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9--32EOZD 7--28EFOZD Operation

1. ADV7384a Vent screw position 1 Vent screw position 2 Fuel filter Fuel injection pump Vent screw position 5 Fuel injection pump screw Figure 3 5 Fuel System Typical 3 5 Air Intake Silencer Cleaner Atthe interval specified in the service schedule clean or replace the air intake filter Clean the filter more frequently if the generator set operates in dirty dusty conditions Follow one of the procedures described below Air Cleaner Service Replacement 9 10EOZD and 7 9EFOZD Models A dry type air cleaner silences and filters the intake air The air intake silencer assembly connects to the intake manifold via a flexible hose 1 Release the spring clips to open the housing and remove the air filter element See Figure 3 6 30 Section 3 Scheduled Maintenance 2 Tap the element lightly against a flat surface to dislodge loose surface dirt Do not clean in any liquid or use compressed air as these will damage the filter element 3 Examine the element and housing for damage and wear Replace the element or housing if necessary 4 Wipe the cover and base with a cl
2. 11 Section 1 Service VIeWS LET TERRE E 13 Section 2 Operation ia rei EG eM LEE 15 21 Prestart Checklist csse Eee Ed MESE 15 2 2 Marine Inspection 16 23 Angular Operation 16 24 Operation in European Union Member Countries 16 25 Load Profile Sag ae AR AE les 16 26 Advanced Digital Control Operation 17 2 6 1 Controls and Indicators 17 2 6 2 Starting the Generator 18 2 6 3 Stopping the Generator 19 264 Power Mode Options 19 2 65 Fault Shutdowns 19 2 6 6 Resetting the Controller after a Fault Shutdown 21 2 Gircuit Protection RIDE rb 22 2 7 1 Line Circuit Breaker TRE RIMIS 22 2 7 2 FUSES gt tas Raa ae E E edu cae 22 Section 3 Scheduled Maintenance
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7. 23 3 1 General Maintenance 23 3 2 Service Schedule 9 32EOZD and 7 28EFOZD Models 24 3 3 Lubrication System 26 3 3 1 Oil Specifications 26 3 3 2 OIEGheCk ERR RR uae 26 q3 3 OibGhange sse deck 27 3 4 Fuel kote ke er 28 3 4 1 Fuel Specifications 28 3 4 2 Fuel Filtera ET 28 343 Priming the Fuel System 29 3 5 Air Intake Silencer Cleaner 30 3 6 Exhaust System eea us pes teen Stag 31 37 Cooling System a cepe dm 32 3 7 1 Closed Heat Exchanger 32 3 7 2 Checking and Filling 32 3 7 8 Flushing and Cleaning 32 37 4 Pressure iuis ee 33 3 75 Seawater PUMP sis cee ede ee idu vu 33 3 746 Siphon Break knie de ce eed 34 3 7 7 Anticorrosion Zinc 36 2 8 Belt Tension
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9. hi ae Ted ai aad 37 3 8 1 Seawater Pump Belt Tensioning Procedure If Equipped 37 3 8 2 Battery Charging Alternator Belt Tensioning Procedure 37 3 95 Battery isi aad rd EQ es 38 3 10 Generator Storage Procedure 38 TP 6710 5 11 Table of Contents Section Troubleshooting 39 441 39 4 2 Controller Troubleshooting 39 Section 5 Wiring Diagrams 43 5 1 Wiring Diagram Reference 43 Appendix A Abbreviations 49 Appendix Operating Hour Service Log 51 4 Table of Contents TP 6710 5 11 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety
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11. 513 59018 M3O0N3S NOlvNH3ITV 9 H3IV3H gt M3lv3H ON393I uos 5 3105 Tand avis ivoz SNOILD ss SNOILO ZN LN SNOIIO3NNOO Zld 1540 5 vis vis 6 lvls ZA 8 19 IHM PA Ty Md d N 5 Sle 61 14 ong SNOILO3 01915 vil D V SNOILO3NNOO OILO3NNCO Fld HS 300 335 SNOL23I 4 lt Qarvinsi n CALVINSNINN 7 1840 ANIONS Figure 5 3 Wiring Diagram for Models 10 32EOZD 8 5 28EFOZD 45 Section 5 Wiring Diagrams TP 6710 5 11 2018 INON
12. Check the breather pipe for obstructions Clean the turbocharger blower if equipped X 1500 hrs Inspect the complete exhaust system 2 2 X ELECTRICAL SYSTEM Keep the battery charged and in good condition 8 X Before operation Check adjust the alternator driving belt tension X Break in period Check and tighten the electrical connections X Clean the battery cables t ENGINE AND MOUNTING Check for water fuel coolant and oil leakage X After operation X Retighten any loose nuts and bolts X Before operation Check the mounting bolts vibromounts and tighten if necessary Adjust the intake exhaust valve clearance X Lap the intake exhaust valve seats X 2000 hrs or 2 yrs Check the compartment condition fuel oil or water leaks REMOTE START PANEL Check the remote start panel operation if equipped GENERATOR Test run the generator set X Before operation X Break in period X Blow dust out of the generator Requires removal of the sound shield door if installed Consult your local distributor dealer for service Qo Consult the battery manufacturer s instructions TP 6710 5 11 Read the WARNING found at the beginning of the manual regarding moving parts Section 3 Scheduled Maintenance 25 3 3 Lubrication System See the Sche
13. J ADV7385 1 Fuses Figure 2 8 Fuse Location on 9EOZD 7EFOZD Model TP 6710 5 11 31 General Maintenance WARNING AS 2 Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator
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17. TP 6703 TP 6703 TP 6703 Service Manual Generator Includes generator and engine information Figure 2 Generator Set Literature 12 Introduction TP 6255 x in 001 005 TP 6710 5 11 Section 1 Service Views OF J 23 24 25 26 13 24EOZD 4 11 20EFOZD Models ADU aR Non Service Side View GM59224 ADC 2100 Control Strain relief for the load lead cable Run Off Reset Auto switch Alternator cooling air inlet Nameplate AC circuit breaker panel Mixing elbow water outlet exhaust outlet far side Fuse panel 9EOZD 7EFOZD model only See Section 2 7 2 Air intake silencer cleaner for other models Lifting eye Engine coolant drain Coolant overflow bottle location varies by model Fuel filter Fuel feed pump Oil check dipstick Coolant pressure cap Seawater drain all models except 13 24EOZD amp 11 20EFOZD Coolant overflow tube models fill engine top Belt guard Lube oil filter V belts Oil fill front gear cover Heat exchanger all models except 13 24EOZD amp Seawater pump and water inlet 11 20EFOZD models Oil drain valve and hose Heat exchanger internal to exhaust manifold 13 24EOZ
18. The controller is powered by the generator set engine starting battery Note Remote communications require an active powered up controller Be advised that the ADC consumes 250 mA when the master switch is in the AUTO position If you do not plan to use your generator set for a long period of time Kohler recommends moving the master switch to the OFF RESET position complete power down mA draw With the generator set master switch in the AUTO position there are three possible controller power mode options Note Have setup and adjustments of the ADC 2100 performed only by authorized Kohler distributor dealer The setup and adjustments are password protected TP 6710 5 11 e 48 hour power down If the ADC 2100 communication parameter setting has a 48 hour power down the controller will power down after 48 hours of inactivity If the generator set has been started the controller will power down 48 hours after the generator set stops Continuous power mode the ADC 2100 communication parameter setting has continuous power mode the controller will not power down The controller remains powered at all times to maintain CAN communications and allow remote start commands from the CAN gauge e 1 hour power down If the ADC 2100 communication parameter setting has a 1 hour power down the controller will power down after 1 hour of inactivity In this mode a remote start stop switch or the generator set master
19. iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 219 bytes Appendix 49 kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display Id shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male ms cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 220 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm MQ milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS mi
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21. y pue jen go 1nus janz Jo yug jeny 10 suonoy esiou euuouqe JO 8AISS92X3 uondunsuoo Jen eunsseJd SjeoulaAQ Jewod syoe jueppns 54015 eDeyo 1ndino JO ON pejs seop yng yuelo you waj sAs suiojdui AS TP 6710 5 11 42 Section 4 Troubleshooting Section 5 Wiring Diagrams WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote co
22. Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper for cracks leaks and corrosion TP 6710 5 11 Section 2 Operation e Check the hoses for softness cracks leaks or dents Replace the hoses as needed e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect 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 e Ensure that the carbon monoxide detector 5 is 1 in the craft 2 functional and 3 energized whenever the generator set operates For your safety Never operate the generator set without a functioning carbon monoxide detector s for your safety and the safety of others on your vessel Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris
23. EA 304 3dWil 157 NOIVNH3ITV N3941 YATIONLNOD 001220 SVANYA 0203 28 8 35 33HHL 034 sy Bt 1 9 99 84 99 xX 9 S9 Tan4 2 xnv T3n4 1 5501 1 31 INv1002 82 19 103135 36 100 Av BH HSY14 1 14 100 AVAX TANA OGInHS Xv 21 14 1 vZ id NOILO3NNOO 5 0 124 NOILO3NNOO 1509 NYA aasn ADV7283A C Figure 5 4 Schematic for Models 9 82EOZD 7 28EFOZD Sheet 1 of 2 TP 6710 5 11 46 Section 5 Wiring Diagrams ADV7283B C 9 INdNI 9 4 SONIA SG 100 AVIAN HSYl4 9 SAd SANG 01315 SNOLOAN ONnOSS 103735 300W 5 9 N ILOJNNO9 272 YOSNAS 34055344 YOSNAS 384055344 aie NOSN3S 5501 13 31 LNY 1002 24 9 13534 2440 AVIS 31038 7 VB ONnOS9 ann
24. OL 00 0 5 vil E SNOILO3NNOO ZTNSNI N3389 NOILOSNNOO 1106 1 5 ger YIWOLSNO TIR QQQ QOQ ai IN 1066 mes avan Jn 9 SS3NHVH OOJO OL Qe Cod LINSNI 39nv9 Wold 1lvL9ld SS3NSVH NOLLO3NNOO JOV4NSLNI YSNOLSNO 34nlv34 TINA NOLLO3NNOO 15 9 lV8BA dd YOL NMOG 1nHS Xnv 0 lt 95 8 NOIVN3N39 335 2 4016 1 15 310N3H Y SS3NMVH NOISN3DG SOIVH3N39 OL 1 9015 15 15 310N34 1 NVO WNHSDG TSA TP 6710 5 11 Figure 5 6 Accessory Diagram for Models 9 32EOZD 7 28EFOZD 48 Section 5 Wiring Diagrams Appendix Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA blk htr BMEP bps br BTDC Btu Bt
25. constitute a violation of European Union Directive 2000 14 EC noise emission standard 16 Section 2 Operation 2 5 Load Profile Whenever operating the generator set Kohler Co recommends maintaining the minimum load profile indicated in Figure 2 1 Maintaining the load profile prevents corrosion formation internal engine components when they re exposed to the breakdown of exhaust gases Extended light loading may result in engine wet stacking Minimum Ideal Load Requirement Load Requirement 30 load 70 load or more Figure 2 2 Load Profile Wet Stacking occurs when water vapor condenses in the exhaust system At normal combustion temperatures water stays vaporized but at low combustion temperatures it condenses back to a liquid When running the generator set under normal loads 30 load or more diesel exhaust stays hot enough to prevent water vapor from condensing At low load situations wet stacking can occur The operator should perform all of the prestart checks Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks TP 6710 5 11 2 6 Advanced Digital Control Operation Figure 2 3 illustrates the user interface on the Advanced Digital Control ADC 2100 Note Have setup and adjustments of the ADC 2100 perfo
26. memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier 5 sec second Sl Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s sq square sq square centimeter sq in square inch 55 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 Laboratorie
27. shutdown Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts Check the fuel supply and battery If there is no output voltage check the line circuit breaker Also check for loose connections Contact an authorized distributor dealer for service Overfrequency shutdown 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 Contact an authorized distributor dealer for service if problem continues Overspeed shutdown Shutdown occurs if the engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service if problem continues Overvoltage shutdown Shutdown occurs if the voltage exceeds 120 of the voltage regulator setpoint for more than 2 seconds Contact an authorized distributor dealer for service if problem continues Underfrequency shutdown Shutdown occurs when the governed frequency falls below 90 of the system s frequency setpoint for more than 5 seconds This protection becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Undervoltage shutdown Shutdown occurs if the voltage falls b
28. through an approved device and after the building marina main switch is turned off Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install ship to shore transfer switch to prevent interconnection of the generator set power and shore power Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under TP 6710 5 11 Hot Parts A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Notice NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute cl
29. capacities Model L Qts 9EOZD and 7EFOZD 3 10ECZD 8 5 9EFOZD 3 6 3 6 13 14 15EOZD 11 11 5 13EFOZD 4 7 5 20 23 24ECZD 17 17 5 20EFOZD 5 8 6 3 8 3 8 5 0 6 1 28 32ECZD and 25 28EFOZD 10 2 10 8 Figure 3 3 Oil Capacities Oil Change Procedure Whenever possible drain the oil while it is still warm 1 Drain the oil a Place the generator set master switch in the OFF position Disconnect the power to the battery charger if equipped Disconnect the generator set engine starting battery negative lead first Remove the oil drain hose from its retaining clip Remove the cap from the oil drain hose and lower the hose into an oil collection container Electric Oil Drain Oil Fill Pump Procedure Connect the pump to the end of the oil drain hose Place the outlet of the pump into an oil collection container Remove the oil fill cap s Open the oil drain valve on the engine Allow time for the engine oil to drain completely Electric Oil Drain Oil Fill Pump Procedure Activate the pump until all of the oil is removed Go to step 2 TP 6710 5 11 g h a Close the oil drain valve Replace the cap on the oil drain hose Replace the oil drain hose in its retaining clip 2 Replace the oil filter Remove the oil filter by rotating it counterclockwise with an oil filter wrench Apply a light coat of clean oil to the rubbe
30. element and inspect If the element is not damaged continue with step 3 If the element is damaged replace it skip step 3 and go to step 4 3 Wash the element in mild detergent and water solution Rinse and air dry the element See Figure 3 8 1 Element Figure 3 8 Element Washing 4 Wipe the intake silencer cover and base with a clean rag to remove any dirt Check the base for damage replace as necessary 5 Reassemble the element and cover assembly to the intake silencer base Make sure that the sealing surfaces fit and reattach the spring clips The air intake silencer duct should be at the 5 o clock position as viewed from the generator end TP 6710 5 11 3 6 Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use Atthe interval specified in the service schedule inspect the exhaust system components exhaust manifold mixing elbow exhaust hose hose clamps silencer and outlet flapper for cracks leaks and corrosion See Section 1 for the exhaust outlet location Ensure that the carbon monoxide detector
31. engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft ft Ibs ft min 9 genset GFI GND gov gph gpm gr GRD gr wt fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH hr HS hsg HVAC HWT Hz ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext 5 J JIS k K kA KB hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output
32. fuel system Use the following procedure 1 Press and hold the Select button located on the ADC See Figure 3 4 2 Move the generator set master switch to the RUN position to enter the programming mode 3 Continue to hold the Select button for 10 seconds The ADC will display Fuel and the fuel priming pump will start 4 Continue to hold the Select button for as long as you want the fuel priming pump to function typically 10 seconds 5 Release the Select button and move the Master switch to the OFF position 6 Place the Master switch to the RUN position to start the unit F S e E A masa 9 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 3 3 E ADV7384 1 ADC control 2 Select button 3 Generator set master switch Figure 3 4 ADC Control TP 6710 5 11 Fuel System Priming Procedure If the above priming procedure does not accomplish adequate fuel system priming use the following procedure Note Connect the battery during the priming procedure to allow engine cranking Note If the ADC 2
33. hours Displays total generator set runtime hours Crank indication Displays 1 CC 2 or CC indicate the first second or third attempt to start the engine The last digit flashes during the crank cycle rest periods Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 2 6 5 Software version See the Generator Set Installation Manual Select and arrow buttons Keypad The keypad is used for controller setup and adjustment only Have setup and adjustments performed only by an authorized distributor dealer The setup and adjustment functions are password protected Generator set master Three position switch switch Figure 2 4 ADC 2100 Controls and Indicators TP 6710 5 11 Switch functions as the generator set operation and controller reset switch Section 2 Operation 17 2 6 2 Starting the Generator Set A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Operating the generator set Carbon monoxide can cause severe nausea fainting or death Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making s
34. if the reed valve material has hardened or deteriorated 34 Section Scheduled Maintenance 6 Install the reed valve into the mounting base with the valve downward See Figure 3 12 item 2 7 Install and only finger tighten the retaining cap Do not overtighten it Note Ensure that the siphon break s capis tight before operating the generator set 1 Cap 2 Reed valve 3 Mounting base Figure 3 12 Siphon Break m sm 003 007 TP 6710 5 11 Waterline 1 Silencer vertical lift 1 2 m 4 ft max Exhaust mixer elbow distance above waterline If less than 23 a siphon break is required Siphon break distance above waterline 30 5 cm 1 ft min Siphon break Exhaust mixer elbow Heat exchanger locations vary by model Coolant recovery tank Locate coolant recovery tank at the same height as the heat exchanger Seawater strainer Figure 3 13 Siphon Break Plastic U Type Installation Note Consult the installation manual for complete explanation of dimensions and other installation considerations TP 6710 5 11 Seacock Intake strainer Engine driven seawater pump Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Water lock optional Silencer distance from exhaust mixer elbow 3 m 10 ft max Maximum distance between silencer and exhaust outlet of 1 5m 5 ft Silencer customer supplied Exhaust ho
35. medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use Operating the generator set Carbon monoxide can cause severe nausea fainting or death Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats and buildings 6 Safety Precautions and Instructions Fuel System A WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from s
36. on or near the generator set Seawater Pump Priming Prime the seawater pump before initial startup To prime the pump 1 close the seacock 2 remove the hose from the seawater filter outlet 3 fill the hose and seawater pump with clean water 4 reconnect the hose to the water filter outlet and 5 open the seacock Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet Section 2 Operation 15 2 2 Marine Inspection Kohler Co recommends that all boat owners have their vessels inspected at the start of each boating season by the US Coast Guard the local Coast Guard Auxiliary or local state agency Kohler Co also recommends having the generator s exhaust system inspected at the start of each boating season by an authorized Kohler distributor dealer Repair any problems identified before operating the generator set WARNING Carbon monoxide Can severe fainting or death nausea The exhaust system must be leakproof and routinely inspected 2 3 Angular Operation See Figure 2 1 for angular operation limits Intermittent Continuous 3 minutes or less 25 30 Maximum value for all directions Figure 2 1 Angular Operation 2 4 Operation in European Union Member Countries This generator set is specifically intended and approved for operation below the deck in the engine compartment Operation above the deck and or outdoors would
37. precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related TP 6710 5 11 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
38. pump or injector failure Note Avoid storing fuel for more than one month Take special precautions to keep all dirt water and other contaminants out of fuel to prevent the growth of microbes Microbes form slime that clogs the fuel filter and lines Note Do not run the generator set out of fuel because the fuel lines will draw in air and necessitate bleeding the fuel system before restarting the unit 3 4 2 FuelFilter The quality and condition of the fuel largely determine the filter s useful life Replace the fuel filter element as listed in the service schedule Section 1 shows the typical location of a fuel filter Use the applicable procedure below to replace the fuel filter Fuel Filter Cleaning Replacement Procedure 9EOZD and 7EFOZD Models 1 Close the fuel supply valve 2 Remove the collar from the fuel filter adapter while holding the filter bowl in place 28 Section 3 Scheduled Maintenance 3 Remove the filter bowl and fuel filter Clean the fuel filter with fresh diesel fuel and blow compressed air from the inside outward Replace a damaged fuel filter Dispose of the fuel filter in an approved manner 4 Wipe off all parts with a clean rag Inspect all mating surfaces and threads for damage replace as necessary 5 Place the fuel filter into the filter bowl and lubricate the rubber seal with fresh diesel fuel 6 With the collar against the filter bowl flange position the fuel filter against the a
39. s is 1 in the craft 2 functional and 3 energized whenever the generator set operates For your safety Never operate the generator set without a functioning carbon monoxide detector s for your safety and the safety of others on your vessel Exhaust System Inspection Points Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect the exhaust system for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed Section 3 Scheduled Maintenance 31 3 7 Cooling System 3 7 4 Closed Heat Exchanger In a closed cooling system the seawater circulates through separate chambers within the heat exchanger or manifold to cool the engine coolant The seawater then mixes with the engine exhaust and ejects out of the exhaust outlet See Figure 3 9 for coolant capacities include coolant recovery tank capacity of 0 24 L 8 oz Model L Qts 9EOZD and 7EFOZD 2 5 2 6 10EOZD 8 5 9EFOZD 2 5 2 6 13 14 15EOZD and 11 11 5 13EFO
40. set TP 6710 5 11 Section 3 Scheduled Maintenance NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces NOTICE The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized distributor dealer perform generator set service Engine Service Perform generator set engine service at the intervals specified by the engine operation manual Generator Set Service Perform generator set service at the intervals specified by the generator set operation manual If the generator set operates under dusty or dirty conditions use dry compressed air to blow dust out of the alternator With the generator set running direct the stream of air in through the cooling slots at the alternator end Routine Maintenance Refer to the following generator set service schedule the engine service schedule and the runtime hours shown on the ADC 2100 to determine when to schedule routine maintenance Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions Service Log Use the Operating Hour Service Log located in the back of this manual to docum
41. set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Engine Backfire Flash Fire WARNING Gh 2 cause severe injury death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the fuel injection system fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner silencer removed Combustible materials A sudden flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the generator set Keep the compartment and the generator set clean and free of debris to minimize the risk of fire Catch fuels in an approved container Wipe up spilled fuels and engine oil Combustible materials A fire can cause severe injury or dea
42. set installation manual and the engine service manual Engine S M to correct the indicated problem Corrective action and testing often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service distributor dealer perform service NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown or questionable Maintain a record of repairs and adjustments performed on the equipment If the procedures in this manual do not explain how to correct the problem contact an authorized distributor dealer Use the record to help describe the problem and repairs or adjustments made to the equipment x gt 001 002a Problem Possible Cause Controller LED display No power to the controller is off longer Controller fuse F3 is blown Low or no battery voltage Continuous power mode jumper is disconnected and the generator set has not run for 48 hours or 4 1 Fault Codes The Advanced Digital Control displays fault codes to aid in troubleshooting Fault codes descriptions and recommended actions are listed in Figure 2 5 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 6 6 4 2 Controlle
43. 10 5 11 CG CID CL cm CMOS cogen Com conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special
44. 100 indicates an overcrank fault during this procedure disconnect the negative wire from the fuel solenoid allowing the fuel injection pump to fill with fuel and repeat this procedure after allowing the starter motor to cool down Note Have arag handy during the bleeding procedure Wipe up all spilled diesel fuel after bleeding the system Wash hands after any contact with fuel oil 9EOZD and 7EFOZD Models 1 Loosen the fuel filter screw at position 1 See Figure 3 5 2 Initiate the auto start sequence until fuel free of air bubbles flows from the vent screw at position 1 Tighten the screw 3 Loosen the fuel filter screw at position 2 4 Initiate the auto start sequence until fuel free of air bubbles flows from the vent screw at position 2 Tighten the screw 5 Loosen the fuel injection pump screw at position 5 6 Initiate the auto start sequence until fuel free of air bubbles flows from the vent screw at position 5 Tighten the screw 10 32 02 and 9 28EFOZD Models 1 Loosen the fuel injection pump screw See Figure 3 5 2 Initiate the auto start sequence until fuel free of air bubbles flows from the injection pump screw 3 Tighten the fuel injection pump screw Section 3 Scheduled Maintenance 29 9EOZD and 7EFOZD Models ADV7385a 10 32EOZD and 9 28EFOZD Models
45. 316 223316 223316 Fuel Filter Element 229715 GM32359 GM32359 GM32359 GM32359 GM32359 GM32359 Oil Filter 229678 GM47465 GM47465 GM47465 GM47465 GM47465 252834 Seawater Pump Impeller Kit 229826 229826 229826 229826 229826 229826 229826 V Belt Alternator GM47044 225428 12 volt 226929 24 volt GM11551 12 volt 344829 24 volt GM11551 12 volt 344829 24 volt GM11551 12 volt 344829 24 volt GM11551 12 volt 344829 24 volt GM66406 12 volt 258955 24 volt V Belt Seawater Pump GM13660 229125 256503 256503 256503 256503 249989 Zinc Anode Figure 1 TP 6710 5 11 267928 267928 Maintenance and Service Parts N A N A N A N A GM79414 x in 001 004 Introduction 11 List of Related Literature Figure 2 identifies related literature available for the generator sets covered in this manual Only trained and qualified personnel should install or service the generator set Literature Type Models 9EOZD and 7EFOZD 10EOZD and 8 5 9EFOZD 13 15EOZD and 11 13EFOZD 20 24EOZD and 17 20EFOZD 28 32EOZD and 25 28EFOZD Installation Manual TP 6711 Operation Manual TP 6710 Parts Catalog TP 6270 TP 6270 TP 6271 TP 6272 TP 6273 Service Manual Engine TP 6709 TP 6703
46. D amp Anticorrosion zinc anode all models except 13 24EOZD 4 11 20EFOZD models 11 20EFOZD models Seawater drain 13 24EOZD amp 11 20EFOZD models Figure 1 1 Service Views Typical 9EOZD 7EFOZD Model Shown Unless Noted Note Consult installation drawings in the spec sheet or installation manual for fuel and battery connection points Consult an authorized distributor dealer or the service manual for items not shown TP 6710 5 11 Section 1 Service Views 13 WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Sound Shield Equipped Models For access to the generator set to perform regular maintenance remove the sound shield doors and roof Sound Shield Roof and Door Removal 1 2 Open the service side door Release the two quarter turn fasteners located underneath the roof See Figure 1 2 Lift up the roof Slide the roof towards the service side of the unit for removal Open the front rear and non service side doors as needed 14 Section 1 Service Views Sound shield roof Quarter turn fastener Alternator end door Service side door Front rail Engine end door Figure 1 2 Sound S
47. Operation Marine Generator Sets F Models 9 32EOZD 7 28EFOZD NATIONALLY REGISTERED KOHLER POWER SYSTEMS TP 6710 5 11 California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number x in 007 001 TP 6710 5 11 Table of Contents Product Identification Information 2 Safety Precautions and Instructions 5 Introduction RO 9 Service Assistante lisse aw ER TEES wa he 10 Maintenance and Service Parts Related
48. ZD 4 4 4 6 20 23 24ECZD 17 17 5 20EFOZD 6 0 6 3 28 32ECZD and 25 28EFOZD 7 6 8 0 Figure 3 9 Engine Coolant Capacities 3 7 2 Checking and Filling Coolant WARNING y Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces 32 Section 3 Scheduled Maintenance 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 additional coolant solution as necessary to the coolant recovery tank Periodically check the coolant level on closed systems by removing the pressure cap Do not rely solel
49. als diagrams drawings from your local distributor dealer The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe prescribed intervals Obtain service from authorized service distributor dealer to keep equipment in top condition Before installing a marine generator set obtain the most current installation manual from your local distributor dealer Only qualified persons should install the generator set Introduction 9 Service Assistance For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPower com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 10 Introduction China North China Regional Office Beijing Pho
50. d COOLING SYSTEM Check the coolant level and fill as necessary X Before operation Check the seawater outlet and clean as necessary X Check adjust the seawater pump belt tension X Break in period Check the function of the siphon break if equipped Check replace the seawater pump impeller X Replace Replace the coolant X Check replace the heat exchanger anticorrosion zinc anode if equipped Requires removal of the sound shield door if installed Consult your local distributor dealer for service Qo 24 Section Scheduled Maintenance Read the WARNING found at the beginning of the manual regarding moving parts Consult the operating instructions supplied with the craft X Replace TP 6710 5 11 Service Schedule 9 32EOZD and 7 28EFOZD Models continued Perform Service at Intervals Indicated X INTAKE EXHAUST SYSTEM Inspect the exhaust system components Reference Section Before operation Every 250 Hrs or3 Months Every 500 Hrs 6 Months Every 1000 Hrs or Yearly Check the exhaust gas condition If the exhaust is blue or black contact your local distributor dealer X During operation Clean the air cleaner element Replace the air cleaner element Clean the exhaust water mixing elbow Inspect the crankcase breather system X 1500 hrs
51. dapter and hand tighten the collar 7 Wash hands after any contact with fuel oil 8 Open the fuel supply valve 9 Prime the system See Section 3 4 3 Priming the Fuel System 10 32 02 and 9 28EFOZD Models 1 Close the fuel supply valve 2 Loosenthe fuel filter by turning it counterclockwise Remove the fuel filter and use rags to clean up spilled fuel oil Dispose of the fuel filter in an approved manner 3 Clean the contact surface of the fuel oil filter adapter 4 Lightly lubricate the gasket surface of the new fuel filter with fresh fuel oil Thread the filter on the adapter until the gasket makes contact hand tighten the filter an additional one half turn Wash hands after any contact with fuel oil 5 Open the fuel supply valve 6 Bleed the system See Section 3 4 3 Priming the Fuel System TP 6710 5 11 3 4 3 Priming the Fuel System Prime the fuel system to bleed the air from the system Trapped air in the fuel system can cause difficult starting and erratic engine operation Prime the fuel system under the following conditions e Before starting the engine for the first time e After running out of fuel and adding fuel to the tank e After fuel system maintenance such as changing the fuel filter draining the fuel water separator or replacing a fuel system component Fuel System Priming Procedure Preferred Note To prevent damage to the starter motor do not crank the engine to prime the
52. duled Maintenance section for oil change and oil filter replacement intervals See Section 1 for the oil drain oil check oil fill and oil filter locations x sm 001 002 3 3 1 Oil Specifications Use oil that meets the American Petroleum Institute API classification of CD or CF Using an unsuitable oil or neglecting an oil change may result in damage and a shorter engine life Figure 3 1 shows 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 Figure 3 1 Engine Oil Selection for Models 9 32EOZD 6 5 28EFOZD 26 Section 3 Scheduled Maintenance 3 3 2 Oil Check Check the oil level in the crankcase daily or before each startup to ensure that the level is in the safe range To check the oil level remove the dipstick and wipe the end clean reinsert as far as possible and remove Maintain the oil level between the Min and Max marks on the dipstick as shown in Figure 3 2 See Section 1 for dipstick location 1 Min mark 2 Max mark Figure 3 2 Oil Level Check Marks TP 5586 3 Note Do not operate the set if the oil level is below the Min mark or above the Max mark TP 6710 5 11 3 3 3 Oil Change Change the oil more frequently if the generator operates under dirty dusty conditions See Figure 3 3 for oil
53. e impeller with soapy water before installation 6 Install the impeller Note During installation push and rotate the impeller in the same direction as the engine rotation until it is thoroughly seated in the impeller housing 7 Inspect the coverplate and gasket for corrosion and or damage Replace components as necessary 8 Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing 9 Open the seacock 10 Start the generator set and check for leaks 11 Stop the generator set and repair leaks or replace damaged or worn components m sm 003 008 Section 3 Scheduled Maintenance 33 3 7 6 Siphon Break A siphon break prevents seawater entry into the generator set s engine when the engine exhaust manifold outlet is less than 230 mm 9 above the waterline of a fully loaded docked or stationary craft See Figure 3 13 The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater Use the following procedure to inspect the siphon break at the intervals listed in the service schedule Siphon Break Inspection 1 Stop the generator set 2 Remove the retaining cap and remove the reed valve for inspection See Figure 3 12 3 Use a mild detergent to remove residue and oxidation from the reed valve 4 Clear blockage from the reed valve opening 5 Replace the siphon break if the reed valve is cracked or
54. ean rag to remove any dirt Make sure that the sealing surfaces fit correctly and reattach the spring clips Figure 3 6 Air Cleaner Element Element 13 20 28 32 020 and 11 17 17 5 25 28bEFOZD Models A dry type air cleaner silences and filters the intake air The air intake silencer assembly connects to the intake manifold via a flexible hose Refer to Figure 3 7 during this procedure 1 Cover 2 Spring clip s 3 Housing 4 Pressure tap 1 8 27 NPT 5 Primary element 6 Dust ejector Figure 3 7 Air Cleaner 1 Release the spring clips to open the housing and remove the air silencer element TP 6710 5 11 2 Tap element lightly against a flat surface to dislodge loose surface dirt Do not clean the element in any liquid or use compressed air as these will damage the filter element 3 Examine the element and housing for damage Replace the element or housing if necessary 4 Wipe the cover and housing with a clean rag to remove dirt Make sure the sealing surfaces fit correctly and reattach the spring clips 14 15 23 24EOZD and 11 5 13 20EFOZD Models A round air cleaner silences and filters the intake air Replace a damaged or dirt contaminated air silencer See Section 1 and refer to the following procedure 1 Release the two spring clips and remove the intake silencer cover 2 Remove the filter
55. ear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown or questionable NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Safety Precautions and Instructions 7 Notes 8 Safety Precautions and Instructions TP 6710 5 11 This manual provides operation instructions for 9 32EOZD and 7 28EFOZD model generator sets Refer to the engine operation manual for generator set engine scheduled maintenance information Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference TP 6710 5 11 Introduction The generator set specification sheets provide specific generator and engine information Refer to the spec sheet for data not supplied in this manual Consult the generator set service manual engine operation manual and engine service manual for additional specifications Obtain copies of the latest spec sheets manu
56. elow 80 of the voltage regulator setpoint for more than 10 seconds Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Controller error 20 Section 2 Operation Indicates a software or communication problem within the ADC 2100 Figure 2 5 ADC 2100 Fault Shutdown Codes Contact an authorized distributor dealer for service if problem continues TP 6710 5 11 Fault Description Check High battery Fault code is displayed if the engine starting battery Check the battery rating and condition voltage warning 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 Low battery Fault code is displayed if the engine starting battery Check the battery rating and condition voltage warning 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 Charge or replace the battery The fault condition clears when the battery voltage returns to a voltage within the limits for more than 2 seconds Figure 2 6 ADC 2100 Fault Warning Codes 2 6 6 Reset
57. elt Type Deflection mm in New 8 12 0 3 0 5 Used 10 14 0 4 0 6 Figure 3 17 Belt Specifications Loosen the adjusting arm pivot screw alternator pivot screw and alternator adjusting screw While prying the alternator outward tighten the alternator adjusting screw Tighten the adjusting arm pivot screw and alternator pivot screw Recheck and adjust as necessary Replace the belt guard Section Scheduled Maintenance 37 3 9 the battery manufacturer s instructions regarding battery care and maintenance 3 10 Generator Storage Procedure Keep the craft afloat for generator operation during the storage procedure Follow the procedure below when storing your generator set for 3 months or more Generator Set Storage Procedure 1 38 Start and run the generator set until it reaches operating temperature or about 15 minutes Stop the generator set Change the oil and oil filter See Section 3 3 3 Close the seacock and remove the hose at the seacock Place the hose in a container having approximately 3 7 7 5 L 1 2 U S gallons of coolant antifreeze Kohler Co recommends using an environmentally friendly potable antifreeze such as RV marine propylene glycol water mix or equivalent Disconnect the lead 287 to the low seawater pressure LWP switch With a suitable container at the exhaust outlet run the generator set
58. ent performed services Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set For example an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months 300 hours or 9 months and so on Section 3 Scheduled Maintenance 23 3 2 Service Schedule 9 32EOZD and 7 28EFOZD Models Perform Service at Intervals Indicated X Check the fuel level and fill as necessary Reference Section Before operation Every 250 Hrs or3 Months Every 500 Hrs or 6 Months Every 1000 Hrs or Yearly Check for any unusual noise t X During operation Remove the sediment from the fuel tank and drain the fuel tank 78 Bleed the fuel system if encountering hard starting Replace the fuel filter element Fuel water separator draining Fuel water separator cleaning Inspect clean and test the fuel injectors 54 X 1500 hrs Inspect the fuel injection nozzle pressure X Adjust the fuel injection timing 2000 hrs or 2 yrs Inspect and adjust the fuel injection pump 2000 hrs or 2 yrs LUBRICATION SYSTEM Check the crankcase oil level and add oil as necessary X Before operation Replace the oil in the crankcase X Break in period Replace the lube oil filter element X Break in perio
59. for possible causes 2 7 1 Line Circuit Breaker A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load The line circuit breaker location is shown in Figure 1 1 Ifthe circuit breaker trips reduce the load and switch the breaker back to the ON position 272 Fuses The engine harness or junction box for the 9EOZD 7EFOZD model contains three 10 amp inline fuses Always identify and correct the cause of a blown fuse before restarting the generator set Refer to section 4 Troubleshooting for conditions that may indicate a blown fuse Obtain service from an authorized distributor dealer Controller Fuse A replaceable 10 amp fuse protects the controller circuitry If the controller display is dark check the battery and battery connections and then check the controller fuse Replace the fuse if it is blown Relay Fuse A replaceable 10 amp fuse protects the engine relays Ifthe generator set does not crank check the battery and battery connections and then check the relay fuse Replace the fuse if it is blown Auxiliary Winding Fuse A replaceable 10 amp fuse protects the alternator 22 Section 2 Operation Fuse Location Auxiliary Winding Lead 55 Relay Interface Board Lead PF2 Controller Lead PF1 See Figure 2 8 for the fuse location on 9EOZD 7EFOZD models Figure 2 7 Fuses
60. generator set master switch to the AUTO position to allow startup by the remote start stop switch or remote digital gauge A remote start stop switch connected to P21 connector leads 3 and 4 or aremote digital gauge connected to P21 pins 1 2 and 5 via CAN can be connected to the customer interface connection See the wiring diagrams in Section 5 Note The ADC 2100 allows three crank cycle attempts before the overcrank shutdown occurs TP 6710 5 11 2 6 3 Stopping the Generator Set The following procedures describe the actions required to stop the generator set Local Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 Move the generator set master switch to the OFF RESET position The engine stops Auto Automatic Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 With the generator set master switch in the AUTO position the generator set stops when the remote start stop switch contacts close momentarily Note If the ADC 2100 is configured for a CAN gauge see Section 2 6 4 for possible power mode options Note 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 See Section 2 6 4 2 6 4 Power Mode Options
61. he pressure cap to simplify draining 2 Drain clean and flush the coolant recovery tank 3 Flush the system with clean water 4 Fill the system with recommended coolant TP 6710 5 11 3 7 4 Pressure Closed heat exchanger systems utilize a pressure to raise the boiling point of the engine coolant enabling proper operating temperatures If the cap leaks replace it with a cap of the same rating The pressure cap typically has the pressure rating stamped on the cap body 3 7 5 Seawater Pump The belt driven seawater pump is located on the service side of the generator set Check and change the seawater pump impeller at the interval specified in the service schedule Follow the instructions included with the impeller kit If the instructions are not included with the kit use the following procedure Impeller Inspection and Replacement Procedure 1 Close the seacock 2 Remove the seawater pump coverplate See Figure 3 10 3 Remove the impeller 4 Inspect the impeller for damaged cracked broken missing or flattened vanes The impeller vanes should be straight and flexible See Figure 3 11 Replace the impeller if it is damaged Seawater pump Coverplate Gasket 8 Mechanical seal 6 Housing 7 Pulley Impeller Bearing if equipped Figure 3 10 Seawater Pump Typical TP 6710 5 11 1 Flattened vane 2 Crack 3 Broken vane Figure 3 11 Worn Impeller 5 Lubricate th
62. hield Roof Removal TP 6710 5 11 21 Prestart Checklist WARNING Carbon monoxide Can severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Operating the generator set Carbon monoxide can cause severe nausea fainting or death Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats and buildings To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Drive Belts Check the belt condition and tension of the water pump and battery charging alternator belt s Exhaust System
63. litary standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg mounting 50 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns oc OD OEM OF opt OS OSHA oz pF PF ph 3 PHC PHH PHM PLC PMG pot ppm PROM psi pt PVC qt qty rad RAM RDO ref rem RFI RH RHM rly megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only
64. mm 1 7 in for 8 9 1 OEOZD 6 5 7 9EFOZD models 76 2 mm 3 0 for 28 322EOZD 23 27EFOZD models Figure 3 15 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 Section 2 1 Prestart Checklist Seawater Pump Priming TP 6710 5 11 3 8 Tension A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when 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 pr
65. mputer 5 1 Wiring Diagram Reference Figure 5 1 lists the wiring diagram numbers locations WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Wiring Model Diagram Figure Schematic Figure Accessory Figure 9EOZD 7 GM50490 F 2 a 2 HR ADV 7283A C Figure 5 4 GM33846 D Fi ix 10 322020 ADV 7283B C Figure 5 5 igure 5 8 5 28EFOZD GM50488 C Figure 5 3 Figure 5 1 Wiring Diagrams TP 6710 5 11 Section 5 Wiring Diagrams 43 86L AOV 335 25 404 9v8ccWD 335 ANOSS3OOV 404 40115 1915 GION310S 8318 15 SS YOLOW N3iNVIS WS UYSI4ILO3N Q3T1081NOO NOOMIS NOS QMVOB 3OVJH3INI AVI3H gly 193NNOO YONO NOIO 3ON3S 3HhSS3Hd 10 540 38055344 N3lVM YIS
66. nded This protection becomes active 3 seconds after crank disconnect Check the cause of the auxiliary fault High engine temperature shutdown Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This protection becomes active after the engine reaches the crank disconnect speed Note The high engine temperature shutdown functions only when the coolant level is in the operating range Check for a low engine coolant level Loss of seawater pressure and flow shutdown Shutdown occurs 5 seconds after a loss of seawater pressure and flow condition is detected This protection becomes active 10 seconds after the engine has reached its stated crank disconnect speed and remains active as long as the generator run command is active Check for a clogged seawater intake or sea strainer Check for a damaged seawater pump impeller Check the exhaust temperature switch and loss of coolant switch wiring for grounded connections Low oil pressure shutdown Shutdown occurs if a low oil pressure condition exists for more than 5 seconds This protection becomes active 30 seconds after the engine has reached crank disconnect speed 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Check for leaks in the lubrication system Check the oil level and add oil if the level is low Overcrank
67. ne 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 TP 6710 5 11 Maintenance and Service Parts Related Literature Maintenance and Service Parts Figure 1 identifies maintenance and service parts for your generator set Obtain a complete list of maintenance and service parts from your authorized generator distributor dealer Part Description Air Filter Element 9EOZD and 7EFOZD 278858 10EOZD and 8 5EFOZD 9EFOZD 278858 13EOZD and 11EFOZD GM24456 Models 14EOZD 15EOZD and 11 5EFOZD 13EFOZD 229442 20EOZD and 17EFOZD 17 5EFOZD GM24456 23EOZD 24EOZD and 20EFOZD 250902 28EOZD 32 02 25EFOZD 27EFOZD GM16944 Fuse Auxiliary Winding F1 10 amp 358337 358337 358337 358337 358337 358337 358337 Fuse Relay Interface Board F2 10 amp 223316 223316 223316 223316 223316 223316 223316 Fuse Controller F3 10 amp 223316 223316 223316 223316 223
68. ocedures Engine driven water pump pulley Adjusting arm pivot screw Battery charging alternator pulley Alternator adjusting screw Alternator pivot screw Check the alternator belt deflection tension here Crankshaft pulley Check the seawater pump belt deflection tension here Seawater pump adjusting screw Seawater pump pulley Pivot screw 1 2 3 4 5 6 7 8 9 0 1 Figure 3 16 Belt Tension Typical TP 6710 5 11 1 2 3 3 8 1 Seawater Pump Belt Tensioning Procedure If Equipped Remove the belt guard 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 3 16 Recheck a new belt tension after 10 minutes of operation Note If the tension is not within specifications go to step 3 If the belt tension is within specifications go to step 7 Loosen the pivot and adjusting screws While prying the seawater pump outward tighten the adjusting screw Tighten the pivot screw Recheck and adjust as necessary Replace the belt guard 3 8 2 Battery Charging Alternator Belt Tensioning Procedure Remove the belt guard Check the belt tension at the midpoint of the longest span of the belt by pressing with your finger See Figure 3 16 and Figure 3 17 Ifthe belt is not within the specifications go to step 3 If the belt is within the specifications go to step 7 B
69. parks 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 Donot 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 container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Hazardous Voltage Moving Parts A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Grounding electrical equipment Hazardous voltage cause severe injury or death Electrocution is possible
70. r Troubleshooting Figure 4 1 contains troubleshooting diagnostic and repair information for the Advanced Digital Control Corrective Action Controller display will automatically activate when a remote start command is received or the generator set master switch is moved to the RUN position Connect the jumper to maintain continuous power to the controller if desired Replace the fuse If the fuse blows again contact the distributor dealer Check connections Check generator set battery position Generator set master switch is in the OFF RESET Move generator set master switch to the AUTO or RUN position reset Figure 4 1 Controller Troubleshooting Chart TP 6710 5 11 Generator set master switch in AUTO but no start command has been received since last controller No action required Controller display will activate when a remote start command is received or the generator set master switch is moved to the RUN position Use the remote switch to start generator set and activate the controller display if desired Section 4 Troubleshooting 39 w s 40 W O Jayem euj eoe deH eoe deJ uejuBi L Jayem 9 5 SIU uuojied Jepeep 1oinquisip ue 1 32245 945 5 5 enue enuen enuen uonejeisu qW 395
71. r seal of the new oil filter Install the new oil filter following the instructions provided with the filter Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner Fill with oil Add new oil of the weight grade and quantity specified in Section 3 3 Electric Oil Drain Oil Fill Pump Procedure Disconnect the pump Close the oil drain valve Replace the cap on the oil drain hose a Check for leaks Check that the generator set master switch is in the OFF position Reconnect the generator set engine starting battery negative lead last Reconnect the power to the battery charger if equipped Start the generator set and check for leaks around the oil filter Stop the generator set and tighten the oil filter to stop any leaks x sm 001 003 Section 3 Scheduled Maintenance 27 3 4 Fuel System 341 Fuel Specifications Use a clean good quality diesel fuel oil with a cetane number of 45 or greater Clean fuel prevents the diesel fuel injectors and pumps from clogging Diesel Fuel Recommendations United States No 2 D No 1 D ASTM D975 94 United Kingdom BS 2869 A1 or A2 European Union EN590 96 Japan JIS K2204 Grade No 2 Korea KSM 2610 China GB252 Note Never store diesel fuel in galvanized containers diesel fuel and the galvanized coating react chemically to produce flaking that quickly clogs filters or causes fuel
72. rmed only by an authorized Kohler distributor dealer The setup and adjustments are password protected r Y CCAS ADVANCED DIGITAL CONTROL DEFINITION Auxillary Fault Crank High Battery Voltage High Engine Temp Low Battery Voltage Low Coolant Level Loss of Coolant Oll Pressure Qver ver Frequency Over Speed Y Under Frequens Under Voltage T OFF RESET 1 LED display 3 GM28707A C 2 Up and down arrow buttons use for setup and adjustment only 3 Generator set master switch 4 Select button use for setup Figure 2 3 ADC 2100 Control Control or Indicator Item Description 2 6 1 Controls and Indicators Figure 2 4 describes the controls and indicators located on the controller The LED display indicates generator set status as shown in Figure 2 4 The display is active when the master switch is in the RUN or AUTO position and remains active until the generator set master switch is moved to the OFF RESET position or the power to the controller is removed The buttons on the controller keypad are used only for system configuration and adjustment The controller is factory set and should not require configuration or adjustment under normal operating conditions If the generator set is reconnected to a different voltage and or frequency refer to an authorized Kohler distributor dealer for system configuration adjustment instructions LED display Runtime
73. s Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6710 5 11 Appendix Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed Enter hours to the operating hours on your generator set and the dates nearest quarter hour OPERATING HOURS SERVICE RECORD DATE TOTAL SERVICE RUN HOURS DATE SERVICE TP 6710 5 11 Appendix 51 TP 6710 5 11 2009 and 2011 by Kohler All rights reserved KOHLER POWER SYSTEMS KOHLER Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
74. se pitch 1 3 cm per 30 5 cm 0 5 in per ft min Exhaust outlet distance above the waterline 10 cm 4 in min Section 3 Scheduled Maintenance 35 3 7 7 Anticorrosion Zinc Anode The heat exchanger on models 9 10EOZD 7 9EFOZD 28 32EOZD and 25 28bEFOZD contains anticorrosion zinc anode plug to prevent electrolytic corrosion by seawater Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule Depending upon operating conditions and seawater properties the anticorrosion zinc anode may require more frequent replacement See Section 1 for the location and use the following procedure Anticorrosion Zinc Anode Replacement 1 With the generator set cooled close the seacock open the petcock on the engine and drain the coolant into a suitable container 2 Remove the anticorrosion zinc anode plug from the heat exchanger 3 Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode Replace the anode according to Figure 3 14 and Figure 3 15 Anticorrosion Zinc Anode Replacement Replace When Percent of Zinc Remaining Is New Anode Models Dimensions mm in 9 10EOZD 7 9EFOZD 28 32EOZD 25 28EFOZD lt 50 of length diameter lt 50 of length diameter 9 0 34 x 76 2 3 0 Figure 3 14 Anticorrosion Zinc Anode Plug Measurements 36 Section Scheduled Maintenance 1 Diameter 9 mm 0 34 in 2 Length 43
75. switch must be used to activate the controller after it has powered down ADC 2100 application code version 1 21 or higher is required for the 1 hour power down option Note After controller power down a remote digital gauge will not have power and therefore will not be able to send a start signal to activate the controller Note Kohler s 2 inch digital gauge allows wake up of the controller remotely 2 6 5 Fault Shutdowns The generator set shuts down automatically under the fault conditions listed in Figure 2 5 and the controller displays a fault code The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 6 6 to reset the controller after a fault shutdown The controller resets automatically after a battery voltage fault condition is corrected Shutdown switches on the generator set automatically reset when the problem is corrected The high engine temperature switch automatically resets when the generator set cools However the fault does not clear until the controller is reset The controller displays a fault code but the generator set does not shut down under the conditions shown in Figure 2 6 Section 2 Operation 19 Auxiliary fault input shutdown Description Input from a customer supplied switch that closes when the fault is active Shutdown occurs 0 3 seconds after the fault is detected and will not start when the fault is active input is grou
76. th Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires as recommended by the local fire code or an authorized agency Train personnel extinguisher operation fire prevention procedures Safety Precautions and Instructions 5 Exhaust System WARNING Carbon monoxide Can severe fainting or death nausea 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 presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision 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
77. ting the Controller after a 4 Start the generator set by moving the generator set Fault Shutdown master switch to RUN Test operate the generator set to verify that the cause of the shutdown has Always identify and correct the cause of a fault been corrected shutdown before resetting the controller Use the following procedure to reset the generator set controller after a fault shutdown 5 Shut the generator off by moving the generator set master switch to the OFF RESET position 1 Move the generator set master switch to the 6 Reconnect the generator set to the load using the OFF RESET position line circuit breaker or ATS 2 Disconnect the generator set from the load using 7 Move the generator set master switch to the AUTO the line circuit breaker or ATS See the safety position for startup by remote transfer switch precautions at the beginning of this manual before remote start stop switch or remote digital gauge proceeding Note The controllers LED display remains off 3 Identify and correct the cause of the fault until an engine start command is received shutdown See the safety precautions at the beginning of this manual before proceeding Refer Opening and closing the remote start stop contact to Section 4 Troubleshooting also resets the controller TP 6710 5 11 Section 2 Operation 21 27 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly see Section 4 Troubleshooting
78. u min cal CARB CB cow CEC cfh cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute TP 67
79. until coolant discharges at the exhaust outlet or until the coolant mixture is depleted Do not allow coolant mixture to flow into waterways Section 3 Scheduled Maintenance 10 11 12 13 14 Reconnect the lead 87 to the low seawater pressure LWP switch Stop the generator set Connecta hose to the seacock Leave the seacock closed Check the coolant level of the heat exchanger and add coolant if necessary Note Use antifreeze capable of withstanding the lowest possible temperatures Clean the exterior ofthe generator set and spread a light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion Disconnect and remove the battery Place the battery in a warm dry location for the storage period Recharge the battery once a month to maintain a full charge Select a well ventilated not humid or dusty location to store the generator Cover the entire unit with a dust cover Note Run the generator set once a month whenever possible TP 6710 5 11 Section 4 Troubleshooting This section contains generator set troubleshooting diagnostic and repair information Use the following charts as a quick troubleshooting reference The table groups generator set faults and suggests likely causes and remedies The table also refers you to more detailed information including sections of this manual the generator set service manual S M the generator
80. ure your exhaust is directed away from other boats and buildings Note Opening the seacock Before starting the generator set open the seacock to allow cooling water passage Failure to do so could damage the seawater pump impeller and cause serious engine overheating damage Note Transfer switch Check that the marine ship to shore transfer switch if equipped is in the ship position 18 Section 2 Operation Note Ifthe generator set does not start after 3 crank attempts an overcrank fault occurs 1 Close the seacock 2 Completely drain the water from the exhaust system at the silencer s drain plug 3 Do not attempt generator set restart 4 Contact authorized Kohler distributor dealer A water filled exhaust piping and silencer may further hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valves Water ingested into the engine may cause major engine damage that the Kohler Co warranty does not cover The following procedures describe the actions required to start the generator set The controller attempts to start the generator set three times f the generator set does not start in three attempts the system shuts down on an overcrank fault Local Starting Move the generator set master switch to the RUN position The ADC 2100 attempts to start the generator set in three crank cycles crank cycle time is pre programmed Auto Automatic Starting Move the
81. whenever electricity is present Ensure you comply with all applicable codes standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn offthe main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution TP 6710 5 11 Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building marina electrical system only
82. y on the level in the coolant recovery tank Add fresh coolant until the level is just below the overflow tube opening Note A coolant solution of 5096 ethylene glycol is required This mix provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F Acoolant solution with less than 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Consult the engine manufacturer s operation manual for engine coolant specifications Note Do not add coolant to an overheated engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled Note Pay special attention to the coolant level After the coolant drains allow time when refilling the coolant for a complete refill of the engine water jacket Check the coolant level as prescribed in the Prestart Checklist 3 7 3 Flushing and Cleaning For optimum protection drain flush and refill the cooling system at the interval listed in the service schedule Flushing and Cleaning Procedure 1 Open the pressure cap and open petcocks located at the heat exchanger engine block and cooling system and let the system drain completely Some models may have petcocks located behind the belt guard Remove t

9--32EOZD 7--28EFOZD Operation

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