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5EKD Instalation Intructions
5EKD Instalation Intructions
INSTALLATION INSTRUCTIONS
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.
Procedure Engine-End View
1
1. Remove the generator set from service.
1.1 Push the generator set power button OFF.
2. Remove the sound shield, if equipped. 1. 5/16 in. x 1.75 in. bolt
2.1 Remove the three 5/16 in. x 2.5 in. bolts from the Figure 3 Engine-End Door Removal
sound shield roof. See Figure 1.
2.4 Remove the 5/16 in. x 1.75 in. bolts to remove the
exhaust panel and the generator-end door. See
1 Top View Figure 4.
Generator-End View
1
2
GM55219C
1. 5/16 in. x 2.5 in. bolts (qty. 3)
Nonservice-Side View
GM55219C
1. Latches (qty. 2)
2.3 Remove the 5/16 in. x 1.75 in. bolt to remove the 1
engine end door. See Figure 3. GM55219C
1
2
1 GM53065-B
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.
GM58164-B
Note: Use LoctiteR 565 on the threads of the new
1. High exhaust temperature switch (249872) and hex cap bolt
seawater pressure switch and the existing
(X-6238-2)
2. Catalyst pipe plug.
Figure 6 Exhaust Temperature Switch Location 4.4 Install the pipe plug (removed in step 4.3) at the
former location of the seawater pressure switch.
3.2 Use a 15 mm open end wrench to remove the hex See Figure 8.
cap bolt and temperature switch and save the
temperature switch for the possible return to
Side View of Exhaust Manifold
Kohler Power Systems. Discard the hex cap bolt
(X-6238-2).
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5.1 Route the relay end of the wiring harness
Nonservice Side 7
(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.
5.6 The connector containing leads F4B and N (from 1. Relay end of wiring harness (route into junction box)
2. Seawater flow switch connector and leads 87A and N5
the new wiring harness) connects to the existing (route to nonservice side)
wiring harness. 3. Fuel pump
4. Lift pump
5.7 The leads that were disconnected from the old 5. Seawater pressure switch (GM54744)
6. Terminal ends of leads 87A and N5
seawater pressure switch now connect to the new
7. Seawater flow switch connector
wiring harness leads 87 and N5.
Figure 9 Wiring Harness (GM90471) Routing
Connects to existing
harness on the service side.
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6. Install the relay in the junction box. 1
6.1 Use a 5/16 in. socket, 1/4 in. drive to remove the
junction box cover.
6.4 Remove the rag and any drill filings from inside of
the junction box.
1
inch
GM40265-D
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7. Install the flow switch. 7.2 For Units With a Siphon Break:
7.1 For Units Without a Siphon Break: 7.2.1 Remove the hose located between the
heat exchanger end cap and the hose
Note: Proceed to Section 7.2 for units with a connector. See Figure 14.
siphon break.
7.2.2 Cut this hose into a 4-inch piece and a
7.1.1 Remove the molded hose located 5-inch piece.
between the heat exchanger end cap and
catalyst. See Figure 13. Save the molded
hose for re-use.
1
GM60007-A
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1 test validates the seawater flow switch
2
operation and wiring.
8.1.4 Shut down the generator set. Note: See Section 9 for seawater flow switch
maintenance.
8.2 Seawater Flow Switch Validation Test
Note: Leave the maintenance procedure
8.2.1 Remove one lead from the seawater (Section 9), service schedule (Section 10),
pressure switch. and wiring diagrams (Section 11) with the
owner for proper maintenance.
8.2.2 Restart the generator set and run for
45 seconds.
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9. Procedure to Clean Seawater Flow 1
Switch
Check and clean the seawater flow switch according to
the Service Schedule in Section 10. 2
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10. Service Schedule
After Every Every Every
Before 50 Hr or 100 Hr or 300 Hr or 500 Hr or
Perform Service at Intervals Indicated (X) Starting 1 Month 3 Months 6 Months 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
X (during
Check seawater outlet and clean as necessary [
operation)
Check function of siphon break, if equipped X
Check and clean seawater flow switch * X
Replace seawater pump impeller *[ X X
(check)
Adjust seawater pump tension *[ X (200 hr) X
Check heat exchanger anticorrosion zinc X
condition *
Replace heat exchanger anticorrosion zinc * X
X (1000 hr/
Flush cooling system *[
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
X (during
Check the exhaust gas condition
operation)
Service backfire flame arrestor * X
Check and/or replace the catalyst assembly *[ X
X (every
Replace the CO sensor module *[ 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
X (break-in
Check remote control operation X
period)
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.
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11. Wiring Diagrams
GM90655A--
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GM90655B--
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ADV8631A--
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Notes
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Notes
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Notes
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KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems
Phone 920-457-4441, Fax 920-459-1646 Asia Pacific Headquarters
For the nearest sales and service outlet in the 7 Jurong Pier Road
US and Canada, phone 1-800-544-2444 Singapore 619159
KOHLERPower.com Phone (65) 6264-6422, Fax (65) 6264-6455
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