Kohler 5ECD User manual

Marine Generator Sets
Models:
5ECD/4EFCD
7.3ECD/6EFCD
5ECD/4EFCD--Low CO
7.3ECD/6EFCD--Low CO
Controller:
Advanced Digital Control
TP-6391 9/08a
Service

TP-6391 9/082

Table of Contents
TP-6391 9/08 Table of Contents 3
Safety Precautions and Instructions 5........................................................
Introduction 9...............................................................................
Service Assistance 10........................................................................
Section 1 Specifications 11...................................................................
1.1 Introduction 11..........................................................
1.2 Generator Set Ratings 11.................................................
1.3 Controller Specifications 11...............................................
1.4 Alternator Specifications 11...............................................
1.5 Alternator Specifications, Continued 12.....................................
1.6 Torque Specifications 12..................................................
1.7 Engine Specifications 13..................................................
1.8 Service View 14.........................................................
Section 2 Scheduled Maintenance 15..........................................................
2.1 General 15..............................................................
2.2 Service Schedule 16.....................................................
Section 3 Troubleshooting 17.................................................................
3.1 Introduction 17..........................................................
3.2 Initial Checks 17.........................................................
3.3 Troubleshooting Chart 17.................................................
Section 4 Controller 23.......................................................................
4.1 Introduction 23..........................................................
4.2 Controller Display and Keypad 24..........................................
4.3 Master Switch 24........................................................
4.4 Sequence of Operation 25................................................
4.4.1 Starting the Generator Set 25......................................
4.4.2 Running Sequence 25............................................
4.4.3 Stopping the Generator Set 25.....................................
4.5 Faults 25...............................................................
4.5.1 Shutdowns 25...................................................
4.5.2 Warnings 25.....................................................
4.5.3 SECM Fault Codes and Diagnostics 29.............................
4.6 Relay Interface Board (RIB) 35............................................
4.7 CO Sensor Module 35....................................................
4.8 K5 Main Power Relay 35..................................................
4.9 Silicon Controlled Rectifier (SCR) Module 36................................
4.10 Controller Replacement 37................................................
4.11 Controller Configuration and Adjustment 38.................................
4.11.1 Voltage Adjustments 38...........................................
4.11.2 Controller Configuration 41........................................
Section 5 Component Testing and Adjustment 45..............................................
5.1 Theory of Operation 45...................................................
5.2 Separate Excitation 45....................................................
5.3 Stator 47................................................................
5.4 Main Field (Rotor) 48.....................................................
5.4.1 Rotor Continuity and Resistance Tests 48...........................
5.5 Slip Rings 50............................................................
5.6 Brushes 50..............................................................
5.7 Voltage 51..............................................................
5.7.1 Voltage Regulation 51............................................
5.7.2 Voltage Adjustment 51............................................

Table of Contents, continued
TP-6391 9/084 Table of Contents
5.8 Voltage Reconnection 52.................................................
5.9 Governor System 52.....................................................
5.10 Fault Shutdown Tests 52..................................................
5.10.1 Controller Fault Shutdown Functions 52.............................
5.10.2 Fault Shutdown Switches 53.......................................
5.11 Electronic Throttle Assembly 57............................................
5.12 Fuses 57...............................................................
5.13 Continuity Checks 58.....................................................
Section 6 Generator Disassembly/Reassembly 59..............................................
6.1 Disassembly 59..........................................................
6.2 Collector Ring and Bearing Replacement 62.................................
6.3 Reassembly 63..........................................................
Section 7 Wiring Diagrams 65................................................................
Appendix A Abbreviations 79..................................................................
Appendix B Common Hardware Application Guidelines 81........................................
Appendix C General Torque Specifications 82...................................................
Appendix D Common Hardware Identification 83.................................................
Appendix E Common Hardware List 84.........................................................

TP-6391 9/08 5Safety Precautions and Instructions
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and accessories,
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has 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.
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.
Accidental Starting
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.
WARNING
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Engine Backfire/Flash
Fire
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
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.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner 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.
Exhaust System
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING