Kohler 6EKOD Service Manual
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Kohler 6EKOD Service Manual

Marine generator sets
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See also: Operating Manual , Installation Manual
Service
Marine Generator Sets
Models:
6EKOD
5EFKOD
9- -11EKOZD
7- -9EFKOZD
TP-6774 2/14a

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Summary of Contents for Kohler 6EKOD

  • Page 1 Service Marine Generator Sets Models: 6EKOD 5EFKOD 9- -11EKOZD 7- -9EFKOZD TP-6774 2/14a...

  • Page 2: Engine Identification

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

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 ............Collector Ring and Bearing Replacement (6EKOD/5EFKOD Model) .
  • Page 5 Section 10 Wiring Diagrams ..............10.1 Wiring Diagram Reference .
  • Page 6 Notes Table of Contents TP-6774 2/14a...

  • Page 7: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting Servicing the fuel system. A flash IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, fire can cause severe injury or death. including generator sets, transfer Do not smoke or permit flames or WARNING switches, switchgear, and accessories, sparks near the fuel injection system, can cause bodily harm and pose fuel line, fuel filter, fuel pump, or other...
  • Page 8 Fuel System Hazardous Voltage/ Carbon monoxide symptoms. Carbon monoxide can cause severe Moving Parts nausea, fainting, or death. Carbon monoxide is a poisonous gas present in WARNING exhaust gases. Carbon monoxide is an WARNING odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time.
  • Page 9 Hot Parts Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can WARNING cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments repairs. Remove all jewelry before servicing the equipment.
  • Page 10 Notes Safety Precautions and Instructions TP-6774 2/14a...

  • Page 11: Introduction

    Information in this publication represents data available and perform required service at the prescribed intervals. at the time of print. Kohler Co. reserves the right to Maintenance work must be performed by appropriately change this publication and the products represented...
  • Page 12 Notes Service Assistance TP-6774 2/14a...

  • Page 13: Section 1 Specifications

    11EKOZD an exhaust mixer. 120/240 127/220 Kohler Co. develops all Kohlerr marine generator set 115/230 ratings using accepted reference conditions of 25_C 5EFKOD (77_F) and pressure of 29.2 in. Hg dry barometer. ISO 3046 and ISO 8528-1 include reference conditions and output calculations.

  • Page 14: Engine

    1.2 Engine 6EKOD/ 9EKOZD/ 11EKOZD/ 11EKOZD/ 5EFKOD 7EFKOZD 9EFKOZD 9EFKOZD (1 Phase) (1 Phase) (1 Phase) (3 Phase) Generator Model Number of cylinders Type 4 cycle, naturally aspirated Engine block material Cast iron with re-borable integral liners Cylinder head material...

  • Page 15: Generator, 4 Lead

    1.3 Generator, 4 Lead 6EKOD 5EFKOD Component Specification Main field (rotor) resistance (cold)—ohms @ 20_C (68_F) 4.4--5.0 Stator output voltages with separately excited generator, using 12-volt battery (60 Hz only) 1--2, 3--4—volts 55--66—volts Cold stator resistance 1--2, 3--4—ohms 0.19 55--66—ohms...

  • Page 16: Service Views

    1.5 Service Views Non Service-Side View ADV7942-A 1. Battery charging module 21. Fuel inlet 2. ADC IId controller 22. Oil filter 3. USB port 23. Customer load lead connection 4. Nameplate (on top of controller) 24. Alternator cooling air inlet 5.

  • Page 17: Torque Specifications

    1.6 Torque Specifications Follow the general torque specification found in Appendix C of this manual unless noted below. 6EKOD/ 5EFKOD Generator Model (1 Phase) Overbolts 23 Nm (17 ft. lbs.) Drive discs to rotor hub 45 Nm (34 ft. lbs.) Rotor fan to flywheel 23 Nm (17 ft.
  • Page 18 Notes Section 1 Specifications TP-6774 2/14a...

  • Page 19: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance 2.1 General WARNING Schedule routine maintenance using the service schedule located in the generator set operation manual and the runtime hours shown on the ADC IId. If the generator set will be subject to extreme operating conditions, service the unit accordingly.

  • Page 20: Lubrication System

    2.2 Lubrication System Note: Failure to observe the oil specifications may cause inadequate lubrication/oil pressure and Use oil that meets the American Petroleum Institute cold-starting difficulties. (API) classification of CD or CF. Using an unsuitable oil or neglecting an oil change may result in damage and a shorter engine life.

  • Page 21: Section 3 Exhaust System

    Section 3 Exhaust System 3.1 Exhaust System Inspection 3.2 Servicing Mixing Elbow The mixing elbow combines high-temperature exhaust WARNING with cooling seawater. See the operation manual for mixing elbow scheduled maintenance. 1. Check the mixing elbow for carbon buildup and corrosion inside the pipe.
  • Page 22 Notes Section 3 Exhaust System TP-6774 2/14a...

  • Page 23: Section 4 Fuel System

    Section 4 Fuel System 4.1 General 3. Disconnect the generator set engine starting battery, negative (--) lead first. In most installations, both the generator set and the 4. Close the fuel supply valve. propulsion engine operate from a common fuel tank with a dual dip tube arrangement.

  • Page 24: Fuel System Bleed

    4.2.1 Fuel System Bleed Typically, running the Prime function on the ADC IId is all that is required. If rough operation continues, use the Bleed air from the fuel system in order to reduce rough following procedure to open the air bleed valve on the running or vapor lock.

  • Page 25: Fuel Pump

    4.3 Fuel Pump 4.4 Governor The fuel pump transfers fuel from a source to the The centrifugal, mechanical governor keeps the engine injection pump. speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load.
  • Page 26 Notes Section 4 Fuel System TP-6774 2/14a...

  • Page 27: Section 5 Cooling System

    Section 5 Cooling System 5.1 General Heat exchanger cooling consists of a heat exchanger with coolant recovery tank, thermostat, rubber impeller seawater pump, centrifugal-type engine circulating pump, water-cooled exhaust manifold, and an exhaust mixer. See Figure 5-1 for cooling system components. Seawater Freshwater (Coolant/Antifreeze) 1.

  • Page 28: Water-Cooled Exhaust Manifold

    5.3 Coolant Replacement Including WARNING Heat Exchanger Service At the interval specified in the Service Schedule, clean the heat exchanger tube. In a closed cooling system, seawater circulates through separate chambers within Hot coolant and steam. the heat exchanger to cool the engine coolant. The Can cause severe injury or death.
  • Page 29 5. Remove the exhaust mixer’s mounting nuts. See Figure 5-5. Figure 5-7 Thermostat Assembly 11. Loosen the rear cover screws. See Figure 5-8. Figure 5-5 Exhaust Mixer’s Mounting Nuts 6. Loosen any hose clamps. 7. Remove the exhaust mixer. 8. Loosen the front cover screws. See Figure 5-6. Figure 5-8 Rear Cover of Heat Exchanger 12.
  • Page 30 13. Dip the heat exchanger tube into a solution of 16. Reassemble the O-ring and front cover and tighten 90% water and 10% hydrochloric acid. Use gloves the screws. See Figure 5-12 and Figure 5-13. and goggles. 14. Rinse the heat exchanger tube in clean water. See Figure 5-10.

  • Page 31: Check And Fill Coolant

    18. Reassemble the O-ring and rear cover and tighten the screws. See Figure 5-15. Figure 5-17 Pressure Cap 24. Replace the pressure cap. Figure 5-15 Rear Cover of Heat Exchanger 5.4 Check and Fill Coolant 19. Replace the thermostat assembly and tighten the screws.

  • Page 32: Flush And Clean Cooling System

    5.5 Flush and Clean Cooling 5.7 Impeller Inspection and System Replacement For optimum protection, drain, flush, and refill the The belt-driven seawater pump is located on the service cooling system at the interval listed in the service side of the generator set. Check and change the schedule.

  • Page 33: Belt Tension

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

  • Page 34: Anticorrosion Zinc Anode

    If water is not discharging at the exhaust outlet, see Prestart Checklist—Seawater Replace When New Anode Percent of Zinc Pump Priming in the operation manual. Dimensions mm (in.) Remaining Is: Models 6EKOD/ 5EFKOD, 9EKOZD/ <50% of 6.35 (0.25) x 20 (0.78) 7EFKOZD, length/diameter 11EKOZD/ 9EFKOZD...

  • Page 35: Siphon Break

    5.10 Siphon Break A siphon break prevents seawater entry into the engine 3. Use a light detergent to clean the reed valve to remove residue and oxidation. when the engine exhaust manifold outlet is less than 23 cm (9 in.) above the waterline of a fully-loaded, 4.
  • Page 36 Notes Section 5 Cooling System TP-6774 2/14a...

  • Page 37: Section 6 Troubleshooting

    Section 6 Troubleshooting 6.1 Introduction Blown fuses. See Figure 6-1 for fuse identification. Always check and replace the fuses before replacing Corrective action and testing in many cases requires other components. See the operation manual or parts catalog for fuse part numbers. knowledge of electrical systems and electronic circuits.
  • Page 38 Troubleshooting Chart Problem Possible Cause Corrective Action Reference Generator Weak or dead battery Recharge or replace battery. Generator O/M set does Battery connections Check for reversed or poor battery connections. — not crank Open circuit in engine/controller Check for loose connections. Section 10 connections Check the wire harness continuity.
  • Page 39 Problem Possible Cause Corrective Action Reference Stops Fault shutdown Check for a fault shutdown code on the controller’s Section 7.10.1 suddenly display. Correct the fault and then reset the controller. Section 7.10.2 Section 8.14 No fuel Check the fuel supply. —...
  • Page 40 Section 8.9 shorted windings) Brush connection Check for loose brush connections. Section 8.6 (6EKOD/5EFKOD models) Check the resistance through the brushes. Resistance through the brushes should be low, 0.1--0.2 ohms without meter lead resistance. Low engine speed causing Check the system voltage/frequency settings.
  • Page 41 Section 10 Open wiring, terminal, or pin in Check continuity. Section 8.16 buildup circuit Section 10 Brushes (6EKOD/5EFKOD Inspect brushes and replace if worn. Section 8.6 models) Check for brushes sticking in brush holder or broken Section 8.6 brush spring.
  • Page 42 Notes Section 6 Troubleshooting TP-6774 2/14a...

  • Page 43: Section 7 Controller

    Section 7 Controller 7.1 Introduction See Figure 7-1 for the locations of the controller and related components. This section covers operation, configuration, adjustment, and replacement of the ADC IId controller. See Section 6 for troubleshooting procedures. 1. Junction box 9. Bushing GM76137 2.

  • Page 44: General Repair Information

    7.2 General Repair Information are functioning correctly before reconnecting them to the new controller. This section contains ADC IId controller repair Go to the Overview Menu and verify that the Software information. Service replacement of the controller is (SW) Version is correct for the generator set model and limited to the items shown in Figure 7-2.

  • Page 45: Sitetecht Software

    7.3 SiteTecht Software ADC IId Controller Replacement Procedure 1. Push the generator set power button OFF. The following items are necessary PC requirements for using the SiteTecht software. 2. Disconnect power to the battery charger, if equipped. SiteTecht Software Version 3.0 or higher by accessing TechTools to download on your PC hard 3.
  • Page 46 GM79009-A 1. P1 2. P2 Figure 7-5 Controller Connections 11. Remove the old controller. 12. Reconnect P1 (35-pin plug) and P2 (8-pin plug) to 1. Sound shield roof 2. Wing nut the new controller assembly. 3. Alternator-end door 4. Service-side door 13.

  • Page 47: Advanced Digital Control Iid Operation

    Press the dial at a given main menu to access the different voltage and/or frequency, refer to an authorized submenus within the selected main menu. Kohler distributor/dealer for system configuration and When in the submenu, rotate the dial to navigate adjustment instructions.

  • Page 48: Starting The Generator Set

    A water-filled exhaust piping and silencer may further hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valves. Water ingested into the engine may cause major engine damage that the Kohler Co. warranty does not cover. Section 7 Controller TP-6774 2/14a...

  • Page 49: Stopping The Generator Set

    7.5.3 Stopping the Generator Set The controller attempts to start the generator set three times. If the generator set does not start in three attempts, the system shuts down on an overcrank fault. The following procedures describe the actions required to stop the generator set.
  • Page 50 System Warning Fault Lamp. Green/Red lamp System Shutdown Fault Lamp. Red lamp indicates identifies an existing fault condition that does not shut that the generator set has shut down because of a fault down the generator set. A continuing system warning condition.

  • Page 51: Digital Display

    7.5.5 Digital Display Generator Set State displays the generator set status: The generator set must be running for some displays to Standby indicate values. If the generator set is not running some Running values will display zero or N/A (not available). Cooldown The 12-character, 2-line backlit alpha-numeric display Stopping...
  • Page 52 Generator Metering Menu Generator Set Run Time Menu Volts displays the alternator output AC voltages. The Engine Run Time displays the total run time hours. display shows all line-to-line and line-to-neutral voltage This value also shows in the Overview Menu. combinations three-phase single-phase...

  • Page 53: Controller Fault Diagnostics

    7.5.6 Controller Fault Diagnostics Event Log Menu This menu allows the user to review up to 1000 entries of This table provides descriptions of the system events system events including shutdown faults, warning and their types—warning, shutdown, status, and notice. faults, and status events.
  • Page 54 System Events Display Message List Warning Shutdown Status/ Relay Function Function Notice Output Description Display Message Engine Functions Engine over speed Eng Speed High Shutdwn Engine start aid active Preheat Engine under speed Eng Speed Low Shutdwn High battery voltage Battery High Warning High coolant temperature Coolnt Temp High Warning...

  • Page 55: Communication Port

    See Figure 7-8 for tested/approved manufacturer’s USB flash drive types that work with the ADC IId controller. CustomUSB (Kohler Power Systems 2-GB “spin” full size Part Number KW-A202) Imation 4-GB full size Lexar...

  • Page 56: Battery Charging Module

    7.9 Battery Charging Module 7.10 Controller Logic Specifications The junction box contains a battery charging module to Refer to Figure 7-14 for inhibit and time delays on fault maintain the engine starting battery. The battery shutdowns. Refer to Figure 7-15 for inhibit and time charging module monitors the battery voltage and delays on warnings.
  • Page 57 Alternator excitation failure: nominal generator below 5% Inspect the brushes AC output voltage of the trip (6EKOD/5EFKOD) and check the for more than 3 point for FN and FP connections. seconds after low AC Contact an authorized crank disconnect.
  • Page 58 Fault Shutdowns Sensing State(s) Inhibit Delay Mechanism Detected Time Time Trip Point Check Code Description Frequency Underfrequency Alternator Post starting 10 sec 10 sec Reduce the load and restart the shutdown occurs output aid, running, frequency generator set. Shutdown when the governed cooldown below 90% Check P2 AC sensing connection at...
  • Page 59 AC Alternator excitation failure: nominal generator voltage Inspect the brushes set AC output fault/ (6EKOD/5EFKOD) and check the voltage after shutdown FN and FP connections. crank disconnect. Contact an authorized distributor/dealer for service. Battery High High battery...

  • Page 60: Controller Resetting (Following System Fault Shutdown)

    7.10.2 Controller Resetting (Following 7.10.4 Voltage Regulator Adjustments System Fault Shutdown) The descriptions of the voltage regulator adjustments and features follow. Always identify and correct the cause of a fault shutdown before resetting the controller. Use the Voltage Adjustment. The voltage adjustment allows following procedure to reset the generator set controller the user to enter the desired generator set output level.

  • Page 61: System Fault Warning Lamp With Digital Displays

    7.10.5 System Fault Warning Lamp with Low Battery Voltage. The fault lamp illuminates green, then red, maybe black when the battery voltage drops Digital Displays below a preset level for more than 90 seconds. The The system FAULT lamp blinks green then red local display shows Battery Low Warning.

  • Page 62: System Fault Shutdown Lamp With Digital Displays

    7.10.6 System Fault Shutdown Lamp Locked Rotor (failed to crank). If none of the speed sensing inputs show engine rotation within the preset With Digital Displays time delay of initiating engine cranking, the ignition and The system FAULT lamp flashes red and the unit shuts crank circuits turn off for the preset period and the cycle down to indicate a fault shutdown under the following repeats.

  • Page 63: Status And Notice Digital Displays

    7.10.7 Status and Notice Digital Displays Overvoltage (Each Phase). The fault lamp flashes red and the unit shuts down when the voltage exceeds the Warnings and shutdown faults appear on the digital overvoltage setting for the preset time delay period. The display and become part of the event history.

  • Page 64: Menu Displays

    Generator Set Calibration (User Defined). This System Ready. This status indicates that the generator selectable display is in the GenSet Metering Menu set is in the AUTO mode and available to start if the start allowing the user to calibrate the controller and circuit is closed.

  • Page 65: Engine Metering

    Menu Summary List (Legend: D First level submenu, d second level submenu) Overview Generator Metering GenSet System Prime Menu Menu Menu Menu D System Frequency D See Section 7.13.10 Available as scrolling or D Volts, L1--L2 * D Battery DC Voltage fixed display text D Volts, L2--L3 * Volt Select...

  • Page 66: Monitoring And Programming Setup

    7.12 Monitoring and Programming Menus displaying the # symbol represent one of the following data types: Setup System-calculated data The user programmer can access the controller data System-measured data with the controller digital display or a personal computer User-entered data (PC) with optional SiteTecht software to monitor and/or program.

  • Page 67: Overview

    7.13.2 Overview Overview (Fixed Display) Overview ----> ### V ##.# Hz Displays basic and commonly sought after information ##.# hr about the generator set. This information scrolls automatically after about 5 minutes of no user input English Display ###_F ###% (pushbutton/rotary selector dial or button activity).

  • Page 68: Generator Metering (And Calibration)

    7.13.4 Generator Metering (and Momentarily press the pushbutton/rotary selector dial. Stop the generator set if not already done. Calibration) Displays generator output data including line-to-line and Generator Metering line-to-neutral voltages and frequency. The menu displays three-phase voltage readings when applicable. Generating---->...

  • Page 69: Genset Information

    7.13.5 GenSet Information Display for Measurement System is user selectable as English or Metric. Displays generator set and controller information. Displayed data is factory entered. Contrast display is user adjustable to help improve digital display visibility in dimly lit rooms or in direct sunlight.

  • Page 70: Voltage Regulator

    7.13.8 Voltage Regulator push and hold the pushbutton/rotary selector dial until the Editing Enabled popup appears. Editing of the Displays the voltage regulator adjustment, volt/Hz, gain, voltage adjustment is now available. and stability adjustment values. The user can change the individual value or can select The voltage regulator value is reviewable at all times Reset VR?- -Yes to reset to the default value.

  • Page 71: Prime Menu

    7.13.10 Prime Menu Volt Select Volt Select: ----> 120/240 V 1 Ph This menu, if confirmed, allows the user to initiate the ###/### V # Ph electric fuel pump to prime the fuel system. Prime the Fuel System 120/208 V 3 Ph Push To Prime ---->...

  • Page 72: Usb Flowchart

    PUSH TO LOAD Complete Rotate Knob Note: Before inserting a mass-storage device (USB CustomUSB host connector), power off and then power on the (Kohler Power Systems 2-GB “spin” full size controller. Part Number KW-A202) Imation 4-GB full size See Figure 7-24 for tested/approved manufacturer’s Lexar...

  • Page 73: Section 8 Component Testing And Adjustment

    ADC IId feeds rectified stator output current to the rotor through the exciter (or brushes/slip rings for model 6EKOD/5EFKOD) to increase the strength of the rotor field. As the rotor field increases in strength, generator output also increases. The ADC IId...
  • Page 74 Grounding electrical equipment. Hazardous voltage can 4. Check for AC output across the stator leads; see cause severe injury or death. Electrocution is possible Section 8.9, Stator. Compare the readings to the whenever electricity is present. Ensure you comply with all output values shown...

  • Page 75: Exciter Field (9--11Ekozd/7--9Efkozd Models)

    8.3 Exciter Field megohmmeter. A reading of approximately 1.5 MOhms and higher indicates the field winding (9- -11EKOZD/7- -9EFKOZD is functional. A reading of less than approximately Models) 1.5 MOhms indicates deterioration of the winding insulation and possible current flow to ground; if so, Direct current from the battery magnetizes the exciter replace the exciter field.

  • Page 76: Exciter Armature (9--11Ekozd And 7--9Efkozd Models)

    8.4 Exciter Armature (9- -11EKOZD and 7- -9EFKOZD Models) The exciter armature supplies excitation current to the generator main field through the rectifier module. Test the exciter armature as described in the following steps. Exciter Armature Test Procedure: 1. Disassemble the alternator. Refer to Section 9. 2.

  • Page 77: Slip Rings (6Ekod/5Efkod Models)

    8.5 Slip Rings (6EKOD/5EFKOD Models) Slip rings acquire a glossy brown finish in normal operation. Do not attempt to maintain a bright, newly-machined appearance on the slip rings. Cleaning with a dry, lint-free cloth is usually sufficient. Use very fine sandpaper (#00) and apply light pressure to remove roughness.

  • Page 78: Rectifier Module (9--11Ekozd And 7--9Efkozd Models)

    8.7 Rectifier Module (9- -11EKOZD 8.8 Rotor and 7- -9EFKOZD Models) The generator rotor (magnetized by DC from the rectifier module) rotating within the stator windings induces AC The rectifier module located between the exciter in the stator windings. Test the generator rotor (main armature and the main field converts AC from the exciter field) as described in the following steps.

  • Page 79: Stator

    6196 Figure 8-12 Alternator Stator Leads TP-5983-7 1. Main field (rotor) 5. Rectifier module 4. Disconnect all the stator leads to isolate the 2. Stator windings 6. Megohmmeter windings. To check the stator continuity, set the 3. Frame connection 7. Armature 4.
  • Page 80 5. Check the cold resistance of the stator windings by connecting the meter leads to the stator leads as shown in Figure 8-13 or Figure 8-14. Section 1, Specifications for the stator resistance values. If the stator resistance test is inconclusive, perform a megohmmeter test on the stator as described in the next step.

  • Page 81: Voltage Regulator

    8.10 Voltage Regulator 8.10.2 Voltage Regulator Adjustments The descriptions of the voltage regulator adjustments WARNING and features follow. Voltage Adjustment. The voltage adjustment allows the user to enter the desired generator set output level. This regulated level setting is the average of the three Hazardous voltage.

  • Page 82: Voltage Regulator

    8.10.3 Voltage Regulator push and hold the pushbutton/rotary selector dial until the Editing Enabled popup appears. Editing of the Displays the voltage regulator adjustment, volt/Hz, gain, voltage adjustment is now available. and stability adjustment values. The user can change the individual value or can select The voltage regulator value is reviewable at all times Reset VR?- -Yes to reset to the default value.

  • Page 83: Voltage Reconnection

    8.11 Voltage Reconnection WARNING Use the following voltage reconnection procedure to change the voltage of 4- and 12-lead generator sets. Frequency changes require voltage regulator and governor adjustments. Hazardous voltage. Moving parts. Can cause severe injury or death. Refer to the following procedure and the connection schematics.
  • Page 84 Voltage Reconnection Procedure 4. Turn selector dial clockwise counterclockwise until desired voltage 1. Stop the generator set. selection option appears. 2. Turn the controller pushbutton/rotary selector dial 5. Press the selector dial. The second line on the until it stops at the Volt Select menu. display will stop flashing and the new voltage will Figure 8-17.

  • Page 85: Four-Lead Reconnection

    8.12 Four-Lead Reconnection 8.12.2 100- -120/200- -240-Volt Configurations The following information illustrates the reconnection of four-lead generator sets. In all cases, conform to the The 100--120/200--240-volt configuration does not use National Electrical Code (NEC). a jumper lead. If the unit was originally wired for straight 100--120 volt, 3-wire, remove the jumper lead (see NOTICE Figure 8-18 for location).

  • Page 86: 240-Volt Configurations

    8.13 Twelve-Lead Reconnection 8.12.3 200- -240-Volt Configurations The reconnection procedure following details voltage The 200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 100--120 reconnections only. If the generator set requires volt, 3-wire, remove the jumper lead (see Figure 8-18 for frequency changes, adjust the governor.

  • Page 87: Fault Shutdown Tests

    8.14 Fault Shutdown Tests Overspeed Shutdown The overspeed setting is programmed into the ADC IId Verify the operation of the generator set overspeed, controller and is not adjustable. Verify that the following overcrank, high engine temperature, and low oil controller configuration is set correctly for your unit. pressure shutdowns by performing the following tests.

  • Page 88: Fault Shutdown Senders/Switches

    8.14.2 Fault Shutdown Senders/Switches Pressure, psi Resistance, Ohms 240 +2.5/--10.5 Check the senders/switches on the engine by 33.5 +10.5/--7.5 performing the following tests. If the sensor does not function as described, replace it. WARNING Hazardous voltage. Moving parts. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.

  • Page 89: Fuses

    Coolant Temperature Sensor (CTS) The coolant temperature sensor (CTS) is used to monitor engine temperature for the high engine temperature fault shutdown. See Figure 8-26 for the coolant temperature sensor location. Power down the generator set and allow the generator set to cool. Disconnect the CTS and use an ohmmeter to measure the resistance across the sensor.

  • Page 90: Continuity Checks

    8.16 Continuity Checks To further check generator set components, disconnect the battery and remove wiring harness plugs from the ADC IId circuit board. Use an ohmmeter to check the WARNING continuity of the components listed in Figure 8-31. Also see Section 10, Wiring Diagrams. Figure 8-31 gives resistance readings for functional components.

  • Page 91: Section 9 Generator Disassembly/Reassembly

    Section 9 Generator Disassembly/Reassembly 9.1 Disassembly Sound Shield Equipped Models: For access to the generator set to perform regular maintenance, remove Disconnect all of the external connections—battery the sound shield doors and roof. cables at the battery (negative (--) lead first), AC-output 5.
  • Page 92 10. Loosen and remove the four controller mounting 12. Refer to Figure 9-4 while performing steps 13 screws securing the controller and carefully lift the to 20. controller. See Figure 9-2. 13. Remove the controller. Note: Be careful of the leads and harness 14.
  • Page 93 GM76137 1. Junction box 9. Bushing 2. Preheat relays (qty. 2) located inside junction box 10. Vibromounts (qty. 4) 3. F1, F2, and F3 fuses (qty. 3) 11. Junction box controller panel 4. Fuse holders (qty. 3) 12. Screws and washers (qty. 4) 5.
  • Page 94 See Section 8.6. 17. Studs. Torque to 23 Nm (17 ft. lbs.) 5. Gasket Figure 9-5 6EKOD/5EFKOD Alternator Assembly (Disassembly/Reassembly) Follow the general torque specification found in Appendix C of this manual unless noted above or in Section 1.6, Torque Specifications.
  • Page 95 Note: Use cable ties to restrain loose harness leads from entangling in rotor. GM73474-A 1. Screws and washers 16. Lock washer 2. End bracket panel 17. Washer 3. Overbolts. Torque to 23 Nm (17 ft. lbs.) 18. Exciter armature. Note: Apply a thin coat of anti-seize 4.
  • Page 96 See screws to remove the brush holder cover and brush Figure 9-7. cover gasket. 26. 6EKOD/5EFKOD Model: Push the brushes into the holder. Secure the brushes into position by sliding a retainer into the brush keeping holder. See Section 8.6.
  • Page 97 32. Install a sling capable of handling the weight of the stator housing on the stator housing. Figure 9-10. GM73473-A 1. Bolts (6) 2. Rotor assembly Figure 9-11 Rotor/Fan Assembly 558867 1. Sling 2. Fan guard 3. Two-jaw puller Figure 9-10 Stator Assembly Removal 33.

  • Page 98: Collector Ring And Bearing Replacement (6Ekod/5Efkod Model)

    9.2 Collector Ring and Bearing 9.3 Reassembly Replacement (6EKOD/5EFKOD 1. Clamp the rotor in a soft-jaw vise. Install a new Model) drive disc and fan on the rotor. Tighten the six bolts to 45 Nm (34 ft. lbs.) See Figure 9-15.
  • Page 99 19. Replace the junction box controller panel. 8. 6EKOD/5EFKOD Model: Feed the brush leads inside the stator housing up through the opening. 20. Reconnect the P1 (35 pin) and P2 (8 pin) Secure the brush holder using the original screws.
  • Page 100 Notes 100 Section 9 Generator Disassembly/Reassembly TP-6774 2/14a...

  • Page 101: Section 10 Wiring Diagrams

    10.1 Wiring Diagram Reference Model Point-to-Point Figure Schematic Figure Accessory Figure 6EKOD/5EFKOD 9EKOZD/7EFKOZD GM79008-C Figure 10-3 ADV-7995-C Figure 10-4 GM33846-D Figure 10-7 11EKOZD/9EFKOZD Figure 10-1 Wiring Diagrams for Units without Isolated Ground...
  • Page 102 GM79008-C Figure 10-3 Wiring Diagram, Point-to-Point 102 Section 10 Wiring Diagrams TP-6774 2/14a...
  • Page 103 ADV7995-C Figure 10-4 Wiring Diagram, Schematic TP-6774 2/14a Section 10 Wiring Diagrams...
  • Page 104 GM79009-E Figure 10-5 Isolated Ground Wiring Diagram, Point-to-Point 104 Section 10 Wiring Diagrams TP-6774 2/14a...
  • Page 105 ADV7996-D Figure 10-6 Isolated Ground Wiring Diagram, Schematic TP-6774 2/14a Section 10 Wiring Diagrams...
  • Page 106 GM33846-D Figure 10-7 Accessory Interconnection Drawing 106 Section 10 Wiring Diagrams TP-6774 2/14a...

  • Page 107: Manual Marine (Ship-To-Shore) 2 Wire And 3 Wire Transfer Switches

    10.2 Manual Marine (Ship-to-Shore) 2 Wire and 3 Wire Transfer Switches Electro Switch 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load To Load Kraus Naimler/American Solenoid (Early Rectangular Design) 2-Wire Generator Sets 3-Wire Generator Sets To Shore To Generator...

  • Page 108: Manual Marine (Ship-To-Shore) 4 Wire Transfer Switch

    10.3 Manual Marine (Ship-to-Shore) 4 Wire Transfer Switch Kraus Naimer/American Solenoid 4-Wire, three phase Generator Sets To Generator To Shore Power L3 L0 To Load I-940 108 Section 10 Wiring Diagrams TP-6774 2/14a...

  • Page 109: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E-Stop emergency stop alternating current cubic inch displacement etc. et cetera (and so forth) analog to digital centerline...
  • Page 110 Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute kilogram microfarad right side F kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...

  • Page 111: Appendix B Common Hardware Application Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 112: Appendix C General Torque Specifications

    Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Aluminum Torque Grade 2 Grade 5 Grade 8 Size Measurement Grade 2 or 5 8-32 Nm (in. lb.) (16) (20) — 10-24 Nm (in.

  • Page 113: Appendix D Common Hardware Identification

    Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)

  • Page 114: Appendix E Common Hardware List

    Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
  • Page 115 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Full Thread), Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), continued continued M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M933-12016-60...
  • Page 116 Metric, continued Part No. Dimensions Type Hex Nuts M934-03-50 M3-0.50 Standard M934-04-50 M4-0.70 Standard M934-04-B M4-0.70 Brass M934-05-50 M5-0.80 Standard M934-06-60 M6-1.00 Standard M934-06-64 M6-1.00 Std. (green) M6923-06-80 M6-1.00 Spiralock M982-06-80 M6-1.00 Elastic Stop M934-08-60 M8-1.25 Standard M6923-08-80 M8-1.25 Spiralock M982-08-80 M8-1.25 Elastic Stop...
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  • Page 120 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com Kohler Power Systems Asia Pacific Headquarters TP-6774 2/14a 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 E 2012 and 2014 by Kohler Co. All rights reserved.

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