Kohler 10EKD-Low CO Operation Download Page 45

TP-6591 10/13

Appendix 45

Appendix A Abbreviations

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

A, amp

ampere

ABDC

after bottom dead center

AC

alternating current

A/D

analog to digital

ADC

analog to digital converter

adj.

adjust, adjustment

ADV

advertising dimensional

drawing

AHWT

anticipatory high water

temperature

AISI

American Iron and Steel

Institute

ALOP

anticipatory low oil pressure

alt.

alternator

Al

aluminum

ANSI

American National Standards

Institute

(formerly American Standards

Association, ASA)

AO

anticipatory only

API

American Petroleum Institute

approx.

approximate, approximately

AR

as required, as requested

AS

as supplied, as stated, as

suggested

ASE

American Society of Engineers

ASME

American Society of

Mechanical Engineers

assy.

assembly

ASTM

American Society for Testing

Materials

ATDC

after top dead center

ATS

automatic transfer switch

auto.

automatic

aux.

auxiliary

A / V

audiovisual

avg.

average

AVR

automatic voltage regulator

AWG

American Wire Gauge

AWM

appliance wiring material

bat.

battery

BBDC

before bottom dead center

BC

battery charger, battery

charging

BCA

battery charging alternator

BCI

Battery Council International

BDC

before dead center

BHP

brake horsepower

blk.

black (paint color), block

(engine)

blk. htr.

block heater

BMEP

brake mean effective pressure

bps

bits per second

br.

brass

BTDC

before top dead center

Btu

British thermal unit

Btu/min.

British thermal units per minute

C

Celsius, centigrade

cal.

calorie

CARB

California Air Resources Board

CB

circuit breaker

cc

cubic centimeter

CCA

cold cranking amps

ccw.

counterclockwise

CEC

Canadian Electrical Code

cfh

cubic feet per hour

cfm

cubic feet per minute

CG

center of gravity

CID

cubic inch displacement

CL

centerline

cm

centimeter

CMOS

complementary metal oxide

substrate (semiconductor)

cogen.

cogeneration

Com

communications (port)

conn.

connection

cont.

continued

CPVC

chlorinated polyvinyl chloride

crit.

critical

CRT

cathode ray tube

CSA

Canadian Standards

Association

CT

current transformer

Cu

copper

cu. in.

cubic inch

cw.

clockwise

CWC

city water-cooled

cyl.

cylinder

D/A

digital to analog

DAC

digital to analog converter

dB

decibel

dBA

decibel (A weighted)

DC

direct current

DCR

direct current resistance

deg.,

degree

dept.

department

dia.

diameter

DI/EO

dual inlet/end outlet

DIN

Deutsches Institut fur Normung

e. V.

(also Deutsche Industrie

Normenausschuss)

DIP

dual inline package

DPDT

double-pole, double-throw

DPST

double-pole, single-throw

DS

disconnect switch

DVR

digital voltage regulator

E, emer.

emergency (power source)

EDI

electronic data interchange

EFR

emergency frequency relay

e.g.

for example (

exempli gratia)

EG

electronic governor

EGSA

Electrical Generating Systems

Association

EIA

Electronic Industries

Association

EI/EO

end inlet/end outlet

EMI

electromagnetic interference

emiss.

emission

eng.

engine

EPA

Environmental Protection

Agency

EPS

emergency power system

ER

emergency relay

ES

engineering special,

engineered special

ESD

electrostatic discharge

est.

estimated

E-Stop

emergency stop

etc.

et cetera (and so forth)

exh.

exhaust

ext.

external

F

Fahrenheit, female

fglass.

fiberglass

FHM

flat head machine (screw)

fl. oz.

fluid ounce

flex.

flexible

freq.

frequency

FS

full scale

ft.

foot, feet

ft. lbs.

foot pounds (torque)

ft./min.

feet per minute

g

gram

ga.

gauge (meters, wire size)

gal.

gallon

gen.

generator

genset

generator set

GFI

ground fault interrupter

GND,

ground

gov.

governor

gph

gallons per hour

gpm

gallons per minute

gr.

grade, gross

GRD

equipment ground

gr. wt.

gross weight

H x W x D height by width by depth
HC

hex cap

HCHT

high cylinder head temperature

HD

heavy duty

HET

high exhaust temperature

hex

hexagon

Hg

mercury (element)

HH

hex head

HHC

hex head cap

HP

horsepower

hr.

hour

HS

heat shrink

hsg.

housing

HVAC

heating, ventilation, and air

conditioning

HWT

high water temperature

Hz

hertz (cycles per second)

IC

integrated circuit

ID

inside diameter, identification

IEC

International Electrotechnical

Commission

IEEE

Institute of Electrical and

Electronics Engineers

IMS

improved motor starting

in.

inch

in. H

2

O

inches of water

in. Hg

inches of mercury

in. lbs.

inch pounds

Inc.

incorporated

ind.

industrial

int.

internal

int./ext.

internal/external

I/O

input/output

IP

iron pipe

ISO

International Organization for

Standardization

J

joule

JIS

Japanese Industry Standard

k

kilo (1000)

K

kelvin

kA

kiloampere

KB

kilobyte (2

10

bytes)

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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