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TP-6053 - Atlantis Marine Power

1. A 358000A A Start stop switch 2 18 Fuel filter Controller 19 Oil filter Nameplate 20 Oil drain valve and hose Hourmeter 21 Fuel feed pump DC circuit breaker 22 Oil check AC circuit breaker 23 Air cleaner Coolant recovery bottle Pressure cap Fuel inlet connection 24 Low oil pressure safety shutdown switch 25 Wet exhaust manifold Fuel return connection 26 Thermostat High water temperature shutdown switch 27 AC load lead connector Oil fill 28 Remote start connector Seawater pump water inlet 29 High exhaust temperature safety shutdown switch V belts 30 Mixing elbow Heat exchanger 31 Engine starter Coolant drain fresh water 32 Water temperature sender Anticorrosion zinc anode 33 Battery charging alternator OMANDARWN Figure 1 2 Generator Set Service View 8EOZ 6 5EFOZ TP 6053 7 04 Section 1 Specifications 3
2. Start stop switch Controller Nameplate Hourmeter DC circuit breaker AC circuit breaker Air cleaner Coolant overflow bottle Low oil pressure safety shutdown switch Pressure cap Oil fill High water temperature safety shutdown switch V belts Seawater pump water inlet Fuel filter Oil drain valve and hose Oil filter OMANDARWN A 358000A A Fuel feed pump Fuel inlet connection Oil check Coolant drain fresh water Fuel return Wet exhaust manifold Thermostat AC load lead connector Remote start connector High exhaust temperature safety shutdown switch Mixing elbow Anticorrosion zinc anode Engine starter Heat exchanger Coolant drain fresh water Water temperature sender Battery charging alternator Figure 1 3 Generator Set Service View 9 10EOZ and 8 9EFOZ 4 Section 1 Specifications TP 6053 7 04 1 3 Engine Generator Model 5EOZ 4EFOZ 8EOZ 6 5EFOZ 9EOZ 8EFOZ 10EOZ 9EFOZ Engine manufacturer Yanmar Engine model 3TNE68 3TNE74 3TNE78A 3TNE82A Number of cylinders 3 Cylinder block material Cast iron Cylinder head material Cast iron Piston rings 2 compression 1 oil Crankshaft material Stamped forging Connecting rod material Forge
3. Main field rotor Stator windings Rectifier module Ohmmeter Armature Exciter field Figure 7 8 Exciter Armature Ohmmeter Test 5 Check if the exciter armature winding is ground Use a megohmmeter to apply 500 volts DC to either armature lead and the armature frame Ohmmeter i Fram connection Follow the instructions of the megohmmeter s Exciter armature manufacturer when performing this test See _ Exciter field Figure 7 9 A reading of approximately 500 kOhms Figure 7 7 Megohmmeter Connections on the 1 2 megohm and higher indicates that the exciter Exciter Field armature is functional A reading of less than approximately 500 kOhms indicates deterioration of the winding insulation and possible current flow 7 6 Exciter Armature to ground Repair or replace the exciter armature The exciter armature supplies excitation current to the generator main field through the rectifier module There will be low or no generator output if the exciter armature is inoperative Test the exciter armature as described in the following steps Disassemble the generator set prior to performing this test Exciter Armature Test Procedure 1 Disassemble the alternator 2 Disconnect the armature leads from the rectifier module AC terminals 3 With an
4. TP 598654 120 volts AC Variable transformer AC voltmeter Voltage regulator PowerBoost IIE Stator rotor connections for reference only Lead color 120 volt 100 watt lamp Figure 7 4 PowerBoost IIIE Voltage Regulator Test 7 4 2 Voltage Regulator Adjustment Kohler Co sets the voltage regulator and under normal circumstances the regulator requires no further adjustment However if the voltage regulator has been replaced or tampered with or if voltage frequency reconnection has been done readjust the voltage regulator according to the following procedure The following paragraphs describe the voltage regulator components Voltage Adjustment Pot adjusts the generator output within the range of 100 130 volts Stabilizer Pot fine tunes regulator circuitry to reduce light flicker Volts Hz Pot adjustment determines the engine speed Hz at which the generator output voltage begins to drop Note The volts Hz adjustment does not apply to the following models 4 6 5 8 9EFOZ and 5 8 9 10EOZ On these models turn the volts Hz adjustment pot full counterclockwise to stop and seal No further volts Hz adjustments are required Section 7 Generator Troubleshooting 35 Voltage Regulator Adjustment Procedure 1 Stop the generator set 2 Turn the remote rheostat if equipped to the midpoint Turn the voltage and stability pots fully counterclockwise Connectthe voltmeter
5. 71 e n 71 x20 N CAR 70 E EN foo 70 k25 N M25 p HN P4 1 A P4 20 HER N L70 lt lt FP P9 2 __ P9 1 43 STOP PREHEAT i ie A START 9 47 43 A P3 6 STOP PREHEAT lt REMOTE START P3 5 47 VOLTAGE REGULATOR P4 17 q P4 21 v4 66 P8 2 P8 6 P6 1 amp Z EXCITER PT d FIELD j 4 4 l CAAA CAAA MAIN FIELD QADDADDDAL RRO RRR B1 B2 1 2 P8 5 B2 a B1 P8 4 54 Section 10 Voltage Reconnection and Wiring Diagrams LEGEND AH AIR HEATER BCA BATTERY CHARGING ALTERNATOR BV BATTERY VOLTMETER CB CIRCUIT BREAKER CTS COOLANT TEMPERATURE SENDER ETS EXHAUST TEMPERATURE SWITCH FP FUEL PUMP FS FUEL SOLENOID GND GROUND GP GLOW PLUGS GPR GLOW PLUG RELAY HCT HIGH COOLANT TEMPERATURE SWITCH HR HOUR METER K RELAY LOP LOW OIL PRESSURE SWITCH OPS OIL PRESSURE SENDER P PLUG SM STARTER MOTOR SS STARTER SOLENOID 229294 N TP 6053 7 04 10 4 Wiring Diagram Point to Point REMOTE PANEL BACK VIEW OF PANEL 2 AND 4 GAUGE REMOTE PANEL NOTE CONNECTOR SHOWN FROM PIN INSERTION END VIOLET HOUR VIOLET YEURED ia violet 5 VIOLEF VIOLEF STOP PREHEAT VIOLET BLK
6. Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Check the belt tensions at the interval specified in the service schedule If the tensions are not within specifications adjust as necessary using the following procedure Belt Tensioning Procedure 1 Stop the generator set 2 Disconnect the generator set engine starting battery negative lead first 3 Remove the belt guard 4 Check the belt tension at the midpoint of the longest span of the belt by pressing the belt with your finger and measuring the resulting deflection See Figure 5 6 and Figure 5 7 If the belt is not within specifications go to step 5 If the belt is within specifications go to step 9 5 Loosen the adjusting arm pivot screw alternator pivot screw and alternator adjusting screw 6 While prying the alternator outward tighten the alternator screw 22 Section 5 Cooling System 7 Tighten the adjusting arm pivot screw and alternator pivot screw 8 Recheck and adjust the belt tension as necessary 9 Replace the belt guard 10 Reconnect the generator set engine starting battery negative lead last Belt Type Deflection mm in Force kgf N New 7 9 0 3 0 4 Used 10 15 0 4 0 6
7. GREY BLK CONTROLLER RELAY BOARD P2 e 47 REMOTE HALON SYSTEM CUSTOMER SUPPLIED A E O HALON TERMINAL UNIT crut te 1 HALON 16 GRNWHT PRESSURE SWITCH 46 BLK DARE JOSE CONTROL STATION GROUND BUSS 37 43 L VOLTAGE REGULATOR PBIIIE ENGINE T CTS OPTIONAL INSULATED END wE E STNE6S 3TNETBA P4 GENERATOR 3 J8 OLOR CO oie O FE oae DAA QOY 66 21 u o SEE GENERATOR CONNECTIONS RESISTOR ASSEMBLY TP 6053 7 04 OPS OPTIONAL KW re L 16 L ops OPTIONAL KWa 5 9 KW SEA RAY Fp EN Fi F2 ANEN ARMATURE RECTIFIER FOR VOLT RECONNECTABLE CONFIGURATIONS SEE ADV 5857 d EA 4 LEAD STATOR LEGEND AH AIR HEATER BCA BATTERY CHARGING ALTERNATOR CB CIRCUIT BREAKER CTS COOLANT TEMPERATURE SENDER ETS EXHAUST TEMPERATURE SWITCH FP FUEL PUMP FS FUE
8. 4 Refer to Figure 2 which depicts the preceding hardware configuration possibilities i Cap screw Entry hole types Standard nut and SAE washer 4 Whiz nut or spiralock up to 1 2 in dia hardware Weld nuts above 1 2 in dia hardware Exit hole types Figure 2 Acceptable Hardware Combinations Appendix A 3 Appendix C General Torque Specifications Use the following torque specifications when service literature instructions give no specific torque values The charts list values for new plated zinc phosphate or oiled threads Increase values by 15 for nonplated threads All torque values are 0 10 American Standard Fasteners Torque Specifications Torque Assembled into Cast Iron or Steel Assembled into Aluminum Measurement Grade 2 1 8 Grade 5 Grade 8 Grade 2 or 5 1 8 2 9 2 9 2 9 6 8 6 8 8 1 8 1 13 6 13 6 14 9 14 9 24 0 24 0 27 0 39 0 43 0 60 0 66 0 81 0 91 0 113 0 128 0 199 0 147 222 0 164 259 0 191 283 0 209 Metric Fasteners Torque Specifications Measured in Nm ft Ib Assembled into Cast Iron or Steel Size mm M6 x 1 00 Grade 5 8 5 6 Grade 8 8 Grade 10 9 Assembled into Aluminum Grade 5 8 or 8 8 M8 x 1 25 13 6 M8 x 1 00 21 0 M10 x 1 50 27 0 M10 x 1 25 39 0 M12
9. Note When taking an ohmmeter reading using lead 55 make the connection prior to the in line fuse 5 Check the stator for a short to ground using a megohmmeter Apply 500 volts DC to any stator lead from each winding and the stator frame Follow the instructions of the megohmmeter manufacturer when performing this test Repeat the test on the other leads until all the stator windings have been tested A reading of approximately 500 kOhms 1 2 megohm and bie field a 2 e s P ator windings higher indicates the stator is good A reading of 3 Rectifier module 7 Exciter field less than approximately 500 kOhms indicates 4 Shaft connection deterioration of the winding insulation and possible current flow to ground Repair or replace the stator Figure 7 15 Megohmmeter Connections on Stator 40 Section 7 Generator Troubleshooting TP 6053 7 04 Section 8 Component Troubleshooting 8 1 General See Figure 8 1 through Figure 8 3 for component testing With the generator set battery connected check the generator wiring harness and the components listed in the following tables Check each component using a multimeter to verify that the switches function and that voltage is present at each component 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 Compone
10. Figure 2 1 Engine Oil Selection Section 2 Scheduled Maintenance 7 Electric Oil Drain Oil Fill Procedure 1 Connect the pump to the end of the oil drain hose 2 Place the pump outlet hose into a container Remove the oil fill cap s One is located near the top of the engine on the valve cover and one is located near the governor 3 Activate the pump until all of the oil is removed Allow ample time for all of the oil to drain 4 Turn the valve at the base of the oil drain hose to the closed position 5 Replace the engine oil filter 6 Fill the engine crankcase to the specified level with oil The figures in Section 1 show typical oil fill locations See Figure 2 1 for oil selection and Figure 2 2 for oil capacities 7 Start the generator set and check for oil leaks 8 Stop the generator set Check the oil level Add oil as necessary to bring the level up to the Max mark on the dipstick ee o O 5EOZ and 4EFOZ 3 0 3 2 8EOZ and 6 5EFOZ 2 3 2 4 5 2 5 5 5 2 5 5 9EOZ and 8EFOZ 10EOZ and 9EFOZ Figure 2 2 Oil Capacities 8 Section 2 Scheduled Maintenance 2 3 Battery Consult the battery manufacturer s regarding battery care and maintenance instructions 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
11. Figure 5 6 Belt Specifications 10 98 10 98 Adjusting arm pivot screw Battery charging alternator pulley Adjusting screw Alternator pivot screw Check alternator belt tension here Crankshaft pulley Check seawater pump belt tension here Adjusting screw Seawater pump pulley Pivot screw 1 2 3 4 5 6 7 8 9 0 Figure 5 7 Belt Tension Typical TP 6053 7 04 5 9 Siphon Break A siphon break prevents seawater entry into the engine when the engine exhaust manifold outlet is less than 23 cm 9 in above waterline Check the siphon break at the interval listed in the service schedule Use the following procedure and Figure 5 8 to ensure correct functioning of the siphon break Siphon Break Inspection Procedure 1 Stop the generator set 2 Remove the retaining cap and the reed valve for inspection See Figure 5 8 3 Use a light detergent to clean the reed valve 4 Check that the reed valve opening is clear 5 Replace the siphon break if it is cracked or if the reed valve material has hardened or deteriorated 6 Install the reed valve downward into the mounting base 7 Install the retaining cap and finger tighten only Do not overtighten Note Consult the installation manual for a complete explanation of the dimensions and other installation considerations Waterline Mounting holes Retaining cap Reed valve assembly Silencer vertica
12. As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See Appendix C General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance 3 1 1 2 of bolt diameter 2 Min 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths TP 6053 7 04 Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nut and SAE washer Hardware 1 2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut See Figure 2 3 Follow these SAE washer rules after determining exit hole type a Always use a washer between hardware and a slot b Always use a washer under a nut see 2 above for exception c Use a washer under a bolt when the female thread is fixed weld nut
13. Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Consult the boat builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times Operating the generator set Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Use the following precautions when installing and operating the generator set Donot install the exhaust outlet where exhaust can be drawn in through portholes vents or air conditioners If the generator set exhaust discharge outlet is near the waterline water could enter the exhaust discharge outlet and close or restrict the flow of exhaust Never operate the generator set without a functioning carbon monoxide detector Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed awa
14. No Yes l Replace the S relay Replace the starter motor TP 6053 7 04 Does the engine start Go to B next page No Is 12 volts DC No present at the fuel solenoid check wiring y Is the 10 amp fuse okay m No _ Is the K4 relay LED lit Replace the fuse y Do the local and remote Engine fault check the fuel Is the K25 relay functioning start stop switches supply fuel feed pump fuel correctly function correctly injection pump etc Replace the circuit board inoperative K4 relay Replace Replace the inoperative the K25 start stop switch relay y e Check the P1 8 connection e Check the P4 14 connection e Replace the circuit board the K2 relay is inoperative Figure 6 5 Troubleshooting Relay Controller Circuit Board 2 of 4 TP 6053 7 04 Section 6 Controller Troubleshooting 29 Does the engine continue to run after the start switch is released Can the engine be stopped by using the stop switch No No Yy Did the K4 relay LED light Does the K1 relay LED light Go to C next page Does the K5 relay LED No y Yes Generator set checks out
15. Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces lt Seawater lt Coolant Antifreeze 60531099 Heat exchanger Engine seawater pump Seawater strainer Seacock Intake strainer Engine driven water pump Section 5 Cooling System 19 5 2 Water Cooled Exhaust Manifold Each generator set is equipped with a water cooled exhaust manifold Engine coolant circulates through the manifold reducing the amount of heat radiated from the exhaust into the surrounding area The engine thermostat is located in the manifold See Section 1 for the thermostat location See Figure 5 2 and Figure 5 3 for exhaust manifold bolt tightening sequence and torques gE0Z 6 5EFOZ 6 PAN MACON wor ___ 9 10EOZ and 8 9EFOZ Figure 5 2 Water Cooled Exhaust Manifold Bolt Tightening Sequence 5EOZ 4EFOZ 8 Nm 6 ft Ibs 8 9 10EOZ and 6 5 8 9EFOZ 19 Nm 14 ft Ibs Figure 5 3 Exhaust Manifold Bolt Tightening Torques 5 3 Clo
16. and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set TP 6053 7 04 Section 2 Scheduled Maintenance 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 Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Note See the generator set operation manual for the service schedule and other service not included in this manual 2 2 Lubrication System The following paragraphs describe the engine lubrication system Use oil that meets the American Petroleum Institute API classification of CD CC CD or CC Using unsuitable oil or neglecting an oil change may result in damage and a shorter engine life Figure 2 1 shows the recommended Society of Automotive Engineers SAE viscosity designation for given operating temperature ranges Note Failure to observe these standards may cause inadequate lubrication oil pressure and cold starting difficulties SAE Service Grade C 30 20 10 0 10 20 30 40 C F 0 20 40 60 80 Operating Temperature 100 F TP 5856 1
17. 1 Specifications 1 1 2 Service Views OMANDARWN N o1 N EN NINDeNIN a AAA a aan e9 s arar a a TA ERREI wo Start stop switch Hourmeter Controller Nameplate DC circuit breaker AC circuit breaker Air cleaner Fuel solenoid Fuel injectors Fuel return connection High water temperature switch Oil fill V belts Seawater pump water inlet Coolant fresh water drain Heat exchanger Coolant drain fresh water Figure 1 1 Generator Set Service View 5EOZ 4EFOZ 2 Section 1 Specifications J DK 250000 18 Anticorrosion zinc anode 19 Fuel filter 20 Oil filter 21 Oil drain valve and hose 22 Fuel feed pump 23 Oil check 24 Fuel inlet connection 25 Low oil pressure safety shutdown switch 26 Wet exhaust manifold 27 Thermostat 28 AC load lead connector 29 Remote start connector 30 High exhaust temperature safety shutdown switch 31 Mixing elbow 32 Water temperature sender 33 Engine starter 34 Battery charging alternator TP 6053 7 04
18. 8 16 x 1 00 X 6238 4 3 8 16 x 1 25 X 6238 5 3 8 16 x 1 50 X 6238 1 3 8 16 x 1 75 X 6238 6 3 8 16 x 2 00 X 6238 17 3 8 16 x 2 25 X 6238 7 3 8 16 x 2 50 X 6238 8 3 8 16 x 2 75 X 6238 9 3 8 16 x 3 00 X 6238 19 3 8 16 x 3 25 X 6238 12 3 8 16 x 3 50 X 6238 20 3 8 16 x 3 75 X 6238 13 3 8 16 x 4 50 X 6238 18 3 8 16 x 5 50 X 6238 25 3 8 16 x 6 50 A 6 Appendix Part No Dimensions Hex Head Bolts cont X 6238 14 3 8 24 x 75 X 6238 16 3 8 24 x 1 25 X 6238 21 3 8 24 x 4 00 X 6238 22 3 8 24 x 4 50 X 6024 5 7 16 14 x 75 X 6024 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2 13 x 1 25 X 129 19 1 2 13 x 1 50 X 129 20 1 2 13 x 1 75 X 129 21 1 2 13 x 2 00 X 129 22 1 2 13 x 2 25 X 129 23 1 2 13 x 2 50 X 129 24 1 2 13 x 2 75 X 129 25 1 2 13 x 3 00 X 129 27 1 2 13 x 3 50 X 129 29 1 2 13 x 4 00 X 129 30 1 2 13 x 4 50 X 463 9 1 2 13 x 5 50 X 129 44 1 2 13 x 6 00 X 129 51 1 2 20 x 75 X 129 45 1 2 20 x 1 25 X 129 52 1 2 20 x 1 50 X 6021 3 5 8 11 x 1 00 X 6021 4 5 8 11 x 1 25 X 6021 2 5 8 11 x 1 50 X 6021 1 5 8 11 x 1 75 273049 5 8 11 x 2 00 X 6021 5 5 8 11 x 2 25 X 6021 6 5 8 11 x 2 50 X 6021 7 5 8 11 x 2 75 X 6021 12 5 8 11 x 3 75 X 6021 11 5 8 11 x 4 50 X 6021 10 5 8 11 x 6 00 X 6021 9 5 8 18 x 2 50 X 6239 1 3 4 10 x 1 00 X 6239 8 3 4 10 x 1 25 X 6239 2 3 4 10 x 1 50 X 6239 3 3 4 10
19. Inches Or Screw Number Size Internal Dimension Metric Screws Bolts Studs and Nuts M8 1 25 x 20 Lock Washers Length In Millimeters Screws and Bolts 5 8 Distance Between Threads In Millimeters a Internal Dimension Major Thread Diameter In Millimeters TP 6053 7 04 Appendix A 5 Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Dimensions Hex Head Bolts Grade 5 X 465 17 1 4 20 x 38 X 465 6 1 4 20 x 50 X 465 2 1 4 20 x 62 X 465 16 1 4 20 x 75 X 465 18 1 4 20 x 88 X 465 7 1 4 20 x 1 00 X 465 8 1 4 20 x 1 25 X 465 9 1 4 20 x 1 50 X 465 10 1 4 20 x 1 75 X 465 11 1 4 20 x 2 00 X 465 12 1 4 20 x 2 25 X 465 14 1 4 20 x 2 75 X 465 21 1 4 20 x 5 00 X 465 25 1 4 28 x 38 X 465 20 1 4 28 x 1 00 X 125 33 5 16 18 x 50 X 125 23 5 16 18 x 62 X 125 3 5 16 18 x 75 X 125 31 5 16 18 x 88 X 125 5 5 16 18 x 1 00 X 125 24 5 16 18 x 1 25 X 125 34 5 16 18 x 1 50 X 125 25 5 16 18 x 1 75 X 125 26 5 16 18 x 2 00 230578 5 16 18 x 2 25 X 125 29 5 16 18 x 2 50 X 125 27 5 16 18 x 2 75 X 125 28 5 16 18 x 3 00 X 125 22 5 16 18 x 4 50 X 125 32 5 16 18 x 5 00 X 125 35 5 16 18 x 5 50 X 125 36 5 16 18 x 6 00 X 125 40 5 16 18 x 6 50 X 125 43 5 16 24 x 1 75 X 125 44 5 16 24 x 2 50 X 125 30 5 16 24 x 75 X 125 39 5 16 24 x 2 00 X 125 38 5 16 24 x 2 75 X 6238 2 3 8 16 x 62 X 6238 10 3 8 16 x 75 X 6238 3 3 8 16 x 88 X 6238 11 3
20. Note If the hourmeter is not illuminated test it by connecting it to a 12 volt battery Note The hourmeter is polarity sensitive If 12 volts DC is present and the component does not function after the J3 is connected to the controller P3 replace the component s Water temperature gauge Connect the red test lead to P3 4 socket side and black test lead to P3 2 socket side Start the generator set for the test If 0 5 12 volts DC is present and the gauge does not function after the J3 is connected to controller replace the gauge Oil pressure gauge Connect the red test lead to P3 4 socket side and black test lead to P3 3 socket side Start the generator set for the test If 0 5 12 volts DC is present and the gauge does not function after the J3 is connected to the controller replace the gauge Note Check continuity of gauge wiring and extension harness before replacing components Figure 8 6 Remote Start Panels Troubleshooting 44 Section 8 Component Troubleshooting TP 6053 7 04 Section 9 Generator Disassembly Reassembly 9 1 Disassembly Disconnect all the external connections battery cables at the battery negative lead first AC output leads in the controller remote start panel at the controller P3 connector water line at the seawater pump fuel line at the fuel pump filter inlet and exhaust line at the mixing elbow Observe all the safety precautions
21. a faulty voltage regulator it is possible to determine if a running fault exists in the rotor and or stator A generator component that appears functional while static stationary may exhibit a running open or short circuit while dynamic moving Centrifugal forces acting on the windings during rotation or insulation breakdown as temperatures increase can cause short circuits Separate Excitation Procedure 1 Disconnect all the leads from the voltage regulator 2 Disconnect the P10 F1 F2 connector 3 Connect a separate excitation circuit as shown in Figure 7 2 Connect an ammeter and a 10 amp fuse in series with F1 Note and record the ammeter reading 4 The approximate ammeter reading should equal battery voltage divided by the specified exciter resistances cold Disconnect the resistor leads and determine the resistance value using an ohmmeter See Section 1 Specifications for the correct values Example 12 Volts Battery Voltage _ 3 4 amp 3 5 Ohms Exciter Resistance Exciter Current Voltage regulator 10 amp fuse DC ammeter Battery Ground to generator frame Exciter armature Exciter field 10 or 15 ohm resistor P6 connector disconnect P6 connector before separate excitation OMNOARWON gt Figure 7 2 Separate Excitation Connections 34 Section 7 Generat
22. cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner silencer removed Combustible materials A sudden flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the 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 Il 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 these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area w
23. filter s useful life Replace the fuel filter element according to the service schedule Section 1 2 shows the location of the fuel filter There are two types of fuel filtering systems the spin on fuel filter and the fuel filter element Use the applicable procedure below to replace the fuel filter See Figure 4 2 or Figure 4 3 Spin On Fuel Filter Replacement Procedure 1 Place the generator set start stop switch in the STOP position 2 Disconnect the generator set engine starting battery negative lead first 3 Close the fuel supply valve 4 Remove the fuel filter See Figure 4 2 5 Clean the contact surface of the fuel filter adapter 6 Lightly lubricate the gasket surface of the new fuel filter with fresh fuel Thread the filter onto the adapter until the gasket makes contact hand tighten the filter an additional one half turn 7 Open the fuel supply valve 8 Reconnect the generator set engine starting battery negative lead last 9 Bleed the fuel system See Section 4 4 TP 606111 Fuel filter adapter Fuel filter Removal counterclockwise Installation clockwise Figure 4 2 Spin On Fuel Oil Filter Section 4 Fuel System 13 Fuel Filter Element Replacement Procedure 1 Place the generator set start stop switch in the STOP position 2 Disconnect the generator set engine starting battery negative lead first 3 Close the fuel supply valve 4 Remove the retaining ring f
24. lead Note The J4 and P4 leads must be connected to perform this test Controller 10 amp circuit breaker and wiring Place the ohmmeter on the R x 1000 scale Figure 8 2 Engine Generator Component Testing Relay Controller 42 Section 8 Component Troubleshooting If functional zero or very low ohms No reading infinity open circuit or circuit breaker tripped TP 6053 7 04 Ohmmeter Connections Disconnect the P10 and P11 connectors and connect the ohmmeter to P10 1 and P10 2 leads Component Main field rotor Procedure Place the ohmmeter on the Rx 1 scale Results If the resistance readings match those specified in Section 1 Specifications the rotor is functional Low resistance rotor windings shorted High resistance rotor windings open Connect the ohmmeter to the P11 1 and P11 2 leads Note Disconnect P11 and J11 to perform this test B1 B2 stator windings Place the ohmmeter on the Rx 1 scale If the resistance readings match those specified in Section 1 Specifications the B1 B2 windings are functional Low resistance B1 B2 windings shorted High resistance B1 B2 windings open Connect the ohmmeter to the P1 9 and ground P1 ground connection Place the ohmmeter on the Rx 1 scale If functional zero ohms continuity Any other reading indicates a poor ground connection Connect the ohmmeter to the P1 15 and engine block ground Note
25. ohmmeter on the R x 1 scale check the Main field rotor resistance across the exciter armature leads See Stator windings A Rectifier module Figure 7 8 The armature resistance should be hmiheter 0 6 0 8 ohms continuity No continuity indicates Shaftconnectioti an open armature winding Replace the armature Armature Exciter field 4 Perform a megohmmeter test on the exciter armature as described in the next step Consider the exciter armature good if the resistance reading continuity is low and there is no evidence of a shorted winding heat discoloration Figure 7 9 Megohmmeter Connections on Exciter Armature TP 6053 7 04 Section 7 Generator Troubleshooting 37 7 7 Rectifier Module The rectifier module located between the exciter armature and the main field converts the AC from the exciter armature to DC which magnetizes the generator main field Test the rectifier module as described in the following steps Rectifier Module Test Procedure 1 Disconnect the exciter armature and the main field leads from the rectifier module 2 Use an ohmmeter on the R x 100 scale to check the resistance between the rectifier diodes as shown in Figure 7 10 The ohmmeter should show resistance in one direction and upon reversing the ohmmeter leads a high resistance in the other direction Replace the rectifier module if any of the diodes tests differently than described 1 Diode terminal Figure 7 10
26. okay m Yes Is the fuel solenoid functioning correctly Do the local and remote start stop switches function correctly Replace the fuel solenoid light after 5 10 seconds of running time No Replace the circuit Replace the inoperative board the K5 relay start stop switch is inoperative No Did the K4 relay LED light y y Replace the circuit board the K4 relay is inoperative Is the K25 relay functioning correctly Do the local and remote start stop switches function No correctly Replace the circuit board inoperative K1 or K2 relay Yes Replace the inoperative start stop switch y Does the low oil pressure LOP safety shutdown switch check out okay Replace the LOP safety shutdown switch Yes Yes gt Does the engine have proper oil pressure Use a mechanical gauge to verify pressure Do the temperature No the K25 Replace relay Replace the circuit board inoperative K4 relay safety shutdown switches check out okay relay Replace the circuit board inoperative K4 Check the oil level No gt Repair replace oil p
27. or death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment TP 6053 7 04 7 2 General Troubleshooting To determine the cause of no or low AC output refer to the following steps and the troubleshooting flow chart Figure 7 1 General Troubleshooting Procedure 1 Check the condition of the voltage regulator s 8 amp fuse 2 If the fuse is functional separately excite the generator See Section 7 3 The separate excitation test duplicates the role of the voltage regulator by providing excitation current to the rotor Generator has no output Separately excite generator Generator has output i j Test voltage regulator and wiring Generator has no output l Test the exciter circuit and rectifier module i Test rotor Test stator TP 598651 Figure 7 1 General Troubleshooting Section 7 Generator Troubleshooting 33 7 3 Separate Excitation By separately exciting the generator to determine the presence of
28. 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 TP 6053 7 04 Pipe sealant Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Use pipe sealant on all threaded fittings to prevent fuel leakage Use pipe sealant that resists gasoline grease lubrication oil common bilge solvents salt deposits and water Ignition protected equipment Explosive fuel vapors can cause severe injury or death Gasoline vapors can cause an explosion USCG Regulation 33CFR183 requires that all electrical devices ship to shore transfer switch remote start panel etc must be ignition protected when used in a gasoline and gaseous fueled environment The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous fueled environment such as an engine roomor near fuel tanks Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash Hazardous Noise A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged e
29. set load LO Neutral O LO GRD Ground Load 2 gt M Side 1 Pole Circuit Breaker 100 120 Volt 2 Wire 4 3 2 Stator Leads 60 Hz 50 Hz 100 120 Volt 100 120 Volt 100 120 Volt 100 120 Volt LO L1 LO L2 Figure 10 2 100 120 Volt 2 Wire Section 10 Voltage Reconnection and Wiring Diagrams 51 10 1 2 100 120 200 240 Volt Configurations This configuration does not use a jumper lead If the unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 10 1 and Figure 10 2 for location Select a circuit breaker manufactured with a 2 pole circuit breaker Two 1 pole circuit breakers do not conform to NEC requirements when supplying a 200 240 volt load This is true even if they are mechanically attached together Since leads Li and L2 are different phases never connect them together LO Neutral O gt LO GRD y gt L2 Load o 4 Side O Ground Factory 2 Pole Circuit O Breaker 100 120 200 240 Volt 3 Wire 3 2 Stator Leads 60 Hz 50 Hz 100 120 Volt 100 120 Volt 100 120 Volt 100 120 Volt 200 240 Volt 200 240 Volt LO L1 LO L2 L1 L2 Figure 10 3 100 120 200 240 Volt 3 Wire 52 Section 10 Voltage Reconnection and Wiring Diagrams 10 1 3 200 240 Volt Configurations This configuration does not use a jumper lead If the unit was originally wired for straight 100 200 volt
30. 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 atthe tank ifthe generator set has a coolant recovery tank Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation TP 6053 7 04 Moving Parts 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 A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place A WARNING A Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air TP 6053 7 04 Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the
31. x 1 75 47 0 M12 x 1 50 65 0 M14 x 2 00 74 0 M14 x 1 50 100 0 103 M16 x 2 00 115 0 200 0 148 M16 x 1 50 141 0 104 M18 x 2 50 155 0 114 275 0 203 M18 x 1 50 A 4 Appendix 196 0 145 210 0 155 305 0 225 TP 6053 7 04 Appendix D Common Hardware Identification Screw Bolts Studs Hex Head or Machine Head Hex Head W Grade 2 Hex Head or Machine Head i with Washer Lock or Elastic Grade 5 Flat Head FHM Square Grade 8 Grade 8 9 Hex Socket Head Metric Round Head RHM Cap or Acorn Pan Head Wing Number stamped on Hex Socket Head Cap or Washers hardware 5 8 shown Allen Head Cap Washer Styles Hex Socket Head or Allen Head Shoulder Bolt Plain Sheet Metal Screw Split Lock or Spring Stud Spring or Wave Drive Styles External Tooth Lock Hex Internal Tooth Lock Hex and Slotted Internal External Tooth Lock Phillips Slotted Hex Socket Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company Sample Dimensions American Standard Screws Bolts Studs and Nuts Plain Washers 1 4 20 x 1 L Length In Inches Screws and Bolts 9 32 x 5 8 x 146 Thickness Threads Per Inch External Dimension Major Thread Diameter In Fractional
32. 0 M125A 04 80 M125A 05 80 M125A 06 80 M125A 08 80 M125A 10 80 M125A 12 80 M125A 14 80 M125A 16 80 M125A 18 80 M125A 20 80 M125A 24 80 Dimensions M3 0 50 M4 0 70 M4 0 70 M5 0 80 M6 1 00 M6 1 00 M6 1 00 M6 1 00 M8 1 25 M8 1 25 M8 1 25 M10 1 50 M10 1 25 M10 1 50 M10 1 50 M10 1 50 M12 1 75 M12 1 25 M12 1 75 M12 1 75 M14 2 00 M16 2 00 M16 2 00 M18 2 5 M18 2 50 M20 2 50 M20 2 50 M22 2 50 M24 3 00 M24 3 00 M30 3 50 ID 3 2 4 3 5 3 6 4 8 4 10 5 13 0 15 0 17 0 19 0 21 0 25 0 OD 7 0 9 0 10 0 12 0 16 0 20 0 24 0 28 0 30 0 34 0 37 0 44 0 Type Standard Standard Brass Standard Standard Std green Spiralock Elastic Stop Standard Spiralock Elastic Stop Standard Standard Spiralock Spiralockt Elastic Stop Standard Standard Spiralock Elastic Stop Elastic Stop Spiralock Elastic Stop Standard Elastic Stop Standard Elastic Stop Standard Standard Elastic Stop Standard Bolt Thick Screw M3 M4 M5 M6 M8 M10 M12 M14 M16 3 0 M18 3 0 M20 4 0 M24 OVEL T OO SCAN0THAHOON This metric hex nut s hardness is grade 8 A 8 Appendix TP 6053 7 04 TP 6053 7 04a 2000 and 2004 by Kohler Co All rights reserved KOHLER POVVER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower
33. 030 82 M961 10035 60 M933 10035 60 M933 10035 82 M961 10040 60 M4 0 70 x 6 M5 0 80 x 30 M5 0 80 x 35 M5 0 80 x 50 M6 1 00 x 10 M6 1 00 x 12 M6 1 00 x 14 M6 1 00 x 16 M6 1 00 x 20 M6 1 00 x 25 M6 1 00 x 30 M6 1 00 x 40 M6 1 00 x 50 M7 1 00 x 25 M8 1 25 x 10 M8 1 25 x 12 M8 1 25 x 16 M8 1 25 x 20 M8 1 25 x 25 M8 1 25 x 30 M8 1 25 x 30 M10 1 50 x 12 M10 1 25 x 20 M10 1 50 x 20 M10 1 50 x 25 M10 1 25 x 25 M10 1 50 x 25 M10 1 25 x 30 M10 1 50 x 30 M10 1 50 x 30 M10 1 25 x 35 M10 1 50 x 35 M10 1 50 x 35 M10 1 25 x 40 Part No Dimensions Hex Head Bolts Full Thread continued M933 12016 60 M933 12020 60 M961 12020 60F M933 12025 60 M933 1 2025 82 M961 12030 60 M933 12030 82 M961 12030 82F M933 12030 60 M933 12035 60 M961 12040 82 M933 12040 60 M933 12040 82 M961 14025 60 M933 14025 60 M961 14050 82 M961 16025 60 M933 16025 60 M961 16030 82 M933 16030 82 M933 16035 60 M961 16040 60 M933 16040 60 M961 16045 82 M933 16045 82 M933 16050 60 M933 16050 82 M933 16060 60 M933 16070 60 M933 18035 60 M933 18050 60 M933 18060 60 M933 20050 60 M933 20055 60 M933 24060 60 M933 24065 60 M933 24070 60 M12 1 75 x 16 M12 1 75 x 20 M12 1 50 x 20 M12 1 75 x 25 M12 1 75 x 25 M12 1 25 x 30 M12 1 75 x 30 M12 1 50 x 30 M12 1 75 x 30 M12 1 75 x 35 M12 1 25 x 40 M12 1 75 x 40 M12 1 75 x 40 M14 1 50 x 25 M14 2 00 x 25 M14 1 50 x 50 M16 1 50 x 25 M16 2 00 x
34. 1 50 x 120 M10 1 50 x 130 M10 1 50 x 140 M10 1 50 x 180 M10 1 50 x 235 M10 1 50 x 260 M10 1 25 x 330 M12 1 75 x 45 M12 1 25 x 50 M12 1 25 x 50 M12 1 75 x 50 M12 1 75 x 50 M12 1 75 x 55 M12 1 75 x 60 M12 1 75 x 60 M12 1 75 x 65 M12 1 75 x 75 M12 1 75 x 80 M12 1 75 x 90 M12 1 75 x 100 M12 1 75 x 110 Part No Hex Head Bolts Partial Thread continued M960 16090 60 M931 16090 60 M931 16100 60 M931 16100 82 M931 16120 60 M931 16150 60 M931 20065 60 M931 20090 60 M931 20100 60 M931 20120 60 M931 20140 60 M931 20160 60 M931 22090 60 M931 22120 60 M931 22160 60 M931 24090 60 M931 24120 60 M931 24160 60 M931 24200 60 Dimensions M16 1 50 x 90 M16 2 00 x 90 M16 2 00 x 100 M16 2 00 x 100 M16 2 00 x 120 M16 2 00 x 150 M20 2 50 x 65 M20 2 50 x 90 M20 2 50 x 100 M20 2 50 x 120 M20 2 50 x 140 M20 2 50 x 160 M22 2 50 x 90 M22 2 50 x 120 M22 2 50 x 160 M24 3 00 x 90 M24 3 00 x 120 M24 3 00 x 160 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M933 05030 60 M933 05035 60 M933 05050 60 M933 06010 60 M933 06012 60 M933 0601 4 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06030 60 M933 06040 60 M933 06050 60 M933 07025 60 M933 08010 60 M933 08012 60 M933 08016 60 M933 08020 60 M933 08025 60 M933 08030 60 M933 08030 82 M933 10012 60 M961 10020 60 M933 10020 60 M933 10025 60 M961 10025 60 M933 10025 82 M961 10030 60 M933 10030 60 M933 10
35. 25 M16 1 50 x 30 M16 2 00 x 30 M16 2 00 x 35 M16 1 50 x 40 M16 2 00 x 40 M16 1 50 x 45 M16 2 00 x 45 M16 2 00 x 50 M16 2 00 x 50 M16 2 00 x 60 M16 2 00 x 70 M18 2 50 x 35 M18 2 50 x 50 M18 2 50 x 60 M20 2 50 x 50 M20 2 50 x 55 M24 3 00 x 60 M24 3 00 x 65 M24 3 00 x 70 Pan Head Machine Screws M7985A 03010 20 M7985A 0301 2 20 M7985A 04010 20 M7985A 04016 20 M7985A 04020 20 M7985A 04050 20 M7985A 04100 20 M7985A 05010 20 M7985A 0501 2 20 M7985A 05016 20 M7985A 05020 20 M7985A 05025 20 M7985A 05030 20 M7985A 05080 20 M7985A 05100 20 M7985A 06100 20 M3 0 50 x 10 M3 0 50 x 12 M4 0 70 x 10 M4 0 70 x 16 M4 0 70 x 20 M4 0 70 x 50 M4 0 70 x 100 M5 0 80 x 10 M5 0 80 x 12 M5 0 80 x 16 M5 0 80 x 20 M5 0 80 x 25 M5 0 80 x 30 M5 0 80 x 80 M5 0 80 x 100 M6 1 00 x 100 Flat Head Machine Screws M965A 04012 SS M965A 05012 SS M965A 05016 20 M965A 0601 2 20 M4 0 70 x 12 M5 0 80 x 12 M5 0 80 x 16 M6 1 00 x 12 Appendix A 7 Metric continued Part No Hex Nuts M934 03 50 M934 04 50 M934 04 B M934 05 50 M934 06 60 M934 06 64 M6923 06 80 M982 06 80 M934 08 60 M6923 08 80 M982 08 80 M934 10 60 M934 10 60F M6923 10 80 M6923 10 62 M982 10 80 M934 12 60 M934 12 60F M6923 12 80 M982 12 80 M982 14 60 M6923 16 80 M982 16 80 M934 18 80 M982 18 60 M934 20 80 M982 20 80 M934 22 60 M934 24 80 M982 24 60 M934 30 80 Washers Part No M125A 03 8
36. 3 wire remove the jumper lead see Figure 10 1 and Figure 10 2 for location LO Neutral O LO GRD Ground gt ui CO 1 Pole Circuit Breaker Q D Tape to insulate from ground 4 3 2 200 220 240 Volt 2 Wire Stator Leads 60 Hz 50 Hz not used 200 240 Volt Figure 10 4 200 240 Volt 2 Wire TP 6053 7 04 10 2 Marine Manual Ship to Shore Transfer Switch Electro Switch 2 Mire Generator Sets 3 Wire Generator Sets I1 lt O O L1 o oo o 2 1 3 4 To Generator To Shore Set Power L2 lt O Me O ed 6 8 To Shore To Generator Power Set LO VY To Load To Load Kraus Naimler American Solenoid Early Rectangular Design 2 Wire Generator Sets 3 Wire Generator Sets LI lt _ 1 To Generator 5 To Shore Set Power L2 __ ToGenerator 3 7 To Shore Set Power lo lt _ 9 Kraus Naimler American Solenoid Newer Round Design 2 Wire Generator Sets 3 Wire Generator Sets LI lt OO 4 1 To Shore Power To Generator 3 Set To Generator 7 5 To Shore Set Power Lo O Yy y 11 To Load To Load TP 5399 5 TP 6053 7 04 Section 10 Voltage Reconnection and Wiring Diagrams 53 10 3 Wiring Diagram Schematic SCHEMATIC BC 12 VOLT HIN N gt J10 1 37 P1 15 P4 5 lt 37 lt e D4 sa 1A P1 7 lt P1 10 lt gt D3 1A
37. 4 Generator end panel Figure 9 1 Covers 1 Controller mount locknut 2 Neutral stud LO Figure 9 2 Controller Removal Section 9 Generator Disassembly Reassembly 45 9 Disconnect the P7 FP and FN and P6 F1 and F2 connectors See Figure 9 3 10 Remove the four bolts to remove the exciter field See Figure 9 3 11 Remove the three bolts and spacers from the rectifier board 558864 1 P7 connector 2 P6 connector 3 F1 connector 4 Exciter field Figure 9 3 Exciter Field Removal 558865 1 Armature 2 Armature retaining bolt 3 Rotor leads 4 Rectifier board Figure 9 4 Armature Removal 46 Section 9 Generator Disassembly Reassembly 12 Disconnect the main field rotor leads from the rectifier board positive negative terminals Remove the bolt and washer 13 Remove the armature from the shaft guiding rotor leads through the armature bores See Figure 9 4 14 Remove the tie wraps and disconnect the P5 83 44 55 B1 and B2 wire connector 15 Attach the hoist hook to the generator hoisting eye Note The hoist capacity rating should be one half ton or greater 16 Remove the two vibromount bolts See Figure 9 5 17 Raise the alternator end and place a wood block under the locator plate Lower the alternator until the wood block supports the locator plate See Figure 9 5 18 Remove the four overbolts from the end bracket See Figure 9 5 P5
38. 70 82 M931 08075 60 M931 08080 60 M931 08090 60 M931 08095 60 M931 08100 60 M931 08110 60 M931 08120 60 M931 08130 60 M931 08140 60 M931 08150 60 M931 08200 60 M931 10040 82 M931 10040 60 M931 10045 60 M931 10050 60 M931 10050 82 M931 10055 60 M931 10060 60 M931 10065 60 M931 10070 60 M931 10080 60 M931 10080 82 M931 10090 60 M931 10090 82 M931 10100 60 M931 10110 60 M931 10120 60 M931 10130 60 M931 10140 60 M931 10180 60 M931 10235 60 M931 10260 60 M960 10330 60 M931 12045 60 M960 12050 60 M960 12050 82 M931 12050 60 M931 12050 82 M931 12055 60 M931 12060 60 M931 12060 82 M931 12065 60 M931 12075 60 M931 12080 60 M931 12090 60 M931 12100 60 M931 12110 60 This metric hex bolt s hardness is grade 10 9 TP 6053 7 04 Dimensions M5 0 80 x 55 M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M6 1 00 x 145 M6 1 00 x 150 M8 1 25 x 35 M8 1 25 x 40 M8 1 25 x 45 M8 1 25 x 50 M8 1 25 x 55 M8 1 25 x 55 M8 1 25 x 60 M8 1 25 x 70 M8 1 25 x 70 M8 1 25 x 75 M8 1 25 x 80 M8 1 25 x 90 M8 1 25 x 95 M8 1 25 x 100 M8 1 25 x 110 M8 1 25 x 120 M8 1 25 x 130 M8 1 25 x 140 M8 1 25 x 150 M8 1 25 x 200 M10 1 25 x 40 M10 1 50 x 40 M10 1 50 x 45 M10 1 50 x 50 M10 1 25 x 50 M10 1 50 x 55 M10 1 50 x 60 M10 1 50 x 65 M10 1 50 x 70 M10 1 50 x 80 M10 1 25 x 80 M10 1 50 x 90 M10 1 50 x 90 M10 1 50 x 100 M10 1 50 x 110 M10
39. ETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice 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 6053 7 04 Accidental Starting A WARNING PLA Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the gene
40. Hz the AC voltage should decline Perform the following test to check the regulator output Voltage Regulator Test Use the following components to test the voltage regulator e Variable transformer 0 140 volts 0 5 amp minimum e Plug 120 volts AC e Lamp 120 volt 100 watt e AC voltmeter e Insulated copper wire 14 AWG minimum Regulator Test Procedure 1 Connect the components as shown in Figure 7 4 2 Turn the variable transformer setting to zero Plug in the variable transformer 3 Turn the variable transformer on Slowly increase the variable transformer voltage to 100 volts The test lamp should light If the lamp does not light turn the voltage adjustment potentiometer pot clockwise If the lamp still does not light the voltage regulator is inoperative Replace the voltage regulator An inoperative voltage regulator causes a generator no low output condition 4 Slowly increase the voltage to 120 volts The lamp should go out and stay out as the voltage increases If the lamp remains lit turn the voltage adjustment pot counterclockwise If the lamp still remains lit replace the voltage regulator An inoperative voltage regulator causes a generator high voltage output condition 5 Turn the variable transformer to zero and unplug the AC cord Note For applications requiring fine voltage adjustment connect a remote rheostat to voltage regulator terminal 66 TP 6053 7 04
41. L SOLENOID GND GROUND GP GLOW PLUGS GPR GLOW PLUG RELAY HCT HIGH COOLANT TEMPERATURE SWITCH HR HOUR METER J CONNECTOR K RELAY LOP LOW OIL PRESSURE SWITCH OPS OIL PRESSURE SENDER P PLUG SM STARTER MOTOR SS STARTER SOLENOID SSS STOP START SWITCH 229294 N Section 10 Voltage Reconnection and Wiring Diagrams 55 10 5 Remote Start Panel 10 6 Remote Start and 2 Meter Stop 10 amp Local O Hise switch x Start Relay circuit board Relay circuit board Start 43 WT sender P2 3 P2 7 7 P2 8 P2 9 2 P4 3 43 Be ye Grey a P3 4 p3 5 Black 70 47 43 N 5 7C J3 4 a A As A P3 4 P3 5 Black P36 P3 1 P3 2 P3 3 Violet J3 4 J3 5 N wae T us 3 i T Yellow Remote Violet Black Tan Red L Blue switch Yellow Rem te Red F switch Gen ON light TP 5588 7 Gen ON light Water temp gauge Oil pressure gauge 56 Section 10 Voltage Reconnection and Wiring Diagrams TP 6053 7 04 10 7 Remote Start and 4 Meter Panel W T O P sender sender circuit board 4 N 5 A Grey N 4 P3 5 Black P3 6 P3 1 P3 2 J3 4 J3 5 ae S J3 1 J3 2 Violet Stop oO 53 6 Black Tan Yellow aaa Red Stat switch 6 Gen ON light Water temp gauge Oil pressure DC voltme
42. 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 10 when used with SI units male ms 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 millionm 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 A 2 Appendix MTBF MTBO mtg MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns Oc OD OEM OF opt OS OSHA OV oz p Pp PC PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH mean time between failure mean time between overhauls mounting megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton met
43. RT STOP HOUR SWITCH METER zu CIRCUIT BREAKER saat ode J STOP PREHEAT i A 229301 N 1 Voltage regulator 2 DC circuit breaker 3 K25 relay 4 Hourmeter 5 K20 relay 6 START STOP switch 7 Controller circuit board Figure 6 1 Controller Internal Components 6 2 Controller Sequence of Operation The following text covers the controller s sequence of operation during generator start run stop and fault TP 6053 7 04 shutdown modes Use this as a starting point for controller fault identification Use the LEDs on the controller circuit board to assist in the troubleshooting process An illuminated LED indicates that the respective relay is receiving power the LED does not indicate whether that relay is energized Additional relay test procedures are covered later in this section Refer to the wiring diagrams in Section 10 Voltage Reconnection and Wiring Diagrams to assist in the troubleshooting procedure 6 2 1 Start Close the start stop switch between N ground and 47 local or remote starting The K2 relay energizes The normally open K2 contacts close to energize the K3 relay LED3 lights the K25 fuel solenoid relay the controller hourmeter and the generator armature exciter field The K25 relay normally open contacts close to energize the fuel solenoid The K3 relay normally open contacts close to energize the K20 starter relay The K20 relay normal
44. Remove and isolate the LOP switch lead High exhaust temperature HET low coolant LCS safety shutdown switches Place the ohmmeter on the R x 1000 scale If functional open circuit Any continuity suggests an inoperative temperature switch es Replace the switch es Connect the ohmmeter to the P13 1 and engine block ground Low oil pressure LOP safety shutdown switch Place the ohmmeter on the R x 1000 scale This test is not conclusive until the temperature shutdown switches are checked Figure 8 3 Engine Generator Component Testing Relay Controller 8 2 Remote Panels Optional Kohler Co offers three remote panels for connection to the generator set e A panel with a start stop switch e A panel with a start stop switch and two gauges engine oil pressure and water temperature e Apanel with a start stop switch and four gauges DC voltmeter engine oil pressure water temperature and hourmeter If difficulty with the remote operation occurs test the switch gauges and gauge senders using the following procedures See Sections 10 5 through 10 7 for wiring diagrams TP 6053 7 04 If functional zero ohms continuity Then disconnect the LOP switch lead and isolate the terminal Meter reading should show an open circuit Troubleshooting Remote Start Panels Generally ifthe sender changes its resistance values as its respective pressure temperature changes it is work
45. Service Marine Generator Sets Models NATIONALLY REGISTERED KOHLER POVVER SYSTEMS ress Safety Precautions and Instructions l Introduction ssssssssssssnsssnssssssne i Service Assistance 00ceeee eee eeeee i Section 1 Specifications 1 Tl General saeti manaa o A E eke 1 1 2 Service Views cee eee ees 2 T ENJINS portin eie pen aia neha neat d ete 5 1 4 Generator 0 eee 6 Section 2 Scheduled Maintenance 7 231 General jai e aides eid een teed 7 2 2 Lubrication System 0 0 ee eee 7 23 Battery orgnr erroi nee pinna aiaa Aoki 8 2 4 Generator Storage cece eee 9 Section 3 Intake and Exhaust System 11 3 1 Air Intake Silencer Filter 11 3 2 Exhaust System 00 cee eee eee 11 3 3 Mixing Elbow eee eee 11 Section 4 Fuel System 22 0eeeeeee 13 41 General ached seek opinie set cbe tan kee aktes 13 4 2 Fuel Specifications 0008 13 43 Fuel Fiter mesir aan ha a ee ove 13 4 4 Bleed the Fuel System 005 14 4 5 Fuel Solenoid cee eee eee 15 4 6 FuelsPump eea tiwag ween aaa 16 4 7 Governor 00 cee 17 Section 5 Cooling System 2 05 19 Oil General i grie gibonni pagia ei pe nae 19 5 2 Water Cooled Exhaust Manifold 20 5 3 Closed Heat Exchanger 045 20 5 4 Fil
46. Systems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
47. Testing Rectifier Module 38 Section 7 Generator Troubleshooting 7 8 Rotor The generator rotor magnetized by DC current from the rectifier module rotating within the stator windings induces AC voltage in the stator windings Test the generator rotor main field as described in the following steps Rotor Test Procedure 1 Disassemble the generator 2 Disconnect the generator main field windings from rectifier module terminals F and F 3 Check the main field resistance by connecting an ohmmeter across the main field F and F leads See Figure 7 11 The resistance reading for a cold main field should be approximately 2 5 4 5 ohms A low reading indicates an internal short and a high reading indicates an open winding Replace the main field if the ohmmeter readings indicate that the main field is inoperative 4 Perform a megohmmeter test on the main field as described in the next step 1 Main field rotor 2 Stator windings 3 Rectifier module 4 Ohmmeter 5 Armature 6 Exciter field Figure 7 11 Ohmmeter Connections on Main Field TP 6053 7 04 5 Check the main field for a grounded condition by using a megohmmeter Apply 500 volts DC to either field lead and the main field frame Follow the instructions of the megohmmeter s manufacturer when performing this test See Figure 7 12 A reading of approximately 500 kOhms 1 2 megohm and higher indicates the main field is good A rea
48. Toggle the start stop switch until fuel free of air bubbles flows from the vent screw at position 2 Tighten the screw 5 Loosen the fuel injection pump screw at position 5 6 Toggle the start stop switch until fuel free of air bubbles flows from the vent screw at position 5 Tighten the screw TP 6053 7 04 5 8EOZ and 4 6 5EFOZ Models arn Oo m Gna 2 WIPE DA CN i aU Si lz De OO NAV I Vent screw position 1 Vent screw position 2 Fuel return Fuel filter Fuel injection pump Vent screw position 5 Figure 4 4 Fuel System Bleed Points Typical TP 6053 7 04 4 5 Fuel Solenoid The fuel solenoid serves to pull the injector pump lever to the fuel on position when energized The fuel solenoid is spring loaded to return the injector pump lever to the fuel off position when deenergized The generators in this manual use a 3 lead fuel solenoid This solenoid has a white lead P which energizes the pull in coil only during cranking During operation the red lead energizes the hold coil and the black lead is the common ground Current amps and resistance readings are shown in Figure 4 5 Resistance readings determine if the solenoid windings are open or shorted These readings must be taken with fuel solenoid disconnected from engine wiring harness Pull In 50 Amps Hold 1 0 Amps Black White P Lead
49. arding voltage reconnection last 17 Open the seacock and the fuel valve TP 6053 7 04 Section 9 Generator Disassembly Reassembly 49 Notes 50 Section 9 Generator Disassembly Reassembly TP 6053 7 04 Section 10 Voltage Reconnection and Wiring Diagrams 10 1 Voltage Reconnection The following information illustrates the proper reconnection of 4 lead generator sets In all cases follow the National Electrical Code NEC NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer 10 1 1 100 120 Volt Configurations LO Neutral Ground Load Side Factory 2 Pole or 2 1 Pole Circuit Breakers Jumper Lead 4 3 2 100 120 Volt 3 Wire Stator Leads 60 Hz 50 Hz 100 120 Volt 100 120 Volt 100 120 Volt 100 120 Volt LO L1 LO L2 Figure 10 1 100 120 Volt 3 Wire TP 6053 7 04 Do not connect the load side terminals of the circuit breaker together when using a factory 2 pole circuit breaker See Figure 10 1 If the installation requires a 100 120 volt 2 wire system use a 1 pole circuit breaker See Figure 10 2 When connecting stator phase leads together size the output lead L1 accordingly Use a jumper lead on the line side of the circuit breaker to balance the generator
50. as light emitting diodes LEDs which indicate relay coil power and aid in the circuit board and the generator fault detection When the K1 K2 K8 K4 or K5 relays receive power the corresponding LED lights The LED does not indicate whether the relay coil is energized Determine if the relay coil is energized by analyzing the generator faults when performing a continuity test on the relay coil TP 6053 7 04 Ohmmeter on R x 10 If functional approximately 510 ohms Low resistance continuity shorted coil High resistance open coil LOP DELAY C gt i ie L c2 401 m oe amp me PCB ASSY H 289563 l NAY LYYLS VR1 yED4 STOP J I DDD AOA D9 4 RO _ONINNNY N39 ia La R8 12 10 9 7 6 TE lt O OMNOTARWN Engine crank control relay K3 P1 connector P2 connector Time delay relay K5 LEDS LED2 Engine run relay K2 AC crank disconnect relay K1 LED1 Fault shutdown relay K4 Relay schematic LED4 LEDS Figure 6 3 Controller Circuit Board Section 6 Controller Troubleshooting 27 6 5 Troubleshooting Use the following flow chart as an aid in troubleshooting the main circuit board and the entire generator set Ifthe prescribed rem
51. 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 certificate certification certified cubic feet per hour TP 6053 7 04 cfm CG CID CL cm CMOS cogen com coml Coml Rec conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resista
52. bly Removal 3 Locknut 4 Rotor assembly 1 Drive disc 2 Rotor 3 Bolt Figure 9 8 Drive Disc Section 9 Generator Disassembly Reassembly 47 4 Inspect the O ring in the end bracket bearing bore and replace the O ring if damaged Use a sling to support the stator assembly while installing the stator over the rotor Be careful not to damage the rotor See Figure 9 9 Install the four overbolts the two long bolts in the lower holes Check that the alignment marks on the stator housing and locator plate match See Figure 9 10 Tighten the overbolts to 40 Nm 30 ft Ibs Use the hoist to raise the alternator end Remove the wood block from under the locator plate Lower the generator set and install a bolt a large washer two small washers and a locknut in each vibromount Tighten the mounting bolts to 28 Nm 20 ft Ibs Apply antiseize compound to the keyed end of the rotor shaft Bring the rotor leads through the bores in the armature while installing the armature on the shaft Check the keyway of the shaft and key of the armature for damage Install the armature retaining bolt and washer 8 Use screws and lock washers to install the rotor leads to the rectifier board at the positive and negative terminals Note Position the lock washers against the rectifier board 9 Install three spacers and bolts to mount the rectifier board to the armature 10 Install the exciter field using four b
53. cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery 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 itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases TP 6053 7 04 2 4 Generator Storage Perform the generator storage procedure while
54. connector Backplate Wood block Vibromount bolts Overbolts Figure 9 5 Supporting the Generator TP 6053 7 04 19 Install a sling on the stator housing See Figure 9 6 20 Use a two jaw puller to pull the end bracket stator assembly from the bearing on the rotor shaft See Figure 9 6 21 Remove the stator assembly from the rotor Remove or rotate the fan guard if necessary to clear the vibromounts 22 Remove the four locknuts and remove the fan and fan spacer See Figure 9 7 23 Remove the six metric bolts to remove the drive disc rotor assembly from the engine flywheel See Figure 9 7 24 Clamp the rotor in a soft jaw vise Remove the eight bolts and remove the drive disc assembly from the rotor See Figure 9 8 9 2 Reassembly 1 Clamp the rotor in a soft jaw vise Install the drive disc on the rotor with disc studs facing the rotor Tighten the eight bolts to 40 Nm 30 ft Ibs See Figure 9 8 2 Install the rotor drive disc assembly on the engine flywheel using six washers and bolts Tighten the bolts to 27 Nm 20 ft Ibs 3 Install the fan to the drive disc using four spacers washers and locknuts Note Install the fan with the flange side facing away from the flywheel Space the studs so that they allow the fan installation in one position only TP 6053 7 04 JENN Sra BLL Sy 1 Sling 2 Fan guard 3 Two jaw puller 4 End bracket Figure 9 6 Stator Assem
55. d int int ext 1 0 IP ISO J JIS hex cap high cylinder head temperature heavy duty high exhaust temperature high engine 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 Appendix A 1 k kilo 1000 K kelvin kA kiloampere KB kilobyte 21 bytes 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 by width by height Ib pound pounds lbm 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
56. d carbon steel Governor Centrifugal mechanical Bore x stroke mm in 68 x 72 2 67 x 2 83 74 x 78 2 91 x 3 07 78 x 84 3 07 x 3 30 82 x 84 3 22 x 3 30 Displacement L CID 0 784 47 83 1 006 61 39 1 204 73 45 1 330 81 14 Compression ratio 23 0 1 18 0 1 Horsepower 60 50 Hz 10 1 8 4 14 11 6 17 7 14 8 RPM 60 50 Hz 1800 1500 EE end Cgunterelockwise Lubrication system Pressure trochoid pump Lube oil capacity w filter L qts 3 3 2 2 4 2 3 5 2 5 5 3 4 3 6 Oil recommendation API CD CD CC or CC Engine firing order 4 3 2 1 cylinder nearest to flywheel Fuel injection timing BTDC 14 1 16 1 10 1 as injection pressure 120 1706 200 2844 g cm sq psi Combustion system Indirect injection swirl precombustion chamber Direct injection Battery voltage 12 volt negative ground Battery recommendation min 500 CCA 100 amp hr Battery charging alternator 40 amps 12 volts 50 amps 12 volts Fuel recommendation Diesel ISO 8217 DMA BS 2869 Part 1 Class A1 or Part 2 Class A2 Fuel shutoff solenoid system Electric Fuel feed pump Electric rotary vane Fuel pump priming Electric He fuel pump 1 2 4 Coolant capacity L qts 1 8 1 9 3 9 4 12 5 2 5 5 FEN recovery tank capacity 0 24 8 0 oz Recommended coolan
57. der i JEZ VZ no load 1 Locknut 2 Speed adjusting screw ED 250000A N Check the engine speed using a frequency meter connected to the load leads Loosen the locking nut on the speed adjusting screw Turn the screw clockwise to increase the speed and frequency Turn the screw counterclockwise to decrease the speed Tighten the locknut at the new setting See Figure 4 8 or Figure 4 9 Figure 4 9 Governor 8 9 10EOZ and 6 5 8 9EFOZ DK 250000B D 1 Locknut 2 Speed adjusting screw Figure 4 8 Governor 5EOZ 4EFOZ TP 6053 7 04 Section 4 Fuel System 17 Notes 18 Section 4 Fuel System TP 6053 7 04 Section 5 Cooling System 5 1 General The heat exchanger cooling system consists of a heat exchanger with a coolant recovery tank a thermostat a rubber impeller seawater pump a centrifugal type engine circulating pump a water cooled exhaust manifold and an exhaust mixer See Figure 5 1 for cooling system components A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Engine block Exhaust manifold Exhaust mixer elbow Outlet flapper Silencer Thermostat Figure 5 1 Cooling System Components TP 6053 7 04 Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool
58. ding of less than approximately 500 kOhms indicates the deterioration of the winding insulation and possible current flow to ground Repair or replace the main field 1 Main field rotor 5 Megohmmeter 6 Armature 7 Exciter field 2 Stator windings 3 Rectifier module 4 Shaft connection Figure 7 12 Megohmmeter Connections on Main Field 7 9 Stator The stator consists of a series of coils of wire laid ina laminated steel frame The stator leads supply voltage to the AC load and exciter regulator Leads 1 2 3 and 4 are the generator output leads Leads 33 44 and 55 are the voltage regulator supply and sensing leads The output of leads B1 and B2 are rectified by BR1 to supply the control voltage BR1 is located on the controller circuit board Prior to testing inspect the stator for heat discoloration and visible damage to the housing lead wires or exposed and varnished areas of the frame laminations Be sure the stator is securely fastened in the stator housing The stator produces electrical output AC as the magnetized main field rotates within the stator windings Test the condition of the stator according to the following procedure Refer to the schematic in Figure 7 13 when performing the following tests TP 6053 7 04 Stator Test Procedure 1 Check the generator output lead connections See Section 10 Voltage Reconnection and Wiring Diagrams 2 Disconnect all t
59. e exciter field according to the following procedure Exciter Field Test Procedure 1 Place the start stop switch in the STOP position 2 Disconnect the generator set engine starting battery negative lead first 3 Disconnect the P6 and P7 connectors 4 Check the exciter field resistance by connecting an ohmmeter across exciter field FP and FN leads See Section 1 Specifications for the resistance reading of a cold exciter field A low reading indicates an internal short and a high reading indicates an open winding Repair or replace the exciter field if the ohmmeter readings indicate a inoperative exciter field If the resistance test proves inconclusive perform a megohmmeter test on the exciter field as described in the next step 1 Ohmmeter 2 Exciter field 3 Exciter armature Figure 7 6 Exciter Field Resistance Check TP 6053 7 04 5 Check the exciter field for a grounded condition Use a megohmmeter to apply 500 volts DC to the FP or FN lead and the exciter field frame Follow the instructions of the megohmmeter manufacturer when performing this test A reading of approximately 500 kOhms 1 2 megohm and higher indicates the field winding is functional A reading of less than approximately 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground Repair or replace the exciter field
60. e leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Welding the generator set Can cause severe electrical equipment damage Before welding the generator set perform the following steps 1 Remove the battery cables negative lead first 2 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connectors 4 Disconnect the engine battery charging alternator connections 5 Attach the weld ground connection close to the weld location Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is present at the voltage regulator heat sink To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator PowerBoost PowerBoost III and PowerBoost V voltage regulator models only IV Safety Precautions and Instructions Electrical backfeed to t
61. e unit with a breathable dust cover Section 2 Scheduled Maintenance 9 Notes 10 Section 2 Scheduled Maintenance TP 6053 7 04 Section 3 Intake and Exhaust System 3 1 Air Intake Silencer Filter A dry type air cleaner silences and filters the intake air The air intake silencer assembly connects to the intake manifold via a flexible hose At the interval specified in the service schedule clean or replace the air intake silencer Clean or replace the air cleaner more frequently in dirty dusty conditions Follow the procedure described below Air Cleaner Service Replacement Procedure 1 Release the four spring clips to open the housing and remove the air silencer element 2 Tap the element lightly against a flat surface to dislodge loose surface dirt Do not clean the element in any liquid or use compressed air as these will damage the filter element 3 Examine the element and its housing for damage and wear Replace the element or its housing if necessary 4 Wipe the cover and base with a clean rag to remove any dirt Make sure the sealing surfaces fit correctly and reattach the spring clips 3 2 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 crafts occupants install a carbon monoxide de
62. edy does not correct the problem the circuit board may have to be replaced Press the start switch local or remote GotoA next page Does the engine crank No Is the K2 relay LED lit Is the K3 relay LED lit Is voltage present at y the K20 relay coil Is the K2 relay functioning correctly No Is the K3 relay functioning correctly No Is the 10 amp controller circuit breaker okay y y Replace The K3 relay or Replace the circuit board i Is voltage present at the S relay coil y the circuit Reset the board circuit breaker K1 relay is faulty Replace the circuit board Check the P1 4 connection Check the condition connections of the No start stop switch N 43 and 47 Check the battery condition and connections Check the connections at P1 14 Do all check okay Yes y Replace the circuit board D9 open 28 Section 6 Controller Troubleshooting Is the K20 relay functioning correctly Replace the K20 relay Figure 6 4 Troubleshooting Relay Controller Circuit Board 1 of 4 Is voltage present at the S relay contact starter motor side Check P4 22 Connection
63. ematic Procedure Ohmmeter on R x 10 scale Results If functional approximately 270 ohms Low resistance continuity shorted coil High resistance open coil K2 Relay Coil K2 coil terminals see relay schematic Ohmmeter on R x 10 scale If functional approximately 270 ohms Low resistance continuity shorted coil High resistance open coil K3 Relay Coil K3 coil terminals see relay schematic Ohmmeter on R x 10 scale If functional approximately 400 ohms Low resistance continuity shorted coil High resistance open coil K4 Relay Coil K4 coil terminals Ohmmeter on R x 10 If functional approximately 125 ohms see relay schematic scale Low resistance continuity shorted coil High resistance open coil K5 coil terminals see relay schematic K5 Relay Coil scale Figure 6 2 Relay Testing 6 4 Controller Circuit Board Some controller circuit board components can be tested without removing the component from the circuit board Perform these checks prior to installing a new circuit board and attempting startup Use a high quality multimeter and follow the manufacturer s instructions To obtain accurate readings when testing remove all the circuit board connectors and conformal coating transparent insulation from component terminals Use the chart in Figure 6 2 and the controller circuit board illustration in Figure 6 3 The controller circuit board h
64. enerator 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 e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Z Senia 122 12 rue des Hauts Flouviers 94517 Thiais Cedex France Phone 83 1 41 735500 Fax 33 141 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 TP 6053 7 04 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 important for safe and efficient operation Inspect the parts often and perform required service at the prescribed intervals Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operati
65. er 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 quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference round head RHM round head machine screw rly relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier S sec second Sl Systeme international d unites International System of Units SI EO side in end out sil silence
66. erminals at the bottom of the fuel pump The pump terminals are labeled and See Figure 4 7 2 Connect the inlet side of the pump to a fuel source Disconnect the outlet hose from the fuel filter and place the hose end in a container to catch the fuel 3 Connect the positive terminal of the 12 volt battery to the positive terminal of the fuel pump Connect the negative terminal of the fuel pump to the negative terminal of the battery You should hear the pump operate and see the fuel discharge from the pump outlet Replace the pump if it does not operate Ss 1 7 A 2 3 1 Fuel inlet 2 Negative terminal 3 Positive terminal 4 Fuel outlet Figure 4 7 Fuel Pump TP 6053 7 04 4 7 Governor The centrifugal mechanical governor keeps the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load No regular service is required on the governor The factory adjusts the governor during run in and further adjustment should not be needed unless poor governor control develops after extended generator usage yy p 2 iN uU 60 Hz generator sets are designed to operate at 57 63 Hz 1800 rpm under full load and 1890 rpm under no load a IL UU 50 Hz generator sets are designed to operate at j N ae ue l 47 53 Hz 1500 rpm under full load and 1590 rpm un
67. generator set engine 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 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 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 NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent
68. h the impeller kit If the instructions are not included with the kit use the following procedure Inspection and Replacement Procedure 1 Close the seacock 2 Remove the seawater pump coverplate See Figure 5 4 3 Remove the impeller 4 Inspect the impeller for damage including visible cracked broken worn or missing fins The impeller vanes should be straight and flexible See Figure 5 5 5 Lubricate the impeller with soapy water before re installation 6 While installing the impeller always rotate the drive shaft and the impeller together in the same direction as the engine rotation 7 Inspect the coverplate and gasket for corrosion and or damage Replace damaged or worn components 8 Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing TP 6053 7 04 9 Open the seacock 10 Start the generator set and check for leaks 11 Stop the generator set and repair leaks or replace components as necessary K o o o A oer a cs Seawater pump Coverplate Gasket Impeller TP 5936 28 6 Housing 7 Pulley 8 Drive shaft 9 Washer 10 Nut Bearing TP 5936 57 1 Flat spot 2 Crack 3 Broken vane Figure 5 5 Worn Impeller Section 5 Cooling System 21 5 8 Belt Tension A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place
69. he stator leads to isolate the windings To check the stator continuity set the ohmmeter on the R x 1 scale Contact the red and black ohmmeter leads adjust the ohmmeter to zero ohms Check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 7 13 Perform the stator tests on all the stator windings See Figure 7 14 3 Contact the ohmmeter leads and readjust the ohmmeter to zero ohms Check the cold resistance of the stator windings by connecting the meter leads to the stator leads 1 and 2 3 and 4 B1 and B2 etc See Section 1 Specifications for the stator resistance values Replace the stator if readings do not fall within the specified value Note The stator resistance will vary directly with increased temperature 4 Ohmmeter 5 Armature 6 Exciter field 1 Main field rotor 2 Stator windings 3 Rectifier module Figure 7 13 Stator Ohmmeter Connections Between Leads Continuity 1 and 2 3 and 4 33 and 44 33 and 55 B1 and B2 1 and 3 4 33 44 55 1 and 55 B1 and B2 4 and B1 and B2 55 and B1 and B2 Any stator lead and ground Figure 7 14 Stator Continuity Section 7 Generator Troubleshooting 39 4 Perform a megohmmeter test on the stator as described in the next step Consider the stator good if the resistance reading continuity is low and there is no evidence of shorted windings heat discoloration
70. he utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building marina electrical system only through an approved device and after the building marina main switch is opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a ship to shore transfer switch to prevent interconnection of the generator set power and shore power Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under Hot Parts A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure A WARNING Hot engine and exhaust
71. ilter cup o ring fuel filter element and spring 5 Replace the fuel filter element and install as shown in Figure 4 3 6 Open the fuel supply valve 7 Reconnect the generator set engine starting battery negative lead last 8 Bleed the fuel system See Section 4 4 TP 561633 1 Fuel strainer assembly 2 Body 3 Fuel element 4 Spring Figure 4 3 Fuel Oil Filter Element 5 O ring 6 Filter cup 7 Retaining ring 14 Section 4 Fuel System 4 4 Bleed the Fuel System Bleed the air from the fuel system to prevent starting failures and or erratic operation One or more of the following causes air to collect in the fuel system 1 The generator set operates until the fuel supply is emptied 2 The air leaks in the suction side of the fuel system 3 Replacing the fuel filter 4 Vapor lock Note Connect the battery during the priming procedure to allow engine cranking Do not allow the engine generator to start To prevent starting toggle the start stop switch by momentarily placing the start stop switch in the START position for a few seconds and then placing the switch in the STOP position Close the seacock during bleeding Fuel System Bleeding Procedure 1 Loosen the fuel filter screw at position 1 See Figure 4 4 2 Toggle the start stop switch until fuel free of air bubbles flows from the vent screw at position 1 Tighten the screw 3 Loosen the fuel filter screw at position 2 4
72. ing correctly An inoperative sender will either be open or shorted Refer to Figure 8 4 and Figure 8 5 for resistance values 2 Meter and 4 Meter Panels Temperature Resistance 60 C 140 F 134 0 10 ohms 90 C 194 F 51 5 100 C 212 F 38 0 4 ohms 3 ohms Figure 8 4 Water Temperature Sender Resistance 2 Meter and 4 Meter Panels Resistance 10 ohms 80 ohms 135 ohms Pressure OkPa Opsi 50 psi 345 kPa 690 kPa 100 psi Figure 8 5 Oil Pressure Sender Resistance Section 8 Component Troubleshooting 43 Refer to Figure 8 6 for troubleshooting information on the remote start panels Component Remote start stop switch Ohmmeter Connections Remote switch yellow red wire terminal and black wire terminal Procedure Place the ohmmeter on the Rx 1 scale Press the rocker switch to the START position Results Continuity the switch is functional Open replace switch Remote switch grey black wire terminal and black wire terminal Place the ohmmeter on the Rx 1 scale Press the rocker switch to the STOP position Continuity the switch is functional Generator set ON light gauge lights DC voltmeter and hourmeter Connect the red test lead to P3 4 and black test lead to P3 1 Place the controller rocker switch to the START position Stop the generator set when the test is complete Generator set does not need to be running just cranking for this test
73. ith a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A 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 e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e 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 Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems resulting in exhaust water leakage
74. ixing elbow combines high temperature exhaust and cooling seawater The mixture when exposed to engine vibration makes conditions conducive to rapid deterioration and failure if not correctly maintained If any damage is detected with the mixing elbow or other exhaust components replace the damaged components to prevent engine exhaust carbon monoxide leakage Section 3 Intake and Exhaust System 11 Notes 12 Section 3 Intake and Exhaust System TP 6053 7 04 4 1 General In most installations both the generator set and the propulsion engine operate from a common fuel tank with a dual dip tube arrangement The generator set dip tube is shorter than the propulsion engine s dip tube With this arrangement fuel may not be available to the generator set when the fuel supply is low See Figure 4 1 for a fuel system schematic Propulsion Generator Set 1 Fuel tank 2 Dual dip tubes 3 Fuel filter 4 Fuel feed pump Figure 4 1 Fuel System Schematic Typical 4 2 Fuel Specifications Use a clean good quality diesel fuel oil with a cetane number of 45 or greater Clean fuel prevents diesel fuel injectors and pumps from clogging Fuel Recommendation ISO 8217 DMA BS 2869 Part 1 Class A1 or Part 2 Class A2 BS 2869 1983 Part 2 Class A2 DIN 51 601 1978 United States United Kingdom Germany TP 6053 7 04 Section 4 Fuel System 4 3 Fuel Filter The quality and condition of the fuel largely determine the
75. l Check and Coolant 045 20 5 5 Flush and Clean Cooling System 20 5 6 Pressure Cap cece eee eee 21 5 7 Impeller Inspection and Replacement 21 5 8 Belt Tension 2 cee eee eee 22 5 9 Siphon Break 0 cc eee 23 5 10 Anticorrosion Zinc Anode 24 Section 6 Controller Troubleshooting 25 6A General tack s cdeun de ee eed oes 25 6 2 Controller Sequence of Operation 25 6 2 1 Starts renra ira het Mathie neat eae s 25 6 2 2 PRUNES thee ieee Mirae a 25 6 2 3 SIOPE tricia a tri Pees Pees 26 6 3 Engine Safety Shutdown Switches 26 6 3 1 Low Oil Pressure LOP Shutdown 26 TP 6053 7 04 Table of Contents 6 3 2 High Water Temperature and High Exhaust Temperature Shutdown Switch 26 6 4 Controller Circuit Board 0 27 6 5 Troubleshooting 0c eee ee eee 28 Section 7 Generator Troubleshooting 33 Tl vGe efal veces ese tions eee Cave wibe E 33 7 2 General Troubleshooting 4 33 7 3 Separate Excitation 0 000 34 7 4 PowerBoost IIIE Voltage Regulators 34 7 4 1 Voltage Regulator Test 35 7 4 2 Voltage Regulator Adjustment 35 7 5 Exciter Field e pnier ne ee depen densi eens 36 7 6 Exciter Armature 0 cece eee 37 7 7 Rectifier Module 00 38 C82 ROW asstesi ts cue ao
76. l can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Consult the engine manufacturer s operation manual for engine coolant specifications 5 5 Flush and Clean Cooling System For optimum protection drain flush and refill the cooling system at the interval listed in the operation manual s service schedule Pay special attention to the coolant level Check the coolant level as described earlier Flush and Clean Procedure 1 Remove the pipe plug located in the heat exchanger 2 Open the petcocks on the engine block and cooling system and let the system drain completely Some models may have petcocks located behind the belt guard 3 Remove the pressure cap to simplify draining 4 Drain clean and flush the cooling system including the coolant recovery tank with clean water 5 Close the petcocks 6 Fill the cooling system with recommended coolant TP 6053 7 04 5 6 Pressure Cap Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant enabling higher operating temperatures If the cap leaks replace it with a cap having the same temperature rating 5 7 Impeller Inspection and Replacement The belt driven seawater pump is located on the service side of the generator set Check and change the seawater pump impeller at the interval specified in the service schedule Follow the instructions included wit
77. l lift 1 2 m 4 ft max Exhaust mixer elbow distance above waterline If less than 23 cm 9 in a siphon break is required Siphon break distance above waterline 30 5 cm 1 ft min Siphon break Exhaust mixer elbow Heat exchanger locations vary by model Coolant recovery tank locations vary by model Figure 5 8 Siphon Break Plastic U Type TP 6053 7 04 17 igg 11 Seawater strainer 12 Seacock 13 Intake strainer 14 Engine driven seawater pump 15 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min 16 Water lock optional 17 Silencer distance from exhaust mixer elbow 3 m 10 ft max 18 Silencer customer supplied 19 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min 20 Exhaust outlet distance above waterline 10 cm 4 in min 21 Seawater outlet Section 5 Cooling System 23 5 10 Anticorrosion Zinc Anode The heat exchanger contains an anticorrosion zinc anode plug to prevent electrolytic corrosion of generator components by seawater Check and replace the zinc anode at intervals recommended by the operation manual s service schedule 2 y Sy 5 Fd F S GA 250000C G 9 10EOZ and 8 9EFOZ 1 A
78. listed at the beginning of this manual during the disassembly reassembly procedures Note Because this manual covers several models the procedure for disassembly may vary because of product updates and the assembly variations Note The voltage regulator is located in the controller box Remove the controller cover to service the voltage regulator Adjustments are possible without removing the voltage regulator from the controller 1 Remove the end panel from the alternator end of the generator set See Figure 9 1 2 Loosen the four screws and lift off the controller cover 3 Disconnect the P4 22 pin connector from J4 4 Remove the bolt and disconnect the ground strap Note It is possible to connect the output leads in various positions for different volt configurations Mark leads 1 2 3 and 4 for correct reconnection 5 Disconnect the generator output leads 1 2 3 and 4 from the circuit breaker and neutral stud LO 6 Remove the four controller mount locknuts See Figure 9 2 7 Lift the controller from the rubber mounts while guiding the leads through the bottom hole of the controller box TP 6053 7 04 8 Remove the tie wraps from the wire harness as necessary Disconnect the F1 connectors from the resistor leads oO N aN p ERE E E 3 CD 250000 AJ 1 Controller cover 2 P4 22 pin connector 3 Ground strap
79. ly open contacts close to energize the S relay starter solenoid The S relay normally open contacts close to energize the starter motor 6 2 2 Run The B1 and B2 windings of the stator supply AC voltage to the bridged rectifier BR1 the K1 relay energizes LED1 lights After a 5 10 second time delay the K5 relay energizes LED5 lights Note Voltage to the K1 and K5 relays is rectified and regulated at 12 volts DC by the bridge rectifier BR1 and the voltage regulator VR1 Stator winding 33 34 provides a voltage sensing source to the voltage regulator PBIIIE The normally open K1 contacts close to maintain voltage to the K2 relay LED2 remains lit The normally open K2 contacts remain closed to maintain voltage to the fuel solenoid and the controller hourmeter Section 6 Controller Troubleshooting 25 The normally open K1 contacts close to energize the optional oil pressure coolant temperature battery voltmeter and hourmeter gauges and the generator ON light The normally open K5 contacts close to permit the high water temperature HWT high exhaust temperature HET and low oil pressure LOP switches to function Note The low oil pressure LOP switch contacts open when the engine develops oil pressure One set of normally closed K1 contacts opens to disconnect the circuit to the positive connection of the exciter fields field flashing A set of normally closed K1 contacts opens to disconnect
80. na Meshes ead Ra se og 38 LO Sfat meine ater hae Saabs wa eee 39 Section 8 Component Troubleshooting 41 8 1 General iseer ee ded dada eee ede 41 8 2 Remote Panels Optional 43 Section 9 Generator Disassembly Reassembly 22 ces cccacteei ener einer eas 45 9 1 Disassembly 00 00 cece 45 9 2 Reassembly 0 cee eee 47 Section 10 Voltage Reconnection and Wiring Diagrams 00 eee eee eee 51 10 1 Voltage Reconnection 51 10 1 1 100 120 Volt Configurations 51 10 1 2 100 120 200 240 Volt Configurations 00000 52 10 1 3 200 240 Volt Configurations 52 10 2 Marine Manual Ship to Shore Transfer Switch 00 53 10 3 Wiring Diagram Schematic 54 10 4 Wiring Diagram Point to Point 55 10 5 Remote Start Panel 0005 56 10 6 Remote Start and 2 Meter Panel 56 10 7 Remote Start and 4 Meter Panel 57 Appendix A Abbreviations A 1 Appendix B Common Hardware Application Guidelines iiu ecar erniet i cee nea Cae a s A 3 Appendix C General Torque Specifications 02cc cece eee eee A 4 Appendix D Common Hardware Identification 0 0c e eee eee eee eee A 5 Appendix E Common Hardware List A 6 Table of Contents Notes Table of Contents TP 6053 7 04 Safety Precautions and Instructions IMPORTANT SAF
81. nce 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 exh ext F fglass FHM fl oz flex freq FS ft ft Ib ft min g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc in
82. ngine to reach normal operating oil pressure The normally closed LOP contacts open when the generator set develops adequate oil pressure The normally closed K4 contacts open to deenergize the K25 relay The K25 normally open contacts open to deenergize the fuel solenoid The normally open K4 contacts close to maintain ground to the K4 relay As the generator set shuts down the K1 relay deenergizes LED1 goes out The normally open K1 contacts open to deenergize the K2 relay LED2 goes out The normally closed K2 contacts close to ground the circuit to the K4 relay until the generator set comes to a complete stop 6 3 2 High Water Temperature HWT and High Exhaust Temperature HET Shutdown Switch When a high temperature is encountered at one or both of these sources the shutdown switch contacts close and energize the K4 relay LED4 lights The normally closed K4 contacts open to deenergize the K25 relay The K25 normally open contacts open to deenergize the fuel solenoid The normally open K4 contacts close to maintain ground to the K4 relay As the generator set shuts down the K1 relay deenergizes LED1 goes out The normally open K1 contacts open to deenergize the K2 relay LED2 goes out The normally closed K2 contacts close to ground the circuit to the K4 relay until the generator set comes to a complete stop TP 6053 7 04 Component K1 Relay Coil Ohmmeter Connections K1 coil terminals see relay sch
83. nt Voltmeter Connections Connect the red test lead to the hourmeter positive terminal Connect the black test lead to the hourmeter negative terminal Hourmeter and wiring 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 Procedure Set the voltmeter to 12 volts DC or greater Start the generator set Results A 12 volt DC reading indicates the wiring harness is functional None see Procedure Disconnect the hourmeter leads and apply 12 volts DC to the hourmeter The hourmeter is polarity sensitive If functional hourmeter operates Connect the AC voltmeter leads to the B1 and B2 windings at connector P11 Stator auxiliary winding B1 and B2 Figure 8 1 TP 6053 7 04 Stop the generator set Connect a voltmeter to the B1 and B2 windings Crank the generator set and allow the set to reach rated its speed Engine Generator Component Testing Relay Controller A reading of 12 15 volts AC indicates a functional B1 B2 winding Section 8 Component Troubleshooting 41 To further check the generator set components disconnect the battery and remove the wiring harness plugs from the controller circuit board Use an ohmmeter to check the continui
84. nticorrosion zinc anode seawater drain 2 Heat exchanger 3 Coolant drain Figure 5 9 Anticorrosion Zinc Anode 24 Section 5 Cooling System Anticorrosion Zinc Anode Replacement Procedure 1 With the generator set cooled close the seacock remove the zinc plug from the heat exchanger and drain the coolant into a container 2 Remove the corrosion on the zinc anode Replace the anode when the percent of the zinc remaining is less than 50 of the length and diameter shown in Figure 5 10 3 Clean the threaded opening of the heat exchanger and coat the threads of the zinc anode with pipe sealant 4 Install the zinc anode into the heat exchanger 5 Open the seacock 6 Refill the cooling system 7 Start the generator set and check for leaks at the zinc anode s location The pump is operating if cooling water flows from the exhaust outlet If water is not discharging at the exhaust outlet stop the generator set For seawater pump priming see the Prestart Checklist in the operation manual 1 Diameter 9 mm 0 34 in 2 Length 43 mm 1 7 in Figure 5 10 Anticorrosion Zinc Anode Plug TP 6053 7 04 Section 6 Controller Troubleshooting 6 1 General The following section covers the controller troubleshooting procedure for generator sets equipped with the relay controller and related engine components Refer to Figure 6 1 to identify the controller components STA
85. olts and washers The field leads are at the top Connect the P6 P7 and F1 connectors See Figure 9 11 1 P7 connector 2 P6 connector 3 F1 connector 4 Exciter field 1 Alignment marks Figure 9 10 Alignment Marks Figure 9 11 Installing Exciter Field 48 Section 9 Generator Disassembly Reassembly TP 6053 7 04 11 Install tie wraps to secure the wires as necessary 13 Connect the P4 22 pin connector Connect the ground strap using a bolt washer and lock washer 12 Route output leads 1 2 3 and 4 through the install the lock washer against the ground strap bottom of the controller box Check that the grommet is intact and there are no sharp edges 14 Install the controller cover exposed that could damage the wiring Install the box on the rubber mounts and install the four 15 Install the end panel with the louvered openings locknuts Connect the leads to the circuit breaker down and neutral stud LO as marked during disassembly 16 Reconnect all the external connections the exhaust line to the mixing elbow the fuel line to the Note Check the generator se s nameplate to fuel pump filter inlet the water line to the seawater verify the original voltage configuration See pump the remote start panel to the controller P3 Section 10 Voltage Reconnection and connector the AC output leads in controller and Wiring Diagrams for more information the battery cables to the battery negative lead reg
86. on and service Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 Fax Introduction i Product 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 Number Specification Number Serial Number Accessory Number Accessory Description ii Introduction Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Number Serial Number TP 6053 7 04 1 1 General This manual covers the operation maintenance tr
87. or Troubleshooting 5 Start the engine and check that the ammeter remains stable An increasing meter reading indicates a shorted rotor A decreasing meter reading to zero or unstable reading suggests a running open in the rotor If the ammeter is stable continue with step 6 6 Check for AC output across the stator leads and compare the measured output to the values in Section 1 Specifications If the output varies considerably from those listed a faulty stator rotor rectifier module or armature is the likely cause Note See Section 1 Specifications for the stator output voltages with separately excited generator These specifications are based ona battery of 12 volts Should the battery voltage vary the resulting stator output values will also vary If there is no generator output during normal operation but output is available when the generator set is separately excited the voltage regulator is probably inoperative 7 4 PowerBoost IllIE Voltage Regulators The generator set is equipped with a PowerBoost IIIE voltage regulator See Figure 7 3 The voltage regulator monitors the output voltage to the generator exciter field If the regulator s 8 amp fuse blows the generator set will shut down Verify that the regulator fuse is functional before proceeding with the test tei TP 598653 Figure 7 3 PowerBoost IIIE Voltage Regulator TP 6053 7 04 7 4 1 When the frequency drops below 57 5 47 5
88. oubleshooting and repair of the alternating current marine generator sets Have an authorized service dealer distributor perform required servicing to assure your unit continues to meet USCG requirements Please take a few moments to read this manual then carefully follow all service recommendations See Figure 1 1 through Figure 1 3 for identification and location of components The 5EOZ 4EFOZ models are powered by a Yanmar three cylinder water cooled four cycle diesel engine The three cylinder engine with heat exchanger is model 3TNE68 The 8EOZ 6 5EFOZ models are powered by a Yanmar three cylinder water cooled four cycle diesel engine The three cylinder engine with heat exchanger is model 3TNE74 TP 6053 7 04 Section 1 Specifications The 9EOZ 8EFOZ models are powered by a Yanmar three cylinder water cooled four cycle diesel engine The three cylinder engine with heat exchanger is model 3TNE78A The 10EOZ 9EFOZ models are powered by a Yanmar three cylinder water cooled four cycle diesel engine The three cylinder engine with heat exchanger is model 3TNE82A Kohler Co develops all Kohler marine generator set ratings using accepted reference conditions of 25 C 77 F and pressure of 98 9 kPa 29 2 in Hg dry barometer ISO 3046 and ISO 8528 1 include reference conditions and output calculations Obtain technical information bulletin TIB 101 on ratings guidelines for complete ratings definitions Section
89. r 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 Ww watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6053 7 04 Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide
90. rator 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 equipment connected to the set disable the generator set as follows 1 Place the generator set start stop switch in the STOP position 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch 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 Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in haza
91. rdous 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 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 l Battery short circuits Explosion can
92. 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 diagram when the ampere rating is unknown or questionable NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Safety Precautions and Instructions V Notes VI Safety Precautions and Instructions TP 6053 7 04 This manual provides troubleshooting and repair instructions for 5 10EOZ EFOZ model generator sets controllers and accessories Refer to the engine service manual for generator set engine service information 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 on g
93. s 0 12 0 26 Ohms Black Red Leads 11 13 Ohms Figure 4 5 Fuel Solenoid Readings Section 4 Fuel System 15 In addition to the ohmmeter test check for smooth non binding movement of the plunger It is important that the linkage between the fuel solenoid and the fuel injection pump lever be properly adjusted to allow the solenoid plunger to fully compress Improper adjustment may cause burnout of the pull in coil If the fuel solenoid setting is suspected to be incorrect use the following procedure to correct and see Figure 4 6 Fuel Solenoid Adjustment Procedure 1 Remove the fuel solenoid linkage 2 With the fuel solenoid s plunger fully compressed align the linkage and check injection pump lever for travel The fuel solenoid should fully compress and the injection pump lever should be 1 6 mm 0 05 in before the lever reaches the stop internal full open position Note The fuel solenoid must compress bottom fully or burnout of the fuel solenoid pull in coil will occur 3 If the alignment is not correct check the linkage and mounting brackets Loosen locknuts and adjust the ball joint s length in or out to attain proper alignment Tighten the locknut 1 Fuel solenoid 2 Locknuts 3 Ball joints Figure 4 6 Fuel Solenoid Linkage 16 Section 4 Fuel System 4 6 Fuel Pump The fuel pump transfers fuel from a source to the fuel injection pump Fuel Pump Test Procedure 1 Remove the two leads from the t
94. sed Heat Exchanger In a closed cooling system the seawater circulates through separate chambers within the heat exchanger to cool the engine water The seawater then mixes with engine exhaust and ejects out the exhaust outlet See Section 1 3 for the coolant capacities Add an additional 0 24 L 8 0 oz of coolant to the coolant recovery tank 5 4 Fill Check and Coolant Keep the coolant recovery tank approximately 1 4 full Before filling the cooling system close all petcocks and tighten all hose clamps Use a solution of 50 ethylene 20 Section 5 Cooling System glycol and 50 clean softened water to inhibit rust and corrosion and to prevent freezing Add additional coolant mixture as necessary to the coolant recovery tank Periodically check the coolant level on closed systems by removing the pressure cap Do not rely solely on the level in the coolant recovery tank Add fresh coolant mixture until the level is just below the overflow tube opening Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled Note Coolant solution A coolant solution of 50 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F Acoolant solution with less than 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glyco
95. t 50 ethylene glycol 50 clean softened water Thermostat 71 C 160 F Pressure cap rating kPa psi 96 5 14 0 1 8 kW Bendix Starter motor 0 8 kW Bendix automotive type gear reduction automotive type TP 6053 7 04 Section 1 Specifications 5 Engine continued Generator Model 5EOZ 4EFOZ Intake exhaust valve clearance cold mm in 0 15 0 25 0 006 0 010 8EOZ 6 5EFOZ 9EOZ 8EFOZ 10EOZ 9EFOZ Belt tension force 10 kg 22 Ibs mm in 10 15 0 4 0 6 Flex plate to rotor bolt torque 3 8 16 Nm ft Ibs 36 6 27 45 35 Flex plate to flywheel bolt torque M8 1 25 Nm ft Ibs 38 28 25 20 Overbolt torque M10 1 5 Nm ft Ibs 34 25 45 35 Inlet water line hose ID seawater pump inlet mm in 16 5 8 Outlet water line hose ID mixing elbow outlet mm in 51 2 Fuel inlet fuel pump inlet 1 4 NPT Fuel return size type 1 4 Generator Generator Model Hot exciter field voltage current readings at rated voltage 1 4 NPT 5 8EOZ and 4 6 5EFOZ 9 10EOZ and 8 9EFOZ No load 63 Hz volts amps Full load 60 Hz volts amps Resistor F1 lead to exciter field ohms Cold exciter field resistance ohms Cold exciter armature resistance ohms Cold main field rotor resistance ohms 5 0 Stator output voltages with separately excited generator using 12
96. tector Consult the boat builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times TP 6053 7 04 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 outlet flapper 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 and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks 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 inthe craft 2 functional and 3 energized whenever the generator set operates 3 3 Mixing Elbow Check the mixing elbow for carbon buildup and corrosion inside the pipe Clean the residual carbon buildup with a wire brush Inspect the exhaust manifold flange for cracking and corrosion The m
97. ter Hourmeter TP 5588 7 TP 6053 7 04 Section 10 Voltage Reconnection and Wiring Diagrams 57 Notes 58 Section 10 Voltage Reconnection and Wiring Diagrams TP 6053 7 04 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt 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 C cal CARB CB cc CCA CCW CEC cert cfh 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 as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery
98. the circuit to the negative connection of the exciter field field flashing The normally closed K1 contacts open to deenergize the K3 relay LED3 goes out and prevent accidental reenergizing of the starter motor The K3 contacts open to deenergize the K20 relay The K20 contacts open to deenergize the S relay The S contacts open to deenergize the starter motor When the generator set is running the start switch contacts N and 47 open by releasing the start stop rocker switch 6 2 3 Stop Close the start stop switch between N and 43 local or remote The K4 relay energizes LED4 lights The normally closed K4 contacts open to deenergize the K25 relay The K25 normally open contacts open to deenergize the fuel solenoid The normally open K4 contacts close to maintain ground to the K4 relay As the generator set shuts down the K1 relay deenergizes LED 1 goes out The normally open K1 contacts open to deenergize the K2 relay LED 2 goes out The normally closed K2 contacts close to ground the circuit to the K4 relay until the generator set comes to a complete stop 26 Section 6 Controller Troubleshooting 6 3 Engine Safety Shutdown Switches 6 3 1 Low Oil Pressure LOP Shutdown When low oil pressure occurs the LOP shutdown switch contacts close and energize the K4 relay LED4 lights Note During cranking the low oil pressure shutdown switch is deactivated until the K5 relay energizes This delay allows the e
99. the craft is afloat Follow the procedure below when storing your generator set for 3 months or more Storage Procedure 1 Start and run the generator set until it reaches operating temperature about 30 minutes Stop the generator set Change the oil and oil filter See the generator set operation manual Drain the seawater from the heat exchanger by removing the coolant drain plug Close the seacock and remove the hose at the seacock Place the hose in a container having approximately 3 7 7 5 L 1 2 gal of marine antifreeze Use an environmentally safe marine antifreeze with corrosion inhibitors With a container at the exhaust outlet run the generator set until coolant discharges at the exhaust outlet or until depleting the coolant mixture Do not allow the coolant mixture to flow into waterways TP 6053 7 04 10 11 12 Connect the hose to the seacock Stop the generator set Leave the seacock closed Check the coolant level in the heat exchanger and add coolant if necessary Note Use antifreeze with the lowest available temperature rating Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces which may be subject to rust or corrosion Disconnect and remove the battery Place the battery in a dry location for the storage period Recharge the battery once a month to maintain a full charge Cover the entir
100. ting 31 Notes 32 Section 6 Controller Troubleshooting TP 6053 7 04 Section 7 Generator Troubleshooting 7 1 General Before beginning the following troubleshooting procedures read all the safety precautions at the beginning of this manual The following tests include additional safety precautions OBSERVE THESE PRECAUTIONS 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 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 Ill and PowerBoost V voltage regulator models only 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 High voltage test Hazardous voltage can cause severe injury
101. to the AC circuit or an electrical outlet 3 Start the generator set 4 Adjust the engine speed to 1800 rpm on 60 Hz units and 1500 rpm on 50 Hz units 5 Rotate the voltage adjustment pot clockwise to increase the voltage or counterclockwise to decrease the voltage to achieve the desired output voltage 6 Rotate the stability pot clockwise until the light flickers minimally 7 Readjust the voltage adjustment pot to achieve the desired output voltage 242 1 Voltage adjustment potentiometer Stabilizer potentiometer Volt Hz potentiometer Exciter connections for reference only Lead color DC output Exciter Rotor Armature 8 amp fuse AC power input aux Main 2 and 1 Control Stator Sensing Main 3 and 4 Remote rheostat optional 1 2 3 4 5 6 7 8 9 Figure 7 5 PowerBoost IIE Voltage Regulator Adjustment 36 Section 7 Generator Troubleshooting 8 Use the remote rheostat if equipped to make final voltage adjustments 9 Stop the generator set 7 5 Exciter Field DC current from the battery magnetizes the exciter field When the exciter armature rotates within the magnetized exciter field windings an electrical current develops within the exciter armature There will be low or no generator output if the exciter field is inoperative Test th
102. ty of the components and to isolate inoperative components Refer to Figure 8 2 and Figure 8 3 Component Ohmmeter Connections Connect the ohmmeter to the P2 6 and P2 4 leads Start stop switch Connect the ohmmeter to the P2 6 and P2 5 leads Note Before performing ohmmeter checks disconnect the generator set battery to prevent damage to the ohmmeter Procedure Place the ohmmeter on the R x 1000 scale Place the rocker switch in the START position Place the ohmmeter on the R x 1000 scale Place the rocker switch in the STOP position Results If the switch is functional zero ohms continuity Any resistance other than zero or very low ohms replace the switch If the switch is functional zero ohms continuity Any resistance other than zero or very low ohms replace the switch Connect the ohmmeter to the P1 4 and P1 9 leads K20 relay coil and wiring Place the ohmmeter on the Rx 1 scale If functional 85 ohms Low resistance shorted C relay coil and or wiring High resistance open C relay and or wiring Replace the controller board Connect the ohmmeter to the P4 22 lead and the battery positive cable Note The J4 and P4 leads must be disconnected to perform this test Starter solenoid S relay Place the ohmmeter on the Rx 1 scale If functional approximately 0 5 0 6 ohms at 27 C 80 F Connect the ohmmeter to the battery positive cable and the P1 14
103. ump Replace the inoperative temperature switch es Figure 6 6 Troubleshooting Relay Controller Circuit Board 3 of 4 30 Section 6 Controller Troubleshooting TP 6053 7 04 Is there AC output when the start button gt is HELD and the unit is running No Is there 12VDC at the exciter field No l Replace the controller circuit board y Is AC output at the correct voltage e g 120 volts AC field Test the stator and the main of the preceding page Go to B at the beginning y OPTIONAL Separately excite the generator set to determine if other components are inoperative Is AC output voltage at spec See Section 7 3 Separate Excitation Test the voltage regulator y Is the voltage regulator fuse okay Is there 12VAC output at the B1 B2 stator winding m No field rotor and Yes Replace the controller circuit board Test the stator main exciter armature Replace the fuse Test the voltage regulator Test the stator main field rotor and exciter armature Figure 6 7 Troubleshooting Relay Controller Circuit Board 4 of 4 TP 6053 7 04 Section 6 Controller Troubleshoo
104. volt battery 60 Hz only 1 2 3 4 33 44 volts 81 33 55 volts 105 B1 B2 volts 10 Cold stator resistance 1 2 3 4 33 44 ohms 0 3 33 55 ohms 2 1 B1 B2 ohms Includes resistor in exciter field circuit 6 Section 1 Specifications TP 6053 7 04 2 1 General A WARNING DP 05 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 equipment connected to the set disable the generator setas follows 1 Place the generator setstart stop switch in the STOP position 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch 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
105. x 2 00 X 6239 4 3 4 10 x 2 50 X 6239 5 3 4 10 x 3 00 X 6239 6 3 4 10 x 3 50 X 792 1 1 8 x 2 25 X 792 5 1 8 x 3 00 X 792 8 1 8 x 5 00 Part No Hex Nuts X 6009 1 X 6210 3 X 6210 4 X 6210 5 X 6210 1 X 6210 2 X 6210 6 X 6210 7 X 6210 8 X 6210 9 X 6210 10 X 6210 11 X 6210 12 X 6210 15 X 6210 14 X 85 3 X 88 12 X 89 2 Washers Part No X 25 46 X 25 9 X 25 48 X 25 36 X 25 40 X 25 85 X 25 37 X 25 34 X 25 26 X 25 15 X 25 29 X 25 127 1 062 Dimensions Type 1 8 Standard 6 32 Whiz 8 32 Whiz 10 24 Whiz 10 32 Whiz 1 4 20 Spiralock 1 4 28 Spiralock 5 16 18 Spiralock 5 16 24 Spiralock 3 8 16 Spiralock 3 8 24 Spiralock 7 16 14 Spiralock 1 2 13 Spiralock 7 16 20 Spiralock 1 2 20 Spiralock 5 8 11 Standard 3 4 10 Standard 1 2 20 Standard Bolt ID OD Thick Screw 125 250 022 4 156 375 049 6 188 438 049 8 219 500 049 10 281 625 065 1 4 344 687 065 5 16 406 812 065 3 8 469 922 065 7 16 531 1 062 095 1 2 656 1 312 095 5 8 812 1 469 134 3 4 2 000 134 1 TP 6053 7 04 Metric Hex head bolts are hardness grade 8 8 unless noted Part No Hex Head Bolts Partial Thread M931 05055 60 M931 06040 60 M931 06055 60 M931 06060 60 M931 06060 SS M931 06070 60 M931 06070 SS M931 06075 60 M931 06090 60 M931 06145 60 M931 06150 60 M931 08035 60 M931 08040 60 M931 08045 60 M931 08050 60 M931 08055 60 M931 08055 82 M931 08060 60 M931 08070 60 M931 080
106. xposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage 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 A CAUTION Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Safety Precautions and Instructions Ill 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 th
107. y from other boats and buildings Avoid overloading the craft TP 6053 7 04 Fuel System A WARNING 4 W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Installing the fuel system Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Do not modify the tank or the propulsion engine fuel system Equip the craft with a tank that allows one of the two pickup arrangements described in the installation section The tank and installation must conform to USCG Regulations 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

TP-6053 - Atlantis Marine Power

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