Kohler 6EKOD Operation Manual
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Kohler 6EKOD Operation Manual

Marine generator sets
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See also: Service Manual , Installation Manual
Operation
Marine Generator Sets
Models:
6EKOD
9- -11EKOZD
5EFKOD
7- -9EFKOZD
TP-6772
2/14b

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Summary of Contents for Kohler 6EKOD

  • Page 1 Operation Marine Generator Sets Models: 6EKOD 9- -11EKOZD 5EFKOD 7- -9EFKOZD TP-6772 2/14b...

  • Page 2: Product Identification Information

    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 Engine Identification Product identification numbers determine service parts. 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.

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ............. Safety Precautions and Instructions .
  • Page 4 Fuel System ............3.4.1 Fuel Specifications .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting Servicing the fuel system. A flash IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, fire can cause severe injury or death. including generator sets, transfer Do not smoke or permit flames or WARNING switches, switchgear, and accessories, sparks near the fuel injection system, can cause bodily harm and pose fuel line, fuel filter, fuel pump, or other...
  • Page 6 Fuel System Hazardous Voltage/ Carbon monoxide symptoms. Carbon monoxide can cause severe Moving Parts nausea, fainting, or death. Carbon monoxide is a poisonous gas present in WARNING exhaust gases. Carbon monoxide is an WARNING odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time.
  • Page 7 Hot Parts Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can WARNING cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments repairs. Remove all jewelry before servicing the equipment.
  • Page 8 Notes 8 Safety Precautions and Instructions TP-6772 2/14b...

  • Page 9: Introduction

    Information in this publication represents data available distributor/dealer. at the time of print. Kohler Co. reserves the right to change this publication and the products represented The equipment service requirements are very important without notice and without any obligation or liability to safe and efficient operation.

  • Page 10: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KOHLERPower.com. Fax: (86) 21 6288 0550 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.

  • Page 11: Maintenance And Service Parts/Related Literature

    Maintenance and Service Parts/Related Literature Maintenance and Service Parts Figure 1 identifies maintenance and service parts for your generator set. Obtain a complete list of maintenance and service parts from your authorized generator distributor/dealer. Models 6EKOD 9EKOZD 11EKOZD 11EKOZD 5EFKOD...
  • Page 12 Notes 12 Introduction TP-6772 2/14b...

  • Page 13: Section 1 Service Views

    Section 1 Service Views Non Service-Side View ADV7942-A 1. ADC-IId controller 17. Fuel feed pump 2. USB port 18. Fuel inlet 3. Nameplate (on top of controller) 19. Oil filter 4. Fuses (F1, F2, and F3) 20. Customer load lead connection 5.
  • Page 14 WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Sound Shield Equipped Models: For access to the generator set to perform regular maintenance, remove the sound shield doors and roof.

  • Page 15: Section 2 Operation

    Section 2 Operation 2.1 Prestart Checklist Inspect the exhaust system components (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and outlet flapper) for cracks, leaks, and corrosion. WARNING Check the hoses for softness, cracks, leaks, or dents. Replace the hoses as needed. Check for corroded or broken metal parts and replace them as needed.

  • Page 16: Marine Inspection

    2.2 Marine Inspection 2.5 Load Profile Kohler Co. recommends that all boat owners have their Whenever operating the generator set, Kohler Co. vessels inspected at the start of each boating season by recommends maintaining the minimum load profile the US Coast Guard, the local Coast Guard Auxiliary, or indicated in Figure 2-1.

  • Page 17: Advanced Digital Control Iid Operation

    Press the dial at a given main menu to access the different voltage and/or frequency, refer to an authorized submenus within the selected main menu. Kohler distributor/dealer for system configuration and When in the submenu, rotate the dial to navigate adjustment instructions.

  • Page 18: Starting The Generator Set

    A water-filled exhaust piping and silencer may further 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. Section 2 Operation TP-6772 2/14b...

  • Page 19: Stopping The Generator Set

    2.6.3 Stopping the Generator Set The controller attempts to start the generator set three times. If the generator set does not start in three attempts, the system shuts down on an overcrank fault. The following procedures describe the actions required to stop the generator set.
  • Page 20 System Warning Fault Lamp. Green/Red lamp System Shutdown Fault Lamp. Red lamp indicates identifies an existing fault condition that does not shut that the generator set has shut down because of a fault down the generator set. A continuing system warning condition.

  • Page 21: Digital Display

    2.6.5 Digital Display Generator Set State displays the generator set status: The generator set must be running for some displays to Standby indicate values. If the generator set is not running some Running values will display zero or N/A (not available). Cooldown The 12-character, 2-line backlit alpha-numeric display Stopping...
  • Page 22 Generator Metering Menu Generator Set Run Time Menu Volts displays the alternator output AC voltages. The Engine Run Time displays the total run time hours. display shows all line-to-line and line-to-neutral voltage This value also shows in the Overview Menu. combinations three-phase single-phase...

  • Page 23: Controller Fault Diagnostics

    2.6.6 Controller Fault Diagnostics Event Log Menu This menu allows the user to review up to 1000 entries of This table provides descriptions of the system events system events including shutdown faults, warning and their types—warning, shutdown, status, and notice. faults, and status events.
  • Page 24 System Events Display Message List Warning Shutdown Status/ Relay Function Function Notice Output Description Display Message Engine Functions Engine over speed Eng Speed High Shutdwn Engine start aid active Preheat Engine under speed Eng Speed Low Shutdwn High battery voltage Battery High Warning High coolant temperature Coolnt Temp High Warning...

  • Page 25: Communication Port

    See Figure 2-5 for tested/approved manufacturer’s USB flash drive types that work with the ADC IId controller. CustomUSB (Kohler Power Systems 2-GB “spin” full size Part Number KW-A202) Imation 4-GB full size Lexar...
  • Page 26 Fault Shutdowns Sensing State(s) Inhibit Delay Mechanism Detected Time Time Trip Point Check Code Description AC Sens The loss of AC Frequency Post starting 10 sec 3 sec AC voltage Contact an authorized Loss Low voltage shutdown over AC aid, running, reached AC distributor/dealer for service.
  • Page 27 Fault Shutdowns Sensing State(s) Inhibit Delay Mechanism Detected Time Time Trip Point Check Code Description Frequency Underfrequency Alternator Post starting 10 sec 10 sec Reduce the load and restart the shutdown occurs output aid, running, frequency generator set. Shutdown when the cooldown below 90% Contact an authorized...
  • Page 28 Warnings Sensing State(s) Inhibit Delay Mechanism Detected Time Time Code Description Trip Point Check AC Sens Loss of AC Frequency Post starting 10 sec 1 sec AC voltage Contact an authorized Loss voltage warning over AC aid, running, is below distributor/dealer for service.

  • Page 29: Controller Resetting (Following System Fault Shutdown)

    2.7.2 Controller Resetting (Following Voltage Adjustment. The voltage adjustment allows the user to enter the desired generator set output level. System Fault Shutdown) This regulated level setting is the average of the three line-to-line voltages in three-phase configurations or Always identify and correct the cause of a fault L1-to-L2 in single phase configurations.

  • Page 30: System Fault Warning Lamp With Digital Displays

    2.7.5 System Fault Warning Lamp with Low Battery Voltage. The fault lamp illuminates green, then red, maybe black when the battery voltage drops Digital Displays below a preset level for more than 90 seconds. The The system FAULT lamp blinks green then red local display shows Battery Low Warning.

  • Page 31: System Fault Shutdown Lamp With Digital Displays

    2.7.6 System Fault Shutdown Lamp Locked Rotor (failed to crank). If none of the speed sensing inputs show engine rotation within the preset With Digital Displays time delay of initiating engine cranking, the ignition and The system FAULT lamp flashes red and the unit shuts crank circuits turn off for the preset period and the cycle down to indicate a fault shutdown under the following repeats.

  • Page 32: Status And Notice Digital Displays

    2.7.7 Status and Notice Digital Displays Overvoltage (Each Phase). The fault lamp flashes red and the unit shuts down when the voltage exceeds the Warnings and shutdown faults appear on the digital overvoltage setting for the preset time delay period. The display and become part of the event history.

  • Page 33: Menu Displays

    Generator Set Calibration (User Defined). This System Ready. This status indicates that the generator selectable display is in the GenSet Metering Menu set is in the AUTO mode and available to start if the start allowing the user to calibrate the controller and circuit is closed.
  • Page 34 Menu Summary List (Legend: D First level submenu, d second level submenu) Overview Generator Metering GenSet System Prime Menu Menu Menu Menu D See Section 2.10.10 D System Frequency Available as scrolling or D Volts, L1--L2 * D Battery DC Voltage fixed display text D Volts, L2--L3 * Volt Select...

  • Page 35: Monitoring And Programming Setup

    2.9 Monitoring and Programming Menus displaying the # symbol represent one of the following data types: Setup System-calculated data The user programmer can access the controller data System-measured data with the controller digital display or a personal computer User-entered data (PC) with optional SiteTecht software to monitor and/or program.

  • Page 36: Overview

    2.10.2 Overview Overview (Fixed Display) Overview ----> ### V ##.# Hz Displays basic and commonly sought after information ##.# hr about the generator set. This information scrolls automatically after about 5 minutes of no user input English Display ###_F ###% (pushbutton/rotary selector dial or button activity).

  • Page 37: Generator Metering (And Calibration)

    2.10.4 Generator Metering (and Generator Metering Calibration) Generating----> Volts L1--L2: Metering #.# V Displays generator output data including line-to-line and line-to-neutral voltages and frequency. The menu Volts L2--L3: displays three-phase voltage readings when applicable. #.# V All menu displays apply to both single-phase or three- phase voltages on the menu overview.

  • Page 38: Genset Information

    2.10.5 GenSet Information 2.10.7 GenSet System Displays generator set and controller information. Display shows the generator set system data. Use the Displayed data is factory entered. values entered in this menu to help determine shutdown values and time delays. GenSet Information The programming user defines the data shown in the GenSet System menu.

  • Page 39: Voltage Regulator

    2.10.8 Voltage Regulator push and hold the pushbutton/rotary selector dial until the Editing Enabled popup appears. Editing of the Displays the voltage regulator adjustment, volt/Hz, gain, voltage adjustment is now available. and stability adjustment values. The user can change the individual value or can select The voltage regulator value is reviewable at all times Reset VR?- -Yes to reset to the default value.

  • Page 40: Prime Menu

    2.10.10 Prime Menu Volt Select Volt Select: ----> 120/240 V 1 Ph This menu, if confirmed, allows the user to initiate the ###/### V # Ph electric fuel pump to prime the fuel system. Prime the Fuel System 120/208 V 3 Ph Push To Prime ---->...

  • Page 41: Usb Flowchart

    See Figure 2-19 for tested/approved manufacturer’s USB flash drive types that work with the ADC IId controller. CustomUSB (Kohler Power Systems 2-GB “spin” full size Part Number KW-A202) Imation 4-GB full size Lexar...
  • Page 42 Notes Section 2 Operation TP-6772 2/14b...

  • Page 43: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance 3.1 General Maintenance NOTICE Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and WARNING remove salt deposits from metal surfaces. NOTICE The engine and generator set may use both American Standard and metric hardware.

  • Page 44: Service Schedule-6--11Ekod/Ekozd & 5--9Efkod/Efkozd Models

    3.2 Service Schedule—6- -11EKOD/EKOZD & 5- -9EFKOD/EFKOZD Models Every Every Every Every 50 Hrs. 250 Hrs. 500 Hrs. Perform Service at Intervals Reference 1000 Hrs. or 1 or 3 or 6 Indicated (X) Section or Yearly Daily Month Months Months FUEL SYSTEM Check the fuel level and fill as necessary (Before...
  • Page 45 GENERATOR Test run the generator set (Weekly) Blow dust out of the generator *[ 6EKOD/5EFKOD Models: Clean the slip rings and Gen. S/M inspect the brushes *[ Requires removal of the sound shield door, if installed Consult your local distributor/dealer for service Read the WARNING found at the beginning of the manual regarding moving parts Consult the battery manufacturer’s instructions...

  • Page 46: Lubrication System

    3.3 Lubrication System 3.3.2 Oil Check Check the oil level in the crankcase daily or before each See the Scheduled Maintenance section for oil change startup to ensure that the level is in the safe range. To and oil filter replacement intervals. See Section 1 for the check the oil level, remove the dipstick and wipe the end oil drain, oil check, oil fill, and oil filter locations.

  • Page 47: Oil Change

    2. Replace the oil filter. Model L (Qts.) a. Remove filter rotating 6EKOD and 5EFKOD 2.5 (2.6) counterclockwise with an oil filter wrench. 9EKOZD and 7EFKOZD 2.5 (2.6) b. Apply a light coat of clean oil to the rubber seal 11EKOZD and 9EFKOZD (1 Phase) 3.4 (3.6)

  • Page 48: Fuel System

    3.4 Fuel System Note: Do not run the generator set out of fuel because the fuel lines will draw in air and necessitate bleeding the fuel system before restarting the 3.4.1 Fuel Specifications unit. Use a clean, good quality diesel fuel oil with a cetane 3.4.2 Fuel Filter number of 51 or greater.

  • Page 49: Fuel System Bleed

    3.4.3 Fuel System Bleed Typically, running the Prime function on the ADC IId is all that is required. If rough operation continues, use the Bleed air from the fuel system in order to reduce rough following procedure to open the air bleed valve on the running or vapor lock.

  • Page 50: Exhaust System

    3.5 Exhaust System For your safety: Never operate the generator set without functioning carbon monoxide detector(s) for your WARNING safety and the safety of others on your vessel. Exhaust System Inspection Points Check for exhaust leaks and blockages. Check the Carbon monoxide.

  • Page 51: Cooling System

    (include coolant recovery tank capacity of 0.24 L (8 oz.). tube opening. Model L (Qts.) Note: A coolant solution of 50% ethylene glycol is 6EKOD and 5EFKOD 3.0 (3.2) required. This mix provides freezing protection to --37C (--34F) and overheating protection to 9EKOZD and 7EFKOZD 3.0 (3.2)

  • Page 52: Pressure Cap

    3.6.4 Pressure Cap Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the engine coolant, enabling proper operating temperatures. If the cap leaks, replace it with a cap of the same rating. The pressure cap typically has the pressure rating stamped on the cap body.

  • Page 53: Siphon Break

    3.6.6 Siphon Break 6. Install the reed valve into the mounting base with the valve downward. See Figure 3-9, item 2. A siphon break prevents seawater entry into the 7. Install and only finger tighten the retaining cap. Do generator set’s engine when the engine exhaust not overtighten it.
  • Page 54 Waterline TP-5586-3 1. Silencer vertical lift 1.2 m (4 ft.) max. 10. Intake strainer 2. Exhaust mixer elbow distance above waterline. If less than 11. Engine-driven seawater pump 23 cm (9 in.), a siphon break is required. 12. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min. 3.

  • Page 55: Anticorrosion Zinc Anode

    Section 2.1, Prestart New Anode Percent of Zinc Checklist—Seawater Pump Priming. Dimensions mm (in.) Models Remaining Is: 6EKOD/ 5EFKOD, 9EKOZD/ <50% of 6.35 (0.25) x 20 (0.78) 7EFKOZD, length/diameter 11EKOZD/ 9EFKOZD Figure 3-11 Anticorrosion Zinc Anode (Plug) Measurements...

  • Page 56: Belt Tension

    3.7 Belt Tension 3.7.1 Seawater Pump Belt Tensioning Procedure WARNING 1. Remove the belt guard. See Figure 3-13. 2. Check the belt tension at the midpoint of the longest span of the belt by pressing with your finger approx. 10 kg (22 lbs.) of force. See Figure 3-14 for Hazardous voltage.

  • Page 57: Battery

    Place the hose in a container having approximately 3.7--7.5 L (1--2 U.S. gallons) of 13. Select a well-ventilated (not humid or dusty) coolant/antifreeze. Kohler Co. recommends using location to store the generator. an environmentally friendly potable antifreeze such as PeakR RV/marine propylene glycol/water 14.
  • Page 58 Notes Section 3 Scheduled Maintenance TP-6772 2/14b...

  • Page 59: Section 4 Troubleshooting

    Section 4 Troubleshooting This section contains generator set troubleshooting, Maintain a record of repairs and adjustments performed diagnostic, and repair information. on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an Use the following charts as a quick troubleshooting authorized distributor/dealer.
  • Page 60 TP-6772 2/14b Section 4 Troubleshooting...
  • Page 61 TP-6772 2/14b Section 4 Troubleshooting...
  • Page 62 TP-6772 2/14b Section 4 Troubleshooting...

  • Page 63: Section 5 Wiring Diagrams

    5.1 Wiring Diagram Reference Model Point-to-Point Figure Schematic Figure Accessory Figure 6EKOD/5EFKOD 9EKOZD/7EFKOZD GM79008-C Figure 5-3 ADV-7995-C Figure 5-4 GM33846-D Figure 5-7 11EKOZD/9EFKOZD Figure 5-1 Wiring Diagrams for Units without Isolated Ground...
  • Page 64 GM79008-C Figure 5-3 Wiring Diagram, Point-to-Point Section 5 Wiring Diagrams TP-6772 2/14b...
  • Page 65 ADV7995-C Figure 5-4 Wiring Diagram, Schematic TP-6772 2/14b Section 5 Wiring Diagrams...
  • Page 66 GM79009-E Figure 5-5 Isolated Ground Wiring Diagram, Point-to-Point Section 5 Wiring Diagrams TP-6772 2/14b...
  • Page 67 ADV7996-D Figure 5-6 Isolated Ground Wiring Diagram, Schematic TP-6772 2/14b Section 5 Wiring Diagrams...
  • Page 68 GM33846-D Figure 5-7 Accessory Interconnection Drawing Section 5 Wiring Diagrams TP-6772 2/14b...

  • Page 69: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex.
  • Page 70 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter microfarad read only memory F kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat.

  • Page 71: Appendix B Operating Hour Service Log

    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...

  • Page 72: Appendix C Voltage Regulator Definitions And Adjustments

    Appendix C Voltage Regulator Definitions and Adjustments The following definitions and adjustment/setting mathematically by Ohm’s law, which states that power is specifications are intended for users planning to adjust equal to the voltage squared divided by the impedance. the voltage regulator beyond the default settings in As the voltage is reduced, the power delivered by the order to customize the alternator for a specific alternator decreases by a squared relationship.

  • Page 73: Adjustment And Setting

    Frequency Setpoint or Cut-In Point As stated above, three-phase sensing does not eliminate unequal voltage phenomenon. The point at which the underfrequency unloading begins Three-phase sensing balances the inequality of voltage to take effect is adjustable, allowing the system to be between the phases to the desired value.
  • Page 74 Frequency Setpoint As a reference, the present voltage adjust setting is displayed as well as the average value of the line-to-line The frequency setpoint is the cut-in point for voltages. The individual line-to-line voltages are also underfrequency unloading. At any operating frequency displayed on the subsequent menu screens.
  • Page 75 Notes TP-6772 2/14b Appendix 75...
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  • Page 79 TP-6772 2/14b...
  • Page 80 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-6772 2/14b 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 E 2011, 2012, and 2014 by Kohler Co. All rights reserved.

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