Kohler 5EKD User manual

TT-1617 12/13
INSTALLATION INSTRUCTIONS
Original Issue Date: 12/13
Model: 5/7.5/10EKD and 4/6/8EFKD
Market: Marine
Subject: Seawater Flow Switch Kit GM90489
Introduction
Installation of this kit involves adding a seawater flow
switch and replacing/relocating the seawater pressure
switch with a new switch that provides enhanced
protection for loss or low seawater flow.
Required Tools
The following tools and supplies are needed:
DElectrical tape
DTeflon tape
DLoctiteR565 general purpose pipe sealant paste
DDrill and 3/16 in. drill bit
D5/16 in. socket, 1/4 in. drive
D10 mm socket, 1/4 in. drive
D15 mm open end wrench
D13 mm open end wrench
D3/8 in. open end wrench
D7/16 in. open end wrench
D3 in. Phillips screwdriver
D1/4 in. socket
D1/4 in. drive ratchet
DHose cutter knife
DWire cutter
DRags
Safety Precautions
Observe the following safety precautions while
performing this procedure.
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.
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving parts.
WARNING
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)

2TT-1617 12/13
Procedure
1. Remove the generator set from service.
1.1 Push the generator set power button OFF.
1.2 Disconnect power to the battery charger, if
equipped.
1.3 Disconnect the generator set engine starting
battery, negative (--) lead first.
2. Remove the sound shield, if equipped.
2.1 Remove the three 5/16 in. x 2.5 in. bolts from the
sound shield roof. See Figure 1.
1
GM55219C
1. 5/16 in. x 2.5 in. bolts (qty. 3)
Top View
Figure 1 Roof Bolt Removal
2.2 Release the two latches on the service side door
to remove the service-side door. See Figure 2.
1
1. Latches (qty. 2)
GM55219C
Service-Side View
Figure 2 Service-Side Door Removal
2.3 Remove the 5/16 in. x 1.75 in. bolt to remove the
engine end door. See Figure 3.
1
1. 5/16 in. x 1.75 in. bolt
GM55219C
Engine-End
V
iew
Figure 3 Engine-End Door Removal
2.4 Remove the 5/16 in. x 1.75 in. bolts to remove the
exhaust panel and the generator-end door. See
Figure 4.
1
1. 5/16 in. x 1.75 in. bolt on exhaust panel
2. 5/16 in. x 1.75 in. bolt on generator-end door
GM55219C
Generator-End View
2
Figure 4 Exhaust Panel and Generator-End Door
Removal
2.5 Remove the two 5/16 in. x 0.625 in. bolts on the
nonservice-side door. After these bolts are
removed, remove the roof and remaining panels.
1
1. 5/16 in. x 0.625 in. bolts (qty. 2)
GM55219C
Nonservice-Side View
Figure 5 Nonservice-Side Door Removal

TT-1617 12/13 3
3. Remove the high exhaust temperature
switch.
3.1 Cut lead #37 from the existing high exhaust
temperature switch. See Figure 6 for location of
the switch. Tape the end of the lead with electrical
tape and tuck the lead into the split loom of the
wiring harness.
1
GM58164-B
1. High exhaust temperature switch (249872) and hex cap bolt
(X-6238-2)
2. Catalyst
2
Figure 6 Exhaust Temperature Switch Location
3.2 Use a 15 mm open end wrench to remove the hex
cap bolt and temperature switch and save the
temperature switch for the possible return to
Kohler Power Systems. Discard the hex cap bolt
(X-6238-2).
4. Remove, replace, and relocate the
seawater pressure switch.
4.1 Disconnect leads N5 and 87 from the seawater
pressure switch.
Note: Place rags underneath the seawater
pressure switch to absorb a small amount
of water.
4.2 Use a 13 mm open end wrench to remove the
seawater pressure switch and 45_fitting and save
for the possible return to Kohler Power Systems.
1GM53065-B
1. Seawater pressure switch
Top View of Exhaust Manifold
Figure 7 Current Location of Seawater Pressure
Switch
4.3 Use a 3/8 in. open end wrench to remove the pipe
plug and install the new seawater pressure switch
(GM54744) using a 7/16 in. open end wrench at
the location shown in Figure 8. Save the pipe plug.
Note: Use LoctiteR565 on the threads of the new
seawater pressure switch and the existing
pipe plug.
4.4 Installthepipeplug(removedinstep4.3)atthe
former location of the seawater pressure switch.
SeeFigure8.
1GM53065-
1. Seawater pressure switch (GM54744)
2. Pipe plug (X-75-4)
Side View of Exhaust Manifold
2
Figure 8 New Location of Seawater Pressure
Switch and Pipe Plug
5. Install the wiring harness.
Note: For Sound Shielded Units: Ensure that
the sound shield panel that contains the
ADC II controller is loosened enough to
route the new wiring harness (GM90471).
The 5/16 in. x 1.75 in. bolt may need to be
removed and the controller harness may
need to be disconnected for ease of
access.
LoctiteRis a registered trademark of Loctite Corporation.

4TT-1617 12/13
5.1 Route the relay end of the wiring harness
(GM90471) behind the fuel pump, behind the
sound shield ADC II panel (if equipped), and up
into the bottom of the junction box. See Figure 9.
Note: If routing the harness as outlined in
Step 5.1 does not work, pull the harness
through from the inside of the junction box
and leave the relay base end of the
harness inside the junction box.
5.2 Route the flow switch connector (P5) and leads
87A and N5 of the new harness (GM90471) on the
right side of the fuel pump, over the top the stator
shell, and underneath the catalyst to the
nonservice side. See Figure 9.
5.3 Connect leads 87A and N5 from the new wiring
harness (GM90471) to the new seawater
pressures switch (GM54744) on the nonservice
side.
5.4 On the service side, disconnect the blue
connectors from the lift pump and the existing
wiring harness (containing leads F4B/N4 that
connect to leads F4C/N3). See Figure 9 for the lift
pump location.
5.5 The connector containing leads F4 and N (from
the new wiring harness) connects to the lift pump’s
connector.
5.6 The connector containing leads F4B and N (from
the new wiring harness) connects to the existing
wiring harness.
5.7 The leads that were disconnected from the old
seawater pressure switch now connect to the new
wiring harness leads 87 and N5.
1
1. Relay end of wiring harness (route into junction box)
2. Seawater flow switch connector and leads 87A and N5
(route to nonservice side)
3. Fuel pump
4. Lift pump
5. Seawater pressure switch (GM54744)
6. Terminal ends of leads 87A and N5
7. Seawater flow switch connector
2
43
Nonservice Side
Service Side
56
7
Figure 9 Wiring Harness (GM90471) Routing
Connects to new relay in junction box.
Connects to new seawater
pressure switch on the
nonservice side.
Connects to old seawater
pressure switch leads on
the service side.
Connects to existing
harness on the service side.
Connects to existing lift
pump on the service side.
Connects to new seawater flow switch
on the nonservice side.
Figure 10 Wiring Harness (GM90471)

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6. Install the relay in the junction box.
6.1 Use a 5/16 in. socket, 1/4 in. drive to remove the
junction box cover.
6.2 Place a rag inside the junction box to catch any
filings.
6.3 Drill a 3/16 in. hole at the location shown in
Figure 11.
6.4 Remove the rag and any drill filings from inside of
the junction box.
6.5 Mount the relay (GM49746) at the location shown
in Figure 12 using a screw (X-50-1) and nut
(X-70-3).
6.6 Connect the relay-connector end of the new wiring
harness (GM90471) to the new relay (GM49746).
6.7 Use a 5/16 in socket, 1/4 in. drive to reinstall the
junction box cover.
1
GM40265-D
1. 3/16 in. hole
(1 in. down from top edge and 1 in. over from pem stud)
1
inch
Figure 11 Hole Location for Relay (Inside Junction
Box)
1
GM40265-D
1. Relay (GM49746), screw (X-50-1), and nut (X-70-3)
Figure 12 Relay Location (Inside Junction Box)

6TT-1617 12/13
7. Install the flow switch.
7.1 For Units Without a Siphon Break:
Note: Proceed to Section 7.2 for units with a
siphon break.
7.1.1 Remove the molded hose located
between the heat exchanger end cap and
catalyst. See Figure 13. Save the molded
hose for re-use.
1
GM58158-L
1. Remove this hose.
Figure 13 Hose Location (Units Without Siphon
Break)
7.1.2 Install a new hose (X-312-42), flow switch
(GM90436), and hose fittings (GM90472
qty. 2) as shown in Figure 15.
Note: Use Teflon tape on the threads of
the flow switch fittings. Wrap the
tape around at least 3 times.
Note: Avoid any kinks in hoses that
connect to the flow switch.
7.1.3 Reuse the molded hose (removed in
Step 7.1.1) but spin the hose 180_from its
original position. See Figure 15, item 1.
7.1.4 Secure the hoses using hose clamps
(X-426-12 qty. 2) and existing hose
clamps.
7.1.5 Connect the flow switch connector to the
new wiring harness connector that was
routed to the nonservice side in Step 5.2.
7.2 For Units With a Siphon Break:
7.2.1 Remove the hose located between the
heat exchanger end cap and the hose
connector. See Figure 14.
7.2.2 Cut this hose into a 4-inch piece and a
5-inch piece.
1
GM60007-A
1. Remove this hose.
Figure 14 Hose Location (Units With Siphon Break)
7.2.3 Reuse the hose (cut to 4 inches in
Step 7.2.2) as shown in Figure 15, item 4.
Install the flow switch (GM90436), and
hose fittings (GM90472 qty. 2) as shown in
Figure 15.
Note: Units equipped with a siphon break
will not use the new hose X-312-42
supplied in the kit.
Note: Use Teflon tape on the threads of
the flow switch fittings. Wrap the
tape around at least 3 times.
Note: Avoid any kinks in hoses that
connect to the flow switch.
7.2.4 Reuse the hose cut to 5 inches in
Step 7.2.2) as shown in Figure 15, item 2.
7.2.5 Secure the hoses using hose clamps
(X-426-12 qty. 2) and existing hose
clamps.
7.2.6 Connect the flow switch connector to the
new wiring harness connector that was
routed to the nonservice side in Step 5.2.

TT-1617 12/13 7
1
GM58158-M
1. Units without a siphon break: Existing molded hose
routed to catalyst and flow switch.
2. Units with a siphon break: Existing hose cut to a 5-inch
piece routed to siphon break connector and flow switch.
3. Flow switch (GM90436) and hose fittings (GM90472 qty. 2)
4. Units without a siphon break: Hose (X-312-42) or
Units with a siphon break: Existing hose cut to a 4-inch
piece.
3
4
2
IN
OUT
Figure 15 Flow Switch Installation
8. Run and test the generator set
Note: After installing kit GM90489 and before
reinstalling all sound shield panels/doors,
if equipped, perform the following
validation tests.
8.1 Check For Any Water Leaks
8.1.1 Reconnect the engine starting battery,
negative (--) lead last.
8.1.2 Reconnect power to the battery charger, if
equipped.
8.1.3 Start and run the generator set for
5 minutes to verify that there are no water
leaks from the newly installed seawater
flow switch and new/relocated seawater
pressure switch.
8.1.4 Shut down the generator set.
8.2 Seawater Flow Switch Validation Test
8.2.1 Remove one lead from the seawater
pressure switch.
8.2.2 Restart the generator set and run for
45 seconds.
8.2.3 Create a low seawater pressure condition
by closing the seacock. Verify that the
generator set shuts down on “Coolant
loss” after the applicable time delay. This
test validates the seawater flow switch
operation and wiring.
8.2.4 Reset the controller. See the operation
manual for reset procedure.
8.2.5 Reconnect the wire to the seawater
pressure switch that was removed in
Step 8.2.1.
8.3 Seawater Pressure Switch Validation Test
8.3.1 Pull the newly installed relay (P26) from its
base.
8.3.2 Start the generator set and run for
45 seconds.
8.3.3 Close the seacock. Verify that the
generator set shuts down on “Coolant
loss” after the applicable time delay. This
test validates the low seawater pressure
switch operation and wiring.
8.3.4 Reset the controller. See the operation
manual for reset procedure.
8.3.5 Reinstall the relay (P26) to its base.
If either one of these validation tests do not yield the
desired results, verify proper wiring. If the wiring is
correct, replace the part that is failing the validation test.
8.4 If the seawater pressure switch and seawater flow
switch pass the validation tests, replace the sound
shield panels/doors, if equipped, using the
reverse procedure as outlined in Section 2.
8.5 After sound shield panels/doors are reinstalled,
start and run the generator set for 5 minutes. While
applying boat load verify proper operation of the
generator set. If the generator set does not
operate correctly, determine the root cause and
correct. If the generator set operates properly,
return the generator set to service.
Note: See Section 9 for seawater flow switch
maintenance.
Note: Leave the maintenance procedure
(Section 9), service schedule (Section 10),
and wiring diagrams (Section 11) with the
owner for proper maintenance.

8TT-1617 12/13
9. Procedure to Clean Seawater Flow
Switch
Check and clean the seawater flow switch according to
the Service Schedule in Section 10.
9.1 Push the generator set power button OFF.
9.2 Disconnect power to the battery charger, if
equipped.
9.3 Disconnect the generator set engine starting
battery, negative (--) lead first.
9.4 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 16.
9.5 Pull the bonnet assembly out of the housing. Be
careful not to pull on the lead wires.
9.6 Clean the shuttle, stem, spring, retaining clip, and
inside of the housing by lightly scraping and/or
wiping away any debris or buildup.
9.7 Check the O-ring, bonnet assembly, shuttle, and
spring for any damage. Replace the flow switch, if
necessary.
9.8 Reassemble by ensuring the spring is set within
the clips on the shuttle cap.
9.9 Reposition the O-ring in the counter-bored
shoulder of the housing.
9.10 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.
9.11 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.
9.12 Reconnect the engine starting battery, negative
(--) lead last.
9.13 Reconnect power to the battery charger, if
equipped.
1
1. Bonnet assembly
2. Stem
3. Spring
4. Shuttle
5. Retaining clip
6. O-ring
7. Housing
2
43
6
5
7
Figure 16 Flow Switch Assembly
Parts List
Kit: GM90489
Qty. Description Part Number
1Relay, 12 V GM49746
1Switch, seawater pressure
(2.0 psi ±0.5) GM54744
1Switch, flow GM90436
1Harness GM90471
2Fittings, hose GM90472
1Hose(0.63IDx5.0in.) X-312-42
2 Clamp, hose (0.69--1.25 in.) X-426-12
1Screw (#10-32 x 0.5 in.) X-50-1
1Nut (10-32) X-70-3

TT-1617 12/13 9
10. Service Schedule
Perform Service at Intervals Indicated (X)
Before
Starting
After
50 Hr or
1 Month
Every
100 Hr or
3 Months
Every
300 Hr or
6 Months
Every
500 Hr or
Yearly
Fuel System
Check the fuel level and fill as necessary X
Check fuel lines and replace as necessary *[X
Replace the fuel filter *[X
Lubrication System
Check crankcase oil level and add as necessary X
Replace the oil in crankcase * X (200 hr)
Replace the lube oil filter element * X (200 hr)
Cooling System
Check coolant level and fill as necessary * X
Check seawater outlet and clean as necessary [X (during
operation)
Check function of siphon break, if equipped X
Check and clean seawater flow switch * X
Replace seawater pump impeller *[X
(check)
X
Adjust seawater pump tension *[X (200 hr) X
Check heat exchanger anticorrosion zinc
condition *
X
Replace heat exchanger anticorrosion zinc * X
Flush cooling system *[X (1000 hr/
2 years)
Ignition System
Check spark plugs condition and gap * X
Replace spark plugs * X (250 hr)
Intake/Exhaust System
Inspect exhaust system components *[X
Check the exhaust gas condition X (during
operation)
Service backfire flame arrestor * X
Check and/or replace the catalyst assembly *[X
Replace the CO sensor module *[X (every
2 years)
Check the crankcase breather pipe for obstructions *[X
Inspect the complete exhaust system *** X
Electrical System
Keep battery charged and in good condition 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 X (break-in
period) X
Generator
Test run generator set X (weekly)
Blow dust out of generator *[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. Consult battery manufacturer’s instructions.
]Read WARNING found at the beginning of manual regarding moving parts.

10 TT-1617 12/13
11. Wiring Diagrams
GM90655A--
Figure 17 Point-to-Point Wiring Diagram (Sheet 1 of 2)