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Kohler 4EF Operation

Kohler 4EF Operation

Marine generator sets
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Operation
Marine Generator Sets
Models:
5E/4EF
7.3E/6EF
TP-5985 10/02d

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Summary of Contents for Kohler 4EF

  • Page 1 Operation Marine Generator Sets Models: 5E/4EF 7.3E/6EF TP-5985 10/02d...

  • 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 ..........Inside front cover Safety Precautions and Instructions .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting Battery electrolyte is a diluted INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear...
  • Page 6 Battery short circuits. Explosion Combustible materials. A fire can Inspecting the exhaust system. cause severe injury or death. Carbon monoxide can cause severe can cause severe injury or death. Generator set engine fuels and fuel nausea, fainting, or death. For the Short circuits can cause bodily injury vapors are flammable and explosive.
  • Page 7 Fuel System Explosive fuel vapors can cause Hazardous Noise severe injury or death. Take additional precautions when using the CAUTION following fuels: WARNING Gasoline—Store gasoline only in approved containers clearly marked GASOLINE. Draining the fuel system. Explosive fuel vapors can cause severe injury Hazardous noise.
  • Page 8 Disconnecting the electrical load. Testing live electrical circuits. Checking the coolant level. Hazardous voltage cause Hazardous voltage or current can coolant can cause severe injury or severe injury or death. Disconnect cause severe injury or death. Have death. Allow the engine to cool. the generator set from the load by trained and qualified personnel take Release pressure from the cooling...
  • Page 9 Servicing the generator set when it NOTICE WARNING is operating. Exposed moving parts Hardware damage. The engine and can cause severe injury or death. generator set may use both American Keep hands, feet, hair, clothing, and Standard and metric hardware. Use test leads away from the belts and the correct size tools to prevent pulleys when the generator set is...
  • Page 10 Notes Safety Precautions and Instructions TP-5985 10/02...

  • Page 11: Introduction

    Before installing a marine generator set, obtain the Information in this publication represents data available most current installation manual from your local at the time of print. Kohler Co. reserves the right to distributor/dealer. Only qualified persons should change this publication and the products represented install the generator set.

  • 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 SERVICE VIEW ENGINE-END VIEW ADV-6395-A GY-250000-A 1. Electric choke (on carburetor) 18. Anticorrosion zinc anode 19. Seawater drain (remove plate) 2. Carburetor/choke linkage 20. Seawater pump (water inlet) 3. Spark plugs (also one on nonservice side) 21.
  • Page 14 Notes Section 1 Service Views TP-5985 10/02...

  • Page 15: Section 2 Operation

    Coolant Level. Check the coolant level according to 2.2 Marine Inspection the cooling system maintenance information. Kohler Co. recommends that all boat owners have their Exhaust System. Check for exhaust leaks and vessels—especially the exhaust system attached to the blockages.

  • Page 16: Operation In European Union Member Countries

    Water Fuse circuitry. ingested into the engine may cause major engine Remote Start A 6-pin connector on controller damage that the Kohler Co. warranty does not Connector back panel allows connection of cover. (optional) remote start kits Hourmeter Meter records total generator set...

  • Page 17: Starting The Generator Set

    2.6.2 Starting the Generator Set 2.6.3 Remote Panel Gauge Operation The following table describes the actions required to If the generator set has an optional remote panel with start the generator set. gauges, observe the gauges upon engine start-up. If gauge readings are not within the ranges specified, contact an authorized service distributor/dealer.
  • Page 18 Notes Section 2 Operation TP-5985 10/02...

  • Page 19: Section 3 Scheduled Maintenance

    Hot engine and exhaust system. Can cause severe injury or death. Annual Inspection. Kohler Co. recommends that all boat owners have their vessels—especially the exhaust Do not work on the generator set until it cools.

  • Page 20: Service Schedule

    Engine Service. Perform generator set engine service the hourmeter located on the generator set controller to at the intervals specified by the engine operation determine when to schedule routine maintenance. manual. Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions. Generator Set Service.
  • Page 21 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 *...

  • Page 22: 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 23: Oil Filter Change

    Oil Change Procedure 3.3.5 Oil Filter Change 1. Stop the generator set. Replace the oil filter at the interval specified in the service schedule. Change the oil filter more frequently if 2. To drain the oil, open the oil-drain valve. See the generator set operates under dirty, dusty conditions.

  • Page 24: Fuel System

    The carburetor is factory-set. No adjustments are system. Do not use gasoline left over from the previous possible. season. Kohler Co. recommends unleaded fuel because it leaves fewer combustion chamber deposits. Never mix oil with fuel. Note: Consult engine owner’s manual oxygenated fuel recommendations.

  • Page 25: 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 1.

  • Page 26: 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 27: 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 28: Siphon Break

    3.7.4 Siphon Break 6. Install the reed valve into the mounting base with the valve downward. See Figure 3-8, item 3. 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 29 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 mixer elbow distance above waterline. If less than 16.

  • Page 30: 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 31: 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 32 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.

  • Page 33: Battery

    3.9 Battery Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, Consult battery manufacturer’s instructions particularly when it is charging. Do not dispose of a battery in a regarding battery care and maintenance.

  • Page 34: Generator Storage Procedure

    Place the hose in a container having approximately 3.7-7.5 L (1-2 U.S. gallons) of 13. Disconnect and remove the battery. Place the coolant/antifreeze. Kohler Co. recommends using battery in a warm, dry location for the storage an environmentally friendly potable antifreeze period.

  • Page 35: Section 4 Troubleshooting

    Section 4 Troubleshooting This section contains generator set troubleshooting, NOTICE diagnostic, and repair information. Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic). Use the following chart as a quick troubleshooting Do not substitute clear glass-type fuses for ceramic fuses.
  • Page 36 TP-5985 10/02 Section 4 Troubleshooting...
  • Page 37 TP-5985 10/02 Section 4 Troubleshooting...
  • Page 38 TP-5985 10/02 Section 4 Troubleshooting...

  • Page 39: 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 40 359343-F Figure 5-1 Schematic Wiring Diagram Section 5 Wiring Diagrams TP-5985 10/02...
  • Page 41 359343-F Figure 5-2 Point-to-Point Wiring Diagram TP-5985 10/02 Section 5 Wiring Diagrams...
  • Page 42 Notes Section 5 Wiring Diagrams TP-5985 10/02...

  • Page 43: 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 44 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter 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. gas natural gas right side kilojoule...

  • Page 45: 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 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-5985 10/02d 7 Jurong Pier Road Singapore 619159 E 1999, 2001, and 2002 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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