Related Manuals for Kohler 5ECD
Summary of Contents for Kohler 5ECD
- Page 1 Operation Marine Generator Sets Models: 5ECD/4EFCD- -Low CO 7.3ECD/6EFCD- -Low CO TP-6390 1/06a...
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Page 2: Product Identification Information
California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service parts. Engine Identification Record the product identification numbers in the spaces Record the product identification information from the below immediately after unpacking the products so that engine nameplate. -
Page 3: Table Of Contents
Table of Contents Product Identification Information ............Safety Precautions and Instructions . - Page 4 TP-6390 1/06...
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Page 5: Safety Precautions And Instructions
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Battery electrolyte is a diluted Electromechanical equipment, sulfuric acid. Battery acid can cause including generator sets, transfer severe injury or death. Battery acid WARNING switches, switchgear, and accessories, can cause blindness and burn skin. can cause bodily harm and pose Always wear... - Page 6 Battery short circuits. Explosion Combustible materials. A fire can WARNING can cause severe injury or death. cause severe injury or death. Short circuits can cause bodily injury Generator set engine fuels and fuel and/or equipment damage. vapors are flammable and explosive. Disconnect battery before...
- Page 7 Exhaust System Operating the generator set. Carbon WARNING monoxide can cause severe nausea, fainting, or death. Carbon monoxide WARNING is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Use the following precautions when installing Explosion.
- Page 8 The fuel system. Explosive fuel Ignition-protected equipment. Hazardous Voltage/ vapors can cause severe injury or Explosive fuel vapors can cause Electrical Shock death. Vaporized fuels are highly severe injury or death. Gasoline explosive. Use extreme care when vapors can cause an explosion. handling and storing fuels.
- Page 9 Disconnecting the electrical load. Testing live electrical circuits. WARNING Hazardous voltage cause Hazardous voltage or current can severe injury or death. Disconnect cause severe injury or death. Have the generator set from the load by trained and qualified personnel take opening the line circuit breaker or by diagnostic measurements...
- Page 10 Servicing the generator set when it NOTICE WARNING is operating. Exposed moving parts Electrostatic discharge damage. can cause severe injury or death. Electrostatic discharge (ESD) Keep hands, feet, hair, clothing, and damages electronic circuit boards. test leads away from the belts and Prevent electrostatic discharge...
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Page 11: Introduction
Obtain service from authorized service at the time of print. Kohler Co. reserves the right to distributor/dealer to keep equipment in top condition. change this publication and the products represented without notice and without any obligation or liability whatsoever. Before installing a marine generator set, obtain the... -
Page 12: Maintenance And Service Parts/Related Literature
Maintenance and Service Parts/Related Literature Maintenance and Service Parts List of Related Literature Figure 1 identifies maintenance and service parts for Figure 2 identifies related literature available for the your generator set. Obtain a complete list of generator sets covered in this manual. Only trained and maintenance and service parts from your authorized qualified personnel should install or service the generator distributor/dealer. -
Page 13: Section 1 Service Views
Section 1 Service Views 10 11 12 SERVICE VIEW ADV7025A-A 1. Spark plug (also one located on the nonservice side) 18. Catalyst assembly, water outlet/exhaust outlet (nonservice 2. Oil fill side) 19. Seawater drain (remove plate for service) 3. Overflow tube 20. - Page 14 Notes Section 1 Service Views TP-6390 1/06...
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Page 15: Section 2 Operation
2.2 Marine Inspection Inspect the exhaust system components (exhaust Kohler Co. recommends that all boat owners have their manifold, catalyst, exhaust hose, hose clamps, silencer, vessels inspected at the start of each boating season by and outlet flapper) for cracks, leaks, and corrosion. -
Page 16: Angular Operation
Operation above the deck and/or outdoors would constitute a violation of European Union Directive 2000/14/EC noise emission standard. 2.5 Load Profile Whenever operating the generator set, Kohler Co. recommends maintaining the minimum load profile indicated in Figure 2-2. Maintaining the load profile GM28707A-C prevents corrosion formation on internal engine 1. -
Page 17: Starting The Generator Set
Water ingested into the engine may cause major engine damage that the Kohler Co. warranty does not cover. If excessive Explosion. -
Page 18: Stopping The Generator Set
2.6.3 Stopping the Generator Set 2.6.4 Fault Shutdowns The following procedures describe the actions required The generator set shuts down automatically under the to stop the generator set. fault conditions listed in Figure 2-5 and the controller displays a fault code. The generator set cannot be Local Stopping restarted until the fault condition is corrected and the controller is reset. - Page 19 Code Fault Description Check Auxiliary fault Input from a customer-supplied switch that closes Check the cause of the auxiliary fault. input shutdown when the fault is active. Shutdown occurs 0.3 seconds after the fault is detected. This protection becomes active 3-seconds after crank disconnect. CO-1 Carbon monoxide Sensor fault shutdown occurs because of the...
- Page 20 Code Fault Description Check CO-4 Carbon monoxide Fault code is displayed if the presence of CO is Ensure windows are open for proper ventilation. warning detected because of the time-weighted average Operate the blower to expel dangerous fumes. presence of CO. Activates the CO cabin alarms. Move the vessel away from other vessels (as another vessel may be the source for the presence of the CO).
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Page 21: Smartcraftt System View (Sc5000), If Equipped
2.6.5 SmartCraftt System View Fault (SC5000) Display, If Equipped Code Displayed Description The 5/7.3ECD and 4/6EFCD model generator sets can No Faults (Fault Code 0) connect to SmartCraft’s SC5000 (if equipped) via the Throttle Position Sensor Input High generator set’s P19 connector. See the wiring diagrams EC10 Throttle Position Sensor Range High in Section 5 for the P19 location. -
Page 22: Resetting The Controller After A Fault Shutdown
250 mA when the master switch is in the Figure 2-9 Fuse Identification AUTO position. If you do not plan to use your generator set for a long period of time, Kohler recommends Label Fuse Amps moving the master switch to the OFF/RESET position Auxiliary Winding (complete power down—0 mA draw). -
Page 23: Section 3 Scheduled Maintenance
Hardware damage. 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 Hot engine and exhaust system. Can cause severe injury or death. -
Page 24: Service Schedule
Engine Service. Perform generator set engine service determine when schedule routine at the intervals specified by the engine operation maintenance. Service more frequently generator sets manual. that are subject to extreme weather or dusty or dirty conditions. Generator Set Service. Perform generator set service at the intervals specified by the generator set operation Service Log. - Page 25 Service Schedule, continued After Every Every Every 50 Hrs 100 Hrs 300 Hrs 500 Hrs Reference Before Perform Service at Intervals Indicated (X) Section Starting 1 Month 3 Months 6 Months Yearly INTAKE/EXHAUST SYSTEM Inspect exhaust system components *[ Check the exhaust gas condition (during operation) Service backfire flame arrestor *...
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Page 26: Lubrication System
3.3 Lubrication System 3.3.1 Oil Specifications Use oil that meets the American Petroleum Institute (API) classification of SC, SD, SE, SF, SG, or SH. Using unsuitable oil or neglecting an oil change may result in engine damage that is not covered by the engine TP-5586-3 1. -
Page 27: Oil Filter Change
Do not use gasoline left over from the previous safe, approved manner. season. Kohler Co. recommends unleaded fuel because it 3.3.5 Oil Filter Change leaves fewer combustion chamber deposits. Never mix oil with fuel. -
Page 28: Fuel Filter
3.4.2 Fuel Filter The 5/7.3ECD generator sets utilize an in-line type fuel FUEL filter. See Section 1 for the fuel filter location. Replace the filter every 500 hours of running time or when rough operation indicates an engine tune-up may be necessary. -
Page 29: Backfire Flame Arrestor
See Section 1 for location. Carbon monoxide. Replace a damaged flame arrestor. Use only cause severe nausea, USCG-approved Kohler replacement parts. Follow the fainting, or death. procedure described below. exhaust system must leakproof and routinely inspected. Backfire Flame Arrestor Cleaning Procedure Inspecting the exhaust system. -
Page 30: Cooling System
3.7 Cooling System Do not add coolant 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. 3.7.1 Closed Heat Exchanger Note: Coolant solution. A coolant solution of 50% In a closed cooling system, the seawater circulates ethylene glycol provides freezing protection to through separate chambers within the heat exchanger... -
Page 31: Seawater Pump
3.7.3 Seawater Pump The direct-driven seawater pump is located on the generator end of the generator set. Check and change the seawater pump impeller at the interval specified in the service schedule. Follow the instructions included with the impeller kit. If the instructions are not included with the kit, use the following procedure: Impeller Inspection and Replacement Procedure: 1. -
Page 32: Siphon Break
3.7.4 Siphon Break 6. Install the reed valve into the mounting base with the valve downward. See Figure 3-10, item 2. A siphon break prevents seawater entry into the generator set’s engine when the engine exhaust 7. Install and only finger tighten the retaining cap. Do not overtighten it. - Page 33 Waterline TP-5586-3 1. Mounting base 12. Seawater strainer 2. Retaining cap 13. Seacock 3. Reed valve assembly 14. Intake strainer 4. Silencer vertical lift 1.2 m (4 ft.) max. 15. Engine-driven seawater pump 5. Exhaust catalyst assembly distance above waterline. If less 16.
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Page 34: Anticorrosion Zinc Anode
3.7.5 Anticorrosion Zinc Anode The heat exchanger on these models contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion by seawater. Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule. TP-5586-3 1. Diameter: 9 mm (0.34 in.) Depending upon operating conditions and seawater 2. -
Page 35: Ignition System
3.8 Ignition System 3. Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling Service spark plugs at the interval specified in the into the combustion chamber. service schedule using the following procedure. 4. - Page 36 5. Clean spark plugs by wiping them with a rag. File the center electrode to keep it parallel to the side electrode. Note: Do not sandblast, wire brush, scrape, or otherwise service spark plug in poor condition. Obtain a new plug for best results.
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Page 37: Battery
Place the hose in a container having approximately 3.7-7.5 L (1-2 U.S. gallons) of location to store the generator. coolant/antifreeze. Kohler Co. recommends using 17. Cover the entire unit with a dust cover. an environmentally friendly potable antifreeze such as PeakR RV/marine propylene glycol/water Note: Run the generator set once a month mix or equivalent. - Page 38 Notes Section 3 Scheduled Maintenance TP-6390 1/06...
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Page 39: Section 4 Troubleshooting
Section 4 Troubleshooting This section contains generator set troubleshooting, Corrective action and testing often require knowledge of diagnostic, and repair information. electrical and electronic circuits. To avoid additional problems caused by incorrect repairs, have an Use the following charts as a quick troubleshooting authorized service distributor/dealer perform service. - Page 40 TP-6390 1/06 Section 4 Troubleshooting...
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- Page 42 TP-6390 1/06 Section 4 Troubleshooting...
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Page 43: Section 5 Wiring Diagrams
Section 5 Wiring Diagrams WARNING WARNING Hazardous voltage. Moving rotor. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working on the generator set. - Page 44 GM39836A--G Figure 5-1 Point-to-Point Wiring Diagram (Sheet 1 of 2) Section 5 Wiring Diagrams TP-6390 1/06...
- Page 45 GM39836B--G Figure 5-2 Point-to-Point Wiring Diagram (Sheet 2 of 2) TP-6390 1/06 Section 5 Wiring Diagrams...
- Page 46 ADV7029A--G Figure 5-3 Schematic Wiring Diagram (Sheet 1 of 2) Section 5 Wiring Diagrams TP-6390 1/06...
- Page 47 ADV7029B--G Figure 5-4 Schematic Wiring Diagram (Sheet 2 of 2) TP-6390 1/06 Section 5 Wiring Diagrams...
- Page 48 Notes Section 5 Wiring Diagrams TP-6390 1/06...
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Page 49: Appendix A Abbreviations
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex. - Page 50 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter μF microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat.
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Page 51: Appendix B Operating Hour Service Log
Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed. Enter hours to the operating hours on your generator set and the dates nearest quarter hour. OPERATING HOURS SERVICE RECORD DATE HOURS TOTAL... - Page 52 TP-6390 1/06...
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- Page 56 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-6390 1/06a 7 Jurong Pier Road Singapore 619159 E 2006 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...