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 3/13c
 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 Identification Information

Product identification numbers determine service parts. Engine Identification

Record the product identification numbers in the spaces
Record the product identification information from the
below immediately after unpacking the products so that
engine nameplate.
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the Manufacturer
kits. Model Designation
Serial Number
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

 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 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.7.5 Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.7.6 Anticorrosion Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.7.7 Seawater Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.8 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.9 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.10 Generator Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section 5 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix B Operating Hour Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

TP-6591 3/13 Table of Contents 3

 Notes

4 TP-6591 3/13

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, or
substantial 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.
TP-6591 3/13
Safety Precautions and Instructions
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 Precautions and Instructions 5
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 present in
exhaust gases. Carbon monoxide 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.
6 Safety Precautions and Instructions
Operating the generator set. 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 draining the fuel system. Wipe up
spilled fuel after draining the system.
TP-6591 3/13
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. Moving parts.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
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.
TP-6591 3/13
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.
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 remove salt deposits from metal
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
surfaces.
Safety Precautions and Instructions 7
 Notes

8 Safety Precautions and Instructions TP-6591 3/13

 Introduction

This manual provides operation instructions for The equipment service requirements are very important
5/7.5/10EKD and 4/6/8EFKD model generator sets. to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Refer to the engine operation manual for generator set
Obtain service from an authorized service
engine scheduled maintenance information.
distributor/dealer to keep equipment in top condition.
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 Before installing a marine generator set, obtain the
without notice and without any obligation or liability most current installation manual from your local
whatsoever. distributor/dealer. Only qualified persons should
install the generator set.
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.

Service Assistance

For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955

D Visit
the Kohler Power Systems website at East China Regional Office, Shanghai
KOHLERPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444.
(91) 80 3366231
D Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
3 rue de Brennus
93200 Saint Denis Latin America
France Latin America Regional Office
Phone: (33) 1 49 178300 Lakeland, Florida, USA
Fax: (33) 1 49 178301 Phone: (863) 619-7568
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

TP-6591 3/13 Introduction 9

Maintenance and Service Parts/Related Literature
Maintenance and Service Parts List of Related Literature
Figure 1 identifies maintenance and service parts for Figure 2 identifies related literature available for the
your generator set. Obtain a complete list of generator sets covered in this manual. Only trained and
maintenance and service parts from your authorized qualified personnel should install or service the
generator distributor/dealer. generator set.

Part Description Part Number Literature Type Part Number

Backfire Flame Arrestor GM24212 Installation Manual TP-6592
Fuel filter 267987 Operation Manual (Generator) TP-6591
Fuse, (F1) 10 amp, Parts Catalog* TP-6594
GM42337
Customer Connection
Service Manual (Generator) TP-6593
Fuse, (F2) 25 amp, Service Manual (Engine) 66 690 01
GM42339
Voltage Regulator
* One manual combines Generator and Engine information.
Fuse, (F3) 20 amp,
Injectors, CO Sensor, Fuel Pumps, Oxygen GM47427 Figure 2 Generator Set Literature
Sensor, and Coils
Fuse, (F4) 10 amp,
GM42337
Controller
Fuse, (F5) 10 amp,
358337
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

Figure 1 Maintenance and Service Parts

10 Maintenance and Service Parts/Related Literature TP-6591 3/13

 Section 1 Service Views

1 2 3 5 6
9 10 11 12
4 7 8
33
32 13

31 14

30

29 15

28 16
27
26
17
25
24
23 22 21 20 19 18

ADV7439A-B

1. Nameplate (top) 20. Lube oil filter

2. Advanced Digital Control II 21. Fuel filter
3. Generator set start/stop button 22. Fuel pump/cooler
4. AC circuit breaker 23. Fuel pump
5. Seawater pressure switch (appears as auxiliary fault on ADC II) 24. Fuel inlet
6. Optional lifting eye tool 25. Filter screen
7. Pressure cap (coolant fill location after draining coolant) 26. Fuse block (F1, F2, F3, and F4) (see Section 2.7.2)
8. Overflow tube 27. Fuse F5 (see Section 2.7.2)
9. Heat exchanger 28. Cooling air inlet
10. Anticorrosion zinc anode (seawater drain) 29. USB connection
11. Coolant drain 30. Catalyst assembly, water outlet/exhaust outlet (nonservice
12. Spark plug (also one located on the nonservice side) side)
13. Air intake silencer/backfire flame arrestor 31. AC load lead connector (nonservice side)
14. Coolant overflow bottle (daily coolant check/fill location) 32. CO sensor module (inside junction box)
15. Oil fill/check 33. Customer interface connection (nonservice side)
16. V-belt Note: Consult installation drawings in Spec Sheet or Installation
17. Seawater pump Manual for fuel- and battery-connection points.
18. Seawater inlet Note: Consult distributor/dealer or Service Manual for items
19. Oil drain valve not shown.

Figure 1-1 Service Views

TP-6591 3/13 Section 1 Service Views 11

 Notes

12 Section 1 Service Views TP-6591 3/13


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.
Tighten or replace the hose clamps and/or hangers as
needed.
D Check that the exhaust outlet is unobstructed.
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 3/13
Section 2 Operation
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
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
Section 2 Operation 13
2.3 Angular Operation 2.6 Advanced Digital Control II
See Figure 2-1 for angular operation limits for units Operation
covered in this manual.
Figure 2-3 illustrates the user interface on the Advanced
Digital Control.
Angle of Operation
Note: Have setup and adjustments of the Advanced
20_
Digital Control performed only by an authorized
Maximum value for all directions Kohler distributor/dealer. The setup and
at full oil level adjustments are password protected.
Figure 2-1 Angular Operation
1
2
2.4 Operation in European Union
Member Countries
This generator set is specifically intended and approved 5
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 4

Whenever operating the generator set, Kohler Co. 3

recommends maintaining the minimum load profile
indicated in Figure 2-2. Maintaining the load profile GM58225A
prevents corrosion formation on internal engine 1. LCD display
components when they’re exposed to the breakdown of 2. Control knob
exhaust gases. 3. Engine start/stop button
4. Power button
5. LED status indicator
Minimum Ideal
Load Requirement Load Requirement Figure 2-3 Advanced Digital Control II
30% load 70% load or more
2.6.1 Controls and Indicators
Figure 2-2 Load Profile
LCD Display. The LCD display is backlit any time the
generator set is running or for at least 30 seconds after a
The operator should perform all of the prestart checks.
user manipulates a button or the control knob. The LCD
Start the generator set according to the starting
displays generator status, run time hours, fault
procedure in the controller section of this manual. While
shutdowns, and fault warnings.
the generator set is operating, listen for a
smooth-running engine and visually inspect the Control Knob. Rotate the control knob clockwise to
generator set for fluid or exhaust leaks. increase a value or move down the menu structure. See
Figure 2-4 for menu items.

14 Section 2 Operation TP-6591 3/13

 Rotating the LED Status Indicator. The LED provides a summary of
control knob the generator state:
to position: Menu Item
1 Hourmeter/Status D Green indicates no known problem

2 Voltage and D Red indicates one or more faults (i.e. the generator
Frequency
cannot operate)
3 Line 1 to neutral voltage and
Line 2 to neutral voltage D Amber indicates no faults but one or more warnings
4 Engine temperature (°F) (i.e. the generator can operate)
Oil pressure (psi)
5 Battery voltage D Slow blink indicates that the generator is not running
RPM
D Steady indicates that the generator is running
6 Next maintenance interval
7 Software version D Off indicates that the unit is off
8 ECM version
Figure 2-5 shows the possible LED displays:
9 Contrast (lighting)
10 Event log
LED Power
11 Fuel prime Status Indicator Button Engine Condition
Figure 2-4 Menu Items Off Off Stopped Any
Slow blink green On Stopped No fault,
Engine Start/Stop Button. The Engine Start/Stop No warning
button toggles the running state of the engine. When the Steady green On Running No fault,
controller is off, it has no effect. When the controller is in No warning
a low-power mode, the Engine Start/Stop button starts
Slow blink red On Stopped Fault
the engine.
Steady amber On Running Warning
Power Button. The Power button toggles the controller Slow blink amber On Stopped Warning
between on and off. When the controller if off, it does not
Figure 2-5 Possible LED Status Indicator Displays
respond to any input except the Power button.

The controller is factory-set and should not require

configuration or adjustment under normal operating
conditions. If the generator set is reconnected to a
different voltage and/or frequency, refer to an authorized
Kohler distributor/dealer for system configuration and
adjustment instructions.

TP-6591 3/13 Section 2 Operation 15

2.6.2 Starting the Generator Set The controller attempts to start the generator set three
times. If the generator set does not start in three
The following procedures describe the actions required attempts, the system shuts down on an overcrank fault.
to start the generator set.
Local Starting.
WARNING 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

Explosion. set. The Advanced Digital Control II attempts to
Gasoline vapors can cause start the generator set in three crank cycles (crank
explosion and severe injury or cycle time is pre-programmed).
death.
Before starting the generator set, Remote Starting.
operate the blower 4 minutes and A remote start/stop switch (connected to P21 connector,
check the engine compartment for
leads 3 and 4) or a remote digital gauge (connected to
gasoline vapors.
P21 connector, pins 1, 2, and 5 via CAN) can be
connected to the customer interface connection. See
Step Action the wiring diagram in Section 5.
1 Operate the blower.
Note: A remote start/stop switch (connected to P21
Operate the blower 4 minutes and check the engine
compartment for gasoline vapors. connector, leads 3 and 4) is not available when
NOTE: Many boat manufacturers recommend configured for SmartCraftt 1.
continuous blower operation while the generator set
is operating. Read the vessel’s owner’s manual for Press the Power Button to turn the controller on.
further information. Consult the instruction sheet supplied with the remote
2 Open the fuel shut-off valve. start/stop switch or remote digital gauge for starting
Open the manual fuel shut-off valve, if equipped. instructions.
3 Start the generator set.
Note: The ADC II allows three 7-second crank cycle
Place the generator set master switch to the RUN
attempts before the overcrank shutdown occurs.
position.
Remote communications require an active
Note: Opening seacock. Before starting the generator (powered-up) controller. Be advised that when the
set, open the seacock to allow cooling water generator is not running, the Advanced Digital Control II
passage. Failure to do so could damage the enters a low-power state with an average current drain
seawater pump impeller and cause serious of approximately 100 uA.
engine overheating damage.
The ADC II will power down (0 mA draw) after 48 hours
Note: Transfer switch. Check that the marine of inactivity. Press the start switch/button (once for the
ship-to-shore transfer switch, if equipped, is in remote start/stop switch or twice for the remote digital
the ship position. gauge) to “wake up” the ADC II and start the generator
set.
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.

16 Section 2 Operation TP-6591 3/13

2.6.3 Stopping the Generator Set
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.
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 3/13
2.6.4 Fault Shutdowns and Warnings
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.
Section 2 Operation 17
Fault Shutdowns
Sensing Active Inhibit Delay Default
Code Description Mechanism State Time Time Setting Check
Over crank Overcrank Fail to start Excessive 0 sec 7 sec on/ 3 crank Check the fuel supply and battery.
(fault) shutdown occurs crank cycles 15 sec off cycles Also check for loose connections.
after 3 Contact an authorized
unsuccessful distributor/dealer for service if
starting attempts. problem continues.
Locked rotor Overcrank (locked ECM data Excessive 0 sec 3 sec 3 sec Contact an authorized
(fault) rotor) shutdown locked rotor distributor/dealer for service if
cycles problem continues.
Low oil pres Low oil pressure ECM data Below setting 30 sec 5 sec 7 psi Check for leaks in the lubrication
(fault) shutdown occurs if system.
a low oil pressure Check the oil level and add oil if the
condition exists. level is low.
Note: The low oil
pressure shutdown
does not protect
against low oil
level. Check the
oil level at the
engine.
Over speed Overspeed ECM data Above setting 0 sec 1 sec 70 Hz Contact an authorized
(fault) shutdown occurs distributor/dealer for service if
if the engine problem continues.
speed exceeds
the default setting.
Coolant loss Loss of coolant Digital input Grounded 30 sec 5 sec N/A Check for a clogged seawater intake
(fault) shutdown occurs or sea strainer.
after a loss of Check for a damaged seawater pump
coolant condition impeller.
is detected.
Hi eng temp High engine ECM data Above setting 30 sec 5 sec 230_ F Check for a low engine coolant level.
(fault) temperature
Check seawater pump impeller,
shutdown occurs if
strainers, and seacock.
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.
Aux input Auxiliary fault Digital input Grounded 3 sec 0.3 sec N/A Check the cause of the auxiliary fault.
(fault) input shutdown.
Note: Input from a
customer-supplied
switch that closes
when the fault is
active.
Hi CO: Carbon monoxide Pulsed signal 20 Hz 0 sec 10 sec N/A Immediate service required.
sensor presence from Contact an authorized
(fault) sensor. distributor/dealer for service.
Shutdown occurs
Ensure windows are open for proper
because of the
ventilation.
presence of CO.
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).

18 Section 2 Operation TP-6591 3/13

Fault Shutdowns
Sensing Active Inhibit Delay Default
Code Description Mechanism State Time Time Setting Check
Hi CO: Carbon monoxide ECM data Control limit 0 sec 15 sec N/A Immediate service required.
engine fault from ECM. Contact an authorized
(fault) Shutdown occurs distributor/dealer for service.
because of the
Ensure windows are open for proper
presence of CO
ventilation.
or deteriorating
emission-control Operate the blower to expel
components (such dangerous fumes.
as the catalyst).
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).
No CO Carbon monoxide Pulsed signal No signal 0 sec 10 sec N/A Check the connections to the CO
sensor sensor missing sensor. If connections are okay,
(fault) shutdown occurs replace the CO sensor.
if communication
Contact an authorized
is lost between
distributor/dealer for service.
the CO sensor
and the ADC.
Over voltage Overvoltage Alternator Above setting 10 sec 2 sec 120% of Contact an authorized
(fault) shutdown occurs if output nominal distributor/dealer for service if
the voltage problem continues.
exceeds the
default setting of
the voltage
regulator setpoint.
Under volt Undervoltage Alternator Below setting 10 sec 10 sec 80% of Reduce the load and restart the
(fault) shutdown occurs output nominal generator set.
if the voltage falls Check the F5 fuse.
below the default Contact an authorized
setting of the distributor/dealer for service if
voltage regulator problem continues.
setpoint.
Over freq Overfrequency Alternator Above setting 10 sec 5 sec 110% of Contact an authorized
(fault) shutdown occurs output nominal distributor/dealer for service if
when the problem continues.
governed
frequency exceeds
the default setting
of the system’s
frequency setpoint.
Under freq Underfrequency Alternator Below setting 10 sec 5 sec 90% of Reduce the load and restart the
(fault) shutdown occurs output nominal generator set.
when the Contact an authorized
governed distributor/dealer for service if
frequency falls problem continues.
below the default
setting of the
system’s
frequency setpoint
.
Hi exh temp High exhaust Digital input Grounded 15 sec 1 sec 215_ F Check the wiring to the sensor.
temperature ±5_ F Check for a clogged seawater intake
shutdown occurs if or sea strainer.
the engine exhaust Check for a damaged seawater pump
temperature impeller.
exceeds the Check the exhaust system, see
default setting. Section 3.6.
HVR Comm Remote CAN CAN Loss of 0 sec 10 sec N/A Check the remote digital gauge and
Err * communication communication connection.
(fault) loss shutdown
* HVR = Hybrid Voltage Regulator

TP-6591 3/13 Section 2 Operation 19

Fault Shutdowns
Sensing Active Inhibit Delay Default
Code Description Mechanism State Time Time Setting Check
Check A check engine ECM N/A N/A N/A N/A Check for high fuel restrictions.
engine fault occurs when Check for air leaks in the supply side
(fault) [ the ECM sends a of the fuel system.
signal for the Check for an inoperative low or high
generator set pressure fuel pump.
controller to shut
check for fuel vaporization in higher
down because the
than maximum temperature operation
engine has stalled
specifications.
Contact an authorized
distributor/dealer for service if
problem continues.
ECM voltage No or low voltage ECM N/A N/A N/A N/A Check if the 10 amp, F1 fuse is blown
(fault) ] to the ECM 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.
[ 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.

Figure 2-6 Advanced Digital Control II Fault Shutdown

Warnings
Sensing Active Inhibit Delay Default
Code Description Mechanism State Time Time Setting Check
High battery High battery Analog input Above setting 0 sec 10 sec 16 volts Check the battery rating and
voltage warning. for 12 volt condition.
Fault condition system
clears when the
battery voltage
returns to a
voltage within the
limits.
Low battery Low battery Analog input Below setting 0 sec 10 sec 12.6 volts Check the battery rating and
voltage warning. for 12 volt condition.
Fault condition system
Charge or replace the battery.
clears when the
battery voltage
returns to a
voltage within the
limits.
Weak Low cranking Analog input Below setting 0 sec 2 sec 9 VDC Check the battery rating and
battery battery during condition.
cranking
Charge or replace the battery.
Hi CO: High CO from ECM data Control limit 0 sec 5 sec N/A Ensure windows are open for proper
engine ECM. Fault code ventilation.
is displayed if the
Operate the blower to expel
presence of CO is
dangerous fumes.
detected because
of the Move the vessel away from other
time-weighted vessels (as another vessel may be the
average presence source for the presence of the CO).
of CO. Activates
Check the generator exhaust system
the CO cabin
(see Section 3.6).
alarms.
Contact an authorized
distributor/dealer for service.

20 Section 2 Operation TP-6591 3/13

Warnings
Sensing Active Inhibit Delay Default
Code Description Mechanism State Time Time Setting Check
Hi CO: High CO from Pulsed signal 10 Hz 0 sec 10 sec N/A Ensure windows are open for proper
sensor sensor. Fault ventilation.
code is displayed
Operate the blower to expel
if the presence of
dangerous fumes.
CO is detected.
Warning occurs if Move the vessel away from other
the sensor vessels (as another vessel may be the
detects source for the presence of the CO).
acceptable but
Check the generator exhaust system
increasing CO
(see Section 3.6).
levels.
Contact an authorized
distributor/dealer for service.
CO sensr err Faulty CO sensor Pulsed signal 5 Hz 0 sec 10 sec N/A Replace the CO sensor. Contact an
authorized distributor/dealer for service.
Low oil pres Low oil pressure Digital Grounded 30 sec 0 sec 5 psi Check for leaks in the lubrication
system.
Check the oil level and add oil if the
level is low.
Hi eng temp High engine ECM data Above setting 30 sec 0 sec 210_ F Check for a low engine coolant level.
temperature
Check seawater system for reduced
flow.
NOTE: Allow the generator set to
cool down before checking.
Maint req Maintenance Clock N/A 0 sec 0 sec N/A
required

Figure 2-7 Advanced Digital Control II Warnings

In addition to the fault shutdowns and warnings included Warnings:

in Figure 2-6 and Figure 2-7, other fault
EST 1 Low Spark 1 Timing Low
shutdowns/warnings may occur (see Figure 2-8).
EST 1 High Spark 1 Timing High
Contact an authorized Kohler distributor/dealer for
additional diagnostics. EST 2 Low Spark 2 Timing Low
EST 2 High Spark 2 Timing High
Text Displayed Description Injector Injector Fault
Fault Shutdowns: Oil sens err Oil Pressure Sensor
TPS input hi Throttle Position Sensor Input High ETC spring Electronic Throttle Control Spring Test
TPS range hi Throttle Position Sensor Range High Failed

TPS range lo Throttle Position Sensor Range Low ECT input lo Coolant Sensor Input Low
TPS input lo Throttle Position Sensor Input Low O2 sens open O2 Open Circuit
ETC sticking Electronic Throttle Control Sticking O2 limit err O2 Limit Error
ETC driver Electronic Throttle Control Driver Fault Starter Starter Fault
MAP input hi Map Sensor Input High Overload Power Limit Warning
MAP input lo Map Sensor Input Low Figure 2-8 Fault Shutdowns/Warnings
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

TP-6591 3/13 Section 2 Operation 21

2.6.5 Resetting the Controller after a 2.6.6 USB Connection
Fault Shutdown The Advanced Digital Control II includes a USB
Note: A fault is identified by a red blinking light in the connection for updating software and configuring
LED status indicator. parameters. See Figure 1-1 for location.

Note: Have software downloads, setup, and

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.
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.

5. Reconnect the generator set engine starting

battery, negative (--) lead last. 2.7.2 Fuses

6. Push the Advanced Digital Control knob. The junction box contains five fuses. See Figure 1-1 for
the fuse locations. Always identify and correct the cause
7. Rotate the control knob to CONFIRM CLR FAULT: of a blown fuse before restarting the generator set.
YES Refer to section 4 for conditions that may indicate a
blown fuse. Obtain service from an authorized
8. Push the control knob. distributor/dealer.
9. Start the generator set by pressing the generator
set start/stop button to START. Test operate the Schematic
Diagram
generator set to verify that the cause of the
Fuse
shutdown has been corrected. Reference
Number Location Fuse Amps
10. Shut the generator off by pressing the generator
F1 Fuse block position 1 Customer 10
set start/stop to the STOP position. connection
F2 Fuse block position 4 Voltage regulator 25
F3 Fuse block position 5 Injector, 20
CO sensor,
fuel pumps,
oxygen sensor,
and coils
F4 Fuse block position 8 Controller 10
F5 Fuse holder Auxiliary winding 10

Figure 2-9 Fuses

22 Section 2 Operation TP-6591 3/13

 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
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.
WARNING
Hazardous voltage. Moving parts.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
TP-6591 3/13
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 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.
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
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
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
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.
Section 3 Scheduled Maintenance 23
3.2 Service Schedule
After Every Every Every
Reference Before 50 Hr or 100 Hr or 300 Hr or 500 Hr or
Perform Service at Intervals Indicated (X) Section Starting 1 Month 3 Months 6 Months Yearly
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
X (during
Check seawater outlet and clean as necessary [ 3.7.7
operation)
Check function of siphon break, if equipped 3.7.5 X
Replace seawater pump impeller *[ 3.7.3 X X
(check)
Adjust seawater pump tension *[ X (200 hr) X
Check heat exchanger anticorrosion zinc X
3.7.6
condition *
Replace heat exchanger anticorrosion zinc * 3.7.6 X
X (1000 hr/
Flush cooling system *[ 3.7.1
2 years)
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 *[ 3.6 X
X (during
Check the exhaust gas condition 3.6
operation)
Service backfire flame arrestor * 3.5 X
Check and/or replace the catalyst assembly *[ 3.6 X
X (every
Replace the CO sensor module *[ 2 years)
Check the crankcase breather pipe for obstructions *[ X
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
X (break-in
Check remote control operation X
period)
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. ⊕ Consult battery manufacturer’s instructions.
] Read WARNING found at the beginning of manual regarding moving parts.

24 Section 3 Scheduled Maintenance TP-6591 3/13

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.
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.

Do not mix different oil brands. Incompatibility could

cause a breakdown of lubricating ingredients and
reduce engine protection. 1

Recommended SAE Viscosity Grades

2
1. Full mark TP-5586-3
2. Add mark

SAE 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
° F-20 0 20 32 40 50 60 80 100 on the dipstick.
° C-30 --20 --10 0 10 20 30 40

3.3.3 Oil Additions

Figure 3-1 Engine Oil Selection
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 3/13 Section 3 Scheduled Maintenance 25

3.3.4 Oil 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.
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.
26 Section 3 Scheduled Maintenance
3.3.5 Oil Filter Change
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.
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 3/13
3.4.2 Fuel Filter 7. Hold the bleed tool (part number GM46327) onto
the bleed point to remove air from the line. See
The 5/7.5/10EKD and 4/6/8EFKD generator sets utilize Figure 3-5.
an in-line type fuel filter. See Section 1 for the fuel filter
location. Replace the filter every 500 hours of running Note: Use a container at the end of the bleed tool’s hose
time or when rough operation indicates an engine to catch the fuel. Dispose of fuel in an
tune-up may be necessary. Bleed the fuel system (after environmentally safe manner
replacing the fuel filter). See Section 3.4.3.
1
2
3.4.3 Fuel System Bleed
Bleed air from the fuel system in order to reduce rough
running or vapor lock.
PUSH TO
PRIME
WARNING

Fire.
Can cause severe injury or death. 3

Do not smoke or permit flames or

sparks near fuels or the fuel system. GM58225A

1. LCD display
Servicing the fuel system. A flash fire can cause severe 2. Control knob
injury or death. Do not smoke or permit flames or sparks near 3. Power button
the carburetor, fuel line, fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors. Catch fuels in an Figure 3-4 Advanced Digital Control II
approved container when removing the fuel line or carburetor.
1
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.

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 3/13 Section 3 Scheduled Maintenance 27

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 USCG-
approved 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 D Check for corroded or broken metal parts and replace
air silencer fitting and remove the hose. them as needed.

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 dry.
5. Reassemble using the reverse sequence.
D Check for loose, corroded, or missing clamps.
Tighten or 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.

3.6 Exhaust System

3.7 Cooling System
WARNING
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
Carbon monoxide. engine exhaust and ejects out the exhaust outlet. See
Can cause severe nausea, Figure 3-6 for coolant capacity (include coolant
fainting, or death.
recovery tank capacity of 0.47 L (0.5 qt.). See
The exhaust system must be Figure 3-7 for thermostat and pressure cap ratings.
leakproof and routinely inspected.
Model L (Qt.)
Inspecting the exhaust system. Carbon monoxide can
cause severe nausea, fainting, or death. For the safety of All models 3 (3.2)
the craft’s occupants, install a carbon monoxide detector.
Never operate the generator set without a functioning carbon Figure 3-6 Coolant Capacity
monoxide detector. Inspect the detector before each
generator set use. Model 5/7.5/10EKD
At the interval specified in the service schedule, inspect Pressure cap rating 96.5 kPa (14 psi)
the exhaust system components (exhaust manifold, Thermostat rating 79_C (175_F)
catalyst assembly, gasket(s), exhaust hose, hose
clamps, silencer, and outlet flapper) for cracks, leaks, Figure 3-7 Pressure Cap and Thermostat Rating
and corrosion.

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

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

28 Section 3 Scheduled Maintenance TP-6591 3/13


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.
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/corrosion and 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.
TP-6591 3/13
Note: Coolant solution. A coolant solution of 50%
ethylene glycol provides freezing protection to
--37°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.
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.
Section 3 Scheduled Maintenance 29
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.
Figure 3-8.
1 housing.
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.
See
8. Lubricate the gasket with silicon grease and attach
the gasket and coverplate to the seawater pump

9. Open the seacock.

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

11. Stop the generator set and repair leaks or replace

damaged or worn components.
2
m:sm:003:008
3
10
4
5 3.7.4 Belt Tension
6
9 8 7 TP-6053 WARNING
1. Seawater pump 7. Pulley
2. Coverplate 8. Drive shaft
3. Gasket 9. Washer
4. Impeller 10. Nut
5. Bearing 11. Mechanical seal,
6. Housing if equipped Hazardous voltage. Moving parts.
Can cause severe injury or death.
Figure 3-8 Seawater Pump, Typical
Operate the generator set only when
3. Remove the impeller. all guards and electrical enclosures
are in place.
4. Inspect the impeller for damaged, cracked, broken,
missing or flattened vanes. The impeller vanes Servicing the generator set when it is operating. Exposed
should be straight and flexible. See Figure 3-9. moving parts can cause severe injury or death. Keep
Replace the impeller if it is damaged. hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
1 guards, screens, and covers before operating the generator
set.
2
Check the belt tension at the interval specified in the
service schedule. If tension is not within the
3 specifications, adjust as necessary using the following
procedures.

TP-6053
1. Flattened vane
2. Crack
3. Broken vane

Figure 3-9 Worn Impeller

30 Section 3 Scheduled Maintenance TP-6591 3/13

 3.7.5 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 3-12. 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
2. Remove the retaining cap and remove the reed
2 1 valve for inspection. See Figure 3-11.

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

1
2. Seawater pump adjusting screw (behind pulley)
3. Seawater pump pulley 2
4. Pivot screw (behind pulley)

Figure 3-10 Belt Tension 3

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 3-10. 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.
7. Replace the flywheel guard and air intake panel
1. Cap 2. Reed valve 3. Mounting base
Figure 3-11 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 3-11, item 2.
7. Install and only finger tighten the retaining cap. Do
not overtighten it.

TP-6591 3/13 Section 3 Scheduled Maintenance 31

 2

7 8
9
1 10
22
6

4 11
Waterline 20

21
16 12

19

15
17
13

18
14 TP-5586-3

1. Mounting base 12. Seawater strainer

2. Retaining cap 13. Seacock
3. Reed valve assembly 14. Intake strainer
4. Silencer vertical lift 1.2 m (4 ft.) max. 15. Engine-driven seawater pump
5. Exhaust catalyst assembly distance above waterline. If less 16. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.
than 23 cm (9 in.), siphon break is required. 17. Water lock (optional)
6. Siphon break distance above waterline 30.5 cm (1 ft.) min. 18. Silencer distance from exhaust catalyst assembly 3 m (10 ft.)
7. Siphon break max.
8. Exhaust catalyst assembly 19. Silencer (customer-supplied)
9. Heat exchanger (locations vary by model) 20. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.
10. Coolant recovery tank 21. Exhaust outlet distance above waterline 10 cm (4 in.) min.
11. Locate coolant recovery tank at same height as heat exchanger 22. Seawater outlet

Figure 3-12 Siphon Break (Plastic “U” Type) Installation

Note: Consult the installation manual for complete

explanation of dimensions and other installation
considerations.

32 Section 3 Scheduled Maintenance TP-6591 3/13

3.7.6 Anticorrosion Zinc Anode 3. Clean the threaded hole of the heat exchanger and
coat the threads of the anticorrosion zinc anode
The heat exchanger on these models contains an (plug) with pipe sealant suitable for marine
anticorrosion zinc anode (plug) to prevent electrolytic applications. Install the anticorrosion zinc anode
corrosion by seawater. 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
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.

1. With the generator set cooled, close the seacock,

remove the anticorrosion zinc plug from the heat 3.7.7 Seawater Outlet
exchanger, and drain the coolant into a suitable Check the seawater outlet at the interval specified in the
container. service schedule. See Figure 3-12 for location.
Remove any obstructions to keep the outlet clear.
2. Use a wire brush to remove the loose corrosion on
the anticorrosion zinc anode. Replace the anode
according to Figure 3-13 and Figure 3-14. 3.8 Ignition System
Anticorrosion Zinc Anode Replacement Service spark plugs at the interval specified in the
service schedule using the following procedure.
Replace When
New Anode Percent of Zinc
Models Dimensions mm (in.) Remaining Is: Spark Plug Service Procedure
5/7.5/10EKD 1. Remove spark plug wires by grasping the spark
<50% of
and 9 (0.34) x 43 (1.7)
length/diameter plug boot and turning slightly while pulling. Do not
4/6/8EFKD
pull the wire. Pulling on the wire rather than the
Figure 3-13 Anticorrosion Zinc Anode (Plug) boot may damage the wire or terminal.
Measurements
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 3. Use compressed air to remove dirt from around

2
1. Diameter: 9 mm (0.34 in.)
2. Length: 43 mm (1.7 in.)
Figure 3-14 Anticorrosion Zinc Anode (Plug)
each spark plug to prevent dirt particles from falling
into the combustion chamber.
4. Remove spark plugs, one at a time, and examine.
TP-5586-3 Identify a normal spark plug in good operating
condition by observing a light tan or gray deposit on
the firing tip. See Figure 3-15 to evaluate engine
condition by color/condition of a problem spark
plug.

TP-6591 3/13 Section 3 Scheduled Maintenance 33

Problem/Condition
Gap-bridged spark plug
Oil-fouled spark plug
Carbon-fouled spark plug
Lead-fouled spark plug
Preignition damaged spark plug
Overheated spark plug
Worn spark plug
Means of Identification Possible Cause/Solution
Built-up deposits and gap between Oil or carbon fouling. Clean and regap
electrodes closing. the spark plug.
Wet, black deposits on the insulator Excessive oil entering combustion
shell, bore, and electrodes. chamber through worn rings and
pistons, excessive clearance between
valve guides and stems, or worn or
loose bearings. Replace the spark plug.
Black, dry, fluffy carbon deposits on Incorrect spark plug, weak ignition,
insulator tips, exposed shell surfaces clogged air intake, defective fuel pump,
and electrodes. overrich fuel mixture, or excessive
no-load operation. Clean and regap the
spark plug.
Dark gray, black, yellow, or tan deposits; Caused by highly leaded fuel. Replace
or a glazed coating on the insulator tip. the spark plug.
Melted electrodes and possibly blistered Wrong type of fuel, incorrect timing or
insulator. Metallic deposits on insulator advance, too hot a plug, burned valves,
suggest internal engine damage. or engine overheating. Replace the
spark plug.
White or light gray insulator with small Engine overheating, wrong type of fuel,
black or gray/brown spots with bluish loose spark plugs, too hot a plug, low
(burned) appearance on electrodes. fuel pump pressure or incorrect ignition
timing. Replace the spark plug.
Severely eroded or worn electrodes. Caused by normal wear and failure to
replace spark plug at prescribed
interval. Replace the spark plug.

Figure 3-15 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.
1
Note: Do not sandblast, wire brush, scrape, or
otherwise service spark plug in poor
condition. Obtain a new plug for best
results.
2
6. Check the spark plug gap before installing any
spark plug. See Figure 3-16. Attain a correct gap
when the feeler (or wire) passes between the spark
plug electrode. It should pass easily but with some 1-514

resistance or drag; otherwise adjust as necessary. 1. 0.76 mm (0.030 in.) gap

The correct gap is 0.76 mm (0.030 in.). 2. Spark plug electrodes

Figure 3-16 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 3-17.
Position the side electrode directly over the center
electrode.

34 Section 3 Scheduled Maintenance TP-6591 3/13


1-511
Figure 3-17 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.
4. Close the seacock and remove the hose at the
seacock. Place the hose in a container having
TP-6591 3/13
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.
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.
Section 3 Scheduled Maintenance 35
 Notes

36 Section 3 Scheduled Maintenance TP-6591 3/13


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.
TP-6591 3/13
Section 4 Troubleshooting
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:
Section 4 Troubleshooting 37
38
Trouble Symptoms

Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Controller
Generator set master switch in the Move the generator set master switch to the correct position Section 2
x
OFF position (RUN or AUTO).

Section 4 Troubleshooting
The customer connection fuse (F1) Replace the blown F1 fuse. If the fuse blows again, check what Section 2, W/D
x x blown. Note that the remote digital is connected to the generator set.[
gage (if equipped) will not function.
The voltage regulator fuse (F2) blown Replace the blown F2 fuse. If the fuse blows again, Section 2, W/D
x x
troubleshoot the regulator.[
The coil, injector, fuel pumps, oxygen Replace the blown F3 fuse. If the fuse blows again, check the Section 2, W/D
x x sensor, and CO sensor fuse (F3) starter solenoid for sticking.[
blown
The controller fuse (F4) blown Replace the blown F4 fuse. If the fuse blows again, Section 2, W/D
x x x x
troubleshoot the controller.[
The auxiliary winding fuse (F5) blown Replace the blown F5 fuse. If the fuse blows again, Section 2, W/D
x x
troubleshoot the alternator winding.[
x Start/stop switch inoperative Replace the controller. —
x Incorrect controller settings Check and adjust the controller.[ I/M
Remote stop command received from Check and remote switch position.
x
a remote switch
x Controller fault Troubleshoot the controller.[ Gen. S/M
x x x x x Controller circuit board(s) inoperative Replace the controller circuit board. Gen. S/M
Cooling System
x x Air openings clogged Clean the air openings. —
x x Impeller damaged Replace the impeller, check upstream system. Section 3
x x Seawater strainer clogged or restricted Clean the strainer. Section 3
High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling Sec. 3, Eng. O/M
x x
system (add coolant). Check seawater pump and circuit.
x Coolant level low Restore the coolant to normal operating level. Section 3
x Thermostat inoperative Replace the thermostat. Eng. S/M
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram
[ Have an authorized service distributor/dealer perform this service.

TP-6591 3/13
 Trouble Symptoms

TP-6591 3/13
Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Electrical System (DC circuits)
Battery connections loose, corroded, Verify that the battery connections are correct, clean, and tight. Section 3
x x
or incorrect
Battery weak or dead Recharge or replace the battery. The spec sheet provides Section 3, S/S
x x
recommended battery CCA rating.
Engine harness connector(s) not Disconnect the engine harness connector(s) then reconnect it to W/D
x x
TP-6591 tight
locked3/13 the controller.
x Fault shutdown Reset the controller. Section 2
High exhaust temperature switch Replace the inoperative switch. Gen. S/M or W/D
x
inoperative
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
High water temperature switch Replace the inoperative switch. Gen. S/M or W/D
x x
inoperative
x Faulty ground connection Clean and retighten the connection. —
Engine
Air cleaner/backfire flame arrestor Clean or replace the filter element. Section 2
x x x x
clogged
x x x x x Compression weak Check the compression.[ Eng. S/M
Engine overload Reduce the electrical load. See the generator set installation I/M
x x x x x x x
manual for wattage specifications.
Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust Section 3, I/M
x
system components.[
Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system Section 3, I/M
x
components.[
x Vibration excessive Tighten all loose hardware. —
Ignition system inoperative Check the ignition system (ignition coils, spark plugs, spark plug Eng. O/M
x x x
wires, etc.).
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram
[ Have an authorized service distributor/dealer perform this service.

Section 4 Troubleshooting
39
40
Trouble Symptoms

Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Fuel System
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —

Section 4 Troubleshooting
x x Fuel pressure insufficient Check the fuel supply and valves. Check or replace fuel filter.[ S/S, Gen. O/M
x x x x Fuel line restriction Check fuel filter. Check the fuel lines and fuel tank. Eng. O/M
Stale or bad fuel. Incorrect type of Replace fuel. Clean the injector with injector cleaner. Sec. 3, Eng S/M
x x x
fuel
x x x Fuel feed pump inoperative Replace the fuel feed pump. Check wiring.[ Eng. S/M
Generator
AC output circuit breaker open Reset the breaker and check for AC voltage at the generator —
x
side of the circuit breaker.
Overcrank shutdown Reset the controller. If the overcrank fault occurs again, contact —
x
the distributor/dealer.
Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO position. ATS O/M
x
position
Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M, W/D
x
field open
Main field (rotor) inoperative (open or Test and/or replace the rotor.[ Gen. S/M
x
grounded)
x Stator inoperative (open or grounded) Test and/or replace the stator.[ Gen. S/M
x Vibration excessive Tighten loose components.[ —
Lube System
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
Low oil pressure (LOP) switch Replace the LOP switch. Check the engine for damage. W/D
x
inoperative
Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the operating Eng. O/M
x x x x
ambient temperature climate.
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram
[ Have an authorized service distributor/dealer perform this service.

TP-6591 3/13

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.
TP-6591 3/13
Section 5 Wiring Diagrams
WARNING
Hazardous voltage. Moving parts.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
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.
Section 5 Wiring Diagrams 41
 GM58615A--C

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

42 Section 5 Wiring Diagrams TP-6591 3/13

 GM58615B--C

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

TP-6591 3/13 Section 5 Wiring Diagrams 43

 ADV7440A--E

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

44 Section 5 Wiring Diagrams TP-6591 3/13

 Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.
A, amp ampere CG center of gravity fglass. fiberglass
ABDC after bottom dead center CID cubic inch displacement FHM flat head machine (screw)
AC alternating current CL centerline fl. oz. fluid ounce
A/D analog to digital cm centimeter flex. flexible
ADC analog to digital converter CMOS complementary metal oxide freq. frequency
adj. adjust, adjustment substrate (semiconductor) FS full scale
ADV advertising dimensional cogen. cogeneration ft. foot, feet
drawing Com communications (port) ft. lbs. foot pounds (torque)
AHWT anticipatory high water conn. connection ft./min. feet per minute
temperature cont. continued g gram
AISI American Iron and Steel CPVC chlorinated polyvinyl chloride ga. gauge (meters, wire size)
Institute crit. critical
ALOP anticipatory low oil pressure gal. gallon
CRT cathode ray tube gen. generator
alt. alternator CSA Canadian Standards
Al aluminum genset generator set
Association GFI ground fault interrupter
ANSI American National Standards CT current transformer
Institute Cu copper GND, ground
(formerly American Standards gov. governor
Association, ASA) cu. in. cubic inch
cw. clockwise gph gallons per hour
AO anticipatory only
CWC city water-cooled gpm gallons per minute
API American Petroleum Institute
cyl. cylinder gr. grade, gross
approx. approximate, approximately
D/A digital to analog GRD equipment ground
AR as required, as requested
DAC digital to analog converter gr. wt. gross weight
AS as supplied, as stated, as
suggested dB decibel HxWxD height by width by depth
ASE American Society of Engineers dBA decibel (A weighted) HC hex cap
ASME American Society of DC direct current HCHT high cylinder head temperature
Mechanical Engineers DCR direct current resistance HD heavy duty
assy. assembly deg., ° degree HET high exhaust temperature
ASTM American Society for Testing dept. department hex hexagon
Materials dia. diameter Hg mercury (element)
ATDC after top dead center DI/EO dual inlet/end outlet HH hex head
ATS automatic transfer switch DIN Deutsches Institut fur Normung HHC hex head cap
auto. automatic e. V. HP horsepower
aux. auxiliary (also Deutsche Industrie hr. hour
A/V audiovisual Normenausschuss) HS heat shrink
avg. average DIP dual inline package hsg. housing
AVR automatic voltage regulator DPDT double-pole, double-throw HVAC heating, ventilation, and air
AWG American Wire Gauge DPST double-pole, single-throw conditioning
AWM appliance wiring material DS disconnect switch HWT high water temperature
bat. battery DVR digital voltage regulator Hz hertz (cycles per second)
BBDC before bottom dead center E, emer. emergency (power source) IC integrated circuit
BC battery charger, battery EDI electronic data interchange ID inside diameter, identification
charging EFR emergency frequency relay IEC International Electrotechnical
BCA battery charging alternator e.g. for example (exempli gratia) Commission
BCI Battery Council International EG electronic governor IEEE Institute of Electrical and
BDC before dead center EGSA Electrical Generating Systems Electronics Engineers
BHP brake horsepower Association IMS improved motor starting
blk. black (paint color), block EIA Electronic Industries in. inch
(engine) Association in. H2O inches of water
blk. htr. block heater EI/EO end inlet/end outlet in. Hg inches of mercury
BMEP brake mean effective pressure EMI electromagnetic interference in. lbs. inch pounds
bps bits per second emiss. emission Inc. incorporated
br. brass eng. engine ind. industrial
BTDC before top dead center EPA Environmental Protection int. internal
Agency int./ext. internal/external
Btu British thermal unit
EPS emergency power system I/O input/output
Btu/min. British thermal units per minute
ER emergency relay IP iron pipe
C Celsius, centigrade
ES engineering special, ISO International Organization for
cal. calorie engineered special
CARB California Air Resources Board Standardization
ESD electrostatic discharge J joule
CB circuit breaker est. estimated
cc cubic centimeter JIS Japanese Industry Standard
E-Stop emergency stop k kilo (1000)
CCA cold cranking amps etc. et cetera (and so forth)
ccw. counterclockwise K kelvin
exh. exhaust kA kiloampere
CEC Canadian Electrical Code
cfh cubic feet per hour
ext. external KB kilobyte (210 bytes)
F Fahrenheit, female
cfm cubic feet per minute

TP-6591 3/13 Appendix 45

kg kilogram MW megawatt rms root mean square
kg/cm2 kilograms per square mW milliwatt rnd. round
centimeter μF microfarad ROM read only memory
kgm kilogram-meter N, norm. normal (power source) rot. rotate, rotating
kg/m3 kilograms per cubic meter NA not available, not applicable rpm revolutions per minute
kHz kilohertz nat. gas natural gas RS right side
kJ kilojoule NBS National Bureau of Standards RTV room temperature vulcanization
km kilometer NC normally closed SAE Society of Automotive
kOhm, kΩ kilo-ohm NEC National Electrical Code Engineers
kPa kilopascal NEMA National Electrical scfm standard cubic feet per minute
kph kilometers per hour Manufacturers Association SCR silicon controlled rectifier
kV kilovolt NFPA National Fire Protection s, sec. second
kVA kilovolt ampere Association SI Systeme international d’unites,
kVAR kilovolt ampere reactive Nm newton meter International System of Units
kW kilowatt NO normally open SI/EO side in/end out
kWh kilowatt-hour no., nos. number, numbers sil. silencer
kWm kilowatt mechanical NPS National Pipe, Straight SN serial number
L liter NPSC National Pipe, Straight-coupling SPDT single--pole, double--throw
LAN local area network NPT National Standard taper pipe SPST single--pole, single--throw
L x W x H length by width by height thread per general use spec, specs
lb. pound, pounds NPTF National Pipe, Taper-Fine specification(s)
lbm/ft3 pounds mass per cubic feet NR not required, normal relay sq. square
LCB line circuit breaker ns nanosecond sq. cm square centimeter
LCD liquid crystal display OC overcrank sq. in. square inch
ld. shd. load shed OD outside diameter SS stainless steel
LED light emitting diode OEM original equipment std. standard
manufacturer stl. steel
Lph liters per hour
OF overfrequency tach. tachometer
Lpm liters per minute
opt. option, optional TD time delay
LOP low oil pressure
OS oversize, overspeed TDC top dead center
LP liquefied petroleum OSHA Occupational Safety and Health
LPG liquefied petroleum gas TDEC time delay engine cooldown
Administration TDEN time delay emergency to
LS left side OV overvoltage normal
Lwa sound power level, A weighted oz. ounce TDES time delay engine start
LWL low water level p., pp. page, pages TDNE time delay normal to
LWT low water temperature PC personal computer emergency
m meter, milli (1/1000) PCB printed circuit board TDOE time delay off to emergency
M mega (106 when used with SI pF picofarad TDON time delay off to normal
units), male PF power factor temp. temperature
m3 cubic meter
ph., ∅ phase term. terminal
m3/min. cubic meters per minute TIF telephone influence factor
mA milliampere PHC Phillips head crimptite (screw)
PHH Phillips hex head (screw) TIR total indicator reading
man. manual tol. tolerance
max. maximum PHM pan head machine (screw)
PLC programmable logic control turbo. turbocharger
MB megabyte (220 bytes)
PMG permanent-magnet generator typ. typical (same in multiple
MCM one thousand circular mils locations)
MCCB molded-case circuit breaker pot potentiometer, potential
ppm parts per million UF underfrequency
meggar megohmmeter UHF ultrahigh frequency
MHz megahertz PROM programmable read-only
memory UL Underwriter’s Laboratories, Inc.
mi. mile psi pounds per square inch UNC unified coarse thread (was NC)
mil one one-thousandth of an inch pt. pint UNF unified fine thread (was NF)
min. minimum, minute PTC positive temperature coefficient univ. universal
misc. miscellaneous PTO power takeoff US undersize, underspeed
MJ megajoule PVC polyvinyl chloride UV ultraviolet, undervoltage
mJ millijoule qt. quart V volt
mm millimeter VAC volts alternating current
qty. quantity
mOhm, mΩ VAR voltampere reactive
milliohm R replacement (emergency)
power source VDC volts direct current
MOhm, MΩ rad. radiator, radius VFD vacuum fluorescent display
megohm
MOV metal oxide varistor RAM random access memory VGA video graphics adapter
MPa megapascal RDO relay driver output VHF very high frequency
mpg miles per gallon ref. reference W watt
mph miles per hour rem. remote WCR withstand and closing rating
MS military standard RFI radio frequency interference w/ with
m/sec. meters per second RH round head w/o without
MTBF mean time between failure RHM round head machine (screw) wt. weight
MTBO mean time between overhauls rly. relay xfmr transformer
mtg. mounting

46 Appendix TP-6591 3/13

 Appendix B Operating Hour Service Log

Use the log below to keep a cumulative record of required services were performed. Enter hours to the
operating hours on your generator set and the dates nearest quarter hour.

OPERATING HOURS SERVICE RECORD

DATE HOURS TOTAL SERVICE

RUN RUN HOURS DATE SERVICE

TP-6591 3/13 Appendix 47

 Notes

48 TP-6591 3/13
 Notes

TP-6591 3/13 49
 Notes

50 TP-6591 3/13
 Notes

TP-6591 3/13 51
 KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6591 3/13c 7 Jurong Pier Road
Singapore 619159
E 2009, 2011, and 2013 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455