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Kohler 8-32EOZD Service

Marine generator sets
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Marine Generator Sets
Models:
8- -32EOZD
6.5- -27EFOZD
TP-6255 7/06a

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Summary of Contents for Kohler 8-32EOZD

  • Page 1 Service Marine Generator Sets Models: 8- -32EOZD 6.5- -27EFOZD TP-6255 7/06a...

  • Page 2: Product Identification Information

    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 Product Identification Information ............Safety Precautions and Instructions .
  • Page 4 7.3.4 Stopping Sequence, Master Switch Moved to OFF/RESET ..7.3.5 Stopping Sequence, Remote Stop ....... Faults .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Battery electrolyte is a diluted Electromechanical equipment, sulfuric acid. Battery acid can cause including generator sets, transfer severe injury or death. Battery acid WARNING switches, switchgear, and accessories, can cause blindness and burn skin. can cause bodily harm and pose Always wear...
  • Page 6 Battery short circuits. Explosion Combustible materials. A fire can WARNING can cause severe injury or death. cause severe injury or death. Short circuits can cause bodily injury Generator set engine fuels and fuel and/or equipment damage. vapors are flammable and explosive. Disconnect battery before...
  • Page 7 Exhaust System Inspecting the exhaust system. Fuel System Carbon monoxide can cause severe nausea, fainting, or death. For the WARNING safety of the craft’s occupants, install a WARNING carbon monoxide detector. Consult the boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use.
  • Page 8 The fuel system. Explosive fuel Ignition-protected equipment. Grounding electrical equipment. vapors can cause severe injury or Explosive fuel vapors can cause Hazardous voltage cause death. Vaporized fuels are highly severe injury or death. Gasoline severe injury or death. Electrocution explosive. Use extreme care when vapors can cause an explosion.
  • Page 9 Electrical backfeed to the utility. Moving Parts WARNING Hazardous backfeed voltage can cause severe injury or death. WARNING Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is Hot engine and exhaust system. opened.
  • Page 10 Tightening the hardware. Flying NOTICE NOTICE projectiles can cause severe injury Voltage reconnection. Affix a notice Electrostatic discharge damage. or death. Loose hardware can cause to the generator set after reconnecting Electrostatic discharge (ESD) the hardware or pulley to release from the set to a voltage different from the damages electronic circuit boards.

  • 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-6255 7/06...

  • Page 13: Section 1 Specifications

    11.5/17.5/20/23/27EFOZD 115/230 an exhaust mixer. 110/190 Kohler Co. develops all Kohlerr marine generator set 115/230 ratings using accepted reference conditions of 25_C 11.5/17.5/20/23/27EFOZD 120/208 (77_F) and pressure of 29.2 in. Hg dry barometer. ISO...

  • Page 14: Engine

    1.2 Engine 10EOZD/ 8.5EFOZD/ 8EOZD/ 9EOZD/ 13EOZD/ 14EOZD/ 15.5EOZD/ 9EFOZD Generator Model 6.5EFOZD 7EFOZD 11EFOZD 11.5EFOZD 13EFOZD Number of cylinders Type 4 cycle 4 cycle, turbocharged Cylinder block material Cast iron Cylinder head material Cast iron Stamped Crankshaft material Forged steel forging Piston rings 2 compression/1 oil...
  • Page 15 10EOZD/ 8.5EFOZD 8EOZD/ 9EOZD/ 13EOZD/ 14EOZD/ 15.5EOZD/ 9EFOZD Generator Model 6.5EFOZD 7EFOZD 11EFOZD 11.5EFOZD 13EFOZD 51 (2) with sound shield 76 (3) with sound shield Water cooled exhaust outlet hose ID, mm (in.) 51 (2) without sound shield 76 (3) without sound shield 3/8 NPT with sound shield Fuel inlet size 1/4 NPT without sound shield...
  • Page 16 20EOZD/ 17EFOZD/ 28EOZD/ 32EOZD/ 17.5EFOZD 23EFOZD 27EFOZD 23EOZD/ 24EOZD/ (1 and 3 Ph.) (1 and 3 Ph.) Generator Model (1 and 3 Ph.) 20EFOZD 20EFOZD Number of cylinders Type 4 cycle 4 cycle, turbocharged 4 cycle, naturally aspirated Cylinder block material Cast iron Cylinder head material Cast iron...
  • Page 17 20EOZD/ 17EFOZD/ 28EOZD/ 32EOZD/ 17.5EFOZD 23EFOZD 27EFOZD 23EOZD/ 24EOZD/ (1 and 3 Ph.) (1 and 3 Ph.) Generator Model (1 and 3 Ph.) 20EFOZD 20EFOZD 3/8 NPT with sound shield Fuel inlet size 1/4 NPT without sound shield 3/8 NPT with sound shield Fuel return size 1/4 NPT without sound shield Fuel injection pressure, kgf/cm sq.

  • Page 18: Generator, 4 Lead

    1.3 Generator, 4 Lead 8EOZD/ 9EOZD/ 10EOZD/ 13EOZD/ 15.5EOZD/ Component Specification 6.5EFOZD 7EFOZD 9EFOZD 11EFOZD 13EFOZD Hot exciter field voltage/amperage readings at rated voltage No load (63 Hz)—volts/amps 4/0.9 4/0.9 4/0.8 4/0.7 4/0.7 Full load (60 Hz)—volts/amps 9/1.5 9/1.5 12/2.2 12/1.8 14/2.3 Exciter field resistance (cold)—ohms @ 20_C (68_F)

  • Page 19: Generator, 12 Lead

    1.4 Generator, 12 Lead 10EOZD/ 14EOZD/ 20EOZD/ 24EOZD/ Component Specification 8.5EFOZD 11.5EFOZD 17.5EFOZD 20EFOZD Hot exciter field voltage/amperage readings at rated voltage No load (63 Hz)—volts/amps 4/0.9 6/0.9 8/1.4 8/1.4 Full load (60 Hz)—volts/amps 12/2.2 17/2.6 14/2.1 16/2.4 Exciter field resistance (cold)—ohms @ 20_C (68_F) Exciter armature resistance (cold)—ohms (line-to-line) 1.18 0.51...

  • Page 20: Service Views

    1.5 Service Views ADV-6843- 13- -24EOZD & 11- -20EFOZD Models Non Service-Side View GM30645D- 1. ADC 2100 Control 18. Oil drain valve and hose 2. Run-Off/Reset-Auto switch 19. Strain relief for the load lead cable 3. Nameplate 20. Cooling air inlet 4.

  • Page 21: Torque Specifications

    1.6 Torque Specifications Follow the general torque specification found in Appendix C of this manual unless noted below. 10EOZD/ 8.5EFOZD 8EOZD/ 9EOZD/ 13EOZD/ 14EOZD/ 15.5EOZD/ 9EFOZD Generator Model 6.5EFOZD 7EFOZD 11EFOZD 11.5EFOZD 13EFOZD Overbolts 34 Nm (25 ft. lbs.) Rotating diode board 38 Nm (28 ft.
  • Page 22 Notes Section 1 Specifications TP-6255 7/06...

  • Page 23: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance 2.1 General Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator Schedule routine maintenance using the service set as follows: (1) Move the generator set master switch to the schedule located in the generator set operation manual OFF position.

  • Page 24: 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 25: Section 3 Intake And Exhaust System

    Section 3 Intake and Exhaust System 3.1 Air Intake Silencer/Cleaner 14/15.5/23/24EOZD and 11.5/13/20EFOZD Models: At the interval specified in the service schedule, clean or These models round, polyurethane, replace the air intake silencer element. Clean the sound-absorbing-type intake silencer to silence the silencer more frequently if the generator set operates in intake air drawn into the cylinder head from the intake dirty, dusty conditions.

  • Page 26: Exhaust System Inspection

    3.2 Exhaust System Inspection 3.3 Servicing Mixing Elbow The mixing elbow combines high-temperature exhaust WARNING with cooling seawater. The mixture when exposed to engine vibration makes conditions conducive to rapid deterioration and failure if the elbow is not properly maintained. 1.
  • Page 27 TP-6071-32 1. Turbocharger assembly 2. Gaskets 3. Exhaust elbow 4. Exhaust manifold 5. Petcock PT 1/8 TP-6071-32 Figure 3-4 Turbocharger Components, Typical 1. Compressor housing 2. Rotor assembly (turbo) 3. Housing assembly (blower) 4. Plate assembly (seal) 5. Circlips 6. Housing assembly (bearing) 7.
  • Page 28 Notes Section 3 Intake and Exhaust System TP-6255 7/06...

  • Page 29: Section 4 Fuel System

    Section 4 Fuel System 4.1 General Fuel Filter Replacement Procedure In most installations, both the generator set and the 8/9EOZD and 6.5/7EFOZD Models: propulsion engine operate from a common fuel tank with 1. Place the generator set on/off switch in the OFF a dual dip tube arrangement.
  • Page 30 10- -32EOZD and 9- -27EFOZD Models: 9. Bleed the system. See Section 4.2.1, Bleeding the Fuel System. 1. Place the generator set on/off switch in the OFF position. 2. Disconnect the generator set engine starting battery, negative (--) lead first. 3.

  • Page 31: Bleeding The Fuel System

    4.2.1 Bleeding the Fuel System 2. Initiate the auto/start sequence until fuel, free of air bubbles, flows from the injection pump screw. Bleed air from the fuel system to prevent starting failures and/or erratic operation. One or more of the following 3.

  • Page 32: 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 33: Section 5 Cooling System

    Section 5 Cooling System 5.1 General 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 Heat exchanger cooling consists of a heat exchanger release pressure, cover the pressure cap with a thick cloth and with coolant recovery tank, thermostat, rubber impeller then slowly turn the cap counterclockwise to the first stop.

  • Page 34: Water-Cooled Exhaust Manifold

    5.2 Water-Cooled Exhaust 5.3 Closed Heat Exchanger Manifold In a closed cooling system, seawater circulates through separate chambers within the heat exchanger to cool Each marine generator set has a water-cooled exhaust the engine coolant. The seawater then mixes with manifold.

  • Page 35: Flush And Clean Cooling System

    5.5 Flush and Clean Cooling System For optimum protection, drain, flush, and refill the cooling system at the interval listed in the service schedule. Pay special attention to the coolant level. When refilling the cooling system, allow time for complete refill of the engine water jacket.

  • Page 36: Belt Tension

    8. Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing. 9. Open the seacock. 10. Start the generator set and check for leaks. 11. Stop the generator set and repair leaks or replace components as necessary.

  • Page 37: Battery Charging Alternator Belt Tensioning Procedure

    5.8.2 Battery Charging Alternator Belt 2. Remove the anticorrosion zinc anode (plug) from the heat exchanger. Tensioning Procedure 3. Use a wire brush to remove the loose corrosion on 1. Remove the belt guard. the anticorrosion zinc anode. Replace the anode 2.

  • Page 38: Siphon Break

    5.9 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 39: Section 6 Troubleshooting

    Section 6 Troubleshooting 6.1 Introduction 6.3 General Corrective action and testing in many cases requires Before beginning the troubleshooting procedures, read knowledge of electrical systems and electronic circuits. all the safety precautions at the beginning of this Have an authorized service distributor/dealer perform manual.
  • Page 40 Troubleshooting Chart Problem Possible Cause Corrective Action Reference Generator set Weak or dead battery Recharge or replace battery. Generator Set O/M does not crank Battery connections Check for reversed or poor battery — connections. Open circuit in engine/controller Check for loose connections. Section 8.13 connections Check the wire harness continuity.
  • Page 41 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Generator set No fuel Check the fuel supply. — cranks but Loose connection or open circuit Check for loose or open Section 10 does not start connections at the fuel solenoid (lead 70A).
  • Page 42 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Generator set Air cleaner clogged Replace element. Section 3 operates Governor adjustment incorrect Adjust governor stability. Section 4.4 erratically erratically Inadequate cooling (hot engine Inspect air inlet and outlet. — only) Carbon buildup in engine Clean cylinder head.
  • Page 43 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Light flicker Voltage stability (gain) setting Check and adjust the voltage Section 7.5.3 stability (gain) setting using the ADC 2100. Incorrect controller configuration Check and adjust the controller Section 7.5 High generator configuration parameters.
  • Page 44 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference No output Open wiring, terminal, or pin in Check continuity. Section 7.7 voltage buildup circuit or SCR module (continued) circuit Rotor connections Check for open circuit in the rotor Section 8.6 connection circuit (leads FN and FP to the SCR and RIB).

  • Page 45: Section 7 Controller

    Section 7 Controller 7.1 Introduction configuration adjustment covered Section 7.5. This section covers operation, configuration, A silicon controlled rectifier (SCR) module works with adjustment, and replacement of the ADC 2100 the controller to regulate the output voltage. controller. See Section 6 for troubleshooting Section 7.7.

  • Page 46: Advanced Digital Control Display And Keypad

    7.2 Advanced Digital Control Controller Display Display and Keypad Item Description Crank indication Displays CC_1, CC_2, or CC_3 to indicate The Advanced Digital Control has an LED display and a the 1st, 2nd or 3rd attempt to start the engine. The last digit flashes during the three-button keypad.

  • Page 47: Sequence Of Operation

    7.3 Sequence of Operation When the engine comes up to speed, the low oil pressure switch contacts open. The following sections describe the controller sequence Note: The controller circuit board prevents fault of operation during generator start, run, stop, and fault shutdowns during startup until the crank shutdown modes.

  • Page 48: Running Sequence

    7.3.3 Running Sequence 7.4 Faults When the engine speed reaches 750 rpm, the crank 7.4.1 Fault Shutdowns relay deenergizes and the crank LED (3) turns off. When the output voltage on leads 11 and 44 (for 1-phase Under the fault conditions listed in Figure 7-4, the ADC models) or leads 7, 8, and 9 (for 3-phase models) displays a fault code and the generator set shuts down.
  • Page 49 Code Fault Description Check Auxiliary fault Input from a customer-supplied switch that closes Check the cause of the auxiliary fault. input shutdown when the fault is active. Shutdown occurs 0.3 seconds after the fault is detected and will not start when the fault is active (input is grounded).

  • Page 50: Controller Configuration And Adjustment

    7.5 Controller Configuration and Follow the instructions in Figure 7-7 to enter the configuration mode while the engine is not running and Adjustment then step through the following parameters. Use the ∧ ∨ up ( ) and down ( ) arrow buttons to select the The first step in troubleshooting the controller is to verify appropriate setting for the application.
  • Page 51 Parameter Setting Definition Connect Unit’s system voltage and Single phase, 2 Wire, 60 Hz, 100 VAC 1Ph, 2W frequency Single phase, 3 Wire, 60 Hz, 100 VAC 1Ph, 3W Uu00 Uu00 Single phase, 2 Wire, 60 Hz, 120 VAC 1Ph, 2W Single phase, 3 Wire, 60 Hz, 120 VAC 1Ph, 3W Single phase, 3 Wire, 60 Hz, 120/240 VAC...
  • Page 52 Controller Configuration Mode: (Use Figure 7-6 with Controller Parameters.) Hold the Select button: Display: Move the generator set master switch to the RUN position. (The generator set engine will not start.) Wait about 5 seconds until the display shows the 1 0 4 program version number.
  • Page 53 Pressing the up arrow key at the Adnc display (See Figure 7-7) puts you into the Advanced Configuration Mode. Press: E d 0 x To set the engine data input type. To enter battery voltage selection mode. To toggle between 12 and 24 VDC. B t 1 2 12-volt models B t 2 4...
  • Page 54 Output Voltage Adjustment Mode: Display :* x x x x Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours. Hold: Wait about 5 seconds until the display changes from runtime hours to the program version number.

  • Page 55: Controller Application Program

    7.6 Controller Application SCR Module Test Procedure Program Required equipment: The controller’s application program version number is Ohmmeter displayed on the LED screen during the key sequence to 12-volt test lamp (or voltmeter) enter the configuration mode. Hold the Select button 12-volt DC power source and move the generator set master switch to the RUN position.
  • Page 56 9. Connect the positive (+) lead from the DC power source, with the lamp in series, to terminal AC1 on the SCR module. The lamp should not glow. (--) 10. Connect the jumper, with the resistor in series, from the positive lead of the DC power source to terminal G1 on the SCR module.

  • Page 57: Continuous Power Mode Jumper, If Equipped

    7.8 Continuous Power Mode Note: The controller is powered by the generator set engine starting battery. Jumper, if equipped A jumper on connector P7 on the back of the controller Note: The P7 jumper was available on generator sets causes the controller to remain powered at all times. with serial numbers before 2051415.

  • Page 58: Master Switch

    Procedure to disconnect the continuous power 9. Reconnect the generator set engine starting mode jumper (optional). battery, negative (--) lead last. 10. Reconnect power to the battery charger, if Note: The P7 jumper was available on generator sets equipped. with serial numbers before 2051415. 11.

  • Page 59: Relay Interface Board (Rib)

    7.10 Relay Interface Board (RIB) The standard relay interface board (RIB) contains the K2 crank, K3 flash, and K5 run relays. Three LEDs COMMON FAULT indicate relay operation. See Figure 7-14. Refer to the schematic diagram in Section 10 for the standard relay board connections.

  • Page 60: Controller Replacement

    7.11 Controller Replacement 4. Sound-Shielded Models: Open the service-side door. If the troubleshooting procedures in Section 6 identify a 5. Sound-Shielded Models: Release the two faulty controller, use the procedure in this section for quarter-turn fasteners located underneath the roof. controller replacement.
  • Page 61 9. Disconnect wiring harness plugs P1, P15, and P16 13. Verify that the generator set master switch is in the from the ADC controller. OFF position. 10. Loosen and remove the four controller mounting 14. Reconnect the engine starting battery, negative (--) screws at the front of the controller.
  • Page 62 Notes Section 7 Controller TP-6255 7/06...

  • Page 63: Section 8 Component Testing And Adjustment

    Section 8 Component Testing and Adjustment 8.1 Theory of Operation These generator sets utilize a rotating-field alternator to produce AC voltage. Upon activation of the generator master switch, DC current from the battery magnetizes 2100 the rotor (field). When the magnetized rotor rotates within the stator windings, an electrical voltage develops within the stator.
  • Page 64 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 8.7, Stator. Compare the readings to the whenever electricity is present. Turn off the main circuit output values shown...

  • Page 65: Exciter Field

    8.3 Exciter Field 5. Check the exciter field for a short-to-ground condition. Use a megohmmeter to apply 500 volts Direct current from the battery magnetizes the exciter DC to the FN or FP lead and the exciter field frame. Figure 8-5. Follow megohmmeter field.

  • Page 66: Exciter Armature

    8.4 Exciter Armature The exciter armature supplies excitation current to the generator main field through the rectifier module. Test the exciter armature as described in the following steps. Exciter Armature Test Procedure: 1. Disassemble the alternator. Refer to Section 9. 2.

  • Page 67: Rectifier Module

    8.5 Rectifier Module 8.6 Rotor The rectifier module located between the exciter The generator rotor (magnetized by DC from the rectifier armature and the main field converts AC from the exciter module) rotating within the stator windings induces AC armature to DC, which magnetizes the generator main in the stator windings.

  • Page 68: Stator

    6196 Figure 8-11 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 69 Leads Continuity 1 and 4 2 and 5 3 and 6 7 and 10 8 and 11 9 and 12 55 and 66 1 and 2, 3, 7, 8, or 9 1 and 55 Any stator lead and ground TP-5983-7 Figure 8-13 Stator Continuity Test Results on a Good 1.

  • Page 70: Voltage

    8.8 Voltage WARNING 8.8.1 Voltage Regulation Voltage regulation is performed by the Advanced Digital Control (ADC) and the SCR module. The ADC monitors Moving rotor. Hazardous voltage. generator output voltage and adjusts the excitation Can cause severe injury or death. current to the rotor through the SCR module.
  • Page 71 5. Check and readjust the voltage if necessary. 6. Set the voltmeter to measure frequency. Adjust the engine speed to the cut-in frequency shown in Figure 8-17 by adjusting the governor as described in Section 4.4. 7. Set the voltmeter to measure voltage. Adjust the volts/Hz (parameter 3P) until the voltage level measured by the voltmeter begins to drop.

  • Page 72: Four-Lead Reconnection

    8.9 Four-Lead Reconnection 8.9.2 100- -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 73: 240-Volt Configurations

    8.9.3 200- -240-Volt Configurations 8.10 Twelve-Lead Reconnection The 200--240-volt configuration does not use a jumper The reconnection procedure following details voltage 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 74: Fault Shutdown Tests

    8.11 Fault Shutdown Tests WARNING Verify the operation of the generator set overspeed, overcrank, and low oil pressure shutdowns by performing the following tests. If these tests are inconclusive, test individual shutdown circuit Hot engine and exhaust system. components (wiring harness, switch, etc.) as described Can cause severe injury or death.

  • Page 75: Fault Shutdown Switches

    8.11.2 Fault Shutdown Switches replacing the LOP switch. To test the LOP switch, reinstall the switch and start the generator set. If the unit Check the low oil pressure and high engine temperature shuts down, disconnect lead 13 from the LOP switch shutdown switches on the engine by performing the and reset the controller.

  • Page 76: Fuses

    8.12 Fuses 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 engine harness junction connections with tools or jewelry while making adjustments or 9EOZD/7EFOZD models) contains three inline fuses. repairs.
  • Page 77 Generator Set Master Switch Ohmmeter Ohmmeter Ohmmeter Readings for Operative Component Position Connections Scale Components* Generator set master RUN and VBAT R x 100 Zero ohms (continuity). Any other reading switch switch (See Figure 8-29) (See Figure 8 29) indicates a bad switch. OFF/RESET No reading (open circuit).
  • Page 78 Notes Section 8 Component Testing and Adjustment TP-6255 7/06...

  • Page 79: Section 9 Generator Disassembly/Reassembly

    Section 9 Generator Disassembly/Reassembly 9.1 Disassembly 4. Sound-Shielded Models: Open the service-side door. Disconnect all of the external connections—battery 5. Sound-Shielded Models: Release the two cables at the battery (negative (--) lead first), AC-output quarter-turn fasteners located underneath the roof. leads, remote interface connector, water line at the See Figure 9-1.
  • Page 80 9. Disconnect wiring harness plugs P1, P15, and P16 from the ADC 2100. 10. Loosen and remove the four controller mounting screws at the front of the controller. Figure 9-2. Remove the controller. tp6196 1. Controller mounting screws (4 ea.) Figure 9-2 ADC 2100 Mounting Screws 1.
  • Page 81 13. Disconnect the FP and FN leads. 18. Attach a hoist hook to the generator lifting eye. See Figure 9-7. 14. Remove the four bolts to remove the exciter field. See Figure 9-5. Note: The hoist capacity rating should be one-half ton or greater.
  • Page 82 22. Install a sling capable of handling the weight of the stator housing on the stator housing. Figure 9-8. 23. Use a two-jaw puller to pull the end bracket/stator assembly from the bearing on the rotor shaft. See Figure 9-8. 24.

  • Page 83: Reassembly

    Note: Install the fan with the flange side facing away from the flywheel. 4. Replace the O-ring in the end bracket bearing bore. Use a sling to support the stator assembly while installing the stator over the rotor. Do not damage the rotor.
  • Page 84 7. Apply antiseize compound to the keyed end of the 11. Install tie wraps to secure the wires as necessary. rotor shaft. Bring the rotor leads through the bores 12. Reconnect the leads to the circuit breaker and in the armature while installing the armature on the neutral stud (LO) as marked during disassembly.

  • Page 85: Section 10 Wiring Diagrams

    Section 10 Wiring Diagrams WARNING WARNING Moving rotor. Hazardous voltage. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working on the generator set.
  • Page 86 GM30264-F Figure 10-1 Wiring Diagram for All Models Except 9EOZD/7EFOZD (See Figure 10-2 for 9EOZD/7EFOZD Model) Section 10 Wiring Diagrams TP-6255 7/06...
  • Page 87 GM46351- Figure 10-2 Wiring Diagram for 9EOZD/7EFOZD Model TP-6255 7/06 Section 10 Wiring Diagrams...
  • Page 88 ADV6845A-F Figure 10-3 Wiring Schematic for All Models Section 10 Wiring Diagrams TP-6255 7/06...
  • Page 89 ADV6845B-F Figure 10-4 Wiring Diagram, Schematic for All Models TP-6255 7/06 Section 10 Wiring Diagrams...

  • Page 90: Manual Marine (Ship-To-Shore) 2 Wire And 3 Wire Transfer Switches

    10.1 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 91: Manual Marine (Ship-To-Shore) 4 Wire Transfer Switch

    10.2 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 TP-6255 7/06 Section 10 Wiring Diagrams...
  • Page 92 Notes Section 10 Wiring Diagrams TP-6255 7/06...

  • Page 93: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex.
  • Page 94 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter μF microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat.

  • Page 95: 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 96: Appendix C General Torque Specifications

    Appendix C General Torque Specifications Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated literature instructions give no specific torque values. threads. All torque values are +0%/--10%. The charts list values for new plated, zinc phosphate, or American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into...

  • Page 97: 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 98: 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 99 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Hex Nuts M931-06040-60 M6-1.00 x 40 M933-04006-60 M4-0.70 x 6 M934-03-50 M3-0.50 Standard...
  • Page 100 TP-6255 7/06...
  • Page 101 TP-6255 7/06...
  • Page 102 TP-6255 7/06...
  • Page 103 TP-6255 7/06...
  • Page 104 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-6255 7/06a 7 Jurong Pier Road Singapore 619159 E 2004 and 2006 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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