Manual de Operación 5ecd
Manual de Operación 5ecd
Manual de Operación 5ecd
Models:
5ECD/4EFCD--Low CO
7.3ECD/6EFCD--Low CO
TP-6390 1/06a
WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
2 TP-6390 1/06
This manual provides operation instructions for beginning of this manual. Keep this manual with the
5/7.3ECD and 4/6EFCD model generator sets. equipment for future reference.
Refer to the engine operation manual for generator set The equipment service requirements are very important
engine scheduled maintenance information. to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Information in this publication represents data available
Obtain service from an authorized service
at the time of print. Kohler Co. reserves the right to
distributor/dealer to keep equipment in top condition.
change this publication and the products represented
without notice and without any obligation or liability
whatsoever. Before installing a marine generator set, obtain the
Read this manual and carefully follow all procedures most current installation manual from your local
and safety precautions to ensure proper equipment distributor/dealer. Only qualified persons should
operation and to avoid bodily injury. Read and follow the install the generator set.
Safety Precautions and Instructions section at the
x:in:001:002:a
Service Assistance
D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPowerSystems.com Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444 (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
ZI Senia 122
Latin America
12, rue des Hauts Flouviers
Latin America Regional Office
94517 Thiais Cedex
Lakeland, Florida, USA
France
Phone: (863) 619-7568
Phone: (33) 1 41 735500
Fax: (863) 701-7131
Fax: (33) 1 41 735501
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
1 2 3 4 5 6 7 8 9 10 11 12 13
14
15 16
30
17 18
19
20
29 21
22
SERVICE VIEW
28 27 26 25 24 23
ADV7025A-A
1. Spark plug (also one located on the nonservice side) 18. Catalyst assembly, water outlet/exhaust outlet (nonservice
2. Oil fill side)
3. Overflow tube 19. Seawater drain (remove plate for service)
4. Pressure cap (coolant fill location after draining coolant) 20. Seawater pump (water inlet)
5. Seawater pressure switch (appears as auxiliary fault on ADC) 21. Cooling air inlet
6. Lifting eye 22. Fuel filter/fuel inlet
7. Heat exchanger 23. Fuel pump
8. Anticorrosion zinc anode 24. Fuel pump/cooler
9. AC circuit breaker 25. Oil check
10. AC load lead connector (nonservice side) 26. Coolant drain (remove hose clamp to drain coolant)
11. Nameplate (top) 27. Oil drain valve
12. Customer interface connection (nonservice side) 28. Lube oil filter
13. Fuses (F1, F2, F3, F4, F5, F6, and F7) 29. Coolant overflow bottle (daily coolant check/fill location)
30. Air intake silencer/backfire flame arrestor
(see Section 2.7.2)
14. Runtime hour display Note: Consult installation drawings in Spec Sheet or Installation
15. Advanced Digital Control (ADC 2100) Manual for fuel- and battery-connection points.
16. CO sensor module Note: Consult distributor/dealer or Service Manual for items
17. Generator set master switch not shown.
2.1 Prestart Checklist For your safety: Never operate the generator set
without a functioning carbon
To ensure continued satisfactory operation perform the monoxide detector(s) for your
following checks or inspections before or at each safety and the safety of others on
startup, as designated, and at the intervals specified in your vessel.
the service schedule. In addition, some checks require
verification after the unit starts. Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.
Air Inlets. Check for clean and unobstructed air inlets.
Oil Level. Maintain the oil level at or near, not over, the
Air Shrouding. Check for securely installed and full mark on the dipstick.
positioned air shrouding.
Operating Area. Check for obstructions that could
Backfire Flame Arrester. Check for a clean and block the flow of cooling air. Keep the air intake area
installed backfire flame arrester to prevent unfiltered air clean. Do not leave rags, tools, or debris on or near the
from entering the engine. generator set.
Battery. Check for tight battery connections. Consult Seawater Pump Priming. Prime the seawater pump
the battery manufacturer’s instructions regarding before initial startup. To prime the pump: (1) close the
battery care and maintenance. seacock, (2) remove the hose from the water-filter
outlet, (3) fill the hose and seawater pump with clean
Coolant Level. Check the coolant level according to water, (4) reconnect the hose to the water filter outlet,
the cooling system maintenance information. and (5) open the seacock. Confirm seawater pump
operation on startup as indicated by water discharge
Exhaust System. Check for exhaust leaks and from the exhaust outlet.
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.
2.2 Marine Inspection
Inspect the exhaust system components (exhaust
manifold, catalyst, exhaust hose, hose clamps, silencer, Kohler Co. recommends that all boat owners have their
and outlet flapper) for cracks, leaks, and corrosion. vessels inspected at the start of each boating season by
the US Coast Guard, the local Coast Guard Auxiliary, or
D Check the hoses for softness, cracks, leaks, or dents. local state agency.
Replace the hoses as needed.
Kohler Co. also recommends having the generator’s
D Check for corroded or broken metal parts and replace exhaust system inspected at the start of each boating
them as needed. season by an authorized Kohlerr distributor/dealer.
Repair any problems identified before operating the
D Check for loose, corroded, or missing clamps.
generator set.
Tighten or replace the hose clamps and/or hangers
as needed.
WARNING
D Check that the exhaust outlet is unobstructed.
2.6.2 Starting the Generator Set Note: Close seacock if water enters the exhaust
system. If water enters the exhaust system,
The following procedures describe the actions required close the seacock and drain the water from the
to start the generator set. exhaust system at the silencer’s drain plug before
attempting to start the generator set. A
WARNING 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. If excessive
Explosion.
cranking is a chronic problem, have the unit,
Gasoline vapors can cause
explosion and severe injury or including the exhaust system, serviced by an
death. authorized Kohlerr distributor/dealer.
Local Starting.
Step Action
1 Operate the blower. Move the generator set master switch to the RUN
Operate the blower 4 minutes and check the engine position. The ADC 2100 attempts to start the generator
compartment for gasoline vapors. set in three crank cycles (crank cycle time is
NOTE: Many boat manufacturers recommend
continuous blower operation while the generator set
pre-programmed).
is operating. Read the vessel’s owner’s manual for
further information. Auto (Automatic) Starting.
2 Open the fuel shut-off valve. Move the generator set master switch to the AUTO
Open the manual fuel shut-off valve, if equipped. position to allow startup by the remote start/stop switch
3 Start the generator set or remote digital gauge. A remote start/stop switch or
Place the generator set master switch to the RUN digital gauge can be connected to the customer
position. interface connection (P21 connector, leads 3 and 4).
See the wiring diagram in Section 5.
Note: Opening seacock. Before starting the generator
set, open the seacock to allow cooling water Note: The ADC 2100 allows three crank cycle attempts
passage. Failure to do so could damage the before the overcrank shutdown occurs.
seawater pump impeller and cause serious
engine overheating damage.
2. With the generator set master switch in the AUTO The controller displays a fault code but the generator set
position, the generator set stops when the remote does not shut down under the conditions shown in
start/stop switch contacts close momentarily. Figure 2-6.
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.
2. Disconnect the generator set from the load using 2.7.1 Line Circuit Breaker
the line circuit breaker. See the safety precautions
at the beginning of this manual before proceeding. A line circuit breaker interrupts the generator output in
the event of a fault in the wiring between the generator
3. Identify and correct the cause of the fault
and the load. The line circuit breaker location is shown
shutdown. See the safety precautions at the
in Section 1. If the circuit breaker trips, reduce the load
beginning of this manual before proceeding. Refer
and switch the breaker back to the ON position.
to Section 4, Troubleshooting.
4. Start the generator set by moving the generator set 2.7.2 Fuses
master switch to RUN. Test operate the generator
set to verify that the cause of the shutdown has The junction box contains seven fuses. See Section 1
been corrected. and Figure 2-9 for the fuse location. Always identify and
correct the cause of a blown fuse before restarting the
5. Shut the generator off by moving the generator set
generator set. Refer to section 4 for conditions that may
master switch to the OFF/RESET position.
indicate a blown fuse. Obtain service from an
6. Reconnect the generator set to the load using the authorized distributor/dealer.
line circuit breaker.
WARNING
Rotating parts.
Can cause severe injury or death.
Accidental starting. Operate the generator set only when
Can cause severe injury or death. all guards, screens, and covers are in
place.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first Servicing the generator set when it is operating. Exposed
when disconnecting the battery. moving parts can cause severe injury or death. Keep
Reconnect the negative (--) lead last hands, feet, hair, clothing, and test leads away from the belts
when reconnecting the battery. and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the Sound shield removal. Exposed moving parts can cause
generator set or connected equipment, disable the generator severe injury or death. The generator set must be operating
set as follows: (1) Move the generator set master switch to the in order to perform some scheduled maintenance procedures.
OFF position. (2) Disconnect the power to the battery charger. Be especially careful if the sound shield has been removed,
(3) Remove the battery cables, negative (--) lead first. leaving the belts and pulleys exposed.
Reconnect the negative (--) lead last when reconnecting the (Sound-shield-equipped models only)
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote NOTICE
start/stop switch, or engine start command from a remote Saltwater damage. Saltwater quickly deteriorates metals.
computer. Wipe up saltwater on and around the generator set and
remove salt deposits from metal surfaces.
WARNING NOTICE
Hardware damage. The engine and generator set may use
both American Standard and metric hardware. Use the correct
size tools to prevent rounding of the bolt heads and nuts.
Hot engine and exhaust system. Annual Inspection. Kohler Co. recommends that all
Can cause severe injury or death. boat owners have their vessels inspected at the start of
Do not work on the generator set until
each boating season by the US Coast Guard, the local
it cools. Coast Guard Auxiliary, or local state agency.
Do not mix different oil brands. Incompatibility could Note: Do not operate the set if the oil level is below the
cause a breakdown of lubricating ingredients and Add mark on the dipstick or above the Full mark
reduce engine protection. on the dipstick.
10. Stop the generator set. Check the oil level. Add oil,
3.4 Fuel System
as necessary, to bring the level up to the Full mark.
3.4.1 Fuel Specifications
Note: Too high an oil level causes high oil
consumption and engine carbonizing. Too Use a clean, good-quality unleaded fuel with an octane
low a level damages the engine. number of 87. Use fresh gasoline to ensure it is blended
for the season and to reduce the possibility of the
Note: Do not pollute the environment. Dispose of formation of gum deposits that could clog the fuel
used engine oil and other contaminants in a system. Do not use gasoline left over from the previous
safe, approved manner. season.
7 8
9
1 10
22
6
4 11
Waterline 20
21
16 12
19
15
17
13
18
14 TP-5586-3
2. Use a wire brush to remove the loose corrosion on 5. Start the generator set and check for leaks at the
the anticorrosion zinc anode. Replace the anode anticorrosion zinc anode location. The pump is
according to Figure 3-12 and Figure 3-13. operating if cooling water flows from the exhaust
outlet. If water is not discharging at the exhaust
outlet, see Prestart Checklist—Seawater Pump
Anticorrosion Zinc Anode Replacement
Priming.
Replace When
New Anode Percent of Zinc
Models Dimensions mm (in.) Remaining Is: 3.7.6 Seawater Outlet
5/7.3ECD
<50% of Check the seawater outlet at the interval specified in the
and 9 (0.34) x 43 (1.7)
length/diameter service schedule. See Figure 3-11 for location.
4/6EFCD
Remove any obstructions to keep the outlet clear.
Figure 3-12 Anticorrosion Zinc Anode (Plug)
Measurements
This section contains generator set troubleshooting, Corrective action and testing often require knowledge of
diagnostic, and repair information. electrical and electronic circuits. To avoid additional
problems caused by incorrect repairs, have an
Use the following charts as a quick troubleshooting authorized service distributor/dealer perform service.
reference. The table groups generator set faults and
suggests likely causes and remedies. The table also NOTICE
refers you to more detailed information including
Fuse replacement. Replace fuses with fuses of the same
sections of this manual, the generator set service ampere rating and type (for example: 3AB or 314, ceramic).
manual (S/M), the generator set installation manual Do not substitute clear glass-type fuses for ceramic fuses.
(I/M), and the engine service manual (Engine S/M) to Refer to the wiring diagram when the ampere rating is
correct the indicated problem. unknown or questionable.
Use the following charts to diagnose and correct Maintain a record of repairs and adjustments performed
common problems. First check for simple causes such on the equipment. If the procedures in this manual do
as a dead engine starting battery, loose connections, or not explain how to correct the problem, contact an
an open circuit breaker. The charts include a list of authorized distributor/dealer. Use the record to help
common problems, possible causes of the problem, and describe the problem and repairs or adjustments made
recommended corrective actions. to the equipment.
x:gt:001:002a:
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Probable Causes Recommended Actions Reference*
Controller
Generator set master switch in the Move the generator set master switch to the correct position Section 2
x
OFF position (RUN or AUTO).
Section 4 Troubleshooting
The auxiliary winding fuse (F1) blown Replace the blown F1 fuse. If the fuse blows again, troubleshoot Section 2, W/D
x x
the controller.[
The controller fuse (F2) blown Replace the blown F2 fuse. If the fuse blows again, troubleshoot Section 2, W/D
x x x x
TP-6390 1/06
[ Have an authorized service distributor/dealer perform this service.
Trouble Symptoms
TP-6390 1/06
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Probable Causes Recommended Actions Reference*
Electrical System (DC circuits)
Battery connections loose, corroded, Verify that the battery connections are correct, clean, and tight. Section 3
x x
or incorrect
Battery weak or dead Recharge or replace the battery. The spec sheet provides Section 3, S/S
x x
recommended battery CCA rating.
Engine harness connector(s) not Disconnect the engine harness connector(s) then reconnect it to W/D
x x
Section 4 Troubleshooting
41
42
Trouble Symptoms
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Probable Causes Recommended Actions Reference*
Fuel System
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —
Section 4 Troubleshooting
x x Fuel pressure insufficient Check the fuel supply and valves.[ S/S, Gen. O/M
x x x x Fuel line restriction Check the fuel lines and fuel tank. Eng. O/M
x x x Stale or bad fuel. Incorrect type of fuel Replace fuel. Clean the carburetor. Sec. 3, Eng S/M
TP-6390 1/06
Section 5 Wiring Diagrams
WARNING WARNING
The following list contains abbreviations that may appear in this publication.
A, amp ampere CG center of gravity fglass. fiberglass
ABDC after bottom dead center CID cubic inch displacement FHM flat head machine (screw)
AC alternating current CL centerline fl. oz. fluid ounce
A/D analog to digital cm centimeter flex. flexible
ADC analog to digital converter CMOS complementary metal oxide freq. frequency
adj. adjust, adjustment substrate (semiconductor) FS full scale
ADV advertising dimensional cogen. cogeneration ft. foot, feet
drawing Com communications (port) ft. lbs. foot pounds (torque)
AHWT anticipatory high water conn. connection ft./min. feet per minute
temperature cont. continued g gram
AISI American Iron and Steel CPVC chlorinated polyvinyl chloride ga. gauge (meters, wire size)
Institute crit. critical
ALOP anticipatory low oil pressure gal. gallon
CRT cathode ray tube gen. generator
alt. alternator CSA Canadian Standards
Al aluminum genset generator set
Association GFI ground fault interrupter
ANSI American National Standards CT current transformer
Institute Cu copper GND, ground
(formerly American Standards gov. governor
Association, ASA) cu. in. cubic inch
cw. clockwise gph gallons per hour
AO anticipatory only
CWC city water-cooled gpm gallons per minute
API American Petroleum Institute
cyl. cylinder gr. grade, gross
approx. approximate, approximately
D/A digital to analog GRD equipment ground
AR as required, as requested
DAC digital to analog converter gr. wt. gross weight
AS as supplied, as stated, as
suggested dB decibel HxWxD height by width by depth
ASE American Society of Engineers dBA decibel (A weighted) HC hex cap
ASME American Society of DC direct current HCHT high cylinder head temperature
Mechanical Engineers DCR direct current resistance HD heavy duty
assy. assembly deg., ° degree HET high exhaust temperature
ASTM American Society for Testing dept. department hex hexagon
Materials dia. diameter Hg mercury (element)
ATDC after top dead center DI/EO dual inlet/end outlet HH hex head
ATS automatic transfer switch DIN Deutsches Institut fur Normung HHC hex head cap
auto. automatic e. V. HP horsepower
aux. auxiliary (also Deutsche Industrie hr. hour
A/V audiovisual Normenausschuss) HS heat shrink
avg. average DIP dual inline package hsg. housing
AVR automatic voltage regulator DPDT double-pole, double-throw HVAC heating, ventilation, and air
AWG American Wire Gauge DPST double-pole, single-throw conditioning
AWM appliance wiring material DS disconnect switch HWT high water temperature
bat. battery DVR digital voltage regulator Hz hertz (cycles per second)
BBDC before bottom dead center E, emer. emergency (power source) IC integrated circuit
BC battery charger, battery EDI electronic data interchange ID inside diameter, identification
charging EFR emergency frequency relay IEC International Electrotechnical
BCA battery charging alternator e.g. for example (exempli gratia) Commission
BCI Battery Council International EG electronic governor IEEE Institute of Electrical and
BDC before dead center EGSA Electrical Generating Systems Electronics Engineers
BHP brake horsepower Association IMS improved motor starting
blk. black (paint color), block EIA Electronic Industries in. inch
(engine) Association in. H2O inches of water
blk. htr. block heater EI/EO end inlet/end outlet in. Hg inches of mercury
BMEP brake mean effective pressure EMI electromagnetic interference in. lbs. inch pounds
bps bits per second emiss. emission Inc. incorporated
br. brass eng. engine ind. industrial
BTDC before top dead center EPA Environmental Protection int. internal
Agency int./ext. internal/external
Btu British thermal unit
EPS emergency power system I/O input/output
Btu/min. British thermal units per minute
ER emergency relay IP iron pipe
C Celsius, centigrade
ES engineering special, ISO International Organization for
cal. calorie engineered special
CARB California Air Resources Board Standardization
ESD electrostatic discharge J joule
CB circuit breaker est. estimated
cc cubic centimeter JIS Japanese Industry Standard
E-Stop emergency stop k kilo (1000)
CCA cold cranking amps etc. et cetera (and so forth)
ccw. counterclockwise K kelvin
exh. exhaust kA kiloampere
CEC Canadian Electrical Code
cfh cubic feet per hour
ext. external KB kilobyte (210 bytes)
F Fahrenheit, female
cfm cubic feet per minute
Use the log below to keep a cumulative record of required services were performed. Enter hours to the
operating hours on your generator set and the dates nearest quarter hour.