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TP-6591 10/13

7

Safety Precautions and Instructions

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.

Hazardous Noise

Hazardous noise.

Can cause hearing loss.

Never operate the generator set

without a muffler or with a faulty

exhaust system.

CAUTION

Hazardous Voltage/

Moving Parts

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.

Grounding electrical equipment.

Hazardous

voltage

can

cause

severe injury or death.

Electrocution

is possible whenever electricity is

present. Ensure you comply with all

applicable codes and standards.

Electrically ground the generator set,

transfer switch, and related equipment

and electrical circuits. Turn off the main

circuit breakers of all power sources

before servicing the equipment. Never

contact electrical leads or appliances

when standing in water or on wet

ground because these conditions

increase the risk of electrocution.

Disconnecting the electrical load.

Hazardous

voltage

can

cause

severe injury or death.

Disconnect

the generator set from the load by

turning off 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

turned off. 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

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

Notice

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.

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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