Kohler 7.3ECD-Low CO Operation Manual
Kohler 7.3ECD-Low CO is a marine generator set designed for durability, reliability and low carbon monoxide emissions. It offers an impressive range of capabilities that make it an excellent choice for various marine applications. With its advanced features, this generator set provides a stable and efficient power supply for your marine needs.
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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
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
Can cause severe injury or death.
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.
Can cause severe injury or death.
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.
Can cause severe injury or death.
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.
Can cause severe injury or death.
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.
Can cause severe injury or death.
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.
TP-6390 1/06 Safety Precautions and Instructions 7
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.
Explosive fuel vapors can cause severe injury or death.
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.
Explosive fuel vapors can cause severe injury or death.
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.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Grounding electrical equipment.
Hazardous voltage can cause severe injury or death. 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.
8 Safety Precautions and Instructions TP-6390 1/06
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.
Can cause severe injury or death.
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.
Can cause severe injury or death.
Do not work on the generator set until it cools.
WARNING
Hot engine oil.
Can cause severe injury or death.
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.
Do not work on the generator set until it cools.
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.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
TP-6390 1/06 Safety Precautions and Instructions 9
WARNING
Rotating parts.
Can cause severe injury or death.
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.
10 Safety Precautions and Instructions TP-6390 1/06
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.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
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)
3. Generator set master switch
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.
TP-6390 1/06 Section 2 Operation 17
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.
18 Section 2 Operation TP-6390 1/06
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.
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).
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.
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
Contact an authorized distributor/dealer for service if problem continues.
Contact an authorized distributor/dealer for service if problem continues.
Reduce the load and restart the generator set.
Contact an authorized distributor/dealer for service if problem continues.
Reduce the load and restart the generator set.
Contact an authorized distributor/dealer for service if problem continues.
Contact an authorized distributor/dealer for service if problem continues.
TP-6390 1/06 Section 2 Operation 19
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
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).
Contact an authorized distributor/dealer for service if problem continues.
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.
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).
Generator service for emissions required.
Contact an authorized distributor/dealer for service if problem continues.
Fault code is displayed if the CO sensor is inoperative. Replace the CO sensor.
Contact an authorized distributor/dealer for service if problem continues.
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
20 Section 2 Operation TP-6390 1/06
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.
TP-6390 1/06 Section 2 Operation 21
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
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.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
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.
Can cause severe injury or death.
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.)
TP-6390 1/06 Section 3 Scheduled Maintenance 25
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)
26 Section 3 Scheduled Maintenance TP-6390 1/06
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.
TP-6390 1/06 Section 3 Scheduled Maintenance 27
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.
Can cause severe injury or death.
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)
3. Generator set master switch
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
28 Section 3 Scheduled Maintenance TP-6390 1/06
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.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
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.
Can cause severe injury or death.
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.
30 Section 3 Scheduled Maintenance TP-6390 1/06
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
TP-6390 1/06 Section 3 Scheduled Maintenance 31
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
1. Stop the generator set.
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
32 Section 3 Scheduled Maintenance TP-6390 1/06
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
TP-6390 1/06 Section 3 Scheduled Maintenance 33
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.
34 Section 3 Scheduled Maintenance TP-6390 1/06
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
TP-6390 1/06 Section 3 Scheduled Maintenance 35
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.
36 Section 3 Scheduled Maintenance TP-6390 1/06
3.9 Battery
Consult the battery manufacturer’s instructions regarding battery care and maintenance.
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
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.
2. Stop the generator set.
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.
8. Stop the generator set.
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.
TP-6390 1/06 Section 3 Scheduled Maintenance 37
Notes
38 Section 3 Scheduled Maintenance TP-6390 1/06
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
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.
Hazardous voltage.
Moving rotor.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Grounding electrical equipment. Hazardous voltage can cause severe injury or death. 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

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Key features
- - Low Carbon Monoxide Emissions: Meets stringent environmental regulations and ensures a healthier environment on board.
- - Advanced Digital Control: Provides comprehensive control and monitoring, allowing for remote operation and easy troubleshooting.
- - Circuit Protection: Integrated circuit breakers and fuses protect against electrical overloads and short circuits.
- - Durable Construction: Built to withstand harsh marine conditions with corrosion-resistant materials and protective coatings.