volts 84 84

55--66—volts 150 150

Cold stator resistance

1--4, 2--5, 3--6, 7--10, 8--11, 9--12—ohms 0.094 0.094

55--66—ohms 2.1 2.1

23EFOZD

22.7 ±2.3 22.7 ±2.3

2.24 2.24

14EOZD/

11.5EFOZD

32EOZD/

27EFOZD

20EOZD/

17.5EFOZD

24EOZD/

20EFOZD

TP-6255 7/06 19Section 1 Specifications

Page 20

1.5 Service Views

1612

89711105

2120

2423

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

Non Service-Side View

27 2928

ADV-6843-

1. ADC 2100 Control

2. Run-Off/Reset-Auto switch

3. Nameplate

4. Mixing elbow (water outlet/exhaust outlet)

5. Air intake silencer

6. Lifting eye

7. Coolant overflow bottle (location varies by model)

8. Fuel feed pump

9. Oil check

10. Pressure cap

11. Overflow tube

12. Oil fill

13. Lube oil filter

14. High engine temperature sensor

15. Fuel filter

16. Oil fill

17. Seawater pump (water inlet)

18. Oil drain valve and hose

19. Strain relief for the load lead cable

20. Cooling air inlet

21. AC circuit breaker coverplate

22. Anticorrosion zinc anode (seawater drain) (all models except 13--24EOZD & 11--20EFOZD models)

23. Belt guard

24. V-belts

25. Coolant (freshwater) drain (all models except 13--24EOZD & 11--20EFOZD models)

26. Heat exchanger (all models except 13--24EOZD & 11--20EFOZD models)

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

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

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

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

GM30645D-

TP-6255 7/0620 Section 1 Specifications

Page 21

1.6 Torque Specifications

Follow the general torque specification found in Appendix C of this manual unless noted below.

10EOZD/

8EOZD/

Generator Model

Overbolts 34 Nm (25 ft. lbs.)

Rotating diode board 38 Nm (28 ft. lbs.)

Crankshaft pulley 36.6 Nm (27 ft. lbs.)

Thermostat housing

Exhaust manifold 19 Nm (14 ft. lbs.)

Seawater pump pulley

Back plate to engine block 37 Nm (27 ft. lbs.)

Rotor hub to flex. disc 38 Nm (28 ft. lbs.)

Flex disc to flywheel 19 Nm (14 ft. lbs.)

Flywheel bolts

SCR to end bracket 4Nm(35in.lbs.)

6.5EFOZD

21.6 Nm

(192 in. lbs.)

38- -41 Nm

(28- -30 ft. lbs.)

78.5--88.3 Nm (58--65 ft. lbs.)

9EOZD/

7EFOZD

23 Nm

(17 ft. lbs.)

37 Nm

(27 ft. lbs.)

8.5EFOZD 9EFOZD

13EOZD/

11EFOZ D

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

14EOZD/

11.5EFOZD

21.6 Nm (192 in. lbs.)

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

15.5EOZD/ 13EFOZD

20EOZD/

17EFOZD/

17.5EFOZD

Generator Model

Overbolts

Rotating diode board

Back plate to engine block 36.6 Nm (27 ft. lbs.)

Rotor hub to flex. disc

Flex disc to flywheel

Exhaust manifold 22.7 Nm (16.8 ft. lbs.)

Thermostat housing 21.6 Nm (192 in. lbs.)

Rotor fan to flywheel

Crankshaft pulley 36.6 Nm (27 ft. lbs.)

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

Generator adapter to flywheel housing/backplate

Seawater pump pulley 38--41 Nm (28--30 ft. lbs.)

SCR to end bracket 4Nm(35in.lbs.)

(1 and 3 Ph.)

23EOZD/

20EFOZD

34 Nm (25 ft. lbs.)

38 Nm (28 ft. lbs.)

19 Nm (14 ft. lbs.)

24EOZD/

20EFOZD

(1 and 3 Ph.)

N/A

37 Nm (27 ft. lbs.) 45 Nm (34 ft. lbs.)

28EOZD/

23EFOZD

45 Nm (34 ft. lbs.)

53 Nm (39 ft. lbs.)

32EOZD/

27EFOZD

(1 and 3 Ph.)

TP-6255 7/06 21Section 1 Specifications

Page 22

Notes

TP-6255 7/0622 Section 1 Specifications

Page 23

Section 2 Scheduled Maintenance

2.1 General

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

Note: See the generator set operation manual for the

service schedule and other service not included in this manual.

Note: High-mineral content seawater (salt water) can

cause rapid destruction of metals. Wipe up all salt water spillage on and around the generator set and keep metal surfaces free from accumulated salt deposits.

WARNING

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 thegenerator 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.

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 maintenanceprocedures. Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

(Sound-shield-equipped models only)

TP-6255 7/06 23Section 2 Scheduled Maintenance

Page 24

2.2 Lubrication System

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

Note: Failure to observe the oil specifications may

cause inadequate lubrication/oil pressure and cold-starting difficulties.

SAE

Service

Grade

°C°F-- 3 0 -- 2 0 -- 1 0 0 1 0 2 0 3 0 4 0

10W

20W

10W30

15W40

#20

0204060 80 100°C°F

Operating Temperature

Figure 2-1 Engine Oil Selection

#30

#40

TP-5856-1

TP-6255 7/0624 Section 2 Scheduled Maintenance

Page 25

Section 3 Intake and Exhaust System

3.1 Air Intake Silencer/Cleaner

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

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

8/9/10/13/20/28/32EOZD and

6.5/7/9/11/17/17.5/23/27EFOZD Models:

A dry-type air cleaner silences and filters the intake air. The air intake silencer assembly connects to the intake manifold via a flexible hose.

Air Cleaner Service/Replacement Procedure:

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

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

14/15.5/23/24EOZD and

11.5/13/20EFOZD Models:

These models use a round, polyurethane, sound-absorbing-type intake silencer to silence the intake air drawn into the cylinder head from the intake port. Besides providing a silencing effect, the silencer also acts as an air cleaner. Clean the silencer more frequently if operating in dirty, dusty conditions. See Figure 3-2 and refer to the following procedure.

Air Intake Silencer Cleaning Procedure:

1. Remove the intake silencer cover.

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

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

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

Figure 3-1 Air Cleaner Element Element

TP-6071-31

1. Air intake silencer cover

2. Air intake silencer element

3. Base

4. Clamp

5. Turbocharger

Figure 3-2 Air Intake Silencer

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

4. Lightly coat the foam element with oil.

5. Squeeze out any excess oil.

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

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

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

TP-6255 7/06 25Section 3 Intake and Exhaust System

Page 26

3.2 Exhaust System Inspection

3.3 Servicing Mixing Elbow

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 keepthe detector operational at all times.

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

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

The mixing elbow combines high-temperature exhaust with cooling seawater. The mixture when exposed to engine vibration makes conditions conducive to rapid deterioration and failure if the elbow is not properly maintained.

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

2. Clean or replace the mixing elbow as necessary.

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

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

Inspect the compressor (blower) at the specified interval for build-up of carbon residue. Perform all other turbocharger inspection and service as described in the service schedule of the engine service manuals. See Figure 3-3 and Figure 3-4 to inspect the compressor.

Compressor Inspection:

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

For your safety: Never operate the generator set

without a functioning carbon monoxide detector(s) for your safety and the safety of others on your vessel.

Exhaust System Inspection Points

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

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

Replace the hoses as needed.

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps.

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

D Check that the exhaust outlet is unobstructed.

D Visually inspect the exhaust system for exhaust leaks

(blowby). Check for carbon or soot residue on exhaust components. Carbon and soot residue indicates an exhaust leak. Seal leaks as needed.

2. Remove the air intake silencer.

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

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

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

TP-6255 7/0626 Section 3 Intake and Exhaust System

Page 27

1. Compressor housing

2. Rotor assembly (turbo)

3. Housing assembly (blower)

4. Plate assembly (seal)

5. Circlips

6. Housing assembly (bearing)

7. Heat protector

Figure 3-3 Turbocharger Inspection

1. Turbocharger assembly

TP-6071-32

2. Gaskets

3. Exhaust elbow

4. Exhaust manifold

TP-6071-32

5. Petcock PT 1/8

Figure 3-4 Turbocharger Components, Typical

TP-6255 7/06 27Section 3 Intake and Exhaust System

Page 28

Notes

TP-6255 7/0628 Section 3 Intake and Exhaust System

Page 29

Section 4 Fuel System

4.1 General

In most installations, both the generator set and the propulsion engine operate from a common fuel tank with a dual dip tube arrangement. The generator set’s dip tube is shorter than the propulsion engine’s dip tube. With this arrangement fuel may not be available to the generator set when the fuel supply is low. See Figure 4-1 for a fuel system schematic.

To fuel injectors

Propulsion engine

1. Fuel tank

2. Dual dip tubes

3. Fuel filter

4. Fuel feed pump

5. Water trap

Generator set

607141

Fuel Filter Replacement Procedure

8/9EOZD and 6.5/7EFOZD Models:

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

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

3. Close the fuel supply valve.

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

5. Wipe off all parts with a clean rag. Inspect all mating surfaces and threads for damage; replace as necessary.

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

7. Open the fuel supply valve.

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

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

Figure 4-1 Fuel System Schematic, Typical

4.2 Fuel Filter

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

1. Fuel strainer assembly

2. Body

3. Fuel element

4. Spring

5. O-ring

6. Filter cup

7. Retaining ring

Figure 4-2 Fuel Oil Filter Element

TP-561633

TP-6255 7/06 29Section 4 Fuel System

Page 30

10--32EOZD and 9--27EFOZD Models:

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

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

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

3. Close the fuel supply valve.

4. Loosen the fuel filter by turning it counterclockwise. Remove the fuel filter and use rags to clean up spilled fuel oil. Dispose of the fuel filter and rags in an approved manner.

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

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

7. Open the fuel supply valve.

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

1. Fuel filter adapter

2. Fuel filter

3. Removal (counterclockwise)

4. Installation (clockwise)

Figure 4-3 Spin-On Fuel Oil Filter

TP-606111

TP-6255 7/0630 Section 4 Fuel System

Page 31

4.2.1 Bleeding the Fuel System

Bleed air from the fuel system to prevent starting failures and/or erratic operation. One or more of the following causes air to collect in the fuel system:

D Operating the generator set until the fuel supply is

emptied.

D Developing air leaks in the suction side of the fuel

system.

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

3. Tighten the fuel injection pump screw.

8/9EOZD and 6.5/7EFOZD

Models

1254

D Replacing the fuel filter.

Note: Connect the battery during the priming procedure

to allow engine cranking.

Note: If the ADC 2100 indicates an overcrank fault

during this procedure, disconnect the negative wire from the fuel solenoid (allowing the fuel injection pump to fill with fuel) and repeat this procedure after allowing the starter motor to cool down.

Note: Have a rag handy during the bleeding procedure.

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

Procedure to Bleed the Fuel System

8/9EOZD and 6.5/7EFOZD Models and 13--32EOZD and 11--27EFOZD Models with Specs: GM33035-GA1/GA2, GM33036-GA1/GA2, and GM33037-GA1/GA2

1. Loosen the fuel filter screw at position 1. See Figure 4-4.

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

ADV6843a-a

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

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

GM33037-GA1/GA2

10--32EOZD and 9-- 27EFOZD Models

TP-5592-3

3. Loosen the fuel filter screw at position 2.

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

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

6. Initiate the auto/start sequence until fuel, free of air bubbles, flows from the vent screw at position 5. Tighten the screw.

10--32EOZD and 9--27EFOZD Models

1. Loosen the fuel injection pump screw. See Figure 4-4.

TP-6255 7/06 31Section 4 Fuel System

1. Vent screw, position 1

2. Vent screw, position 2

3. Fuel filter

4. Fuel injection pump

5. Vent screw, position 5

6. Fuel injection pump screw

Figure 4-4 Fuel System (Typical)

Page 32

4.3 Fuel Pump

4.4 Governor

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

Fuel Pump Test Procedure:

1. Remove the two leads at the bottom of the fuel pump. The pump terminals are labeled (--) and (+). SeeFigure4-5.

2. Connect the inlet side of the pump to a fuel source. Disconnect the outlet hose from the fuel filter and place the hose end in a container to catch the fuel.

3. Connect the positive (+) terminal of a 12-volt battery to the positive terminal of the fuel pump. Connect the negative terminal of the fuel pump to the negative (--) terminal of the battery. You should hear the pump operate and see fuel discharge from the pump outlet. Replace the pump if it does not operate.

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

. See Section 1 for the

specified fuel pump pressure ratings.

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

60 Hz generator sets are designed to operate in the range of 57-63 Hz (1800 rpm under full load and 1890 rpm under no load).

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

To check the engine speed, use a frequency meter connected to the load leads or use a hand tachometer. If adjustment is needed, loosen the locking nut on the speed adjusting screw. Turn the screw clockwise to increase the speed (and frequency). To decrease the speed, turn the screw counterclockwise. Tighten the locking nut when the correct setting is reached. See Figure 4-6.

1. Fuel inlet

2. Negative (--) terminal

3. Positive (+) terminal

4. Fuel outlet

Figure 4-5 Fuel Pump

I-940

607146

1. Speed adjusting screw

2. Locking nut

Figure 4-6 Governor Adjustment

The generators use a 3-lead fuel solenoid. This solenoid has a white lead (P) which energizes the pull-in coil only during cranking. During operation, the red lead energizes the hold coil and the black lead is the common ground.

TP-6255 7/0632 Section 4 Fuel System

Page 33

Section 5 Cooling System

5.1 General

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

WARNING

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.

Checking the coolant level. Hot coolant can causesevere injury or death. Allow the engine to cool. Release pressure

from the cooling system before removing thepressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank.

NOTICE

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

1. Engine block

2. Exhaust manifold

3. Exhaust mixer elbow

4. Outlet flapper

5. Silencer

6. Thermostat

Seawater

Coolant/antifreeze

607151

7. Heat exchanger

8. Engine seawater pump

9. Seawater strainer

10. Seacock

11. Intake strainer

12. Engine-driven water pump

Figure 5-1 Cooling System Components

TP-6255 7/06 33Section 5 Cooling System

Page 34

5.2 Water-Cooled Exhaust Manifold

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

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

1. Thermostat housing

5.3 Closed Heat Exchanger

In a closed cooling system, seawater circulates through separate chambers within the heat exchanger to cool the engine coolant. The seawater then mixes with engine exhaust and ejects out of the exhaust outlet. See Section 1 for coolant capacity, thermostat and pressure cap ratings.

Note: Coolant solution. A coolant solution of 50%

ethylene glycol provides freezing protection to

-- 3 7 °C(--34°F) and overheating protection to 129°C (265°F). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can cause engine or component damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant. Consult the engine manufacturer’s operation manual for engine coolant specifications.

Figure 5-2 Thermostat Location (10EOZD model

shown)

5.4 Check and Fill Coolant

Note: Do not add coolant to a hot engine. Adding

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

Maintain the coolant level in the coolant recovery tank at approximately 1/4 full. Before filling the cooling system, close all petcocks and tighten all hose clamps. Use a solution of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion and prevent freezing. Add coolant, as necessary, to the coolant recovery tank. Periodically check the coolant level on closed systems by removing the pressure cap. Do not rely solely on the level in the coolant recovery tank. Add fresh coolant until level is just below the overflow tube opening.

Note: Coolant solution. A coolant solution of 50%

ethylene glycol provides freezing protection to

-- 3 7 _C(--34_F) and overheating protection to 129°C (265°F). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can cause engine or component damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant. Consult the engine manufacturer’s operation manual for engine coolant specifications.

TP-6255 7/0634 Section 5 Cooling System

Page 35

5.5 Flush and Clean Cooling System

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

Pay special attention to the coolant level. When refilling the cooling system, allow time for complete refill of the engine water jacket. Check the coolant level as described in Section 5.4.

Flush and Clean Procedure:

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

2. Remove the pressure cap to make draining easier.

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

4. Replace the water drain pipe plug.

5. Fill the cooling system with recommended coolant.

6. Replace the pressure cap.

5.6 Pressure Cap

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

1. Drive shaft assembly

2. Pulley

3. Housing

4. Impeller

5. Gasket

6. Cover plate

7. Snap ring

8. Brass washer

9. Seal

10. Ceramic seat

11. Rubber seat

12. Key (impeller end)

TP-5616

Figure 5-3 Seawater Pump, Typical

3. Remove the impeller.

4. Inspect the impeller for damage, including cracks, broken or flattened vanes. The impeller vanes should be straight and flexible. See Figure 5-4.

5.7 Impeller Inspection and Replacement

The belt-driven seawater pump is located on the service

1. Flattened vane

2. Crack

3. Broken vane

Figure 5-4 Worn Impeller

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

5. Lubricate the impeller with soapy water before installation.

the impeller kit. If the instructions are not included with the kit, use the following procedure.

6. While installing the impeller, always rotate the drive shaft and the impeller together in the same

Impeller Inspection and Replacement Procedure:

1. Close the seacock.

2. Remove the seawater pump coverplate. See

direction as the engine rotation.

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

Figure 5-3.

TP-6255 7/06 35Section 5 Cooling System

607153

Page 36

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

9. Open the seacock.

10. Start the generator set and check for leaks.

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

5.8 Belt Tension

WARNING

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.

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

1. Engine-driven water pump pulley

2. Adjusting arm pivot screw

3. Battery charging alternator pulley

4. Alternator adjusting screw

5. Alternator pivot screw

6. Check the alternator belt tension here

7. Crankshaft pulley

8. Check the seawater pump belt tension here

9. Seawater pump adjusting screw

10. Seawater pump pulley

11. Pivot screw

TP-5586-3

Figure 5-5 Belt Tension (Typical)

5.8.1 Seawater Pump Belt Tensioning Procedure

1. Remove the belt guard.

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

Note: If the belt tension is not within specifications,

go to step 3. If the belt tension is within specifications, go to step 7.

3. Loosen the pivot and adjusting screws.

4. While prying the seawater pump outward, tighten the adjusting screw.

5. Tighten the pivot screw.

6. Recheck and adjust as necessary.

7. Replace the belt guard.

TP-6255 7/0636 Section 5 Cooling System

Page 37

5.8.2 Battery Charging Alternator Belt Tensioning Procedure

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

1. Remove the belt guard.

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

Belt Type Deflection mm (in.)

New 8--12 (0.3--0.5)

Used 10--14 (0.4--0.6)

Figure 5-6 Belt Specifications

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

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

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

6. Recheck and adjust as necessary.

7. Replace the belt guard.

5.8.3 Anticorrosion Zinc Anode

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

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

Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule. Depending upon operating conditions and seawater properties, the anticorrosion zinc anode may require more frequent replacement. See Section 1 for the location and use the following procedure.

Anticorrosion Zinc Anode Replacement

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

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

Anticorrosion Zinc Anode Replacement

Replace When

Percent of Zinc

Remaining Is:

<50% of

length/diameter

<50% of

length/diameter

Models

8/9/10EOZD

6.5/7/9EFOZD

28/32EOZD

23/27EFOZD

New Anode

Dimensions mm (in.)

9 (0.34) x 43 (1.7)

9 (0.34) x 19 (0.75)

Figure 5-7 Anticorrosion Zinc Anode (Plug)

Measurements

1. Diameter: 9 mm (0.34 in.)

2. Length: 43 mm (1.7 in.) for 8/9/10EOZD, 6.5/7/9EFOZD models or 19 mm (0.75 in.) for 28/32EOZD, 23/27EFOZD models

TP-5586-3

Figure 5-8 Anticorrosion Zinc Anode (Plug)

4. Clean the threaded hole of the heat exchanger and coat the threads of the anticorrosion zinc anode (plug) with pipe sealant suitable for marine applications. Cut the anticorrosion zinc to the correct length. Install the anticorrosion zinc anode into the heat exchanger.

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

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

TP-6255 7/06 37Section 5 Cooling System

Page 38

5.9 Siphon Break

A siphon break prevents seawater entry into the engine when the engine exhaust manifold outlet is less than 23 cm (9 in.) above the waterline of a fully-loaded, shut-down craft. Use the following procedure to inspect the siphon break.

Siphon Break Inspection Procedure:

1. Stop the generator set.

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

4. Check that the reed valve opening is clear.

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

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

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

Waterline

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

1. Mounting base

2. Retaining cap

3. Reed valve assembly

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

5. Exhaust mixer elbow distance above waterline; if less than 23 cm (9 in.), siphon break is required

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

7. Siphon break

8. Exhaust mixer elbow

9. Heat exchanger (locations vary by model)

10. Seawater strainer

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

11. Seacock

12. Intake strainer

13. Engine-driven seawater pump

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

15. Water lock (optional)

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

17. Silencer (customer-supplied)

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

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

20. Seawater outlet

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

TP-5586-3

TP-6255 7/0638 Section 5 Cooling System

Page 39

Section 6 Troubleshooting

6.1 Introduction

Corrective action and testing in many cases requires knowledge of electrical systems and electronic circuits. Have an authorized service distributor/dealer perform testing and service.

Refer to the engine service manual for engine service information.

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

6.2 Initial Checks

When troubleshooting, always check for simple problems first. Check for the following common problems before replacing parts:

D Loose connections or damaged wiring.

D Dead battery.

D Fault shutdown. Check for a fault code on the

controller display. Section 7.4 describes the warning and shutdown fault codes.

D Blown fuses. Fuses in the wiring harness protect the

controller, SCR module, and relay interface board. Always check and replace the fuses before replacing other components.

6.3 General

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

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. Turn off 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.

D Incorrect controller settings. Always check the

controller configuration settings before replacing the controller. Section 7.5 contains the instructions for checking and changing the controller configuration.

Some problems may be solved by updating the controller’s application program. Check www.kohlernet.com, Tech Tools, Software, for information on ADC 2100 application program updates. Refer to Section 7.6 for instructions to check the version number of the controller’s application program and for

6.4 Troubleshooting Chart

Use the following tables as a reference in troubleshooting individual problems. Generator set faults are listed in groups and include likely causes and remedies. The simplest and most likely causes of the problem are listed first; follow the recommendations in the order shown. The reference column provides additional sources of information in this and related manuals regarding the problem and solution.

more information on updating the application program.

TP-6255 7/06 39Section 6 Troubleshooting

Page 40

Troubleshooting Chart

Problem Possible Cause Corrective Action Reference

Generator set does not crank

Weak or dead battery Recharge or replace battery. Generator Set O/M

Battery connections Check for reversed or poor battery

Open circuit in engine/controller connections

Blown fuse F3, controller Replace fuse; if fuse blows again,

Blown fuse F2, relay interface board (RIB)

Crank relay on relay interface board (RIB)

Generator set master switch Check connections to the master

Poor ground (--) connection Clean and retighten. — Starter

Controller Check the controller connections

connections. Check for loose connections.

Check the wire harness continuity.

check circuit and components.

Replace fuse. Section 8.12

If fuse blows again, disconnect the board leads one at a time to identify the cause of the blown fuse: Lead 70A at the fuel solenoid Lead 71A at the crank relay Lead FP and FN at the rotor Repair or replace the component causing the blown fuse.

If the fuse continues to blow and the previous step did not identify the cause, remove the leads from the P14 connector using a pin pusher, part #241918 (large) or 241919 (small). If replacing the leads does not solve the problem, replace the RIB.

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

Check for a good ground connection (lead N)

Check crank relay K2 operation (LED3). Replace the RIB if the relay does not operate.

switch on the ADC 2100.

Test function of the switch.

Check the starter connections. Section 10

Rebuild or replace the starter. Engine Service Manual (S/M)

and operation. Check for power to the controller. Move the generator set master switch to the OFF/RESET position and then to the RUN position.

Section 8.13

Section 10 Section 8.12

Section 10

Section 7.10

Section 10

Section 7.10

Section 10

Section 7.10

Section 7.9

Section 8.13

Section 7

Section 10

—

TP-6255 7/0640 Section 6 Troubleshooting

Page 41

Troubleshooting Chart, continued

Problem Possible Cause Corrective Action Reference

Generator set cranks but does not start

Generator set starts hard

Generator set starts but shuts down

Generator set stops suddenly

No fuel Check the fuel supply. —

Loose connection or open circuit Check for loose or open

Air cleaner clogged Clean or replace. Section 3

Incorrect controller configuration Check for correct controller

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

Low battery voltage Check battery voltage, power

Air cleaner clogged Replace element. Section 3

Worn piston rings, valves Check compression. Engine S/M

Fault shutdown Check for a fault shutdown code

No fuel Check the fuel supply. —

Fuel line restriction Inspect fuel lines. —

Air cleaner clogged Replace element. Section 3

Blown controller fuse (F3) Replace fuse. Section 8.12

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

Blown relay interface board (RIB) fuse (F2)

Engine overheated (hot engine only)

Low oil pressure (LOP) shutdown Attempt startup. If the unit shuts

Engine overloaded Reduce electrical load. Generator Set I/M

Loss of generator output voltage to controller

Faulty K3 (flash) relay Check for Flash LED illumination.

connections at the fuel solenoid (lead 70A). Check the controller/engine wiring continuity.

configuration parameters: unit configuration (UC) and engine configuration (EC).

Check for a locked rotor. Section 8.6

supply, and operation.

on the Advance Digital Control’s LED display. Correct the fault and then move the generator set master switch to the OFF/RESET position to reset the ADC.

on the Advanced Digital Control’s LED display. Correct the fault and then move the generator set master switch to the OFF/RESET position to reset the ADC.

test generator components. Replace fuse. Section 8.12

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

down, remove the lead from the LOP switch and reset the controller. A successful restart attempt indicates a faulty LOP shutdown switch. Note: Check the engine oil pressure before performing the test and/or replacing the LOP shutdown switch.

Check connections at P15 plug.

Check continuity of AC sensing leads 11 and 44 (for 1-phase models) or leads 7, 8, and 9 (for 3-phase models).

Check RIB fuse. Replace relay board.

Section 10

Section 7.5

Generator Set O/M

Section 7.4

Section 8.12

Sections 2 and 3

Section 8.11

Section 10

Section 7.10

TP-6255 7/06 41Section 6 Troubleshooting

Page 42

Troubleshooting Chart, continued

ical

voltage

Problem Possible Cause Corrective Action Reference

Generator set operates erra

Generator set lacks power

Air cleaner clogged Replace element. Section 3

Governor adjustment incorrect Adjust governor stability. Section 4.4

Inadequate cooling (hot engine only)

Carbon buildup in engine Clean cylinder head. Engine S/M

Engine valves not seating correctly

Air intake restriction, inadequate cooling

Generator overloaded Reduce load. Generator Set I/M

Engine not running at rated rpm Check controller settings for unit

Inspect air inlet and outlet.

Inspect valves and valve seats. Engine S/M

Inspect air intakes and exhaust for obstructions.

Check the air cleaner. Section 3

Section 7.5 configuration (UC) and engine type (EC).

—

Generator set overheats

Low output or excessive drop in

Adjust governor speed.

Engine power loss Refer to the Engine Service

Governor malfunction or misadjustment

Inadequate cooling Inspect cooling system for

Air cleaner clogged Replace element. Section 3

Generator overloaded Reduce load. Generator Set I/M

Incorrect controller configuration Check and adjust the controller

Incorrect controller voltage settings

Alternator or control system Perform separate excitation

SCR module Check wiring and connections to

Controller Check the controller settings.

Rotor (open, grounded, or shorted windings)

Stator (open, grounded, or shorted windings)

Low engine speed causing voltage roll-off

Manual for troubleshooting and repair instructions.

Test/readjust governor. Section 4.4

obstructions.

configuration parameters.

Check and adjust the controller voltage settings.

procedure to isolate problem to the alternator or the control system.

the SCR module.

Check the auxiliary winding fuse F1 (lead 55).

Replace SCR module and test voltage.

Check the controller fuse, wiring and connections.

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

Test and/or replace. Section 8.6

Test and/or replace. Section 8.7

Check system voltage/frequency (UU) and engine type (EC) parameters.

Section 4.4

Engine S/M

Section 7.5

Section 7.5.3

Section 8.2

Section 7.5

Section 7.7

Section 7.5

Section 7.7

Section 7.11

Section 7.5

—

Adjust the engine governor speed.

Troubleshoot the engine.

Section 4.4

Engine S/M

TP-6255 7/0642 Section 6 Troubleshooting

Page 43

Troubleshooting Chart, continued

Problem ReferenceCorrective ActionPossible Cause

Light flicker Voltage stability (gain) setting Check and adjust the voltage

High generator output voltage

No output voltage

Incorrect controller configuration Check and adjust the controller

Incorrect controller voltage settings

Engine speed too high Check the engine speed using

Loose voltage sensing connections

SCR module Check the wiring and connections

Controller Check fuses, wiring, and

AC output circuit breaker open Check for AC voltage on the

Alternator or control system Perform separate excitation

Aux. winding fuse blown (lead 55) Replace blown fuse. If fuse blows

SCR module Check auxiliary winding fuse F1

Controller Check controller settings. Check

stability (gain) setting using the ADC 2100.

configuration parameters.

Check and adjust the controller voltage settings.

tachometer or frequency meter. Adjust governor as necessary.

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

to the SCR module.

Check the auxiliary winding fuse F1 (lead 55).

Replace SCR module and test voltage.

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

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

procedure to isolate the problem to the alternator or the control system. Then troubleshoot the alternator or control system components as follows.

again, check stator.

(lead 55).

Replace SCR module and test voltage.

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

Section 7.5.3

Section 7.5

Section 7.5.3

Section 4.4

Section 8.7

Section 7.7

Section 7.5

Section 7.7

Section 7.11

—

Section 8.2

Section 8.12

Section 7.7

Section 7.5

Section 7.7

Section 7.11

TP-6255 7/06 43Section 6 Troubleshooting

Page 44

Troubleshooting Chart, continued

(

)

Problem ReferenceCorrective ActionPossible Cause

No output voltage (continued)

Generator set is noisy

Emits black or gray smoke

High oil consumption

Engine knocks

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

Rotor connections Check for open circuit in the rotor

Rotor (open, grounded, or shorted windings)

Stator (open, grounded, or shorted windings)

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

Exhaust system leaks Check and replace as necessary. —

Engine not running smoothly See “Generator set operates

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

Loose or vibrating sheet metal/housing

Exhaust piping or air inlets/outlets not securely installed

Excessive engine/generator vibration

Air intake restriction Check air cleaner and intake. Section 3

Oil level high Check oil level. Section 2 and Generator Set O/M

Worn piston rings, valves, etc. Check compression. Engine S/M

External leakage/defective gaskets

Worn piston rings, valves, etc. Check compression. Engine S/M

Excessive load Reduce load Generator Set I/M

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

Check continuity. Section 7.7

connection circuit (leads FN and FP to the SCR and RIB).

Check voltage and continuity. Section 8.6

Check voltage and continuity. Section 8.7

Check flash LED on RIB.

Check fuse F2 and troubleshoot RIB.

erratically,” this table.

Retighten screws, replace rivets.

Inspect for loose parts and secure if necessary.

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

Replace gaskets. Engine S/M

Section 8.6

Section 7.10

See “Generator set operates

erratically,” this table

Section 9, Disassembly/

Reassembly and Engine S/M

—

TP-6255 7/0644 Section 6 Troubleshooting

Page 45

Section 7 Controller

7.1 Introduction

This section covers operation, configuration, adjustment, and replacement of the ADC 2100 controller. See Section 6 for troubleshooting procedures.

See Figure 7-1 for the locations of the controller and related components. Section 7.2 describes the controller keypad and display.

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

configuration and adjustment are covered in Section 7.5.

A silicon controlled rectifier (SCR) module works with the controller to regulate the output voltage. See Section 7.7.

A relay interface board (RIB) is used with the ADC controller. Section 7.10 describes the standard and optional RIBs.

1. Junction box louvered panel

2. SCR module

3. Relay board

4. Engine harness-to-controller connection

GM29253

5. Generator set master switch

6. ADC 2100

7. Line circuit breaker plate

8. Junction box

Figure 7-1 Advanced Digital Control (ADC 2100)

TP-6255 7/06 45Section 7 Controller

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7.2 Advanced Digital Control Display and Keypad

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

A password key sequence is required to enter the configuration and adjustment menus. Section 7.5 contains the instructions to enter the configuration and adjustment menus and change the settings using the controller keypad.

Controller Display

Item Description

Crank indication Displays CC_1, CC_2, or CC_3 to indicate

Runtime hours Displays total generator set runtime hours

Fault codes Flashes a 2- or 3-letter fault code to indicate

System parameters

Application program version number

the 1st, 2nd or 3rd attempt to start the engine. The last digit flashes during the crank cycle rest periods.

when no other code is displayed.

various fault conditions. See Section 7.4.

Displays 2-letter codes or 4-digit alphanumeric codes during system configuration or adjustment. See Section 7.5.

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

Figure 7-3 Advanced Digital Control’s LED Display

1. LED display

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

3. Up and down arrow buttons (useforsetup and adjustment only)

4. Generator set master switch

GM28707A-C

Figure 7-2 Advanced Digital Control

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7.3 Sequence of Operation

The following sections describe the controller sequence of operation during generator start, run, stop, and fault shutdown modes. Use this as a starting point for controller and relay board fault identification. Refer to the wiring diagrams in Section 10 to assist in the troubleshooting procedure.

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

Note: The controller circuit board prevents fault

shutdowns during startup until the crank disconnect relay energizes.

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

7.3.1 Starting Sequence, Master Switch

Moved to RUN

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

0.5 seconds later. The ADC display indicates the crank

cycle 1 code, CC 1.

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

The factory sets the cranking cycle for three cycles of 15 seconds on time and 15 seconds off time. If the cranking cycle seems shorter than the factory setting, check the engine starting battery.

7.3.2 Starting Sequence, Remote Start

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

The start sequence proceeds as described in Section 7.3.1, Starting Sequence, Master Switch Moved to RUN.

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7.3.3 Running Sequence

When the engine speed reaches 750 rpm, the crank relay deenergizes and the crank LED (3) turns off. When the output voltage on leads 11 and 44 (for 1-phase models) or leads 7, 8, and 9 (for 3-phase models) reaches about 30 VAC, the flash relay deenergizes and the flash LED (2) turns off.

7.3.4 Stopping Sequence, Master

Switch Moved to OFF/RESET

7.4 Faults

7.4.1 Fault Shutdowns

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

Always identify and correct the cause of a fault shutdown before restarting the generator set. Refer to Section 6, Troubleshooting, for instructions to identify and correct the cause of the fault.

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

7.3.5 Stopping Sequence, Remote Stop

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

Note: For units with serial numbers before 2051415:

Disconnecting the P7 jumper will allow the controller to power down 48 hours after generator set shutdown. See Section 7.8, Continuous Power Mode.

Note: For units with serial numbers 2051415 and

later:

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

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

Note: For units with serial numbers before 2051415:

If the power jumper is removed and the controller powers down after a fault shutdown, move the master switch to the OFF/RESET position and then to the RUN position to display the fault code. Moving the master switch to the OFF position again will clear the fault. See Section 7.8 for more information on the continuous power mode jumper.

7.4.2 Warnings

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

If the ADC 2100 is not configured for a CAN gauge, the controller will power down after 48 hours (if the master switch is in the AUTO position). If the generator has been started, the controller will power down 48 hours after the generator stops.

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Code Fault Description Check

AF Auxiliary fault

input shutdown

HE High engine

temperature shutdown

LOC Loss of coolant

shutdown

LOP Low oil pressure

shutdown

OC Overcrank

shutdown

OF Overfrequency

shutdown

OS Overspeed

shutdown

OU Overvoltage

shutdown

UF Underfrequency

shutdown

UU Undervoltage

shutdown

SCF0 Controller error Indicates a software or communication problem within

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

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

Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds. This protection becomes active after the engine reaches the crank disconnect speed.

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

Shutdown occurs 5 seconds after a loss of coolant condition is detected. This protection becomes active 10 seconds after the engine has reached its stated crank disconnect speed and remains active as long as the generator run command is active.

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

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

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

Shutdown occurs when the governed frequency exceeds 110% of the system’s frequency setpoint for more than 5 seconds. This protection becomes active 10 seconds after engine start (10 second inhibit).

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

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

Shutdown occurs when the governed frequency falls below 90% of the system’s frequency setpoint for more than 5 seconds. This protection becomes active 10 seconds after engine start (10-second inhibit).

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

the ADC 2100.

Check the cause of the auxiliary fault.

Check for a low engine coolant level.

Check for a clogged seawater intake or sea strainer. Check for a damaged seawater pump impeller.

Check for leaks in the lubrication system. Check the oil level and add oil if the level is low.

Check the fuel supply and battery. If there is no output voltage, check the line circuit

breaker. Also check for loose connections. Contact an authorized distributor/dealer for service if

problem continues.

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

Reduce the load and restart the generator set. Contact an authorized distributor/dealer for service if

problem continues.

Reduce the load and restart the generator set. Contact an authorized distributor/dealer for service if

problem continues.

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

Figure 7-4 Fault Shutdowns

Code Fault Description Check

HB High battery

voltage warning

LB Low battery

voltage warning

Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 2 seconds when the engine is not running. This fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to a voltage within the limits for more than 2 seconds.

Fault code is displayed if the engine starting battery voltage falls below 9.5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 2 seconds when the engine is not running. This fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to a voltage within the limits for more than 2 seconds.

Check the battery rating and condition.

Charge or replace the battery.

Figure 7-5 Fault Warnings

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7.5 Controller Configuration and Adjustment

The first step in troubleshooting the controller is to verify that the controller is correctly configured for the generator set. The controller’s configuration modes allow setting of the engine type, generator set configuration (marine, mobile, or standby), data input types, and other parameters.

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

∧) and down (∨) arrow buttons to select the

appropriate setting for the application.

Note: Be sure to save your settings before exiting the

configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position.

The controller configuration for each generator model is set at the factory. Generator set reconnection, sender changes, controller replacement, or other changes may result in the need to change the controller configuration. Use the instructions in the following section to check the controller settings and change them, if necessary.

7.5.1 Controller Time Out

The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed. Start the configuration procedure over again from the beginning if the controller exits the configuration mode before the settings have been saved.

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

7.5.2 Controller Configuration

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

Note: This parameter sets the nominal system voltage

and frequency. To adjust the output (measured) voltage and frequency, see Section 4.4, Section 7.5.3, and Figure 7-10.

Unit configuration (Uc). This parameter sets the generator set type: marine, standby, or mobile.

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

Advanced configuration mode (Adnc). The data input types, battery voltage, and communications setting can be changed in the advanced configuration mode. Press the up arrow button when Adnc is displayed to enter the advanced configuration mode.

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

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

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

The controller’s configuration mode allows adjustment of the system parameters listed in this section. Change the system voltage and frequency after reconnection or controller replacement. The unit configuration and engine type are factory-set for each type of generator set and engine and should not require changes unless the controller is replaced.

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

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

7.5.3 Voltage Adjustment

The flowchart in Figure 7-10 outlines the procedures for using the ADC controller to adjust the output voltage. Voltage adjustment may be required after controller replacement, generator set reconnection, or other service procedures. The generator set must be running during this adjustment. Use a multimeter to measure the generator set output voltage during adjustment. Refer to Section 8.8.2, Voltage Adjustment for instructions to measure the output voltage.

Note: Be sure to save your settings before exiting the

configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position.

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Parameter Setting Definition Connect

gyp

gpy

Unit’s system voltage and frequency [

u00

Single phase, 2 Wire, 60 Hz, 100 VAC 1Ph, 2W Single phase, 3 Wire, 60 Hz, 100 VAC 1Ph, 3W Single phase, 2 Wire, 60 Hz, 120 VAC 1Ph, 2W Single phase, 3 Wire, 60 Hz, 120 VAC 1Ph, 3W

u01

Single phase, 3 Wire, 60 Hz, 120/240 VAC 1Ph, 3W

Single phase, 3 Wire, 60 Hz, 120/240 VAC Dogleg Uu02 Single phase, 2 Wire, 50 Hz, 230 VAC 1Ph, 2W Uu03 Three phase, 4 Wire, 50 Hz, 230/400 VAC Wye Uu04 Three phase, 4 Wire, 60 Hz, 277/480 VAC Wye

Single phase, 2 Wire, 50 Hz, 100 VAC 1Ph, 2W

u05

Single phase, 3 Wire, 50 Hz, 100 VAC 1Ph, 3W

Single phase, 2 Wire, 50 Hz, 110 VAC 1Ph, 2W

Single phase, 3 Wire, 50 Hz, 110 VAC 1Ph, 3W Uu06 Single phase, 3 Wire, 50 Hz, 115/230 VAC 1Ph, 3W

u07

Single phase, 3 Wire, 50 Hz, 110/220 VAC 1Ph, 3W

Single phase, 3 Wire, 50 Hz, 110/220 VAC Dogleg Uu08 Single phase, 3 Wire, 60 Hz, 100/200 VAC 1Ph, 3W Uu09 Single phase, 3 Wire, 50 Hz, 100/200 VAC 1Ph, 3W

u10

Three phase, 4 Wire, 60 Hz, 120/240 VAC Delta

Three phase, 4 Wire, 60 Hz, 139/240 VAC Wye Uu11 Three phase, 4 Wire, 60 Hz, 120/208 VAC Wye Uu12 Single phase, 2 Wire, 50 Hz, 220 VAC 1Ph, 2W Uu13 Single phase, 2 Wire, 50 Hz, 240 VAC 1Ph, 2W Uu14 Three phase, 4 Wire, 50 Hz, 115/230 VAC Delta Uu15 Three phase, 4 Wire, 50 Hz, 110/220 VAC Delta Uu16 Three phase, 4 Wire, 60 Hz, 127/220 VAC Wye Uu17 Three phase, 4 Wire, 50 Hz, 110/190 VAC Wye Uu18 Three phase, 4 Wire, 50 Hz, 120/208 VAC Wye Uu19 Three phase, 4 Wire, 60 Hz, 220/380 VAC Wye

u20

Three phase, 4 Wire, 60 Hz, 240/416 VAC Wye

Three phase, 4 Wire, 60 Hz, 230/400 VAC Wye Uu21 Three phase, 4 Wire, 50 Hz, 220/380 VAC Wye Uu22 Three phase, 4 Wire, 50 Hz, 240/416 VAC Wye

Unit configuration Uc00 Marine generator set Engine type

Ec01 8--9EOZD/6.5--7EFOZD Ec02 10--20EOZD/9--17.5EFOZD and 24EOZD/20EFOZD Ec07 28--32EOZD/23--27EFOZD (Units without the preheater option) Ec09 23EOZD/20EFOZD (Units with the preheater option)

Engine data input types (No magnetic pick-up)

Ed00 All digital inputs Ed01 Digital: Low coolant level and low oil pressure. Analog: Low coolant temperature Ed02 Digital: Low coolant level and low coolant temperature. Analog: Low oil pressure Ed03 * Digital: Low coolant level. Analog: Low coolant temperature and low oil pressure Ed08 Digital: Low coolant temperature and low oil pressure. Analog: Low coolant level Ed09 Digital: Low oil pressure. Analog: Low coolant level and low coolant temperature Ed10 Digital: Low coolant temperature. Analog: Low coolant level and low oil pressure Ed11 All analog inputs

Battery Voltage

Bt12 Battery voltage 12 VDC Bt24 Battery voltage 24 VDC

Communications

Cn00 No CAN communications Cn01 SAE J1939 (Used for ADC remote digital gauge) Cn02 Future CANbus

* Factory default setting for 8--32EOZD and 6.5--27EFOZD marine models. [ Check the generator set spec sheet for voltage configurations applicable to each model. Use voltage/frequency parameters Uu07--Uu22 only

with ADC application program version 1.20 or higher.

Figure 7-6 Controller Parameters

TP-6255 7/06 51Section 7 Controller

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

Hold the Select button:

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

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

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

Now release the Select button.

Press:

To set the voltage/frequency setting.

To step to the next parameter, unit configuration Uc.

Display:

. 0

1 0 4

U u 0 x

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

Press:

or To proceed to the save mode without

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

To step to the next parameter, engine type Ec.

To set the engine type, if necessary.

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

To enter advanced configuration mode.

Go to Figure 7-8.

entering the advanced configuration mode.

Go to Figure 7-9.

U c 0 0

E c 0 x

A d n c

E d 0 x

S A V E

Note: Shaded boxes show which number in the controller display changes when the up or down arrow

keyispressed. “x” denotes any number from 0 to 9.

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

TP-6255 7/0652 Section 7 Controller

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

Press:

Note: Shaded boxes show which number in the controller display changes when the up or down arrow

keyispressed. “x” denotes any number from 0 to 9.

Figure 7-8 Advanced Configuration Mode (engine data input types, battery voltage, and engine

communications)

To set the engine data input type.

To enter battery voltage selection mode.

To toggle between 12 and 24 VDC.

To enter communications selection mode.

To set the communications parameter mode.

To enter SAVE mode. Go to Figure 7-9.

12-volt models

24-volt models

E d 0 x

B t 1 2 B t 2 4

C n 0 0

S A V E

There are 3 options when the display says SAVE: Press:

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

To save changes.

To discard changes without saving.

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

Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the

last saved settings when the master switch is moved to the OFF/RESET position.

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

Now move the master switch to OFF/RESET.

S A V E

U u 0 x

Y E S

n o

x x xx

Figure 7-9 Save Mode (after configuring generator set parameters)

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Output Voltage Adjustment Mode:

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

Display :*

x x x x

Hold:

The controller is now in the voltage coarse adjustment mode.

Press:

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

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

To raise or lower the voltage in large increments (approximately 5--7 volts per step).

To enter fine voltage adjustment mode.

To raise or lower the voltage in smaller increments (approximately 0.5--0.7 volts per step).

1 P

x x

To enter coarse voltage stability (gain) adjustment mode.

2 P

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

To enter fine voltage stability (gain) adjustment mode.

x x

2 P

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

To enter volts/Hz adjustment mode.

3 P 0

To save, see Figure 7-9.

* Shaded boxes show which character in the controller display changes for each adjustment. X in the

examples above denotes any number from 0 to 9. The actual values may vary from model-to-model.

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

TP6196

Figure 7-10 Output Voltage Adjustments

TP-6255 7/0654 Section 7 Controller

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7.6 Controller Application Program

SCR Module Test Procedure

Required equipment:

The controller’s application program version number is displayed on the LED screen during the key sequence to enter the configuration mode. Hold the Select button and move the generator set master switch to the RUN position. After about 5 seconds, the application program version number will be displayed on the controller display. For example, u1.04 will be displayed for program version 1.04.

Use the Program Loader Software and a personal computer to update the controller’s application program to the latest version, when necessary. Check www.kohlernet.com, Tech Tools, Software, for information on ADC 2100 application program updates and instructions to obtain the latest application code and Program Loader software. Refer to TT-1285, Program Loader, for instructions to load the application program onto the controller.

7.7 Silicon Controlled Rectifier (SCR) Module

The silicon controlled rectifier (SCR) module works with the ADC 2100 to regulate the output voltage. The ADC 2100 monitors generator output voltage and adjusts the excitation current to the rotor through the SCR module. The SCR module location is shown in Figure 7-1.

The SCR module is powered through stator leads 55 and 66 connected to SCR terminals AC1 and AC2. Leads G connected to terminals G1 and G2 provide the controller signal. Leads FP and FN connected to the positive (+) and negative (--) SCR terminals provide excitation current to the rotor. See Figure 7-11 and the wiring diagrams in Section 10.

The SCR module is protected by a 10-amp fuse (F1) in lead 55 in the wiring harness. Check the fuse and replace it, if blown.

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

D Ohmmeter

D 12-volt test lamp (or voltmeter)

D 12-volt DC power source

D 100--500 ohm resistor

D Jumper

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

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

AC1 --

G2AC2

GM28483

Figure 7-11 Silicon Controlled Rectifier (SCR)

Module

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

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

5. Repeat steps 3 and 4 for AC2.

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

7. Repeat step 6 for G2. You should read low resistance in both directions.

8. See Figure 7-12. Connect the negative (--) lead from the DC power source to the positive (+) terminal on the SCR module.

Note: The SCR module may be damaged if the

power supply is connected incorrectly. Be sure to connect the negative lead from the battery to the positive terminal on the SCR module.

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9. Connect the positive (+) lead from the DC power source, with the lamp in series, to terminal AC1 on

(--)

(+)

the SCR module. The lamp should not glow.

10. Connect the jumper, with the resistorin series, from the positive lead of the DC power source to terminal G1 on the SCR module. The lamp should glow.

(+)

1. 12VDC power source

2. 12 VDC test lamp

3. SCR module

4. Jumper

5. 100--500 ohm resistor

Figure 7-12 SCR Test

AC1

AC2

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

terminal G2.

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

(--)

tp6196

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7.8 Continuous Power Mode Jumper, if equipped

Note: The P7 jumper was available on generator sets

with serial numbers before 2051415.

WARNING

Accidental starting. Can cause severe injury or death.

Note: The controller is powered by the generator set

engine starting battery.

A jumper on connector P7 on the back of the controller causes the controller to remain powered at all times. With the jumper connected, the ADC’s LED display is powered by the generator set’s battery. Also, the remote start/stop command is supported via the ADC remote gauge. See the wiring diagram and schematic drawing in Section 10. Controllers are shipped from the factory with the jumper connected. Disconnecting the jumper allows the controller to power down 48 hours after the generator set shuts down and the remote start/stop command is no longer supported.

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.

Moving rotor.

A jumper across controller pins P7-1 and P7-2 maintains power to the controller at all times. Controllers are shipped with the jumper connected for continuous power. See Figure 7-13.

If the generator set is not used for a long period of time, without exercising, the battery may drain. The P7 connector has either 2 or 3 pins. Disconnecting the jumper or moving the jumper to pins P7-2 and P7-3 allows the controller to power down automatically 48 hours after the generator set shuts down if the generator set master switch is in the AUTO position. A remote start signal (from a transfer switch or a remote start/stop switch connected to controller leads 3 and 4) or moving the generator set master switch to the RUN position turns the controller back on.

Note: For most applications, it is not necessary to

disconnect the continuous power mode jumper. Use the following procedure to disconnect the jumper, if desired.

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

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

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

TP-6255 7/06 57Section 7 Controller

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

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

Note: The P7 jumper was available on generator sets

with serial numbers before 2051415.

Note: For most applications, it is not necessary to

disconnect the continuous power mode jumper.

1. Prevent the generator set from starting.

a. Move the generator set master switch to the

OFF/RESET position.

b. Disconnect power to the battery charger, if

equipped

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

2. Remove the controller from the generator set housing.

a. Disconnect the engine wiring harness

connector P1 plug (35-pin) from the controller. Disconnect the J15 and J16 connectors. See Figure 7-13.

b. Remove the controller from the generator set

housing in order to access the back of the controller.

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

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

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

a. Note the labels on the three leads connected to

the generator set master switch for reconnection later. Disconnect the leads at the pink connectors. See Figure 7-13.

b. Remove the cover screws and remove the

controller’s back cover. See Figure 7-13.

4. Locate the P7 connector near the top of the controller. See Figure 7-13. Remove the jumper from pins 1 and 2 of the P7 connector. If the P7 connector has three pins, connect the jumper across pins 2 and 3 for storage.

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

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

7. Reconnect the J15 and J16 connectors.

8. Reconnect the engine wiring harness connector P1 plug (35-pin) to the controller.

5 34

RUN

VBAT

AUTO

1. Engine wiring harness connector plug (P1)

2. Continuous power mode jumper location (P7)

3. J15 connector

4. J16 connector

5. Generator set master switch

tp6196

Figure 7-13 ADC Controller (back cover removed)

7.9 Master Switch

The generator set master switch is a three-position (RUN\OFF/RESET\AUTO) rocker switch. The leads connecting to the master switch are labeled RUN, VBAT, and AUTO. Check that the three pink connectors are connected to the terminals on the back of the switch as shown in Figure 7-13. Be careful not to reverse the RUN and AUTO leads.

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7.10 Relay Interface Board (RIB)

The standard relay interface board (RIB) contains the K2 crank, K3 flash, and K5 run relays. Three LEDs indicate relay operation. See Figure 7-14.

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

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

D Lead 70A at the fuel solenoid

D Lead 71A at the starter relay

D Leads FP and FN at the rotor

Repair or replace the component causing the blown fuse.

If fuse continues to blow and disconnecting components did not identify the cause, remove the leads from the P14 connector using a pin pusher, part #241918 (large) or 241919 (small). If replacing the leads does not solve the problem, replace the RIB.

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

To replace the RIB:

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

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

COMMON FAULT

CRANK

P13

P14

RUN

AUX RUN

D3D1 D2

VBAT

FLASH

LED2

FLASH

LED3

CRANK

LED1

RUN

1. K1 common fault relay (optional)

2. K2 crank relay (standard)

3. K3 flash relay (standard)

4. K4 auxiliary run relay (optional)

5. K5 run relay (standard)

6. P14, engine harness connection (standard)

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

Figure 7-14 Relay Board

Harness

Lead

Number

88 6 Common fault normally open

89 2 Common fault common

90 3 Common fault normally closed

91 4 Run relay normally open

92 1 Run relay common

93 5 Run relay normally closed

Connector

Pin Number

Connection

GM29779-A

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

The generator set may be equipped with an optional RIB, which contains the K4 auxiliary run relay and K1 common fault relay in addition to the standard relays. The optional relay board kit includes a wiring harness for

Figure 7-15 Optional Common Fault and Run Relay

Board Harness Connections

connection of customer equipment to the K1 and K4 relays. See Figure 7-15 for optional relay connections.

TP-6255 7/06 59Section 7 Controller

Page 60

7.11 Controller Replacement

If the troubleshooting procedures in Section 6 identify a faulty controller, use the procedure in this section for controller replacement. Always check the controller configuration, fuse, wiring, and connections before replacing the controller. For output voltage problems, replace the SCR module and check the operation again before replacing the controller.

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

After the controller configuration has been checked and set to match the generator set, use a voltmeter to check the generator set output voltage. If the output voltage or frequency needs adjustment, use the voltage adjustment procedure in Section 8.8.2 and the governor adjustment instructions in Section 4.4.

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

5. Sound-Shielded Models: Release the two quarter-turn fasteners located underneath the roof. See Figure 7-16.

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

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

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

ADC 2100 Controller Replacement Procedure

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

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

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

WARNING

Accidental starting. Can cause severe injury or death.

1. Sound shield roof

2. Quarter-turn fastener

3. Alternator-end door

4. Service-side door

5. Front rail

6. Engine-end door

5 6

Figure 7-16 Sound Shield Roof Removal

Sound Shield Equipped Models: For access to the

generator set to perform regular maintenance, remove the sound shield doors and roof.

TP-6255 7/0660 Section 7 Controller

Page 61

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

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

10. Loosen and remove the four controller mounting screws at the front of the controller. See Figure 7-17. Remove the controller.

tp6196

1. Controller mounting screws (4 ea.)

Figure 7-17 Controller Mounting Screws

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

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

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

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

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

17. Use a voltmeter to check the output voltage. Follow the instructions in Sections 7.5.3, Voltage Adjustment and 8.8.2, Voltage Adjustment, to adjust the output voltage and stability.

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

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

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

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Notes

TP-6255 7/0662 Section 7 Controller

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Section 8 Component Testing and Adjustment

8.1 Theory of Operation

These generator sets utilize a rotating-field alternator to produce AC voltage. Upon activation of the generator master switch, DC current from the battery magnetizes the rotor (field). When the magnetized rotor rotates within the stator windings, an electrical voltage develops within the stator. As engine speed and generator output increase, the SCR module feeds rectified stator output current to the rotor through the exciter to increase the strength of the rotor field. As the rotor field increases in strength, generator output also increases. The ADC 2100 monitors the generator output voltage through leads 11 and 44 (for 1-phase models) or leads V7, V8, and V9 (for 3-phase models) and adjusts the DC current from the SCR module to the rotor to meet load requirements. See Figure 8-1.

8.2 Separate Excitation

To determine the cause of no- or low-AC output, refer to the troubleshooting flowchart in Figure 8-2. Before beginning the test procedures, read all of the safety precautions at the beginning of this manual. Many of the test procedures include additional safety precautions.

Check the condition of the alternator fuse before performing the separate excitation procedure. The inline fuse is located in lead 55 of the wiring harness. See Figure 8-1. If the fuse is not blown, use the following procedure to separately excite the generator using an external voltage source (a 12-volt automotive battery).

Separately exciting the generator can identify faulty voltage regulation by the ADC 2100 or reveal a running fault in the rotor and/or stator. An external power source duplicates the role of the voltage regulator and excites the generator field (rotor). A generator component that appears to be in good condition while stationary may exhibit a running open or short circuit while moving. Short circuits can be caused by centrifugal forces acting on the windings during rotation or insulation breakdown as temperatures increase.

ADC

2100

55 66

F+

AC1

SCR

AC2

G1 G2

(+)

(--)

345521

1. Fuse

2. Power lead (55)

3. Excitation to rotor

4. Exciter

5. Rectifier module

6. Main field (rotor)

7. Stator windings

8. Sensing leads (11--44)

Figure 8-1 Generator Schematic

(Single-Phase Model Shown)

No Generator Output

Separate Excitation

Output within

Specifications

Check Wiring, Fuses,

Erratic or No Output

SCR Module and

ADC 2100

Check Rotor

Check Stator

Figure 8-2 General Troubleshooting

F+

AC AC AC

F--

TP563273

TP-6255 7/06 63Section 8 Component Testing and Adjustment

Page 64

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

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

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

Separate Excitation Procedure:

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

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

2. Connect a DC ammeter, 20-amp fuse, and a 12-volt automotive battery to the positive (FP) and negative (FN) exciter leads as shown in Figure 8-3. Note and record the ammeter reading.

Note: The approximate ammeter reading should be the

battery voltage divided by the specified rotor resistance. See Section 1, Specifications, for the specified rotor resistance values.

Example :

12 volts (battery voltage)

3.5 ohms (rotor resistance)

= 3.4 amps (rotor current)

3. Start the engine and check that the ammeter reading remains stable. An increasing meter reading indicates a shorted rotor. A decreasing meter reading to zero or an unstable reading suggests a running open. Refer to Section 8.6, Rotor, to test the rotor. If the ammeter reading is stable, proceed to step 4.

4. Check for AC output across the stator leads; see Section 8.7, Stator. Compare the readings to the AC output values shown in Section 1, Specifications. If the readings vary considerably, a faulty stator is likely. Refer to Section 8.7, Stator, for further information.

5. If this test shows that the rotor and stator are in good condition, check the wiring and fuses. Check the SCR module. See Section 7.7, Silicon Controlled Rectifier (SCR) Module. Check the controller settings and connections. See Section 7, Controller.

789

23 4

TP563274

F+

AC AC AC

F--

1. SCR module

2. FN lead disconnected from SCR

3. FP lead disconnected from SCR

4. 10-amp fuse

5. DC ammeter

6. 12V battery

7. Exciter

8. Rectifier module

9. Main field (rotor)

Figure 8-3 Separate Excitation Connections

TP-6255 7/0664 Section 8 Component Testing and Adjustment

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8.3 Exciter Field

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

Exciter Field Test Procedure:

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

5. Check the exciter field for a short-to-ground condition. Use a megohmmeter to apply 500 volts DC to the FN or FP lead and the exciter field frame. See Figure 8-5. Follow the megohmmeter manufacturer’s instructions for using the megohmmeter. A reading of approximately

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

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

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

3. Disconnect the FN/FP leads.

4. Check the exciter field resistance by connecting an ohmmeter across exciter field FN and FP leads. See Figure 8-4. See Section 1, Specifications for the resistance reading of a cold exciter field. A low reading indicates an internal short and a high reading indicates an open winding. Repair or replace the exciter field if the ohmmeter readings indicate an inoperative exciter field (refer to Section 9 for removal). If the resistance test is inconclusive, perform a megohmmeter test on the exciter field as described in the next step.

FN FP

1. ADC 2100

2. Megohmmeter

3. Frame connection

4. Exciter armature

5. Exciter field

6. Main field (rotor)

Figure 8-5 Megohmmeter Connections on the

Exciter Field

TP-5983-7

1. ADC 2100

2. Ohmmeter

3. Exciter field

4. Exciter armature

5. Main field (rotor)

TP-5983-7

Figure 8-4 Exciter Field Resistance Test

TP-6255 7/06 65Section 8 Component Testing and Adjustment

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8.4 Exciter Armature

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

Exciter Armature Test Procedure:

1. Disassemble the alternator. Refer to Section 9.

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

3. With an ohmmeter on the R x 1 scale, check the resistance across the exciter armature leads. See Figure 8-6. See Section 1, Specifications for the armature resistance. No continuity indicates an open armature winding. If the resistance test is inconclusive, perform a megohmmeter test on the exciter armature as described in the next step.

Note: Most ohmmeters will not accurately

measure less than one ohm. Consider the exciter armature functional if the resistance reading (continuity) is low and there is no evidence of a shorted winding (heat discoloration).

4. Check the exciter armature winding for a short-to-ground condition. Use a megohmmeter to apply 500 volts DC to either armature lead and the armature frame. Follow the megohmmeter manufacturer’s instructions for using the megohmmeter. See Figure 8-7. A reading of approximately 1.5 MOhms and higher indicates the exciter armature is functional. A reading of less than approximately 1.5 MOhms indicates deterioration of the winding insulation and possible current flow to ground; if so, replace the exciter armature.

F+

AC AC AC

F--

1. Main field (rotor)

2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Armature

6. Exciter field

Figure 8-6 Exciter Armature Ohmmeter Test

1. Main field rotor

2. Stator windings

3. Rectifier module

4. Megohmmeter

F+

AC AC AC

F--

5. Shaft connection

6. Armature

7. Exciter field

Figure 8-7 Megohmmeter Connections on

Exciter Armature

TP-5983-7

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8.5 Rectifier Module

8.6 Rotor

The rectifier module located between the exciter armature and the main field converts AC from the exciter armature to DC, which magnetizes the generator main field. Test the rectifier module as described in the following steps.

Rectifier Module Test Procedure:

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

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

The generator rotor (magnetized by DC from the rectifier module) rotating within the stator windings induces AC in the stator windings. Test the generator rotor (main field) as described in the following steps. Disassemble the generator prior to performing this test. See Section 9.

Generator Main Field (Rotor) Test Procedure:

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

2. Check the main field resistance by connecting an ohmmeter across the main field F+ and F-- leads. See Figure 8-9. See Section 1, Specifications for the resistance reading. A low reading indicates an internal short and a high reading indicates an open winding. Repair or replace the main field if the ohmmeter readings indicate the main field is inoperative. If the resistance test is inconclusive, perform a megohmmeter test on the main field as described in the next step.

(AC)

1. Diode terminal

2. Diode terminal

3. Ohmmeter

(AC)

Figure 8-8 Rectifier Module Test

AC AC AC

F+

F--

TP-5983-7

+--

TP-5983-7

1. Main field (rotor)

2. Stator windings

3. Rectifier module

4. Ohmmeter

5. Armature

6. Exciter field

Figure 8-9 Ohmmeter Connections on

Main Field

3. Check the main field for a short-to-ground condition by using a megohmmeter. Apply 500 volts DC to either field lead and the main field frame. Follow the megohmmeter manufacturers instructions for using the megohmmeter. See Figure 8-10. A reading of 1.5 MOhms and higher indicates the main field is functional. A reading of less than 1.5 MOhms indicates deterioration of the winding insulation and possible current flow to ground; if so, replace the main field.

TP-6255 7/06 67Section 8 Component Testing and Adjustment

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AC AC AC

F+

F--

1. Main field (rotor)

2. Stator windings

3. Frame connection

4. Shaft connection

5. Rectifier module

6. Megohmmeter

7. Armature

8. Exciter field

TP-5983-7

Figure 8-10 Megohmmeter Connections on

Main Field

8.7 Stator

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

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

The stator produces electrical output (AC) as the magnetized main field rotates within the stator windings. Test the condition of the stator according to the following procedure.

Leads 1, 2, 3, and 4 are the generator output leads. Leads 55 and 66 are the voltage regulator supply and sensing leads. Refer to the schematic in Figure 8-11 when performing the following tests.

6196

Figure 8-11 Alternator Stator Leads

4. Disconnect all the stator leads to isolate the windings. To check the stator continuity, set the ohmmeter on the R x 1 scale. Check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 8-11. See Figure 8-12 for single-phase and Figure 8-13 for three-phase values. Perform the stator tests on all the stator windings.

Leads Continuity

1 and 2

1 and 11

2 and 11

3 and 4

3 and 44

4 and 44

55 and 66

1 and 3, 4, 44, 55, or 66

2 and 3, 4, 44, 55, or 66

3 and 1, 2, 11, 55, or 66

4 and 1, 2, 11, 55, or 66

Any stator lead and ground on stator housing or frame laminations

Yes

Figure 8-12 Stator Continuity Test Results on a Good

Stator (1-Phase)

Stator Test Procedure:

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

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

3. Check the generator output lead connections. See Section 10, Wiring Diagrams.

TP-6255 7/0668 Section 8 Component Testing and Adjustment

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Leads Continuity

1 and 4

2 and 5

3 and 6

7 and 10

Yes 8 and 11

9 and 12

55 and 66

1 and 2, 3, 7, 8, or 9

1 and 55

Any stator lead and ground

Figure 8-13 Stator Continuity Test Results on a Good

Stator (3-Phase)

5. Check the cold resistance of the stator windings by connecting the meter leads to the stator leads as shown in Figure 8-12 or Figure 8-13. See Section 1, Specifications for the stator resistance values. If the stator resistance test is inconclusive, perform a megohmmeter test on the stator as described in the next step.

Note: Consider the stator functional if the

resistance reading (continuity) is low and there is no evidence of shorted windings (heat discoloration).

F1 F2

AC AC AC

66 55 3 4

F+

F--

1. ADC’s voltage regulator power supply leads

2. Sensing leads (208--240 volts nominal)

3. Stator windings

4. Main field (rotor)

5. Rectifier module

6. Frame connection

7. Megohmmeter

8. Armature

9. Exciter field

TP-5983-7

Figure 8-14 Megohmmeter Connections on 1-Phase

Stator

F1 F2

Note: When taking an ohmmeter reading using

lead 55, make the connection before the in-line fuse.

Note: The stator resistance can vary directly with

increased temperature.

If any of the stator readings vary during the previous checks, replace the stator.

6. Check the stator for a short-to-ground condition using a megohmmeter. See Figure 8-14 for a single-phase megohmmeter connections and Figure 8-15 for three-phase megohmmeter connections. Apply 500 volts DC to any stator lead from each winding and the stator frame. Follow the megohmmeter manufacturer’s instructions for using the megohmmeter. Repeat the test on the other leads until all of the stator windings have been tested. A reading of 1.5 MOhms and higher indicates the stator is functional. A reading of less than 1.5 MOhms indicates deterioration of the winding insulation and possible current flow to ground; if so, repair or replace the stator.

1. ADC’s voltage regulator power supply leads

2. Sensing leads (208--240 volts nominal)

3. Stator windings

4. Main field (rotor)

5. Rectifier module

6. Frame connection

7. Megohmmeter

8. Armature

9. Exciter field

TP-5983-7

Figure 8-15 Megohmmeter Connections on 3-Phase

Stator

TP-6255 7/06 69Section 8 Component Testing and Adjustment

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8.8 Voltage

8.8.1 Voltage Regulation

Voltage regulation is performed by the Advanced Digital Control (ADC) and the SCR module. The ADC monitors generator output voltage and adjusts the excitation current to the rotor through the SCR module.

8.8.2 Voltage Adjustment

WARNING

Hazardous voltage. Can cause severe injury or death.

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

Moving rotor.

The factory sets the voltage for correct generator operation under a variety of load conditions. Usually, the voltage needs no further adjustment. Adjust the voltage when necessary according to the following procedure.

The adjustment procedure requires a meter that can measure voltage and frequency.

Use the ADC to adjust the voltage, gain, and volts/Hz. Refer to Section 7 for instructions to adjust each parameter and save the changes using the controller keypad.

Note: The ADC controller will time out and exit the

adjustment mode after approximately 1 minute if no buttons are pressed. Any unsaved changes are discarded if the controller times out before the settings are saved. Refer to Section 7.5 for instructions to save your settings.

Voltage Adjustment. Adjusts generator output between 100 and 130 volts.

Gain (Stability) Adjustment. Fine tunes regulator circuitry to reduce light flicker.

Volts/Hz Adjustment. Determines frequency (Hz) at which generator output voltage begins to drop.

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

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

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

Voltage Adjustment Procedure

1. Connect a digital voltmeter from one side of the circuit breaker to the L0 terminal. See Figure 8-16 for the L0 terminal location. Set the meter to measure voltage.

Note: For 120- or 240-volt systems the voltage

measured from one side of the breaker to L0 should be approximately 120 VAC. For 240-volt systems, the voltage measured from one side of the circuit breaker to the other should be approximately 240 VAC.

The ADC maintains generator output at the specified voltage under load until the generator engine speed drops to a preset level (factory setting 57.5 Hz on 60 Hz models and 47.5 Hz on 50 Hz models). Then the ADC allows the generator voltage and current to drop. The voltage/current drop enables the engine to pick up the load. When the generator speed returns to normal (60 Hz or 50 Hz) as load is accepted, the generator output also returns to normal.

2. Start the generator set.

3. Follow the ADC instructions in Section 7.5 to enter the adjustment mode and increase voltage or decrease voltage (parameter 1P) until the output reaches the desired voltage.

4. Follow the ADC instructions to step to the voltage gain adjustment menu. Adjust the voltage gain (parameter 2P) until the light flicker minimizes. Save the settings.

TP-6255 7/0670 Section 8 Component Testing and Adjustment

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5. Check and readjust the voltage if necessary.

6. Set the voltmeter to measure frequency. Adjust the engine speed to the cut-in frequency shown in Figure 8-17 by adjusting the governor as described in Section 4.4.

7. Set the voltmeter to measure voltage. Adjust the

volts/Hz (parameter 3P) until the voltage level measured by the voltmeter begins to drop. When set, the generator (as load is applied) attempts to

maintain normal output until the engine speed drops below the cut-in frequency set in step 6.

Service-Side View

8--32EOZD Models, Typical

Earlier Models

Generator-End View

(Shown with louvered panel removed)

8--24EOZD Models

4, 5

Later Models

Service-Side View

8. Set the voltmeter to measure frequency. Adjust the engine speed to the operating frequency (50 or 60 Hz) by adjusting the engine governor.

9. Readjust the voltage gain (parameter 2P) until the light flicker minimizes, if necessary.

10. Check the voltage. Readjust the voltage (parameter 1P), if necessary.

11. Save the settings. Refer to Section 7.5 for instructions.

Note: The ADC will revert to the previous settings

at the next startup if the changes are not saved.

12. Stop the generator set.

Frequency Cut-In Frequency

60 Hz 57.5 Hz 50 Hz 47.5 Hz

Figure 8-17 Cut-In Frequencies

(Shown with junction box cover removed)

1. Line circuit breaker

2. Circuit breaker mounting hardware

3. Circuit breaker cover plate

4. Load connection terminal L0

5. Ground connection terminal GRD

Top Vi ew

28/32EOZD Models

Figure 8-16 Circuit Breaker and L0 Terminal Location

TP-6255 7/06 71Section 8 Component Testing and Adjustment

Page 72

8.9 Four-Lead Reconnection

The following information illustrates the reconnection of four-lead generator sets. In all cases, conform to the National Electrical Code (NEC).

NOTICE

8.9.1 100--120-Volt Configurations

8.9.2 100--120/200--240-Volt Configurations

The 100--120/200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 100--120 volt, 3-wire, remove the jumper lead (see Figure 8-18 for location). Select a two-pole circuit breaker. Application of two single-pole circuit breakers does not conform to NEC requirements for supplying a 200--240-volt load, even if the breakers are mechanically attached together. Leads L1 and L2 are for different phases; never connect them together.

If the installation requires a factory two-pole circuit breaker, do not connect the load-side terminals of the circuit breaker together; see Figure 8-18. If the installation requires a 100--120-volt, 2-wire system, use a single-pole circuit breaker. See Figure 8-19. When connecting stator phase leads together, size the output lead (L1) to handle the amperage. Use a jumper lead on the line side of the circuit breaker to balance the load of the generator set.

L0 (Neutral)

Ground

Load Side

Line Side

4321

GRD.

L1 L2

Two-Pole Circuit Breaker

Jumper lead

Figure 8-18 100--120-Volt, 3-Wire Configuration

L0 (Neutral)

Ground

Load Side

Line Side

4321

Stator Leads

60 Hz 50 Hz

L0--L1 100--120 Volt 100--120 Volt L0--L2 100--120 Volt 100--120 Volt

GRD.

Single-Pole Circuit Breaker

Figure 8-19 100--120-Volt, 2-Wire Configuration

L0 (Neutral)

Ground

Load Side

Line Side

GRD.

Factory Two-Pole Circuit Breaker

100--120/200--240-Volt,

4321

Stator Leads

L0--L1 100--120 Volt 100--120 Volt L0--L2 100--120 Volt 100--120 Volt L1--L2 200--240 Volt 200--240 Volt

3-Wire

60 Hz 50 Hz

Figure 8-20 100--120/200--240-Volt, 3-Wire

Configuration

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Page 73

8.9.3 200--240-Volt Configurations

8.10 Twelve-Lead Reconnection

The 200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 100--120 volt, 3-wire, remove the jumper lead (see Figure 8-18 for location). See Figure 8-21.

L0 (Neutral)

Ground

Load Side

Line Side

4321

Stator Leads

60 Hz

L0--L1 200-240 Volt 200-- 220--240 Volt

Single-Pole Circuit Breaker

Tape to insulate from ground

200--220--240 Volt 2 Wire

GRD.

50 Hz

Figure 8-21 200--220--240-Volt, 2-Wire Configuration

for Models with ADC 2100

The reconnection procedure following details voltage reconnections only. If the generator set requires frequency changes, adjust the governor.

The following information illustrates the reconnection of 12-lead generator sets. In all cases, follow the National Electrical Code (NEC) guidelines.

Reconnect the stator leads of the generator set to change output phase or voltage. Refer to the following procedure and connection schematics. Follow all safety precautions at the front of this manual and in the text during reconnection procedure.

NOTICE

Twelve-Lead Reconnection Procedure

1. Move generator set master switch to OFF/RESET position.

2. Disconnect engine starting battery, negative (--) lead first. Disconnect power to battery charger, if equipped.

3. Use Figure 8-22 to determine generator set voltage configuration. Note the original voltage and reconnect the generator set as needed.

115/230

Note: Current Transformers (CTs) are not used on all sets. CT dot or “HI” toward generator.

230

Figure 8-22 Generator Reconnection

EM-250000

TP-6255 7/06 73Section 8 Component Testing and Adjustment

Page 74

8.11 Fault Shutdown Tests

Verify the operation of the generator set overspeed, overcrank, and low oil pressure shutdowns by performing the following tests. If these tests are inconclusive, test individual shutdown circuit components (wiring harness, switch, etc.) as described elsewhere in this section.

WARNING

Hazardous voltage. Can cause severe injury or death.

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

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep

hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

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

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

8.11.1 Controller Fault Shutdown Functions

Check the operation of the fault functions programmed in the ADC 2100 by performing the following tests. If the ADC 2100 does not operate as described, check the ADC configuration settings; see Section 7.5.2. Also check the ADC 2100 wiring and connections; see Section 10.

Overspeed Shutdown

The overspeed setting is programmed into the ADC controller and is not adjustable. Verify that the following controller configuration parameters are set correctly for your unit. See Section 7.5.2 for the settings.

D System voltage/frequency parameter (UU)

D Unit configuration parameter (UC)

D Engine type parameter (EC)

D Engine data input type parameter (ED)

Moving rotor.

WARNING

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

Do not work on the generator set until it cools.

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The

engine and exhaust system components become extremely hot during operation.

Open the generator set output circuit breaker before beginning the test. (See Figure 8-16 for the circuit breaker location.)

Connect a DVM to measure the output frequency. Start the generator set and manually adjust the engine speed. See Section 4.4.

Increase the engine speed to at least 115% of the rated engine speed, 69 Hz on 60 Hz models or 58 Hz on 50 Hz models. Verify that the generator set shuts down on an overspeed fault (OS). If the overspeed shutdown does not operate, the generator set should shut down on an overfrequency fault (OF) after approximately 5 seconds.

Low Oil Pressure (LOP) Shutdown

Connect a jumper wire from the LOP switch (lead 13) to the generator set ground. Start the generator set. Verify that the generator set shuts down after approximately 25--35 seconds of operation. Remove the jumper wire from the LOP switch and ground. Start the generator set and run it for at least 25--35 seconds to verify that the generator set does not shut down.

Overcrank Shutdown

Disconnect the starter motor lead at the starter solenoid (K20) terminal. Move the controller master switch to the RUN position. Observe that the generator set simulates cranking for 15 seconds and then rests for 15 seconds. Check that the generator set shuts down after the third crank/rest cycle.

High Engine Temperature Shutdown

Connect a jumper wire across coolant temperature sensor (CTS) connections P1-8 and P1-9. Start the generator set. Verify that the generator set shuts down approximately 5 seconds after the generator set comes up to speed. Remove the jumper wire. Start the generator set and run it for at least 30 seconds to verify that the generator set does not shut down.

TP-6255 7/0674 Section 8 Component Testing and Adjustment

Page 75

8.11.2 Fault Shutdown Switches

8--32EOZDand

EFOZD

Check the low oil pressure and high engine temperature shutdown switches on the engine by performing the following tests. If the sensor does not function as described, replace it.

replacing the LOP switch. To test the LOP switch, reinstall the switch and start the generator set. If the unit shuts down, disconnect lead 13 from the LOP switch and reset the controller. Restart the generator set and verify that it does not shut down. A successful restart indicates a bad LOP switch. Replace the switch.

WARNING

Hazardous voltage. Can cause severe injury or death.

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

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep

hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

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

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

Temperature Sensor (CTS)

The coolant temperature sensor (CTS) is used to monitor engine temperature for the high engine temperature fault shutdown (HE). See Figure 8-23 for the coolant temperature sensor location. Set the generator set master switch to the OFF position and allow the generator set to cool. Disconnect the CTS and use an ohmmeter to measure the resistance across the sensor. The sensor resistance varies with temperature and should be within the values shown in Figure 8-24. If the resistance is very low (indicated a short circuit) or very high (indicating an open circuit) replace the CTS.

Moving rotor.

1. Coolant Temperature Sensor

Figure 8-23 Coolant Temperature Sensor Location

(8EOZD Model Shown)

Temperature, _C(_F)

30 (86) 2106--2392

100 (212) 182--198

Resistance, Ohms

Figure 8-24 Coolant Temperature Sensor Resistance

Readings

1. Oil pressure switch

Low Oil Pressure (LOP) Switch

Figure 8-25 Oil Pressure Switch Location

(24EOZD Model Shown)

See Figure 8-25 for the low oil pressure (LOP) switch location.

Model

Remove the LOP switch and install an oil pressure gauge to verify that the engine oil pressure is within the range specified in Figure 8-26 before testing or

TP-6255 7/06 75Section 8 Component Testing and Adjustment

Figure 8-26 Oil Pressure Range

.5--27

Oil Pressure Range

MPa (kg/cm

0.29--0.39(3--4)

)

Page 76

8.12 Fuses

The engine harness (or junction box for 9EOZD/7EFOZD models) contains three inline fuses. See Figure 8-27.

Always identify and correct the cause of a blown fuse before restarting the generator set. Refer to Section 6, Troubleshooting, for conditions that may indicate a blown fuse. Replace blown fuses with identical replacement parts.

Part

Fuse Label

Auxiliary Winding, 10 amps

Relay Interface Board, 10 amps

Controller, 10 amps F3 223316 Lead PF3

* See Figure 8-28 for 9EOZD/7EFOZD model fuse location.

Number

F1 358337 Lead 55

F2 223316 Lead PF2

Figure 8-27 Fuses

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.

To further check generator set components, disconnect the battery and remove wiring harness plugs from the ADC circuit board. Use an ohmmeter to check the continuity of the components listed in Figure 8-30. Also see Section 10, Wiring Diagrams.

Figure 8-30 gives resistance readings for functional components. A zero reading on the ohmmeter indicates continuity. No ohmmeter reading indicates very high resistance or an open circuit. A measurement that varies significantly from the value shown in the table indicates a faulty component; replace faulty components.

Note: Disconnect the generator set battery before

performing continuity checks to prevent damage to the ohmmeter.

Back View

Zero ohms (continuity) across

RUN and VBAT terminals

ADV6967-A

1. Fuses

Figure 8-28 Fuse Location on 9EOZD/7EFOZD

Model

8.13 Continuity Checks

WARNING

Hazardous voltage. Can cause severe injury or death.

Moving rotor.

321

Master Switch in RUN Position

RUN

VBAT

AUTO

Back View

Zero ohms (continuity) across

VBAT and AUTO terminals

321

Master Switch in AUTO Position

RUN

VBAT

AUTO

Figure 8-29 Generator Set Master Switch Continuity

Checks

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

TP-6255 7/0676 Section 8 Component Testing and Adjustment

Page 77

Generator Set

switch(SeeFigure829

)

(Sg89

)

Component

Generator set master switch

P1 wiring harness P1-27 and ground Rx1 OFF/RESET Zero ohms (continuity)

Controller fuse and wiring

Auxiliary winding fuse 10 amp fuse

Low oil pressure (LOP) switch *

Temperature sensor (CTS) *

Aux. run relay (K5) Terminals 85 and 86 Rx1 OFF/RESET 12-volt relay: 85±5 ohms coil resistance

* See Section 8.11.2, Fault Shutdown Switches

Connections

RUN and VBAT (See Figure 8-29)

AUTO and VBAT (See Figure 8-29)

P15-1 and P15-3 (stator leads 11 and 44 for 1-phase models) or P15-1, P15-2, and P15-3 (stator leads 7, 8, and 9 for 3-phase models)

P16-3 and P16-6 (stator leads 55 and 66)

P1-24 and battery positive (+)

P16-3 and stator lead 55 R x 100 OFF/RESET Zero ohms (continuity). If no continuity is

Lead 13 and ground (engine block)

P1-8 and P1-9 R x 1000 OFF/RESET 180--2500 ohms, depending on engine

Ohmmeter

Scale

R x 100 RUN Zero ohms (continuity). Any other reading

R x 100 AUTO Zero ohms (continuity). Any other reading

Rx1 OFF/RESET Zero ohms (continuity). If no continuity,

R x 100 OFF/RESET Zero ohms (continuity). If no continuity is

R x 100 OFF/RESET Zero ohms (continuity). No continuity

Master Switch

Position

OFF/RESET No reading (open circuit). Any other

Ohmmeter Readings for Operative

Components*

indicates a bad switch.

reading indicates a bad switch.

indicates a bad switch.

reading indicates a bad switch.

Any other reading indicates a poor ground connection.

check wiring.

check fuse F1 and wiring.

found, check fuse F3 and wiring.

found, check for an open circuit and/or a blown fuse.

indicates a bad switch and/or wiring.

temperature. Zero ohms or an open circuit indicates bad wiring or a bad switch.

24-volt relay: 305±15 ohms coil resistance Lower resistance indicates a shorted relay coil and/or wiring. High resistance indicates an open relay coil and/or wiring.

Figure 8-30 Continuity Checks

TP-6255 7/06 77Section 8 Component Testing and Adjustment

Page 78

Notes

TP-6255 7/0678 Section 8 Component Testing and Adjustment

Page 79

Section 9 Generator Disassembly/Reassembly

9.1 Disassembly

Disconnect all of the external connections—battery cables at the battery (negative (--) lead first), AC-output leads, remote interface connector, water line at the seawater pump, fuel line at the fuel pump filter inlet, and exhaust line at the mixing elbow. Observe all of the safety precautions listed at the beginning of this manual during the disassembly/reassembly procedures.

Note: Because this manual covers several models, the

procedure for disassembly may vary because of product updates and the assembly variations.

Disassembly Procedure:

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

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

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

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

5. Sound-Shielded Models: Release the two quarter-turn fasteners located underneath the roof. See Figure 9-1.

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

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

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

WARNING

Accidental starting. Can cause severe injury or death.

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

1. Sound shield roof

2. Quarter-turn fastener

3. Alternator-end door

4. Service-side door

5. Front rail

6. Engine-end door

5 6

Figure 9-1 Sound Shield Roof Removal

TP-6255 7/06 79Section 9 Generator Disassembly/Reassembly

Page 80

9. Disconnect wiring harness plugs P1, P15, and P16 from the ADC 2100.

10. Loosen and remove the four controller mounting screws at the front of the controller. See Figure 9-2. Remove the controller.

tp6196

1. Controller mounting screws (4 ea.)

Figure 9-2 ADC 2100 Mounting Screws

11. Remove the junction box louvered panel. See Figure 9-3 and Figure 9-4.

1. Junction box louvered panel

2. SCR module

3. Relay board

4. Engine harness-to-controller connection

5. Generator set master switch

6. ADC 2100

7. Line circuit breaker plate

8. Junction box

Figure 9-4 Advanced Digital Control (ADC 2100)

1. ADC 2100

2. Junction box louvered panel

Figure 9-3 Covers

12. Remove the junction box, SCR module, and relay board as necessary. See Figure 9-4.

TP-6255 7/0680 Section 9 Generator Disassembly/Reassembly

Page 81

13. Disconnect the FP and FN leads.

14. Remove the four bolts to remove the exciter field. SeeFigure9-5.

18. Attach a hoist hook to the generator lifting eye. See Figure 9-7.

Note: The hoist capacity rating should be one-half

ton or greater.

19. Remove the two vibromount bolts. See Figure 9-7.

558864

1. Bolts (4)

2. Exciter field

Figure 9-5 Exciter Field Removal

15. Remove the three bolts and spacers from the rectifier board.

16. Disconnect the main field rotor leads from the rectifier board positive/negative terminals. Remove the armature retaining bolt and washer. SeeFigure9-6.

17. Remove the armature from the shaft, guiding the rotor leads through the armature bores. See Figure 9-6.

20. Raise the alternator end and place a wood block under the locator plate. Lower the alternator until the wood block supports the backplate. See Figure 9-7.

21. Remove the four overbolts from the end bracket.

1. Lifting eye

2. Backplate

3. Wood block

4. Vibromounts

558866

Figure 9-7 Supporting the Generator, Typical

1. Armature

2. Armature retaining bolt

3. Rotor leads

4. Rectifier board

558865

Figure 9-6 Armature Removal

TP-6255 7/06 81Section 9 Generator Disassembly/Reassembly

Page 82

22. Install a sling capable of handling the weight of the stator housing on the stator housing. See Figure 9-8.

23. Use a two-jaw puller to pull the end bracket/stator assembly from the bearing on the rotor shaft. See Figure 9-8.

24. Remove the stator assembly from the rotor. Remove or rotate the fan guard, if necessary, to clear the vibromounts.

25. Mark the fan’s position on the rotor/drive disc assembly with a permanent marker.

26. Remove the four screws with spacers and the four screws without spacers. See Figure 9-9.

27. Remove the fan and fan spacers. See Figure 9-9.

28. Remove the eight bolts and remove the drive disc/rotor assembly from the engine flywheel. See Figure 9-10.

29. Clamp the rotor in a soft-jaw vise. Remove the eight bolts and remove the drive disc assembly from the rotor. See Figure 9-11.

558868

1. Fan

2. Screws with spacers (4)

3. Screws without spacers (4)

Figure 9-9 Fan Removal

1. Sling

2. Fan guard

3. Two-jaw puller

Figure 9-8 Stator Assembly Removal

558869

1. Bolts (8)

2. Rotor assembly

Figure 9-10 Disc/Rotor Assembly

558867

TP-6255 7/0682 Section 9 Generator Disassembly/Reassembly

Page 83

Note: Install the fan with the flange side facing

away from the flywheel.

4. Replace the O-ring in the end bracket bearing bore. Use a sling to support the stator assembly while installing the stator over the rotor. Do not damage the rotor. See Figure 9-13.

5588610

1. Drive disc

2. Rotor

3. Bolt

Figure 9-11 Drive Disc

9.2 Reassembly

1. Clamp the rotor in a soft-jaw vise. Install a new drive disc on the rotor. Tighten the eight bolts to 38 Nm (28 ft. lbs.) See Figure 9-12.

1. O-ring

5588612

Figure 9-13 Stator Installation

5. Install the four overbolts (the two long bolts in the lower holes). Check that the alignment marks on the stator housing and locator plate match. See Figure 9-14. Tighten the overbolts to 34 Nm (25 ft. lbs.).

1. Drive disc

2. Rotor

3. Bolt

Figure 9-12 Drive Disc Installation

2. Install the rotor/drive disc assembly on the engine flywheel using eight washers and bolts. Tighten the bolts to 19 Nm (14 ft. lbs.)

3. Align the fan to the rotor/drive disc assembly using the mark created in the disassembly procedure. Install the fan to the drive disc using eight screws, four spacers, washers, and locknuts.

TP-6255 7/06 83Section 9 Generator Disassembly/Reassembly

5588611

1. Alignment marks

Figure 9-14 Alignment Marks

6. Use the hoist to raise the alternator end. Remove the wood block from under the locator plate. Lower the generator set and install a bolt, a large washer, two small washers, and a locknut on each vibromount. Tighten the mounting bolts to 28 Nm (20 ft. lbs.).

5588613

Page 84

7. Apply antiseize compound to the keyed end of the rotor shaft. Bring the rotor leads through the bores in the armature while installing the armature on the shaft. Check the keyway of the shaft and key of the armature for damage. Install the armature retaining bolt and washer.

8. Use screws and lock washers to install the rotor leads to the rectifier board at the positive (+) and negative (--) terminals.

Note: Position the lock washers against the

rectifier board.

9. Install the three spacers and bolts to mount the rectifier board to the armature.

11. Install tie wraps to secure the wires as necessary.

12. Reconnect the leads to the circuit breaker and neutral stud (LO) as marked during disassembly.

Note: Check the generator set nameplate to verify

the original voltage configuration.

13. Reconnect the P1, P15, and P16 connectors. Connect the ground strap using bolt, washer, and lock washer (install the lock washer against the ground strap).

14. Reinstall the ADC 2100.

15. Reinstall the junction box louvered panel.

10. Position the field leads at the top. Install the exciter field using four bolts and washers. See Figure 9-15.

5588614

1. Exciter field bolts (4)

2. Exciter field

Figure 9-15 Installing Exciter Field

16. Reconnect all of the external connections—the exhaust line to the mixing elbow, the fuel line to the fuel pump filter inlet, the water line to the seawater pump, the remote interface connector, the AC output leads, and the battery cables to the battery (negative (--) lead last).

17. Verify that the generator set master switch is in the OFF position.

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

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

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

TP-6255 7/0684 Section 9 Generator Disassembly/Reassembly

Page 85

Section 10 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

Moving rotor.

TP-6255 7/06 85Section 10 Wiring Diagrams

Page 86

GM30264-F

Figure 10-1 Wiring Diagram for All Models Except 9EOZD/7EFOZD (See Figure 10-2 for 9EOZD/7EFOZD Model)

TP-6255 7/0686 Section 10 Wiring Diagrams

Page 87

GM46351-

Figure 10-2 Wiring Diagram for 9EOZD/7EFOZD Model

TP-6255 7/06 87Section 10 Wiring Diagrams

Page 88

Figure 10-3 Wiring Schematic for All Models

ADV6845A-F

TP-6255 7/0688 Section 10 Wiring Diagrams

Page 89

ADV6845B-F

Figure 10-4 Wiring Diagram, Schematic for All Models

TP-6255 7/06 89Section 10 Wiring Diagrams

Page 90

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

Electro Switch

To Generator Set

2-Wire Generator Sets

2134

6578

To Load

To Shore Power

Kraus Naimler/American Solenoid

(Early Rectangular Design)

2-Wire Generator Sets

1265

348 7

To Shore Power

To Generator Set

3-Wire Generator Sets

2134

657 8

10 9 11 12

To Load

3-Wire Generator Sets

1265

348 7

91014 13

To Shore Power

To Generator Set

To Load

Kraus Naimler/American Solenoid

(Newer Round Design)

2-Wire Generator Sets

3241

768 5

To Load

To Shore Power

To Generator Set

To Load

3-Wire Generator Sets

3241

768 5

11 10 12 9

To Load

To Shore Power

TP-5399-5

TP-6255 7/0690 Section 10 Wiring Diagrams

Page 91

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

Kraus Naimer/American Solenoid

4-Wire, three phase

Generator Sets

To Generator

Set

3241

7685

11 10 12 9

15 14 16 13

L2 L3 L0L1

To Load

To Shore

Power

I-940

TP-6255 7/06 91Section 10 Wiring Diagrams

Page 92

Notes

TP-6255 7/0692 Section 10 Wiring Diagrams

Page 93

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-6255 7/06 Appendix 93

Page 94

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-6255 7/0694 Appendix

Page 95

Appendix B Common Hardware Application Guidelines

Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made.

Bolt/Screw Length: When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method.

Washers and Nuts: Use split lock washers as a bolt locking device where specified. Use SAE flat washers with whiz nuts, spiralock nuts, or standard nuts and preloading (torque) of the bolt in all other applications.

See General Torque Specifications and other torque specifications in the service literature.

Preferred Nut/Bolt Clearance

Steps for common hardware application

1. Determine entry hole type: round or slotted.

2. Determine exit hole type: fixed female thread (weld nut), round, or slotted.

For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter, or 1/2 inch in diameter or less. Hardware that is greater than 1/2 inch in diameter takes a standard nut and SAE washer. Hardware 1/2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut. See the diagram below.

3. Follow these SAE washer rules after determining exit hole type:

a. Always use a washer between hardware and a

slot.

b. Always use a washer under a nut (see 2 above

for exception).

c. Use a washer under a bolt when the female

thread is fixed (weld nut).

Unacceptable Nut/Bolt Clearance

1. 1/2 of bolt diameter

2. Minimum 1 full thread beyond top of nut

3. Below top of nut

Figure 1 Acceptable Bolt Lengths

4. Refer to the diagram below, which depicts the preceding hardware configuration possibilities.

G-585

1. Cap screw

2. Entry hole types

3. Standard nut and SAE washer

4. Whiz nut or spiralock: up to 1/2 in. dia. hardware

5. Weld nuts: above 1/2 in. dia. hardware

6. Exit hole types

G-585

Figure 2 Acceptable Hardware Combinations

TP-6255 7/06 95Appendix

Page 96

Appendix C General Torque Specifications

Assembledinto

Use the following torque specifications when service literature instructions give no specific torque values. The charts list values for new plated, zinc phosphate, or

American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel

Torque

Size

8-32 in.lbs.(Nm) 16 (1.8) 20 (2.3) — 16 (1.8) 10-24 in.lbs.(Nm) 26 (2.9) 32 (3.6) — 26 (2.9) 10-32 in.lbs.(Nm) 26 (2.9) 32 (3.6) — 26 (2.9) 1/4-20 in.lbs.(Nm) 60 (6.8) 96 (10.8) 132 (14.9) 60 (6.8) 1/4-28 in.lbs.(Nm) 72 (8.1) 108 (12.2) 144 (16.3) 72 (8.1) 5/16-18 in.lbs.(Nm) 120 (13.6) 192 (21.7) 264 (29.8) 120 (13.6) 5/16-24 in.lbs.(Nm) 132 (14.9) 204 (23.1) 288 (32.5) 132 (14.9) 3/8-16 ft. lbs. (Nm) 18 (24) 28 (38) 39 (53) 18 (24) 3/8-24 ft. lbs. (Nm) 20 (27) 31 (42) 44 (60) 20 (27) 7/16-14 ft. lbs. (Nm) 29 (39) 44 (60) 63 (85) — 7/16-20 ft. lbs. (Nm) 32 (43) 50 (68) 70 (95) — 1/2-13 ft. lbs. (Nm) 44 (60) 68 (92) 96 (130) — 1/2-20 ft. lbs. (Nm) 49 (66) 76 (103) 108 (146) — 9/16-12 ft. lbs. (Nm) 60 (81) 98 (133) 138 (187) — 9/16-18 ft. lbs. (Nm) 67 (91) 109 (148) 154 (209) — 5/8-11 ft. lbs. (Nm) 83 (113) 135 (183) 191 (259) — 5/8-18 ft. lbs. (Nm) 94 (128) 153 (208) 216 (293) — 3/4-10 ft. lbs. (Nm) 147 (199) 240 (325) 338 (458) — 3/4-16 ft. lbs. (Nm) 164 (222) 268 (363) 378 (513) — 1-8 ft. lbs. (Nm) 191 (259) 532 (721) 818 (1109) — 1-12 ft. lbs. (Nm) 209 (283) 582 (789) 895 (1214) —

Measurement

Grade 2 Grade 5 Grade 8

oiled threads. Increase values by 15% for nonplated threads. All torque values are +0%/--10%.

ssembled into

Aluminum

Grade2or5

Metric Fasteners Torque Specifications, Measured in ft. lbs. (Nm)

Assembled into Cast Iron or Steel

Size (mm) Grade 5.8 Grade 8.8 Grade 10.9

M6 x 1.00 4 (5.6) 7 (9.9) 10 (14) 4 (5.6) M8 x 1.25 10 (13.6) 18 (25) 26 (35) 10 (13.6) M8 x 1.00 16 (21) 18 (25) 26 (35) 16 (21) M10 x 1.50 20 (27) 35 (49) 50 (68) 20 (27) M10 x 1.25 29 (39) 35 (49) 50 (68) 29 (39) M12 x 1.75 35 (47) 61 (83) 86 (117) — M12 x 1.50 48 (65) 65 (88) 92 (125) — M14 x 2.00 55 (74) 97 (132) 136 (185) — M14 x 1.50 74 (100) 103 (140) 142 (192) — M16 x 2.00 85 (115) 148 (200) 210 (285) — M16 x 1.50 104 (141) 155 (210) 218 (295) — M18 x 2.50 114 (155) 203 (275) 288 (390) — M18 x 1.50 145 (196) 225 (305) 315 (425) —

Assembled into

luminum

Grade 5.8 or 8.8

TP-6255 7/0696 Appendix

Page 97

Appendix D Common Hardware Identification

Screw/Bolts/Studs

Head Styles

Hex Head or Machine Head

Hex Head or Machine Head with Washer

Flat Head (FHM)

Round Head (RHM)

Pan Head

Hex Socket Head Cap or Allent Head Cap

Hex Socket Head or Allent Head Shoulder Bolt

Sheet Metal Screw

Stud

Drive Styles

Hex

Hex and Slotted

Phillipsr

Nuts

Nut Styles

Hex Head

Lock or Elastic

Square

Cap or Acorn

Wing

Washers

Washer Styles

Plain

Split Lock or Spring

Spring or Wave

External Tooth Lock

Internal Tooth Lock

Internal-External Tooth Lock

Hardness Grades

American Standard

Grade 2

Grade 5

Grade 8

Grade 8/9 (Hex Socket Head)

Metric

Number stamped on hardware; 5.8 shown

5.8

Slotted

Hex Socket

Allent head screw is a trademark of Holo-Krome Co.

Phillipsr screw is a registered trademark of Phillips Screw Company.

Sample Dimensions

American Standard (Screws, Bolts, Studs, and Nuts)

1/4-20 x 1

Metric (Screws, Bolts, Studs, and Nuts)

M8-1.25 x 20

Length In Inches (Screws and Bolts)

Threads Per Inch

Major Thread Diameter In Fractional Inches Or Screw Number Size

Length In Millimeters (Screws and Bolts)

Distance Between Threads In Millimeters

Major Thread Diameter In Millimeters

Plain Washers

9/32

x5/8x 1/16

Lock Washers

5/8

Thickness

External Dimension

Internal Dimension

TP-6255 7/06 97Appendix

Page 98

Appendix E Common Hardware List

The Common Hardware List lists part numbers and dimensions for common hardware items.

American Standard

Part No. Dimensions

Hex Head Bolts (Grade 5)

X-465-17 1/4-20 x .38 X-465-6 1/4-20 x .50 X-465-2 1/4-20 x .62 X-465-16 1/4-20 x .75 X-465-18 1/4-20 x .88 X-465-7 1/4-20 x 1.00 X-465-8 1/4-20 x 1.25 X-465-9 1/4-20 x 1.50 X-465-10 1/4-20 x 1.75 X-465-11 1/4-20 x 2.00 X-465-12 1/4-20 x 2.25 X-465-14 1/4-20 x 2.75 X-465-21 1/4-20 x 5.00 X-465-25 1/4-28 x .38 X-465-20 1/4-28 x 1.00

X-125-33 5/16-18 x .50 X-125-23 5/16-18 x .62 X-125-3 5/16-18 x .75 X-125-31 5/16-18 x .88 X-125-5 5/16-18 x 1.00 X-125-24 5/16-18 x 1.25 X-125-34 5/16-18 x 1.50 X-125-25 5/16-18 x 1.75 X-125-26 5/16-18 x 2.00 230578 5/16-18 x 2.25 X-125-29 5/16-18 x 2.50 X-125-27 5/16-18 x 2.75 X-125-28 5/16-18 x 3.00 X-125-22 5/16-18 x 4.50 X-125-32 5/16-18 x 5.00 X-125-35 5/16-18 x 5.50 X-125-36 5/16-18 x 6.00 X-125-40 5/16-18 x 6.50

X-125-43 5/16-24 x 1.75 X-125-44 5/16-24 x 2.50 X-125-30 5/16-24 x .75 X-125-39 5/16-24 x 2.00 X-125-38 5/16-24 x 2.75

X-6238-2 3/8-16 x .62 X-6238-10 3/8-16 x .75 X-6238-3 3/8-16 x .88 X-6238-11 3/8-16 x 1.00 X-6238-4 3/8-16 x 1.25 X-6238-5 3/8-16 x 1.50 X-6238-1 3/8-16 x 1.75 X-6238-6 3/8-16 x 2.00 X-6238-17 3/8-16 x 2.25 X-6238-7 3/8-16 x 2.50 X-6238-8 3/8-16 x 2.75 X-6238-9 3/8-16 x 3.00 X-6238-19 3/8-16 x 3.25 X-6238-12 3/8-16 x 3.50 X-6238-20 3/8-16 x 3.75 X-6238-13 3/8-16 x 4.50 X-6238-18 3/8-16 x 5.50 X-6238-25 3/8-16 x 6.50

Part No. Dimensions

Hex Head Bolts, cont.

X-6238-14 3/8-24 x .75 X-6238-16 3/8-24 x 1.25 X-6238-21 3/8-24 x 4.00 X-6238-22 3/8-24 x 4.50

X-6024-5 7/16-14 x .75 X-6024-2 7/16-14 x 1.00 X-6024-8 7/16-14 x 1.25 X-6024-3 7/16-14 x 1.50 X-6024-4 7/16-14 x 2.00 X-6024-11 7/16-14 x 2.75 X-6024-12 7/16-14 x 6.50

X-129-15 1/2-13 x .75 X-129-17 1/2-13 x 1.00 X-129-18 1/2-13 x 1.25 X-129-19 1/2-13 x 1.50 X-129-20 1/2-13 x 1.75 X-129-21 1/2-13 x 2.00 X-129-22 1/2-13 x 2.25 X-129-23 1/2-13 x 2.50 X-129-24 1/2-13 x 2.75 X-129-25 1/2-13 x 3.00 X-129-27 1/2-13 x 3.50 X-129-29 1/2-13 x 4.00 X-129-30 1/2-13 x 4.50 X-463-9 1/2-13 x 5.50 X-129-44 1/2-13 x 6.00

X-129-51 1/2-20 x .75 X-129-45 1/2-20 x 1.25 X-129-52 1/2-20 x 1.50

X-6021-3 5/8-11 x 1.00 X-6021-4 5/8-11 x 1.25 X-6021-2 5/8-11 x 1.50 X-6021-1 5/8-11 x 1.75 273049 5/8-11 x 2.00 X-6021-5 5/8-11 x 2.25 X-6021-6 5/8-11 x 2.50 X-6021-7 5/8-11 x 2.75 X-6021-12 5/8-11 x 3.75 X-6021-11 5/8-11 x 4.50 X-6021-10 5/8-11 x 6.00

X-6021-9 5/8-18 x 2.50

X-6239-1 3/4-10 x 1.00 X-6239-8 3/4-10 x 1.25 X-6239-2 3/4-10 x 1.50 X-6239-3 3/4-10 x 2.00 X-6239-4 3/4-10 x 2.50 X-6239-5 3/4-10 x 3.00 X-6239-6 3/4-10 x 3.50

X-792-1 1-8 x 2.25 X-792-5 1-8 x 3.00 X-792-8 1-8 x 5.00

Part No. Dimensions Type

Hex Nuts

X-6009-1 1-8 Standard

X-6210-3 6-32 Whiz X-6210-4 8-32 Whiz X-6210-5 10-24 Whiz X-6210-1 10-32 Whiz

X-6210-2 1/4-20 Spiralock X-6210-6 1/4-28 Spiralock X-6210-7 5/16-18 Spiralock X-6210-8 5/16-24 Spiralock X-6210-9 3/8-16 Spiralock X-6210-10 3/8-24 Spiralock X-6210-11 7/16-14 Spiralock X-6210-12 1/2-13 Spiralock X-6210-15 7/16-20 Spiralock X-6210-14 Spiralock

X-85-3 5/8-11 Standard X-88-12 3/4-10 Standard X-89-2 1/2-20 Standard

Washers

Part No. ID OD Thick. Screw

X-25-46 .125 .250 .022 #4 X-25-9 .156 .375 .049 #6 X-25-48 .188 .438 .049 #8 X-25-36 .219 .500 .049 #10 X-25-40 .281 .625 .065 1/4 X-25-85 .344 .687 .065 5/16 X-25-37 .406 .812 .065 3/8 X-25-34 .469 .922 .065 7/16 X-25-26 .531 1.062 .095 1/2 X-25-15 .656 1.312 .095 5/8 X-25-29 .812 1.469 .134 3/4 X-25-127 1.062 2.000 .134 1

Bolt/

TP-6255 7/0698 Appendix

Page 99

Metric

Hex head bolts are hardness grade 8.8 unless noted.

Part No. Dimensions

Hex Head Bolts (partial thread)

M931-06040-60 M6-1.00 x 40 M931-06055-60 M6-1.00 x 55 M931-06060-60 M6-1.00 x 60 M931-06070-60 M6-1.00 x 70 M931-06075-60 M6-1.00 x 75 M931-06090-60 M6-1.00 x 90

M931-08035-60 M8-1.25 x 35 M931-08040-60 M8-1.25 x 40 M931-08040-82 M8-1.25 x 40* M931-08045-60 M8-1.25 x 45 M931-08050-60 M8-1.25 x 50 M931-08055-82 M8-1.25 x 55* M931-08060-60 M8-1.25 x 60 M931-08070-60 M8-1.25 x 70 M931-08070-82 M8-1.25 x 70* M931-08075-60 M8-1.25 x 75 M931-08080-60 M8-1.25 x 80 M931-08090-60 M8-1.25 x 90 M931-08095-60 M8-1.25 x 95 M931-08100-60 M8-1.25 x 100

M931-10040-60 M10-1.50 x 40 M931-10045-60 M10-1.50 x 45 M931-10050-60 M10-1.50 x 50 M931-10055-60 M10-1.50 x 55 M931-10060-60 M10-1.50 x 60 M931-10065-60 M10-1.50 x 65 M931-10070-60 M10-1.50 x 70 M931-10080-60 M10-1.50 x 80 M931-10090-60 M10-1.50 x 90 M931-10100-60 M10-1.50 x 100

M931-12045-60 M12-1.75 x 45 M931-12050-60 M12-1.75 x 50 M931-12055-60 M12-1.75 x 55 M931-12060-60 M12-1.75 x 60 M931-12065-60 M12-1.75 x 65 M931-12080-60 M12-1.75 x 80 M931-12090-60 M12-1.75 x 90 M931-12100-60 M12-1.75 x 100 M931-12110-60 M12-1.75 x 110

M931-16090-60 M16-2.00 x 90

M931-20065-60 M20-2.50 x 65 M931-20120-60 M20-2.50 x 120 M931-20160-60 M20-2.50 x 160

M931-22090-60 M22-2.50 x 90 M931-22120-60 M22-2.50 x 120 M931-22160-60 M22-2.50 x 160

M931-24090-60 M24-3.00 x 90 M931-24120-60 M24-3.00 x 120 M931-24160-60 M24-3.00 x 160

Part No. Dimensions

Hex Head Bolts (full thread)

M933-04006-60 M4-0.70 x 6

M933-05050-60 M5-0.80 x 50

M933-06010-60 M6-1.00 x 10 M933-06014-60 M6-1.00 x 14 M933-06016-60 M6-1.00 x 16 M933-06020-60 M6-1.00 x 20 M933-06025-60 M6-1.00 x 25 M933-06040-60 M6-1.00 x 40 M933-06050-60 M6-1.00 x 50

M933-08016-60 M8-1.25 x 16 M933-08020-60 M8-1.25 x 20 M933-08025-60 M8-1.25 x 25 M933-08030-60 M8-1.25 x 30

M933-10012-60 M10-1.50 x 12 M961-10020-60 M10-1.25 x 20 M933-10020-60 M10-1.50 x 20 M933-10025-60 M10-1.50 x 25 M933-10030-60 M10-1.50 x 30 M933-10030-82 M10-1.50 x 30* M961-10035-60 M10-1.25 x 35 M933-10035-60 M10-1.50 x 35

M933-12016-60 M12-1.75 x 16 M933-12020-60 M12-1.75 x 20 M933-12025-60 M12-1.75 x 25 M933-12025-82 M12-1.75 x 25* M933-12030-60 M12-1.75 x 30 M933-12040-60 M12-1.75 x 40 M933-12040-82 M12-1.75 x 40*

M961-14025-60 M14-1.50 x 25 M933-14025-60 M14-2.00 x 25

M961-16025-60 M16-1.50 x 25 M933-16025-60 M16-2.00 x 25 M933-16030-82 M16-2.00 x 30* M933-16035-60 M16-2.00 x 35 M933-16040-60 M16-2.00 x 40 M933-16050-60 M16-2.00 x 50 M933-16050-82 M16-2.00 x 50* M933-16060-60 M16-2.00 x 60

M933-18050-60 M18-2.50 x 50 M933-18060-60 M18-2.50 x 60

Pan Head Machine Screws

M7985A-03010-20 M3-0.50 x 10 M7985A-03012-20 M3-0.50 x 12

M7985A-04020-20 M4-0.70 x 20

M7985A-05010-20 M5-0.80 x 10 M7985A-05012-20 M5-0.80 x 12

Flat Head Machine Screws

M965A-05016-20 M5-0.80 x 16

Part No. Dimensions Type

Hex Nuts

M934-03-50 M3-0.50 Standard

M934-04-50 M4-0.70 Standard

M934-05-50 M5-0.80 Standard M982-05-80 M5-0.80 Elastic Stop

M6923-06-80 M6-1.00 Spiralock M934-06-64 M6-1.00 Std. (green) M982-06-80 M6-1.00 Elastic Stop

M6923-08-80 M8-1.25 Spiralock M934-08-60 M8-1.25 Standard M982-08-80 M8-1.25 Elastic Stop

M6923-10-80 M10-1.50 Spiralock M982-10-80 M10-1.50 Elastic Stop

M6923-12-80 M12-1.75 Spiralock M982-12-80 M12-1.75 Elastic Stop

M982-14-80 M14-2.00 Elastic Stop

M6923-16-80 M16-2.00 Spiralock M982-16-80 M16-2.00 Elastic Stop

M982-18-80 M18-2.50 Elastic Stop

M934-20-80 M20-2.50 Standard M982-20-80 M20-2.50 Elastic Stop

M934-22-80 M22-2.50 Standard M982-22-80 M22-2.50 Elastic Stop

M934-24-80 M24-3.00 Standard M982-24-80 M24-3.00 Elastic Stop

Washers

Bolt/

Part No. ID OD Thick. Screw

M125A-03-80 3.2 7.0 0.5 M3 M125A-04-80 4.3 9.0 0.8 M4 M125A-05-80 5.3 10.0 1.0 M5 M125A-06-80 6.4 12.0 1.6 M6 M125A-08-80 8.4 16.0 1.6 M8 M125A-10-80 10.5 20.0 2.0 M10 M125A-12-80 13.0 24.0 2.5 M12 M125A-14-80 15.0 28.0 2.5 M14 M125A-16-80 17.0 30.0 3.0 M16 M125A-18-80 19.0 34.0 3.0 M18 M125A-20-80 21.0 37.0 3.0 M20 M125A-24-80 25.0 44.0 4.0 M24

* This metric hex bolt’s hardness is grade 10.9.

TP-6255 7/06 99Appendix

Page 100

TP-6255 7/06100

Kohler 8-32EOZD, 6.5-27EFOZD Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual