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TP-6591 10/13

23

Section 3 Scheduled Maintenance

Section 3 Scheduled Maintenance

3.1 General Maintenance

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.

WARNING

Disabling the generator set. Accidental starting can

cause severe injury or death.

Before working on the

generator set or equipment connected to the set, disable the

generator set as follows:

(1) Place the generator set

start/stop switch in the STOP position. (2) Disconnect the

power to the battery charger, if equipped. (3) Remove the

battery cables, negative (--) 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.

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

Hazardous voltage.

Can cause severe injury or death.

Operate the generator set only when

all guards and electrical enclosures

are in place.

Moving parts.

WARNING

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.

Saltwater damage.

Saltwater quickly deteriorates metals.

Wipe up saltwater on and around the generator set and

remove salt deposits from metal surfaces.

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.

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 II

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.

Содержание 10EKD-Low CO

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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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