Marine Generator Sets
TP-6593 10/13b
Service
Models:
5EKD/4EFKD--Low CO7.5EKD/6EFKD--Low CO10EKD/8EFKD--Low CO
Controller: Advanced Digital Control II
 
TP-6593 10/132
 
Table of Contents
TP-6593 10/13 Table of Contents 3
Safety Precautions and Instructions 5.........................................................Introduction 9...............................................................................Service Assistance 10.........................................................................Section 1 Specifications 11...................................................................
1.1 Introduction 11...........................................................1.2 Generator Set Ratings 11..................................................1.3 Controller Specifications 11................................................1.4 Alternator Specifications 12................................................1.5 Alternator Specifications, Continued 12......................................1.6 Torque Specifications 13..................................................1.7 Engine Specifications 13..................................................1.8 Service View 14..........................................................
Section 2 Scheduled Maintenance 15..........................................................
2.1 General 15..............................................................2.2 Service Schedule 16......................................................
Section 3 Troubleshooting 17.................................................................
3.1 Introduction 17...........................................................3.2 Initial Checks 17..........................................................3.3 Troubleshooting Chart 17..................................................
Section 4 Controller 23.......................................................................
4.1 Introduction 23...........................................................4.2 Advanced Digital Control II Operation 24....................................4.2.1 Controls and Indicators 24.........................................4.2.2 Starting the Generator Set 25......................................4.2.3 Running Sequence 26............................................4.2.4 Stopping the Generator Set 26.....................................4.2.5 Fault Shutdowns and Warnings 26..................................4.2.6 Resetting the Controller after a Fault Shutdown 38....................4.2.7 USB Connection 38...............................................4.3 Circuit Protection 38......................................................4.3.1 Line Circuit Breaker 38............................................4.3.2 Fuses 39........................................................4.4 CO Sensor Module 39....................................................4.5 Relays 39...............................................................4.6 Controller Replacement 40................................................4.7 Controller Configuration and Adjustment 41..................................4.7.1 Adjusting the Voltage, Gain, and Volts/Hz 41.........................4.7.2 Voltage Adjustment 41............................................
Section 5 Component Testing and Adjustment 47...............................................
5.1 Theory of Operation 47....................................................5.2 Separate Excitation 47....................................................5.3 Stator 49................................................................5.4 Main Field (Rotor) 51.....................................................5.4.1 Rotor Continuity and Resistance Tests 51............................5.5 Slip Rings 52............................................................5.6 Brushes 52..............................................................5.7 Voltage Reconnection 53..................................................5.8 Governor System 53......................................................5.9 Fault Shutdown Tests 53..................................................5.9.1 Fault Shutdown Switches/Senders 53...............................
 
Table of Contents, continued
TP-6593 10/134 Table of Contents
5.10 Electronic Throttle Assembly 58............................................5.11 Fuses 58................................................................5.12 Continuity Checks 59.....................................................
Section 6 Generator Disassembly/Reassembly 61..............................................
6.1 Disassembly 61..........................................................6.2 Collector Ring and Bearing Replacement 64.................................6.3 Reassembly 65..........................................................6.4 Exhaust Manifold/Heat Exchanger Instructions 66............................
Section 7 Wiring Diagrams 67.................................................................Appendix A Abbreviations 71................................................................Appendix B Common Hardware Application Guidelines 73.....................................Appendix C General Torque Specifications 74.................................................Appendix D Common Hardware Identification 75..............................................Appendix E Common Hardware List 76.......................................................
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