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TP-6591 10/13

Introduction

Introduction

This manual provides operation instructions for

5/7.5/10EKD and 4/6/8EFKD 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

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

authorized

service

distributor/dealer to keep equipment in top condition.

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.

Service Assistance

For professional advice on generator set power

requirements and conscientious service, please contact

your nearest Kohler distributor or dealer.

Consult the Yellow Pages under the heading

Generators—Electric.

Visit the Kohler Power Systems website at

KOHLERPower.com.

Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents

included with the product.

Call toll free in the US and Canada 1-800-544-2444.

Outside the US and Canada, call the nearest regional

office.

Headquarters Europe, Middle East

Africa

(EMEA)

Kohler Power Systems Netherlands B.V.

Kristallaan 1

4761 ZC Zevenbergen

The Netherlands

Phone: (31) 168 331630

Fax:

(31) 168 331631

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 6264-6422

Fax:

(65) 6264-6455

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

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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