Page 1 Service Marine Generator Sets Models: 13- 40EKOZD 11- 35EFKOZD Controller: Decision-Makerr 3500 TP-6953 7/19f...
Page 2 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 Section 3 Scheduled Maintenance ............General .
Page 5 9.2.1 Removal ........... . . 9.2.2 Installation .
Page 6 11.8 FRX Alternator Winding Maintenance ........Section 12 Paralleling System Information .
Page 7 13.4.10 Fuel Level Threshold ......... . 13.4.11 Min Gens Online .
Page 8 Appendix A Abbreviations ..............Appendix B Common Hardware Application Guidelines .
Page 9: Safety Precautions And Instructions
Safety Precautions and Instructions Accidental Starting Servicing the air cleaner. A sudden IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, backfire can cause severe injury or including generator sets, transfer death. Do not operate the generator WARNING switches, switchgear, and accessories, with cleaner/silencer can cause bodily harm and pose removed.
Page 10 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 11 Hot Parts High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the WARNING 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.
Page 12 Notes Safety Precautions and Instructions TP-6953 7/19...
Page 13: 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 14 List of Related Literature Figure 1 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set. Models 13EKOZD and 13EKOZD and 15EKOZD and 15EKOZD and 11EFKOZD 11EFKOZD 13EFKOZD 13EFKOZD...
Page 15 Installation Manual TP-7045 Operation Manual TP-7044 Parts Catalog* TP-6954 Service Manual (Engine) TP-6916 Kohler KDI Special Tools Manuals TP-7105, TP-7083, and TP-7084 Service Manual (Generator) TP-6953 SiteTecht Software Operation Manual TP-6701 Modbusr Communications Protocol Operation Manual TP-6113 * Includes generator and engine information.
Page 16 Notes Service Assistance TP-6953 7/19...
Page 17: Section 1 Specifications
Section 1 Specifications 1.1 General 50 Hz Models Voltage Hz Ph 11EFKOZD and This manual covers maintenance, troubleshooting, and 12EFKOZD repair of the alternating current marine generator sets 110/190 listed in Figure 1-1. Consult the generator set nameplate 115/230 for specific generator set ratings. 120/208 11EFKOZD and 12EFKOZD...
Page 18 The 15EKOZD/13EFKOZD and 16EKOZD/13.5EFKOZD (single- and three-phase) models are powered by a Kohler Co. develops all Kohlerr marine generator set three-cylinder, water-cooled, four-cycle diesel engine ratings using accepted reference conditions of 25_C with a heat exchanger.
Page 19: Engine
1.2 Engine 13EKOZD/ 15EKOZD/ 20EKOZD/ 20EKOZD/ 23EKOZD/ 23EKOZD/ 11EFKOZD 13EFKOZD 17.5EFKOZD 16.5EFKOZD 20EFKOZD 19.5EFKOZD 14EKOZD/ 16EKOZD/ 21EKOZD/ 21EKOZD/ 24EKOZD/ 24EKOZD/ 12EFKOZD 13.5EFKOZD 18EFKOZD 17EFKOZD 20.5EFKOZD 20.5EFKOZD Generator Model (1 & 3 Ph.) (1 & 3Ph.) (1 Ph.) (3 Ph.) (1 Ph.) (3 Ph.) Number of cylinders Type...
Page 20 32EKOZD/ 40EKOZD/ 28EFKOZD 35EFKOZD Generator Model (1 & 3 Ph.) (1 & 3 Ph.) Number of cylinders 4 cycle, turbocharged, Type 4 cycle, turbocharged charge air cooled Governor Electronic Engine firing order (#1 cylinder on 1- 3- 4- 2 flywheel end or alternator end) Direction of rotation (as viewed from flywheel) Counterclockwise Combustion system...
Page 21: Service Views
1.3 Service Views Service-Side View Side View Non Service-Side View Top View ADV8558- 1. Emergency stop 17. Fuel pump 2. Decision-Makerr 3500 controller 18. Customer load lead connection 3. Nameplate (on top of controller) 19. Oil drain 4. Lifting eye 20.
Page 22 Service-Side View End View Non Service-Side View Top View ADV8857- 1. Emergency stop 19. Customer load lead connection 2. Decision-Makerr 3500 controller 20. Optional circuit breaker location 3. Nameplate (on front of junction box) 21. Fuel return connection 4. USB port 22.
Page 23: Introduction
1.4 Introduction These generator sets utilize a wound-field alternator to produce AC voltage. Upon activation of the generator The specification sheets for each generator set provide master switch, DC current from the battery magnetizes specific alternator and engine information. Refer to the the rotor (field).
Page 24 See the full wiring diagram in Section 17. ACTIVATOR BOARD GM88453 AUXILIARY POWER WINDINGS AC VOLTAGE SENSING AC VOLTAGE SENSING AC VOLTAGE SENSING EXCITER RECTIFIER ARMATURE AC VOLTAGE SENSING MODULE STATOR WINDINGS NOTE: Refer wiring diagram ADV-5875 in the Section voltage configurations.
Page 25: Permanent Magnet Alternator Concept-40Ekozd And 35Efkozd Models
1.6 Permanent Magnet Alternator The voltage recovery period of this type of alternator is several times faster than the conventionally wound field Concept—40EKOZD and brushless alternator because it does not have to 35EFKOZD Models contend with the inductance of the exciter field. It also has better recovery characteristics than the static A permanent magnet alternator is identified with one of excited machine because it is not dependent upon the...
Page 26 lead 3B 5B lead N A B C TP-6863-1 1. Rotor shaft 7. Exciter armature windings 13. Alternator protection (controller) 2. Rotor field windings (rotor assembly) 8. Exciter field magnets 14. Generator set controller 3. Stator main windings (stator assembly) 9.
Page 27: Electrical Values (13- 32Ekozd/11- 28Efkozd Models)
1.7 Electrical Values (13- 32EKOZD/11- 28EFKOZD Models) 13EKOZD/ 15EKOZD/ 20EKOZD/ 23EKOZD/ 11EFKOZD 13EFKOZD 16.5EFKOZD 19.5EFKOZD 32EKOZD 14EKOZD/ 16EKOZD/ 21EKOZD/ 24EKOZD/ 12EFKOZD 13.5EFKOZD 17EFKOZD 20.5EFKOZD 28EFKOZD Component Specification (12-Lead) 4D3.1 4D3.8 4D4.2 4D5.0 4D8.3 Hot exciter field winding voltage/amperage readings at rated voltage No load (63 Hz)—volts/amps 6/0.7 8/1.2...
Page 28: Electrical Values (40Ekozd And 35Efkozd Models)
1.8 Electrical Values (40EKOZD and 35EFKOZD Models) Generator Models- > 40EKOZD/ 40EKOZD/ 35EFKOZD 3 Phase 35EFKOZD 1 Phase (Alternator Model 4P7BX) (Alternator Model 4Q7BX) Component Specification Cold Resistance Value (in ohms) Stator windings, 12 lead 0.069 Stator windings, 4 lead 0.025 Rotor windings 5.65...
Page 29: Exhaust Temperature Sender (Ets)
1.11 Exhaust Temperature Sender (ETS) GM89516- 1. Exhaust temperature sender Figure 1-9 Exhaust Temperature Sender Location, Typical Sender Shutdown at GM93708 60_C (140_F) 1.12 Low Seawater Pressure Switch (LWP) 13EKOZD Model Shown 24EKOZD Model Shown 32EKOZD Model Shown GM89516- GM102826-B GM102300- 1.
Page 30: Magnetic Pickup Sensor (13- 24Ekozd/11- 20.5Efkozd Models)
1.13 Magnetic Pickup Sensor (13- 24EKOZD/11- 20.5EFKOZD Models) GM89507- 1. Magnetic pickup sensor Figure 1-11 Magnetic Pickup Sensor Location Sensor Resistance Operating Gap GM92350 1 k Ohms ±10% @ 20_C (68_C) 1 mm (0.039 in.) Note: For 32/40EKOZD and 28/35EFKOZD models, consult the Engine Service Manual for speed sensor information. See the List of Related Literature found at the beginning of this manual for the publication number.
Page 31: Alternator Torque Values And Assembly Specifications
1.14 Alternator Torque Values and Assembly Specifications Use the torque values shown below during alternator assembly. For assembly torque values not shown, use the guidelines in Appendix C, General Torque Specifications. GM98819-C Figure 2 Alternator Assembly Torque Specs—13- 24EKOZD and 11- 20.5EFKOZD Models (Parts Shown May Vary Slightly Between Models) Loctiter is a registered trademark of the Henkel Corporation.
Page 32 GM95725-C Figure 1-12 Alternator Assembly Torque Specs—32EKOZD/28EFKOZD Models (Parts Shown May Vary Slightly Between Models) Section 1 Specifications TP-6953 7/19...
Page 33 GM101372-C Figure 1-13 Alternator Assembly Torque Specs—40EKOZD/35EFKOZD Models (Parts Shown May Vary Slightly Between Models) TP-6953 7/19 Section 1 Specifications...
Page 34: Introduction
1.15 Introduction D Generator Management. Programmable generator management based on manual selection, fuel level, or run time to optimize fuel usage, noise, This service manual provides controller and accessory maintenance, etc. troubleshooting and repair information for the following controller: D Historical Data Logging. Total number of successful starts of the generator is recorded and Decision-Makerr 3500 displayed.
Page 35: Decision-Makerr 3500 With Integral Voltage Regulator
1.17 Decision-Makerr 3500 with Voltage Regulation Menu Integral Voltage Regulator Voltage adjustment, 10% of system voltage V/Hz cut-in, 42- 62 Hz The voltage regulator is integral to the controller and Underfrequency unload slope, 0- 10% of system uses a patented hybrid voltage regulator design to voltage provide 0.5% no-load to full-load regulation using root-mean-square (RMS) voltage sensing.
Page 36: Specifications And Features
1.17.1 Specifications and Features Specification/Feature Voltage Regulator Type Integral with Decision-Makerr 3500 Integrated Voltage Regulator Patented Hybrid Design Status and Shutdown Indicators LEDs and Graphical LCD Display Operating Temperature - 40_C to 70_C (- 40_F to 158_F) Storage Temperature - 40_C to 85_C (- 40_F to 185_F) Humidity Withstand 5- 95% Condensing Salt Spray Tolerance...
Page 37: Section 2 Operation
Section 2 Operation 2.1 Prestart Checklist Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections. WARNING Inspect the exhaust system components (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and exhaust outlet) for cracks, leaks, and corrosion.
Page 38: Marine Inspection
2.2 Marine Inspection 2.3 Angular Limits During Operation See Figure 2-1 for angular operation limits. Kohler Co. recommends that all boat owners have their vessels inspected at the start of each boating season by 13- 24EKOZD/11- 20.5EFKOZD Models the US Coast Guard, the local Coast Guard Auxiliary, or...
Page 39: Controller Operation
(indicated by Generator engine may cause major engine damage that the Management) but they remain in Standby Mode Kohler Co. warranty does not cover. ready to start and run if needed. The controller operation includes several types of AUTO-OFF (Press AUTO and OFF together to remove a system start signal, if AUTO-RUN is active).
Page 40 that are in AUTO, will start and run. If the generator sets the Cooldown Delay parameter setting, regardless of the were already running, they will remain running but the coolant temperature. original source of that start signal will be ignored. The If the Cooldown Override is enabled (ON) in the contacts now have control.
Page 41: Battle Mode
EGR valve is properly connected. If 3. Press the generator set OFF/RESET button. all connections are good and the light continues to pulse (blink), see Figure 2-5 or contact an authorized Kohler 4. After resetting all faults using the controller reset distributor/dealer for service.
Page 42: System Fault Warning Lamp With Digital Displays
2.6.5 System Fault Warning Lamp with Average Generator Voltage Low. The fault lamp illuminates yellow and the alarm horn sounds when the Digital Displays generator encounters an under voltage condition. This The system FAULT lamp glows yellow and the alarm condition can be caused by a loss of a diode on the horn sounds indicating a warning fault but does not shut rectifier bridge, sensing problem, a winding failure,...
Page 43 Generator Frequency High. The fault lamp illuminates High Fail To Open Delay. The fault lamp illuminates yellow and the alarm horn sounds when the generator yellow and the alarm horn sounds when the circuit has an overfrequency condition. The output breaker breaker did not open as quickly as the controller trips.
Page 44: System Fault Shutdown Lamp With Digital Displays
Low Battery Voltage. The fault lamp illuminates yellow warning does not function during first the 30 seconds and the alarm horn sounds when the battery voltage after startup. drops below a preset level for more than 90 seconds. Not in Auto (Generator Master Control Switches). The fault lamp illuminates yellow and the alarm horn Engine Electrical Low Battery...
Page 45 Alternator Protection. The fault lamp illuminates red and Generator Total Real Power High. The fault lamp the unit shuts down because of an alternator overload or illuminates red, the alarm horn sounds, and the unit shuts short circuit. See Appendix D, Alternator Protection in the down when the generator set supplies more than 102% Generator Operation Manual for more information.
Page 46 Note: Overvoltage can damage sensitive equipment in Low Generator Frequency. The fault lamp illuminates less than one second. Install separate red, the alarm horn sounds, and the unit shuts down overvoltage protection on online equipment when the frequency drops below the underfrequency requiring faster than 2-second shutdown.
Page 47: Status And Notice Digital Displays
Note: The controller is equipped with an automatic The local display shows Alarm Silence: Auto Only when restart function. When speed drops below 25 Hz the alarm horn can be silenced only when in the AUTO (750 rpm) while the engine is running, the unit mode.
Page 48: Controller Resetting (Following System Shutdown Or Warning)
3. Connect Kohler SiteTecht and upload current button. firmware to the controller. The display will now power up. 4. Use Kohler SiteTecht to determine if the appropriate unit model is identified in the Genset Info menu. If not, re-apply the generator personality profile.
Page 49: Menu Displays
2.7 Menu Displays The Menu Summary List and Figure 2-12 provide a quick reference to the digital display data. Some digital display data may not be identical to your display due to generator set application differences. The closed bullet items represent main level data and the open bullet items are sub-level data.
Page 50 Menu Summary List (Legend: D First level submenu, d second level submenu, Z third level submenu) Metering Metering Generator Information Menu Menu (Continued) Menu (Continued) D Generator Metering CHARGER TEMP: ###_F D Configuration REDUCED OUTPUT ACTIVE: YES/NO L1-L2 VOLTS: ###V GENERATOR CONFIGURATION L2-L3 VOLTS: ###V TEMP COMPENSATION ACTIVE: YES/NO...
Page 51 Generator Information Generator Information Generator Information Menu (Continued) Menu (Continued) Menu (Continued) D Voltage Regulation Z PHASE MATCH WINDOW: ##.#_* Z STOP ACCUMULATOR: ##### Z PHASE DIFFERENCE: ###.#_ Z RUN TIME THRESHOLD: ###.#hrs* AVG GEN VOLTAGE L-L: ###.#V Z PHASE MATCH P GAIN: ##.##* only if in Run Time Management VOLTAGE ADJUST: ###.#V* Z PHASE MATCH I GAIN: ##.##*...
Page 52 Active Events Menu Menu (Continued) Menu D Resistive Input D Digital Input Rotate the dial to view Active Events: Warnings Analog Input 0:1 Digital Input 0:1 Shutdowns Analog Input 0:2 Digital Input 0:2 Statuses Analog Input 0:3 Digital Input 0:3 Notices Analog Input 0:4 Digital Input 0:4...
Page 53 From Controller Power-Up From Controller Sleep/Idle Operation Alternates Alternates every every 8 seconds 8 seconds F Changes after 3 seconds DIAL CLICK METERING GENERATOR INFO CONTROLLER CONFIG ACTIVE EVENTS DIAL TURN DIAL PUSH at METERING. Go to Figure 2-13. DIAL PUSH at GENERATOR INFO. Go to Figure 2-14. DIAL PUSH at CONTROLLER CONFIG.
Page 54 12:00 AM GENERATOR INFO 12/12/12 GENERATOR INFO EVENT HISTORY Note: Battery Charger Configuration menu options appear but do not apply. CONFIGURATION - - > to these models. VOLTAGE REGULATOR Note: Voltage Selector Switch menu options do not apply to these models. VOLTAGE SELECTOR SWITCH - - >...
Page 55 12:00 AM CONTROLLER CONFIG 12/12/12 CONFIGURATION COMMUNICATION SETUP CALIBRATION DIAL TURN DIAL PUSH DIAL PUSH DIAL PUSH 12:00 AM 12:00 AM 12:00 AM CONTROL CONFIG COMM SETUP CALIBRATION 12/12/12 12/12/12 12/12/12 MODBUS BAUD RATE: {M RATE}* GEN L1-L0 VOLTS: ###.#V* LANGUAGE: {LANGUAGE}* MODBUS ADDRESS:...
Page 56: Monitoring And Programming Setup
2.8 Monitoring and Programming Setup Modbusr/ Ethernet Ethernet Network Converter The user programmer can access the controller data Generator Set Personal Controller or with the controller digital display or a personal computer Computer Transfer with NIC (PC) with optional SiteTecht software to monitor and/or Switch Control Remote program.
Page 57: Warning Parameter Default Setting
Inhibit Time Delay. The inhibit time delay is the time Section 2.8.3 and Section 2.8.4 contain warnings and period following crank disconnect during which the faults with ranges and time delays including items that generator set stabilizes and the controller does not do not have user adjustments.
Page 58: Fault Parameter Default Setting
2.8.4 Fault Parameter Default Setting Figure 2-21 lists default settings for common faults. Fault Sensing Fault When Inhibit Time Display Condition Mechanism Condition Active Time Delay Cleared On E-Stop E-Stop switch input Input open Continuous 0, Always 1 sec. Fault removal and reset Locked rotor No rotation...
Page 59: Controller Parameters
Fault Sensing Fault When Inhibit Time Display Condition Mechanism Condition Active Time Delay Cleared On Intake air Engine specific. Running temperature Consult engine specifications. Fuel return Running 100_C temperature AC sensing loss Integral voltage No AC voltage at Running 10 sec. 3 sec.
Page 60 Parameter List Write Decision-Maker 3500 SiteTecht Parameter Access Units User Interface Notes Identity Vendor None Product None Firmware Version None Software Version: XXXXXXXX Engine Metering Engine Speed None R/min Engine Speed: ####RPM The speed at which the engine is presently running Engine Oil Pressure None Oil Pressure: ###PSI...
Page 61 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Generator Voltage L2-L3 None L2- L3 Volts: ###V Generator Voltage L3-L1 None L3- L1 Volts: ###V Generator Voltage Average Line To Line None AVG Gen Voltage L- L: ###V Generator Voltage L1-N None L1- L0 Volts: ###V Generator Voltage L2-N...
Page 62 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Engine Total Run Time Loaded None Hours Loaded: #####hrs The total number of hours that the engine has been running while supplying more than 1% of rated genset load Engine Total Run Time Unloaded None Hours Unloaded: #####hrs The total number of hours...
Page 63 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Genset Controller Date Format Always Date Format: Month Date Year/Date Month Year Genset Controller Time Format Always Time Format: Hr 12/Hr 24 Genset Personality Profile Ecm Model Locked Maximum Alternator Current None Used by thermal protection algorithm...
Page 64 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Gen Rating 1 50HZ Wye 190 380 Locked Gen Rating 1 50HZ Wye 200 400 Locked Gen Rating 1 50HZ Wye 208 415 Locked Gen Rating 1 50HZ Wye 220 440 Locked Gen Rating 1 50Hz Delta Locked...
Page 65 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Voltage Selector Switch Voltage Selector Switch Position Voltage Selector Switch Max Positions Voltage Selector Switch Position 1 Voltage Voltage Selector Switch Position 1 Frequency Voltage Selector Switch Position 1 Voltage Phase Connection Voltage Selector Switch Position 2 Voltage Not supported for these models.
Page 66 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Genset Fuel Type Stopped Fuel Type: Natural Gas/LP/ Gasoline/Diesel/ Unknown Battle Mode Always Emergency Battlemode: On/Off ECM Powered Mode Stopped Indicates whether the ECM Power is turned on Genset Application Locked Application Type: None/Marine/ Mobile/Standby/Prime...
Page 67 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Engine Crank Pause Delay Always Crank Pause Delay: ##s The length of time for the off-period of the crank cycle Engine Number Of Crank Cycles Stopped Crank Cycles Limit: ## The number of crank cycles before an over crank fault is indicated...
Page 68 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Genset Low Voltage Shutdown Limit Always Undervoltage: ##% Percentage of System Voltage that the generator voltage must drop below for an under voltage condition to be indicated Genset High Voltage Shutdown Limit Always Overvoltage: ##% Percentage of System...
Page 69 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Programmable Analog Resistive Input Analog Resistive Input Board Number Analog Resistive Input Io Number Analog Resistive Input Metered Value Analog Resistive Input Metered Relative Value Analog Resistive Input Enabled Analog Resistive Input Switch Logic Analog Resistive Input Function Analog Resistive Input Protectives Enabled Analog Resistive Input Event...
Page 70 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Voltage Input Critically High Warning Limit Analog Voltage Input High Shutdown Limit Analog Voltage Input Deadband Analog Voltage Input Relative Upper Range Limit Analog Voltage Input Relative Lower Range Limit Analog Voltage Input Relative Range Limit Deadband Not supported for these models.
Page 71 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Circuit Breaker Current Fault Delay Always CB Current Fault Delay: ##.#s 10 = 1.0 Sec Volts Hertz Okay Time Delay Always Volts-Hz OK Delay: ##.#s Sync Mode In Auto Always Sync Mode in Auto: Invalid/Off/Passive/Check/ Active/Dead Field...
Page 72 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Torque Sharing Integral Gain Always Torque Sharing Derivative Gain Always Frequency Trim Proportional Gain Always Freq Trim P Gain: ##.## Frequency Trim Integral Gain Always Freq Trim I Gain: ##.## Frequency Trim Derivative Gain Always Freq Trim D Gain: ##.##...
Page 73 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Gen Management Total Bus Capacity None Total Bus Capacity: #####kW Modbus Modbus Baud Rate Always Modbus Baud Rate: OFF/9600 Mpac DM: 0 = 9600; b/s/19200 b/s/38400 b/s/ 1 = 19200; 3 = 57600 57600 b/s/115200 b/s Modbus Slave Address Always...
Page 74 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Critically Low Warning Delay Always The time that the input must be within its warning operating range before a warning protective is indicated Analog Resistive Input High Warning Delay Always High Warning Delay: ##s The time that the input...
Page 75 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Relative Range Limit Delay Always Specifies what the debounce time is on the input after the inhibit time is met Analog Resistive Input Description Always Description: A user-defined description of this IO Programmable Analog Resistive Input 101 (See Figure 2-22) Analog Resistive Input Board Number...
Page 76 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input High Warning Delay Always High Warning Delay: ##s The time that the input must be within its warning operating range before a warning protective is indicated Analog Resistive Input Critically High Warning Delay Always The time that the input must be within its...
Page 77 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Description Always Description: A user-defined description of this IO Programmable Analog Resistive Input 102 (See Figure 2-22) Analog Resistive Input Board Number None I/O Board Number: X Indicates board number this IO point is located on Analog Resistive Input Io Number...
Page 78 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Critically High Warning Delay Always The time that the input must be within its warning operating range before a warning protective is indicated Analog Resistive Input Low Shutdown Delay Always Low Shutdown Delay: ##s The time that the input...
Page 79 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Io Number None Indicates the point number, of this IO type on this board, for this configuration Analog Resistive Input Metered Value None Measurement: ###.# Ohms The current value of the input (scaled to the units of the function ID) Analog Resistive Input Metered Relative Value...
Page 80 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Low Shutdown Delay Always Low Shutdown Delay: ##s The time that the input must be within its shutdown operating range before a shutdown protective is indicated Analog Resistive Input High Shutdown Delay Always High Shutdown Delay: ##s The time that the input...
Page 81 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Metered Value None Measurement: ###.# Ohms The current value of the input (scaled to the units of the function ID) Analog Resistive Input Metered Relative Value None The value of the input relative to the full range of the input...
Page 82 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Low Shutdown Delay Always Low Shutdown Delay: ##s The time that the input must be within its shutdown operating range before a shutdown protective is indicated Analog Resistive Input High Shutdown Delay Always High Shutdown Delay: ##s The time that the input...
Page 83 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Metered Value None Measurement: ###.# Ohms The current value of the input (scaled to the units of the function ID) Analog Resistive Input Metered Relative Value None The value of the input relative to the full range of the input...
Page 84 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Resistive Input Low Shutdown Delay Always Low Shutdown Delay: ##s The time that the input must be within its shutdown operating range before a shutdown protective is indicated Analog Resistive Input High Shutdown Delay Always High Shutdown Delay: ##s The time that the input...
Page 85 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Programmable Analog Voltage Input 106 (See Figure 2-22) Analog Voltage Input Board Number Not supported for these models. Analog Voltage Input Io Number Analog Voltage Input Metered Value None Measurement: ###.# Ohms The current value of the input (scaled to the units of the function ID)
Page 86 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Analog Voltage Input Low Shutdown Delay Analog Voltage Input High Shutdown Delay Analog Voltage Input Low Warning Limit Analog Voltage Input Critically Low Warning Limit Analog Voltage Input Low Shutdown Limit Analog Voltage Input High Warning Limit Analog Voltage Input Critically High Warning Limit Analog Voltage Input High Shutdown Limit...
Page 87 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Programmable Digital Input 109 (See Figure 2-22) Digital Input Board Number None I/O Board Number: X Indicates board number this IO point is located on Digital Input Io Number None Indicates the point number, of this IO type on this board, for this...
Page 88 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Digital Input Status None The current value of the input (scaled to the units of the function ID) Digital Input Enabled Always Enabled: On/Off Indicates whether this input is enabled Digital Input Logic Always The type of switch that is...
Page 89 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Digital Input Logic Always The type of switch that is connected to the input, where “normal” refers to the non-activated state Digital Input Function Always Function: Indicates the functionality of this IO point Digital Input Event Always Event:...
Page 90 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Digital Output Description Always Description: A user-defined description of this IO point. Programmable Digital Output 116 NOTE: Tied to the CBC output (See Figure 2-22) Digital Output Board Number None I/O Board Number: X Indicates board number this IO point is located on...
Page 91 Write Decision-Maker 3500 Access Units Notes SiteTecht Parameter User Interface Special Parameters Profile Saved Date File Version Address Password * Some functions require optional input sensors or are engine ECM dependent on some generator set models. [ ECM inputs are engine manufacturer dependent. TP-6953 7/19 Section 2 Operation...
Page 92: Programmable Inputs/Outputs
2.9.1 Programmable Inputs/Outputs SiteTecht Decision-Makerr Parameter 3500 Parameter Description Programmable Analog Resistive Inputs (See Figure 2-23 when Programmable Analog Resistive Inputs are used as Digital Inputs) This input measures the resistance applied between P1 pin 18 and P1 pin 31 on the controller. This input measures the resistance applied between P1 pin 30 and P1 pin 31 on the controller.
Page 93 Programmable Analog Resistive Input #1, used as Digital: Programmable Resistive Input #1 can be used as a Digital Input. When configured as a Digital Input, it can be configured under Programmable Digital Input 100. NOTE: This input is not recommended for connection to devices further than 30 m (98 ft.) from the generator set to avoid the potential damage to the sensitive resistive input measurement circuitry.
Page 94 Programmable Analog Resistive Input #4, used as Digital: Programmable Resistive Input #4 can be used as a Digital Input. When configured as a Digital Input, it can be configured under Programmable Digital Input 103. NOTE: This input is not recommended for connection to devices further than 30 m (98 ft.) from the generator set to avoid the potential damage to the sensitive resistive input measurement circuitry.
Page 95 Section 3 Scheduled Maintenance 3.1 General WARNING Schedule routine maintenance using the service schedule located in the generator set operation manual and the runtime hours shown on the controller. If the generator set will be subject to extreme operating conditions, service the unit accordingly. Accidental starting.
Page 96 Notes Section 3 Scheduled Maintenance TP-6953 7/19...
Page 97 Section 4 Exhaust System 4.1 Exhaust System Inspection 1. Press the generator set OFF/RESET button to shut down the generator set. WARNING 2. Disconnect the power to the battery charger, if equipped. 3. Disconnect the generator set engine starting battery, negative (- ) lead first. Carbon monoxide.
Page 98 4.2 Servicing Mixing Elbow 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 The mixing elbow combines high-temperature exhaust generator set as follows: (1) Press the generator set off/reset with cooling seawater.
Page 99 Section 5 Fuel System 5.1 General tube is shorter than the propulsion engine’s dip tube. With this arrangement, fuel may not be available to the In most installations, both the generator set and the generator set when the fuel supply is low. propulsion engine operate from a common fuel tank with Figure 5-1 for a fuel system schematic.
Page 100 Disabling the generator set. Accidental starting can Fuel Filter Cleaning/Replacement/Bleed Procedure cause severe injury or death. Before working on the (Secondary Filter on 32- 40EKOZD/28- 35EFKOZD generator set or equipment connected to the set, disable the Models) generator set as follows: (1) Press the generator set off/reset button to shut down the generator set.
Page 101 Fuel System Bleed Procedure (14- 24EKOZD/12- 20.5EFKOZD Models) 1. Loosen the fuel filter’s air vent screw. Figure 5-3. Place a suitable container underneath to collect the fuel. 2. Initiate the auto/start sequence until fuel, free of air bubbles, flows from the vent screw at the fuel filter. 3.
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Page 103 Section 6 Cooling System 6.1 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 6-1 for cooling system components. Seawater Freshwater (Coolant/Antifreeze) 1.
Page 104 6.2 Water-Cooled Exhaust WARNING Manifold Each marine generator set has a water-cooled exhaust manifold. The coolant solution circulates through the manifold, reducing the amount of heat radiated from the Hot coolant and steam. exhaust into the surrounding area. Can cause severe injury or death. Before removing the pressure cap, The engine thermostat is located at the location shown stop the generator set and allow it to...
Page 105 6.3 Coolant Replacement Including Heat Exchanger Service WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working generator set. Remove the negative (- ) lead first when disconnecting the battery. 1. Hose Reconnect the negative (- ) lead last when reconnecting the battery.
Page 106 10. Remove the heat exchanger tube. See Figure 6-8. Figure 6-5 Front Cover of Heat Exchanger 7. Remove the front cover and O-ring. Figure 6-8 Heat Exchanger Tube 8. Loosen the rear cover screws of the heat 11. Dip the heat exchanger tube into a solution of exchanger.
Page 107 Figure 6-13 Heat Exchanger’s Circlip 16. Reassemble the O-ring and rear cover and tighten the screws. See Figure 6-14. Figure 6-10 Reinstall Heat Exchanger 14. Reassemble the O-ring and front cover and tighten the screws. See Figure 6-11 and Figure 6-12. Figure 6-11 Reinstall the O-ring and Front Cover Figure 6-14 Rear Cover of Heat Exchanger 17.
Page 108 19. Check that the generator set is OFF. Note: For 20/23EKOZD and 21/24EKOZD 60 Hz models, proceed to Step 2. For all other models, 20. Reconnect the generator set engine starting proceed to Step 6. battery, negative (- ) lead last. 2.
Page 109 6.5 Flush and Clean Cooling Bleed Procedure (32/40EKOZD & 28/35EFKOZD Models) System 1. Remove the coolant fill cap. See Figure 1-2 for location. WARNING 2. Slowly fill the coolant system. Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working generator set.
Page 110 6.7 Impeller Inspection and Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe Replacement manner and in accordance with all applicable laws. WARNING 7. Replace the water drain pipe plug. 8. Fill the cooling system with recommended coolant. 9.
Page 111 8. Lubricate the impeller with soapy water before installation. 9. While installing the impeller, always rotate the drive shaft and the impeller together in the same direction as the engine rotation. 10. Inspect the coverplate and gasket for corrosion and/or damage. Replace components as necessary.
Page 112 WARNING Note: Unit shown with belt guard removed. Hazardous voltage. Moving parts. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death.
Page 113 7. While prying the seawater pump outward, tighten the adjusting screw. 8. Tighten the pivot screw. 9. Recheck and adjust as necessary. 10. Replace the belt guard. 11. Check that the generator set is OFF. 12. Reconnect the generator set engine starting battery, negative (- ) lead last.
Page 114 7. Clean the threaded hole of the heat exchanger and Anticorrosion Zinc Anode Replacement coat the threads of the anticorrosion zinc anode Replace When (plug) with pipe sealant suitable for marine New Anode Percent of Zinc applications. Cut the anticorrosion zinc to the Dimensions mm (in.) Models Remaining Is:...
Page 115 6.10 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.
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Page 117 Section 7 Troubleshooting 7.1 Introduction WARNING This section contains generator set troubleshooting, diagnostic, and repair information. Corrective action and testing often require knowledge of electrical and electronic circuits. To avoid additional Accidental starting. problems caused by incorrect repairs, have an Can cause severe injury or death.
Page 118 Controller firmware. Some problems may be solved by updating the controller’s application program. Check Tech Tools on the Kohler Power Resource Center for more information. A personal computer (laptop) and Kohlerr SiteTecht software are required to update the firmware.
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Page 145 Section 8 Decision-Makerr 3500 Controller 8.1 General Repair Information Go to the Overview Menu and verify that the Software (SW) Version is correct for the generator set model and This section contains Decision-Makerr 3500 controller alternator voltage. Use the operation manual for details repair information.
Page 146 8.3 Request and Status Messages 8.4 Factory Reserved Inputs Available user inputs dependent Request and Status Messages factory-reserved inputs for specific engine types, engine controls, and paralleling applications. See Figure 8-2 Display messages require the user to enter additional and Figure 8-3 for analog and digital inputs that are not data, confirm the previous entry or require time to user-selectable.
Page 147 Analog Resistive Input Analog Digital Oil Pressure (Resistive Sensor 1) (Continued) P1 Main Connector (35-Pin) Coolant Temperature (Resistive Sensor 2) Controller Ground (wire N4) (Battery - ) Lloyd’s Oil Pressure 2 (Resistive Sensor 3) Digital Input 4 (Lloyd’s High Oil Temp) High Exhaust Temperature (Resistive Sensor 4) (wire 69) Unused (Resistive Sensor 5)
Page 148 The service technician must SiteTecht Software Version 4.1 or higher from the install the three files into the replacement controller. Kohler Power Resource Center website using the TechTools button to download on your PC hard drive Application program contains the software that or disk if not already installed on your PC.
Page 149 8.6.3 Installation Procedure 3. Remove the existing controller and disconnect the electrical connections. WARNING a. Remove the junction box panels as needed to access the wiring. b. Remove the four controller panel screws. Note: Clearly mark disconnected leads/connectors from the controller Accidental starting.
Page 150 5. Restore power to the generator set. e. Disconnect the USB cable. a. Reconnect the generator set engine starting f. Power down the unit by using the battery battery, negative (- ) lead last. disconnect switch equipped) disconnecting the battery negative (- ) terminal. b.
Page 151 8.7 Synchronizing Test (Integral) Gain, Phase Match D (Derivative) Gain, and Speed Bias are highlighted. Synchronizing is the action of matching the RMS 5. Provide the generator set with a start signal voltage amplitude, cycle frequency and phase of the (AUTO-RUN).
Page 152 Notes 152 Section 8 Decision-Makerr 3500 Controller TP-6953 7/19...
Page 153 Section 9 Component Testing and Adjustment This section provides testing and troubleshooting Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury information on select controller and generator set and/or equipment damage. Do not contact electrical accessories.
Page 154 possibility of carbon monoxide poisoning. Seek medical Label wiring when disconnecting it for reconnection attention if the condition of affected persons does not improve later. within minutes of breathing fresh air. Remove wiring harnesses with plug connectors by Inspecting the exhaust system. Carbon monoxide can pressing the locking tab(s) and pulling on the plug cause severe nausea, fainting, or death.
Page 155 9.4 Leads/Wires/Connectors/ 9.2.1 Removal Wiring Harnesses 1. Disconnect wiring from the part(s), noting the locations from which wiring was removed for later reconnection. Tape and label the wires as needed. WARNING 2. Note the position of the part(s) and loosen or remove hardware that holds the part(s) in place.
Page 156 9.4.1 24- to 12-Volt Converter Large Connector (with Red Tab) (32/40EKOZD and 28/35EFKOZD 1. Pull the locking red tab down. 24-Volt Models Only) 2. Press the red and black tab downward and inward If replacing the converter, carefully disconnect the two to raise the area of the connector shown in connectors as follows.
Page 157 9.5 Crank Relay 9.6 Current Transformers The test procedure for the following crank relay WARNING (Figure 9-6) applies to other applications of the same type relay including: Crank relay Run relay Cold start relay Accidental starting. Flash relay Can cause severe injury or death. Disconnect the battery cables before working generator...
Page 158 9.7 Engine Pressure and When replacing the current transformer or stator assembly, install the current transformer according to Temperature Sensors the generator reconnection decal on the generator set, or see the wiring diagrams. Observe the correct current 9.7.1 General transformer position when installing the stator leads. The current transformer dot or HI mark position and the Use this section to test engine sensors (switches or stator lead direction are essential for correct component...
Page 159 9.7.3 Switch Testing generator set is shut down and when it is running at operating temperature to the values shown in Section 1, Before testing switch, disconnect the switch lead(s). Specifications. Use a mechanical oil pressure gauge to further verify Pressure Switch correct readings.
Page 160 3500 controller. See Figure 9-11 for the USB connection at the Decision-Makerr 3500 controller. 2. Connect the Kohler Diagnostic Tool from a Laptop to the ECU Diagnostic port on the generator. See Figure 9-11 for the port location. Figure 9-12 Genset System Configuration Parameter (in SiteTecht) 1.
Page 161 9.9 Fault Warning and Shutdown Test Method 1 Testing Remove the sensor lead and ground the lead to the engine block ground or connect a jumper wire from the Adapted from Service Bulletin SB-616 6/14o, a sensor terminal to the engine block ground. cumulative collection of generator set models.
Page 162 Overcrank Engine Sensors (A) External Sensors (B) Model Engine Governor Type 13EKOZD/11EFKOZD 14EKOZD/12EFKOZD 15EKOZD/13EFKOZD 16EKOZD/13.5EFKOZD 20EKOZD/16.5EFKOZD 20EKOZD/17.5EFKOZD Mechanical Kohler 21EKOZD/18EFKOZD 21EKOZD/17EFKOZD 23EKOZD/19.5EFKOZD 23EKOZD/20EFKOZD 24EKOZD/20.5EFKOZD 32EKOZD/28EFKOZD Electronic 40EKOZD/35EFKOZD Figure 9-15 Feasibility of Fault Warning and Shutdown Tests High Coolant High Coolant...
Page 163 9.10 Motor-Operated Circuit The voltage and frequency of the generator. There is no benefit to closing the paralleling breaker Breakers (if equipped) to a dead bus if the generator is not producing rated voltage and frequency. The breaker will not close Decision-Makerr 3500 controller...
Page 164 Live Bus Closure: System configuration parameters: Synch Mode in Auto The Decision-Makerr 3500 controller monitors the following to determine if it is safe to close the paralleling If the generator is operating in Auto Mode (the LED breaker to a live bus: above the Auto button is illuminated), this parameter must be set to one of the following for Voltage and frequency of the paralleling bus as...
Page 165 9.10.2 Automatic Opening of the Breaker The Decision-Makerr 3500 controller controls the speed and voltage as follows: The Decision-Makerr 3500 controller opens the paralleling breaker for any of the following conditions: The average single- or three-phase RMS amplitude of the generator set voltage is controlled to match the Generator set fault average single- or three-phase RMS amplitude of the paralleling bus.
Page 166 9.10.4 Troubleshooting Non-Operating Breaker Unable to control motor operated breaker Place switch in Is switch on motor Auto operator in Auto? Does the Is the charge Verify wiring indicator on the motor receiving feeding the motor operator 24VDC between breaker show charged? A1 (- ) and B4(+)? Is the charge...
Page 167 Go back to previous page Set the breaker mode to manual, close the breaker by pressing the On button and open the breaker by pressing the Off button Does the breaker recharge if placed in Auto? Set the Event for both Digital Output 115 and Digital Output 116 to Not In Auto on the...
Page 168 Navigate to Controller Config - > Communication Setup on the UI or open the Note: UI = User Interface at the controller. Synchronization Control section in SiteTech Enable Stand Alone Mode (Gen Info - > Are at least 2 Are at least 2 Parallel Operation - >...
Page 169 Generator is not producing voltage when running Navigate to Metering - > Parallel Metering on UI or Synchronization Note: UI = User Interface at the controller. Control in SiteTech (look at Generator Paralleling Breaker) Controller indicates Failure to Open (High Fail To Open Delay) Does the controller indicate that Continue with...
Page 170 9.11 Battery Charging Module, 9.12 Battery Charging Module, 13- 24EKOZD/12- 20.5EFKOZD 13- 24EKOZD/12- 20.5EFKOZD Original (12/24 Volt: GM77373) Revised (12 Volt: GM105398 and 24 Volt: GM105399) Note: For generator set variation numbers with serial numbers before: Note: For generator set variation numbers with serial GM102825-MA1: 336KGMGG0006 numbers shown below and later:...
Page 171 9.12.2 Protection Modes Stage 3: Float Mode Float mode is the final stage of the charging routine. Note: See Figure 9-21 for battery charger LED During float mode, the voltage on the battery is held indicator information. constant and maintained at approximately 13.5 volts for a 12 volt battery.
Page 172 9.12.4 Charger Troubleshooting 4. Charger LEDs indicate an overtemp condition: Confirm adequate ventilation in the charger 1. No charger LEDs illuminate: vicinity. Confirm AC/DC connections are tight and Provide cooling and/or allow time for the charger correct. to cool. Inspect AC/DC cable connectors for wear and Normal operation will resume automatically tear.
Page 173 Section 10 Alternator Component Testing and Adjustment (11- 32 kW Generator Sets Equipped with 4D/4E Alternators) Note: See Section 11 for 35- 40 kW generator sets DANGER equipped with 4PX/4QX alternators. 10.1 Introduction This section provides information on troubleshooting Hazardous voltage. the alternator and testing components of the generator Will cause severe injury or death.
Page 174 10.2 Separate Excitation 1. Stop the generator set. Refer to the operation manual as needed. To determine the cause of no- or low-AC output, refer to 2. Disconnect the FP/FN connector. the troubleshooting flowchart in Figure 10-1. Before beginning the test procedures, read all of the safety 3.
Page 175 8. Use a voltmeter and check for AC output across the stator main windings and compare it to the values in Section 1, Specifications. If the stator main  windings output varies considerably from those listed, a faulty stator, rotor, rectifier module, or exciter armature is likely.
Page 176 10.3.1 Exciter Armature WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools.  Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter TP-6878-3 armature.
Page 177  TP-6878-3 (AC) 1. Main field (rotor) 5. Exciter armature frame 2. Stator windings (shaft connection) (AC) 3. Rectifier module 6. Exciter armature 4. Megohmmeter 7. Exciter field winding Figure 10-6 Megohmmeter Connections on Exciter Armature (AC) 10.3.2 Rectifier Module TP-6878-3 1.
Page 178 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.  High voltage test. Hazardous voltage can cause severe TP-6878-3 injury or death. Follow the instructions of the test equipment 1.
Page 179 10.5 Stator leads on three-phase models. Leads 60, 61, and 62 are the auxiliary power winding leads. Refer to the schematic in Figure 10-10 or Figure 10-11 when WARNING performing the following tests. Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools.
Page 180 6. Check the stator for a short-to-ground condition Leads Continuity using a megohmmeter. See Figure 10-14 for a 1 and 2 3 and 4 — single-phase megohmmeter connections and 60 and 61 61 and 62 60 and 62 Figure 10-15 three-phase megohmmeter 1 and 3...
Page 181 10.6 Voltage Regulator The cranking battery provides input voltage without a second power source to the activator board only These generator sets have controller when it is not receiving power from the auxiliary windings. The activator board energizes a relay that (Decision-Makerr 3500) that has an integrated voltage disconnects the DC input to the activator board when regulator.
Page 182 10.7.3 Activator Board Function and WARNING Connections Activator board GM88453 provides the connection between the controller with integrated voltage regulator and the alternator assembly with wiring for the rotor exciter field leads (FN and FP) and auxiliary power Accidental starting. windings (60, 61, and 62).
Page 183 Activator Board Description Comments P17- 1 PWM target current signal, 5B, LED(- ) LED is 1.2 VDC max. Can be connected to a 12-volt battery negative terminal as an activator troubleshooting test. Add a 120 ohm resistor when using a 12 VDC (battery). P17- 2 Normal power input P17- 3...
Page 184 Generator does not make voltage Remove 14-pin connector from activator and check for Are both LEDs on battery voltage on pins 7 and activator board 8 when the generator set is illuminated? running. If voltage is present, activator board may be faulty. Note: Some multimeters have a single Remove 14-pin connector position on the selection dial for...
Page 185 Generator makes low voltage Remove 14-pin connector and check for battery voltage Are both LEDs on on pins 7 and 8 when the activator board generator set is running. If illuminated? voltage is present, activator board may be faulty. Remove fast-on connectors for 60 and 62 where they enter Verify wiring to flash the harness to the to the...
Page 186 Notes 186 Section 10 Alternator Component Testing and Adjustment TP-6953 7/19...
Page 187 Section 11 Alternator Component Testing and Adjustment (35- 40 kW Generator Sets Equipped with 4PX/4QX Alternators) Note: See Section 10 for 11- 32 kW generator sets Disconnecting the electrical load. Hazardous voltage can cause severe injury or death. Disconnect the generator set equipped with 4D/4E alternators.
Page 188 GENERATOR SET CONTROLLER WITH INTEGRATED VOLTAGE REGULATOR V7 V8 V9 CONTROL RELAY CONTACTS 12 LEAD STATOR ASSEMBLY SOLENOID STARTER BATTERY CONNECTOR MAGNETS ROTOR ASSEMBLY FIELD WINDING MAGNETS FRX ACTIVATOR LED OPTIC EXCITER ARMATURE BOARD BOARD TP-6783-3 Figure 11-1 AC Voltage Control Components Components and Circuits to Test Under Certain Alternator Output Conditions Alternator Controller with...
Page 189 11.2.1 Troubleshooting Alternator, No Output Voltage No output voltage is detected. If DC voltage of Perform flashlight test on FRX Is DC voltage 6- 12 volts is activator board. See Section 11.3, present at LED present, replace LED Optic Board Test. Is 190- 277 optic board? LED optic board AC output voltage present?
Page 190 11.2.2 Troubleshooting Alternator, Overvoltage Overvoltage is detected. Measure sensing voltage Troubleshoot (190- 277 volts) at controller controller with fuse block V7 and V8. Is voltage regulator. sensing voltage high? If sensing voltage is low or correct, check Troubleshoot voltage on all phases. controller with Is voltage balanced voltage regulator.
Page 191 11.2.3 Troubleshooting Alternator, Fluctuating Voltage Fluctuating voltage is detected. Check the alternator output leads for proper connection per Make the the voltage reconnection found necessary wiring in the generator set operation connections. manual and/or wiring diagrams. Are the connections correct? Are the connections to the Tighten the loose controller with voltage regulator,...
Page 192 11.3 LED Optic Board Test Testing the photo transistor circuit board. Hazardous voltage can cause severe injury or death. When the end cover is removed, do not expose the photo transistor circuit The following procedure provides information on testing board mounted on the generator set end bracket to any the LED optic board.
Page 193 3. Observe the AC output voltage controller display or 5. With the generator set running at no load, connect a voltmeter to the output leads. High AC approximately 1- 2 volts DC should be observed at output voltage indicates the FRX activator board is 3B (+) and 5B (- ) at the LED optic board.
Page 194 11.4 FRX Activator Board Test The FRX activator board is mounted on the exciter armature and controls current flow to the alternator field. See Figure 11-6. WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working generator set.
Page 195 This test simulates the normal operation of the components when the alternator is running. WARNING Hazardous voltage. Moving parts. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Grounding electrical equipment. Hazardous voltage can cause severe injury or death.
Page 196 11.5 Exciter Armature Test 7. Repeat steps 2- 5. Replace the FRX activator board if it fails either test. WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the alternator.
Page 197 Disabling the generator set. Accidental starting can specification readings indicate cause severe injury or death. Before working on the non-functional exciter armature requiring generator set or equipment connected to the set, disable the replacement. Low resistance readings indicate a generator set as follows: (1) Press the generator set off/reset shorted winding.
Page 198 11.6 Rotor Assembly Field Winding Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the Test generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set.
Page 199 11.7 Stator Assembly Winding Test Rotor Shaft WARNING (Ground) Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter armature.
Page 200 Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the 10 8 11 9 generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set.
Page 201 11.8 FRX Alternator Winding 6. Repair the leads if damaged or open. Solder and insulate the splices. Use new sleeving as needed Maintenance when tying leads to the core. Be aware that dirt covering the stator or rotor windings is 7.
Page 202 Notes 202 Section 11 Alternator Component Testing and Adjustment TP-6953 7/19...
Page 203 Note: Non-ECM engines will require an electronic governor and an appropriate Kohler governor calibration in order to permit speed adjustment. TP-6953 7/19...
Page 204 12.1.3 Internal Paralleling First-On Logic The Decision-Makerr 3500 controller uses dynamic The speed and voltage bias are ignored after the breaker first-on logic. The first generator to reach rated speed is closed in internal paralleling operation mode except in and voltage will be given permission to close the System Sync mode and System Load Control mode paralleling breaker.
Page 205 12.2.2 External Paralleling Generator Management The Decision-Makerr 3500 controller contains integral Many applications require paralleling with existing Generator Management. This functionality is disabled generators. Because the Decision-Makerr 3500 by default, but can be enabled to manage fuel controller is intended to parallel only with generators consumption, wear and tear, and sound levels.
Page 206 12.3.1 Low Wye 12.3.4 Single Phase Decision-Makerr 3500 controller supports Decision-Makerr 3500 controller supports paralleling in a low wye configuration. This connection is paralleling in a single-phase configuration, but it is the simplest and the least likely to cause confusion. In important that the metering inputs are connected low wye configuration, the sensing leads (L1, L2, L3) are appropriately for accurate power metering.
Page 207 12.4.3 First-On Logic After the generator controller has attempted to close the circuit breaker for the number of close attempts, the The First-On Logic is responsible to ensure that only controller will issue a close attempts fault, indicate that it one generator closes its paralleling breaker to the dead is unavailable to the other nodes, and start the breaker bus.
Page 208 In addition, the controller possesses underfrequency In Synchronism: After the voltage amplitude, unload (Volts/Hz) so the bus voltage may be frequency, and phase of the generator matches that of significantly lower than rated voltage if the load on the the bus, the controller considers the generator to be ’In bus exceeds the generating capacity of the online Synchronism’...
Page 209 12.4.5 System Synchronization If the speed bias is decreased, the engine governor will try to decrease the air/fuel flow to the engine to cause it Enabling System Synchronization mode in any to decelerate. If the engine speed is unable to change, controller on a paralleling bus will make all the the engine torque will steadily decrease as long as the generators on that paralleling bus respond to the speed...
Page 210 Baseload Soft Load/Unload Real Power Baseload mode operates similarly to kW The Real Power Control references a ramping target sharing mode except that the target power level is a (according to the Real Power Ramp Rate) from 0 kW to stored controller parameter instead of an average bus the mode-related target for the Real Power Control load.
Page 211 kVAR Control Reactive Power Baseload is enabled when Real Power Baseload is enabled (if the VAR control mode The reactive power controller measures and controls is set to VAR control). Baseload mode is not reactive power (kVAR). Some modes allow direct control responsive to changes in the reactive load of the kVAR to a target that is independent of the real requirement on the paralleling bus, so placing a...
Page 212 Power Factor Control System Control The reactive power controller measures and controls System Power Factor Control mode controls the reactive power (kVAR). Power factor is the ratio of the power factor level of all generators on a paralleling generator real power to the generator apparent power bus to a target level that is determined by the voltage (which is the geometric sum of the real and reactive bias input.
Page 213 12.4.8 Faults Bus Sensing Connection Error (the Bus sensing is reading incorrectly, but none of the phases are The Decision-Makerr 3500 controller supports a variety reading as expected—probably more than one wire is of faults and warnings to make troubleshooting and disconnected).
Page 214 Close Attempt Fault Over Frequency. This protective function is intended to protect any motors that are fed by the generator A Close Attempt Fault indicates that the breaker from overspeeding and potentially damaging the attempted to close and that the breaker did not close equipment that they drive.
Page 215 12.4.9 Start Modes Note: The baseload input takes priority over the System control and System Sync input. Baseload mode The generator controller supports a system start will not ramp to the target if load enable is off. (Auto-Run, remote start contacts, CAN gauge start Baseload can be used to exercise generators signal, SiteTecht start signal) and local start (pressing against the utility with a fixed load, it should not be...
Page 216 12.6 Parameter Descriptions 12.4.13 Communication Failure When a PGEN node fails to reply for 30 consecutive Individual descriptions of the functionality of each frames (about one second) the other nodes will detect a parameter within the paralleling logic. loss of communication with it and will default to droop sharing and time slice based first-on logic.
Page 217 12.6.2 First-On Pickup Acceptable Voltage Window. The Voltage must remain within this percentage of the system The First-On logic ensures that two generators won’t voltage for the duration of the Volts Hertz Okay Time close to the paralleling bus simultaneously. Because the Delay in order for the voltage to be considered synchronizing is performed relative to the paralleling bus, acceptable to supply a customer’s load.
Page 218 Pickup Acceptable Frequency Window. Dropout Acceptable Frequency Window. Once the generator frequency must remain within this window for Voltage and Frequency are considered to be the duration of the Volts Hertz Okay Time Delay before it acceptable, the frequency has to be outside the Dropout is considered to be acceptable.
Page 219 12.6.3 Synchronization Dead Field Synchronizing parameters are found under the The Synch mode cannot be set to this value in standard applications. Synchronization Control heading in SiteTecht and under the Generator Info -> Paralleling Operation -> Setting Dead Field Synch mode will cause this unit to Synchronizing Setup menu on the user interface of the start, close the breaker at a given engine RPM, and controller.
Page 220 Sync Frequency Window Setting the dwell time too short may cause the breaker to close when the generator frequency does not match the The Frequency Window is the maximum difference in bus frequency very closely (resulting in a small real output frequency between the bus and the generator at power discrepancy when the breaker first closes).
Page 221 Frequency Match Proportional Gain Phase Match Integral Gain The Frequency Match Proportional Gain adjusts the The Phase Match Integral Gain adjusts the Speed Bias Speed Bias by an amount that is directly related to the at a rate that is related to the phase difference between difference between the generator frequency and the bus the generator L1-L2 voltage and the bus L1-L2 voltage.
Page 222 Sync Time Remaining Sync Status Frequency Matched The remaining time before the controller issues a fail to This parameter indicates that the frequency of this sync warning. The fail to sync warning will cause the generator is within the Frequency Match Window of the Generator Management to consider this generator bus frequency.
Page 223 12.6.4 Load Sharing Real Power Sharing Integral Gain Load Sharing Parameters are found under the Real The Real Power Sharing Integral Gain determines the contribution of the real power sharing integral Power Load Sharing heading in SiteTecht and under term to the speed bias. The integral term ramps at a the Generator Info ->...
Page 224 Torque Sharing Derivative Gain Reactive Load Sharing Reactive Droop Slope The Torque Sharing Derivative Gain determines the contribution of the torque sharing derivative term to the This controls the rate at which the target voltage of the speed bias. The derivative term is directly related to voltage regulator decreases with increasing reactive the rate of change in the difference between the load.
Page 225 Reactive Power Sharing Proportional Gain Voltage Trim Proportional Gain The Reactive Power Sharing Proportional Gain The Voltage Trim Proportional Gain determines the determines the contribution of the reactive power contribution of the voltage trim proportional term to sharing proportional term to the voltage bias. The the voltage bias.
Page 226 12.6.5 Power Control Real Power Baseload Integral Gain The Real Power Baseload Integral Gain determines the Real Power Disconnect Level contribution of the real power control integral term to the speed bias. The integral term ramps at a rate directly The Real Power Disconnect Level is the real power related to the difference between the baseload setpoint threshold below which the generator circuit breaker will...
Page 227 System Real Load Control Derivative Gain Reactive Power Baseload Derivative Gain The System Real Load Control Derivative Gain The Reactive Power Baseload Derivative Gain determines the contribution of the real power control determines the contribution of the reactive power derivative term to the speed bias. The derivative term is control derivative term to the speed bias.
Page 228 Power Factor Baseload Integral Gain System Reactive Load Control Integral Gain The Power Factor Baseload Integral Gain determines The System Reactive Load Control Integral Gain the contribution of the reactive power control integral determines the contribution of the reactive power term to the voltage bias.
Page 229 System Power Factor Baseload Integral Gain Note: All generators must have different orders. If two or more generators have the same The System Power Factor Baseload Integral Gain order, Generator Management is disabled determines the contribution of the reactive power (all available generators will run, but no fault control integral term to the voltage bias.
Page 230 Fuel Level Enabled This permits disabling all Generator Management The Generator Start/Stop Order is selected features. When Generator Management is disabled, a automatically by the controller based on the fuel level generator will not alert the user of a Generator measured by each generator.
Page 231 Start Percentage The Stop Percentage should be set so that the generator system keeps enough generators online to The Percentage of Rated Capacity on the paralleling supply any transient loading that the application may system (the generators that are running and are active demand (such as large chillers, air conditioners, pumps, in Generator Management) above which a generator is or bow thrusters), while allowing unneeded generators...
Page 232 Stable Delay Min Load Shed Priority The Stable Delay is the delay between the system Generator Management will be disabled any time the reaching a typical loading scenario and Generator load control sheds a priority below this level. Setting the Management becoming active.
Page 233 Genset Maximum Percent Capacity Base Overload Shed Time The Genset Maximum Percent Capacity is the The Base Overload Shed Time is the time required to maximum level that the load management system will shed a load with 10% overload on the generator system automatically place on the generator.
Page 234 Fail to Close Delay Speed Bias The Fail to Close Delay determines the time that the The amount that the controller is attempting to adjust the controller will hold the close signal on during a close output frequency of the generator (100% bias = +5% on attempt.
Page 235 Voltage Bias Stand Alone Operation The amount that the controller is attempting to adjust the This Parameter forces the controller to solve paralleling output voltage (100% bias = +10% on the output logic, even when it is not seeing PGEN communications voltage, -100% = -10% on the output voltage).
Page 236 Disable Synchronization System Sync Control The Disable Synchronization parameter allows blocking System Sync Control mode is intended for use in the controller from closing the paralleling breaker, but applications where it is necessary to synchronize a does not trip the breaker if asserted while the breaker is paralleling bus containing multiple generators to a utility closed.
Page 237 VAR Control Mode The VAR Control mode parameters set the means that the controller uses to control reactive power in baseload and system control mode. This parameter has no effect when the generators are islanded and are merely sharing the power supplied to the load between them. The modes are: PF Control Mode = 0.
Page 238 Notes 238 Section 12 Paralleling System Information TP-6953 7/19...
Page 239 Section 13 Generator Management Information 13.1 Generator Management 13.2.1 Sequence of Operation Purpose This sequence follows the operation of a normal paralleling system which uses Generator Management. Generator Management is intended to decrease fuel consumption, environmental emissions, and sound When a start signal is applied to any of the generators in emissions while improving...
Page 240 As the other generators were synchronizing and Figure 13-2, the system capacity is at a maximum for all connecting to the paralleling bus, the Load Add/Shed generators in the paralleling system, as the generators system added a load priority, increasing the load on the are all connected to and supplying the load.
Page 241 By the time the Generator Management Stability Delay can start timing to stop Generator 4 because the system has expired (see Figure 13-4), the load has settled load is below the stop kW of Generator 4. down to a steady-state level. Generator Management Figure 13-4 The Stability Timer has Expired When its Stop Delay is complete, Generator 4 will Generator 4 has stopped, the system continues to feed...
Page 242 When the load decreases below the Stop Load Level for unload and disconnect from the paralleling bus, leaving Generator 3, Generator Management will begin the stop only Generators 1 and 2 to supply the load (see delay. When the stop delay expires, Generator 3 will soft Figure 13-6).
Page 243 In Figure 13-8, the load increases well past the start kW for Generator 3, causing the generator to start, synchronize, and connect to the bus. Figure 13-8 Generator 3 Restarts Due to Increase in Load When the Start signal goes away, all generators disconnect from the paralleling bus and stop (see Figure 13-9).
Page 244 Note: The generator order in the examples above more comprehensive fault handling than centralized matches the generator numbers for simplicity, but Generator Management. it is not required or even customary for the Individual Generator Management controls each Start/Stop order of managed generators to match their generator numbers.
Page 245 13.2.3 Timing Approach Stop Timing The Stop Timing is directly related to the system The Generator Management in the Decision-Makerr load—increasing system load will increase the time to 3500 controller uses Overload-Based Start Timing and stop generator. This allows Generator Capacity-Based Stop Timing.
Page 246 13.3 Generator Management 13.4 Generator Management Setup Considerations Generator Management requires consideration of several factors as each parameter is configured. The Generator Management is disabled by default on the default settings will only work in certain scenarios. Decision-Makerr 3500 controller. It is important to consider the following before enabling Generator Management: 13.4.1 Control Mode...
Page 247 13.4.2 Enabled If all the generators are running, the order re-sorts automatically any time the runtime hours of a higher This permits disabling all Generator Management order generator drop below the hours on a lower order features. When Generator Management is disabled, a generator.
Page 248 13.4.7 Stop Delay The Start Percentage should always be at least 10% higher than the stop percentage. A time factor that represents the time that Generator Management will wait to stop a generator if the load on 13.4.5 Stop Percentage the lower-order running generators drops below the Stop Percentage of this generator by 10% and all The Percentage of Rated Capacity on the other...
Page 249 13.5 Generator Management 13.4.11 Min Gens Online Detailed Functional This parameter indicates how many generators the Description system will run with no load on the system. It can be used to keep an additional generator online, but is not intended to convert a system to N+1 redundancy. N+1 13.5.1 Stability Timer Redundancy can be accomplished by setting the start and stop percentages considerably lower.
Page 250 13.5.2 Stop Signal 13.5.3 Stop Behavior Generator Management is supplemental to a paralleling Because the paralleling system is not dependent on generator system. The paralleling functionality of the Generator Management, the Paralleling Logic behavior system is not effected by or dependent on Generator is also independent from Generator Management.
Page 251 Unload Signal Activation Logic: Runtime Threshold of all generators. The unload signal sets the Load Enable input to the paralleling logic to false and turns the synchronizer off. Fuel Level Threshold of all generators. The paralleling logic will go into power control mode, Order Selection Method of all generators.
Page 252 Fuel Level Difference if only one of the generators is If the Minimum Gens Online is set to 2, the lowest 2 stopped) or if the fuel level of a lower-order generator is available generators will have a stop kW of 0. less than the fuel level of this generator (including the Fuel Level Difference if only one of the generators is 13.5.7 Start/Stop Accumulators...
Page 253 Low Engine Fuel Pressure Warning (This indicates 0 if the system load is greater than or equal to the stop kW. that the engine is not receiving enough fuel. Possible causes: day tank transfer pump failure, dip-tube (The Total Capacity of Paralleling Bus is the sum of the failure, lift pump failure, high pressure pump failure).
Page 254 13.6 Generator Management Detailed Functional Sequence Figure 13-15 Generator Management Functional Sequence Generator Management has four basic functional Manual Mode Order Update Required Logic modules which fit the architecture illustrated in The order will attempt to re-negotiate if any of the Figure 13-15.
Page 255 Manual Mode Order Update Logic Fuel Level Mode Order Update Logic Generator Management looks for two orders that are the The order is computed by adding the fuel level threshold same, if they are, it finds the first available sequential to all units that are connected to the paralleling bus to get order and adjusts all generators with orders between the effective fuel level (including the fuel level threshold).
Page 256 Notes 256 Section 13 Generator Management Information TP-6953 7/19...
Page 257 Section 14 Load Management 14.1 Purpose 14.2.1 Sequence of Operation—Single Generator System Load Management intended disconnect 1. Startup Shed. When a remote start signal is low-importance loads from the generator system in applied to the generator, the generator will start and order to allow the generator system to continue to all the load priorities will shed to ensure that the supply important loads.
Page 258 Each priority will add after a time delay as specified Note: In a real-world application, the requirements in the curve above. of the load vary enough that priority 4 would never add, as all that is required to reset the In the example system illustrated in Figure 14-1, timer is to exceed the 55 kW (Genset the 99 kW generator is loaded to 25% of capacity...
Page 259 Figure 14-6 indicates that at 95% of rated capacity, Load Management will wait for 30 seconds before shedding a priority. Because priority 6 is the first priority to shed from a stable state, the shed timing Load 94kW is identical to what is indicated by Figure 14-6. Shed Panel Generator...
Page 260 14.2.2 Sequence of Operation— Paralleling System This sequence follows the operation of a normal paralleling system which uses Load Management. The Load Management logic uses the paralleling bus frequency and the paralleling bus percentage of rated capacity to determine a need to add or shed load. A generator does not have to be running to support Load Management.
Page 261 Load Load 14kW 15kW 14kW Shed Shed 40kW 41kW Panel Panel Generator #1 Generator #2 Generator #3 Generator #1 Generator #2 Generator #3 (50kW rating) (50kW rating) (50kW rating) (50kW rating) (50kW rating) (50kW rating) 25kW 18kW 3kW 10kW 12kW 5kW 25kW 18kW 3kW 10kW 12kW 5kW...
Page 262 14.3 Considerations 14.3.4 Criticality of the Loads The generator must be sized to support at least the Load Management is not required or desired in all critical loads in the application. A generator that is able applications. Although it is active any time that the to support the critical loads may be significantly smaller generator is receiving a system start signal, it must be than the entire load requires.
Page 263 14.4 Setup 14.4.4 Base Load Add Time The Base Load Add Time defines the time to add a load if Load Management requires consideration of several the generator has 25% available capacity. Available factors as each parameter is configured. The default capacity is the difference between the power output settings will work in most scenarios, but many level of the generator and 15% below the Genset...
Page 264 14.5 Detailed Functional Description 14.5.2 Output Configuration Although Load Shed notices can be seen in SiteTecht 14.5.1 Activation/Deactivation Logic and on the display of the controller, the load shed notices only drive external relays (using RDOs or the CAN Load Management is only active when the generator option board) if they are configured to do so.
Page 265 14.5.4 Generator Capacity Load Add The Add Accumulator fills at a rate that is dependent on the Reserve Capacity and the Base Load Add Time Generator Capacity Load Add uses the percent loading such that the time to add a priority is defined as: of the generator system and the Genset Maximum Percent Capacity to compute an Available Capacity.
Page 266 14.5.5 Overload Shed Degree of Overload is computed according to the following formula: Overload Shed uses the percent loading of the Degree of Overload = (Generator Overloaded Percent – generator system and the Generator Overloaded Generator System % load) Percent to compute a Degree of Overload. The percent loading of the generator system is taking from the The kW Shed Accumulator fills at a rate that is dependent generator metering in a single-generator application...
Page 267 14.5.6 Under Frequency Shed Logic The under Frequency Shed Accumulator fills at a rate that is dependent on the Frequency Droop and the Base Under Frequency Shed uses the output frequency of the Under Frequency Shed Time such that the time to shed generator system and the under Frequency Shed Level the first priority after the overload condition occurred is to compute a Frequency Droop.
Page 268 Notes 268 Section 14 Load Management TP-6953 7/19...
Page 269 Section 15 Alternator Disassembly/Reassembly Note: Refer to Section 16 for unique differences on Any cranes, hoists, or other lifting devices used in the 35- 40 kW generator sets equipped with disassembly or reassembly procedure must be rated for 4PX/4QX alternators. one-half ton or greater.
Page 270 TP6954 1. Screws (qty. 4) 16. Plain washers (qty. 8) 2. 4D/4E end bracket cover 17. Hex. cap screws (qty. 8) 3. Screws (qty. 4) 18. Drive disc 4. Plain washers (qty. 4) 19. 4D/4E alternator fan 5. Exciter field assembly 20.
Page 271 TP6954 1. Plain washers 17. Tie wrap snap-in base 2. Pan head screws 18. Push-on trim seal 3. Junction box harness 19. Cable connector 4. Battery charger assembly 20. Air inlet guard 5. RFI power line filter 21. Crimptite screws 6.
Page 272 The fuel system. Explosive fuel vapors can cause severe WARNING 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.
Page 273 3. Disconnect fuel, cooling, and exhaust systems as 6. Attach a hoist hook to the engine lifting eye. See necessary to tilt generator set. Disconnect output Figure 15-5. leads or load circuit cables at generator set. Note: The hoist capacity rating should be 500 kg 4.
Page 274 5588613 1. Alignment marks Figure 15-6 Alignment Marks on Stator and Engine 558866 Adapter 1. Lifting eye 3. Wood block 2. Backplate 4. Vibromounts Figure 15-5 Supporting the Generator, Typical 10. Use a permanent marker (or scribe) and make an alignment mark on the stator and engine adapter for reference during reassembly.
Page 275 16. Remove the alternator fan. See Figure 15-8. 17. Remove the eight bolts and remove the drive disc/rotor assembly from the engine flywheel. See Figure 15-9. 18. Clamp the rotor in a soft-jaw vise. Remove the eight bolts and remove the drive disc assembly from the rotor.
Page 276 15.3 Reassembly 8. Align the end bracket holes over the studs and position the end bracket over the rotor bearing Refer to Section 1, Specifications for Torque Values and 9. Install the nuts on the studs and torque the Assembly Specifications and Appendix C, General studs/nuts to specifications.
Page 277 5588613 1. Alignment marks Figure 15-13 Alignment Marks 1. Exciter armature retaining bolt/washer 2. Rotor leads F1 and F2 TP-6878-4 11. Apply antiseize compound to the keyed end of the 3. Rectifier module 4. Exciter armature leads rotor shaft. 5. Exciter armature 12.
Page 278 18. Use tie wraps to secure the wires as necessary. 19. Install the alternator guard and hardware. 20. Reinstall the junction box and/or control box components and related wiring. Do not install the panels at this time. 21. Reconnect the leads to the circuit breaker and neutral stud (LO) as marked during disassembly.
Page 279 Section 16 Additional 4PX/4QX Alternator Information Note: See Section 15 for basic rotor/stator disassembly The following procedures cover many models and some and reassembly procedures. Unique differences steps may not apply to a particular engine. for the 35- 40 kW generator sets equipped with Figure 16-1 to help understand component descriptions 4PX/4QX alternators are mentioned in this and general configuration of the alternator.
Page 280 The fuel system. Explosive fuel vapors can cause severe WARNING 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.
Page 281 16.1 Disassembly 1. Remove the junction box panels. Disconnect all controller-to-engine engine-to-alternator harnesses and wiring. Remove the junction box and controller as a unit. 2. Remove the fan guard from the alternator adapter. 3. Disconnect the two-lead P6 connector at the LED optic board.
Page 282 Thread-forming screws qty. 2 (5 mm x 35 mm long). Align the alternator assembly and skid. Lower the Kohler part number M7500D-05035-85 alternator and tighten the vibromount mounting bolts. Engage the exciter armature using the harmonic 2.
Page 283 9. Use 5 terminals and 5 stainless steel hex nuts to connect leads AC1, AC2, AC3, F1 and F2 to the spacer studs. Torque to 1.3 Nm (12 in. lbs.). Locate the terminal barrels down inside the spacer pockets. See Figure 16-10 and Figure 16-13. No electrical connection (F- ) GC70113B-B/GC70064-E...
Page 284 12. Mount the LED optic board to the LED optic board holder using one screw. 13. Attach the LED optic board holder to the end bracket using four screws and torque to 6.2 Nm (4.6 ft. lbs.). 14. Reconnect the two-lead P6 connector at the LED optic board.
Page 285 Side View GC79429-43 Listed in order of assembly: 1. Spacer (GM98936) 5. Activator board (GM98939-1) 2. Thread- forming Torx head screw (M7500CE-05020-85 qty. 6) 6. Thread-forming screw (X-6071-8) 3. Terminal (X-283-58 qty. 5), not shown 7. Stainless steel nylock nut (M985-04-SS qty. 5) 4.
Page 286 Notes Section 16 Additional 4PX/4QX Alternator Information TP-6953 7/19...
Page 287 Section 17 Wiring Diagrams WARNING WARNING Hazardous voltage. Moving parts. 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 generator set.
Page 288 17.1 Wiring Diagram Reference System Remote Display Model Point-to-Point Figure Schematic Figure Accessory Figure Figure 13EKOZD/11EFKOZD 15EKOZD/13EFKOZD 17.5/16.5EFKOZD 20/19.5EFKOZD Figure 17-1 Figure 17-3 GM92288-H ADV-8672-G Figure 17-2 Figure 17-4 14EKOZD/12EFKOZD 16EKOZD/13.5EFKOZD 18/17EFKOZD 20.5EFKOZD 20EKOZD (12 volt) 23EKOZD (12 volt) Figure 17-5 Figure 17-7 GM96796-G ADV-8780-F...
Page 289 GM92288A-H Figure 17-1 Wiring Diagram, Point-to-Point (Sheet 1 of 2) for 13- 16EKOZD & 11- 20.5EFKOZD Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 290 GM92288B-H Figure 17-2 Wiring Diagram, Point-to-Point (Sheet 2 of 2) for 13- 16EKOZD & 11- 20.5EFKOZD Models 290 Section 17 Wiring Diagrams TP-6953 7/19...
Page 291 ADV8672A-G Figure 17-3 Wiring Diagram, Schematic (Sheet 1 of 2) for 13- 16EKOZD & 11- 20.5EFKOZD Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 292 ADV8672B-G Figure 17-4 Wiring Diagram, Schematic (Sheet 2 of 2) for 13- 16EKOZD & 11- 20.5EFKOZD Models 292 Section 17 Wiring Diagrams TP-6953 7/19...
Page 293 GM96796A-G Figure 17-5 Wiring Diagram, Point-to-Point (Sheet 1 of 2) for 20- 24EKOZD 12-Volt Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 294 GM96796B-G Figure 17-6 Wiring Diagram, Point-to-Point (Sheet 2 of 2) for 20- 24EKOZD 12-Volt Models 294 Section 17 Wiring Diagrams TP-6953 7/19...
Page 295 ADV8780A-F Figure 17-7 Wiring Diagram, Schematic (Sheet 1 of 2) for 20- 24EKOZD 12-Volt Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 296 ADV8780B-F Figure 17-8 Wiring Diagram, Schematic (Sheet 2 of 2) for 20- 24EKOZD 12-Volt Models 296 Section 17 Wiring Diagrams TP-6953 7/19...
Page 297 GM99447A-D Figure 17-9 Wiring Diagram, Point-to-Point (Sheet 1 of 2) for 20- 24EKOZD 24-Volt Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 298 GM99447B-D Figure 17-10 Wiring Diagram, Point-to-Point (Sheet 2 of 2) for 20- 24EKOZD 24-Volt Models 298 Section 17 Wiring Diagrams TP-6953 7/19...
Page 299 ADV8835A-D Figure 17-11 Wiring Diagram, Schematic (Sheet 1 of 2) for 20- 24EKOZD 24-Volt Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 300 ADV8835B-D Figure 17-12 Wiring Diagram, Schematic (Sheet 2 of 2) for 20- 24EKOZD 24-Volt Models 300 Section 17 Wiring Diagrams TP-6953 7/19...
Page 301 GM101901A-C Figure 17-13 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 302 GM101901B-C Figure 17-14 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models 302 Section 17 Wiring Diagrams TP-6953 7/19...
Page 303 GM101901C-C Figure 17-15 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 304 ADV8939A-C Figure 17-16 Wiring Diagram, Schematic (Sheet 1 of 2) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models 304 Section 17 Wiring Diagrams TP-6953 7/19...
Page 305 ADV8939B-C Figure 17-17 Wiring Diagram, Schematic (Sheet 2 of 2) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 306 GM101903A-D Figure 17-18 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models 306 Section 17 Wiring Diagrams TP-6953 7/19...
Page 307 GM101903B-D Figure 17-19 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 308 GM101903C-D Figure 17-20 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models 308 Section 17 Wiring Diagrams TP-6953 7/19...
Page 309 ADV8941A-B Figure 17-21 Wiring Diagram, Schematic (Sheet 1 of 2) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 310 ADV8941B-B Figure 17-22 Wiring Diagram, Schematic (Sheet 2 of 2) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models 310 Section 17 Wiring Diagrams TP-6953 7/19...
Page 311 GM101902A-C Figure 17-23 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 312 GM101902B-C Figure 17-24 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models 312 Section 17 Wiring Diagrams TP-6953 7/19...
Page 313 GM101902C-C Figure 17-25 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 314 ADV8940A-C Figure 17-26 Wiring Diagram, Schematic (Sheet 1 of 2) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models 314 Section 17 Wiring Diagrams TP-6953 7/19...
Page 315 ADV8940B-C Figure 17-27 Wiring Diagram, Schematic (Sheet 2 of 2) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 316 GM101904A-D Figure 17-28 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models 316 Section 17 Wiring Diagrams TP-6953 7/19...
Page 317 GM101904B-D Figure 17-29 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 318 GM101904C-D Figure 17-30 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models 318 Section 17 Wiring Diagrams TP-6953 7/19...
Page 319 ADV8942A-B Figure 17-31 Wiring Diagram, Schematic (Sheet 1 of 2) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 320 ADV8942B-B Figure 17-32 Wiring Diagram, Schematic (Sheet 2 of 2) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models 320 Section 17 Wiring Diagrams TP-6953 7/19...
Page 321 GM102540A-C Figure 17-33 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 322 GM102540B-C Figure 17-34 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models 322 Section 17 Wiring Diagrams TP-6953 7/19...
Page 323 GM102540C-C Figure 17-35 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 324 ADV8960A-C Figure 17-36 Wiring Diagram, Schematic (Sheet 1 of 2) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models 324 Section 17 Wiring Diagrams TP-6953 7/19...
Page 325 ADV8960B-C Figure 17-37 Wiring Diagram, Schematic (Sheet 2 of 2) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 326 GM102542A-D Figure 17-38 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models 326 Section 17 Wiring Diagrams TP-6953 7/19...
Page 327 GM102542B-D Figure 17-39 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 328 GM102542C-D Figure 17-40 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models 328 Section 17 Wiring Diagrams TP-6953 7/19...
Page 329 ADV8962A-B Figure 17-41 Wiring Diagram, Schematic (Sheet 1 of 2) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 330 ADV8962B-B Figure 17-42 Wiring Diagram, Schematic (Sheet 2 of 2) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models 330 Section 17 Wiring Diagrams TP-6953 7/19...
Page 331 GM102541A-C Figure 17-43 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 332 GM102541B-C Figure 17-44 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models 332 Section 17 Wiring Diagrams TP-6953 7/19...
Page 333 GM102541C-C Figure 17-45 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 334 ADV8961A-C Figure 17-46 Wiring Diagram, Schematic (Sheet 1 of 2) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models 334 Section 17 Wiring Diagrams TP-6953 7/19...
Page 335 ADV8961B-C Figure 17-47 Wiring Diagram, Schematic (Sheet 2 of 2) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 336 GM102543A-D Figure 17-48 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models 336 Section 17 Wiring Diagrams TP-6953 7/19...
Page 337 GM102543B-D Figure 17-49 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 338 GM102543C-D Figure 17-50 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models 338 Section 17 Wiring Diagrams TP-6953 7/19...
Page 339 ADV8963A-B Figure 17-51 Wiring Diagram, Schematic (Sheet 1 of 2) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models TP-6953 7/19 Section 17 Wiring Diagrams...
Page 340 ADV8963B-B Figure 17-52 Wiring Diagram, Schematic (Sheet 2 of 2) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models 340 Section 17 Wiring Diagrams TP-6953 7/19...
Page 341 GM88254A-C Figure 17-53 Accessory Interconnection Drawing (Sheet 1 of 2) TP-6953 7/19 Section 17 Wiring Diagrams...
Page 342 GM88254B-C Figure 17-54 Accessory Interconnection Drawing (Sheet 2 of 2) 342 Section 17 Wiring Diagrams TP-6953 7/19...
Page 343 GM92060-A Figure 17-55 System Remote Display TP-6953 7/19 Section 17 Wiring Diagrams...
Page 344 ADV5875-Y Figure 17-56 Reconnection Diagram, ADV-5875 (Sheet 1 of 2) 344 Section 17 Wiring Diagrams TP-6953 7/19...
Page 345 ADV5875-Y Figure 17-57 Reconnection Diagram, ADV-5875 (Sheet 2 of 2) TP-6953 7/19 Section 17 Wiring Diagrams...
Page 346 Notes 346 Section 17 Wiring Diagrams TP-6953 7/19...
Page 347 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 348 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 349 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 350 Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Torque Aluminum Grade 2 Grade 5 Grade 8 Size Measurement Grade 2 or 5 8-32 Nm (in. lb.) (16) (20) — 10-24 Nm (in.
Page 351 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 352 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 353 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 354 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...
Page 355 Appendix F Electrical Noise and Wiring Practices Adapted from Service Bulletin SB-640 4/04. High-Power Distribution. Circuits to high-power loads such as large electric motors and heaters can Electrical noise is an unwanted electrical signal that can emit transient high levels of broad-spectrum noise. cause errors in measurement, loss of control, Loads on high-power distribution circuits are nearly malfunctions in microprocessor-based control systems,...
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Page 360 TP-6953 7/19f KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Original Instructions (English) For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2015, 2016, 2017, 2018, and 2019 by Kohler Co. All rights reserved.

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Kohler EKOZD Series Service

Safety Precautions and Instructions

Introduction

Service Assistance

Section 1 Specifications

Section 2 Operation

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