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Kohler 10EG Operation

Kohler 10EG Operation

Marine generator sets
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Operation
Marine Generator Sets
Models:
10EG
13EG
15EG
13EGZ
15EGZ
TP-6323
3/06b

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Summary of Contents for Kohler 10EG

  • Page 1 Operation Marine Generator Sets Models: 10EG 13EG 15EG 13EGZ 15EGZ TP-6323 3/06b...

  • 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-6323 3/06...

  • 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 Avoid high pressure fluids.
  • Page 8 Pipe sealant. Explosive fuel vapors Hazardous Voltage/ Electrical backfeed to the utility. can cause severe injury or death. Hazardous backfeed voltage can Electrical Shock Fuel leakage can cause an explosion. cause severe injury or death. Use pipe sealant on all threaded fittings Connect the generator set to the to prevent fuel leakage.
  • Page 9 Notice WARNING WARNING NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use Hot engine and exhaust system. the correct size tools to prevent Rotating parts. Can cause severe injury or death. rounding of the bolt heads and nuts. Can cause severe injury or death.
  • Page 10 Notes Safety Precautions and Instructions TP-6323 3/06...

  • Page 11: Introduction

    Information in this publication represents data available distributor/dealer to keep equipment in top condition. at the time of print. Kohler Co. reserves the right to change this publication and the products represented 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 SERVICE-SIDE VIEW ENGINE-END VIEW NONSERVICE-SIDE VIEW GM34482- 1. Oil check 18. Fuse location inside junction box (F4, F5, F6, and F7) 2. Coolant overflow bottle 19. Air intake silencer/backfire flame arrestor 3. Oil fill (on valve cover) 20.
  • Page 14 Notes Section 1 Service Views TP-6323 3/06...

  • Page 15: Section 2 Operation

    Check for exhaust leaks and 2.2 Marine Inspection blockages. Check the silencer and piping condition and Kohler Co. recommends that all boat owners have their check for tight exhaust system connections. vessels inspected at the start of each boating season by...

  • Page 16: Angular Operation

    Digital Control (ADC 2100). adjustment under normal operating conditions. If the generator set is reconnected to a different voltage Note: Have setup and adjustments of the ADC 2100 and/or frequency, refer to an authorized Kohler performed only by an authorized Kohler distributor/dealer system configuration distributor/dealer.

  • 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 2-4 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. High engine Shutdown occurs if the engine coolant temperature Check for a low engine coolant level.

  • Page 20: Resetting The Controller After A Fault Shutdown

    If you do not plan to use your 2. Disconnect the generator set from the load using generator set for a long period of time, Kohler the line circuit breaker or ATS. See the safety recommends moving the master switch to the precautions at the beginning of this manual before OFF/RESET position (0 mA draw).

  • Page 21: Fuses

    2.7.2 Fuses Battery Charging Alternator Fuse. A replaceable 15-amp fuse protects the battery charging alternator. The junction box contains seven fuses. Always identify Fuel Pump Fuse. A replaceable 15-amp fuse protects and correct the cause of a blown fuse before restarting the fuel pump.
  • Page 22 Notes Section 2 Operation TP-6323 3/06...

  • Page 23: Section 3 Scheduled Maintenance

    Annual Inspection. Kohler Co. recommends that all WARNING boat owners have their vessels inspected at the start of each boating season by the US Coast Guard, the local Coast Guard Auxiliary, or local state agency.

  • Page 24: Service Schedule

    Engine Service. Perform generator set engine service the runtime hours shown on the ADC2100 to determine at the intervals specified by the engine operation when to schedule routine maintenance. Service more manual. frequently generator sets that are subject to extreme weather or dusty or dirty conditions.
  • 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 the exhaust system components * Check the exhaust gas condition (during operation)

  • Page 26: Lubrication System

    3.3 Lubrication System 3.3.1 Oil Specifications Use oil that displays the American Petroleum Institute (API) “Starburst” certification mark for gasoline engines on the container. Using unsuitable oil or neglecting an oil change may result in engine damage that is not 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: Backfire Flame Arrestor

    See Figure 3-4 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 29: Cooling System

    3.7 Cooling System Maintain the coolant level in coolant recovery tank at approximately 1/4 full. Before filling the cooling system, close all petcocks and tighten all hose clamps. Use a 3.7.1 Closed Heat Exchanger solution of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion and prevent In a closed cooling system, the seawater circulates freezing.

  • Page 30: Pressure Cap

    3.7.4 Pressure Cap Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant, enabling higher operating temperatures. If the cap leaks, replace it with a cap of the same rating. Find the pressure cap rating in Figure 3-6.

  • Page 31: Siphon Break

    3.7.6 Siphon Break 6. Install the reed valve into the mounting base with the valve downward. See Figure 3-9, 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 32 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 33: Anticorrosion Zinc Anode

    3.7.7 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 (11/32 in.) Depending upon operating conditions and seawater 2.

  • Page 34: 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 35 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 36: Battery

    4. Close the seacock and remove the hose at the seacock. Place the hose in a container having approximately 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.

  • Page 37: 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 38 TP-6323 3/06 Section 4 Troubleshooting...
  • Page 39 TP-6323 3/06 Section 4 Troubleshooting...
  • Page 40 TP-6323 3/06 Section 4 Troubleshooting...

  • Page 41: 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 42 GM36189A-F Figure 5-1 Wiring Diagram (Sheet 1 of 2) Section 5 Wiring Diagrams TP-6323 3/06...
  • Page 43 GM36189B-F Figure 5-2 Wiring Diagram (Sheet 2 of 2) TP-6323 3/06 Section 5 Wiring Diagrams...
  • Page 44 ADV6959A-F Figure 5-3 Schematic Diagram (Sheet 1 of 2) Section 5 Wiring Diagrams TP-6323 3/06...
  • Page 45 ADV6959B-F Figure 5-4 Schematic Diagram (Sheet 2 of 2) TP-6323 3/06 Section 5 Wiring Diagrams...
  • Page 46 GM33846-A Figure 5-5 Accessory Wiring Diagram Section 5 Wiring Diagrams TP-6323 3/06...

  • Page 47: 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 48 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.

  • Page 49: 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 50 TP-6323 3/06...
  • Page 51 TP-6323 3/06...
  • Page 52 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-6323 3/06a 7 Jurong Pier Road Singapore 619159 E 2004 and 2006 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...

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