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5ECD/4EFCD--Low CO 7.3ECD/6EFCD-

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6. 37 Section 4 Troubleshooting 39 Section 5 Wiring Diagrams 5 2 o 2 ma 43 Appendix A Abbreviations 49 Appendix B Operating Hour Service Log 51 TP 6390 1 06 Table of Contents 3 TP 6390 1 06 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has severaltypes ofsafety precautions and instructions Danger Warning Caution and Notice DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that cause severe personalinjury death or substantial property damage CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related
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9. ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext 1 0 IP ISO J JIS k K kA KB hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 219 bytes Appendix 49 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local
10. ones 11 Maintenance and Service Parts Related 12 Section 1 Service Views 13 Section 2 Operation 1 n A E E EE ERES 15 2 1 dat 15 2 2 Marine Inspection 15 2 3 Angular Operation aia 16 2 4 Operation in European Union Member Countries 16 2 5 boad A le quia hisk i asa 16 2 6 Advanced Digital Control Operation 16 2 6 1 Controls and Indicators 16 2 62 Starting the Generator 5 1 17 263 Stopping the Generator 18 264 Fault Shutdowns 18 265 SmartCraft System View SC5000 If Equipped 21 2 6 6 Resetting the Controller after a Fault Shutdown 22 2 6 7 Continuous Power Mode 22 2 7 Gircuit Protection cvi esl e Y Ree rr a eT Y ed 22 2 7 1 Line Circuit Breaker 22 2 7 2 FUSES unaqman etd ema pee be eed dne 22 Section Scheduled Maintenance
11. 23 3 1 General Maintenance e Lila rel v RR is 23 3 2 Service Schedule oia candy iR cds URSI e m RR 24 3 3 Lubrication System un nenne ey XY ed 26 3 3 1 Oil Specifications 26 33 2 Check nase se 26 Q 39 3 Oll Additions iocos e 26 334 Oil Change 2 menn D Re e RE ne RR HRS os 26 33 5 Oil Filter Change 2 ERR Ea em RE wu 27 344 F el System sy utu ao SO hn 27 3 4 1 Fuel Specifications uy u a D ee 27 3 4 2 Filter na Pun 28 3 43 Fuel System Bleed 28 3 5 Backfire Flame Arrestor 29 3 6 Exhaust System 29 3 7 Gooling System 4 ce ave xd Vw cis e 30 3 7 1 Closed Heat Exchanger 30 3 7 2 Pressure Cap ee heh Gad dao daa 30 3 43 Seawater es da DE PERSE 31 3 74 Siphon Break ner Odea M e EINE Qus 32 3 7 5 Anticorrosion Zinc Anode 34 3 7 6 Seawater Outlet is conscius ann eee 34 3 8 ignition SYSTEM 22 Sins and sei da ihn ne ar 35 3 9 t Battery o bal etna cade EA E 37 3 10 Generator Storage Procedure
12. Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seekimmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service this may result hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area 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 particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove jewelry before servicing the equ
13. TP 6390 1 06 3 1 General Maintenance WARNING aS x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation TP 6390 1 06 Section 3 Scheduled Maintenance WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place Servicing the generat
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15. installthe exhaustoutlet where exhaust can be drawn in through portholes vents or air conditioners Avoid overloading the craft If the generator set exhaust discharge outlet is near the waterline water could enter the exhaust discharge outlet and close or restrict the flow of exhaust Never operate the generator set without a functioning carbon monoxide detector Be especially careful if operating the generator set when moored anchored under calm conditions because gases may accumulate operating 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 other boats and buildings Fuel System A WARNING t gt Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels WARNING Explosion Gasoline vapors can cause explosion and severe injury or death Before starting the generator set operate the blower 4 minutes and check the engine compartment for gasoline vapors WARNING Avoid high pressure fluids Can cause severe injury or death Do not work on high pressure fuel or hydraulic systems without protective equipment to protect hands eyes and body Avoid the hazard by relieving pressure before disconnecting fuel injection pressure lines Search for leaks using a piece of cardboard
16. port connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft ft lbs ft min g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set
17. properties the anticorrosion zinc anode may require more frequent replacement See Section 1 Service Views for location and use the following procedure Anticorrosion Zinc Anode Replacement Procedure 1 With the generator set cooled close the seacock remove the anticorrosion zinc plug from the heat exchanger and drain the coolant into a suitable container 2 Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode Replace the anode according to Figure 3 12 and Figure 3 13 Anticorrosion Zinc Anode Replacement Replace When New Anode Percent of Zinc Models Dimensions mm in Remaining Is 5 7 3ECD 50 of and 9 0 34 x 43 1 7 Sos 4 6EFCD length diameter Figure 3 12 Anticorrosion Zinc Anode Plug Measurements 34 Section 3 Scheduled Maintenance 1 Diameter 9 mm 0 34 in 2 Length 43 mm 1 7 in Figure 3 13 Anticorrosion Zinc Anode Plug 3 Clean the threaded hole of the heat exchanger and coat the threads of the 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 generator set and check for leaks at the anticorrosion zinc anode location The pump is operating if cooling water flows from the exhaust outlet If water is not discharging at the exhaust outlet see Prestart Checklist Seawater Pump Pr
18. Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building marina electrical system only through an approved device and after the building marina main switch is opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a ship to shore transfer switch to prevent interconnection of the generator set power and shore power TP 6390 1 06 Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes andfollowthe instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on adry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap t
19. Kohler recommends moving the master switch to the OFF RESET position complete power 0 mA draw 22 Section 2 Operation A remote start signal from a transfer switch or a remote start stop switch connected to P21 connector leads 3 and 4 or moving the generator set master switch to the RUN position turns the controller back on 2 7 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly see Section 4 for possible causes 2 7 1 Line Circuit Breaker A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load The line circuit breaker location is shown in Section 1 If the circuit breaker trips reduce the load and switch the breaker back to the ON position 2 7 2 Fuses The junction box contains seven fuses See Section 1 and Figure 2 9 for the fuse location Always identify and correct the cause of a blown fuse before restarting the generator set Refer to section 4 for conditions that may indicate a blown fuse authorized distributor dealer Obtain service from an OVA pom cono ADV7025A A Figure 2 9 Fuse Identification Auxiliary Winding Controller Customer Connection Coils Injectors ECM Sensor and Fuel Pumps Voltage Regulator and Battery Charging Alternator Starter Motor and Crank Solenoid Figure 2 10 Fuses
20. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6390 1 06 Accidental Starting A WARNING Pa or Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death
21. Shutdown occurs if the engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service if problem continues Overvoltage shutdown Shutdown occurs if the voltage exceeds 120 of the voltage regulator setpoint for more than 2 seconds Contact an authorized distributor dealer for service if problem continues Underfrequency shutdown Shutdown occurs when the governed frequency falls below 90 of the system s frequency setpoint for more than 5 seconds This protection becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Undervoltage shutdown Shutdown occurs if the voltage falls below 80 of the voltage regulator setpoint for more than 10 seconds Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Controller error TP 6390 1 06 Indicates a software or communication problem within the ADC 2100 Figure 2 5 ADC 2100 Fault Shutdown Codes Contact an authorized distributor dealer for service if problem continues Section 2 Operation 19 Carbon monoxide warning Description Fault code is displayed if the presence of CO is detected because of the time weighted average presence of CO Activates the CO cabin alarms
22. a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Consultthe boat builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times TP 6390 1 06 Operating the generator set Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Use the following precautions when installing andoperating the generator set Do not
23. cause severe injury or death Allow the engine to cool Release pressure fromthe cooling system before removing the pressure cap To release pressure coverthe pressure cap with athick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released andthe engine has cooled Checkthe coolant level atthe tank if the generator set has a coolant recovery tank NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Checking and Filling Coolant 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 solution of 5096 ethylene glycol and 5096 clean softened water to inhibit rust corrosion and prevent freezing Add additional coolant as necessary to the coolant recovery tank Periodically check the coolant level on closed systems by removing the pressure cap Do not rely solely on level in coolant recovery tank Add fresh coolant until the level is just below the overflow tube opening 30 Section 3 Scheduled Maintenance 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 Note Coolant solution A coolant solution of 5096 ethylene glycol provides freezing protect
24. drip from the hose on the bleed tool release the Select button and replace the cap Note Use acontainer at the end of the bleed tool s hose to catch the fuel Dispose of fuel in an environmentally safe manner 28 Section Scheduled Maintenance 1 LED display r DISPLAY REMAINS ACTIVE DURING GENERATOR OPERATION FUEL r Y JV KOHLER DIGITAL CONTROL DEFINITION Auxillary Fault Crank Cycle High Battery Voltage High Engine Tem Low Battery Volta Lev Over Frequency Speed r Voltage Under Frequency Under Voltage OFF RESET GM28707A C 2 Select button use for setup and adjustment only 3 Generator set master switch 2 Figure 3 4 ADC 2100 Control 1 Bleed point with the cap removed 2 Bleed tool with fuel drain hose attached Figure 3 5 Bleed Location TP 6390 1 06 3 5 Backfire Flame Arrestor Atthe interval specified in the service schedule inspect clean or replace the backfire flame arrestor Clean the arrestor more frequently if the generator set operates in dirty dusty conditions Check the element for accumulated oil or dirt that could clog the element and cause poor performance See Section 1 for location Replace a damaged flame arrestor Use only USCG approved Kohler replacement parts Follow the procedure described below Backfire Flame Arrestor Cleaning Procedure 1 Loosen the hose clamp at the breather hose at the air silencer fittin
25. fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Use pipe sealant on all threaded fittings to prevent fuel leakage Use pipe sealant that resists gasoline grease lubrication oil common bilge solvents salt deposits and water 8 Safety Precautions and Instructions Ignition protected equipment Explosive fuel vapors can cause severe injury or death Gasoline vapors can cause an explosion USCG Regulation 33CFR183 requires that all electrical devices ship to shore transfer switch remote start panel etc must be ignition protected when used in a gasoline and gaseous fueled environment The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous fueled environmentsuch as an engine room or near fuel tanks Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Wear hearing protection when near an operating generator set Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Hazardous Voltage Electrical Shock WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all gua
26. included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 21 Senia 122 12 rue des Hauts Flouviers 94517 Thiais Cedex France Phone 33 1 41 735500 Fax 33 141 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 TP 6390 1 06 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 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 Fax Introduction 11 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 par
27. source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers s
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30. 407 QN3931 AVTIH ANVEO vor ZINSNI set EINS WHO 021 j SNNn g9S ed ic 95 49 aa F1HM 1 TA 4 XXI SNOILO3NNOO ATNO ZIINSNI WHO 021 Ni9 iu ma Y umn 1 Hansi OL Q3103NNOO 9 z 1V1S SNOLLOSNNOO A0y2 021 HOS sO OL Q3103NNOO 8 1 1 15 ivis AAA A ACA A A A A P A A A STONIS S8S AQV 33S SNOLLOINNOO 99 s H nait eog Ll ls ma T Javor Hsnug ANTINSNI 2 1NSN 109 NOLLIN I ON I 1303 TAN PNIA 3snd W3 INNON 10H1NOO 3NION3 30010 0 t 3qN3S 141000 SLO 94 09d 94 vor GION31OS ANVEO SO HOSN3S NOLLISOd ANVEO 545 SNLYLS 3OIXONON NO8HVO OO LINOBIO 889 HOLVNHALTY ABALLIVG YOR 0 va 4 19 gt 10 13 99 20 PS 805 A 9uo ss 134 99 134 99 4 ias 9 814 Suo ss Suo ss 8 9 5 1 91 DO rre v4 qau a o TOHLNOO ATH HSV13 57714
31. 9 82 HONH3AOS HONH3AO9 YL HONH3AOS 91 HONH3AOS NONNOO 2 3109 Av 138 H31V3H HIV OL IVNDIS AV 13H H31HVIS 88 14 58 14 ld 12 14 08 14 62 Ld 82 ld 12 92 1 92 14 valid 14 14 12 14 02 19 61 14 81 14 21 14 91 14 91 14 71 81 14 21 14 01 14 6 14 8 14 1 9 14 6 14 bold 9 4 etd bid SNOLLO3NNOO Id H3TIOHINOO 0012 20 ADV7029B G Figure 5 4 Schematic Wiring Diagram Sheet 2 of 2 47 Section 5 Wiring Diagrams TP 6390 1 06 Notes 48 Section 5 Wiring Diagrams TP 6390 1 06 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cc CCA cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institu
32. 90 1 06 Waterline TP 5586 3 Mounting base 12 Seawater strainer Retaining 13 Seacock Reed valve assembly 14 Intake strainer Silencer vertical lift 1 2 m 4 ft max 15 Engine driven seawater pump Exhaust catalyst assembly distance above waterline If less 16 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min than 23 cm 9 in siphon break is required 17 Water lock optional Siphon break distance above waterline 30 5 cm 1 ft min 18 Silencer distance from exhaust catalyst assembly 3 m 10 ft Siphon break max Exhaust catalyst assembly 19 Silencer customer supplied Heat exchanger locations vary by model 20 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Coolant recovery tank 21 Exhaust outlet distance above waterline 10 cm 4 in min Locate coolant recovery tank at same height as heat exchanger 22 Seawater outlet Figure 3 11 Siphon Break Plastic U Type Installation Note Consult the installation manual for complete explanation of dimensions and other installation considerations TP 6390 1 06 Section 3 Scheduled Maintenance 33 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 Depending upon operating conditions and seawater
33. Always protect hands eyes and body from high pressure fluids If an accident occurs seek medical attention immediately Safety Precautions and Instructions 7 The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donotoperatethe generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when drainingthe fuel system Wipe up spilled fuel after draining the system Pipe sealant Explosive
34. Ensure windows are open for proper ventilation Operate the blower to expel dangerous fumes Move the vessel away from other vessels as another vessel may be the source for the presence of the CO Check the generator exhaust system see Section 3 6 Contact an authorized distributor dealer for service if problem continues Carbon monoxide warning Fault code is displayed if the presence of CO is detected Warning occurs if the sensor detects acceptable but increasing CO levels Ensure windows are open for ventilation Operate the blower to expel dangerous fumes Move the vessel away from other vessels as another vessel may be the source for the presence of the CO Check the generator exhaust system see Section 3 6 Generator service for emissions required Contact an authorized distributor dealer for service if problem continues Carbon monoxide sensor warning Fault code is displayed if the CO sensor is inoperative Replace the CO sensor Contact an authorized distributor dealer for service if problem continues High battery voltage warning Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 2 seconds when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 2 seco
35. ICE VIEW Spark plug also one located on the nonservice side Oil fill Overflow tube Pressure cap coolant fill location after draining coolant Seawater pressure switch appears as auxiliary fault on ADC Lifting eye Heat exchanger Anticorrosion zinc anode AC circuit breaker AC load lead connector nonservice side Nameplate top Customer interface connection nonservice side Fuses F1 F2 F3 F4 F5 F6 and F7 see Section 2 7 2 Runtime hour display Advanced Digital Control ADC 2100 CO sensor module Generator set master switch Service Views TP 6390 1 06 26 25 24 23 ADV7025A A Catalyst assembly water outlet exhaust outlet nonservice side Seawater drain remove plate for service Seawater pump water inlet Cooling air inlet Fuel filter fuel inlet Fuel pump Fuel pump cooler Oil check Coolant drain remove hose clamp to drain coolant Oil drain valve Lube oil filter Coolant overflow bottle daily coolant check fill location Air intake silencer backfire flame arrestor Note Consult installation drawings in Spec Sheet or Installation Manual for fuel and battery connection points Note Consult distributor dealer or Service Manual for items not shown Section 1 Service Views 13 Notes 14 Section 1 Service Views TP 6390 1 06 2 1 Prestart Checklist To ensure continued satisfactory operation perform the fo
36. Operation Marine Generator Sets F Models 5ECD 4EFCD Low CO 7 3ECD 6EFCD Low CO NATIONALLY REGISTERED KOHLER POVER OY TEV O ii 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 Record the product identification numbers in the spaces 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 Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number x in 007 001 TP 6390 1 06 Table of Contents Product Identification Information 2 Safety Precautions and Instructions 5 Intr ducti n fis icc sss uisa ma gira Peed GG 11 Service Assistance 24 u ceca pega
37. a INOOO ss 2 9 455 z avon 170A Opz 0z1 SNOLLO3NNOO YAWOLSND HOSN3S AQOB 311108HL SAL HOLVIS 1915 La 399 HOLOW H31HVIS WS O3TIOHINOO NOOTIIS EOS 29 808 9 AV 3H 815 A18W3ssv HO1SIS3u Mu 1O3NNOO A9INO NODO HOLO3NNOO d 8ld HOSN3S N39AXO SO T 5 3unssaud SdO HOSNAS dVN dv 3unssaud H31VM MOT BOTY Ose TOY LION UNAS HOLWNUALTY 01 H3MOd 9 ANTINSNI 4 TQ SNI 109 NOLLINDI ON H3TIOHINOO QNO cid dWnd TaN 03 m HOLO3INI 1304 07 o1 Obd 54 O 2 10 os 8 2 3 24d 2 814 24 9 9 43 8 93 rad 3504 a Ud 310GON 1OH1NOO an 1983 Nek Nid 3NION3 M993 dar Wa SNOILO3NNOO 814 HOLIMS 3ufl1vH3dW31 LNY1009 SLO NOLLO3NNOO OION31OS SO HOSNAS NOLLISOd ANVEO 582 983 s da LIQOHIO 89 HOLVNUALTY ONIDHVHO VO ed za 92 GN3931 2 91 o 4 1 4v89 LEVAS 800 on le GALWINSNINN 95 81 19 an 674 e T sN SNOLLOSNNOO vid Sz 1d O 902
38. area network LxWxH length by width by height Ib pound pounds Ibm ft pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQ milliohm MOhm megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg mounting 50 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns OD OEM OF opt OS OSHA OV OZ p pp PC PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly megawatt milliwatt microfarad normal power
39. cap leaks replace it with a cap of the same rating Find the pressure cap rating in Figure 3 7 TP 6390 1 06 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 Close the seacock 2 Remove the seawater pump coverplate See Figure 3 8 3 Remove the impeller 4 Inspectthe impeller for damaged cracked broken missing or flattened vanes The impeller vanes should be straight and flexible See Figure 3 9 Replace the impeller if it is damaged Seawater pump Pulley Coverplate Drive shaft Gasket Washer Impeller Nut Bearing Mechanical seal Housing if equipped Figure 3 8 Seawater Pump Typical TP 6390 1 06 1 Flattened vane 2 Crack 3 Broken vane 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 impeller in the same direction as the engine rotation until it is thoroughly seated in the impeller housing 7 Inspect the coverplate and gasket for corrosion and or damage Replace components as necessary 8 Lubricate the gasket with sil
40. cfm standard cubic feet per minute SCR silicon controlled rectifier s sec second SI Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s Sq square sq cm square centimeter sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency w watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6390 1 06 Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of re
41. down before resetting the controller Use the following procedure to reset the generator set controller after a fault shutdown 1 Move the generator set master switch to the OFF RESET position 2 Disconnect the generator set from the load using the line circuit breaker See the safety precautions atthe beginning of this manual before proceeding 3 Identify and correct the cause of the fault shutdown See the safety precautions at the beginning of this manual before proceeding Refer to Section 4 Troubleshooting 4 Startthe generator set by moving the generator set master switch to RUN Test operate the generator set to verify that the cause of the shutdown has been corrected 5 Shut the generator off by moving the generator set master switch to the OFF RESET position 6 Reconnect the generator set to the load using the line circuit breaker 7 Move the generator set master switch to the AUTO position for startup by remote transfer switch remote start stop switch or remote digital gauge Opening and closing the remote start stop contact also resets the controller 2 6 7 Continuous Power Mode if Equipped with a Remote Gauge The controller is powered by the generator set engine starting battery Remote communications require an active powered up controller Be advised that the ADC consumes 250 mA when the master switch is in the AUTO position If you do not plan to use your generator set for a long period of time
42. e schedule Change the oil filter more frequently if the generator set operates under dirty dusty conditions Refer to the following procedure See Section 1 for oil filter location TP 6390 1 06 Cil Filter Change Procedure 1 Loosen the oil filter by turning it counterclockwise Remove the oil filler and use rags to clean up spilled oil Dispose of the oil filter in an approved manner 2 Clean the contact surface of the oil filter adapter 3 Lightly lubricate the gasket surface of the new filter with fresh engine oil Thread the filter on the adapter until the gasket makes contact and hand tighten the filter an additional one half turn Wash hands after any contact with engine oil Note If also performing an oil change skip steps 4 and 5 and go back to oil change procedure 4 Start the generator set and check for oil leaks 5 Stop the generator set Check oil level Add oil as necessary to bring level up to Full mark 3 4 Fuel System 3 4 1 Fuel Specifications Use a clean good quality unleaded fuel with an octane number of 87 Use fresh gasoline to ensure itis blended for the season and to reduce the possibility of the formation of gum deposits that could clog the fuel system Do not use gasoline left over from the previous season Kohler Co recommends unleaded fuel because it leaves fewer combustion chamber deposits Never mix oil with fuel Note Consult the engine owners manual for oxygenated fuel recomm
43. e severe injury or death Do not smoke or permit flames or sparks near the generator set Keep the compartment and the generator set clean and free of debris to minimize the risk of fire Catch fuels in an approved container Wipe up spilled fuels and engine oil 6 Safety Precautions and Instructions Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation fire prevention procedures Engine Fluids and Chemical Products A WARNING Handling caustic engine fluids and chemical products Can cause severe chemical burns nausea fainting or death Most chemicals such as used engine oil antifreeze coolant rustproofing agent inhibiting oil degreasing agent spray paint and adhesives are hazardous to health Read andfollow the user information found on the packaging Avoid inhalation and skin contact Use only in well ventilated areas and use a protective mask when spraying Store engine fluids and chemical products in a locked cabinet Contact your local recycling center for disposal information and locati
44. eck and or replace the catalyst assembly Replace the CO sensor module Check the crankcase breather pipe for obstructions Inspect the complete exhaust system Keep battery charged and in good condition Check and tighten electrical connections Clean battery cables t Check for water fuel coolant and oil leakage Retighten all nuts and bolts Check tightness of mounting bolts vibromounts Check and adjust valve clearance Clean combustion chamber REMOTE CONTROL SYSTEM Check remote control operation period x GENERATOR Test run generator set Blow dust out of generator x Clean slip rings and inspect brushes Requires removal of sound shield if installed Consult your local distributor dealer for service Read WARNING found at the beginning of manual regarding moving parts Should be performed by your local distributor dealer Consult battery manufacturer s instructions TP 6390 1 06 X 1000 hrs Section 3 Scheduled Maintenance 25 3 3 Lubrication System 3 3 1 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 warranty Figure 3 1 shows the recommended Society of Automotive Engineers SAE viscosit
45. endations Section 3 Scheduled Maintenance 27 3 4 2 FuelFilter The 5 7 generator sets utilize in line type 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 Bleed the fuel system after replacing the fuel filter See Section 3 4 3 3 4 3 Fuel System Bleed Bleed air from the fuel system in order to reduce rough running or vapor lock A WARNING Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Fuel System Bleed Procedure 1 Press and hold the Select button on the ADC See Figure 3 4 2 While holding the Select button move the generator set master switch into the RUN position See Figure 3 4 3 Keep holding the Select button until step 6 The ADC software version and then FUEL will appear on the ADC s LED display See Figure 3 4 4 Remove the cap from the location shown in Figure 3 5 5 Hold the bleed tool part number GM46327 onto the bleed point to remove air from the line 6 When fuel begins to
46. exhaust leak Seal leaks as needed e Ensure that the carbon monoxide detector 5 is 1 in the craft 2 functional and 3 energized whenever the generator set operates TP 6390 1 06 Section 2 Operation For your safety Never operate the generator set without a functioning carbon monoxide detector s for your safety and the safety of others on your vessel Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set Seawater Pump Priming Prime the seawater pump before initial startup To prime the pump 1 close the seacock 2 remove the hose from the water filter outlet 3 fill he hose and seawater pump with clean water 4 reconnect the hose to the water filter outlet and 5 open the seacock Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet 2 2 Marine Inspection Kohler Co recommends that all 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 Kohler Co also recommends having the generator s exhaust system inspected at the start of each boating season by an a
47. g and remove the hose 2 Loosen the hose clamp attaching the air silencer assembly to the carburetor 3 Lift off the air silencer assembly 4 Clean the assembly in evaporative solvent and wipe clean Allow to dry 5 Reassemble using the reverse sequence TP 6390 1 06 3 6 Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Consult the boat builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times Atthe interval specified in the service schedule inspect the exhaust system components exhaust manifold catalyst assembly gasket s exhaust hose hose clamps silencer and outlet flapper for cracks leaks and corrosion Ensure that the carbon monoxide detector 5 is 1 in the craft 2 functional and 3 energized whenever the generator set operates For your safety Never operate the generator set without a functioning carbon monoxide detector s for your safety and the safety of others on your vessel Exhaust S
48. generator set only when allguards screens and covers place WARNING 2 Airborne particles Can cause severe injury blindness Wear protective goggles and clothing when using power tools hand tools or compressed air Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator setengine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware 10 Safety Precautions and Instructions Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Sound shield removal Exposed moving parts can cause severe injury or death The generator set must be operating in order to perform some scheduled maintenance procedures Be especially careful ifthe sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only Notice NOTICE Hardware da
49. gine 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 Introduction 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 atthe prescribed intervals Obtain service from an 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 x in 001 002 a Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPowerSystems com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents
50. guides and stems or worn or loose bearings Replace the spark plug Oil fouled spark plug Carbon fouled spark plug Black dry fluffy carbon deposits on insulator tips exposed shell surfaces and electrodes Incorrect spark plug weak ignition clogged air intake defective fuel pump overrich fuel mixture or excessive no load operation Clean and regap the spark plug Lead fouled spark plug Dark gray black yellow or tan deposits or a glazed coating on the insulator tip Caused by highly leaded fuel Replace the spark plug Preignition damaged spark plug Melted electrodes and possibly blistered insulator Metallic deposits on insulator suggest internal engine damage Wrong type of fuel incorrect timing or advance too hot a plug burned valves or 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 type of fuel loose spark plugs too hot a plug low fuel pump pressure or incorrect ignition timing Replace the spark plug Worn spark plug Severely eroded or worn electrodes Figure 3 14 Engine Evaluation Using Spark Plug Condition TP 6390 1 06 Caused by normal wear and failure to replace spark plug at prescribed interval Replace the spark plug Section 3 Scheduled Maintenance 35 5 Clean spark plugs by wiping t
51. hem 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 6 Check the spark plug gap before installing any spark plug See Figure 3 15 Attain a correct gap when the feeler or wire passes between the spark plug electrode It should pass easily but with some resistance or drag otherwise adjust as necessary The correct gap is 0 6 0 7 mm 0 024 0 028 in Figure 3 16 Spark Plug Gap Adjustment 8 Reinstall the spark plug Do not bump the electrode against the cylinder head Rotate the spark plug clockwise until feeling resistance 9 Use a torque wrench to torque each spark plug to 12 17 Nm 9 12 ft lbs Otherwise hand tighten spark plug until feeling resistance 10 Use a ratchet wrench to final tighten an additional 1 4 turn Do not overtighten as doing so may strip threads or alter electrode gap setting 11 Check spark plug wire connector in boot for accumulated dirt grease and other debris and clean as necessary 1 0 6 0 7 mm 0 024 0 028 in gap 2 Spark plug electrodes Figure 3 15 Spark Plug Gap Inspection 12 Firmly push spark plug boot onto spark plug 7 Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap See Figure 3 16 Position the side electrode directly over the cen
52. hile the generator set is operating Read the vessel s owner s manual for further information Open the fuel shut off valve Open the manual fuel shut off valve if equipped Start the generator set Place the generator set master switch to the RUN position Note Opening seacock Before starting the generator set open the seacock to allow cooling water passage Failure to do so could damage the seawater pump impeller and cause serious engine overheating damage Note Transfer switch Check that the marine ship to shore transfer switch if equipped is in the ship position TP 6390 1 06 Switch functions as the generator set operation and controller reset switch Note Close seacock if water enters the exhaust system f water enters the exhaust system close the seacock and drain the water from the exhaust system atthe silencer s drain plug before attempting to start the generator set A water filled exhaust hose and silencer may hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valves Water ingested into the engine may cause major engine damage that the Kohler Co warranty does not cover excessive cranking is a chronic problem have the unit including the exhaust system serviced by an authorized Kohler distributor dealer The controller attempts to start the generator set three times If the generator set does not start in three attempts the system shu
53. icon grease and attach the gasket and coverplate to the seawater pump housing 9 Open the seacock 10 Start the generator set and check for leaks 11 Stop the generator set and repair leaks or replace damaged or worn components m sm 003 008 Section 3 Scheduled Maintenance 31 3 7 4 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 11 The siphon break malfunction when the generator set operates while the craft is in contaminated waters or saltwater Use the following procedure to inspect the siphon break at the intervals listed in the service schedule Siphon Break Inspection 1 Stop the generator set 2 Remove the retaining cap and remove the reed valve for inspection See Figure 3 10 3 Use a mild detergent to remove residue and oxidation from the reed valve 4 Clear blockage from the reed valve opening 5 Replace the siphon break if the reed valve is cracked or if the reed valve material has hardened or deteriorated 32 Section 3 Scheduled Maintenance 6 Install the reed valve into the mounting base with the valve downward See Figure 3 10 item 2 7 Install and only finger tighten the retaining cap Do not overtighten it 1 Cap 2 Reed valve 3 Mounting base Figure 3 10 Siphon Break m sm 003 007 TP 63
54. iming 3 7 6 Seawater Outlet Check the seawater outlet at the interval specified in the service schedule See Figure 3 11 for location Remove any obstructions to keep the outlet clear TP 6390 1 06 3 8 Service spark plugs at the interval specified in the service schedule using the following procedure 3 Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling into the combustion chamber Ignition System 4 Remove spark plugs one at a time and examine Identify a normal spark plug in good operating condition by observing a lighttan or gray deposit on the firing tip See Figure 3 14 to evaluate engine condition by color condition of a problem spark plug Spark Plug Service Procedure 1 Remove spark plug wires by grasping the spark plug boot and turning slightly while pulling Do not pull the wire Pulling on the wire rather than the boot may damage the wire or terminal 2 Loosen the spark plug with a ratchet and 5 8 in spark plug socket with a rubber insert to prevent spark plug damage Means of Identification Built up deposits and gap between electrodes closing Wet black deposits on the insulator shell bore and electrodes Problem Condition Gap bridged spark plug Possible Cause Solution Oil or carbon fouling Clean and regap the spark plug Excessive oil entering combustion chamber through worn rings and pistons excessive clearance between valve
55. ion to 37 C 34 F and overheating protection to 129 C 265 F A coolant solution with less than 5096 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Consult the engine manufacturer s operation manual for engine coolant specifications Pressure Cap Rating 96 5 kPa 14 psi 91 195 F Thermostat Rating Figure 3 7 Pressure Cap and Thermostat Rating Procedure for Flushing and Cleaning Cooling System For optimum protection drain flush and refill the cooling system at the interval listed in the service schedule Pay special attention to the coolant level After the coolant drains allow time for complete refill of the engine water jacket Check the coolant level as described earlier 1 Remove the hose clamp at the coolant hose See Section 1 for location of the hose 2 Remove the pressure cap to make draining easier 3 Drain clean and flush the coolant recovery tank 4 Flush the system with clean water 5 Replace the hose clamp to secure the coolant hose 6 Fill the system with the recommended coolant 7 Replace the pressure cap 3 7 2 Pressure Cap Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant enabling higher operating temperatures If the
56. ipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Safety Precautions and Instructions 5 Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire WARNING 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the backfire flame arrester A sudden backfire can cause severe injury or death Do not operate the generator set with the backfire flame arrester removed Combustible materials A sudden flash fire can caus
57. lant Sensor Input Low Oxygen Sensor Input High Oxygen Sensor Input Low Seawater Pump Pressure Engine Overspeed Fault Coolant Sensor Range High Trim Valve Output Fault Trim Valve Lower DC Fault Trim Valve Upper DC Fault O2 Switching Fault Gaseous O2 Adapt Limit Fault CAN Receive Message Fault Fuel Pump Fault Starter Fault Figure2 7 SECM Fault Codes Appears on the ADC 2100 Display and Remote Digital Gauge TP 6390 1 06 2 6 5 SmartCraft System View SC5000 Display If Equipped The 5 7 3ECD and 4 6EFCD model generator sets can connect to SmartCraft s SC5000 if equipped via the generator set s P19 connector See the wiring diagrams in Section 5 for the P19 location The SC5000 displays important generator set information as shown in Figure 2 8 Consult the SmartCraft SC5000 literature provided with your vessel for display operation KOHLER GENSET ENG DATA OIL PRESSURE ENGINE TEMP PSI F T 0 0 E BATTERY AC VOLTS OK V VAC 13 6 118 KOHLER GENSET ENG DATA AC FREQUENCY AC VOLTS RUN TIME 2HR 26MIN STATUS Figure 2 8 5 7 3ECD and 4 6EFCD Generator Display Screens on SC5000 Typical SmartCraft is a trademark of Mercury Marine a division of Brunswick Corporation Section 2 Operation 21 2 6 6 Resetting the Controller after a Fault Shutdown Always identify and correct the cause of a fault shut
58. llowing checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Inlets Check for clean and unobstructed air inlets Air Shrouding Check for securely installed and positioned air shrouding Backfire Flame Arrester Check for a clean and installed backfire flame arrester to prevent unfiltered air from entering the engine Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold catalyst exhaust hose hose clamps silencer and outlet flapper for cracks leaks and corrosion e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an
59. mage 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 NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Electrostatic discharge damage Electrostatic discharge ESD damages electronic circuit boards Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits An approved grounding wrist strap provides a high resistance about 1 megohm not a direct short to ground NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown or questionable NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces TP 6390 1 06 This manual provides operation instructions for 5 7 3ECD and 4 6EFCD model generator sets Refer to the engine operation manual for generator set en
60. n Shutdown occurs 5 seconds after a loss of coolant condition is detected This protection becomes active 10 seconds after the engine has reached its stated crank disconnect speed and remains active as long as the generator run command is active Check for a clogged seawater intake or sea strainer Check for a damaged seawater pump impeller Low oil pressure shutdown Shutdown occurs if a low oil pressure condition exists for more than 5 seconds This protection becomes active 30 seconds after the engine has reached crank disconnect speed 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Check for leaks in the lubrication system Check the oil level and add oil if the level is low Overcrank shutdown Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts Check the fuel supply and battery If there is no output voltage check the line circuit breaker Also check for loose connections Contact an authorized distributor dealer for service if problem continues Overfrequency shutdown Shutdown occurs when the governed frequency exceeds 110 of the system s frequency setpoint for more than 5 seconds This protection becomes active 10 seconds after engine start 10 second inhibit Contact an authorized distributor dealer for service if problem continues Overspeed shutdown
61. n authorized distributor dealer for service Ensure windows are open for proper ventilation Operate the blower to expel dangerous fumes Move the vessel away from other vessels as another vessel may be the source for the presence of the CO Check the generator exhaust system see Section 3 6 Carbon monoxide shutdown Shutdown occurs because of the presence of CO or deteriorating emission control components such as the catalyst Immediate service required Contact an authorized distributor dealer for service Ensure windows are open for proper ventilation Operate the blower to expel dangerous fumes Move the vessel away from other vessels as another vessel may be the source for the presence of the CO Check the generator exhaust system see Section 3 6 Carbon monoxide sensor shutdown Shutdown occurs if communication is lost between the CO sensor and the ADC Check the connections to the CO sensor If connections are okay replace the CO sensor Contact an authorized distributor dealer for service High engine temperature shutdown Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This protection becomes active after the engine reaches the crank disconnect speed Note The high engine temperature shutdown functions only when the coolant level is in the operating range Check for a low engine coolant level Loss of coolant shutdow
62. nds Check the battery rating and condition Low battery voltage warning Fault code is displayed if the engine starting battery voltage falls below 9 5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 2 seconds when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 2 seconds Figure 2 6 ADC 2100 Fault Warning Codes 20 Section 2 Operation Check the battery rating and condition Charge or replace the battery TP 6390 1 06 Fault Code Displayed No Faults Fault Code 0 Throttle Position Sensor Input High Throttle Position Sensor Range High Throttle Position Sensor Range Low Throttle Position Sensor Input Low Speed Bias Pot Input High Speed Bias Pot Input Low Electronic Throttle Control Sticking EST 1 Low EST 1 High EST 2 Low EST 2 High EST 3 Low EST 3 High Injector Fault Low Oil Pressure Electronic Throttle Control Spring Test Failed Map Sensor Input High Map Sensor Input Low Electronic Throttle Control Driver Fault Battery Sensor Input High Battery Sensor Input Low XDRP Sensor Input High XDRP Sensor Input Low Intake Air Temp Input Sensor High Intake Air Temp Input Sensor Low Coolant Sensor Input High Coo
63. ng Every 100 Hrs or 3 Months Every 300 Hrs or 6 Months FUEL SYSTEM Check the fuel level and fill as necessary Check fuel lines and replace as necessary Replace the fuel filter LUBRICATION SYSTEM Check crankcase oil level and add as necessary Replace the oil in crankcase x 20 hrs break in period Replace the lube oil filter element Check coolant level and fill as necessary x 20 hrs break in period Check seawater outlet and clean as necessary x during operation Check function of siphon break if equipped Replace seawater pump impeller Check heat exchanger anticorrosion zinc condition Replace heat exchanger anticorrosion zinc Flush cooling system 400 hrs IGNITION SYSTEM Clean and regap spark plugs Replace spark plugs Requires removal of sound shield if installed Consult your local distributor dealer for service 24 Section 3 Scheduled Maintenance X TP 6390 1 06 Service Schedule continued Perform Service at Intervals Indicated X Reference Section Before Starting After 50 Hrs or 1 Month Every 100 Hrs or 3 Months Every 300 Hrs or 6 Months Every 500 Hrs or Yearly INTAKE EXHAUST SYSTEM Inspect exhaust system components Check the exhaust gas condition x during operation Service backfire flame arrestor Ch
64. o relieve pressure WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools WARNING Hot engine oil Can cause severe injury or death Avoid skin contact with hot oil Do not start or operate the generator set with the engine oil filler cap removed as hot oil can spray out Ensure that the lubrication system is not under pressure when servicing Do not work on the generator set until it cools Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank ifthe generator set has a coolant recovery tank Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Moving Parts A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Safety Precautions and Instructions 9 WARNING Rotating parts Can cause severe injury or death Operate the
65. ons WARNING 7 d 4 Flammable engine solvents cleaners Can cause severe injury or death Do not smoke or permit flames or sparks near flammable engine solvents and cleaners Read and follow the user information found on the packaging Use only in well ventilated areas Never use gasoline or low flash point solvents as cleaning agents Leaking or accumulated engine fluids A fire can cause severe injury or death Clean up engine fluids including fuel oil grease and coolant Determine the source of engine leaks and correct before starting the generator set Keep the generator set area clean and remove combustible materials Used engine oil Contact with used engine oil may cause severe skin irritation Repeated and prolonged skin exposure may have other health risks Used engine oil is a suspected carcinogen Avoid contact with skin Thoroughly wash your hands and nails with soap and water shortly after handling used engine oil Wash or dispose of clothing or rags containing used engine oil Dispose of used engine oil in a responsible manner Contact your local recycling center for disposal information and locations TP 6390 1 06 Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is
66. or a digital gauge the controller will power down after 48 hours if the master switch is in the AUTO position If the generator has been started the controller will power down 48 hours after the generator stops 18 Section 2 Operation 2 6 4 Fault Shutdowns The generator set shuts down automatically under the fault conditions listed in Figure 2 5 and the controller displays a fault code The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 6 6 to reset the controller after a fault shutdown The controller resets automatically after a battery voltage fault condition is corrected Shutdown switches on the generator set automatically reset when the problem is corrected The high engine temperature switch automatically resets when the generator set cools However the fault does not clear until the controller is reset The controller displays a fault code but the generator set does not shut down under the conditions shown in Figure 2 6 TP 6390 1 06 Auxiliary fault input shutdown Description Input from a customer supplied switch that closes when the fault is active Shutdown occurs 0 3 seconds after the fault is detected This protection becomes active 3 seconds after crank disconnect Check the cause of the auxiliary fault Carbon monoxide shutdown Sensor fault shutdown occurs because of the presence of CO Immediate service required Contact a
67. or set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Sound shield removal Exposed moving parts can cause severe injury or death The generator set must be operating in orderto perform some scheduled maintenance procedures Be especially careful if the sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Usethe correct size tools to prevent rounding of the bolt heads and nuts Annual Inspection Kohler Co recommends that all 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 Kohler Co also recommends having the generator s exhaust system inspected at the start of each boating season by an authorized Kohler distributor dealer Repair any problems identified before operating the generator set See the Safety Precautions and Instructions at the beginning of this manual before attempting to service
68. quired services were performed Enter hours to the operating hours on your generator set and the dates nearest quarter hour OPERATING HOURS SERVICE RECORD DATE TOTAL SERVICE RUN HOURS DATE SERVICE TP6390 1 06 Appendix 51 52 TP 6390 1 06 TP 6390 1 06 53 54 TP 6390 1 06 TP 6390 1 06 55 TP 6390 1 06a O 2006 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 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 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
69. rds and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Turn off the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution TP 6390 1 06 Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The 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 equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment
70. re the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water oron wet ground because these conditions increase the risk of electrocution Section 5 Wiring Diagrams 43 GM39836A G 6 1 15 ON 11515 SNOILO3NNOO Std Kom 138341430 33S OILVA3HO9S HOW 3SvHd 319NIS S9S AgV 1083 335 SNOLLO3NNOO HO1VH3N39 SLON 5 19 99 E va 69 499 da N 6 899 a 23 3 899 405 080 29 898 orig HN SNOLLO3NNOO 91d v gt suiNn es N GNri 189 NO 07 2 NO 07 EN INO00 ss zov uos 99 G 0vd 9 iinsND ss 1v1S T ELINSND v 60 z gz 133HS OL gt GIIdOD SNOILOANNOO Obd 001zoaV SNOLLO3NNOO Ld GWS 1viS v 0 1 15 v 91d 038 4 1 914 O9 o OvNolLdO 292 189 1 8gli d
71. re to flow into waterways Reconnect the lead 87 to the low seawater pressure LWP switch Stop the generator set Leave the seacock closed Check the coolant level of the heat exchanger and add coolant if necessary Note Use antifreeze capable of withstanding the lowest possible temperatures Drain fuel completely from the fuel tank Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs Seal the air inlet exhaust pipe and fuel tank cap with tape Disconnect and remove the battery Place the battery in a warm dry location for the storage period Recharge the battery once a month to maintain a full charge Select a well ventilated not humid or dusty location to store the generator Cover the entire unit with a dust cover Note Run the generator set once a month whenever possible Section 3 Scheduled Maintenance 37 Notes 38 Section Scheduled Maintenance TP 6390 1 06 This section contains generator set troubleshooting diagnostic and repair information Use the following charts as a quick troubleshooting reference The table groups generator set faults and suggests likely causes and remedies The table also refers you to more detailed information including sections of this manual the generator
72. refer to an authorized Kohler distributor dealer for system configuration adjustment instructions TP 6390 1 06 Control or Indicator LED display Description Runtime hours Displays total generator set runtime hours Crank indication Displays CC_1 CC_2 or CC_3 to indicate the first second or third attempt to start the engine The last digit flashes during the crank cycle rest periods Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 2 6 4 Software version See TP 5982 Generator Set Installation Manual Keypad buttons Select and arrow The keypad is used for controller setup and adjustment only Have setup and adjustments performed only by an authorized distributor dealer The setup and adjustment functions are password protected Generator set master Three position switch switch Figure 2 4 ADC 2100 Controls and Indicators 2 6 2 Starting the Generator Set The following procedures describe the actions required to start the generator set WARNING Explosion Gasoline vapors cause explosion and severe injury or death Before starting the generator set operate the blower 4 minutes and check the engine compartment for gasoline vapors Action Operate the blower Operate the blower 4 minutes and check the engine compartment for gasoline vapors NOTE Many boat manufacturers recommend continuous blower operation w
73. repair or operate the generator set Have an authorized distributor dealer perform generator set service Section 3 Scheduled Maintenance 23 Engine Service Perform generator set engine service at the intervals specified by the engine operation manual Generator Set Service Perform generator set service at the intervals specified by the generator set operation manual If the generator set operates under dusty or dirty conditions use dry compressed air to blow dust out of the alternator With the generator set running directthe stream of air in through the cooling slots atthe alternator end Routine Maintenance Refertothe following generator set service schedule the engine service schedule and the runtime hour display located on the generator set s 3 2 Service Schedule ADC to determine when to schedule routine maintenance Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions Service Log Use the Operating Hour Service Log located in the back of this manual to document performed services Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set For example an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months 300 hours or 9 months and so on x sm 004 001 Perform Service at Intervals Indicated X Reference Section Before Starti
74. s jou seop yng yuelo you s oq suiojdui AS 42 Section 4 Troubleshooting Section 5 Wiring Diagrams WARNING Qe aS gt Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe powertothe battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer TP 6390 1 06 WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Turn off the main circuit breakers of all power sources before servicing the equipment Configu
75. set service manual S M the generator set installation manual and the engine service manual Engine S M to correct the indicated problem Use the following charts to diagnose and correct common problems First check for simple causes such as a dead engine starting battery loose connections or an open circuit breaker The charts include a list of common problems possible causes ofthe problem and recommended corrective actions TP 6390 1 06 Section 4 Troubleshooting Corrective action and testing often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service distributor dealer perform service NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown or questionable Maintain a record of repairs and adjustments performed on the equipment If the procedures in this manual do not explain how to correct the problem contact an authorized distributor dealer Use the record to help describe the problem and repairs or adjustments made to the equipment x gt 001 002a Section 4 Troubleshooting 39 enuey 5 enuen Tenuen uonej eisuj 4 WN I 19S c uec ui6u3a Buy 1
76. t the generator set for fluid or exhaust leaks 16 Section 2 Operation 2 6 Advanced Digital Control Operation Figure 2 3 illustrates the user interface on the Advanced Digital Control ADC 2100 Note Have setup and adjustments of the ADC 2100 performed only by an authorized Kohler distributor dealer The setup and adjustments are password protected KOHLER ADVANCED DIGITAL CONTROL DEFINITION Auxillary Fault Crank Cycle High Battery Voltage Qver Gran ver Frequency Over Speed r Voltage Under Frequency Under Voltage OFF RESET 3 GM28707A C 1 LED display 2 Up and down arrow buttons use for setup and adjustment only 3 Generator set master switch 4 Select button use for setup and adjustment only Figure 2 3 ADC 2100 Control 2 6 1 Controls and Indicators Figure 2 4 describes the controls and indicators located on the controller The LED display indicates generator set status as shown in Figure 2 4 The display is active when the master switch is in the RUN or AUTO position and remains active until the generator set master switch is moved to the OFF RESET position or the power to the controller is removed The buttons on the controller keypad are used only for system configuration and adjustment 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
77. te approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute TP 6390 1 06 CG CID CL cm CMOS cogen Com conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications
78. ter electrode 36 Section 3 Scheduled Maintenance TP 6390 1 06 3 9 Battery Consult the battery manufacturer s instructions regarding battery care and maintenance WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles clothing Battery acid may cause blindness and burn skin 3 10 Generator Storage Procedure Keep the craft afloat for generator operation during the storage procedure Follow the procedure below when storing your generator set for a long period 3 months or more 1 Start and run the generator set until it reaches operating temperature or about 15 minutes Stop the generator set Change the oil and oil filter see Section 3 3 4 Oil Change and Section 3 3 5 Oil Filter Change 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 Peak RV marine propylene glycol water mix or equivalent Disconnect the lead 87 to the low seawater pressure LWP switch TP 6390 1 06 10 11 12 13 14 15 16 17 Connect the hose to the seacock With a suitable container at the exhaust outlet run the generator set until coolant discharges at the exhaust outlet or until depleting the coolant mixture Do not allow coolant mixtu
79. the service schedule or before generator set storage Change the oil more frequently if the generator set operates under dirty dusty conditions Change the oil while the engine is still warm See Figure 3 3 for oil capacity See Section 1 Service Views for oil fill oil check and oil filter locations Model L Qts All models 1 36 1 44 Figure 3 3 Oil Capacity with Filter TP 6390 1 06 Oil Change Procedure 1 Stop the generator set 2 To drain the oil open the oil drain valve See Section 1 for the valve location 3 Drain the oil into a suitable container 4 Allow ample time for all oil to drain 5 Close the oil drain valve 6 Remove the oil fill cap 7 Replace the engine oil filter according to the service schedule and the procedure in Section 3 3 5 8 Fill crankcase with oil Section 1 shows the oil fill location See Figure 3 1 for oil selection and Figure 3 3 for oil capacity Replace the oil fill cap 9 Start the generator set and check for oil leaks 10 Stop the generator set Check the oil level Add oil as necessary to bring the level up to the Full mark Note Too high an oil level causes high oil consumption and engine carbonizing Too low a level damages the engine Note 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 servic
80. ts down on an overcrank fault Local Starting Move the generator set master switch to the RUN position The ADC 2100 attempts to start the generator set in three crank cycles crank cycle time is pre programmed Auto Automatic Starting Move the generator set master switch to the AUTO position to allow startup by the remote start stop switch or remote digital gauge A remote start stop switch or digital gauge can be connected to the customer interface connection P21 connector leads 3 and 4 See the wiring diagram in Section 5 Note The ADC 2100 allows three crank cycle attempts before the overcrank shutdown occurs Section 2 Operation 17 2 6 3 Stopping the Generator Set The following procedures describe the actions required to stop the generator set Local Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 Move the generator set master switch to the OFF RESET position The engine stops Auto Automatic Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 With the generator set master switch in the AUTO position the generator set stops when the remote start stop switch contacts close momentarily Note If the ADC 2100 is configured for a digital gauge the controller will not power down if the master switch is in the AUTO position See Section 2 6 7 Note If the ADC 2100 is not configured f
81. ts from your authorized qualified personnel should install or service the generator distributor dealer generator set Part Description Part Number Literature Type Part Number Fuse F1 10 amp Installation Manual TP 5982 Auxiliary Windi 358337 A Operation Manual Generator TP 6390 de 10 223316 Operation Manual Engine TP 6001 onyo Si Parts Catalog TP 5987 Fuse F3 10 amp 223316 Service Manual Generator TP 6391 Customer Connection Service Manual Engine TP 6002 Fuse F4 15 amp 283645 Service Manual Supplement Engine TP 6008 Coils Injectors Fuse F5 15 amp ECM Sensor and Fuel Pumps Fuse F6 15 amp Voltage Regulator and Battery Charging 283645 Alternator Fuse F7 20 amp Starter Motor and Crank Solenoid Oil Filter 359771 One manual combines Generator and Engine information 283645 Figure 2 Generator Set Literature x in 001 005 GM39266 Seawater Pump Impeller Kit 359978 Spark Plug GM46180 Spray Paint White 221335 Zinc Anode 260085 Figure 1 Maintenance and Service Parts x in 001 004 12 Maintenance and Service Parts Related Literature TP 6390 1 06 O QI gt Q N pare Figure 1 1 Section 1 Service Views 8 9 10 11 12 13 SERV
82. uthorized Kohler9 distributor dealer Repair any problems identified before operating the generator set WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Section 2 Operation 15 2 3 Angular Operation See Figure 2 1 for angular operation limits for units covered in this manual Intermittent Continuous 3 minutes or less 25 30 Maximum value for all directions Figure 2 1 Angular Operation 2 4 Operation in European Union Member Countries This generator set is specifically intended and approved for operation below the deck in the engine compartment 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 prevents corrosion formation on internal engine components when they re exposed to the breakdown of exhaust gases Minimum Ideal Load Requirement Load Requirement 3096 load 7096 load or more Figure 2 2 Load Profile The operator 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 running engine and visually inspec
83. y JI 4 4e ojjuoo ay esnj y eui asejday 14 eu L uono s OLAV 10 NN uonisod 1284100 SY 0 U31IAS Jejseuu 195 JoJeJauab eui anoyy uonisod 440 ay ul U91IAS 5 195 x JO uonoes suonoy sasney o qeqoJd esiou jeuuouqe JO uonduunsuoo Jen YBIH eunsseud Jewod sxyoe1 Ajueppns 54015 eDeyoA 1ndino JO ON prey sueis yeys seop syueio 5 l qnoiuL TP 6390 1 06 40 Section 4 Troubleshooting W o y eds uous Y28049 Aluo euioseB seb weIs s uoniuB sjy uuoped Jepeep 1ojnquisip eones pezuouine BAeH weu erg BuutlW Q M 3eeus eds s s enuen enuen enuen uoneeisu qW 495 4 uec eutBu3 Bua yms 1eJsue1 6 sy JO uonoes pejequinu uomnoeg 995 y esoo je uay L UOneJgiA W s 8u3 4 SeA e ysnipy 3091000 eoueJee o ALA uonoes 4 sjueuodujoo ulejs s 1sneuxe esoo
84. y designation for given operating temperature ranges Cil Specifications Do not mix different oil brands Incompatibility could cause a breakdown of lubricating ingredients and reduce engine protection Recommended SAE Viscosity Grades SAE10W 30 SAE 10W 40 F 4 14 32 C 20 10 0 Using multigrade oil causes greater oil consumption Figure 3 1 Engine Oil Selection 3 3 2 Oil Check Check 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 generator set level to get an accurate reading To check the oil level remove the dipstick and wipe the end clean reinsert and remove Maintain the oil level between the Full and Add marks on the dipstick as shown in Figure 3 2 See Section 1 Service Views for the dipstick location 26 Section 3 Scheduled Maintenance 1 Full mark 2 Add mark Figure 3 2 Oil Level Check Note Do not operate the set if the oil level is below the Add mark on the dipstick or above the Full mark on the dipstick 3 3 3 Oil Additions Adding some oil between oil changes is normal The amount varies with generator set usage Open the oil fill cap and pour in a small amount of oil using a funnel or other suitable pouring device See Section 1 Service Views for the oil check and oil fill locations 3 3 4 Oil Change Change the oil according to
85. ystem Inspection Points Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect the exhaust system for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed Section 3 Scheduled Maintenance 29 3 7 Cooling System 3 7 4 Closed Heat Exchanger In a closed cooling system the seawater circulates through separate chambers within the heat exchanger to cool the engine water The seawater then mixes with engine exhaust and ejects out the exhaust outlet See Figure 3 6 for coolant capacity include coolant recovery tank capacity of 0 8L 0 85 gts See Figure 3 7 for thermostat and pressure cap ratings Model All models L Qts 2 84 3 0 Figure 3 6 Coolant Capacity WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Checking the coolant level Hot coolant can

5ECD/4EFCD--Low CO 7.3ECD/6EFCD-

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