Kohler 5EKD-Low CO, 4EFKD-Low CO, 7.5EKD-Low CO, 6EFKD-Low CO, 10EKD-Low CO Operation Manual

Operation

Marine Generator Sets

Models:

5EKD/4EFKD--Low CO

7.5EKD/6EFKD--Low CO
10EKD/8EFKD--Low CO

Controller:

Advanced Digital Control II

TP-6591 10/13d

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 I dentification 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

Table of Contents

Product Identification Information 2.............................................................

Safety Precautions and Instructions 5.........................................................

Introduction 9...............................................................................

Service Assistance 9.........................................................................

Maintenance and Service Parts/Related Literature 10............................................

Section 1 Service Views 11....................................................................

Section 2 Operation 13........................................................................

2.1 Prestart Checklist 13......................................................

2.2 Marine Inspection 13......................................................

2.3 Angular Operation 14.....................................................

2.4 Operation in European Union Member Countries 14...........................

2.5 Load Profile 14...........................................................

2.6 Advanced Digital Control II Operation 14....................................

2.6.1 Controls and Indicators 14.........................................

2.6.2 Starting the Generator Set 16......................................

2.6.3 Stopping the Generator Set 17.....................................

2.6.4 Fault Shutdowns and Warnings 17..................................

2.6.5 Resetting the Controller after a Fault Shutdown 22....................

2.6.6 USB Connection 22...............................................

2.7 Circuit Protection 22......................................................

2.7.1 Line Circuit Breaker 22............................................

2.7.2 Fuses 22........................................................

Section 3 Scheduled Maintenance 23..........................................................

3.1 General Maintenance 23..................................................

3.2 Service Schedule 24......................................................

3.3 Lubrication System 25....................................................

3.3.1 Oil Specifications 25..............................................

3.3.2 Oil Check 25.....................................................

3.3.3 Oil Additions 25..................................................

3.3.4 Oil Change 26...................................................

3.3.5 Oil Filter Change 26..............................................

3.4 Fuel System 26..........................................................

3.4.1 Fuel Specifications 26.............................................

3.4.2 Fuel Filter 27.....................................................

3.4.3 Fuel System Bleed 27.............................................

3.5 Backfire Flame Arrestor 28................................................

3.6 Exhaust System 28.......................................................

3.7 Cooling System 28.......................................................

3.7.1 Closed Heat Exchanger 28........................................

3.7.2 Pressure Cap 29.................................................

3.7.3 Seawater Pump 30...............................................

3.7.4 Seawater Flow Switch 30..........................................

3.7.5 Belt Tension 31...................................................

3.7.6 Siphon Break 32.................................................

3.7.7 Anticorrosion Zinc Anode 34.......................................

3.7.8 Seawater Outlet 34...............................................

3.8 Ignition System 34........................................................

3.9 Battery 36

3.10 Generator Storage Procedure 36...........................................

Section 4 Troubleshooting 37.................................................................

Section 5 Wiring Diagrams 41.................................................................

Appendix A Abbreviations 45................................................................

Appendix B Operating Hour Service Log 47...................................................

...............................................................

TP-6591 10/13 Table of Contents 3

Notes

TP-6591 10/134

Safety Precautions and Instructions

IMPORTANTSAFETY 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 several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a
hazard that will cause severe

personal injury,death,orsubstantial
property damage.

WARNING

Warning indicates the presence of a
hazard that can cause severe

personal injury, 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.

Accidental Starting

WARNING

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
equipment connected to the set,
disable the generator set as follows:
(1) Place the generator set start/stop
switch in the STOP position.
(2) Disconnect the power to the battery
charger, if equipped. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.

Engine Backfire/Flash
Fire

WARNING

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 cause 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.

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 or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.

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-6591 10/13 5Safety Precautions and Instructions

Exhaust System

WARNING

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon

monoxide is a poisonous gas presentin
exhaust gases. Carbonmonoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Carbon
monoxide poisoning symptoms include
but are not limited to the following:

D Light-headedness, dizziness
D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate
or speak clearly, blurred vision

D 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
not improve 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. Never
operate the generator set without a
functioning carbon monoxide detector.
Inspect the detector before each
generator set use.

Operating the generatorset. Carbon
monoxide can cause severe nausea,
fainting, or death. Be especially

careful if operating the generator set
when moored or anchored under calm
conditions because gases may
accumulate. If 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

WARNING

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.

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. Do not operate the
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 container to catch fuel
when drainingthe fuel system. Wipe up
spilled fuel after draining the system.

TP-6591 10/136 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.

Hazardous Noise

CAUTION

Hazardous noise.
Can cause hearing loss.

Never operate the generator set
without a muffler or with a faulty
exhaust system.

Hazardous Voltage/
Moving Parts

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

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.

Moving parts.

Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution

is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turnoff the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.

Disconnecting the electrical load.
Hazardous voltage can cause
severe injury or death. Disconnect

the generator set from the load by
turning off 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.

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
turned off. 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.

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 and follow the instructions of the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, 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
to relieve pressure.

Notice

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-6591 10/13 7Safety Precautions and Instructions

Notes

TP-6591 10/138 Safety Precautions and Instructions

Introduction

This manual provides operation instructions for
5/7.5/10EKD and 4/6/8EFKD model generator sets.

Refer to the engine operation manual for generator set
engine 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
beginning of this manual. Keep this manual with the
equipment for future reference.

For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric.

D Visit the Kohler Power Systems website at

KOHLERPower.com.

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents
included with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside the US and Canada, call the nearest regional

office.

Headquarters Europe, Middle East, Africa
(EMEA)

Kohler Power Systems Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]

Asia Pacific

Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]

The equipment service requirementsare very important
to safe and efficient operation. Inspect the parts often
and perform required service at the 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.

Service Assistance

China

North China Regional Office, Beijing
Phone: [phone]

(86) 10 6518 7951
(86) 10 6518 7952

Fax: [phone]

East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

Latin America

Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

TP-6591 10/13 9Introduction

Maintenance and Service Parts/Related Literature

Maintenance and Service Parts

Figure 1 identifies maintenance and service parts for
your generator set. Obtain a complete list of
maintenance and service parts from your authorized
generator distributor/dealer.

Part Description Part Number

Backfire Flame Arrestor GM24212

Fuel filter 267987

Fuse, (F1) 10 amp,

Customer Connection

Fuse, (F2) 25 amp,

Voltage Regulator

Fuse, (F3) 20 amp,

Injectors, CO Sensor, Fuel Pumps, Oxygen
Sensor, and Coils

Fuse, (F4) 10 amp,

Controller

Fuse, (F5) 10 amp,

Auxiliary Winding

Oil Filter 52 050 02-S

Seawater Pump Impeller Kit 359978

Seawater Pump Belt GM53040

Spark Plug 25 132 16-S

Spray Paint (Matterhorn White) GM48126

Zinc Anode 260085

GM42337

GM42339

GM47427

GM42337

358337

List of Related Literature

Figure 2 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.

Literature Type Part Number

Installation Manual TP-6592

Operation Manual (Generator) TP-6591

Parts Catalog* TP-6594

Service Manual (Generator) TP-6593

Service Manual (Engine) 66 690 01

* One manual combines Generator and Engine information.

Figure 2 Generator Set Literature

Figure 1 Maintenance and Service Parts

TP-6591 10/1310 Maintenance and Service Parts/Related Literature

32

1 3

2

Service Side

5

4 6

Section 1 Service Views

10

9

8

7

11

30

29

28

27

31

26

25

24

23

22 21 17

20

19

18

Nonservice Side

12

13

14

15

16

33

ADV7439A-

GM58158

34

1. Nameplate (top)

2. Advanced Digital Control II

3. Generator set start/stop button

4. AC circuit breaker

5. Optional lifting eye tool

6. Pressure cap (coolant fill location after draining coolant)

7. Overflow tube

8. Heat exchanger

9. Anticorrosion zinc anode (seawater drain)

10. Coolant drain

11. Spark plug (also one located on the nonservice side)

12. Air intake silencer/backfire flame arrestor

13. Coolant overflow bottle (daily coolant check/fill location)

14. Oil fill/check

15. V-belt

16. Seawater pump

17. Seawater inlet

18. Oil drain valve

19. Lube oil filter

20. Fuel filter

21. Fuel pump/cooler

22. Fuel pump

23. Fuel inlet

24. Filter screen

25. Fuse block (F1, F2, F3, and F4) (see Section 2.7.2)

26. Fuse F5 (see Section 2.7.2)

27. Cooling air inlet

28. USB connection

29. Catalyst assembly, water outlet/exhaust outlet (nonservice
side)

30. AC load lead connector (nonservice side)

31. CO sensor module (inside junction box)

32. Customer interface connection (nonservice side)

33. Seawater flow switch (nonservice side)

34. Seawater pressure switch (nonservice side)

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.

Figure 1-1 Service Views

TP-6591 10/13 11Section 1 Service Views

Notes

TP-6591 10/1312 Section 1 Service Views

Section 2 Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation perform the
following 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.

D Check the hoses for softness, cracks, leaks, or dents.

Replace the hoses as needed.

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps.

Tightenor replace the hose clamps and/or hangers as
needed.

D Check that the exhaust outlet is unobstructed.

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 the 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 authorized Kohlerr distributor/dealer.
Repair any problems identified before operating the
generator set.

WARNING

D Visually inspect 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.

D Ensure that the carbon monoxide detector(s) is (1) in

the craft, (2) functional, and (3) energized whenever
the generator set operates.

TP-6591 10/13 13Section 2 Operation

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

2.3 Angular Operation

See Figure 2-1 for angular operation limits for units
covered in this manual.

Angle of Operation

20_

Maximum value for all directions

at full oil level

2.6 Advanced Digital Control II

Operation

Figure 2-3 illustrates the user interface on the Advanced
Digital Control.

Note: Have setup and adjustments of the Advanced

Digital Control performed only by an authorized
Kohler distributor/dealer. The setup and
adjustments are password protected.

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

Load Requirement

30% load 70% 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 inspect the
generator set for fluid or exhaust leaks.

Ideal

Load Requirement

1

2

5

4

3

GM58225A

1. LCD display

2. Control knob

3. Engine start/stop button

4. Power button

5. LED status indicator

Figure 2-3 Advanced Digital Control II

2.6.1 Controls and Indicators

LCD Display. The LCD display is backlit any time the

generator set is running or for at least 30 seconds after a
user manipulates a button or the control knob. The LCD
displays generator status, run time hours, fault
shutdowns, and fault warnings.

Control Knob. Rotate the control knob clockwise to
increase a value or move down the menu structure. See
Figure 2-4 for menu items.

TP-6591 10/1314 Section 2 Operation

Rotating the

control knob

to position:

1 Hourmeter/Status

2 Voltage and

3 Line 1 to neutral voltage and

4

5 Battery voltage

6 Next maintenance interval

7 Software version

8 ECM version

9 Contrast (lighting)

10 Event log

11 Fuel prime

Frequency

Line 2 to neutral voltage

Engine temperature (F)
Oil pressure (psi)

RPM

Menu Item

Figure 2-4 Menu Items

Engine Start/Stop Button. The Engine Start/Stop

button toggles the running state of the engine. When the
controller is off, it has no effect. When the controller is in
a low-power mode, the Engine Start/Stop button starts
the engine.

Power Button. The Power button toggles the controller
between on and off. When the controller if off, it does not
respond to any input except the Power button.

LED Status Indicator. The LED provides a summary of
the generator state:

D Green indicates no known problem

D Red indicates one or more faults (i.e. the generator

cannot operate)

D Amber indicates no faults but one or more warnings

(i.e. the generator can operate)

D Slow blink indicates that the generator is not running

D Steady indicates that the generator is running

D Off indicates that the unit is off

Figure 2-5 shows the possible LED displays:

LED

Status Indicator

Off Off Stopped Any

Slow blink green On Stopped No fault,

Steady green On Running No fault,

Slow blink red On Stopped Fault

Steady amber On Running Warning

Slow blink amber On Stopped Warning

Power

Button

Engine Condition

No warning

No warning

Figure 2-5 Possible LED Status Indicator Displays

The controller is factory-set and should not require
configuration or adjustment under normal operating
conditions. If the generator set is reconnected to a
differentvoltage and/or frequency,refer to an authorized
Kohler distributor/dealer for system configuration and
adjustment instructions.

TP-6591 10/13 15Section 2 Operation

2.6.2 Starting the Generator Set

The following procedures describe the actions required
to start the generator set.

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.

Step Action

1 Operate the blower.

Operate the blower 4 minutes and check the engine
compartment for gasoline vapors.
NOTE: Many boat manufacturers recommend
continuous blower operation while the generator set
is operating. Read the vessel’s owner’s manual for
further information.

2 Open the fuel shut-off valve.

Open the manual fuel shut-off valve, if equipped.

3 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.

Note: Close seacock if water enters the exhaust

system. If water enters the exhaust system,

close the seacock and drain the water from the
exhaust system at the 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. If excessive
cranking is a chronic problem, have the unit,
including the exhaust system, serviced by an
authorized Kohlerr distributor/dealer.

The controller attempts to start the generator set three
times. If the generator set does not start in three
attempts, the system shuts down on an overcrank fault.

Local Starting.

1. Press the Power Button to turn the controller on.
The LED Status Indicator appears green and
begins flashing.

2. Press the Start/Stop Button to start the generator
set. The Advanced Digital Control II attempts to
start the generator set in three crank cycles (crank
cycle time is pre-programmed).

Remote Starting.

A remote start/stop switch (connected to P21 connector,
leads 3 and 4) or a remote digital gauge (connected to
P21 connector, pins 1, 2, and 5 via CAN) can be
connected to the customer interface connection. See
the wiring diagram in Section 5.

Note: A remote start/stop switch (connected to P21

connector, leads 3 and 4) is not available when
configured for SmartCraftt 1.

Press the Power Button to turn the controller on.
Consult the instruction sheet supplied with the remote
start/stop switch or remote digital gauge for starting
instructions.

Note: The ADC II allows three 7-second crank cycle

attempts before the overcrank shutdown occurs.

Remote communications require an active
(powered-up) controller. Be advised that when the
generator is not running, the Advanced Digital Control II
enters a low-power state with an average current drain
of approximately 100 uA.

The ADC II will power down (0 mA draw) after 48 hours
of inactivity. Press the start switch/button (once for the
remote start/stop switch or twice for the remote digital
gauge) to “wake up” the ADC II and start the generator
set.

TP-6591 10/1316 Section 2 Operation

2.6.3 Stopping the Generator Set

2.6.4 Fault Shutdowns and Warnings

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. Press the Start/Stop button to stop the generator
set. The engine stops.

3. Press the Power Button to turn the controller off.

Remote Stopping.

1. Run the generator set at no load for at least
2 minutes to ensure adequate engine cooldown.

2. The generator set stops when the remote start/stop
switch or remote digital gauge contacts close
momentarily.

Consult the instruction sheet supplied with the remote
start/stop switch or remote digital gauge for stopping
instructions.

The generator set shuts down automatically under the
fault conditions listed in Figure 2-6 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 2.6.5 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 warning text but the generator
set does not shut down under the conditions shown in
Figure 2-7.

Note: ADC II powers down after 48 hours of inactivity. If

the generator has been started, the controller will
power down 48 hours after the generator stops.

TP-6591 10/13 17Section 2 Operation

Fault Shutdowns

Code Description

Over crank
(fault)

Locked rotor
(fault)

Low oil pres
(fault)

Over speed
(fault)

Coolant loss
(fault)

Hi eng temp
(fault)

Aux input
(fault)

Overcrank
shutdown occurs
after 3
unsuccessful
starting attempts.

Overcrank (locked
rotor) shutdown

Low oil pressure
shutdown occurs if
a low oil pressure
condition exists.
Note: The low oil
pressure shutdown
does not protect
against low oil
level. Check the
oil level at the
engine.

Overspeed
shutdown occurs
if the engine
speed exceeds
the default setting.

Loss of coolant
shutdown occurs
after a loss of
coolant condition
is detected.

High engine
temperature
shutdown occurs if
the engine coolant
temperature
exceeds the
default setting.
Note: The high
engine temp.
shutdown
functions only
when the coolant
level is in the
operating range.

Auxiliary fault
input shutdown.
Note: Input from a
customer-supplied
switch that closes
when the fault is
active.

Sensing

Mechanism

Fail to start Excessive

ECM data Excessive

ECM data Below setting 30 sec 5sec 7psi Check for leaks in the lubrication

ECM data Above setting 0sec 1sec 70 Hz Contact an authorized

Digital input Grounded 30 sec 5sec N/A Check for a clogged seawater intake

ECM data Above setting 30 sec 5sec 230_ F Check for a low engine coolant level.

Digital input Grounded 3sec 0.3 sec N/A Check the cause of the auxiliary fault.

Active

State

crank cycles

locked rotor
cycles

Inhibit

Time

0sec 7 sec on/

0sec 3sec 3sec Contact an authorized

Delay

Time

15 sec off

Default
Setting

3 crank
cycles

Check

Check the fuel supply and battery.
Also check for loose connections.
Contact an authorized

distributor/dealer for service if
problem continues.

distributor/dealer for service if
problem continues.

system.
Check the oil level and add oil if the

level is low.

distributor/dealer for service if
problem continues.

or sea strainer.
Check for a damaged seawater pump

impeller.
Check for a clogged or dirty s eawater

flow switch.
Check for damaged water lines.
Check for proper installation.
Check for inlet restriction exceeding

the seawater pump’s maximum inlet
restriction.

Check seawater pump impeller,
strainers, and seacock.

TP-6591 10/1318 Section 2 Operation

Fault Shutdowns

Code Description

Hi CO:
sensor
(fault)

Hi CO:
engine
(fault)

No CO
sensor
(fault)

Over voltage
(fault)

Under volt
(fault)

Over freq
(fault)

Under freq
(fault)

HVR Comm
Err *
(fault)

* HVR = Hybrid Voltage Regulator

Carbon monoxide
presence from
sensor.
Shutdown occurs
because of the
presence of CO.

Carbon monoxide
fault from ECM.
Shutdown occurs
because of the
presence of CO or
deteriorating
emission-control
components (such
as the catalyst).

Carbon monoxide
sensor missing
shutdown occurs
if communication
is lost between
the CO sensor
and the ADC.

Overvoltage
shutdown occurs if
the voltage
exceeds the
default setting of
the voltage
regulator setpoint.

Undervoltage
shutdown occurs
if the voltage falls
below the default
setting of the
voltage regulator
setpoint.

Overfrequency
shutdown occurs
when the
governed
frequency exceeds
the default setting
of the system’s
frequency setpoint.

Underfrequency
shutdown occurs
when the governed
frequency falls
below the default
setting of the
system’s frequency
setpoint .

Remote CAN
communication
loss shutdown

Sensing

Mechanism

Pulsed signal 20 Hz 0sec 10 sec N/A Immediate service required.

ECM data Control limit 0sec 15 sec N/A Immediate service required.

Pulsed signal No signal 0sec 10 sec N/A Check the connections to the CO

Alternator
output

Alternator
output

Alternator
output

Alternator
output

CAN Loss of

Active

State

Above setting 10 sec 2sec 120% of

Below setting 10 sec 10 sec 80% of

Above setting 10 sec 5sec 110% of

Below setting 10 sec 5sec 90% of

communication

Inhibit

Time

0sec 10 sec N/A Check the remote digital gauge and

Delay

Time

Default
Setting

nominal

nominal

nominal

nominal

Check

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).

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).

sensor. If connections are okay,
replace the CO sensor.

Contact an authorized
distributor/dealer for service.

Contact an authorized
distributor/dealer for service if
problem continues.

Reduce the load and restart the
generator set.

Check the F5 fuse.
Contact an authorized

distributor/dealer for service if
problem continues.

Contact an authorized
distributor/dealer for service if
problem continues.

Reduce the load and restart the
generator set.

Contact an authorized
distributor/dealer for service if
problem continues.

connection.

TP-6591 10/13 19Section 2 Operation

Fault Shutdowns

Sensing

Code Description

Check
engine
(fault) [

ECM voltage
(fault) ]

[ Note: Available on software version 1.3.0 or higher. On software version 1.2.0 and below, this condition was displayed as Out of fuel.

] Note: Available on software version 1.3.0 or higher. On software version 1.2.0 and below, this condition was displayed as Low battery fault.

A check engine
fault occurs when
the ECM sends a
signal for the
generator set
controller to shut
down because the
engine has stalled

No or low voltage
to the ECM

Mechanism

ECM N/A N/A N/A N/A Check for high fuel restrictions.

ECM N/A N/A N/A N/A Check if the 10 amp, F1 fuse is blown

Active

State

Inhibit

Time

Delay

Time

Default
Setting

Check

Check for air leaks in the supply side
of the fuel system.

Check for an inoperative low or high
pressure fuel pump.

check for fuel vaporization in higher
than maximum temperature operation
specifications.

Contact an authorized
distributor/dealer for service if
problem continues.

or missing.
Check if lead 70 circuit is open

between plug, P1--4 and the battery
during cranking attempts.

Check for low voltage on lead 70.
Contact an authorized

distributor/dealer for service if
problem continues.

Figure 2-6 Advanced Digital Control II Fault Shutdown

Warnings

Code Description

High battery High battery

Low battery Low battery

Weak
battery

Hi CO:
engine

voltage warning.
Fault condition
clears when the
battery voltage
returns to a
voltage within the
limits.

voltage warning.
Fault condition
clears when the
battery voltage
returns to a
voltage within the
limits.

Low cranking
battery

High CO from
ECM. 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.

Sensing

Mechanism

Analog input Above setting 0sec 10 sec 16 volts

Analog input Below setting 0sec 10 sec 12.6 volts

Analog input Below setting 0sec 2sec

ECM data Control limit 0sec 5sec N/A Ensure windows are open for proper

Active

State

Inhibit

Time

Delay

Time

during
cranking

Default
Setting

for 12 volt
system

for 12 volt
system

9VDC Check the battery rating and

Check

Check the battery rating and
condition.

Check the battery rating and
condition.

Charge or replace the battery.

condition.

Charge or replace the battery.

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.

TP-6591 10/1320 Section 2 Operation

Warnings

Sensing

Code Description

Hi CO:
sensor

CO sensr err Faulty CO sensor Pulsed signal 5Hz 0sec 10 sec N/A Replace the CO sensor. Contact an

Low oil pres Low oil pressure Digital Grounded 30 sec 0sec 5psi Check for leaks in the lubrication

Hi eng temp High engine

Maint req Maintenance

High CO from
sensor. Fault
code is displayed
ifthepresenceof
CO is detected.
Warning occurs if
the sensor detects
acceptable but
increasing CO
levels.

temperature

required

Mechanism

Pulsed signal 10 Hz 0sec 10 sec N/A Ensure windows are open for proper

ECM data Above setting 30 sec 0sec 210_ F Check for a low engine coolant level.

Clock N/A 0sec 0sec N/A

Active

State

Inhibit

Time

Delay

Time

Default
Setting

Check

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.

authorized distributor/dealer for service.

system.
Check the oil level and add oil if the

level is low.

Check seawater system for reduced
flow.

NOTE: Allow the generator set to
cool down before checking.

Figure 2-7 Advanced Digital Control II Warnings

In addition to the fault shutdowns and warnings included
in Figure 2-6 and Figure 2-7, other fault
shutdowns/warnings may occur (see Figure 2-8).
Contact an authorized Kohler distributor/dealer for
additional diagnostics.

Text Displayed

Fault Shutdowns:

TPS input hi Throttle Position Sensor Input High

TPS range hi Throttle Position Sensor Range High

TPS range lo Throttle Position Sensor Range Low

TPS input lo Throttle Position Sensor Input Low

ETC sticking Electronic Throttle Control Sticking

ETC driver Electronic Throttle Control Driver Fault

MAP input hi Map Sensor Input High

MAP input lo Map Sensor Input Low

Trans hi XDRP Sensor Input High

Trans lo XDRP Sensor Input Low

IAT input hi Intake Air Temp. Input Sensor High

IAT input lo Intake Air Temp. Input Sensor Low

ECT input hi Coolant Sensor Input High

O2 input hi Oxygen Sensor Input High

O2 input lo Oxygen Sensor Input Low

O2 adapt O2 Adapt Limit Fault

CAN loss CAN Receive Message Fault

Overload Power Limit Shutdown

Description

Warnings:

EST 1 Low Spark 1 Timing Low

EST 1 High Spark 1 Timing High

EST 2 Low Spark 2 Timing Low

EST 2 High Spark 2 Timing High

Injector Injector Fault

Oil sens err Oil Pressure Sensor

ETC spring Electronic Throttle Control Spring Test Failed

ECT input lo Coolant Sensor Input Low

O2 sens open O2 Open Circuit

O2 limit err O2 Limit Error

Starter Starter Fault

Overload Power Limit Warning

Figure 2-8 Fault Shutdowns/Warnings

TP-6591 10/13 21Section 2 Operation

2.6.5 Resetting the Controller after a
Fault Shutdown

Note: A fault is identified by a red blinking light in the

LED status indicator.

2.6.6 USB Connection

The Advanced Digital Control II includes a USB
connection for updating software and configuring
parameters. See Figure 1-1 for location.

Always identify and correct the cause of a fault
shutdown before resetting the controller. Use the
following procedure to reset the generator set controller
after a fault shutdown.

1. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.

2. Disconnect the generator set from the load. See
the safety precautions at the 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. Reconnect the generator set to the load.

5. Reconnect the generator set engine starting
battery, negative (--) lead last.

6. Push the Advanced Digital Control knob.

7. Rotate the control knob to CONFIRM CLR FAULT:
YES

8. Push the control knob.

Note: Have software downloads, setup, and

adjustments of the Advanced Digital Control
performed only by an authorized Kohler
distributor/dealer.

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 five fuses. See Figure 1-1 for
the fuse locations. 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. Obtain service from an authorized
distributor/dealer.

9. Start the generator set by pressing the generator
set start/stop button to START. Test operate the
generator set to verify that the cause of the
shutdown has been corrected.

10. Shut the generator off by pressing the generator
set start/stop to the STOP position.

Schematic

Diagram

Fuse

Reference

Number

F1 Fuse block position 1 Customer

F2 Fuse block position 4 Voltage regulator 25

F3 Fuse block position 5 Injector,

F4 Fuse block position 8 Controller 10

F5 Fuse holder Auxiliary winding 10

Location Fuse Amps

connection

CO sensor,
fuel pumps,
oxygen sensor,
and coils

Figure 2-9 Fuses

10

20

TP-6591 10/1322 Section 2 Operation

Section 3 Scheduled Maintenance

3.1 General Maintenance

WARNING

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 equipment connected to the set, disable the
generator set as follows: (1) Place the generator set
start/stop switch in the STOP position. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch.

WARNING

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.

Saltwater damage. Saltwater quickly deteriorates metals.
Wipe up saltwater on and around the generator set and
remove salt deposits from metal surfaces.

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.

Annual Inspection. Kohler Co. recommends that all
boat owners have their vessels inspected at the start o f
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 Kohlerr 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,
repair,or operate the generator set. Have an authorized
distributor/dealer perform generator set service.

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

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.

conditions, use dry compressed air to blow dust out of the
alternator. With the generator set running, direct the
stream of air in through the cooling slots at the alternator
end.

Routine Maintenance. Refer to the following generator
set service schedule, the engine service schedule, and the
runtime hour display located on the generator set’s ADC II

WARNING

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

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Moving parts.

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.

TP-6591 10/13 23Section 3 Scheduled Maintenance

3.2 Service Schedule

Reference

Perform Service at Intervals Indicated (X)

Fuel System

Check the fuel level and fill as necessary 2.1 X
Check fuel lines and replace as necessary *[ X
Replace the fuel filter *[ X

Lubrication System

Check crankcase oil level and add as necessary 3.3.2 X

Replace the oil in crankcase * 3.3.4 X (200 hr)

Replace the lube oil filter element * 3.3.5 X (200 hr)

Cooling System

Check coolant level and fill as necessary * 3.7.1 X

Check seawater outlet and clean as necessary [ 3.7.8

Check function of siphon break, if equipped 3.7.6 X

Check and clean seawater flow switch * 3.7.4 X
Replace seawater pump impeller *[ 3.7.3 X

Adjust seawater pump tension *[ X (200 hr) X

Check heat exchanger anticorrosion zinc
condition *

Replace heat exchanger anticorrosion zinc * 3.7.7 X

Flush cooling system *[ 3.7.1

Ignition System

Check spark plugs condition and gap * 3.8 X

Replace spark plugs * 3.8 X (250 hr)

Intake/Exhaust System

Inspect exhaust system components *[

Check the exhaust gas condition 3.6

Service backfire flame arrestor * 3.5 X
Check and/or replace the catalyst assembly *[

Replace the CO sensor module *[

Check the crankcase breather pipe for obstructions *[

Inspect the complete exhaust system *** 3.6 X

Electrical System

Keep battery charged and in good condition  3.9 X

Check and tighten electrical connections * X
Clean battery cables [ X (200 hr)

Engine And Mounting

Check for water, fuel, coolant, and oil leakage *[] X

Retighten all nuts and bolts * X

Check tightness of mounting bolts/vibromounts * X (200 hr)

Remote Control System

Check remote control operation

Generator

Test run generator set X (weekly)
Blow dust out of generator *[ 3.1 X
Clean slip rings and inspect brushes *[ X (1000 hr.)

* Requires removal of sound shield, if installed. *** Should be performed by your local distributor/dealer.

[ Consult your local distributor/dealer for service.
] Read WARNING found at the beginning of manual regarding moving parts.

Section

3.7.7

3.6 X

3.6 X

Before

Starting

X (during

operation)

X (during

operation)

50 Hr or
1 Month

X (break-in

period)

 Consult battery manufacturer’s instructions.

After

Every
100 Hr or
3 Months

X

Every

300 Hr or

6 Months

(check)

X

Every

500 Hr or

Yearly

X

X (1000 hr/

2 years)

X (every
2 years)

X

TP-6591 10/1324 Section 3 Scheduled Maintenance

3.3 Lubrication System

3.3.1 Oil Specifications

Use high-quality detergent oils (including synthetic) that
meets the American Petroleum Institute (API)
classification of SJ or higher. 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) viscosity designation for given
operating temperature ranges.

Do not mix different oil brands. Incompatibility could
cause a breakdown of lubricating ingredients and
reduce engine protection.

Recommended SAEViscosity Grades

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.

1

32 40 60 80 10020

0

 C-30

 F-20

0

-- 2 0 -- 1 0

Figure 3-1 Engine Oil Selection

SAE

50

10 20 30 40

1. Full mark

2. Add mark

2

TP-5586-3

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.

TP-6591 10/13 25Section 3 Scheduled Maintenance

3.3.4 Oil Change

3.3.5 Oil Filter Change

Change the oil according to 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 (Qt.)

All models 1.9 (2.0)

Figure 3-3 Oil Capacity (with Filter)

Oil Change Procedure

1. Stop the generator set.

2. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.

3. To drain the oil, open the oil-drain valve. See
Section 1 for the valve location.

4. Drain the oil into a suitable container.

5. Allow ample time for all oil to drain.

Replace the oil filter at the interval specified in the
service 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.

Oil Filter Change Procedure

1. Loosen the oil filter by turning it counterclockwise.
Remove the oil filter 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.

6. Close the oil-drain valve.

7. Remove the oil-fill cap.

8. Replace the engine oil filter according to the
service schedule and the procedure in
Section 3.3.5.

9. 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.

10. Reconnect the generator set engine starting
battery, negative (--) lead last.

11. Start the generator set and check for oil leaks.

12. 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.

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 it is 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 owner’s manual for

oxygenated fuel recommendations.

TP-6591 10/1326 Section 3 Scheduled Maintenance

3.4.2 Fuel Filter

The 5/7.5/10EKD and 4/6/8EFKD generator sets utilize
an 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.

WARNING

7. Hold the bleed tool (part number GM46327) onto
the bleed point to remove air from the line. See
Figure 3-5.

Note: Use a container at the end of the bleed tool’s hose

to catch the fuel. Dispose of fuel in an
environmentally safe manner

1

2

PUSH TO
PRIME

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. Push the Power Button on the Advanced Digital
Control II to the ON position.

2. When the run time hours appear on the LCD
screen, rotate the control knob until “PUSH TO
PRIME” appears on the LCD screen.

3. Push the control knob.

4. Rotate the control knob to “CONFIRM PRIME:
Yes” .

5. Remove the cap from the location shown in
Figure 3-5.

3

GM58225A

1. LCD display

2. Control knob

3. Power button

Figure 3-4 Advanced Digital Control II

1

6. Push the control knob to begin the fuel priming

1. Cap location (bleed point)

procedure. A 30 second priming sequence begins
automatically. If necessary, push the control knob

Figure 3-5 Bleed Point Location

to stop the priming procedure before the
30 seconds are up.

TP-6591 10/13 27Section 3 Scheduled Maintenance

3.5 Backfire Flame Arrestor

At the 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 USCG­approved Kohler replacement parts. Follow the
procedure described below.

Backfire Flame Arrestor Cleaning Procedure

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 System Inspection Points

Check for exhaust leaks and blockages. Check the
silencer and piping condition and check for tight exhaust
system connections.

D Check the hoses for softness, cracks, leaks, or dents.

Replace the hoses as needed.

1. Loosen the hose clamp at the breather hose at the
air silencer fitting 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 d ry.

5. Reassemble using the reverse sequence.

3.6 Exhaust System

WARNING

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

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.
Never operate the generator set without a functioning carbon
monoxide detector. Inspect the detector before each
generator set use.

At the 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.

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps.

Tightenor replace the hose clamps and/or hangers as
needed.

D Check that the exhaust outlet is unobstructed.

D 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.

3.7 Cooling System

3.7.1 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 0.47 L (0.5 qt.). See
Figure 3-7 for thermostat and pressure cap ratings.

Model L (Qt.)

All models 3 (3.2)

Figure 3-6 Coolant Capacity

Model 5/7.5/10EKD

Pressure cap rating 96.5kPa(14psi)

Thermostat rating

Figure 3-7 Pressure Cap and Thermostat Rating

79_C (175_F)

Ensure that the carbon monoxide detector(s) is (1) in the
craft, (2) functional, and (3) energized whenever the
generator set operates.

TP-6591 10/1328 Section 3 Scheduled Maintenance

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.

Note: Coolant solution. A coolant solution of 50%

ethylene glycol provides freezing protection to

-- 3 7 C(--34F) and overheating protection to
129C (265F). A coolant solution with less than
50% ethylene glycol may not provide adequate
freezing and overheating protection. A coolant
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.

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 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 50% ethylene glycol and 50% clean, softened
water to inhibit rust/corrosionand 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.

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.

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 cap leaks, replace it with a
cap of the same rating. Find the pressure cap rating in
Figure 3-7.

TP-6591 10/13 29Section 3 Scheduled Maintenance

3.7.3 Seawater Pump

The belt-driven seawater pump is located on the
crankshaft 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.

1

11

2

10

9

1. Seawater pump

2. Coverplate

3. Gasket

4. Impeller

5. Bearing

6. Housing

5

6

78

7. Pulley

8. Drive shaft

9. Washer

10. Nut

11. Mechanical seal,

3

4

TP-6053

if equipped

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 silicon 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

3.7.4 Seawater Flow Switch

The seawater flow switch is located on the nonservice
side of the generator set. See Figure 3-10. Check and
clean the seawater flow switch at the interval specified in
the service schedule.

1

2

Figure 3-8 Seawater Pump, Typical

3. Remove the impeller.

4. Inspect the 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.

1

2

3

TP-6053

1. Flattened vane

2. Crack

3. Broken vane

Figure 3-9 Worn Impeller

OUT

IN

GM58158-M

3

1. Units without a siphon break: Molded hose routed to

catalyst and flow switch.

2. Units with a siphon break: Hose routed to siphon break

connector and flow switch.

3. Flow switch

Figure 3-10 Seawater Flow Switch Location

TP-6591 10/1330 Section 3 Scheduled Maintenance

Seawater Flow Switch Inspection and Cleaning
Procedure:

8. Reassemble by ensuring the spring is set within the
clips on the shuttle cap.

1. Push the generator set power button OFF.

2. Disconnect power to the battery charger, if
equipped.

3. Disconnect the generator set engine starting
battery, negative (--) lead first.

1

2

4

6

7

1. Bonnet assembly

2. Stem

3. Spring

4. Shuttle

5. Retaining clip

6. O-ring

7. Housing

3

5

Figure 3-11 Flow Switch Assembly

4. Firmly grasp the housing and turn the bonnet
assembly 45_ counterclockwise (as indicated on
the top of the bonnet) to unlock the mating tabs on
the two parts. See Figure 3-11.

5. Pull the bonnet assembly out of the housing. Be
careful not to pull on the lead wires.

6. Clean the shuttle, stem, spring, retaining clip, and
inside of the housing by lightly scraping and/or
wiping away any debris or buildup.

7. Check the O-ring, bonnet assembly, shuttle, and
spring for any damage. Replace the flow switch, if
necessary.

9. Reposition the O-ring in the counter-bored
shoulder of the housing.

10. Insert the bonnet assembly into the housing,
allowing the tabs on the bonnet to clear the mating
lugs on the housing. Ensure bonnet stem end
aligns with centering feature in the housing.

11. Lock the bonnet assembly by firmly grasping the
housing and turning the bonnet 45_ clockwise as
indicated on the top of the bonnet. This engages
the mating tabs on the two parts.

12. Reconnect the engine starting battery, negative (--)
lead last.

13. Reconnect power to the battery charger, if
equipped.

3.7.5 Belt Tension

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

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.

Check the belt tension at the interval specified in the
service schedule. If tension is not within the
specifications, adjust as necessary using the following
procedures.

Moving parts.

TP-6591 10/13 31Section 3 Scheduled Maintenance

3.7.6 Siphon Break

A siphon break prevents seawater entry into the
generator set’s engine when the engine exhaust
manifold outlet is less than 230 mm (9 in.) above the
waterline of a fully loaded, docked or stationary craft.
See Figure 3-14. The siphon break may malfunction
when the generator set operates while the craft is in
contaminated waters or saltwater. Use the following

4

procedure to inspect the siphon break at the intervals
listed in the service schedule.

Siphon Break Inspection

1. Stop the generator set.

3

21

1. Check the seawater pump belt deflection (tension) here

2. Seawater pump adjusting screw (behind pulley)

3. Seawater pump pulley

4. Pivot screw (behind pulley)

Figure 3-12 Belt Tension

Seawater Pump Belt Tensioning Procedure

1. Remove the air intake panel in order to remove the
flywheel guard.

2. Check the belt tension at the midpoint of the
longest span of the belt using a belt-tensioning tool
set to 55 lbs. See Figure 3-12. Recheck a new belt
tension after 10 minutes of operation.

Note: If the belt tension is not within specifications,

go to step 3. If the belt tension is within
specifications, go to step 7.

3. Loosen the pivot and adjusting screws.

4. While prying the seawater pump outward, tighten
the adjusting screw.

5. Tighten the pivot screw.

6. Recheck and adjust as necessary.

2. Remove the retaining cap and remove the reed
valve for inspection. See Figure 3-13.

1

2

3

1. Cap 2. Reed valve 3. Mounting base

Figure 3-13 Siphon Break

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.

6. Install the reed valve into the mounting base with
the valve downward. See Figure 3-13, item 2.

7. Install and only finger tighten the retaining cap. Do
not overtighten it.

7. Replace the flywheel guard and air intake panel

TP-6591 10/1332 Section 3 Scheduled Maintenance

2

3

1

22

Waterline

20

21

19

1. Mounting base

2. Retaining cap

3. Reed valve assembly

4. Silencer vertical lift 1.2 m (4 ft.) max.

5. Exhaust catalyst assembly distance above waterline. If less
than 23 cm (9 in.), siphon break is required.

6. Siphon break distance above waterline 30.5 cm (1 ft.) min.

7. Siphon break

8. Exhaust catalyst assembly

9. Heat exchanger (locations vary by model)

10. Coolant recovery tank

11. Locate coolant recovery tank at same height as heat exchanger

7

8

9

10

6

5

4

16

17

15

11

12

13

18

14

12. Seawater strainer

13. Seacock

14. Intake strainer

15. Engine-driven seawater pump

16. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

17. Water lock (optional)

18. Silencer distance from exhaust catalyst assembly 3 m (10 ft.)
max.

19. Silencer (customer-supplied)

20. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

21. Exhaust outlet distance above waterline 10 cm (4 in.) min.

22. Seawater outlet

TP-5586-3

Figure 3-14 Siphon Break (Plastic “U” Type) Installation

Note: Consult the installation manual for complete

explanation of dimensions and other installation
considerations.

TP-6591 10/13 33Section 3 Scheduled Maintenance

3.7.7 Anticorrosion Zinc Anode

The heat exchanger on these models contains an
anticorrosion zinc anode (plug) to prevent electrolytic
corrosion by seawater.

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.

Check and replace the anticorrosion zinc anode at
intervals recommended in the service schedule.
Depending upon operating conditions and seawater
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 3-15 and Figure 3-16.

Anticorrosion Zinc Anode Replacement

Replace When

PercentofZinc

Remaining Is:

<50% of

length/diameter

Models

5/7.5/10EKD
and
4/6/8EFKD

New Anode

Dimensions mm (in.)

9 (0.34) x 43 (1.7)

Figure 3-15 Anticorrosion Zinc Anode (Plug)

Measurements

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
Priming.

3.7.8 Seawater Outlet

Check the seawater outlet at the interval specified in the
service schedule. See Figure 3-14 for location.
Remove any obstructions to keep the outlet clear.

3.8 Ignition System

Service spark plugs at the interval specified in the
service schedule using the following procedure.

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.

1

2

1. Diameter: 9 mm (0.34 in.)

2. Length: 43 mm (1.7 in.)

Figure 3-16 Anticorrosion Zinc Anode (Plug)

TP-5586-3

3. Use compressed air to remove dirt from around
each spark plug to prevent dirt particles from falling
into the combustion chamber.

4. Remove spark plugs, one at a time, and examine.
Identify a normal spark plug in good operating
condition by observing a light tan or gray deposit on
the firing tip. See Figure 3-17 to evaluate engine
condition by color/condition of a problem spark
plug.

TP-6591 10/1334 Section 3 Scheduled Maintenance

Problem/Condition Means of Identification Possible Cause/So lution

Gap-bridged spark plug Built-up deposits and gap between

electrodes closing.

Oil-fouled spark plug Wet, black deposits on the insulator

shell, bore, and electrodes.

Carbon-fouled spark plug Black, dry, fluffy carbon deposits on

insulator tips, exposed shell surfaces
and electrodes.

Lead-fouled spark plug Dark gray, black, yellow, or tan deposits;

or a glazed coating on the insulator tip.

Preignition damaged spark plug Melted electrodes and possibly blistered

insulator. Metallic deposits on insulator
suggest internal engine damage.

Overheated spark plug White or light gray insulator with small

black or gray/brown spots with bluish
(burned) appearance on electrodes.

Worn spark plug Severely eroded or worn electrodes. Caused by normal wear and failure to

Oil or carbon fouling. Clean and regap
the spark plug.

Excessive oil entering combustion
chamber through worn rings and
pistons, excessive clearance between
valve guides and stems, or worn or
loose bearings. Replace the spark plug.

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.

Caused by highly leaded fuel. Replace
the spark plug.

Wrong type of fuel, incorrect timing or
advance, too hot a plug, burned valves,
or engine overheating. Replace the
spark plug.

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.

replace spark plug at prescribed
interval. Replace the spark plug.

Figure 3-17 Engine Evaluation Using Spark Plug Condition

5. Clean spark plugs by wiping them with a rag. File
the center electrode to keep it parallel to the side
electrode.

Note: Do not sandblast, wire brush, scrape, or

otherwise service spark plug in poor
condition. Obtain a new plug for best
results.

6. Check the spark plug gap before installing any
spark plug. See Figure 3-18. 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 0.76 mm (0.030 in.).

1

2

1-514

1. 0.76 mm (0.030 in.) gap

2. Spark plug electrodes

Figure 3-18 Spark Plug Gap Inspection

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 3-19.
Position the side electrode directly over the center
electrode.

TP-6591 10/13 35Section 3 Scheduled Maintenance

1-511

approximately 3.7-7.5 L (1-2 U.S. gallons) of
coolant/antifreeze. Kohler Co. recommends using
an environmentally friendly potable antifreeze
such as PeakR RV/marine propylene glycol/water
mix or equivalent.

5. Disconnect the lead (#87) to the low seawater
pressure (LWP) switch.

6. 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 mixture to flow into
waterways.

Figure 3-19 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

24.4--29.8 Nm (18--22 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.

12. Firmly push spark plug boot onto spark plug.

3.9 Battery

Consult the battery manufacturer’s instructions
regarding battery care and maintenance.

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.

2. Stop the generator set.

3. Change the oil and oil filter; see Section 3.3.4—Oil
Change and Section 3.3.5—Oil Filter Change.

7. Reconnect the lead (#87) to the low seawater
pressure (LWP) switch.

8. Stop the generator set.

9. Connect the hose to the seacock. Leave the
seacock closed.

10. Run fuel out of pumps.

11. Check the coolant level of the heat exchanger and
add coolant if necessary.

Note: Use antifreeze capable of withstanding the

lowest possible temperatures.

12. Drain fuel completely from the fuel tank.

13. 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.

14. Keep spark plugs in their holes or seal spark plug
holes with suitable threaded metal plugs.

15. Seal the air inlet, exhaust pipe, and fuel tank cap
with tape.

16. 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.

17. Select a well-ventilated (not humid or dusty)
location to store the generator.

18. Cover the entire unit with a dust cover.

Note: Run the generator set once a month

whenever possible.

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

TP-6591 10/1336 Section 3 Scheduled Maintenance

Section 4 Troubleshooting

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 set service
manual (S/M), the generator set installation manual
(I/M), 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 of the problem, and
recommended corrective actions.

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:

TP-6591 10/13 37Section 4 Troubleshooting

Section or

Reference*

Publication

Section 2

Move the generator set master switch to the correct position

(RUN or AUTO).

Section 2, W/D

Replace the blown F1 fuse. If the fuse blows again, check what

Section 2, W/D

Section 2, W/D

is connected to the generator set.[

troubleshoot the regulator.[

Replace the blown F3 fuse. If the fuse blows again, check the

Section 2, W/D

Section 2, W/D

starter solenoid for sticking. [

troubleshoot the controller.[

I/M

troubleshoot the alternator winding.[

Check and adjust the controller.[

Gen. S/M

Check and remote switch position.

Troubleshoot the controller.[

Sec. 3, Eng. O/M

system (add coolant). Check seawater pump and circuit.

Trouble Symptoms

Probable Causes Recommended Actions

Generator set master switch in the
abnormal noise
Excessive or

consumption
High fuel

pressure
Low oil

Overheats

Lacks power

suddenly
Stops

output voltage
No or low

Starts hard

does not start
Cranks but

crank
Does not

x

Controller

OFF position

The customer connection fuse (F1)

blown. Note that the remote digital

gage (if equipped) will not function.

x x

The voltage regulator fuse (F2) blown Replace the blown F2 fuse. If the fuse blows again,

x x

The coil, injector, fuel pumps, oxygen

sensor, and CO sensor fuse (F3)

x x

blown

The controller fuse (F4) blown Replace the blown F4 fuse. If the fuse blows again,

The auxiliary winding fuse (F5) blown Replace the blown F5 fuse. If the fuse blows again,

x x

x x x x

x Start/stop switch inoperative Replace the controller. —

Remote stop command received from

x Incorrect controller settings

a remote switch

x

x Controller fault

x x x x x Controller circuit board(s) inoperative Replace the controller circuit board. Gen. S/M

x x Air openings clogged Clean the air openings. —

Cooling System

High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling

x x Impeller damaged Replace the impeller, check upstream system. Section 3

x x Seawater strainer clogged or restricted Clean the strainer. Section 3

x Coolant level low Restore the coolant to normal operating level. Section 3

x Thermostat inoperative Replace the thermostat. Eng. S/M

x x

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this m anual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

38 Section 4 Troubleshooting

TP-6591 10/13

Section or

Section or

Reference*

Reference*

Publication

Publication

Recommended ActionsProbable Causes

Recommended ActionsProbable Causes

Section 3, S/S

W/D

Verify that the battery connections are correct, clean, and tight. Section 3

recommended battery CCA rating.

Disconnect the engine harness connector(s) then reconnect it to

the controller.

Replace the inoperative switch. Gen. S/M or W/D

Replace the inoperative switch. Gen. S/M or W/D

Eng. S/M

I/M

Section 3, I/M

Section 3, I/M

Clean or replace the filter element. Section 2

Check the compression.[

manual for wattage specifications.

system components.[

Eng. O/M

components.[

wires, etc.).

Trouble Symptoms

Battery connections loose, corroded,
abnormal noise
Excessive or

consumption
High fuel

pressure
Low oil

Overheats

Lacks power

suddenly
Stops

output voltage
No or low

Starts hard

does not start
Cranks but

crank
Does not

x x

Electrical System (DC circuits)

or incorrect

Battery weak or dead Recharge or replace the battery. The spec sheet provides

Engine harness connector(s) not

x x

locked tight

TP-6591 10/13

x x

x Fault shutdown Reset the controller. Section 2

High exhaust temperature switch

inoperative

x

x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M

High water temperature switch

inoperative

x x

x Faulty ground connection Clean and retighten the connection. —

Air cleaner/backfire flame arrestor

x x x x

Engine

clogged

x x x x x Compression weak

Engine overload Reduce the electrical load. See the generator set installation

Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust

x

x x x x x x x

Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system

x

Ignition system inoperative Check the ignition system (ignition coils, spark plugs, spark plug

x Vibration excessive Tighten all loose hardware. —

x x x

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this m anual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

39Section 4 TroubleshootingTP-6591 10/13

Section or

Section or

Reference*

Reference*

Publication

Publication

Recommended ActionsProbable Causes

Recommended ActionsProbable Causes

S/S, Gen. O/M

Eng. S/M

—

—

Gen. S/M

Gen. S/M

—

Eng. O/M

Trouble Symptoms

abnormal noise
Excessive or

consumption
High fuel

pressure
Low oil

Overheats

Lacks power

suddenly
Stops

output voltage
No or low

Check the fuel supply and valves. Check or replace fuel filter.[

Replace the fuel feed pump. Check wiring.[

side of the circuit breaker.

AC output circuit breaker open Reset the breaker and check for AC voltage at the generator

Overcrank shutdown Reset the controller. If the overcrank fault occurs again, contact

x

the distributor/dealer.

Move the transfer switch test switch to the AUTO position. ATS O/M

Check for continuity. Gen. S/M, W/D

Test and/or replace the rotor.[

Test and/or replace the stator.[

Transfer switch test switch in the OFF

position

Wiring, terminals, or pin in the exciter

field open

x

Main field (rotor) inoperative (open or

grounded)

x

Tighten loose components.[

x Vibration excessive

x Stator inoperative (open or grounded)

x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M

x x Low oil pressure shutdown Check the oil level. Check the LOP switch Eng. O/M

Replace the LOP switch. Check the engine for damage. W/D

Change the oil. Use oil with a viscosity suitable for the operating

Low oil pressure (LOP) switch

inoperative

Crankcase oil type incorrect for

x

climate.

ambient temperature

Starts hard

does not start
Cranks but

x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —

crank
Does not

Fuel System

40 Section 4 Troubleshooting

x x Fuel pressure insufficient

x x x x Fuel line restriction Check fuel filter. 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 injector with injector cleaner. Sec. 3, Eng S/M

x x x Fuel feed pump inoperative

x

Generator

x

Lube System

x x x x

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this m anual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

TP-6591 10/13

Section 5 Wiring Diagrams

WARNING

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 equipment connected to the set, disable the
generator set as follows: (1) Place the generator set
start/stop switch in the STOP position. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch.

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible

whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Never contact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.

Moving parts.

TP-6591 10/13 41Section 5 Wiring Diagrams

Figure 5-1 Point-to-Point Wiring Diagram (Sheet 1 of 2)

GM90655A--

TP-6591 10/1342 Section 5 Wiring Diagrams

GM90655B--

Figure 5-2 Point-to-Point Wiring Diagram (Sheet 2 of 2)

TP-6591 10/13 43Section 5 Wiring Diagrams

Figure 5-3 Schematic Wiring Diagram (Sheet 1 of 1)

ADV8631A--

TP-6591 10/1344 Section 5 Wiring Diagrams

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere
ABDC after bottom dead center
AC alternating current
A/D analog to digital
ADC analog to digital converter
adj. adjust, adjustment
ADV advertising dimensional

AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure
alt. alternator
Al aluminum
ANSI American National Standards

AO anticipatory only
API American Petroleum Institute
approx. approximate, approximately
AR as required, as requested
AS as supplied, as stated, as

ASE American Society of Engineers
ASME American Society of

assy. assembly
ASTM American Society for Testing

ATDC after top dead center
ATS automatic transfer switch
auto. automatic
aux. auxiliary
A /V audiovisual
avg. average
AVR automatic voltage regulator
AWG American Wire Gauge
AWM appliance wiring material
bat. battery
BBDC before bottom dead center
BC battery charger, battery

BCA battery charging alternator
BCI Battery Council International
BDC before dead center
BHP brake horsepower
blk. black (paint color), block

blk. htr. block heater
BMEP brake mean effective pressure
bps bits per second
br. brass
BTDC before top dead center
Btu British thermal unit
Btu/min. British thermal units per minute
C Celsius, centigrade
cal. calorie
CARB California Air Resources Board
CB circuit breaker
cc cubic centimeter
CCA cold cranking amps
ccw. counterclockwise
CEC Canadian Electrical Code
cfh c ubic feet per hour
cfm cubic feet per minute

drawing

temperature

Institute

Institute
(formerly American Standards
Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

CG center of gravity
CID c ubic inch displacement
CL centerline
cm centimeter
CMOS complementary metal oxide

cogen. cogeneration
Com communications (port)
conn. connection
cont. continued
CPVC chlorinated polyvinyl chloride
crit. critical
CRT cathode ray tube
CSA Canadian Standards

CT current transformer
Cu copper
cu. in. cubic inch
cw. clockwise
CWC city water-cooled
cyl. cylinder
D/A digital to analog
DAC digital to analog converter
dB decibel
dBA decibel (A weighted)
DC direct current
DCR direct current resistance
deg.,  degree
dept. department
dia. diameter
DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung

DIP dual inline package
DPDT double-pole, double-throw
DPST double-pole, single-throw
DS disconnect switch
DVR digital voltage regulator
E, emer. emergency (power source)
EDI electronic data interchange
EFR emergency frequency relay
e.g. for example (exempli gratia)
EG electronic governor
EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet
EMI electromagnetic interference
emiss. emission
eng. engine
EPA Environmental Protection

EPS emergency power system
ER emergency relay
ES engineering special,

ESD electrostatic discharge
est. estimated
E-Stop emergency stop
etc. et cetera (and so forth)
exh. exhaust
ext. external
F Fahrenheit, female

substrate (semiconductor)

Association

e. V.
(also Deutsche Industrie
Normenausschuss)

Association

Association

Agency

engineered special

fglass. fiberglass
FHM flat head machine (screw)
fl. oz. fluid ounce
flex. flexible
freq. frequency
FS full scale
ft. foot, feet
ft. lbs. foot pounds (torque)
ft./min. feet per minute
ggram
ga. gauge (meters, wire size)
gal. gallon
gen. generator
genset generator set
GFI ground fault interrupter

GND,
gov. governor
gph gallons per hour
gpm gallons per minute
gr. grade, gross
GRD equipment ground
gr. wt. gross weight
H x W x D height by width by depth
HC hex cap
HCHT high cylinder head temperature
HD heavy duty
HET high exhaust temperature
hex hexagon
Hg mercury (element)
HH hex head
HHC hex head cap
HP horsepower
hr. hour
HS heat shrink
hsg. housing
HVAC heating, ventilation, and air

HWT high water temperature
Hz hertz (cycles per second)
IC integrated circuit
ID inside diameter, identification
IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting
in. inch
in. H
in. Hg inches of mercury
in. lbs. inch pounds
Inc. incorporated
ind. industrial
int. internal
int./ext. internal/external
I/O input/output
IP iron pipe
ISO International Organization for

J joule
JIS Japanese Industry Standard
k kilo (1000)
Kkelvin
kA kiloampere
KB kilobyte (2

ground

conditioning

Commission

Electronics Engineers

O inches of water

2

Standardization

10

bytes)

TP-6591 10/13 Appendix 45

kg kilogram

2

kg/cm

kgm kilogram-meter
kg/m

kilograms per square
centimeter

3

kilograms per cubic meter
kHz kilohertz
kJ kilojoule
km kilometer
kOhm, k 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 area network
L x W x H length by width by height
lb. pound, pounds

3

lbm/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
L

wa

sound power level, A weighted
LWL low water level
LWT low water t emperature
m meter, milli (1/1000)
M mega (10

3

m

3

m

units), male

cubic meter

/min. cubic meters per minute

6

when used with SI

mA milliampere
man. manual
max. maximum
MB megabyte (2

20

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, m

MOhm, M

milliohm

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

MW megawatt
mW milliwatt
F microfarad
N, norm. normal (power source)
NA not available, not applicable
nat. gas natural gas
NBS National Bureau of Standards
NC normally closed
NEC National Electrical Code
NEMA National Electrical

NFPA National Fire Protection

Manufacturers Association

Association
Nm newton meter
NO normally open
no., nos. number, numbers
NPS National Pipe, Straight
NPSC National Pipe, Straight-coupling
NPT National Standard taper pipe

thread per general use
NPTF National Pipe, Taper-Fine
NR not required, normal relay
ns nanosecond
OC overcrank
OD outside diameter
OEM original equipment

manufacturer
OF overfrequency
opt. option, optional
OS oversize, overspeed
OSHA Occupational Safety and Health

Administration
OV overvoltage
oz. ounce
p., pp. page, pages
PC personal computer
PCB printed circuit board
pF picofarad
PF power factor

ph.,

 phase

PHC Phillips head crimptite (screw)
PHH Phillips hex head (screw)
PHM pan head machine (screw)
PLC programmable logic control
PMG permanent-magnet generator
pot potentiometer, potential
ppm parts per million
PROM programmable read-only

memory
psi pounds per square inch
pt. pint
PTC positive temperature coefficient
PTO power takeoff
PVC polyvinyl chloride
qt. quart
qty. quantity
R replacement (emergency)

power source
rad. radiator, radius
RAM random access memory
RDO relay driver output
ref. reference
rem. remote
RFI radio frequency interference
RH round head
RHM round head machine (screw)
rly. 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
scfm 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. s quare
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
Vvolt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
Wwatt
WCR withstand and closing rating
w/ with
w/o without
wt. weight
xfmr transformer

TP-6591 10/1346 Appendix

Appendix B Operating Hour Service Log

Use the log below to keep a cumulative record of
operating hours on your generator set and the dates

OPERATING HOURS SERVICE RECORD

DATE

RUN

HOURS

RUN

TOTAL

HOURS

SERVICE

DATE

required services were performed. Enter hours to the
nearest quarter hour.

SERVICE

TP-6591 10/13 Appendix 47

Notes

TP-6591 10/1348

Notes

TP-6591 10/13 49

Notes

TP-6591 10/1350

Notes

TP-6591 10/13 51

TP-6591 10/13d

E 2009, 2011, and 2013 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044
Phone [phone], Fax [phone]
For the nearest sales/service outlet in the
US and Canada, phone [phone]
KOHLERPower.com

Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]