Kodiak LS3 Bedienungsanleitung

KODIAK MARINE

Marine Operators Manual

2.4L 4.3L 5.7L 6.0L AND 6.2L LS3 ENGINES

KEM EQUIPMENT INC

10800 SW HERMAN RD

TUALATIN, OR. 97062

PHONE (503) 692-5012

FAX (503) 692-1098

KM 10701 REV A

IMPORTANT DEFINITIONS

A WARNING indicates a potentially hazardous situation that, if not avoided,

could result in death or serious injury.

A CAUTION indicates a potentially hazardous situation that, if not avoided,

could result in damage to engine or property.

A NOTE provides other helpful information that does not fall under the

warning or caution categories.

WARNING—DANGER OF DEATH OR PERSONAL INJURY

WARNING: FOLLOW INSTRUCTIONS

Read this entire manual and all other publications pertaining to the work to

be performed before installing, operating, or servicing this equipment.

Failure to follow instructions can cause personal injury and/or property

damage

WARNING: FOLLOW ALL SAFETY PRECAUTIONS AND

REGULATIONS

Anyone involved in operation of equipment shall be familiar with the

information in the warnings, cautions and notes. These safety precautions

are mandatory and used to augment formal safety (U.S. Coast Guard)

regulations. Anyone operating this equipment should become thoroughly

familiar with details of operation of the equipment. Such knowledge,

constantly and properly practiced is the only method for ensuring safety as

well as reliable and economical equipment. In any boating situation, common

sense and logic rule the waterways.

WARNING: ELECTRICAL SHOCK HAZARD

The ignition system can cause severe shock if proper precautions are not

taken.

WARNING: OVER-SPEED PROTECTION

The engine is equipped with an over-speed protection device to protect

against runaway or damage to the engine with possible personal injury, loss

of life, or property damage. Diagnostic codes such as over temperature or

low oil pressure may cause engine speed reduction.

WARNING: PROPER USE

Any unauthorized modifications to or use of this engine outside its specified

mechanical, electrical, or other operating limits may cause personal injury

and/or property damage, including damage to the engine. Any such

unauthorized modifications: (i) constitute "misuse" and/or "negligence"

within the meaning of the product warranty thereby excluding warranty

coverage for any resulting damage, and (ii) invalidate product certifications

or listings.

CAUTION: POSSIBLE DAMAGE TO ENGINE OR PROPERTY

CAUTION: BATTERY CHARGING

To prevent damage to a control system that uses an alternator or battery-

charging device, make sure the charging device is turned off before

disconnecting the battery from the system.

CAUTION: ELECTROSTATIC DISCHARGE

Electronic controls contain static-sensitive parts. Observe the following

precautions to prevent damage to these parts.

-Discharge body static before handling the control (with power to the control

turned off, contact a grounded surface and maintain contact while handling

the control).

-Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around

printed circuit boards.

-Do not touch the components or conductors on a printed circuit board with

your hands or with conductive devices.

CAUTION: WELDING When welding on the vessel, disconnect the

battery switch along with the connectors for the Engine Control Module

(ECM). If left connected there is a chance of damage to the ECM.

WARNING: BATTERY GROUNDING: Do not connect battery ground or

any accessory ground wires to the starter mounting bolts. Doing so can

cause a loose bolt situation over time that will cause starter failure or a

possible damaged engine block.

WARNING: CARBON MONOXIDE EXPOSURE

Carbon Monoxide is an odorless, colorless and tasteless gas that cannot be

smelled, seen or tasted. Over exposure to carbon monoxide gas may lead to

brain damage, unconsciousness or even death.

Carbon Monoxide is a hazardous gas that is produced when items containing

carbon are burned. Items such as wood, charcoal, gasoline, natural gas, propane,

and petroleum products such as oil. Carbon Monoxide is found in many areas and

is produced by all types of internal combustion engines, heaters, charcoal grills,

and any other open flame appliances. There are many possible situations for the

accumulation of carbon monoxide to occur in your vessel. Wind direction, boat

speed, and being close to other vessels are just a few of the possible ways that

would permit exposure to carbon monoxide gases. It is important that regular

inspections of the exhaust system and the engine’s fresh air vents are clean and

free of obstructions. Check that all maintenance is properly performed by a

qualified technician. Adequate air ventilation in all areas of your boat is necessary

in order to prevent build-up of carbon monoxide gas.

Table of Contents

Introduction Page 8-9

Safety Summary

How to use this manual

Engine Identification Page 10-13

Engine ID

Warranty Card

Component ID

Pre Operational Inspection Page 14-16

Engine fluid levels

Belts

Battery connections

Hoses

Flame Arrestor

Malfunction Indicator Light (MIL)

Starting the Engine Page 17-18

Starting Mode Fuel injection

Clear Flood

Cold Start

Stopping the Engine Page 19

Normal Conditions

Abnormal conditions (overheating)

Maintenance Instructions Page 20-26

General Engine Specifications

Quick Reference Guide

Maintenance Schedule

Changing Engine Oil and Filter Page 27-28

Engine Oil Quality

Engine Oil recommendations

Oil Filter

Engine Flame Arrestor Page 28

Clean or Replace Flame Arrester

Cooling System Page 29-30

Heat Exchanger

Coolant Level

Serpentine Belt

Fuel Injection System Page 31-32

Fuel Filter

Fuel Recommendation

Fuel Type

Fuel Quality Changes

Power Loss at Higher Elevations

Ignition System Page 33

Troubleshooting Page 34-37

Engine Does Not Crank

Engine Will Crank Intermittently

When the Engine Makes a Stuttering or Chattering Noise

Engine Cranks But Does Not Start

Engine Runs Hot

Clear Flood Mode

Emissions

Storage Page 38

Short Term Lay-up

Long Term Lay-up

Periodic Maintenance Inspections Page 39-40

100, 400, 800, 900, Hour Inspections

Warranty Page 41-46

On Board Diagnostic (OBD) System Check Page 47-48

Diagnostic Codes Page 49-53

Service Dealer Locations Page 54-55

United States, Canada, Russia

Wiring Diagrams Page 56-60

INTRODUCTION

KEM Equipment, Inc. is pleased that you have selected a Kodiak engine for your

requirements. KEM Equipment, Inc. takes great pride in our tradition of quality

products produced from the GM Powertrain line of marine gasoline fuel engines.

KEM Equipment, Inc. engines are inspected and tested before leaving the factory.

However, certain checks should be made before placing the engine into regular

service. Please read the initial start-up inspection requirements in the

Maintenance section of this manual.

This Marine Operators Manual covers the 2.4L, 4.3L, 5.7L, 6.0L AND THE 6.2L

LS3 Marine Engines. In this manual we have included tables for General Engine

Specifications and tables for General Maintenance. Using this Manual will help you

get acquainted with your engine and its functions, as well as help with routine

service and maintenance to keep your Kodiak Marine Engine performing to its full

potential. General engine specifications and quick reference guides starts on page

20.

KEM Equipment Inc. reserves the right to discontinue models or accessories at

any time or to change specifications or designs without notice and without incurring

obligation.

Please read and follow any and all specific Warnings, Cautions, and Notations

contained in this text.

KEM Equipment, Inc., / Kodiak Marine reserves the right to request any pertinent

maintenance information of your engine prior to authorization of warranties. Overall

safety and equipment reliability depend on continuous observation of sound

operating practices. Always observe required scheduled maintenance activities as

outlined. Never attempt to correct problems or repairs for which you are not

qualified. At the end of this manual, you will find a list of qualified Kodiak Marine

service dealers to assist you in your area.

WARNING:

-Always STOP the engine before refueling.

-Always STOP the engine prior to any inspection / check or repair work.

-Always maintain proper ventilation when working around gas or oil.

-Always run the bilge blower for a minimum of 10 minutes prior to starting

the engine.

-Do not stand close or hover over the engine prior to starting.

Ensure all safety guards are in place prior to starting the engine.

How to Use this Manual

This manual is designed to help you get to know your engine and become familiar

with it’s various controls. During instruction, you will learn how to take care of your

engine and what services need to be performed to keep it in excellent running

condition. The table of contents will assist you in locating a specific subject. Please

contact a service dealer if you have reached a point of needing further instruction.

Any un-authorized work can void any potential warranties. We urge you to read

this manual prior to start up of the engine.

KEM Equipment, Inc. engines are built with a variety of standard and/or optional

components to suit a broad range of customer requirements. This manual does

not identify equipment as standard or optional. All the equipment described in this

manual may or may not be found on your engine. The description and

specifications contained in this manual were in effect at the time of publication.

ENGINE IDENTIFICATION

Model Identification

An identification placard is affixed to the engine. The label contains the engine

family number and a model, which identifies the engine from other KEM engines.

The engine model number and serial number are required when seeking

information concerning the engine and/or ordering replacement service parts.

This manual covers the 2.4L 4.3L 5.7L 6.0L and the 6.2L LS3 Marine Engines.

Fill in the information from your engine in the above representation of the engine

tag for future reference.

MODEL: This is the part number for the engine, and this number should be

recorded for ease of obtaining information or parts for this engine.

SERIAL NUMBER: This number identifies each individual engine. This number

should also be recorded for the ease of obtaining information for this engine. If you

have a request or need to order service parts, this serial number will be requested

to aid our parts dept in fulfilling your order. The serial number will confirm that you

are ordering the correct parts for your engine.

WARRANTY CARD: The warranty card shipped with your engine must be

filled out and returned to KEM within 30 days of receipt of your new vessel.

This warranty card will also need to be filled out and returned if a re-power is

being performed with a new Kodiak engine. Failure to fill out and return your

warranty card to KEM within this time period can void all warranties related

to this engine. This warranty card also helps to identify your engine and its

related parts.

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