Kohler 5EKD-Low CO Operation
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Kohler 5EKD-Low CO Operation

Marine generator sets. controller: advanced digital control ii
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Operation
Marine Generator Sets
Models:
5EKD/4EFKD- -Low CO
7.5EKD/6EFKD- -Low CO
10EKD/8EFKD- -Low CO
Controller:
Advanced Digital Control II
TP-6591 10/13d

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Summary of Contents for Kohler 5EKD-Low CO

  • Page 1 Operation Marine Generator Sets Models: 5EKD/4EFKD- -Low CO 7.5EKD/6EFKD- -Low CO 10EKD/8EFKD- -Low CO Controller: Advanced Digital Control II TP-6591 10/13d...

  • 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 Engine Identification Product identification numbers determine service parts. 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 Notes TP-6591 10/13...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting Engine Backfire/Flash IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, Fire including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose WARNING life-threatening danger when improperly installed, operated, maintained. To prevent accidents be aware of potential dangers and act safely.
  • Page 6 Exhaust System Operating the generator set. Carbon The fuel system. Explosive fuel monoxide can cause severe nausea, vapors can cause severe injury or fainting, or death. Be especially death. Vaporized fuels are highly WARNING careful if operating the generator set explosive.
  • Page 7 Ignition-protected equipment. Grounding electrical equipment. Testing live electrical circuits. Explosive fuel vapors can cause Hazardous voltage cause Hazardous voltage or current can severe injury or death. Gasoline severe injury or death. Electrocution cause severe injury or death. Have vapors can cause an explosion. is possible whenever electricity is trained and qualified personnel take USCG Regulation 33CFR183 requires...
  • Page 8 Notes Safety Precautions and Instructions TP-6591 10/13...

  • Page 9: Introduction

    Information in this publication represents data available at the time of print. Kohler Co. reserves the right to Before installing a marine generator set, obtain the change this publication and the products represented...

  • Page 10: 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 11: Section 1 Service Views

    Section 1 Service Views Service Side Nonservice Side ADV7439A- GM58158 1. Nameplate (top) 21. Fuel pump/cooler 2. Advanced Digital Control II 22. Fuel pump 3. Generator set start/stop button 23. Fuel inlet 4. AC circuit breaker 24. Filter screen 5. Optional lifting eye tool 25.
  • Page 12 Notes Section 1 Service Views TP-6591 10/13...

  • Page 13: Section 2 Operation

    Inspect the exhaust system components (exhaust manifold, catalyst, exhaust hose, hose clamps, silencer, Kohler Co. recommends that all boat owners have their and outlet flapper) for cracks, leaks, and corrosion. vessels inspected at the start of each boating season by the US Coast Guard, the local Coast Guard Auxiliary, or Check the hoses for softness, cracks, leaks, or dents.

  • Page 14: 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 GM58225A prevents corrosion formation on internal engine 1.
  • Page 15 The controller is factory-set and should not require configuration or adjustment under normal operating conditions. If the generator set is reconnected to a different voltage and/or frequency, refer to an authorized Kohler distributor/dealer for system configuration and adjustment instructions. TP-6591 10/13 Section 2 Operation...

  • Page 16: Starting The Generator Set

    Water ingested into the engine may cause major engine damage that 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.

  • Page 17: Stopping The Generator Set

    2.6.3 Stopping the Generator Set 2.6.4 Fault Shutdowns and Warnings 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 2-6 and the controller displays a fault code. The generator set cannot be Local Stopping.
  • Page 18 Fault Shutdowns Sensing Active Inhibit Delay Default Mechanism State Time Time Setting Check Code Description Over crank Overcrank Fail to start Excessive 0 sec 7 sec on/ 3 crank Check the fuel supply and battery. (fault) shutdown occurs crank cycles 15 sec off cycles Also check for loose connections.
  • Page 19 Fault Shutdowns Sensing Active Inhibit Delay Default Mechanism State Time Time Setting Check Code Description Hi CO: Carbon monoxide Pulsed signal 20 Hz 0 sec 10 sec Immediate service required. sensor presence from Contact an authorized (fault) sensor. distributor/dealer for service. Shutdown occurs Ensure windows are open for proper because of the...
  • Page 20 Fault Shutdowns Sensing Active Inhibit Delay Default Mechanism State Time Time Setting Check Code Description Check A check engine Check for high fuel restrictions. engine fault occurs when Check for air leaks in the supply side (fault) [ the ECM sends a of the fuel system.
  • Page 21 EST 1 Low Spark 1 Timing Low shutdowns/warnings may occur (see Figure 2-8). EST 1 High Spark 1 Timing High Contact an authorized Kohler distributor/dealer for EST 2 Low Spark 2 Timing Low additional diagnostics. EST 2 High Spark 2 Timing High...

  • Page 22: Resetting The Controller After A Fault Shutdown

    Always identify and correct the cause of a fault adjustments of the Advanced Digital Control shutdown before resetting the controller. Use the performed only by an authorized Kohler following procedure to reset the generator set controller distributor/dealer. after a fault shutdown.

  • Page 23: Section 3 Scheduled Maintenance

    Remove the negative (--) lead first Annual Inspection. Kohler Co. recommends that all when disconnecting the battery. boat owners have their vessels inspected at the start of Reconnect the negative (--) lead last each boating season by the US Coast Guard, the local when reconnecting the battery.

  • Page 24: Service Schedule

    3.2 Service Schedule After Every Every Every Reference Before 50 Hr or 100 Hr or 300 Hr or 500 Hr or Section Starting Perform Service at Intervals Indicated (X) 1 Month 3 Months 6 Months Yearly Fuel System Check the fuel level and fill as necessary Check fuel lines and replace as necessary *[ Replace the fuel filter *[ Lubrication System...

  • Page 25: Lubrication System

    3.3 Lubrication System 3.3.2 Oil Check Check the oil level in the crankcase daily or before each 3.3.1 Oil Specifications start-up to ensure that the level is in the safe range. Do not check the oil level while operating the unit. Stop the Use high-quality detergent oils (including synthetic) that generator set and keep the generator set level to get an meets...

  • Page 26: Oil Change

    (--) lead last. season. 11. Start the generator set and check for oil leaks. Kohler Co. recommends unleaded fuel because it leaves fewer combustion chamber deposits. Never mix 12. Stop the generator set. Check the oil level. Add oil, oil with fuel.

  • Page 27: Fuel Filter

    3.4.2 Fuel Filter 7. Hold the bleed tool (part number GM46327) onto the bleed point to remove air from the line. See The 5/7.5/10EKD and 4/6/8EFKD generator sets utilize Figure 3-5. an in-line type fuel filter. See Section 1 for the fuel filter location.

  • Page 28: Backfire Flame Arrestor

    See Section 1 for location. Check for exhaust leaks and blockages. Check the Replace a damaged flame arrestor. Use only USCG- silencer and piping condition and check for tight exhaust approved Kohler replacement parts. Follow the system connections. procedure described below.

  • Page 29: Pressure Cap

    Note: Coolant solution. A coolant solution of 50% WARNING ethylene glycol provides freezing protection to --37C (--34F) and overheating protection to 129C (265F). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant Hot coolant and steam.

  • Page 30: Seawater Pump

    3.7.3 Seawater Pump 5. Lubricate the impeller with soapy water before installation. The belt-driven seawater pump is located on the crankshaft end of the generator set. Check and change 6. Install the impeller. the seawater pump impeller at the interval specified in Note: During installation push and rotate the the service schedule.

  • Page 31: Belt Tension

    Seawater Flow Switch Inspection and Cleaning 8. Reassemble by ensuring the spring is set within the Procedure: clips on the shuttle cap. 1. Push the generator set power button OFF. 9. Reposition the O-ring in the counter-bored shoulder of the housing. 2.

  • Page 32: Siphon Break

    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, docked or stationary craft. See Figure 3-14. The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater.
  • 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.

  • Page 34: Anticorrosion Zinc Anode

    3.7.7 Anticorrosion Zinc Anode 3. Clean the threaded hole of the heat exchanger and coat the threads of the anticorrosion zinc anode The heat exchanger on these models contains an (plug) with pipe sealant suitable for marine anticorrosion zinc anode (plug) to prevent electrolytic applications.
  • Page 35 Problem/Condition Means of Identification Possible Cause/Solution Gap-bridged spark plug Built-up deposits and gap between Oil or carbon fouling. Clean and regap electrodes closing. the spark plug. Oil-fouled spark plug Wet, black deposits on the insulator Excessive oil entering combustion shell, bore, and electrodes. chamber through worn rings and pistons, excessive clearance between valve guides and stems, or worn or...

  • Page 36: Battery

    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. Disconnect the lead (#87) to the low seawater pressure (LWP) switch. 6. With a suitable container at the exhaust outlet, run...

  • Page 37: 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 38 TP-6591 10/13 Section 4 Troubleshooting...
  • Page 39 TP-6591 10/13 Section 4 Troubleshooting...
  • Page 40 TP-6591 10/13 Section 4 Troubleshooting...

  • Page 41: Section 5 Wiring Diagrams

    Section 5 Wiring Diagrams WARNING WARNING Hazardous voltage. Moving parts. 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 generator set.
  • Page 42 GM90655A-- Figure 5-1 Point-to-Point Wiring Diagram (Sheet 1 of 2) Section 5 Wiring Diagrams TP-6591 10/13...
  • Page 43 GM90655B-- Figure 5-2 Point-to-Point Wiring Diagram (Sheet 2 of 2) TP-6591 10/13 Section 5 Wiring Diagrams...
  • Page 44 ADV8631A-- Figure 5-3 Schematic Wiring Diagram (Sheet 1 of 1) Section 5 Wiring Diagrams TP-6591 10/13...

  • Page 45: 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 46 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter microfarad read only memory F 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.

  • Page 47: 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 48 Notes TP-6591 10/13...
  • Page 49 Notes TP-6591 10/13...
  • Page 50 Notes TP-6591 10/13...
  • Page 51 Notes TP-6591 10/13...
  • Page 52 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com Kohler Power Systems Asia Pacific Headquarters TP-6591 10/13d 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 E 2009, 2011, and 2013 by Kohler Co. All rights reserved.

This manual is also suitable for:

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