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Operation Manual, 40-150EOZ/33-125EFOZ (TP-6109)

1. Nameplate Controller Decision Maker expanded controller shown Generator set master switch Hourmeter Air cleaner Exhaust outlet nonservice side Fuel return Lifting eye Fuel filter Fuel inlet Fuel pump Seawater pump Oil fill Coolant overflow bottle Figure 1 2 Service Views Typical 4 Section 1 Specifications ADV 6581A 15 Pressure cap 16 Overflow tube 17 Heat exchanger 18 Anticorrosion zinc anode 19 Fuel injection pump 20 Oil drain optional location 21 Seawater inlet drain 22 Coolant drain 23 Belt guard 24 Oil dipstick check 25 Oil filter 26 Oil drain valve and hose 27 Cooling air inlets generator TP 6109 11 02 1 4 Remote Annunciator Kit A remote annunciator provides convenient monitoring of the generator set s condition from a remote location See Figure 1 3 The remote annunciator includes an alarm horn alarm silence switch lamp test and the same lamp indicators except air damper and auxiliary pr
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3. ze PHCT NOT USED PLOP NOT USED Wiring Diagram Decision Maker 1 Expanded Controller Sheet 2 of 6 TP 6109 11 02 NOTE TAPE AND SECURE LEADS 40A 41A 26 2 amp 2 WHEN NOT USED GM24453B Section 5 Wiring Diagrams 37 GM24453C 995 S133HS OL 9957 S133HS OL oz 13S3u 440 0181 91 8 r 01 e1 8er steer dn 9 19 00 dn 34A OA N sr el H3TIOHLNOO 7 YATIOULNOO Figure 5 7 Wiring Diagram Decision Maker 1 Expanded Controller Remote Panel Options Sheet of 6 TP 6109 11 02 38 Section 5 Wiring Diagrams STANVd SLOWSY 16 OML 2 TANVd SLOWSY 1 INO OML IHL SMOTIV W31SAS IHL ALON 4 021 dois 2 jus sss N 1 16 4018 310W3H 5 ee 888
4. 81 6A 1aD 81 4 181 ZA AIJ8WSSSV ANIS ed we STONIS 589 86 SSVHd 3 5 85 SOILDSNNOO 9d 38S SNOLLOSNNOO SNOILOSNNOO 9d HOLVH3N3O HO YOLVHANSD Maker 1 Standard Controller Sheet 1 of 3 ision Dec iagram D iring Figure 5 1 TP 6109 11 02 32 Section 5 Wiring Diagrams 133HS OL gt v oA N H3TIOHINOO 111 111 l3S3u 440 Su o SUNOS LON 1 02 s ezr 27 7 8g 7 GM24452B Figure 5 2 Wiring Diagram Decision Maker 1 Standard Controller Remote Panel Options Sheet 2 of 3 Section 5 Wiring Diagrams 33 TP 6109 11 02 CUSTOMER CONNECTIONS NOT REQ D NEGATIVE TO 47 TAPE amp SECURE 128 CONNECTIONS CONTROLLER CONTROLLER 7C CUSTOMER SUPPLIED REMOTE PANEL START STOP ONLY REMOTE STOP START PANEL EXTENSION HARNESS IOVS BA FROM SHEET 2 6 62 27 P29 CONNECTIONS 428 CONNECTIONS CONTROLLER CONTROLLER 7C REMOTE STOP START PANEL
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6. 19 3 2 Generator Set Service Schedule 20 3 3 Cooling System ER ss 21 3 3 1 Siphon Break SA eI RA re ede 21 3 3 2 Impeller Inspection and Replacement Procedure 22 34 ExhaustSystem eel pex ep ee 23 3 5 Storage Procedure i or We eee 24 3 5 1 Lubricating System 24 3 5 2 oer oe Ue pe PS 24 3 53 Systemi oor VEDI ERI Rev ELM DEP 24 TP 6109 11 02 Table of Contents 3 54 Exterior zoo ele eae EDS 3 5 5 Battery 4 LUE Mil eat ae ecu S 24 Section 4 General Troubleshooting 25 Section 5 Wiring Diagrams 31 Appendix A Abbreviations eee einer a ER ene o edd eR d A 1 Appendix Operating Hour Service Log A 3 Table of Contents TP 6109 11 02 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 poten
7. N 14 7 Gp gt s a N 0 vor Owe 9 t 9 CH Ni P G dei 10 93 LON Nnu ili 11 13534 4340 8 191 WNOLLdO tuoi N3HM 3HnO3S 3dv 1 ISN HAWOLSNO t 281 aa1vinsNiNn en wa 2 2 6 29 LHM e zr 98 01 inva SNOILOSNNOO Id 2 19 01 ez en ek BOF 05 015 020 8 9 02 e en 5 1 40 02 4 N OA 28 2 9r r L voL i sr H3TIOHINOO iva CR be 78H N 01 18 3798 d dye MOTA 78H N 8 05 91 a i N 98 05 rici N 6 Nr V MUN WS 258 We lt gt 20 OS CSG DORAL a31vinsNINn ZS 01 Sd Z 5 oN avs ZA GM24453A HOLVY
8. 85 vor 02 018 6 1 6 HolvnLov am 55 6 02 SNOILOSNNOO GA v amp D ATawassy LV3H 0 90 z 3SVHd 319NIS 2985 Ay as 3SVHd 1 285 33S SNOLOSNNOO SNOILOSNNOO 9d HOL1VH3N39 ILON YOLVYANAD Figure 5 5 Wiring Diagram Decision Maker 1 Expanded Controller Sheet 1 of 6 TP 6109 11 02 36 Section 5 Wiring Diagrams TO SHEET 1 Figure 5 6 FUEL SYSTEM ENGINE 33 99 KW 125 150 KW 70 2 7 22 SN 245 0 5 7 77 AN m 4 BATTERY 101 D2 24 14P P2 12 71 2 1 BOSCH 83 99 KW 10 00 NL a NIPPONDENSO 125 150 KW E 10P 02 3 10 N pi 70 10 70 G 14N P2 5 7 TB10 7N NEA D1 LCL OPTIONAL J 26 CONTROLLER LOL OPTIONAL K 26 CONTROLLER L 41A P2 23 40A P2 16 7C OPG S 13 P2 22 S 5 CTG S T 34 P2 21
9. 5 RJA _ 133 5 SIHL GM24454D A SNOLLOSNNOO Hawoisno TANVd SLOWSY Q3riddns YAWOLSND 3u8niv3d TINA 1 wa HOLIMS 103136 HOLIMS HOLOSTSS HOLIMS HOLOSTSS HOLIMS HOLOSTSS YBLSWLIOA OV H313ALT0A Ov avos uiaddn Jos 3unssaud 1491009 1 cro eiaD 10 218 o10 2iaD 07 018 5 940 s 919 n oz 24 s SNOLLO3NNOO 2 5 3015 1918 3ALLVO3N 133HS SIHL 2133HS Figure 5 15 Wiring Diagram Decision Maker 3 Controller Remote Panel Options Sheet 4 7 TP 6109 11 02 46 Section 5 Wiring Diagrams SELSW 2 SELSW 7 SELSW 9 uz 2 VM VM MSLU vo 101 102 uP V7 P36 12 9 7 P36 CONNECTIONS 12 13 5 1 8 884 27 STANDARD REMOTE STOP START PANEL P38 CONNECTIONS C10 P36 7 70 36 4 FULL FEATURE REMOTE STOP START PANEL C12 P36 9 C11
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18. P38 CONNECTIONS DUAL LOCATION FULL FEATURE USING FULL FEATURE AND STANDARD REMOTE STOP START PANELS GM24453F 1 Expanded Controller Remote Panel Options Sheet 6 of 6 Section 5 Wiring Diagrams 41 BCA j t 10 NIPPONDENSO LEGEND AUTOMATIC VOLTAGE REGULATOR BCA BATTERY CHARGING ALTERNATOR BATTERY VOLTMETER CT 4 CURRENT TRANSFORMER CTG COOLANT TEMPERATURE GAUGE CTS COOLANT TEMPERATURE SENDER D DIODE EBG ENGINE BLOCK GROUND ETS EXHAUST TEMPERATURE SWITCH F FUSE GND CONTROLLER GROUND HCT HIGH COOLANT TEMPERATURE SWITCH HR HOUR METER HZ FREQUENCY METER IPS INJECTOR PUMP SOLENOID K1 5 CONTROLLER BOARD RELAYS K10 CONTROLLER AUXILIARY RUN RELAY K20 CRANK RELAY LED LIGHT EMITTING DIODE LCL LOW COOLANT LEVEL SWITCH LOL LOW OIL LEVEL SWITCH LOP LOW OIL PRESSURE SWITCH MSLL METER SCALE LAMP LOWER MSLU METER SCALE LAMP UPPER OPG OIL PRESSURE GAUGE OPS OIL PRESSURE SENDER O RS OFF RESET SWITCH PLUG PHCT PRELIMINARY HIGH COOLANT TEMPERATURE SWITCH PLOP PRELIMINARY LOW OIL PRESSURE SWITCH PMG PERMANENT MAGNET GENERATOR QCON QUICK CONNECT R f RESISTOR SELSW SELECTOR SWITCH SFG SAFEGUARD BREAKER SLB STATIONARY LED BOARD SM STARTER MOTOR SS STARTER SOLENOID SSEN SPEED SENSOR SSS START STOP SWITCH REMOTE STAT STATOR 12 LEAD TB f TERMINAL BL
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21. e EE Er 1 Maintenance and Service Parts Related 2 Section Specifications Hele a 3 14 dntrod ctlon 2 c ede 3 1 2 Specifications nes deese La eed tele 3 1 3 Serviee VIEWS cubes tede IR ONT RS E EPI Re US 4 1 4 Remote Annunciator Kit 5 1 5 Safeguard Breaker 5 16 Line Gire it Breaker Gk oe 5 Run Relay Kit ete enter Rd e RA 5 Section 2 c sleet Deal oss desi 7 24 Prestart Checklist eS Ae PR be 7 2 2 Marine Inspection 7 2 3 Angular Operation Rania ated eee aoe 7 2 4 Operation in European Union Member Countries 7 2 5 Exercising the Generator Set 8 2 6 Decision Maker 3 16 Light Microprocessor Controller Operation 8 2 6 1 Controls and Indicators 9 2 6 2 Fuses and Terminal Strips 10 2 6 3 Auxiliary Fault Lamp Conditions 11 2 6 4 Starting the Generator 5
22. 40 Section 5 Wiring Diagrams P36 CONNECTIONS Figure 5 10 Wiring Diagram Decision Maker TP 6109 11 02 SELSW 2 SELSW 7 47 6 NIC 7 9 12 5 Sa fo V SNSN a RINGS INS CAC N SN RN 5 NDA PASA sy EM MC 5 RAS OL E SN 5 Aa 5 2 J HARNESS 8 LOW MSLL 16 9 201 e1 9ed 101 V7 P36 12 P36 11 7C P36 3 sss C10 P36 7 C12 P36 9 C11 P36 8 C13 P36 10 LOW P36 16 Y CONNECTOR HARNESS RY __ START N P36 1 47 P36 5 FULL FEATURE REMOTE STOP START PANEL STANDARD REMOTE STOP START PANEL 02 1 N my N pa n SE e FEA OG oN A ea Ah I 45 AA SAMBA OA CY Sy CY NUM ATA CC SS C eM SANE EVEN RN NON NS IA HG SARIA I AI i 5 J28 CONNECTIONS SHEET 3 FROM SHEETS JUNCTION BOX DETAIL LOW TB2 LW 16 20 TB12 C11 8 G EXTENSION HARNESS PDK TB12 C13 TB2 VO vo 10 11 El
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24. Moving the generator set master switch to the OFF RESET position disables all controller functions Moving the generator set master switch to the AUTO position restores controller functions Enabling and Disabling the Prime Power Mode Enable the prime power mode by connecting jumpers across the following terminals on terminal strip TB2 on the controller circuit board e TB2 1P and TB2 2P e TB2 3P and TB2 4P e TB2 3 and TB2 4 See Figure 2 3 Remove the jumpers listed above to disable the prime power mode Prime Power Starting The prime power mode provides local starting only at the controller When the generator set master switch is in the OFF RESET position the controller functions are inoperative Move the generator set master switch to the AUTO position to start the generator set Do not start the generator set with the master switch in the RUN position because the alarm horn will sound Note Move the generator set master switch to the AUTO position to return controller functions to normal Prime Power Stopping Move the generator set master switch to the OFF RESET position to stop the generator set and power down the controller Note The controller functions are inoperative when the generator set master switch is in the OFF RESET position TP 6109 11 02 2 6 7 Fault Shutdowns The generator set shuts down automatically under the following fault conditions and cannot be restarted until the fault condition is cor
25. eer 91 19 P BATT 4 9 or viaJD 92 61 9180 1 18 96 6er bb 08 6 09 K3 5 7 K9 Kt 2 14 21 8 T 7 r vigU e vla ver 6 I T 5 42 2 4 J 01 6 92 6 21 6 96 2 428 139 4 11 6 21 61 650 nN 2 6 GM24454G A Figure 5 18 Wiring Diagram Decision Maker 3 Controller Remote Annunciator Options Sheet 7 of 7 TP 6109 11 02 Section 5 Wiring Diagrams 49 Jl NIPPONDENSO 100 150KW T 78 10 Le 7 700 4 BOSCH 85 99KW 4 1 12VDC BATTERY mem 55 AUXILIARY DELAY 31 9 SHUTDOWN AUXILIARY DELAY 31 SHUTDOWN AUXILIARY IMMEDIATE 30 SHUTDOWN PLOP CONTROLLER BOARD P1 12 TO FUSE 1 GROUND 1 5 FUSE 2 FUSE 3 BATTERY VOLTAGEP1 7 FUSE 3 BATTERY VOLTAGEP1 3 FUSE 3 INHIBIT FOR 30 SEC AFTER START THEN 5 SECO
26. 133HS AINO 4015 1 15 TANVd 310W3H 5 H3WOlsno SNOILO3NNOO H3Woisno ied 4 018 0 6 940 22 6 919 5 cien SNOILOSNNOO ezf e bw v wy Ye 133HS woud 1 Expanded Controller Remote Panel Options Sheet 4 of 6 Figure 5 8 Wiring Diagram Decision Maker 39 Section 5 Wiring Diagrams TP 6109 11 02 GM24453E TANVd 1 15 4016 SLOWS 3univ34 TINS ZH 4za za 2729 281 6 ms1as 60 218 8135 212 2180 ms7as Ho eieD e ms1as 010 218 sss de ap sw 659 o oc ola msn 8 64 24 5 40 0 13 44 18 16 4018 1 TINS wa 6 00 6 6 910 s wa 659 6 SNOLLO3NNOO SNOLLO3NNOO y ved 04 6 84 92 Wiad 19 8015 TP 6109 11 02 2 N OA LA 8 red 210 AO msn ont 91 ved mom 3 msw cory T7 1 s1 vea an 019 ci ved ri ved 201 STANVd 1HV1S dOLS SLOWSY 9 133HS 9 133HS SIHL OL 170 NOLLONAr 01 6 8 210 LLO 0919 eve
27. HIGH ENGINE TEMPERATURE INDICATOR LOW OIL PRESSURE INDICATOR OVERSPEED INDICATOR OFF RESET COMMAND ACTIVE LOW AUTO COMMAND ACTIVE LOW RUN COMMAND ACTIVE LOW AIR DAMPER INDICATOR SYSTEM READY INDICATOR GENERATOR IN COOLDOWN GENERATOR RUNNING NOT IN AUTO INDICATOR AUXILIARY PREALARM CUSTOMER DEFINED LOW WATER TEMPERATURE PREALARM HIGH ENGINE TEMP INDICATOR PREALARM LOW OIL PRESSURE INDICATOR EMERGENCY STOP RELAY GROUND EMERGENCY STOP RELAY COIL NEGATIVE EMERGENCY STOP INDICATOR BATTERY CHARGER FAULT ACTIVE LOW LOW BATTERY VOLTS ACTIVE LOW STANDARD CONTROLLER REQUIRES PREALARM KIT TO OPERATE USED FOR DEC 3 ACCESSORIES LOW FUEL ACTIVE LOW MUST HAVE JUMPER IF THERE IS NO EMERGENCY STOP KIT CONNECTED PRIME POWER OPERATION PRIME POWER OPERATION REQUIRES OPTIONAL PRIME POWER OPERATION PRIME POWER OPERATION HIGH BATTERY VOLTAGE 127 BLK 9 Cod TB3 BREAKER IS USED NOTE CURRENT TRANSFORMER DOT OR TOWARD GENERATOR MSLU B ae MSLL YEL vio lt Go
28. 70 REMOTE STOP START PANEL N EXTENSION HARNESS o AN QS 8 16 02 N 02 Lea 27 P31 CONNECTIONS Y CONNECTOR HARNESS EXTENSION HARNESS YIN AGOM NL N 8 5 EXTENSION HARNESS wae YON Mete NEZ gt MS AN 9 VIS MU NI LA 25 TOY NYS OO ML WS 5 4 4 TYNES 2z w tg 328 CONNECTIONS CONTROLLER CONTROLLER 7C 3 P33 CONNECTIONS DUAL LOCATION REMOTE STOP START PANEL GM24452C Figure 5 3 Wiring Diagram Decision Maker 1 Standard Controller Remote Panel Options Sheet of 3 34 Section 5 Wiring Diagrams TP 6109 11 02 Di 70D LEGEND 15 0HM WATT AVR AUTOMATIC VOLTAGE REGULATOR E j 4 NBC 7 BCA BATTERY CHARGING ALTERNATOR NIPPONDENSO Boscu CT CURRENT TRANSFORMER 400v 908 CTS COOLANT TEMPERATURE SENDER 125 150KW 83 99KW DIODE ENGINE BLOCK GROUND ETS EXHAUST TEMPERATURE SWITCH FUSE GND CONTROLLER GROUND HIGH COOLANT TEMPERATURE SWITCH HR HOUR METER 12VDC BATTERY IPS INJECTOR PUMP SOLENOID K1 5 CONTROLLER BOARD RELAYS K10 CONTROLLER AUXILIARY RUN RELAY K20 CR
29. Middle East London Regional Office Langley Slough England Phone 44 1753 580 771 Fax 44 1753 580 036 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 TP 6109 11 02 Introduction Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service at the prescribed intervals 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 x in 001 002 a 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 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
30. 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 TP 6109 11 02 3 4 Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Consult the boat builder or dealer for approved detector location and installation Inspect the detector before each generator set use n addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times Atthe interval specified in the service schedule inspect the exhaust system See Section 1 for the exhaust outlet location TP 6109 11 02 Inspection Points Inspect the the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper for cracks leaks and corrosion 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
31. 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 IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext ISO 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 iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 219 bytes Appendix A 1 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m8 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm KQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length
32. 0 SXee JO 195 101eJeueB joedsu eui eJojseH suonoy sesney o qeqoJd uoneoiqng 10 uonoegs esiou JO uonduunsuoo Jen eunsseJd Jewod syoe jueppns sdolS 1ndino JO ON sueis jou seop jou seoq suiojdui AS Section 4 Troubleshooting 29 TP 6109 11 02 Notes 30 Troubleshooting TP 6109 11 02 Section 5 Wiring Diagrams WARNING KS 5 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 star
33. AAG PHOTO COUPLING LAAAAAY SPEED SENSOR ACTUATOR ROTATING PHOTO TRANSISTOR BOARD E 12 v va 7 YY YY NE MAIN FIELD HEAT SINK ASSY 8 EXCITER ARMATURE NOTE CT WIRES GO DIRECTLY TO WHEN SAFEGUARD NOT NOTE BLANK DENOTES CONTACT OPEN DENOTES CONTACT CLOSED DENOTES MAKE BEFORE BREAK CONTACT LEGEND AM AMMETER AVR AUTOMATIC VOLTAGE REGULATOR BCA BATTERY CHARGING ALTERNATOR BV BATTERY VOLTMETER CT CURRENT TRANSFORMER CTG COOLANT TEMPERATURE GAUGE ENGINE BLOCK GROUND CTS COOLANT TEMPERATURE SENDER ESS EMERGENCY STOP SWITCH ETS EXHAUST TEMPERATURE SWITCH GND CONTROLLER BOX GROUND HCT HIGH COOLANT TEMPERATURE SWITCH HR HOUR METER HZ FREQUENCY METER IPA INDICATOR PANEL ASSEMBLY IPS INJECTOR PUMP SOLENOID GOVERNOR CONTROL RELAY 20 CRANK RELAY LCL LOW COOLANT LEVEL SWITCH MSLL METER SCALE LAMP LOWER MSLU METER SCALE LAMP UPPER LOL LOW OIL LEVEL SWITCH LOP LOW OIL PRESSURE SWITCH OPG OIL PRESSURE GAUGE OPS OIL PRESSURE SENDER PHCT PRELIMINARY HIGH COOLANT TEMPERATURE SWITCH PLOP PRELIMINARY LOW OIL PRESSURE SWITCH SELSW SELECTOR SWITCH SFG SAFEGUARD BREAKER SLB STATIONARY LED BOARD SM STARTER MOTOR STAT STATOR TB1 CONTROLLER BOARD TER
34. Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 X in 008 001a Introduction 1 Maintenance and Service Parts Related Literature Maintenance and Service Parts Figure 1 identifies maintenance and service parts for your generator set Obtain a complete list of maintenance and service parts from your authorized generator distributor dealer Models 40 02 50 02 65EOZ 80EOZ 99 02 125 02 150 02 Part Description 33EFOZ 40EFOZ 55EFOZ 70EFOZ 80EFOZ 100EFOZ 125EFOZ Air Filter Element GM15397 GM15397 GM15397 GM15398 GM15398 324134 324134 Belt Alternator and Seawater Pump GM15402 GM15402 GM15402 GM15402 GM15402 GM18704 GM18704 Dec Standard Controller Input Fuse 10 amp 223316 223316 223316 223316 223316 223316 223316 Dec Expanded Controller Input Fuse 10 amp 223316 223316 223316 223316 223316 223316 223316 Dec 3 Controller Remote Annunciator Fuse 3 amp 243273 243273 243273 243273 243273 243273 243273 Controller Fuse 3 amp 243273 243273 243273 243273 243273 243273 243273 Engine amp Accessory Fuse 15 amp 283645 283645 283645 283645 283645 283645 283645 Fuel Filter Element GM15399 GM15399 GM15399 GM15399 GM15399 GM18808 GM18808 Oil Filter GM15400 GM15400 GM15400 GM15400 GM15400 223673 223673 Seawater Pump Impeller Kit GM15401 GM15401 GM1
35. O Bulges WOO oeds ay y peep 10 pue ueejo suonoeuuoo y 10 suonoeuuoo 10 suonoy ajqeqoid asiou jeuJuouqe JO uonduunsuoo eunsseJd Jamod syoe 1ndino MO JO ON sueis jou seop jou seoq swojdwAs Section 4 Troubleshooting 27 TP 6109 11 02 enuen W S enuey uonejedo qW O enuen uoneresu NI au umop sinus jun 19594 19 1 ua N S siu WUOLed jJepeep 1ojnquisip ue 4 YOUMS JeJsueJ lt 32945 eds s s siy jo pejequinu uonoes 2eS x uonoes
36. SHUTDOWN JUMPERS OVERCRANK CRANK DISCONNECT 9 d 9 10 S2 SHIELD GROUND 1 11 X 1 4 sra 12VDC 1 5 gt 24 RED OPTIONAL G33dSH3AO SPEED SPEED INPUT SENSOR 1 8 je 16 WHT co On OPTIONAL e 12 CT2 OPTIONAL Qv Le OPTIONAL 24 RED 2 NOTE wen BLK CURRENT TRANSFORMER UL DOT OR 1 TOWARD SSEN GENERATOR o BOARD NOOO Sex MAIN FIELD FOR GENERATOR CONNECTIONS SEE ADV 5875 THREE PHASE 5857 SINGLE PHASE PHOTO COUPLING SPEED PMG SENSOR EXCITER HEAT SINK ACTUATOR FIELD ASSEMBLY ADV6740 ue Figure 5 4 Wiring Diagram Schematic Decision Maker 1 Standard Controller Sheet 1 of 1 TP 6109 11 02 Section 5 Wiring Diagrams 35 LvZ9 AQV 335 WvHOVIG 8 Z133HS 133HS OL ame Asuo 151011 3ONvHO 3ONVHO 7 5 xovis MOTE s o S 5 i i zn 7 ama 3ONVHO
37. 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 7 d 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner silencer removed Combustible materials A sudden flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the fuel system Keep the compartment and the generator set clean and free of debris to minimize the risk of fire Wipe up spilled fuels and engine oil Safety Precautions and Instructions Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle the
38. VIO RED Vo WHT vio N LWO CIO Cac 2 BLK c c vo 250v 250v 15 15A d GROUND 1 11 S2 SHIELD Va rt 12VDC 1 5 033454310 vo i6 wN SPEED SPEED INPUT SENSOR NOTE WHEN OPTIONAL SAFEGUARD BREAKER IS NOT USED WIRE CT WIRES DIRECTLY TO 24 RED 67 68 SFG 2 OPTIONAL BLK 8 PHOTO BOARD um MAIN FIELD FOR GENERATOR 19a CONNECTIONS SEE AC AAAA ADV 5875 THREE PHASE ADV 5857 SINGLE PHASE F AAAA PMG EXCITER FIELD PHOTO COUPLING SPEED SENSOR ACTUATOR HEAT SINK ASSEMBLY ADV6741 Figure 5 11 Wiring Diagram Schematic Decision Maker 1 Expanded Controller Sheet 1 of 1 42 Section 5 Wiring Diagrams TP 6109 11 02 2 9 385 WWHOVIC yovie WME ZH Nua j WA aoo Gen nsi b 34 A 6 28 980 91 EL
39. as necessary Check the function of the siphon break if equipped Check replace the seawater pump impeller X Replace EXHAUST SYSTEM X Inspect the exhaust system components Before operation Check the exhaust gas condition If the exhaust is blue or black contact your local distributor dealer X During operation Clean the exhaust water mixing elbow Inspect the complete exhaust system 8 ENGINE AND MOUNTING Check for water fuel coolant and oil leakage 72 TUM operation Check the mounting bolts vibromounts and tighten if necessary GENERATOR Test run the generator set Blow dust out of the generator Requires removal of the sound shield if installed Consult your local distributor dealer for service Qo He Should be performed by your local distributor dealer 20 Section 3 Scheduled Maintenance Read the WARNING found at the beginning of the manual regarding moving parts TP 6109 11 02 3 3 Cooling System WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure fromthe cooling system before removing the pressure cap To release pressure coverthe press
40. by width by height Ib pound pounds Ibm ft 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 1 units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 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 military standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg mounting A 2 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT pp ph 2 PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standard
41. 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 andfollowthe 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 Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure IV Safety Precautions and Instructions A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank ifthe generator set has a coolant recovery tank Servicing the exhaust
42. death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation A 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 itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set 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 Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Section 3 Scheduled Maintenance 19 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 ser
43. fault The high exhaust temperature shutdown does not function during the first 5 seconds after startup Low coolant level Shutdown occurs 5 seconds after the fault Low coolant level shutdown does not function during the first 5 seconds after startup Low oil pressure Shutdown occurs 5 seconds after the fault Low oil pressure shutdown does not function during the first 5 seconds after startup NOTE The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Overcrank Shutdown occurs after 30 seconds of continuous cranking Shutdown occurs after 30 seconds if the engine or starter does not turn locked rotor Shutdown occurs immediately when the governed frequency on 50 and 60 Hz models exceeds 70 Hz x 0p 004 005 18 Section 2 Operation 2 8 5 Controller Resetting Procedure Following Fault Shutdown Use the following procedure to restart the generator set after a fault shutdown 1 Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch See the Safety Precautions at the beginning of this section before proceeding Correct the cause of the fault shutdown See the Safety Precautions at the beginning of this section before proceeding Start the generator set by moving the generator set master switch to RESET OFF and then to RUN Verify that the cause of the shutdown has been correcte
44. 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 ifthe sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only TP 6109 11 02 Notice NOTICE This generator set has been rewired from its nameplate voltage to 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 TP 6109 11 02 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 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 diag
45. to controller terminals TB1 3 and TB1 4 Note The controller provides up to 30 seconds of continuous cranking before overcrank shutdown occurs 2 7 3 Stopping the Generator Set The following procedure describe how to stop the generator set Normal Stopping 1 Cooldown Run the generator set at no load for 5 minutes to ensure adequate engine cooldown 2 Stopping Move the generator set master switch to the OFF RESET position The engine stops x 0p 002 004 2 7 4 Fault Shutdowns The generator set shuts down automatically under the following fault conditions and cannot be restarted until the fault condition is corrected The system automatically resets when the problem is corrected or the generator set cools if high engine temperature was the fault The fault lamp does not stay lit after the generator set shuts down on a fault condition 16 Section 2 Operation Fault Description High engine Shutdown occurs 5 seconds after the temperature fault The high engine temperature shutdown does not function during the first 5 seconds after startup Note The high temperature shutdown functions only when the coolant level is in the operating range Shutdown occurs 5 seconds after the fault The high exhaust temperature shutdown does not function during the first 5 seconds after startup High exhaust temperature Low coolant level Shutdown occurs 5 seconds after the fault The low coolant level shutdown do
46. 01 HOLIMS 13 31 1NY 1009 191 AVTIH 024 ATEWASSY TANVd HOLVOIONI YALA ZH H313 UNOH HOLIMS dW31 LNY 1009 LOH H3TIOHINOO QNO IMS 3uni vuiaidal LSNVHXS 513 HOLIMS 9015 AON3Ou3W3 553 40078 3NION3 983 191009 519 WO 3t vida 1 1000 919 H3WHOJSNVH L 912 UBI3ALTOA ANO _ oma Wd 8 100 840 aunssaud 10 940 HOLVNH3LTV AH3LLV8 HOLVINDSY 39v L10A HAV 6 9 34 61 6146 91 11800 13A 5195 6 M 0 B T 10Hd 10H T id vor 2 0 ve gA t 5 980 54 02 0181 aor dor wot 081 621 4 02 1 89 89 redo iu L 0 840 134 HOLVH3N39 QHVMOL HO 10 8 LON 02 0181 01 ATLOSHIC 8I 0181 OL ATLOSYIC SIHIM 10 103NNO
47. 1 12 2 6 5 Stopping the Generator 5 1 12 2 6 6 Prime Power Mode Operation 13 267 Fault Shutdowns 13 2 6 8 Controller Resetting 14 2 6 9 Resetting the Emergency Stop 14 2 7 Expanded Decision Maker 1 Controller Operation 15 2 7 1 Controls and Indicators 15 2 7 2 Starting the Generator 5 1 16 2 7 3 Stopping the Generator 5 1 16 2 7 4 Fault Shutdowns 16 2 75 Controller Resetting Procedure 16 2 8 Standard Decision Maker 1 Controller Operation 17 2 8 1 Controls and Indicators 17 2 8 2 Starting the Generator 5 1 17 2 8 3 Stopping the Generator 5 1 17 2 84 Fault Shutdowns 18 2 85 Controller Resetting Procedure 18 Section Scheduled Maintenance 19 3 1 General Maintenance
48. 19 103NNOO ISN LON SI 5 LON 6 54 04 6 29 0 6 54 60 281 22 281 22 10 280 12 lt ION ve y UWS vaL 6 89 wis 5 50 SIN 13 780 201 et 5 5 Erian vie 8 1 IHM 9 So S ta vz 07 18D 0 00 x QNO 00 0181 09 0 y o o 0 0 9 02 281 00 GA v8L 8A ZA OA za 9 02 101 6 9 g g vog aor E 559 1 99 as 8 19 NOOO SNOILO3NNOO 00 0 itd z L 20 0181 20 0 9 10 09 ana 6 0 ox 2 0 SNOIIOSNNOO So vi r sua ve 0 N3SS LHM Nass NASS GALWINSNINN 983 2 29 2 8 24 LHM 6 9I 24 28 Nass OLOHd ald 9Wd
49. 5 12 Wiring Diagram Decision Maker 3 Controller Sheet 1 of 7 TP 6109 11 02 1 201 S133HS OL seve S133HS 01 91 820 MOT 1 8 2 SS3NHVH 3NION3 ze 19 dil 6 27 oz amp 02 29 os 8 gt 2 se 2 09 96 les H3TIOHLINOO H313A GM24454B A Figure 5 13 Wiring Diagram Decision Maker 3 Controller Remote Panel Options Sheet 2 of 7 TP 6109 11 02 44 Section 5 Wiring Diagrams STANVd 310W3H 5 OML 310W3H 5 Sfrid 5 OML SNIMOTIOS JHL SMOTIY WALSAS SHL ALON TANVd 1 15 4015 SLOWSY SN1d GYVONVLS ONISN 659 zv 02 s eed zv
50. 5401 GM15401 GM15401 GM18793 GM18793 Spray Paint White 221335 221335 221335 221335 221335 221335 221335 Touch Up Paint White GM19490 GM19490 GM19490 GM19490 GM19490 GM19490 GM19490 Zinc Anode GM15403 GM15403 GM15403 GM15404 GM15404 GM15404 GM15404 Figure 1 Maintenance and Service Parts Related Literature Figure 2 identifies related literature available for the generator sets covered in this manual Only trained and qualified personnel should install or service the generator set Models 40 7 50EOZ 65 02 80 02 99 02 125 02 150 02 Literature 33EFOZ 40EFOZ 55EFOZ 70EFOZ 80EFOZ 100EFOZ 125EFOZ Installation Manual TP 6069 TP 6069 TP 6069 TP 6069 TP 6069 TP 6069 TP 6069 Parts Catalog TP 5738 TP 5738 TP 5738 TP 5738 TP 5738 TP 5738 TP 5738 Operation amp Service Manual Engine TP 6084 TP 6084 TP 6084 TP 6084 TP 6084 N A N A Service Manual Generator TP 5737 TP 5737 TP 5737 TP 5737 TP 5737 TP 5737 TP 5737 ncludes the generator and engine information Figure 2 Generator Set Literature x in 001 005 2 Maintenance and Service Parts Related Literature TP 6109 11 02 11 Introduction The specification sheets for each generator set provide specific generator and engine information Refer to the respective specification sheet for data not supplied in this manual Consult the generator set service manual installation m
51. 708 s 940 6 915 ly oz oL N SNOLLO3NNOO SNOLLO3NNOO uawoisno 3univeadwa 1NV1000 dOLS LUVIS 2 gt ge 213395 Figure 5 14 Wiring Diagram Decision Maker 3 Controller Remote Panel Options Sheet 3 of 7 45 Section 5 Wiring Diagrams TP 6109 11 02 TANVd 1 15 9015 SLOWSY SHNLW3s TINS ZA 04 4015 s ved zv L ved N 4uvis sss G ve2 019 5135 8 ved 6 ved 210 9 6 an 1 Lor ZOL 1HVIS dOLS SLOWSY S 133HS 9 133HS SIHL OL 10 msn msn wa Sig TANVd 15 4015 310W3H 99019337713 ZH 2 6 z ms13s ms73s 9 550 4 sss 0 motea s o20 56 915 5 wa sss SNOILOSNNOO 1 81 12 218 0 18 010 2181 04 018 5 940 5 910 iv oz s N SNOLLO3NNOO SS3NHVH 5 8 NOISN31X3 SO OI TEN mr VASAS a Ao 8 No A NGS AM A A AX MULA
52. ANK RELAY LED LIGHT EMITTING DIODE LCL LOW COLLANT LEVEL SWITCH LOL LOW OIL LEVEL SWITCH LOP LOW OIL PRESSURE SWITCH OPS OIL PRESSURE SENDER O RS OFF RESET SWITCH PLUG PHCT PRELIMINARY HIGH COOLANT TEMPRATURE SWITCH PLOP PRELIMINARY LOW OIL PRESSURE SWITCH PMG PERMANENT MAGNET GENERATOR QCON QUICK CONNECT R f RESISTOR 70 70 27 SFG SAFEGUARD BREAKER SLB STATIONARY LED BOARD 100 150 KW SM STARTER MOTOR SS STARTER SOLENOID SSEN SPEED SENSOR SSS START STOP SWITCH REMOTE STAT STATOR 12 LEAD TERMINAL BLOCK VADJ VOLTAGE ADJUST 93 99 KW 70 FOR CUSTOMER 10A USE INPUT 70 OPTIONAL 5 26 C3 RED O NOTE WHEN OPTIONAL SAFEGUARD y BREAKER 5 NOT USED 26 CONNECT WIRE 18 DIRECTLY TO 10 70 CONTROLLER BOARD LOGIC ee OPTIONAL BOARD LOE 26 4 P1 10 lt L RED OPTIONAL PLOP FLASH P1 6 FLASH P1 3 AUX CRANK DISCONNECT 1 13 EXTERNAL FAULT LATCH 14 START OPTIONAL BOARD OPS POWER 4 1 14 NY USED ENGINE RUNNING 70A 10 FAULT LAMP FAULT LAMP 1 1 LOW COOLANT LEVEL OR ENGINE FAULT 1 7
53. B2 9A for continuous cranking leave TB2 9 open cyclic cranking see starting instructions in Section 2 Operation 9A Crank mode ground Note To use prime power mode place jumpers across TB2 1P to TB2 2P TB2 3P to TB2 4P and TB2 3 to TB2 4 To deactivate prime power mode remove jumpers across TB2 1P to TB2 2P TB2 3P to TB2 4P and TB2 3 to TB2 4 Figure 5 21 Controller TB2 Terminal Strip Decision Maker 3 Controller Section 5 Wiring Diagrams 51 Notes 52 Section 5 Wiring Diagrams TP 6109 11 02 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min cc CCA cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required a
54. Do not leave rags tools or debris on or near the generator set Seawater Pump Priming Prime the seawater pump before initial startup To prime the pump 1 close the seacock 2 remove the hose from the water filter outlet 3 fill the hose and seawater pump with clean water 4 reconnect the hose to the water filter outlet and 5 open the seacock Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet 2 2 Marine Inspection Kohler Co recommends that all boat owners have their vessels especially the exhaust system attached to the generator set inspected at the start of each boating season by the local Coast Guard Auxiliary If there is no Coast Guard Auxiliary in the area contact an authorized Kohler distributor dealer for the inspection 2 3 Angular Operation See Figure 2 1 for angular operation limits for units covered in this manual Intermittent Continuous 3 minutes or less 25 30 Maximum value for all directions Figure 2 1 Angular Operation m op 001 004 2 4 Operation in European Union Member Countries This generator set is specifically intended and approved for operation below the deck in the engine compartment Operation above the deck and or outdoors would constitute a violation of European Union Directive 2000 14 EC noise emission standard Section 2 Operation 7 2 5 Exercising the Generator Set Operate the generator set under load onc
55. MINAL BLOCK TB2 CONTROLLER BOARD TERMINAL BLOCK TB3 CT METER SCALE TERMINAL BLOCK TB4 A C FUSE TERMINAL BLOCK TB10 SAFEGUARD BREAKER TERMINAL BLOCK VM VOLTMETER 12 LEAD STATOR FOR GENERATOR CONNECTIONS SEE ADV 5875 THREE PHASE 5857 SINGLE PHASE ADV6742 Figure 5 19 Wiring Diagram Schematic Decision Maker 3 Controller Sheet 1 of 1 50 Section 5 Wiring Diagrams TP 6109 11 02 Terminal Purpose Ground emergency stop relay K4 connect emergency stop across terminals TB1 1 and 1A Emergency stop relay K4 coil negative side connect emergency stop across terminals TB1 1 and 1A Ground terminal Overcrank OC indicator Auxiliary AUX indicator Common fault prealarm line 1 A V alarm or common fault relay activated by OC 12 AUX 26 LWT 35 HET 36 LOP 38 OS 39 PHET 40 PLOP 41 and LF 63 faults Common fault prealarm line 2 A V alarm or common fault relay activated by AUX 26 HET 36 LOP 38 OS 39 and E Stop 48 faults Low water temperature LWT indicator High engine temperature HET indicator Low oil pressure LOP indicator Overspeed OS indicator Prealarm high engine temperature PHET indicator Prealarm low oil pressure PLOP indicator Battery voltage fuse 1 protected accessory power supply customer may also provide separate accessory power source Emergency stop ES i
56. NDS BATTERY VOLTAGE P1 1 FUSE 3 ac crank P23 DISCONNECT P2 5 OVERVOLTAGE IMMEDIATE P2 2 SHUTDOWN SHUTDOWN BATTERY VOLTAGE FUSE poi GROUND 2 6 HG PREALARM CRANK DISCONNECT OVERCRANK LOCK ROTOR OVERSPEED P1 9 AUTOMATIC RESTART 1 8 12VDC REGULATED FUSE 2 1 2 GROUND 1 6 SHIELD GROUND ZEER FEES 5 7 4 2 46 38 48 40 8 4 5 6 7 pa 3 p2 21po 8 413 47 43 32 63 6162 56 41 35 80 60 36 OPTIONAL ELECTRONIC GOVERNOR CONTROL D UP H poruon IPS P27 B PULL IN COIL P27 A HOLD COIL P27 C COIL COMMON 100 150 KW SELSW CONTACTS SHOWN WITH SWITCH IN OFF POSITION 85 99 KW TB1 TB2 P3 P4 amp T27 TERMINAL 0 DESCRIPTION 42A BATTERY VOLTAGE FUSE 1 PROTECTED GROUND REMOTE START GROUND REMOTE START ACTIVE LOW CRANK MODE OPEN OYOLIC GROUND CONTINUOUS CRANK MODE GROUND OVERCRANK INDICATOR 12VDC REGULATED AUXILIARY INDICATOR COMMON FAULT PRE ALARM LINE 1 ACTIVATED BY HET PLOP OS LWT OC LF AUX FAULTS COMMON FAULT LINE 2 ACTIVATED BY E STOP OS HET AUX FAULTS
57. O 5 LON SI 8 5 N3HM LON 9 2 54 19 ead 2 3 88 13A 4 ase 01 910 0 90 i 8 0 02 59 4090 6 19 02 0L 683 Nz 6 54 NZ 7 NLOLEO 69 281 20 GM24454A A 43 Section 5 Wiring Diagrams 6 134 9 919 na 9 940 919 ez Ed o ea 9 19 58019 OSNSGNOddIN 9 265 LHM vog oH NZ 018D NZ ra 6 14 Nov n iiu dvi re UI NA 081 921 66 8 W31SAS 1905 sia Nass NISS o31vansNiNn 5 Nass 2 SNOILO3NNOO 14 ano ZH ZH 34 redo 04 SNOLLOANNOO f 6 S3NHVH 3NION3 dvi 92 5195 N ij 12 MS13S Il NN 09 681 09 on sw on ng
58. OCK VADJ VOLTAGE ADJUST 70 VM AC VOLTMETER 70 gt 70 9 70 F2 10 2 3 2 SFG b NOTE 70 OPTIONAL WHEN OPTIONAL SAFEGUARD SEX BREAKER IS NOT USED CONNECT WIRE 18 DIRECTLY TO TB10 70 125 150KW 12VDC BATTERY 12 4 70 70 27 100 150 KW VS 33 99 KW 2 SELSW 12 3 iH aol 75 m ssl ifs Tte m 19 2 D 19 294 101 CONTACTS SHOWN WITH SWITCH IN OFF POSITION CONTROLLER BOARD LOGIC BOARD POWER 1 10 e START SWITCH ee P1 2 BLANK DENOTES CONTACT OPEN C DENOTES CONTACT CLOSED M DENOTES MAKE BEFORE BREAK CONTACT FOR CUSTOMER USE AUX CRANK DISCONNECT EXTERNAL FAULTLATCH T4 START BOARD POWER P1 14 OPTIONAL ENGINE RUNNING 1 4 MSLU YEL LOW COOLANT LEVEL OR ENGINE FAULT FAULT SHUTDOWN iE Bs 2 13 TBI OVERCRANK CRANK DISCONNECT NOT USED 2 10 31 ORG
59. Operation Marine Generator Sets Models 33EFOZ 40EOZ 40 2 50 2 55EFOZ 65EOZ 70EFOZ 80EOZ 80EFOZ 99EOZ 100EFOZ 125EOZ 125EFOZ 150EO0Z NATIONALLY REGISTERED KOHLER POWER SYSTEMS oss 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 Table of Contents Product Information inside front cover Safety Precautions and Instructions Introduction cocos ns REL 1 Service
60. P36 8 C13 P36 10 EXTENSION HARNESS UP P36 1 z M NY ZIJN Y CONNECTOR 5 iy 5 OO Ces pz 25 4 DACO Sg O H pe DUAL LOCATION FULL FEATURE USING FULL FEATURE AND STANDARD REMOTE STOP START PANELS LOW TB3 LOW T812 C11 T812 C12 T812 C13 128 CONNECTIONS FROM SHEET 4 JUNCTION BOX C T DETAIL GM24454E A Figure 5 16 Wiring Diagram Decision Maker 3 Controller Remote Panel Annunciator Options Sheet 5 of 7 TP 6109 11 02 Section 5 Wiring Diagrams 47 TO SHEET 7 TOSHEET7 ee Y OO J39 CONNECTIONS 2 23 TB2B 27 63 3 27090 IE J39 CONNECTIONS EXTENSION OG 2 8 Mag AB AB A C CC BIN AZ AM 27 EXTENSION e lt 9 5 BRAC IANO NR f eJ DAOC CN ANA ANE CYC HARNESS Y CONNECTOR CC C X oN DUAL LOCATION REMOTE ANNUNICATOR EXTENSION D a OM DA gs 05248248202 Lot REMOTE ANNUNCIATOR REMOTE ANNUNCIATOR NOOK AJAN REMOTE ANNUNCIATOR GM24454F A Figure 5 17 Wiring Diagram Decision Maker 3 Controller Remote Annunciator Opt
61. SNSO LSNOVW LN3NVINH3d HOLIMS MOT 7 dO 1d HOLIMS INV1009 HOIH AHVNIATI3d LOHd 10 580 110 640 HOLIMS 13S3H 44O SH O Y3ddN dv FOS YILIN NISW 370 TISW HOLIMS 38056344 10 401 HOLIMS 13 31 101 HOLIMS 18 31 INV1000 101 ANTH 3NION 014 ovr Wr GIONS1OS HOLOAPNI H313W ZH Y313W HOLIMS 1491009 LOH H3TTOHINOO GND 3504 24 NI1 ND 3604 13 HOLIMS 1SnvHX3 513 49018 3NION3 983 191009 519 36nvo 3unive3dWaL INV1009 919 HSWHOSSNVHL 1N3HHnO 10 HBL3IALTOA A VOS HOLVINDAY OLLVNOLNY HAV H3ISWAV WY PAVA A9009 vNIWH3L 081 YOLVLS 1V1S HOLIMS dOLS LUVLS SSS HOSNAS 03345 NISS GIONS10S 5 SS HOLOW 15 WS auvnosJvs 945 HOLIMS 0193135 5785 1O3NNOO HOLVH3N39 HO 100 H3 HOJSNVHL 1N3HBDO ILON 02 0181 01 ATLOAYIC SHIM 0181 OL ATLOSHIC S3HIM
62. a container with 4 L 1 gal of water and 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 fromthe 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 Safety Precautions and Instructions 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
63. acturer s recommendations 6 Maintain a full charge to extend battery life TP 6109 11 02 This section contains generator set troubleshooting diagnostic and repair information Use the following chart as a quick troubleshooting reference The table groups generator set faults and suggests likely causes and remedies The table also refers you to more detailed information including sections of this manual the generator set service manual S M the generator set installation manual I M and the engine service manual Engine S M to correct the indicated problem Corrective action and testing often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service distributor dealer perform service TP 6109 11 02 Section 4 Troubleshooting 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 Section 4 Troubleshooting 25 W S 40 W O
64. and Indicators located on the controller Name Description AC ammeter Meter displays the AC output amperage Use the selector switch to choose the phase current Lamp test switch Switch tests the controller indicator lamps Low oil pressure lamp Lamp illuminates if the generator set shuts down because of low oil pressure Shutdown occurs 5 seconds after the engine reaches oil pressure shutdown range AC voltmeter Meter displays the AC output voltage Use the selector switch to choose the output lead circuits DC voltmeter Meter displays the voltage of the starting battery ies Alarm horn Horn sounds if any fault or anticipatory condition exists Place the generator set master switch in the AUTO position before silencing the horn See the Controller Resetting Procedure later in this section Alarm silence switch Switch disconnects the alarm during service place the generator set master switch in the AUTO position before silencing the alarm horn Restore the alarm horn switches at all locations controller remote annunciator and audio visual alarm to normal positions after correcting the fault shutdown to avoid reactivating the alarm horn See the Controller Resetting Procedure later in this section Overcrank lamp Lamp illuminates and cranking stops if the engine does not start after 45 seconds of continuous cranking or 75 seconds of cyclic cranking Cranking s
65. anual engine operation manual and engine service manual for additional specifications 1 2 Specifications The alternator is a 4 pole rotating field unit with a brushless permanent magnet generator PMG excitation system The generator set excitation system uses permanent magnet exciter with silicon controlled rectifier SCR assembly that controls the amount of DC current supplied to the generator field The voltage regulator sends a signal to the SCR assembly through an optical coupling The voltage regulator bases the signal on engine speed and generator output voltage The signal turns a stationary light emitting diode LED on or off The LED is mounted on the end bracket opposite a photo transistor board that rotates on the shaft The photo transistor receives the signal from the LED and signals the SCR assembly to turn on or off See Figure 1 1 PMG Fast Response generator sets offer the following advantages e The voltage recovery period of this type of generator is several times faster than the conventional PMG generators because the generator set does not have to contend with the inductance of the 2 exciter field e Better recovery characteristics than static excited generators because the system doesn t draw excitation power from the generator output voltage e The inherent ability to support short circuit current and allow system coordination for tripping downstream branch circuit breakers The PMG ex
66. citer system changes the level of exciter current to the main field within 0 05 seconds of a load change For the duration of a short circuit the load circuit s the output voltage drops and the amperage momentarily rises to 200 30096 of the generator set s rated current TP 6109 11 02 Section 1 Specifications and 200 300 for the duration of the short circuit The SCR assembly sends full exciter power to the main field and the generator sustains up to 300 of rated current The sustained high current causes the correspondingly rated load circuit fuses breakers to trip The safeguard breaker kit collapses the generator set s main field during a sustained heavy overload or short circuit YYY 1 2 3 4 5 6 7 8 9 Field Main generator alternator SCR assembly Exciter generator alternator Exciter field magnets Exciter armature Optical coupling Starting battery Safegaurd breaker optional AC voltage regulator LED board Photo transistor board Stator Figure 1 1 Alternator Schematic Section 1 Specifications 3 1 3 Service Views
67. d by test operating the generator set Reconnect the generator set to the load using the line circuit breaker or automatic transfer switch Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch x 0p 004 006 TP 6109 11 02 Section 3 Scheduled Maintenance 31 General Maintenance WARNING KS x 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 Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools TP 6109 11 02 Servicing the exhaust system Hot parts can cause severe injury or
68. e The lamp needs an optional prealarm sender kit to function Prealarm low oil pressure lamp Lamp illuminates when the engine oil pressure approaches shutdown range The lamp needs an optional prealarm sender kit to function System ready lamp Lamp illuminates when the generator set master switch is in AUTO position and the system senses no faults Emergency stop switch 10 Section 2 Operation Switch if activated instantly shuts down the generator set in emergency situations Use the emergency stop switch for emergency shutdowns only Use the generator set master switch for normal shutdowns 2 6 2 Fuses and Terminal Strips The following table describes the controller circuit board fuses and controller terminal strips Name Description 3 amp remote annunciator fuse Fuse protects the remote annunciator circuit A V alarm and isolated alarm kit if equipped 3 amp controller fuse Fuse protects the controller circuit board speed sensor and lamp circuit board 15 amp engine and accessories fuse Fuse protects the engine starting circuitry and accessories Controller TB1 terminal strip Terminal strip provides connection points for customer supplied sensing devices and generator set accessories such as the emergency stop switch remote start stop switch audio visual alarms etc to the controller Figure 2 3 shows the location of the TB1 terminal strip on the contro
69. e each week for one hour with an operator present The operator should perform all of the prestart checks before starting the exercise procedure Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks x 0p 001 005 EMERGENCY STOP 16 Fuses inside controller Frequency meter AC voltmeter Controller TB1 and TB2 terminal strips on circuit board AC ammeter Scale lamps upper lower Selector switch Annunciator panel lamps Alarm silence switch OANDAARWND Figure 2 2 Decision Maker 8 Section 2 Operation 2 6 Decision Maker 3 16 Light Microprocessor Controller Operation The Decision Maker 3 16 light microprocessor controller has a prime power mode of operation See Section 2 6 6 for prime power mode operation Figure 2 2 identifies the relay controller s indicators and controls and their functions OD Q LOW WATER TEMPERATURE Oow Fue ADV 5849 P1 Lamp test Generator set master switch Alarm horn DC voltmeter Emergency stop switch if equipped Water temperature gauge Voltage adjustment Oil pressure gauge Hourmeter 3 16 Light Microprocessor Controller TP 6109 11 02 2 6 1 The following table describes the controls and indicators Controls
70. e hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Electrical Shock A WARNING Hazardous voltage Moving rotor 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 Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment 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 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 break
71. ealarm as the microprocessor controller plus the following lamps Line Power lamp illuminates to indicate that the commercial utility is the power source Generator Power lamp illuminates to indicate that the generator set is the power source PREALARM HIGH ENGINE 7 TEMPERATURE 7 HIGH ENGINE BATTERY UNE TEMPERATURE CHARGER FAULT POWER PREALARM W OIL LOW OIL PRESSURE y LOW BATTERY GENERATOR PRESSURE VOLTAGE _ POWER 7 LOW WATER 7 EMERGENCY AUXILARY SYSTEM 7 TEMPERATURE STOP FAULT _ READY GENERATOR Low Fuel OVERCRANK NY SWITCH 7 NOT IN AUTO SILENCE NORMAL ALARM TEST a FBA 1_10 AMP 14 Relay Dry Contact Box 293983 Figure 1 3 Remote Annunciator with 14 Relay Dry Contact Box 1 5 Safeguard Breaker The safeguard breaker senses output current on each generator phase and shuts off the AC voltage regulator if a sustained overload or short circuit occurs It is nota line circuit breaker and does not disconnect the generator set from the load See Figure 1 4 TP 6109 11 02 Figure 1 4 Safeguard Breaker 1 6 Line Circuit Breaker The line circuit breaker interrupts generator outp
72. em 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 TP 6109 11 02 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 explosion USCG Regulation 33CFR183 requires that all electrical devices ship to shore transfer switch remote start panel etc must be ignition protected when used in a gasoline and gaseous fueled environment The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous fueled environment such as an engine room or near fuel tanks Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can caus
73. emote transfer switch or remote start stop switch x 0p 002 006 TP 6109 11 02 2 8 Standard Decision Maker 1 Controller Operation For identification of the standard basic controller s indicators and controls and their functions refer to Figure 2 5 VOLTAGE ADJUST Hourmeter Voltage adjustment 10 amp controller fuse Fault lamp Generator set master switch Figure 2 5 Decision Maker 1 Controller x 0p 004 001 2 8 1 Controls and Indicators Thefollowing table describes the controls and indicators located on the controller Name Description Fault lamp Lamp illuminates during engine shutdown if the engine shuts down because of one of the following faults high engine temperature low water level low oil pressure overcrank or overspeed See Section 2 8 4 Fault Shutdowns for additional shutdown information Generator set master Switch functions as the controller switch reset and generator operation switch Hourmeter Hourmeter records the generator set total operating hours for reference in maintenance scheduling Voltage adjust potentiometer Potentiometer fine tunes 5 generator output voltage 10 amp controller Fuse protects the controller fuse circuitry from short circuits and overloads x 0p 004 002 TP 6109 11 02 2 8 2 Starting the Generator Set The following procedures describe starting the generator se
74. engine operation manual 3 Run the generator set for 30 minutes to redistribute added coolant x sm 002 003 24 Section Scheduled Maintenance 3 5 3 Fuel System Prepare the fuel system for storage as follows Diesel Fueled Engines 1 Fill the fuel tank with 2 diesel fuel 2 Condition the fuel system with compatible additives to control microbial growth 3 Change the fuel filter separator and bleed the fuel system See the service manual 3 5 4 Exterior Prepare the exterior for storage as follows 1 Clean the exterior surface of the generator set 2 Seal all engine openings except for the air intake with nonabsorbent adhesive tape 3 To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake 4 Mask electrical connections 5 Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion x sm 002 006a 3 5 5 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the battery ies negative lead first 3 Clean the battery Refer to the battery manufacturer s instructions for the battery cleaning procedure 4 Place the battery in a cool dry location 5 Connect the battery to a float equalize battery charger or charge it monthly with a trickle battery charger Refer to the battery charger manuf
75. er 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 Safety Precautions and Instructions Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is present at the voltage regulator heat sink To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator PowerBoost PowerBoost III and PowerBoost V voltage regulator models only Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building marina electrical system only through an approved device and after the building marina main switch is opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a ship to shore transfer switch to prevent interconnection of the generator set power and shore power Testing live electrical circuits Hazardous voltage or current can
76. erator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop Switch or engine start command from a remote computer Battery A 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 Seekimmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to
77. es not function during the first 5 seconds after startup Shutdown occurs 5 seconds after the fault The low oil pressure shutdown does not function during the first 5 seconds after startup Low oil pressure Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Shutdown occurs after 30 seconds of continuous cranking Shutdown occurs after 30 seconds if the engine or starter does not turn locked rotor Overcrank Shutdown occurs immediately when the governed frequency on the 50 and 60 Hz models exceeds 70 Hz X 0p 002 005 2 7 5 Controller Resetting Procedure Following Fault Shutdown Use the following procedure to restart the generator set after a fault shutdown 1 Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch See the Safety Precautions at the beginning of this section before proceeding 2 Correct the cause of the fault shutdown See the Safety Precautions at the beginning of this section before proceeding 3 Startthe generator set by moving the generator set master switch to RESET OFF and then to RUN 4 Verify that the cause of the shutdown has been corrected by test operating the generator set 5 Reconnect the generator set to the load using the line circuit breaker or automatic transfer switch 6 Move the generator set master switch to the AUTO position for startup by r
78. ions Sheet 6 of 7 48 Section 5 Wiring Diagrams TP 6109 11 02 01 18 19 1 180 59 181 0 18 29 BOX 8 181 1 181 08 93 181 09 69 18 12 11 10 9 8 7 6 5 4 3 2 13 14 15 16 17 18 19 20 21 22 23 24 A 181 180 69 180 92 61 181 8 14P 40A ia1 z 181 ver 24 CONTROLLER BOARD ENGINE HARNESS JUNCTION BOX 1z 8181 02 88 se 22 881 81 9181 29 DRY CONTACT BOARD TB2B 9181 19 NEGATIVE ENGINE CONNECTION CUT AND CONNECTION AND N LEAD TO BATTERY TERMINATE LEADS AS REQUIRED NOTE CUSTOMER CONNECTION USING HARNESS SUPPLIED HARD WIRE P LEAD TO BATTERY POSITIVE ENGINE 8 0 8 1 er 21 8180 tv 2 2 59 91 8181 08 Kio 6 718 09 2012122123124 25 26 27 28
79. ircuit labels measures amperage on the lead shown in the upper label and measures voltage between the two leads shown in the lower label The AC ammeter and voltmeter function only with the switch in the ON position Hourmeter TP 6109 11 02 Hourmeter records the generator set total operating hours for reference in maintenance scheduling Voltage adjustment potentiometer Potentiometer fine tunes 5 the generator set output voltage Fine adjustment 5 of generator output voltage level Section 2 Operation 9 Name Description Auxiliary prealarm lamp Lamp illuminates when customer provided sensing devices activate the pump Emergency stop lamp Lamp illuminates and the generator set shuts down when the operator energizes the optional emergency stop switch The lamp needs the optional emergency stop switch to function Generator switch not in auto lamp Lamp illuminates when the generator set master switch is in the RUN or OFF RESET position Low fuel lamp Lamp illuminates when the fuel level in the tank approaches empty The lamp needs a low fuel sensor in the fuel tank to function High water temperature lamp Lamp illuminates when the water temperature approaches shutdown range The lamp needs an optional prealarm sender kit to function Prealarm high engine temperature lamp Lamp illuminates when the engine coolant temperature approaches shutdown rang
80. 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 is 1 in the craft 2 functional and 3 energized whenever the generator set operates x 0p 001 002 Section 3 Scheduled Maintenance 23 3 5 Storage Procedure Perform the following storage procedure before taking a generator set out of service for three months or longer Follow the engine manufacturer s recommendations if available for fuel system internal engine component storage x sm 002 001 3 5 1 Lubricating System Prepare the engine lubricating system for storage as follows 1 Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature 2 Stop the generator set 3 With the engine still warm drain the oil from the crankcase 4 Remove and replace the oil filter 5 Refill the crankcase with oil suited to the climate 6 Run the generator set for two minutes to distribute the clean oil 7 Stop the generator set 8 Check the oil level and adjust if needed x sm 002 002 3 5 2 Cooling System Prepare the cooling system for storage as follows 1 Check the coolant freeze protection using a coolant tester 2 Add or replace coolant as necessary to ensure adequate freezing protection Use the guidelines included in the
81. lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats and buildings Avoid overloading the craft TP 6109 11 02 Fuel System WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Installing the fuel syst
82. ller circuit board Refer to the wiring diagrams for information on connecting accessories to the TB1 terminal strip Controller TB2 terminal strip Terminal strip provides connection points for crank mode selection cyclic or continuous and remote start stop switch inputs of operation Figure 2 8 shows the location of the TB2 terminal strip on the controller circuit board Refer to the wiring diagrams for connection information eels 1 TB1 terminal strip 2 TB2 terminal strip 3 Fuses A 336415 A Figure 2 3 TB1 and TB2 Terminal Strips on Decision Maker 3 Controller Circuit Board TP 6109 11 02 2 6 3 Auxiliary Fault Lamp Conditions The following descriptions define the possible auxiliary fault lamp conditions Flashing Lamp Conditions No AC Output The auxiliary lamp flashes immediately if the controller senses no AC output while the generator set runs except during the first 10 seconds after startup The flashing stops and the light goes out when the controller senses AC output The controller requires no manual reset Low Battery Voltage The auxiliary lamp flashes if the ba
83. n and Replacement Procedure The gear driven seawater pump is located on the service side of the generator set Check and change the seawater pump impeller at the interval specified in the service schedule Follow the instructions included with the impeller kit If the instructions are not included with the kit use the following procedure Impeller Inspection and Replacement Procedure 1 Close the seacock 2 Remove the seawater pump coverplate See Figure 3 2 a E 3 4 5 Seawater pump Coverplate Gasket Impeller Bearing 6 Housing 7 Pulley 8 Drive shaft 9 Washer 10 Nut Figure 3 2 Seawater Pump Typical 3 Remove the impeller 4 Inspect the impeller for damaged cracked broken missing or flattened vanes The impeller vanes should be straight and flexible See Figure 3 3 Replace the impeller if it is damaged 22 Section Scheduled Maintenance 1 Flattened vane 2 Crack 3 Broken vane Figure 3 3 Worn Impeller 5 Lubricate the impeller with soapy water before installation 6 Install the impeller Note During installation push and rotate the impeller in the same direction as the engine rotation until it is thoroughly seated in the impeller housing 7 Inspect the coverplate and gasket for corrosion and or damage Replace components as necessary 8 Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing 9
84. nated 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 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 g ga gal gen genset 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
85. ndicator Air damper AD indicator if equipped standard on all 200 2000 kW Detroit Diesel powered models System ready indicator Battery charger fault connect battery charger alarm contact to TB1 61 to activate fault lamp active low if used Low battery volts connect battery charger alarm contact to TB1 62 to activate fault lamp active low if used Low fuel LF fault connect fuel level sensor to TB1 63 to activate fault lamp active low if used 70C Generator in cool down mode signal 70R Generator in running mode signal 80 Not in auto indicator Connect jumper across terminals 1 and 1A if emergency stop switch is not used Use a remote annunciator and or A V alarm kit as an indicator with a dry contact kit connected to controller terminal strip TB1 Note Not all terminals are used for all generator sets see appropriate wiring diagrams for specific generator set model Figure 5 20 Controller TB1 Terminal Strip Decision Maker 3 Controller TP 6109 11 02 Terminal Purpose Prime power operation Prime power operation Remote start ground connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Remote start connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Crank mode selection open cyclic crank ground continuous crank connect TB2 9 to T
86. nected to auxiliary immediate shutdown ports P1 17 and P1 18 activate them x 0p 005 004 Section 2 Operation 11 2 6 4 Starting the Generator Set The following procedures describe starting the generator set Local Starting Nonautomatic Move the generator set master switch to the RUN position to start the generator set at the controller Automatic Auto Starting Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or remote start stop switch connected to controller terminals TB1 3 and TB1 4 Note The alarm horn sounds whenever the generator set master switch is not in the AUTO position Note The transient start stop function of the Decision Maker 3 controller prevents accidental cranking of the rotating engine When the generator set master switch is momentarily placed in the OFF RESET position then quickly returned to RUN the generator set slows to 249 rpm and then recranks before returning to its rated speed Note The Decision Maker 3 controller s automatic restart function attempts to restart the generator set if the engine speed drops below 390 rpm generator output frequency of 13 Hz Continued decreased engine speed causes an overcrank fault condition Crank Mode Selection The Decision Maker 3 controller cranks continuously for up to 45 seconds or cyclically for up to 75 seconds crank 15 seconds rest 15 seconds crank 15 seconds e
87. nnect the generator to the load via the line circuit breaker or automatic transfer switch 7 Place the generator set master switch in the AUTO position for startup by a remote transfer switch or remote start stop switch Place the A V annunciator alarm switch if equipped in the NORMAL position 8 Place the generator set master switch in the AUTO position before silencing the alarm horn x 0p 005 008 14 Section 2 Operation 2 6 9 Resetting the Emergency Stop Switch Use the following procedure to restart the generator set after an emergency stop switch shutdown Refer to the Controller Resetting Procedure in this section to restart the generator set following a fault shutdown The generator set does not crank until the operator completes the resetting procedure Note The controller auxiliary lamp lights when the generator set master switch is in the RUN or AUTO position during the resetting procedure Procedure to Restart the Generator Set After an Emergency Stop Shutdown 1 Determine the cause of the emergency stop and correct the problem s 2 Reset the controller emergency stop switch by rotating the switch clockwise until the switch springs back to the original position 3 Toggle the generator set master switch to OFF RESET and then to RUN or AUTO to restart the generator set TP 6109 11 02 2 7 Expanded Decision Maker 1 Controller Operation For identification of the expanded controller s indicato
88. ond 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 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 watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6109 11 02 Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed Enter hours to the operating hours on your gene
89. onger Overvoltage optional NOTE Overvoltage can damage sensitive equipment in less than one second Install separate overvoltage protection on on line equipment requiring faster shutdown x 0p 005 007 Section 2 Operation 13 2 6 8 Controller Resetting Procedure Following Fault Shutdown Use the following procedure to restart the generator set after a fault shutdown Refer to Resetting the Emergency Stop Switch in this section to reset the generator set after an emergency stop 1 Place the controller alarm horn silence switch in the SILENCE position to activate the A V annunciator alarm horn and lamp if equipped Place the A V annunciator alarm switch in the SILENCE position to stop the alarm horn The A V annunciator lamp stays lit The A V alarm uses one lamp to indicate a fault shutdown the respective fault lamp on the remote annunciator lights to indicate a fault condition 2 Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch 3 Correct the cause of the fault shutdown See the Safety Precautions at the beginning of this section before proceeding 4 Place the generator set master switch in the OFF RESET position and then in the RUN position to start the generator set The A V annunciator alarm horn sounds and the lamp if equipped darkens 5 Test operate the generator set to verify that the cause of the shutdown has been corrected 6 Reco
90. or set master switch Hourmeter x 0p 002 001 Switch functions as the controller reset and generator set operation switch Hourmeter records the generator set total operating hours for reference in maintenance scheduling Oil pressure gauge Gauge displays the engine oil pressure Scale lamps upper lower Lamps indicate which AC voltmeter and or ammeter scales to read Selector switch Switch selects the generator set output circuits to measure When switched to a position with two circuit labels measure amperage on the lead shown in the upper label and measure voltage between the two leads shown in the lower label The AC ammeter and voltmeter function only with the switch in the ON position Voltage adjustment potentiometer Potentiometer fine tunes 5 the generator set output voltage Water temperature gauge Gauge displays the engine coolant temperature 10 amp controller fuse Fuse protects the controller circuitry from short circuits and overloads x 0p 002 002 Section 2 Operation 15 2 7 2 Starting the Generator Set The following procedures describe starting the generator set Local Starting Move the generator set to the RUN position to immediately start the generator set Auto Automatic Starting Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or the remote start stop switch connected
91. r belt Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and exhaust outlet for cracks leaks and corrosion 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 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 s is 1 in the craft 2 functional and 3 energized whenever the generator set operates Note Never operate the generator set without a functioning carbon monoxide detector TP 6109 11 02 Section 2 Operation Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Lamp Test Press the lamp test button if equipped to verify that all controller LEDs illuminate Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean
92. ram 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 V Notes VI Safety Precautions and Instructions TP 6109 11 02 This manual provides operation instructions for 40 50 65 80 99 125 150EOZ and 33 40 55 70 80 100 125EFOZ model generator sets equipped with the following controllers e Decision Maker 3 16 Light e Decision Maker 1 Expanded e Decision Maker 1 Standard x in 001 001 This manual may be used for models not listed on the front cover Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever For professional advice generator 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 KohlerPowerSystems com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Africa Europe
93. rator set and the dates nearest quarter hour OPERATING HOURS SERVICE RECORD DATE TOTAL SERVICE RUN HOURS DATE SERVICE TP 6109 11 02 Appendix A 3 TP 6109 11 02b 2000 2001 and 2002 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
94. rected The system automatically resets when the problem is corrected or the generator set cools if high engine temperature was the fault Name Description High engine Shutdown occurs 5 seconds after temperature the fault The high engine temperature shutdown does not function during the first 5 seconds after startup NOTE The high temperature shutdown functions only when the coolant level is in the operating range Shutdown occurs 5 seconds after the fault The high exhaust temperature shutdown does not function during the first 5 seconds after startup High exhaust temperature Shutdown occurs 5 seconds after fault The low coolant level shutdown does not function during the first 5 seconds after startup Low coolant level water cooled engines only Shutdown occurs 5 seconds after the fault The low oil pressure shutdown does not function during the first 5 seconds after startup Low oil pressure NOTE The low oil pressure shutdown does not protect against low oil level Check the engine oil level Shutdown occurs after 45 seconds of continuous cranking or 75 seconds of cyclic cranking crank 15 seconds rest 15 seconds crank 15 seconds etc Overcrank Shutdown occurs immediately when the governed frequency on 50 and 60 Hz models exceeds 70 Hz The generator set shuts down and the auxiliary lamp lights when voltage is 15 or more over the nominal voltage for 2 seconds or l
95. rs and controls and their functions refer to Figure 2 4 HERTZ Frequency meter AC voltmeter AC ammeter Scale lamps upper lower Selector switch Hourmeter Generator set master switch Figure 2 4 Expanded Decision Maker 1 Controller 271 Controls and Indicators The following table describes the controls and indicators located on the controller Name Description AC voltmeter Meter displays the AC output voltage Use the selector switch to choose the output lead circuits AC ammeter Meter displays the AC output amperage Use the selector switch to choose the phase currents DC voltmeter Meter displays the voltage of the starting 125 Fault lamp Lamp illuminates during engine shutdown if the engine shuts down because of one of the following faults high engine temperature low water level low oil pressure overcrank or overspeed See Section 2 7 4 Fault Shutdowns for additional shutdown information Frequency meter Meter displays the frequency Hz of the generator set output TP 6109 11 02 3 USE UPPER METER SCALES OFF L1 AMPS L1 L2 VOLTS L2 AMPS 2 13 VOLTS 13 AMPS 1 13 VOLTS 7 USE LOWER METER SCALES OFF AUTO VOLTAGE RUN 8 Voltage adjustment potentiometer Fault lamp 10 amp controller fuse DC voltmeter Water temperature gauge Oil pressure gauge Generat
96. s 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 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 sec
97. s 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 6109 11 02 CG CID CL cm CMOS cogen Com conn cont CPVC crit CRT CSA CT 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 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 chlori
98. se 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 fire prevention procedures Exhaust System WARNING Carbon monoxide Can cause 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 poisoning symptoms include but are not limited to the following 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 medical attention if the condition of affected persons does notimprove 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 Sulf
99. system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Moving Parts WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place 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 blindness Wear protective goggles and clothing when using power tools hand tools or compressed air Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator setengine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen 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
100. t Local Starting Move the generator set master switch to the RUN position to immediately start the generator set Automatic Auto Starting Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or the remote start stop switch connected to controller terminals TB1 3 and TB1 4 Note The controller provides up to 30 seconds of continuous cranking before the overcrank shutdown occurs 2 8 3 Stopping the Generator Set The following procedure describe how to stop the generator set Normal Stopping 1 Cooldown Run the generator set at no load for 5 minutes to ensure adequate engine cooldown 2 Stopping Move the generator set master switch to the OFF RESET position The engine stops x 0p 004 004 Section 2 Operation 17 2 8 4 Fault Shutdowns The generator set shuts down automatically under the following fault conditions and cannot be restarted until the fault condition is corrected The system automatically resets when the problem is corrected or the generator set cools if high engine temperature was the fault Fault Description High engine Shutdown occurs 5 seconds after temperature the fault The high engine temperature shutdown does not function during the first 5 seconds after startup NOTE The high temperature shutdown functions only when the coolant level is in the operating range High exhaust Shutdown occurs 5 seconds after temperature the
101. t command from a remote computer TP 6109 11 02 WARNING Hazardous voltage Moving rotor 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 Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Section 5 Wiring Diagrams 31 ASN LON HOLIMS 13037110 HOLIMS 18 31 1 1000 92 SQv31 SUNOS 2 ASN LON SLINN 9NION3S 53 4 9 AWIL INYIOOO N3HM 9 8 1 5 310N aasn 10N 590 assn Lon 10 810 0v 9 AQv 336 OLLWWSHOS
102. tc before overcrank shutdown Select the crank mode cyclic or continuous on the controller circuit board terminal strip For cyclic cranking leave circuit board terminal TB2 9 open For continuous cranking attach a jumper between circuit board terminal TB2 9A ground and terminal TB2 9 12 Section 2 Operation 2 6 5 Stopping the Generator Set The following procedures describe stopping the generator set Normal Stopping 1 Cooldown Run the generator set at no load for 5 minutes to ensure adequate engine cooldown 2 Stopping Move the generator set master switch to the OFF RESET position The engine stops Note The generator set continues running during a 5 minute cooldown cycle if a remote switch or automatic transfer switch signals the engine to stop Emergency Stopping Move the generator set master switch to the OFF RESET position or activate the remote emergency stop if equipped for immediate shutdown The controller AUXILIARY lamp lights and the generator set shuts down on activation of the emergency stop switch The remote annunciator and or A V alarms if equipped signal an emergency stop TP 6109 11 02 2 6 6 Prime Power Mode Operation The Decision Maker 3 controller operates in either the normal mode or the prime power mode In prime power mode the controller draws less current minimizing the battery drain Consider using the prime power mode for installations that do not have a battery charger
103. tial 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 A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6109 11 02 Accidental Starting WARNING Pa Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator 561 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 gen
104. tops and overcrank lamp lights after 15 seconds if the starter or engine does not turn locked rotor Overcrank lamp flashes if speed sensor signal is absent longer than one second NOTE The generator set controller s automatic restart function attempts to restart the generator set if the engine speed drops below 13 Hz 390 rpm Continued decreased engine speed causes an overcrank condition Overspeed lamp Lamp illuminates if the generator set shuts down because governed frequency on 50 and 60 Hz models exceeds 70 Hz Water temperature gauge Gauge displays the engine coolant temperature Auxiliary fault lamp Lamp flashes or lights when the controller detects a fault See the lamp conditions section following Oil pressure gauge Gauge displays the engine oil pressure Frequency meter Meter displays the frequency Hz of the generator set output voltage Scale lamps upper lower Lamps indicate which AC voltmeter and or ammeter scales to read Generator set master switch Switch functions as the controller reset and generator set operation switch High engine temperature lamp Lamp illuminates if the generator set shuts down because of high engine temperature Shutdown occurs 5 seconds after the engine reaches temperature shutdown range Selector switch Switch selects which generator set output circuits to measure When switched to a position with two c
105. ttery power was reconnected or was low and then restored while the generator set master switch was in the RUN or AUTO position A possible cause is a temporary low battery condition when the battery is weak or undersized for the application To clear the low battery voltage condition place the generator set master switch in the OFF RESET position Continuous On Lamp Conditions Emergency Stop Switch Energized Upon activation of the emergency stop switch if equipped the auxiliary lamp lights and the generator set shuts down immediately TP 6109 11 02 Emergency Stop Switch Reset Resetting the optional emergency stop switch while the generator set master switch is in the AUTO or RUN position causes the auxiliary lamp to light Place the generator set master switch in the OFF RESET position to clear the auxiliary lamp ON condition Note Auxiliary Delay Shutdown The auxiliary lamp lights and the engine shuts down 5 seconds after the high oil temperature P1 13 or auxiliary delay shutdown P1 15 fault if equipped occurs Auxiliary Delay Shutdown is inhibited during the first 30 seconds after crank disconnect Note Overvoltage Shutdown If a generator set is equipped with this kit the auxiliary lamp lights and the engine shuts down immediately when an overvoltage condition occurs Note Auxiliary Immediate Shutdown The auxiliary lamp lights and the engine shuts down immediately when any customer supplied sensing devices con
106. ur 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 Consultthe boat builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times Operating the generator set Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Use the following precautions when installing andoperating the generator set Do not installthe exhaustoutlet where exhaust can be drawn in through portholes vents or air conditioners 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 f operating the generator set dockside moor the craft so that the exhaust discharges on the
107. ure cap with athick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released andthe engine has cooled Checkthe coolant level atthe tank if the generator set has a coolant recovery tank 3 3 1 Siphon Break A siphon break prevents seawater entry into the generator set s engine when the engine exhaust manifold outlet is less than 230 mm 9 in above the waterline of a fully loaded docked or stationary craft The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater Use the following procedure to inspect the siphon break at the intervals listed in the service schedule TP 6109 11 02 Siphon Break Inspection 1 Stop the generator set 2 Remove the retaining cap and remove the reed valve for inspection See Figure 3 1 3 Use a mild detergent to remove residue and oxidation from the reed valve 4 Clear blockage from the reed valve opening Replace the siphon break if the reed valve 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 See Figure 3 1 item 3 7 Install and only finger tighten the retaining cap Do not overtighten it 1 Mounting base 2 Retaining cap 3 Reed valve Figure 3 1 Siphon Break m sm 003 007 Section 3 Scheduled Maintenance 21 3 3 2 Impeller Inspectio
108. ut if an overload or short circuit occurs Use the line circuit breaker to manually disconnect the generator set from the load during generator set service See Figure 1 5 TP 5352 1 Figure 1 5 Line Circuit Breaker 1 7 Run Relay Kit The run relay kit includes three sets of contacts that energize only during generator set operation The run relay kit can control air intake louvers radiator louvers alarms and other signaling devices See Figure 1 6 Figure 1 6 Run Relay Kit Section 1 Specifications 5 Notes 6 Section 1 Specifications TP 6109 11 02 21 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Air Shrouding Check for securely installed and positioned air shrouding Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Drive Belts Check the belt condition and tension of the water pump and battery charging alternato
109. vice Engine Service Perform generator set engine service at the intervals specified by the engine operation manual Generator Set Service Perform generator set service at the intervals specified by the generator set operation manual If the generator set operates under dusty or dirty conditions use dry compressed air to blow dust out of the alternator With the generator set running direct the stream of air in through the cooling slots at the alternator end 3 2 Generator Set Service Schedule Perform Service at Intervals Indicated X Reference Section Routine Maintenance Refer to the following generator set service schedule the engine service schedule and the hourmeter located on the generator set controller to determine when to schedule routine maintenance Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions Service Log Use the Operating Hour Service Log located in the back of this manual to document performed services Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set For example an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months 300 hours or 9 months and so on x sm 004 001 Every Every 200 Hrs 400 Hrs or3 or6 Months Months Every 1000 Hrs or Yearly COOLING SYSTEM Check the seawater outlet and clean

Operation Manual, 40-150EOZ/33-125EFOZ (TP-6109)

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