Kohler 11.5EFOZ Service Manual Download Page 31

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TP-6071 3/00

Section 6 Controller Troubleshooting

6.1 Controller

This section covers the controller troubleshooting
procedure for generator sets equipped with a relay
controller and related engine components. Refer to the

operation manual to identify the controller’s external
components.

Refer to Figure 6-1 to identify the

controller’s internal components.

A-359146

AC--CIRCUIT

BREAKER

START

STOP/

HOUR

METER

BREAKER

DC--CIRCUIT

PREHEAT

1. Controller circuit board
2. K25 relay
3. K20 relay
4. Hourmeter

5. DC circuit breaker
6. Start/stop switch
7. Voltage regulator circuit board
8. Overspeed circuit board (opt.)

Figure 6-1

Controller Internal Components

Summary of Contents for 11.5EFOZ

Page 1: ...Marine Generator Sets Models 13EOZ 11EFOZ 14EOZ 11 5EFOZ 15 5EOZ 13EFOZ 20EOZ 16EFOZ 20EOZ 17 5EFOZ 23EOZ 19EFOZ 24EOZ 20EFOZ TP 6071 3 00 Service...

Page 2: ......

Page 3: ...w Oil Pressure LOP Shutdown Switch 22 6 3 2 High Water Temperature HWT and High Exhaust Temperature HET Shutdown Switch 22 6 3 3 Overspeed Safety Shutdown SDR 23 6 4 Controller Circuit Board 23 6 5 Tr...

Page 4: ...TP 6071 3 00 Table of Contents...

Page 5: ...ons to prevent the starting of the generator set by the remote start stop switch Battery Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid m...

Page 6: ...res or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System Carbon monoxide Can cause severe n...

Page 7: ...The tank and installation must conform to USCG Regulations The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling a...

Page 8: ...servicing the equipment Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is present at the voltage regulator heat sink To prevent electrical shock do not t...

Page 9: ...osed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replaceguards screens and covers befor...

Page 10: ...TP 6071 3 00 VI Safety Precautions and Instructions Notes...

Page 11: ...s represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to...

Page 12: ...sland Australia Phone 617 3893 0061 Fax 617 3893 0072 China China Regional Office Shanghai People s Republic of China Phone 86 21 6482 1252 Fax 86 21 6482 1255 India Bangladesh Sri Lanka India Regiona...

Page 13: ...OZ 17 5EFOZ are powered by a four cylinder water cooled four cycle diesel engine with a heat exchanger The 23EOZ 19EFOZ and 24EOZ 20EFOZ are powered by a four cylinder water cooled four cycle turbocha...

Page 14: ...amp alternator Battery recommendation minimum 500 CCA 100 amp hr Starter motor 1 8 kW Bendix gear reduction automotive type Generator Model 20EOZ 16 17 5EFOZ 23 24EOZ 19 20EFOZ Engine manufacturer Yan...

Page 15: ...24 kW Recommended coolant 50 ethylene glycol 50 clean softened water Coolant capacity approx L U S qts add 0 24L 8 oz for the coolant recovery tank 4 4 4 6 6 0 6 3 Thermostat 71_C 160_F Pressure cap...

Page 16: ...4 135 135 95 55 66 180 180 125 B1 B2 17 17 12 Cold stator resistance ohms 1 2 3 4 V1 V4 0 12 0 12 0 07 55 66 1 5 1 5 1 3 B1 B2 0 07 0 07 0 06 1 6 Generator 12 Lead Component Specification 14EOZ 11 5EF...

Page 17: ...controller 8 Mixing elbow water outlet exhaust outlet 9 Air intake silencer 10 Lifting eye 11 Coolant overflow bottle 12 Pressure cap coolant fill 13 Fuel filter separator 14 High water temp shutdown...

Page 18: ...TP 6071 3 00 6 Section 1 Specifications Notes...

Page 19: ...dental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Disconnect the power to the battery charge...

Page 20: ...ine life Oil must meet the API classification of CD or CC Recommended SAE viscosity designation for given temperature ranges is listed in Figure 2 1 Note Failure to observe these standards may cause i...

Page 21: ...y from engine 3 2 Exhaust System Inspection Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected WARNING Inspecting the exhaust system...

Page 22: ...schedule of the Yanmar service manuals See Figure 3 2 and Figure 3 3 to inspect the compressor Compressor Inspection 1 Remove the breather hose from the air intake silencer connector if equipped 2 Rem...

Page 23: ...adapter 4 Lightly lubricate the gasket surface of the new fuel filter with fresh fuel oil Thread the filter on the adapter until the gasket makes contact hand tighten the filter an additional one hal...

Page 24: ...nnect the inlet side of the pump to a fuel source Disconnect the outlet hose from the fuel filter and place the hose end in a container to catch the fuel 3 Connect the positive terminal of a 12 volt b...

Page 25: ...sets are designed to operate in the range of 57 63 Hz 1800 rpm under full load and 1890 rpm under no load 50 Hz generator sets are designed to operate in the range of 47 5 52 5 Hz 5 1500 rpm under fu...

Page 26: ...TP 6071 3 00 14 Section 4 Fuel System Notes...

Page 27: ...pressure from the cooling system before removing the pressure cap To releasepressure coverthepressure capwith athick clothand then slowly turn the cap counterclockwise to the first stop Remove the ca...

Page 28: ...s and tighten all hose clamps Use a solution of 50 ethylene glycol and 50 clean softened water to inhibit rust corrosion and prevent freezing Add coolant as necessary to the coolant recovery tank Peri...

Page 29: ...0 Nut 607152 Figure 5 2 Seawater Pump Typical 3 Remove the impeller 4 Inspect the impeller for damage including cracks broken or flattened vanes The impeller vanes should be straight and flexible See...

Page 30: ...finger tighten only Do not overtighten Waterline 1 2 3 7 8 9 17 10 11 12 13 14 15 16 20 18 6 5 4 TP 5586 3 19 1 Mounting base 2 Retaining cap 3 Reed valve assembly 4 Silencer vertical lift 1 2 m 4 ft...

Page 31: ...r to the operation manual to identify the controller s external components Refer to Figure 6 1 to identify the controller s internal components A 359146 7 5 2 3 6 4 1 AC CIRCUIT BREAKER START STOP HOU...

Page 32: ...e to maintain voltage to the K2 relay LED2 remains lit The normally open K2 contacts remain closed to maintain voltage to the fuel solenoid and controller hourmeter The normally open K1 contacts close...

Page 33: ...TP 6071 3 00 21 Section 6 Controller Troubleshooting 229938 Figure 6 2 Sequence of Operation Wiring Diagram...

Page 34: ...eenergizes LED1 goes out The normally open K1 contacts open to deenergize the K2 relay LED2 goes out The normally closed K2 contacts close to ground the circuit to the K4 relay until the generator set...

Page 35: ...to a complete stop 6 4 Controller Circuit Board Some controller circuit board components can be tested without removing the component from the circuit board Test the components before replacing the c...

Page 36: ...tart stop switch N 43 and 47 Check for voltage at connection P1 14 Is the K2 relay functioning No Yes Replace the circuit board The K3 or K1 relay is faulty Replace the circuit board Is voltage presen...

Page 37: ...Is voltage present at the fuel solenoid P4 14 and P check wiring and connectors Is the 10 amp F2 fuse functional No Yes Is the K25 relay functioning properly No Yes Replace the K25 relay Is the P4 14...

Page 38: ...t checks out okay Go to D next page Do the local and remote start stop switches function Yes Replace the inoperative start stop switch Replace the fuel solenoid No Did the K4 relay LED light Yes No Ye...

Page 39: ...No Separately excite the generator set to determine if other components are inoperative Replace the controller circuit board Yes No Is AC output voltage at the specified level See Section 7 Separate E...

Page 40: ...pressure LOP safety shutdown switch function No Replace the LOP safety shutdown switch Yes No Did the K4 relay LED light Replace the circuit board inoperative K4 relay No Do the local and remote start...

Page 41: ...with tools or jewelry while making adjustments or repairs Remove wristwatch rings and jewelry before servicing the equipment 7 2 Generator Troubleshooting To determine the cause of no or low AC outpu...

Page 42: ...nerator set is separately excited the voltage regulator is probably inoperative Note See Section 1 Specifications for the stator output voltages with separately excited generator These specifications...

Page 43: ...s 120 volts use 120 volt lamp 3 Turn the volts potentiometer pot fully clockwise 4 Set the variac to zero or minimum volt 5 Plug the power cord into outlet 6 Turn the power variac on The AC voltmeter...

Page 44: ...regulator power supply leads Figure 7 5 PowerBoostt V Voltage Regulator Connection TP 5983 7 8 7 6 5 4 3 2 1 Input Green Output Red STAB Sensing Yellow V HZ VOLTS 1 2 3 4 5 6 1 LED1 green input power...

Page 45: ...er field resistance by connecting an ohmmeter across exciter field F1 and F2 leads See Figure 7 7 See Section 1 Specifications for the resistance reading of a cold exciter field A low reading indicate...

Page 46: ...m Consider the exciter armature functional if the resistance reading continuity is low and there is no evidence of a shorted winding heat discoloration 4 Check the exciter armature winding for a short...

Page 47: ...nerator prior to performing this test See Section 9 Generator Main Field Rotor Test Procedure 1 With the generator disassembled disconnect the generator main field windings at the rectifier module ter...

Page 48: ...and B2 is rectified by BR1 to supply the control voltage BR1 is located on the controller circuit board Refer to the schematic in Figure 7 14 when performing the following tests Stator Test Procedure...

Page 49: ...a short to ground condition using a megohmmeter See Figure 7 17 for a single phase megohmmeter connections and Figure 7 18 for three phase megohmmeter connections Apply 500 volts DC to any stator lead...

Page 50: ...TP 6071 3 00 38 Section 7 Generator Troubleshooting Notes...

Page 51: ...onnect the black test lead to the hourmeter negative terminal Set the voltmeter to 12 volts DC or greater Start the generator set A 12 volt DC reading indicates the wiring harness is functional None s...

Page 52: ...onal 85 ohms Low resistance shorted C relay coil and or wiring High resistance open C relay and or wiring Replace the controller board Starter solenoid S relay Connect the ohmmeter to the P4 22 lead a...

Page 53: ...shutdown switch Connect the ohmmeter to the P13 1 and engine block ground Place the ohmmeter on the R x 1000 scale This test is not conclusive until the temperature shutdown switches are checked If fu...

Page 54: ...omplete Generator set does not need to be running just cranking for this test Note If the hourmeter is not illuminated test it by connecting it to a 12 volt battery Note The hourmeter is polarity sens...

Page 55: ...out removing the voltage regulator from the controller Disassembly Procedure 1 Remove the end panel from the alternator end of the generator set See Figure 9 1 2 Loosen the four screws and lift off th...

Page 56: ...the shaft guiding the rotor leads through the armature bores See Figure 9 4 14 Remove the tie wraps and disconnect the P8 33 44 55 B1 and B2 wire connector 15 Attach a hoist hook to the generator lift...

Page 57: ...sembly with a permanent marker 23 Remove the four screws with spacers and the four screws without spacers See Figure 9 7 24 Remove the fan and fan spacers See Figure 9 7 25 Remove the eight bolts and...

Page 58: ...spacers washers and locknuts Note Install the fan with the flange side facing away from the flywheel 4 Replace the O ring in the end bracket bearing bore Use a sling to support the stator assembly whi...

Page 59: ...13 Installing Exciter Field 11 Install tie wraps to secure the wires as necessary 12 Route the output leads 1 2 3 and 4 through the bottom of the controller box Check that the grommet is intact and th...

Page 60: ...TP 6071 3 00 48 Section 9 Generator Disassembly Reassembly Notes...

Page 61: ...e lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Hazardous voltage Can cause severe injury or death Opera...

Page 62: ...ler American Solenoid Early Rectangular Design Kraus Naimler American Solenoid Newer Round Design 2 1 3 4 6 5 7 8 1 2 6 5 3 4 8 7 L1 L2 To Generator Set To Shore Power To Load 3 2 4 1 7 6 8 5 L1 L2 To...

Page 63: ...10 2 Manual Marine Ship to Shore 4 Wire Transfer Switch 7 6 8 5 11 10 12 9 15 14 16 13 L2 L3 To Generator Set To Shore Power To Load 4 Wire three phase Generator Sets L0 3 2 4 1 L1 L2 L3 L0 L1 L2 L3...

Page 64: ...Start Stop Stop 10 amp fuse P3 4 J3 4 J3 5 J3 1 J3 6 TP 5588 7 10 4 Remote Start and Two Meter Panel P3 2 J3 2 Start P P 7C K1 70 47 43 N Oil pressure gauge Water temp gauge Gen ON light Remote switch...

Page 65: ...Oil pressure gauge Water temp gauge Gen ON light Remote switch 5 P3 5 P3 6 P3 1 P3 2 P3 3 P2 3 P2 7 P2 8 P2 9 P4 2 P4 3 K2 P1 14 47 P2 4 43 P2 5 P2 6 N P1 9 N Relay circuit board Local switch Violet T...

Page 66: ...TP 6071 3 00 54 Section 10 Wiring Diagrams Notes...

Page 67: ...TP 6071 3 00 55 Section 10 Wiring Diagrams 10 6 Wiring Diagram 4 Lead 229937 C...

Page 68: ...TP 6071 3 00 Section 10 Wiring Diagrams 56 10 7 Wiring Diagram 12 Lead 229938 A...

Page 69: ...n cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg...

Page 70: ...overspeed OSHA Occupational Safety and Health Administration O V overvoltage oz ounce p pp page pages PA packed accessory PC personal computer PCB printed circuit board pF picofarad PF power factor p...

Page 71: ...elow top of nut Figure 1 Acceptable Bolt Lengths Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slo...

Page 72: ...27 7 16 14 ft lbs Nm 29 39 44 60 63 85 7 16 20 ft lbs Nm 32 43 50 68 70 95 1 2 13 ft lbs Nm 44 60 68 92 96 130 1 2 20 ft lbs Nm 49 66 76 103 108 146 9 16 12 ft lbs Nm 60 81 98 133 138 187 9 16 18 ft l...

Page 73: ...al External Tooth Lock Hardness Grades American Standard Grade 2 Grade 5 Grade 8 Grade 8 9 Hex Socket Head Metric Number stamped on hardware 5 8 shown 5 8 Allent head screw is a trademark of Holo Krom...

Page 74: ...6024 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2...

Page 75: ...25 x 20 M933 10020 60 M10 1 50 x 20 M933 10025 60 M10 1 50 x 25 M933 10030 60 M10 1 50 x 30 M933 10030 82 M10 1 50 x 30 M961 10035 60 M10 1 25 x 35 M933 10035 60 M10 1 50 x 35 M933 12016 60 M12 1 75...

Page 76: ...381 Web site www kohlergenerators com Fax 920 459 1646 U S A Sales Fax 920 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444 Kohlerr Power System...

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