Kohler 7.3ECD-Low CO Operation Manual

Operation

Marine Generator Sets

Models:

5ECD/4EFCD--Low CO

7.3ECD/6EFCD--Low CO

TP-6390 1/06a

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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.

Generator Set Identification Numbers

Record the product identification numbers from the generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

x:in:007:001

2 TP-6390 1/06

Table of Contents

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

11 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Service Parts/Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

12

Section 1 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Prestart Checklist

2.2

Marine Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Angular Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Operation in European Union Member Countries

2.5

Load Profile

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Advanced Digital Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1

Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.2

Starting the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.3

Stopping the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.4

Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.5

SmartCraft t System View (SC5000), If Equipped

. . . . . . . . . . . . . . . . .

2.6.6

Resetting the Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . .

2.6.7

Continuous Power Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7

Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1

Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.2

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

16

16

16

16

16

17

18

18

21

22

22

22

22

22

15

15

15

Section 3 Scheduled Maintenance

3.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Maintenance

3.2

Service Schedule

Exhaust System

Ignition System

Battery

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1

Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

3.9

3.3.2

Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3

Oil Additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4

Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5

Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6

3.4.2

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.3

Fuel System Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Backfire Flame Arrestor

3.7

Cooling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.1

Closed Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.2

Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.3

Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.4

Siphon Break

3.7.5

Anticorrosion Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.6

Seawater Outlet

3.10 Generator Storage Procedure

Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5 Wiring Diagrams

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

30

30

30

31

32

34

34

35

37

37

23

23

27

27

27

28

28

29

24

26

26

26

26

26

39

43

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B Operating Hour Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

51

TP-6390 1/06 Table of Contents 3

4 TP-6390 1/06

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.

Read and follow all safety precautions and instructions.

SAVE

THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions: Danger,

Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.

The decals are shown throughout this publication to improve operator recognition.

Replace missing or damaged decals.

Safety Precautions and Instructions

Accidental Starting

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set.

Remove the negative (--) lead first when disconnecting the battery.

Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Battery

WARNING

Sulfuric acid in batteries.


Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.

Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.

Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.

Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.

Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.

Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

TP-6390 1/06 Safety Precautions and Instructions 5

Battery short circuits.

Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage.

Disconnect the battery before generator set installation or maintenance.

Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash

Fire

WARNING

Combustible materials. A fire can cause severe injury or death.

Generator set engine fuels and fuel vapors are flammable and explosive.

Handle these materials carefully to minimize the risk of fire or explosion.

Equip the compartment or nearby area with a fully charged fire extinguisher.

Select a fire extinguisher rated ABC or

BC for electrical fires or as recommended by the local fire code or an authorized agency.

Train all personnel on fire extinguisher operation and fire prevention procedures.

Engine Fluids and

Chemical Products

WARNING

Fire.


Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the backfire flame arrester.

A sudden backfire can cause severe injury or death. Do not operate the generator set with the backfire flame arrester removed.

Combustible materials. A sudden flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the generator set. Keep the compartment and the generator set clean and free of debris to minimize the risk of fire. Catch fuels in an approved container. Wipe up spilled fuels and engine oil.

Handling caustic engine fluids and chemical products.

Can cause severe chemical burns, nausea, fainting, or death.

Most chemicals such as used engine oil, antifreeze/coolant, rustproofing agent, inhibiting oil, degreasing agent, spray paint, and adhesives are hazardous to health. Read and follow the user information found on the packaging. Avoid inhalation and skin contact. Use only in well-ventilated areas and use a protective mask when spraying. Store engine fluids and chemical products in a locked cabinet. Contact your local recycling center for disposal information and locations.

WARNING

Flammable engine solvents and cleaners.


Do not smoke or permit flames or sparks near flammable engine solvents and cleaners.

Read and follow the user information found on the packaging.

Use only in wellventilated areas. Never use gasoline or low flash-point solvents as cleaning agents.

Leaking or accumulated engine fluids. A fire can cause severe injury or death.

Clean up engine fluids including fuel, oil, grease, and coolant.

Determine the source of engine leaks and correct before starting the generator set. Keep the generator set area clean and remove combustible materials.

Used engine oil. Contact with used engine oil may cause severe skin irritation. Repeated and prolonged skin exposure may have other health risks.

Used engine oil is a suspected carcinogen. Avoid contact with skin. Thoroughly wash your hands and nails with soap and water shortly after handling used engine oil. Wash or dispose of clothing or rags containing used engine oil.

Dispose of used engine oil in a responsible manner.

Contact your local recycling center for disposal information and locations.

6 Safety Precautions and Instructions TP-6390 1/06

Exhaust System

WARNING

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Carbon monoxide symptoms.

Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases.

Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness

D Physical fatigue, weakness in joints and muscles

D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea

If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.

Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

Inspecting the exhaust system.

Carbon monoxide can cause severe nausea, fainting, or death.

For the safety of the craft’s occupants, install a carbon monoxide detector. Consult the boat builder or dealer for approved detector location and installation.

Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.

Operating the generator set. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Use the following precautions when installing and operating the generator set. Do not install the exhaust outlet where exhaust can be drawn in through portholes, vents, or air conditioners.

Avoid overloading the craft. If the generator set exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow of exhaust.

Never operate the generator set without a functioning carbon monoxide detector.

Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate.

If operating the generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always be aware of others, making sure your exhaust is directed away from other boats and buildings.

Fuel System

WARNING

Explosive fuel vapors.


Use extreme care when handling, storing, and using fuels.

WARNING

Explosion.

Gasoline vapors can cause explosion and severe injury or death.

Before starting the generator set, operate the blower 4 minutes and check the engine compartment for gasoline vapors.

WARNING

Avoid high pressure fluids.


Do not work on high pressure fuel or hydraulic systems without protective equipment to protect hands, eyes, and body. Avoid the hazard by relieving pressure before disconnecting fuel injection pressure lines.

Search for leaks using a piece of cardboard. Always protect hands, eyes, and body from high pressure fluids. If an accident occurs, seek medical attention immediately.


The fuel system.

Explosive fuel vapors can cause severe 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.

Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines.

Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.

Repair fuel systems before resuming generator set operation.


Take additional precautions when using the following fuels:

Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE.

Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.

Pipe sealant. Explosive fuel vapors can cause severe injury or death.

Fuel leakage can cause an explosion.

Use pipe sealant on all threaded fittings to prevent fuel leakage.

Use pipe sealant that resists gasoline, grease, lubrication oil, common bilge solvents, salt deposits, and water.

Ignition-protected equipment.


Gasoline vapors can cause an explosion.

USCG Regulation 33CFR183 requires that all electrical devices (ship-to-shore transfer switch, remote start panel, etc.) must be ignition protected when used in a gasoline and gaseous-fueled environment.

The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous-fueled environment such as an engine room or near fuel tanks. Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash.

Hazardous Noise

CAUTION

Hazardous noise.

Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

Engine noise. Hazardous noise can cause hearing loss.

Wear hearing protection when near an operating generator set Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss.

Hazardous Voltage/

Electrical Shock

WARNING

Hazardous voltage.

Moving rotor.


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. Electrocution is possible whenever electricity is present.

Turn off the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards.

Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.


Disconnecting the electrical load.

Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads.

High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load.

Short circuits.

Hazardous voltage/current can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage.

Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

Remove all jewelry before servicing the equipment.

Electrical backfeed to the utility.

Hazardous backfeed voltage can cause severe injury or death.

Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is opened.

Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near the work area.

Some states and localities prohibit unauthorized connection to the utility electrical system.

Install a ship-to-shore transfer switch to prevent interconnection of the generator set power and shore power.

Testing live electrical circuits.

Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits.

Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry.

(2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure.

(4) Be prepared for the system to operate automatically.

(600 volts and under)

Hot Parts

WARNING

Hot coolant and steam.


Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

WARNING

Hot engine and exhaust system.


Do not work on the generator set until it cools.

WARNING

Hot engine oil.


Avoid skin contact with hot oil. Do not start or operate the generator set with the engine oil filler cap removed, as hot oil can spray out. Ensure that the lubrication system is not under pressure when servicing.


Checking the coolant level.

Hot coolant can cause severe injury or death.

Allow the engine to cool.

Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled.

Check the coolant level at the tank if the generator set has a coolant recovery tank.

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.

The engine and exhaust system components become extremely hot during operation.

Moving Parts

WARNING

Hazardous voltage.

Moving rotor.




WARNING

Rotating parts.


Operate the generator set only when all guards, screens, and covers are in place.

WARNING

Airborne particles.

Can cause severe injury or blindness.

Wear protective goggles and clothing when using power tools, hand tools, or compressed air.

Tightening the hardware.

Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury.

Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.

Servicing the generator set when it is operating. Exposed 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. Replace guards, screens, and covers before operating the generator set.

Sound shield removal.

Exposed moving parts can cause severe injury or death.

The generator set must be operating in order to perform some scheduled maintenance procedures. Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

(Sound-shield-equipped models only)

Notice

NOTICE

Hardware damage. The engine and generator set may use both American

Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware.

Screws and nuts are available in different hardness ratings.

To indicate hardness, American

Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE

Electrostatic discharge damage.

Electrostatic discharge (ESD) damages electronic circuit boards.

Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about

1 megohm), not a direct short, to ground.

NOTICE

Fuse replacement.

Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic).

Do not substitute clear glass-type fuses for ceramic fuses.

Refer to the wiring diagram when the ampere rating is unknown or questionable.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.


This manual provides operation instructions for

5/7.3ECD and 4/6EFCD model generator sets.

Refer to the engine operation manual for generator set engine scheduled maintenance information.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products 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 avoid bodily injury. Read and follow the

Safety Precautions and Instructions section at the

Introduction

beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals.

Obtain service from an authorized service distributor/dealer to keep equipment in top condition.

For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D

Consult the Yellow Pages under the heading

Generators—Electric

D

Visit the Kohler Power Systems website at

KohlerPowerSystems.com

D

Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product

D

Call toll free in the US and Canada 1-800-544-2444

D

Outside the US and Canada, call the nearest regional office

Headquarters Europe, Middle East, Africa

(EMEA)

Kohler Power Systems

ZI Senia 122

12, rue des Hauts Flouviers

94517 Thiais Cedex

France

Phone: (33) 1 41 735500

Fax: (33) 1 41 735501

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 6264-6422

Fax: (65) 6264-6455

Before installing a marine generator set, obtain the most current installation manual from your local distributor/dealer. Only qualified persons should install the generator set.

x:in:001:002:a

Service Assistance

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131

TP-6390 1/06 Introduction 11

Maintenance and Service Parts/Related Literature

Maintenance and Service Parts

Figure 1 identifies maintenance and service parts for your generator set.

Obtain a complete list of maintenance and service parts from your authorized generator distributor/dealer.

Part Description

Fuse, (F1) 10 amp,

Auxiliary Winding

Fuse, (F2) 10 amp,

Controller

Fuse, (F3) 10 amp,

Customer Connection

Fuse, (F4) 15 amp,

Coils/Injectors

Fuse, (F5) 15 amp,

ECM, O

2

Sensor, and Fuel Pumps

Fuse, (F6) 15 amp,

Voltage Regulator and Battery Charging

Alternator

Fuse, (F7) 20 amp,

Starter Motor and Crank Solenoid

Oil Filter

Seawater Pump Impeller Kit

Spark Plug

Spray Paint (White)

Zinc Anode

Part Number

Figure 1 Maintenance and Service Parts

358337

223316

223316

283645

283645

283645

GM39266

359771

359978

GM46180

221335

260085 x:in:001:004

List of Related Literature

Figure 2 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set.

Literature Type

Installation Manual

Operation Manual (Generator)

Operation Manual (Engine)

Parts Catalog*

Service Manual (Generator)

Service Manual (Engine)

Service Manual Supplement (Engine)

Part Number

TP-5982

TP-6390

TP-6001

TP-5987

TP-6391

TP-6002

TP-6008

* One manual combines Generator and Engine information.

Figure 2 Generator Set Literature x:in:001:005

12 Maintenance and Service Parts/Related Literature TP-6390 1/06

Section 1 Service Views

1 2 3 4 5 6 7 8 9 10 11 12

13

30

29

14

15

17

18

16

19

22

21

20

28 27

SERVICE VIEW

26 25 24 23

1. Spark plug (also one located on the nonservice side)

2. Oil fill

3. Overflow tube

4. Pressure cap (coolant fill location after draining coolant)

5. Seawater pressure switch (appears as auxiliary fault on ADC)

6. Lifting eye

7. Heat exchanger

8. Anticorrosion zinc anode

9. AC circuit breaker

10. AC load lead connector (nonservice side)

11. Nameplate (top)

12. Customer interface connection (nonservice side)

13. Fuses (F1, F2, F3, F4, F5, F6, and F7)

(see Section 2.7.2)

14. Runtime hour display

15. Advanced Digital Control (ADC 2100)

16. CO sensor module

17. Generator set master switch

Figure 1-1 Service Views

ADV7025A-A

18. Catalyst assembly, water outlet/exhaust outlet (nonservice side)

19. Seawater drain (remove plate for service)

20. Seawater pump (water inlet)

21. Cooling air inlet

22. Fuel filter/fuel inlet

23. Fuel pump

24. Fuel pump/cooler

25. Oil check

26. Coolant drain (remove hose clamp to drain coolant)

27. Oil drain valve

28. Lube oil filter

29. Coolant overflow bottle (daily coolant check/fill location)

30. Air intake silencer/backfire flame arrestor

Note: Consult installation drawings in Spec Sheet or Installation

Manual for fuel- and battery-connection points.

Note: Consult distributor/dealer or Service Manual for items not shown.

TP-6390 1/06 Section 1 Service Views 13

Notes

14 Section 1 Service Views TP-6390 1/06

2.1 Prestart Checklist

To ensure continued satisfactory operation perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.

Air Inlets. Check for clean and unobstructed air inlets.

Air Shrouding.

Check for securely installed and positioned air shrouding.

Backfire Flame Arrester.

Check for a clean and installed backfire flame arrester to prevent unfiltered air from entering the engine.

Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.

Coolant Level. Check the coolant level according to the cooling system maintenance information.

Exhaust System.

Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections.

Inspect the exhaust system components (exhaust manifold, catalyst, exhaust hose, hose clamps, silencer, and outlet flapper) for cracks, leaks, and corrosion.

D

Check the hoses for softness, cracks, leaks, or dents.

Replace the hoses as needed.

D

Check for corroded or broken metal parts and replace them as needed.

D

Check for loose, corroded, or missing clamps.

Tighten or replace the hose clamps and/or hangers as needed.

D

Check that the exhaust outlet is unobstructed.

D

Visually inspect for exhaust leaks

(blowby). Check for carbon or soot residue on exhaust components.

Carbon and soot residue indicates an exhaust leak.

Seal leaks as needed.

D

Ensure that the carbon monoxide detector(s) is (1) in the craft, (2) functional, and (3) energized whenever the generator set operates.

Section 2 Operation

For your safety: Never operate the generator set without a functioning carbon monoxide detector(s) for your safety and the safety of others on your vessel.

Fuel Level. Check the fuel level and keep the tank(s) full to ensure adequate fuel supply.

Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.

Operating Area.

Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.

Seawater Pump Priming. Prime the seawater pump before initial startup. To prime the pump: (1) close the seacock, (2) remove the hose from the water-filter outlet, (3) fill the hose and seawater pump with clean water, (4) reconnect the hose to the water filter outlet, and (5) open the seacock.

Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet.

2.2 Marine Inspection

Kohler Co. recommends that all boat owners have their vessels inspected at the start of each boating season by the US Coast Guard, the local Coast Guard Auxiliary, or local state agency.

Kohler Co. also recommends having the generator’s exhaust system inspected at the start of each boating season by an authorized Kohler r distributor/dealer.

Repair any problems identified before operating the generator set.

WARNING

Carbon monoxide.



TP-6390 1/06 Section 2 Operation 15

2.3 Angular Operation

See Figure 2-1 for angular operation limits for units covered in this manual.

Continuous

25

_

Intermittent—

3 minutes or less

30

_

Maximum value for all directions

Figure 2-1 Angular Operation

2.4 Operation in European Union

Member Countries

This generator set is specifically intended and approved for operation below the deck in the engine compartment.

Operation above the deck and/or outdoors would constitute a violation of European Union Directive

2000/14/EC noise emission standard.

2.5 Load Profile

Whenever operating the generator set, Kohler Co.

recommends maintaining the minimum load profile indicated in Figure 2-2.

Maintaining the load profile prevents corrosion formation on internal engine components when they’re exposed to the breakdown of exhaust gases.

Minimum

Load Requirement

30% load

Figure 2-2 Load Profile

Ideal

Load Requirement

70% load or more

The operator should perform all of the prestart checks.

Start the generator set according to the starting procedure in the controller section of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks.

2.6 Advanced Digital Control

Operation

Figure 2-3 illustrates the user interface on the Advanced

Digital Control (ADC 2100).

Note: Have setup and adjustments of the ADC 2100 performed only by an authorized Kohler distributor/dealer.

The setup and adjustments are password protected.

1

2

4

3 GM28707A-C

1. LED display

2. Up and down arrow buttons (use for setup and adjustment only)


4. Select button (use for setup and adjustment only)

Figure 2-3 ADC 2100 Control

2.6.1

Controls and Indicators

Figure 2-4 describes the controls and indicators located on the controller. The LED display indicates generator set status as shown in Figure 2-4. The display is active when the master switch is in the RUN or AUTO position and remains active until the generator set master switch is moved to the OFF/RESET position or the power to the controller is removed.

The buttons on the controller keypad are used only for system configuration and adjustment. The controller is factory-set and should not require configuration or adjustment under normal operating conditions. If the generator set is reconnected to a different voltage and/or frequency, refer to an authorized Kohler distributor/dealer for system configuration and adjustment instructions.

16 Section 2 Operation TP-6390 1/06

Control or Indicator Item Description

Runtime hours Displays total generator set runtime hours.

Crank indication Displays CC_1, CC_2, or CC_3 to indicate the first, second or third attempt to start the engine. The last digit flashes during the crank cycle rest periods.

Fault codes Flashes a 2- or 3-letter fault code to indicate various fault conditions. See Section 2.6.4.

Keypad

Generator set master switch

Software version See TP-5982, Generator Set Installation Manual.

Select and arrow buttons

The keypad is used for controller setup and adjustment only. Have setup and adjustments performed only by an authorized distributor/dealer. The setup and adjustment functions are password-protected.

Three-position switch

Switch functions as the generator set operation and controller reset switch.

Figure 2-4 ADC 2100 Controls and Indicators

2.6.2

Starting the Generator Set

The following procedures describe the actions required to start the generator set.

WARNING

Explosion.

Gasoline vapors can cause explosion and severe injury or death.

Before starting the generator set, operate the blower 4 minutes and check the engine compartment for gasoline vapors.

Note: Close seacock if water enters the exhaust system.

If water enters the exhaust system, close the seacock and drain the water from the exhaust system at the silencer’s drain plug before attempting to start the generator set.

A water-filled exhaust hose and silencer may hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valves. Water ingested into the engine may cause major engine damage that the Kohler

Co. warranty does not cover.

If excessive cranking is a chronic problem, have the unit, including the exhaust system, serviced by an authorized Kohler r distributor/dealer.

The controller attempts to start the generator set three times.

If the generator set does not start in three attempts, the system shuts down on an overcrank fault.

1

2

3

Operate the blower.

Operate the blower 4 minutes and check the engine compartment for gasoline vapors.

NOTE: Many boat manufacturers recommend continuous blower operation while the generator set is operating. Read the vessel’s owner’s manual for further information.

Open the fuel shut-off valve.

Open the manual fuel shut-off valve, if equipped.

Start the generator set

Place the generator set master switch to the RUN position.

Note: Opening seacock. Before starting the generator set, open the seacock to allow cooling water passage.

Failure to do so could damage the seawater pump impeller and cause serious engine overheating damage.

Note: Transfer switch.

Check that the marine ship-to-shore transfer switch, if equipped, is in the ship position.

Local Starting.

Move the generator set master switch to the RUN position. The ADC 2100 attempts to start the generator set in three crank cycles (crank cycle time is pre-programmed).

Auto (Automatic) Starting.

Move the generator set master switch to the AUTO position to allow startup by the remote start/stop switch or remote digital gauge. A remote start/stop switch or digital gauge can be connected to the customer interface connection (P21 connector, leads 3 and 4).

See the wiring diagram in Section 5.

Note: The ADC 2100 allows three crank cycle attempts before the overcrank shutdown occurs.


2.6.3

Stopping the Generator Set

The following procedures describe the actions required to stop the generator set.

Local Stopping

1. Run the generator set at no load for at least

2 minutes to ensure adequate engine cooldown.

2. Move the generator set master switch to the

OFF/RESET position. The engine stops.

Auto (Automatic) Stopping.

1. Run the generator set at no load for at least

2 minutes to ensure adequate engine cooldown.

2. With the generator set master switch in the AUTO position, the generator set stops when the remote start/stop switch contacts close momentarily.

Note: If the ADC 2100 is configured for a digital gauge, the controller will not power down (if the master switch is in

Section 2.6.7.

the AUTO position).

See

Note: If the ADC 2100 is not configured for a digital gauge, the controller will power down after

48 hours (if the master switch is in the AUTO position). If the generator has been started, the controller will power down 48 hours after the generator stops.

2.6.4

Fault Shutdowns

The generator set shuts down automatically under the fault conditions listed in Figure 2-5 and the controller displays a fault code. The generator set cannot be restarted until the fault condition is corrected and the controller is reset.

See Section 2.6.6 to reset the controller after a fault shutdown. The controller resets automatically after a battery voltage fault condition is corrected.

Shutdown switches on the generator set automatically reset when the problem is corrected. The high engine temperature switch automatically resets when the generator set cools. However, the fault does not clear until the controller is reset.

The controller displays a fault code but the generator set does not shut down under the conditions shown in

Figure 2-6.


Code Fault

AF Auxiliary fault input shutdown

CO-1 Carbon monoxide shutdown

CO-2 Carbon monoxide shutdown

CO-3 Carbon monoxide sensor shutdown

HE High engine temperature shutdown

LOC Loss of coolant shutdown

Description

Input from a customer-supplied switch that closes when the fault is active. Shutdown occurs

0.3 seconds after the fault is detected. This protection becomes active 3-seconds after crank disconnect.

Check

Check the cause of the auxiliary fault.

Sensor fault shutdown occurs because of the presence of CO.

Shutdown occurs because of the presence of CO or deteriorating emission-control components (such as the catalyst).

Shutdown occurs if communication is lost between the

CO sensor and the ADC.

Immediate service required. Contact an authorized distributor/dealer for service.

Ensure windows are open for proper ventilation.

Operate the blower to expel dangerous fumes.

Move the vessel away from other vessels (as another vessel may be the source for the presence of the CO).

Check the generator exhaust system (see Section 3.6).

Immediate service required. Contact an authorized distributor/dealer for service.





Check the connections to the CO sensor.

If connections are okay, replace the CO sensor.

Contact an authorized distributor/dealer for service.

Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than

5 seconds. This protection becomes active after the engine reaches the crank disconnect speed.

Note: The high engine temperature shutdown functions only when the coolant level is in the operating range.

Shutdown occurs 5 seconds after a loss of coolant condition is detected. This protection becomes active

10 seconds after the engine has reached its stated crank disconnect speed and remains active as long as the generator run command is active.

Check for a low engine coolant level.

Check for a clogged seawater intake or sea strainer.

Check for a damaged seawater pump impeller.

LOP

OC

OF

OS

OU

UF

UU

Low oil pressure shutdown

Overcrank shutdown

Overfrequency shutdown

Overspeed shutdown

Overvoltage shutdown

Underfrequency shutdown

Undervoltage shutdown

SCF0 Controller error

Shutdown occurs if a low oil pressure condition exists for more than 5 seconds. This protection becomes active 30 seconds after the engine has reached crank disconnect speed (30 second inhibit).

Note: The low oil pressure shutdown does not protect against low oil level. Check the oil level at the engine.

Shutdown occurs after 3 unsuccessful starting attempts. The crank cycle is set for three starting attempts.

Check for leaks in the lubrication system.

Check the oil level and add oil if the level is low.

Check the fuel supply and battery.

If there is no output voltage, check the line circuit breaker. Also check for loose connections.

Contact an authorized distributor/dealer for service if problem continues.


Shutdown occurs when the governed frequency exceeds 110% of the system’s frequency setpoint for more than 5 seconds. This protection becomes active

10 seconds after engine start (10 second inhibit).

Shutdown occurs if the engine speed exceeds 115% of the normal running speed for more than 0.3 seconds.

Shutdown occurs if the voltage exceeds 120% of the voltage regulator setpoint for more than 2 seconds.

Shutdown occurs when the governed frequency falls below 90% of the system’s frequency setpoint for more than 5 seconds. This protection becomes active

10 seconds after engine start (10-second inhibit).

Shutdown occurs if the voltage falls below 80% of the voltage regulator setpoint for more than 10 seconds.

Indicates a software or communication problem within the ADC 2100.

Figure 2-5 ADC 2100 Fault Shutdown Codes



Reduce the load and restart the generator set.


Reduce the load and restart the generator set.




Code Fault

CO-4 Carbon monoxide warning

CO-5 Carbon monoxide warning

CO-6 Carbon monoxide sensor warning

HB

LB

High battery voltage warning

Low battery voltage warning

Description

Fault code is displayed if the presence of CO is detected because of the time-weighted average presence of CO. Activates the CO cabin alarms.

Check






Fault code is displayed if the presence of CO is detected. Warning occurs if the sensor detects acceptable but increasing CO levels.

Ensure windows are open for ventilation.




Generator service for emissions required.


Fault code is displayed if the CO sensor is inoperative. Replace the CO sensor.


Check the battery rating and condition.

Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than

2 seconds when the engine is not running. This fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to a voltage within the limits for more than

2 seconds.

Fault code is displayed if the engine starting battery voltage falls below 9.5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than

2 seconds when the engine is not running. This fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to a voltage within the limits for more than

2 seconds.

Check the battery rating and condition.

Charge or replace the battery.

Figure 2-6 ADC 2100 Fault Warning Codes


EC61

LOC

OS

HE

EC66

EC67

EC68

EC69

EC70

LB

EC54

EC55

EC56

EC57

EC58

EC59

EC60

EC72

EC73

EC74

EC45

EC46

LOP

EC48

EC49

EC50

EC51

HB

EC12

EC17

EC18

EC39

EC40

EC41

EC42

EC43

EC44

Fault

Code

Displayed Description

No Faults (Fault Code 0)

EC9

EC10

EC11

Throttle Position Sensor Input High

Throttle Position Sensor Range High

Throttle Position Sensor Range Low

Throttle Position Sensor Input Low

Speed Bias Pot Input High

Speed Bias Pot Input Low

Electronic Throttle Control Sticking

EST 1 Low

EST 1 High

EST 2 Low

EST 2 High

EST 3 Low

EST 3 High

Injector Fault

Low Oil Pressure

Electronic Throttle Control Spring Test Failed

Map Sensor Input High

Map Sensor Input Low

Electronic Throttle Control Driver Fault

Battery Sensor Input High

Battery Sensor Input Low

XDRP Sensor Input High

XDRP Sensor Input Low

Intake Air Temp. Input Sensor High

Intake Air Temp. Input Sensor Low

Coolant Sensor Input High

Coolant Sensor Input Low

Oxygen Sensor Input High

Oxygen Sensor Input Low

Seawater Pump Pressure

Engine Overspeed Fault

Coolant Sensor Range High

Trim Valve Output Fault

Trim Valve Lower DC Fault

Trim Valve Upper DC Fault

O

2

Switching Fault

Gaseous O

2

Adapt Limit Fault

CAN Receive Message Fault

Fuel Pump Fault

Starter Fault

Figure 2-7 SECM Fault Codes (Appears on the

ADC 2100 Display and Remote Digital

Gauge)

2.6.5

SmartCraft t System View

(SC5000) Display, If Equipped

The 5/7.3ECD and 4/6EFCD model generator sets can connect to SmartCraft’s SC5000 (if equipped) via the generator set’s P19 connector. See the wiring diagrams in Section 5 for the P19 location. The SC5000 displays important generator set information as shown in

Figure 2-8.

Consult the SmartCraft t SC5000 literature provided with your vessel for display operation.

Figure 2-8 5/7.3ECD and 4/6EFCD Generator

Display Screens on SC5000, Typical

SmartCraft t is a trademark of Mercury Marine, a division of

Brunswick Corporation.


2.6.6

Resetting the Controller after a

Fault Shutdown

Always identify and correct the cause of a fault shutdown before resetting the controller.

Use the following procedure to reset the generator set controller after a fault shutdown.

1. Move the generator set master switch to the

OFF/RESET position.

2. Disconnect the generator set from the load using the line circuit breaker. See the safety precautions at the beginning of this manual before proceeding.

3. Identify and correct the cause of the fault shutdown.

See the safety precautions at the beginning of this manual before proceeding. Refer to Section 4, Troubleshooting.

4. Start the generator set by moving the generator set master switch to RUN. Test operate the generator set to verify that the cause of the shutdown has been corrected.

5. Shut the generator off by moving the generator set master switch to the OFF/RESET position.

6. Reconnect the generator set to the load using the line circuit breaker.

7. Move the generator set master switch to the AUTO position for startup by remote transfer switch, remote start/stop switch, or remote digital gauge.

Opening and closing the remote start/stop contact also resets the controller.

A remote start signal (from a transfer switch or a remote start/stop switch connected to P21 connector, leads 3 and 4) or moving the generator set master switch to the

RUN position turns the controller back on.

2.7 Circuit Protection

If the generator set circuit breaker trips or the fuses blow repeatedly, see Section 4 for possible causes.

2.7.1

Line Circuit Breaker

A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. The line circuit breaker location is shown in Section 1. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position.

2.7.2

Fuses

The junction box contains seven fuses. See Section 1 and Figure 2-9 for the fuse location. Always identify and correct the cause of a blown fuse before restarting the generator set. Refer to section 4 for conditions that may indicate a blown fuse.

Obtain service from an authorized distributor/dealer.

F1 F2 F3

F6

2.6.7

Continuous Power Mode if

Equipped with a Remote Gauge

The controller is powered by the generator set engine starting battery.

Remote communications require an active

(powered-up) controller.

Be advised that the ADC consumes 250 mA when the master switch is in the

AUTO position. If you do not plan to use your generator set for a long period of time, Kohler recommends moving the master switch to the OFF/RESET position

(complete power down—0 mA draw).

22 Section 2 Operation

F4

F5

F7

ADV7025A-A

Figure 2-9 Fuse Identification

Label Fuse

F1 Auxiliary Winding

F2 Controller

F3 Customer Connection

F4 Coils/Injectors

F5 ECM, O

2

Sensor, and Fuel Pumps

F6 Voltage Regulator and Battery Charging

Alternator

F7 Starter Motor and Crank Solenoid

Figure 2-10 Fuses

TP-6390 1/06

Amps

10

10

10

15

15

15

20

Section 3 Scheduled Maintenance

WARNING

3.1 General Maintenance

WARNING








Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the

OFF position. (2) Disconnect the power to the battery charger.

(3) Remove the battery cables, negative (--) lead first.


WARNING

Hot engine and exhaust system.



Servicing the exhaust system.

Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.

Rotating parts.


Operate the generator set only when all guards, screens, and covers are in place.

Servicing the generator set when it is operating. Exposed 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.

Replace guards, screens, and covers before operating the generator set.

Sound shield removal. Exposed moving parts can cause severe injury or death. The generator set must be operating in order to perform some scheduled maintenance procedures.

Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

(Sound-shield-equipped models only)

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals.

Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

NOTICE

Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

Annual Inspection. Kohler Co. recommends that all boat owners have their vessels inspected at the start of each boating season by the US Coast Guard, the local

Coast Guard Auxiliary, or local state agency.

Kohler Co. also recommends having the generator’s exhaust system inspected at the start of each boating season by an authorized Kohler r distributor/dealer.

Repair any problems identified before operating the generator set.

See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized distributor/dealer perform generator set service.

TP-6390 1/06 Section 3 Scheduled Maintenance 23

Engine Service. Perform generator set engine service at the intervals specified by the engine operation manual.

Generator Set Service. Perform generator set service at the intervals specified by the generator set operation manual.

If the generator set operates under dusty or dirty conditions, use dry compressed air to blow dust out of the alternator. With the generator set running, direct the stream of air in through the cooling slots at the alternator end.

Routine Maintenance. Refer to the following generator set service schedule, the engine service schedule, and the runtime hour display located on the generator set’s

ADC to determine when to schedule routine maintenance. Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions.

Service Log. Use the Operating Hour Service Log located in the back of this manual to document performed services.

Service Schedule. Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set.

For example, an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months, 300 hours or 9 months, and so on.

x:sm:004:001

3.2 Service Schedule

Perform Service at Intervals Indicated (X)

FUEL SYSTEM

Check the fuel level and fill as necessary

Check fuel lines and replace as necessary *

[

Replace the fuel filter *

[

LUBRICATION SYSTEM

Check crankcase oil level and add as necessary

Reference

Section

Before

Starting

After

50 Hrs or

1 Month

Every

100 Hrs or

3 Months

Every

300 Hrs or

6 Months

Every

500 Hrs or

Yearly

2.1

3.3.2

X

X

X

X

Replace the oil in crankcase *

Replace the lube oil filter element *

3.3.4

3.3.5

X

(20 hrs break-in period)

X

(20 hrs break-in period)

X

X

(200 hrs)

COOLING SYSTEM

Check coolant level and fill as necessary *

Check seawater outlet and clean as necessary

[

Check function of siphon break, if equipped

Replace seawater pump impeller *

[

Check heat exchanger anticorrosion zinc condition *

Replace heat exchanger anticorrosion zinc *

Flush cooling system *

[

IGNITION SYSTEM

Clean and regap spark plugs *

Replace spark plugs *

* Requires removal of sound shield, if installed.

[ Consult your local distributor/dealer for service.

3.7.1

3.7.6

3.7.4

3.7.3

3.7.5

3.7.5

3.7.1

3.8

3.8

X

X

(during operation)

X

X

X

X (check)

X

X

X

X

(400 hrs)

24 Section 3 Scheduled Maintenance TP-6390 1/06

Service Schedule, continued

Perform Service at Intervals Indicated (X)

INTAKE/EXHAUST SYSTEM

Inspect exhaust system components *

[

Check the exhaust gas condition

Service backfire flame arrestor *

Check and/or replace the catalyst assembly *

[

Replace the CO sensor module *

[

Check the crankcase breather pipe for obstructions *

[

Inspect the complete exhaust system ***

ELECTRICAL SYSTEM

Keep battery charged and in good condition

⊕

Check and tighten electrical connections *

Clean battery cables

[

ENGINE AND MOUNTING

Check for water, fuel, coolant, and oil leakage *

[]

Retighten all nuts and bolts *

Check tightness of mounting bolts/vibromounts *

Check and adjust valve clearance *

[

Clean combustion chamber *

[

REMOTE CONTROL SYSTEM

Check remote control operation

Reference

Section

Before

Starting

After

50 Hrs or

1 Month

Every

100 Hrs or

3 Months

Every

300 Hrs or

6 Months

Every

500 Hrs or

Yearly

3.6

3.6

3.5

3.6

3.6

3.9

X

X

(during operation)

X

X

X

X

X

(break-in period)

X

X

(200 hrs)

X

(200 hrs)

X

X

X

X

X

(Every

2 years)

X

X

GENERATOR

Test run generator set

Blow dust out of generator *

[

Clean slip rings and inspect brushes *

[

3.1

* Requires removal of sound shield, if installed.

[ Consult your local distributor/dealer for service.

] Read WARNING found at the beginning of manual regarding moving parts.

*** Should be performed by your local distributor/dealer.

⊕

Consult battery manufacturer’s instructions.

X

(weekly)

X

X

(1000 hrs.)


3.3 Lubrication System

3.3.1

Oil Specifications

Use oil that meets the American Petroleum Institute

(API) classification of SC, SD, SE, SF, SG, or SH. Using unsuitable oil or neglecting an oil change may result in engine damage that is not covered by the engine warranty. Figure 3-1 shows the recommended Society of Automotive Engineers (SAE) viscosity designation for given operating temperature ranges.

Do not mix different oil brands. Incompatibility could cause a breakdown of lubricating ingredients and reduce engine protection.

Recommended SAE Viscosity Grades

SAE40

SAE30

SAE10W-30/SAE 10W-40*

SAE5W-20*

°F -4

°C -20

14

-10

32

0

50

10

68

20

* Using multigrade oil causes greater oil consumption.

Figure 3-1 Engine Oil Selection

86

30

104

40

3.3.2

Oil Check

Check the oil level in the crankcase daily or before each start-up to ensure that the level is in the safe range. Do not check the oil level while operating the unit. Stop the generator set and keep the generator set level to get an accurate reading. To check the oil level, remove the dipstick and wipe the end clean, reinsert and remove.

Maintain the oil level between the Full and Add marks on the dipstick, as shown in Figure 3-2. See Section 1,

Service Views for the dipstick location.

1

2

1. Full mark

2. Add mark

Figure 3-2 Oil Level Check

TP-5586-3

Note: Do not operate the set if the oil level is below the

Add mark on the dipstick or above the Full mark on the dipstick.

3.3.3

Oil Additions

Adding some oil between oil changes is normal. The amount varies with generator set usage. Open the oil fill cap and pour in a small amount of oil using a funnel or other suitable pouring device. See Section 1, Service

Views for the oil check and oil fill locations.

3.3.4

Oil Change

Change the oil according to the service schedule or before generator set storage.

Change the oil more frequently if the generator set operates under dirty, dusty conditions. Change the oil while the engine is still warm. See Figure 3-3 for oil capacity. See Section 1,

Service Views for oil fill, oil check, and oil filter locations.

Model

All models

L (Qts.)

1.36 (1.44)

Figure 3-3 Oil Capacity (with Filter)


Oil Change Procedure

1. Stop the generator set.

2. To drain the oil, open the oil-drain valve.

See

Section 1 for the valve location.

3. Drain the oil into a suitable container.

4. Allow ample time for all oil to drain.

5. Close the oil-drain valve.

6. Remove the oil-fill cap.

7. Replace the engine oil filter according to the service schedule and the procedure in

Section 3.3.5.

8. Fill crankcase with oil. Section 1 shows the oil fill location. See Figure 3-1 for oil selection and

Figure 3-3 for oil capacity. Replace the oil-fill cap.

9. Start the generator set and check for oil leaks.

10. Stop the generator set. Check the oil level. Add oil, as necessary, to bring the level up to the Full mark.

Note: Too high an oil level causes high oil consumption and engine carbonizing. Too low a level damages the engine.

Note: Do not pollute the environment. Dispose of used engine oil and other contaminants in a safe, approved manner.

3.3.5

Oil Filter Change

Replace the oil filter at the interval specified in the service schedule. Change the oil filter more frequently if the generator set operates under dirty, dusty conditions.

Refer to the following procedure. See Section 1 for oil filter location.

Oil Filter Change Procedure

1. Loosen the oil filter by turning it counterclockwise.

Remove the oil filter and use rags to clean up spilled oil. Dispose of the oil filter in an approved manner.

2. Clean the contact surface of the oil filter adapter.

3. Lightly lubricate the gasket surface of the new filter with fresh engine oil. Thread the filter on the adapter until the gasket makes contact and hand-tighten the filter an additional one-half turn.

Wash hands after any contact with engine oil.

Note: If also performing an oil change, skip steps 4 and 5 and go back to oil change procedure.

4. Start the generator set and check for oil leaks.

5. Stop the generator set. Check oil level. Add oil, as necessary, to bring level up to Full mark.

3.4 Fuel System

3.4.1

Fuel Specifications

Use a clean, good-quality unleaded fuel with an octane number of 87. Use fresh gasoline to ensure it is blended for the season and to reduce the possibility of the formation of gum deposits that could clog the fuel system. Do not use gasoline left over from the previous season.

Kohler Co. recommends unleaded fuel because it leaves fewer combustion chamber deposits. Never mix oil with fuel.

Note: Consult the engine owner’s manual for oxygenated fuel recommendations.


3.4.2

Fuel Filter

The 5/7.3ECD generator sets utilize an in-line type fuel filter. See Section 1 for the fuel filter location. Replace the filter every 500 hours of running time or when rough operation indicates an engine tune-up may be necessary. Bleed the fuel system (after replacing the fuel filter). See Section 3.4.3.

3.4.3

Fuel System Bleed

Bleed air from the fuel system in order to reduce rough running or vapor lock.

WARNING

2

FUEL

1

3

Fire.


Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor.

Fuel System Bleed Procedure

1. Press and hold the Select button on the ADC. See

Figure 3-4.

2. While holding the Select button, move the generator set master switch into the RUN position.

See Figure 3-4.

3. Keep holding the Select button until step 6. The

ADC software version and then FUEL will appear on the ADC’s LED display. See Figure 3-4.

4. Remove the cap from the location shown in

Figure 3-5.

5. Hold the bleed tool (part number GM46327) onto the bleed point to remove air from the line.

6. When fuel begins to drip from the hose (on the bleed tool) release the Select button and replace the cap.

Note: Use a container at the end of the bleed tool’s hose to catch the fuel.

Dispose of fuel in an environmentally safe manner.

1. LED display

2. Select button (use for setup and adjustment only)


GM28707A-C

Figure 3-4 ADC 2100 Control

1

2

1. Bleed point (with the cap removed)

2. Bleed tool (with fuel drain hose attached)

Figure 3-5 Bleed Location


3.5 Backfire Flame Arrestor

At the interval specified in the service schedule, inspect, clean, or replace the backfire flame arrestor. Clean the arrestor more frequently if the generator set operates in dirty, dusty conditions.

Check the element for accumulated oil or dirt that could clog the element and cause poor performance. See Section 1 for location.

Replace a damaged flame arrestor.

Use only

USCG-approved Kohler replacement parts. Follow the procedure described below.

Backfire Flame Arrestor Cleaning Procedure

1. Loosen the hose clamp at the breather hose at the air silencer fitting and remove the hose.

2. Loosen the hose clamp attaching the air silencer assembly to the carburetor.

3. Lift off the air silencer assembly.

4. Clean the assembly in evaporative solvent and wipe clean. Allow to dry.

5. Reassemble using the reverse sequence.

TP-6390 1/06

3.6 Exhaust System

WARNING

Carbon monoxide.



Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of the craft’s occupants, install a carbon monoxide detector.

Consult the boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.

At the interval specified in the service schedule, inspect the exhaust system components (exhaust manifold, catalyst assembly, gasket(s), exhaust hose, hose clamps, silencer, and outlet flapper) for cracks, leaks, and corrosion.

Ensure that the carbon monoxide detector(s) is (1) in the craft, (2) functional, and (3) energized whenever the generator set operates.

For your safety: Never operate the generator set without a functioning carbon monoxide detector(s) for your safety and the safety of others on your vessel.

Exhaust System Inspection Points

Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections.

D

Check the hoses for softness, cracks, leaks, or dents.

Replace the hoses as needed.

D

Check for corroded or broken metal parts and replace them as needed.

D

Check for loose, corroded, or missing clamps.

Tighten or replace the hose clamps and/or hangers as needed.

D

Check that the exhaust outlet is unobstructed.

D

Visually inspect the exhaust system for exhaust leaks

(blowby).

Check for carbon or soot residue on exhaust components.

Carbon and soot residue indicates an exhaust leak. Seal leaks as needed.

Section 3 Scheduled Maintenance 29

3.7 Cooling System

3.7.1

Closed Heat Exchanger

In a closed cooling system, the seawater circulates through separate chambers within the heat exchanger to cool the engine water. The seawater then mixes with engine exhaust and ejects out the exhaust outlet. See

Figure 3-6 for coolant capacity (include coolant recovery tank capacity of 0.8 L (0.85 qts.).

See

Figure 3-7 for thermostat and pressure cap ratings.

Model

All models

Figure 3-6 Coolant Capacity

L (Qts.)

2.84 (3.0)

WARNING

Hot coolant and steam.


Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop.

Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals.

Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

Checking and Filling Coolant

Maintain the coolant level in coolant recovery tank at approximately 1/4 full. Before filling the cooling system, close all petcocks 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 additional coolant, as necessary, to the coolant recovery tank. Periodically check the coolant level on closed systems by removing the pressure cap.

Do not rely solely on level in coolant recovery tank. Add fresh coolant until the level is just below the overflow tube opening.

Do not add coolant to a hot engine. Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until engine has cooled.

Note: Coolant solution. A coolant solution of 50% ethylene glycol provides freezing protection to

--37

°C (--34°F) and overheating protection to

129

°C (265°F). A coolant solution with less than

50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can cause engine or component damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant.

Consult the engine manufacturer’s operation manual for engine coolant specifications.

Model

Pressure Cap Rating

Thermostat Rating

5/7.3ECD

96.5 kPa (14 psi)

91

_C (195_F)

Figure 3-7 Pressure Cap and Thermostat Rating

Procedure for Flushing and Cleaning Cooling

System

For optimum protection drain, flush, and refill the cooling system at the interval listed in the service schedule.

Pay special attention to the coolant level. After the coolant drains, allow time for complete refill of the engine water jacket.

Check the coolant level as described earlier.

1. Remove the hose clamp at the coolant hose. See

Section 1 for location of the hose.

2. Remove the pressure cap to make draining easier.

3. Drain, clean, and flush the coolant recovery tank.

4. Flush the system with clean water.

5. Replace the hose clamp to secure the coolant hose.

6. Fill the system with the recommended coolant.

7. Replace the pressure cap.

3.7.2

Pressure Cap

Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant, enabling higher operating temperatures. If the cap leaks, replace it with a cap of the same rating. Find the pressure cap rating in

Figure 3-7.


3.7.3

Seawater Pump

The direct-driven seawater pump is located on the generator end of the generator set. Check and change the seawater pump impeller at the interval specified in the service schedule. Follow the instructions included with the impeller kit. If the instructions are not included with the kit, use the following procedure:

Impeller Inspection and Replacement Procedure:

1. Close the seacock.

2. Remove the seawater pump coverplate.

See

Figure 3-8.

3. Remove the impeller.

4. Inspect the impeller for damaged, cracked, broken, missing or flattened vanes. The impeller vanes should be straight and flexible. See Figure 3-9.

Replace the impeller if it is damaged.

1

11

2

10

3

4

5

6

9 8

1. Seawater pump

2. Coverplate

3. Gasket

4. Impeller

5. Bearing

6. Housing

7

7. Pulley

8. Drive shaft

9. Washer

10. Nut

11. Mechanical seal, if equipped

TP-6053

Figure 3-8 Seawater Pump, Typical

1

2

3

TP-6053

1. Flattened vane

2. Crack

3. Broken vane

Figure 3-9 Worn Impeller

5. Lubricate the impeller with soapy water before installation.

6. Install the impeller.

Note: During installation push and rotate the impeller in the same direction as the engine rotation until it is thoroughly seated in the impeller housing.

7. Inspect the coverplate and gasket for corrosion and/or damage.

Replace components as necessary.

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

9. Open the seacock.

10. Start the generator set and check for leaks.

11. Stop the generator set and repair leaks or replace damaged or worn components.

m:sm:003:008


3.7.4

Siphon Break

A siphon break prevents seawater entry into the generator set’s engine when the engine exhaust manifold outlet is less than 230 mm (9 in.) above the waterline of a fully loaded, docked or stationary craft.

See Figure 3-11. The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater. Use the following procedure to inspect the siphon break at the intervals listed in the service schedule.

Siphon Break Inspection


2. Remove the retaining cap and remove the reed valve for inspection. See Figure 3-10.

3. Use a mild detergent to remove residue and oxidation from the reed valve.

4. Clear blockage from the reed valve opening.

5. Replace the siphon break if the reed valve is cracked or if the reed valve material has hardened or deteriorated.

6. Install the reed valve into the mounting base with the valve downward. See Figure 3-10, item 2.

7. Install and only finger tighten the retaining cap. Do not overtighten it.

1

2

3

1. Cap

2. Reed valve

3. Mounting base

Figure 3-10 Siphon Break m:sm:003:007


2

3

7

8

9

1

10

22

6

5

4

11

Waterline

20

21

16

12

19

15

17

13

18

14

TP-5586-3

1. Mounting base

2. Retaining cap

3. Reed valve assembly

4. Silencer vertical lift 1.2 m (4 ft.) max.

5. Exhaust catalyst assembly distance above waterline. If less than 23 cm (9 in.), siphon break is required.

6. Siphon break distance above waterline 30.5 cm (1 ft.) min.

7. Siphon break

8. Exhaust catalyst assembly

9. Heat exchanger (locations vary by model)

10. Coolant recovery tank

11. Locate coolant recovery tank at same height as heat exchanger

Figure 3-11 Siphon Break (Plastic “U” Type) Installation

Note: Consult the installation manual for complete explanation of dimensions and other installation considerations.

12. Seawater strainer

13. Seacock

14. Intake strainer

15. Engine-driven seawater pump

16. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

17. Water lock (optional)

18. Silencer distance from exhaust catalyst assembly 3 m (10 ft.) max.

19. Silencer (customer-supplied)

20. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

21. Exhaust outlet distance above waterline 10 cm (4 in.) min.

22. Seawater outlet


3.7.5

Anticorrosion Zinc Anode

The heat exchanger on these models contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion by seawater.

Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule.

Depending upon operating conditions and seawater properties, the anticorrosion zinc anode may require more frequent replacement. See Section 1—Service

Views for location and use the following procedure.

Anticorrosion Zinc Anode Replacement Procedure

1. With the generator set cooled, close the seacock, remove the anticorrosion zinc plug from the heat exchanger, and drain the coolant into a suitable container.

2. Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode. Replace the anode according to Figure 3-12 and Figure 3-13.

Anticorrosion Zinc Anode Replacement

Models

New Anode

Dimensions mm (in.)

Replace When

Percent of Zinc

Remaining Is:

5/7.3ECD

and

4/6EFCD

9 (0.34) x 43 (1.7)

<50% of length/diameter

Figure 3-12 Anticorrosion Zinc Anode (Plug)

Measurements

1

2

1. Diameter: 9 mm (0.34 in.)

2. Length: 43 mm (1.7 in.)

Figure 3-13 Anticorrosion Zinc Anode (Plug)

TP-5586-3

3. Clean the threaded hole of the heat exchanger and coat the threads of the anticorrosion zinc anode

(plug) with pipe sealant suitable for marine applications. Install the anticorrosion zinc anode into the heat exchanger.

4. Open the seacock. Refill the cooling system.

5. Start the generator set and check for leaks at the anticorrosion zinc anode location. The pump is operating if cooling water flows from the exhaust outlet. If water is not discharging at the exhaust outlet, see Prestart Checklist—Seawater Pump

Priming.

3.7.6

Seawater Outlet

Check the seawater outlet at the interval specified in the service schedule.

See Figure 3-11 for location.

Remove any obstructions to keep the outlet clear.


3.8 Ignition System

Service spark plugs at the interval specified in the service schedule using the following procedure.

Spark Plug Service Procedure

1. Remove spark plug wires by grasping the spark plug boot and turning slightly while pulling. Do not pull the wire. Pulling on the wire rather than the boot may damage the wire or terminal.

3. Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling into the combustion chamber.

4. Remove spark plugs, one at a time, and examine.

Identify a normal spark plug in good operating condition by observing a light tan or gray deposit on the firing tip. See Figure 3-14 to evaluate engine condition by color/condition of a problem spark plug.

2. Loosen the spark plug with a ratchet and 5/8-in.

spark plug socket with a rubber insert to prevent spark plug damage.

Problem/Condition

Gap-bridged spark plug

Oil-fouled spark plug

Carbon-fouled spark plug

Lead-fouled spark plug

Preignition damaged spark plug

Overheated spark plug

Worn spark plug

Means of Identification

Built-up deposits and gap between electrodes closing.

Wet, black deposits on the insulator shell, bore, and electrodes.

Black, dry, fluffy carbon deposits on insulator tips, exposed shell surfaces and electrodes.

Dark gray, black, yellow, or tan deposits; or a glazed coating on the insulator tip.

Melted electrodes and possibly blistered insulator. Metallic deposits on insulator suggest internal engine damage.

White or light gray insulator with small black or gray/brown spots with bluish

(burned) appearance on electrodes.

Severely eroded or worn electrodes.

Possible Cause/Solution

Oil or carbon fouling. Clean and regap the spark plug.

Excessive oil entering combustion chamber through worn rings and pistons, excessive clearance between valve guides and stems, or worn or loose bearings. Replace the spark plug.

Incorrect spark plug, weak ignition, clogged air intake, defective fuel pump, overrich fuel mixture, or excessive no-load operation. Clean and regap the spark plug.

Caused by highly leaded fuel. Replace the spark plug.

Wrong type of fuel, incorrect timing or advance, too hot a plug, burned valves, or engine overheating. Replace the spark plug.

Engine overheating, wrong type of fuel, loose spark plugs, too hot a plug, low fuel pump pressure or incorrect ignition timing. Replace the spark plug.

Caused by normal wear and failure to replace spark plug at prescribed interval. Replace the spark plug.

Figure 3-14 Engine Evaluation Using Spark Plug Condition


5. Clean spark plugs by wiping them with a rag. File the center electrode to keep it parallel to the side electrode.

Note: Do not sandblast, wire brush, scrape, or otherwise service spark plug in poor condition.

Obtain a new plug for best results.

6. Check the spark plug gap before installing any spark plug. See Figure 3-15. Attain a correct gap when the feeler (or wire) passes between the spark plug electrode. It should pass easily but with some resistance or drag; otherwise adjust as necessary.

The correct gap is 0.6-0.7 mm (0.024-0.028 in.).

1

2

1-514

1. 0.6-0.7 mm (0.024-0.028 in.) gap

2. Spark plug electrodes

Figure 3-15 Spark Plug Gap Inspection

7. Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap. See Figure 3-16.

Position the side electrode directly over the center electrode.

1-511

Figure 3-16 Spark Plug Gap Adjustment

8. Reinstall the spark plug.

Do not bump the electrode against the cylinder head. Rotate the spark plug clockwise until feeling resistance.

9. Use a torque wrench to torque each spark plug to

12-17 Nm (9-12 ft. lbs.). Otherwise, hand-tighten spark plug until feeling resistance.

10. Use a ratchet wrench to final tighten an additional

1/4 turn. Do not overtighten, as doing so may strip threads or alter electrode gap setting.

11. Check spark plug wire connector in boot for accumulated dirt, grease, and other debris, and clean as necessary.

12. Firmly push spark plug boot onto spark plug.


3.9 Battery

Consult the battery manufacturer’s instructions regarding battery care and maintenance.

WARNING

Sulfuric acid in batteries.


Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

3.10 Generator Storage Procedure

Keep the craft afloat for generator operation during the storage procedure. Follow the procedure below when storing your generator set for a long period (3 months or more).

1. Start and run the generator set until it reaches operating temperature or about 15 minutes.


3. Change the oil and oil filter; see Section 3.3.4—Oil

Change and Section 3.3.5—Oil Filter Change.

4. Close the seacock and remove the hose at the seacock. Place the hose in a container having approximately 3.7-7.5 L (1-2 U.S. gallons) of coolant/antifreeze. Kohler Co. recommends using an environmentally friendly potable antifreeze such as Peak

R RV/marine propylene glycol/water mix or equivalent.

5. Disconnect the lead (#87) to the low seawater pressure (LWP) switch.

6. With a suitable container at the exhaust outlet, run the generator set until coolant discharges at the exhaust outlet or until depleting the coolant mixture. Do not allow coolant mixture to flow into waterways.

7. Reconnect the lead (#87) to the low seawater pressure (LWP) switch.


9. Connect the hose to the seacock.

Leave the seacock closed.

10. Check the coolant level of the heat exchanger and add coolant if necessary.

Note: Use antifreeze capable of withstanding the lowest possible temperatures.

11. Drain fuel completely from the fuel tank.

12. Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion.

13. Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs.

14. Seal the air inlet, exhaust pipe, and fuel tank cap with tape.

15. Disconnect and remove the battery.

Place the battery in a warm, dry location for the storage period.

Recharge the battery once a month to maintain a full charge.

16. Select a well-ventilated (not humid or dusty) location to store the generator.

17. Cover the entire unit with a dust cover.

Note: Run the generator set once a month whenever possible.


Notes


Section 4 Troubleshooting

This section contains generator set troubleshooting, diagnostic, and repair information.

Use the following charts as a quick troubleshooting reference. The table groups generator set faults and suggests likely causes and remedies. The table also refers you to more detailed information including sections of this manual, the generator set service manual (S/M), the generator set installation manual

(I/M), and the engine service manual (Engine S/M) to correct the indicated problem.

Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, and recommended corrective actions.

Corrective action and testing often require knowledge of electrical and electronic circuits. To avoid additional problems caused by incorrect repairs, have an authorized service distributor/dealer perform service.

NOTICE

Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic).

Do not substitute clear glass-type fuses for ceramic fuses.

Refer to the wiring diagram when the ampere rating is unknown or questionable.

Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/dealer. Use the record to help describe the problem and repairs or adjustments made to the equipment.

x:gt:001:002a:

TP-6390 1/06 Section 4 Troubleshooting 39

abnormalnoise

Excessiveor consumption

Highfuel pressure

Lowoil

Overheats

Lackspower suddenly

Stops outputvoltage low Noor

Startshard start doesnot

Cranksbut crank

Doesnot

40 Section 4 Troubleshooting

TP-6390 1/06

start

TP-6390 1/06 low doesnot

Cranksbut crank

Doesnot

Startshard outputvoltage

Noor

Stops suddenly

Lackspower

Overheats pressure

Lowoil

Highfuel consumption

Excessiveor abnormalnoise

Section 4 Troubleshooting 41

abnormalnoise

Excessiveor consumption

Highfuel pressure

Lowoil

Overheats

Lackspower suddenly

Stops outputvoltage low Noor

Startshard start doesnot

Cranksbut crank

Doesnot

42 Section 4 Troubleshooting

TP-6390 1/06

Section 5 Wiring Diagrams

WARNING

WARNING








Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the

OFF position. (2) Disconnect the power to the battery charger.

(3) Remove the battery cables, negative (--) lead first.


Hazardous voltage.

Moving rotor.



Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.

Turn off the main circuit breakers of all power sources before servicing the equipment.

Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

TP-6390 1/06 Section 5 Wiring Diagrams 43

Figure 5-1 Point-to-Point Wiring Diagram (Sheet 1 of 2)

44 Section 5 Wiring Diagrams

GM39836A--G

TP-6390 1/06

Figure 5-2 Point-to-Point Wiring Diagram (Sheet 2 of 2)

TP-6390 1/06

GM39836B--G

Section 5 Wiring Diagrams 45

Figure 5-3 Schematic Wiring Diagram (Sheet 1 of 2)

46 Section 5 Wiring Diagrams

ADV7029A--G

TP-6390 1/06

Figure 5-4 Schematic Wiring Diagram (Sheet 2 of 2)

TP-6390 1/06

ADV7029B--G

Section 5 Wiring Diagrams 47

Notes

48 Section 5 Wiring Diagrams TP-6390 1/06

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere

ABDC after bottom dead center

AC

A/D alternating current analog to digital

ADC adj.

ADV

AHWT analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature

AISI

ALOP alt.

Al

ANSI

AO

API approx.

approximate, approximately

AR

AS as required, as requested as supplied, as stated, as suggested

ASE

ASME assy.

ASTM

American Society of Engineers

American Society of

Mechanical Engineers assembly

ATDC

ATS auto.

aux.

American Iron and Steel

Institute anticipatory low oil pressure alternator aluminum

American National Standards

Institute

(formerly American Standards

Association, ASA) anticipatory only

American Petroleum Institute

American Society for Testing

Materials after top dead center automatic transfer switch automatic auxiliary

A/V avg.

AVR

AWG

AWM bat.

BBDC

BC audiovisual average automatic voltage regulator

American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging

BCA

BCI

BDC

BHP battery charging alternator

Battery Council International before dead center brake horsepower blk.

black (paint color), block

(engine) blk. htr.

block heater

CARB

CB cc

CCA ccw.

CEC cfh cfm

BMEP bps br.

BTDC brake mean effective pressure bits per second brass before top dead center

Btu British thermal unit

Btu/min.

British thermal units per minute

C cal.

Celsius, centigrade calorie

California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise

Canadian Electrical Code cubic feet per hour cubic feet per minute

CT

Cu cu. in.

cw.

CWC cyl.

D/A

DAC dB dBA

DC

DCR deg.,

° dept.

dia.

DI/EO

DIN

CG

CID

CL cm

CMOS cogen.

Com conn.

cont.

CPVC crit.

CRT

CSA center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogeneration communications (port) connection continued chlorinated polyvinyl chloride critical cathode ray tube

Canadian Standards

Association current transformer copper cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter decibel decibel (A weighted) direct current direct current resistance degree department diameter dual inlet/end outlet

Deutsches Institut fur Normung e. V.

(also Deutsche Industrie

Normenausschuss)

DIP

DPDT

DPST

DS dual inline package double-pole, double-throw double-pole, single-throw disconnect switch

DVR digital voltage regulator

E, emer.

emergency (power source)

EDI

EFR electronic data interchange emergency frequency relay e.g.

EG

EGSA

EIA for example (exempli gratia) electronic governor

Electrical Generating Systems

Association

Electronic Industries

Association

EI/EO

EMI emiss.

eng.

EPA

EPS

ER

ES end inlet/end outlet electromagnetic interference emission engine

Environmental Protection

Agency emergency power system emergency relay engineering special, engineered special

ESD est.

electrostatic discharge estimated

E-Stop emergency stop etc.

et cetera (and so forth) exh.

ext.

F exhaust external

Fahrenheit, female

TP-6390 1/06 fglass.

FHM fl. oz.

flex.

freq.

FS ft.

ft. lbs.

fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) ft./min.

feet per minute g gram ga.

gal.

gauge (meters, wire size) gallon gen.

genset

GFI generator generator set ground fault interrupter

HD

HET hex

Hg

HH

HHC

HP hr.

HS hsg.

HVAC

GND, gov.

gph gpm gr.

GRD ground governor gallons per hour gallons per minute grade, gross equipment ground gr. wt.

gross weight

H x W x D height by width by depth

HC

HCHT hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning

J

JIS k

K kA

KB

HWT

Hz

IC

ID

IEC

IEEE

IMS in.

improved motor starting inch in. H

2 in. Hg

O inches of water inches of mercury in. lbs.

inch pounds

Inc.

ind.

incorporated industrial int.

internal int./ext.

internal/external

I/O

IP

ISO high water temperature hertz (cycles per second) integrated circuit inside diameter, identification

International Electrotechnical

Commission

Institute of Electrical and

Electronics Engineers input/output iron pipe

International Organization for

Standardization joule

Japanese Industry Standard kilo (1000) kelvin kiloampere kilobyte (2

10 bytes)

Appendix 49

kg kg/cm

2 kilogram kilograms per square centimeter kgm kg/m

3 kHz kJ kilogram-meter kilograms per cubic meter kilohertz kilojoule km kilometer kOhm, k

Ω kilo-ohm kPa kilopascal kph kilometers per hour kV kVA kVAR kW kWh kWm

L

LAN kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical liter local area network

L x W x H length by width by height lb.

lbm/ft

3 pound, pounds pounds mass per cubic feet

LCB

LCD line circuit breaker liquid crystal display ld. shd.

load shed

LED light emitting diode

Lph

Lpm

LOP

LP liters per hour liters per minute low oil pressure liquefied petroleum

LPG

LS liquefied petroleum gas left side

L wa

LWL

LWT

MB

MCM sound power level, A weighted low water level man.

max.

low water temperature m

M meter, milli (1/1000) mega (10

6 when used with SI m

3 m

3 units), male cubic meter

/min.

cubic meters per minute mA milliampere manual maximum megabyte (2

20 bytes) one thousand circular mils

MOV

MPa mpg mph

MS m/sec.

MTBF

MTBO mtg.

MCCB molded-case circuit breaker meggar megohmmeter

MHz mi.

megahertz mile mil min.

misc.

MJ one one-thousandth of an inch minimum, minute miscellaneous megajoule mJ millijoule mm millimeter mOhm, m

Ω milliohm

MOhm, M

Ω megohm metal oxide varistor megapascal miles per gallon miles per hour military standard meters per second mean time between failure mean time between overhauls mounting

MW megawatt mW

μF milliwatt microfarad

N, norm.

normal (power source)

NA not available, not applicable nat. gas natural gas

NBS

NC

National Bureau of Standards normally closed

NEC

NEMA

National Electrical Code

National Electrical

Manufacturers Association

NFPA National Fire Protection

Association newton meter Nm

NO normally open no., nos.

number, numbers

NPS

NPSC

NPT

National Pipe, Straight

National Pipe, Straight-coupling

National Standard taper pipe thread per general use

NPTF

NR ns

OC

OD

OEM

OF opt.

OS

OSHA

National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option, optional oversize, overspeed

Occupational Safety and Health

Administration

OV oz.

p., pp.

PC

PCB pF overvoltage ounce page, pages personal computer printed circuit board picofarad psi pt.

PTC

PTO

PVC qt.

qty.

R rad.

RAM

RDO ref.

rem.

RFI

RH

RHM rly.

PF ph., power factor

∅ phase

PHC

PHH

Phillips head crimptite (screw)

Phillips hex head (screw)

PHM

PLC

PMG pot ppm

PROM pan head machine (screw) programmable logic control permanent-magnet generator potentiometer, potential parts per million programmable read-only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement (emergency) power source radiator, radius random access memory relay driver output reference remote radio frequency interference round head round head machine (screw) relay

VAC

VAR

VDC

VFD

VGA

VHF

W

WCR w/ w/o wt.

xfmr rms rnd.

ROM rot.

rpm

RS

RTV

SAE scfm

SCR s, sec.

SI root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization

Society of Automotive

Engineers standard cubic feet per minute silicon controlled rectifier second

Systeme international d’unites,

International System of Units

UF

UHF

UL

UNC

UNF univ.

US

UV

V

TDOE

TDON temp.

term.

TIF

TIR tol.

turbo.

typ.

SI/EO sil.

SN

SPDT side in/end out silencer serial number single--pole, double--throw

SPST single--pole, single--throw spec, specs specification(s) sq.

sq. cm sq. in.

SS std.

stl.

tach.

TD

TDC

TDEC

TDEN

TDES

TDNE square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency

Underwriter’s Laboratories, Inc.

unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer

50 Appendix TP-6390 1/06

Appendix B Operating Hour Service Log

Use the log below to keep a cumulative record of operating hours on your generator set and the dates

DATE

RUN

OPERATING HOURS

HOURS

RUN

TOTAL

HOURS

SERVICE

DATE required services were performed. Enter hours to the nearest quarter hour.

SERVICE RECORD

SERVICE

TP6390 1/06 Appendix 51

52 TP-6390 1/06

TP-6390 1/06 53

54 TP-6390 1/06

TP-6390 1/06 55

TP-6390 1/06a

E 2006 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044

Phone 920-565-3381, Fax 920-459-1646

For the nearest sales/service outlet in the

US and Canada, phone 1-800-544-2444

KohlerPowerSystems.com

Kohler Power Systems

Asia Pacific Headquarters

7 Jurong Pier Road

Singapore 619159

Phone (65)6264-6422, Fax (65)6264-6455

No results