Kohler 10EKD-Low CO Operation Download

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TP-6591 10/13

Table of Contents

Table of Contents

Product Identification Information

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Safety Precautions and Instructions

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Introduction

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Service Assistance

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Maintenance and Service Parts/Related Literature

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Section 1 Service Views

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Section 2 Operation

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2.1

Prestart Checklist

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2.2

Marine Inspection

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2.3

Angular Operation

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2.4

Operation in European Union Member Countries

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2.5

Load Profile

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2.6

Advanced Digital Control II Operation

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2.6.1

Controls and Indicators

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2.6.2

Starting the Generator Set

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2.6.3

Stopping the Generator Set

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2.6.4

Fault Shutdowns and Warnings

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2.6.5

Resetting the Controller after a Fault Shutdown

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2.6.6

USB Connection

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2.7

Circuit Protection

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2.7.1

Line Circuit Breaker

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2.7.2

Fuses

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Section 3 Scheduled Maintenance

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3.1

General Maintenance

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3.2

Service Schedule

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3.3

Lubrication System

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3.3.1

Oil Specifications

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3.3.2

Oil Check

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3.3.3

Oil Additions

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3.3.4

Oil Change

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3.3.5

Oil Filter Change

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3.4

Fuel System

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3.4.1

Fuel Specifications

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3.4.2

Fuel Filter

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3.4.3

Fuel System Bleed

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3.5

Backfire Flame Arrestor

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3.6

Exhaust System

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3.7

Cooling System

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3.7.1

Closed Heat Exchanger

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3.7.2

Pressure Cap

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3.7.3

Seawater Pump

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3.7.4

Seawater Flow Switch

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3.7.5

Belt Tension

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3.7.6

Siphon Break

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3.7.7

Anticorrosion Zinc Anode

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3.7.8

Seawater Outlet

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3.8

Ignition System

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3.9

Battery

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3.10 Generator Storage Procedure

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Section 4 Troubleshooting

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Section 5 Wiring Diagrams

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Appendix A Abbreviations

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Appendix B Operating Hour Service Log

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Summary of Contents for 10EKD-Low CO

Page 1: ...Marine Generator Sets TP 6591 10 13d Operation Models 5EKD 4EFKD Low CO 7 5EKD 6EFKD Low CO 10EKD 8EFKD Low CO Controller Advanced Digital Control II...

Page 2: ...es 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 Identificati...

Page 3: ...2 7 Circuit Protection 22 2 7 1 Line Circuit Breaker 22 2 7 2 Fuses 22 Section 3 Scheduled Maintenance 23 3 1 General Maintenance 23 3 2 Service Schedule 24 3 3 Lubrication System 25 3 3 1 Oil Specif...

Page 4: ...TP 6591 10 13 4 Notes...

Page 5: ...e battery Reconnect the negative lead last when reconnecting the battery WARNING Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or...

Page 6: ...g 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 oth...

Page 7: ...e 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...

Page 8: ...TP 6591 10 13 8 Safety Precautions and Instructions Notes...

Page 9: ...s should install the generator set Service Assistance For professional advice on generator set power requirementsand conscientiousservice pleasecontact your nearest Kohler distributor or dealer D Cons...

Page 10: ...ils GM47427 Fuse F4 10 amp Controller GM42337 Fuse F5 10 amp Auxiliary Winding 358337 Oil Filter 52 050 02 S Seawater Pump Impeller Kit 359978 Seawater Pump Belt GM53040 Spark Plug 25 132 16 S Spray P...

Page 11: ...mp 17 Seawater inlet 18 Oil drain valve 19 Lube oil filter 20 Fuel filter 21 Fuel pump cooler 22 Fuel pump 23 Fuel inlet 24 Filter screen 25 Fuse block F1 F2 F3 and F4 see Section 2 7 2 26 Fuse F5 see...

Page 12: ...TP 6591 10 13 12 Section 1 Service Views Notes...

Page 13: ...ot 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 when...

Page 14: ...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...

Page 15: ...ummary of the generator state D Green indicates no known problem D Red indicates one or more faults i e the generator cannot operate D Amber indicates no faults but one or more warnings i e the genera...

Page 16: ...t 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 Kohlerr distributor dealer The controller attemp...

Page 17: ...ADC II powers down after 48 hours of inactivity If the generator has been started the controller will power down 48 hours after the generator stops 2 6 4 Fault Shutdowns and Warnings The generator set...

Page 18: ...ault Overspeed shutdown occurs if the engine speed exceeds the default setting ECM data Above setting 0 sec 1 sec 70 Hz Contact an authorized distributor dealer for service if problem continues Coolan...

Page 19: ...ec N A Check the connections to the CO sensor If connections are okay replace the CO sensor Contact an authorized distributor dealer for service Over voltage fault Overvoltage shutdown occurs if the v...

Page 20: ...tion was displayed as Low battery fault Figure 2 6 Advanced Digital Control II Fault Shutdown Warnings Code Description Sensing Mechanism Active State Inhibit Time Delay Time Default Setting Check Hig...

Page 21: ...l Control II Warnings In addition to the fault shutdowns and warnings included in Figure 2 6 and Figure 2 7 other fault shutdowns warnings may occur see Figure 2 8 Contact an authorized Kohler distrib...

Page 22: ...art stop to the STOP position 2 6 6 USB Connection The Advanced Digital Control II includes a USB connection for updating software and configuring parameters See Figure 1 1 for location Note Have soft...

Page 23: ...rfaces 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...

Page 24: ...00 hr 2 years Ignition System Check spark plugs condition and gap 3 8 X Replace spark plugs 3 8 X 250 hr Intake Exhaust System Inspect exhaust system components 3 6 X Check the exhaust gas condition 3...

Page 25: ...eck 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 g...

Page 26: ...e 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 sch...

Page 27: ...els in an approved container when removing the fuel line or carburetor Fuel System Bleed Procedure 1 Push the Power Button on the Advanced Digital Control II to the ON position 2 When the run time hou...

Page 28: ...ld 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 energi...

Page 29: ...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 provi...

Page 30: ...ned vane 2 Crack 3 Broken vane TP 6053 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 impell...

Page 31: ...9 Reposition the O ring in the counter bored shoulder of the housing 10 Insert the bonnet assembly into the housing allowing the tabs on the bonnet to clear the mating lugs on the housing Ensure bonn...

Page 32: ...panel 3 7 6 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 d...

Page 33: ...odel 10 Coolant recovery tank 11 Locate coolant recovery tank at same height as heat exchanger 12 Seawater strainer 13 Seacock 14 Intake strainer 15 Engine driven seawater pump 16 Exhaust hose pitch 1...

Page 34: ...e 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...

Page 35: ...engine overheating Replace the spark plug Overheated spark plug White or light gray insulator with small black or gray brown spots with bluish burned appearance on electrodes Engine overheating wrong...

Page 36: ...y 3 7 7 5 L 1 2 U S gallons of coolant antifreeze Kohler Co recommends using an environmentally friendly potable antifreeze such as PeakR RV marine propylene glycol water mix or equivalent 5 Disconnec...

Page 37: ...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 electric...

Page 38: ...ontroller Section 2 W D x x The auxiliary winding fuse F5 blown Replace the blown F5 fuse If the fuse blows again troubleshoot the alternator winding Section 2 W D x Start stop switch inoperative Repl...

Page 39: ...noperative Replace the starter or starter solenoid Eng S M x x High water temperature switch inoperative Replace the inoperative switch Gen S M or W D x Faulty ground connection Clean and retighten th...

Page 40: ...x Overcrank shutdown Reset the controller If the overcrank fault occurs again contact the distributor dealer x Transfer switch test switch in the OFF position Move the transfer switch test switch to t...

Page 41: ...ve lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Hazardous voltage Can...

Page 42: ...TP 6591 10 13 42 Section 5 Wiring Diagrams GM90655A Figure 5 1 Point to Point Wiring Diagram Sheet 1 of 2...

Page 43: ...TP 6591 10 13 43 Section 5 Wiring Diagrams GM90655B Figure 5 2 Point to Point Wiring Diagram Sheet 2 of 2...

Page 44: ...TP 6591 10 13 44 Section 5 Wiring Diagrams ADV8631A Figure 5 3 Schematic Wiring Diagram Sheet 1 of 1...

Page 45: ...oled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO...

Page 46: ...OS oversize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase P...

Page 47: ...Log Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were performed Enter hours to the nearest quarter hour OPERATING HOURS SERVIC...

Page 48: ...TP 6591 10 13 48 Notes...

Page 49: ...TP 6591 10 13 49 Notes...

Page 50: ...TP 6591 10 13 50 Notes...

Page 51: ...TP 6591 10 13 51 Notes...

Page 52: ...nearest sales service outlet in the US and Canada phone 1 800 544 2444 KOHLERPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 626...

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