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Kohler 14EKOZD Operation

Marine generator sets
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Operation
Marine Generator Sets
Models:
14/16/21/24/32/40EKOZD
12/13.5/17/18/20.5/28/35EFKOZD
Controller:
®
Decision Maker
3500
TP-7044 6/23e

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Summary of Contents for Kohler 14EKOZD

  • Page 1 Operation Marine Generator Sets Models: 14/16/21/24/32/40EKOZD 12/13.5/17/18/20.5/28/35EFKOZD Controller: ® Decision Maker 3500 TP-7044 6/23e...
  • Page 2 WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............................5 Introduction ....................................9 Service Assistance................................... 10 Maintenance and Service Parts/Related Literature ....................... 11 Section 1. Service Views ............................13 Section 2. Operation ..............................17 Prestart Checklist ..............................17 Marine Inspection ..............................18 Angular Operation ..............................
  • Page 4 Section 3. Scheduled Maintenance ........................67 General Maintenance ............................. 67 Service Schedule for 14-24EKOZD/12-20.5EFKOZD Models ................69 Service Schedule for 32-40EKOZD/28-35EFKOZD Models ................... 71 Engine Break-In Period ............................73 Lubrication System ..............................73 3.5.1 Oil Specifications ............................. 73 3.5.2 Oil Check ..............................73 3.5.3 Oil Change ...............................

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions 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.
  • Page 6 Engine Backfire/Flash Fire WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the fuel injection system, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.
  • Page 7 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. 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.
  • Page 8 Short circuits. Hazardous voltage/current will 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.

  • Page 9: Introduction

    Refer to the engine operation manual for generator set engine scheduled maintenance information. 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 without notice and without any obligation or liability whatsoever.

  • Page 10: Service Assistance

    (86) 10 6518 7950 • Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7951 • Look at the labels and decals on your Kohler product (86) 10 6518 7952 or review the appropriate literature or documents Fax: (86) 10 6518 7955 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 21EKOZD, 14EKOZD and 16EKOZD and 24EKOZD, 18EFKOZD, 12EFKOZD 13.5EFKOZD and 20.5EFKOZD...
  • Page 12 TP-7045 Installation Manual TP-7044 Operation Manual TP-6954 Parts Catalog* TP-6939 Service Manual (Engine) TP-6953 Service Manual (Generator) TP-7105 Kohler KDI Special Tools Manual TP-6701 SiteTech™ Software Operation Manual TP-6113 ® Modbus Communications Protocol Operation Manual 21EKOZD 21EKOZD 24EKOZD 24EKOZD 18EFKOZD 17EFKOZD 20.5EFKOZD...

  • Page 13: Service Views

    Section 1. Service Views Service-Side View Side View Non Service-Side View Top View ADV8880- Emergency stop 17. Customer load lead connection ® Decision-Maker 3500 controller 18. Oil drain Nameplate (on front of controller) 19. Optional circuit breaker location (opposite side of junction box) Lifting eye 20.
  • Page 14 Service-Side View End View Non Service-Side View Top View ADV-9908 Emergency stop 18. Oil drain ® Decision-Maker 3500 controller 19. Customer load lead connection Nameplate (on front of controller) 20. Optional circuit breaker location USB port 21. Fuel return connection Air filter element 22.
  • Page 15 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. Sound Shield Equipped Models: For access to the generator set to perform regular maintenance, remove the sound shield doors and roof.
  • Page 16 Notes TP-7044 6/23...

  • Page 17: Operation

    Section 2. Operation 2.1 Prestart Checklist WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. 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.

  • Page 18: Marine Inspection

    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 ®...

  • Page 19: Operation In European Union Member Countries

    European Union Directive 2000/ 14/EC noise emission standard. 2.5 Load Profile Whenever operating the generator set, Kohler Co. recommends maintaining the minimum load profile indicated in Figure 7. Maintaining the load profile prevents corrosion formation on internal engine components when they’re exposed to the breakdown of exhaust gases.

  • Page 20: Decision-Maker 3500 Controller Information

    If the user parameters are included on the personality disk, the disk label should indicate Site Program—Yes. Note: After the unit is set up on the vessel, Kohler authorized distributor/dealer saves any user parameter changes to an external medium. Kohler authorized distributor/dealer passes this information onto the owner. The owner should store this information for possible future use such as controller replacement or other circumstances requiring a backup.

  • Page 21: Controller Features

    2.9 Controller Features The controller features include the annunciator lamp, graphical display and pushbutton/rotary selector dial, switches and controls, and terminal blocks. See Figure 8 for an illustration of the controller front panel. The following paragraphs detail the features by general topics. The controller provides: •...

  • Page 22: Switches And Controls

    2.9.1 Switches and Controls Note: US/Metric Display is selectable in the Controller Configuration Menu section. Alarm Horn. The alarm horn alerts the operator or other attendants that a warning or shutdown condition exists. Alarm (Horn) Silence. The alarm silence switch silences the alarm horn at the operator’s discretion. Press the master control switch AUTO button before pressing the alarm silence button.

  • Page 23: Exhaust Gas Recirculation (Egr) Lamp

    If the light pulses more than one time, verify that the ECU module is properly connected and verify that the EGR valve is properly connected. If all connections are good and the light continues to pulse, contact an authorized Kohler distributor/dealer for service.

  • Page 24: Graphical Display

    System Shutdown Fault Lamp. Red lamp indicates that the generator set has shut down because of a fault condition. The unit will not start without resetting the controller, see the Controller Resetting procedure section. See the System Fault Shutdown Lamp with Digital Displays section, for definitions of the items listed. Note: Always identify and correct the cause of a fault shutdown before resetting the controller.

  • Page 25: Engine Metering Submenu

    2.10.2 Engine Metering Submenu Note: Not all of these engine metering submenus may apply. • Engine Speed (Tachometer) displays the engine speed (RPM) at which the engine is presently running. • Oil Pressure displays the engine oil pressure. • Coolant Temperature displays the engine coolant temperature. •...

  • Page 26: Paralleling Metering Submenu

    2.10.4 Paralleling Metering Submenu Note: ® The paralleling metering is only valid if the Decision-Maker 3500 controller is controlling a motor-operated circuit breaker. • Connected to Bus displays if the generator is connected to the paralleling bus (the output breaker or contactor is closed).

  • Page 27: Event History Submenu

    Note: ® Have setup and adjustments of the Decision-Maker 3500 controller performed only by an authorized Kohler distributor/dealer. The setup and adjustments are password protected. • Operating Mode displays the programmer entered generator set application configuration as Standby or Prime.
  • Page 28 The time delays are user adjustable using SiteTech™. Have setup and adjustments of the Decision-Maker ® 3500 controller performed only by an authorized Kohler distributor/dealer. The setup and adjustments are password protected. • Overvoltage displays the percentage of the system voltage that the generator voltage must exceed for an overvoltage condition to be indicated.

  • Page 29: Voltage Regulation Submenu

    2.11.4 Voltage Regulation Submenu Note: ® Have setup and adjustments of the Decision-Maker 3500 controller performed only by an authorized Kohler distributor/dealer. The setup and adjustments are password protected. ® The Decision-Maker 3500 controller has a built-in voltage regulation function. This means that no external voltage regulator is necessary.

  • Page 30: Voltage Selector Switch

    The user can change the individual value or can select Reset Regulator Defaults?-Yes to reset to the default value. The Reset Regulator Defaults display will only show if editing is enabled. Start-Up Ramp Rate. Slowly ramps the voltage to its target to minimize voltage overshoot at startup. 2.11.5 Voltage Selector Switch The voltage selector switch menu does not apply to the EKOZD and EFKOZD models.
  • Page 31 synchronizer disabled. To remove a generator from service manually, set the Sync Mode in Auto to OFF, wait for any additional generators to start, and set the Load Enable to OFF. When the breaker/contactor trips, stop the generator by pressing the OFF button, then set the Sync Mode back to Active and the Load Enable back to ON.
  • Page 32 Note: This value is only accurate if the generator is running and the bus is energized. The phase angle must be established between two waveforms. Dwell Time Remaining. The remaining time for the dwell timer in seconds. The generator is considered to be in Sync when the dwell timer expires.
  • Page 33 Protective Relays The protective relays serve two purposes: To protect the generator from damage To protect the loads supplied by the generator from damage The protective relays are configured during commissioning and should not be adjusted except by a trained commissioning agent. These settings are often taken into consideration for breaker trip curves, load control settings, and generator management settings.
  • Page 34 Gen Management Modes The method that generator management uses to determine the starting and stopping order of the available generators. All the generators in the system must have the same setting for this parameter for the generator management to operate. If this parameter is changed, it will be updated on all the generators which are connected to the PGEN network.
  • Page 35 Gen Management Order. Determines the Start/Stop Order of this generator. Generators with a lower order will start before generators with a higher order, higher order generators stop before lower order generators. If the Generator Management Order for a generator changes, generator management will start any generators which were involved in the order changing process (including automatic re-sort).
  • Page 36 The generator may remain running and connected to the paralleling bus for a few seconds after the Stop Accumulator reaches 0%. During this time, the generator is unloading so that it can trip the circuit breaker/contactor connecting it to the bus with minimal wear on the contacts in the breaker/contactor and minimal disturbance to the voltage and frequency of the system.
  • Page 37 Min Loads Added. The Load Shed priority that must be online before generator management will consider stopping a generator. This is implemented so that generators aren’t stopped prematurely (before all the available load has been applied to the system). All the generators in the system must have the same setting for Min Loads Added for the generator management to operate. If this parameter is changed, it will be updated on all the generators which are connected to the PGEN network.

  • Page 38: Controller Configuration Menu

    Additional load control settings are provided in SiteTech™, but they are configured during commissioning and should not require ® adjustment after commissioning is complete. Have setup and adjustments of the Decision-Maker 3500 controller performed only by an authorized Kohler distributor/dealer. 2.12 Controller Configuration Menu 2.12.1 Controller Configuration Submenu •...

  • Page 39: Communication Setup Submenu

    2.12.2 Communication Setup Submenu ® Modbus Communications ® ® The controller communicates using Modbus as a slave connection with the Modbus master initiating the communication. The ® controller seeks the system and alternator parameters and diagnostic information then responds back to the Modbus master.

  • Page 40: Calibration Submenu

    Note: Have calibration adjustments performed by an authorized Kohler distributor/dealer. To enable calibration, when the line is highlighted, push and hold the pushbutton/rotary selector dial to enable the calibration capability.

  • Page 41: I/O Setup Menu

    ® Have setup and adjustments of the Decision-Maker 3500 controller performed only by an authorized Kohler distributor/dealer. There is a lot of setup information that can be accessed on this screen, but the parameters should be adjusted only during commissioning.

  • Page 42: Controller Fault Diagnostics

    Each relay provides one set of SPST contacts for field connection of customer supplied indicators or alarms. Contacts are rated for a maximum resistive load of 10A at 120VAC. The fifteen-relay dry contact board has four digital inputs and two analog inputs. There are fourteen programmable relay outputs and one common fault relay output.
  • Page 43 Alarm Fault Programmed Programmed (Failure Mode Level Horn Lamp Input Output Indicator) Event ID/Parameter at Local Display High Engine Coolant Temperature * Shutdown Open Circuit Engine Coolant Temperature * Shutdown Shorted High (3) Engine Coolant Temperature * Shutdown Shorted Low (4) Engine Coolant Temperature * Shutdown High...
  • Page 44 Alarm Fault Programmed Programmed (Failure Mode Level Horn Lamp Input Output Indicator) Event ID/Parameter at Local Display Coolant Pressure Warning Yellow AC Sensing Lost Warning Yellow AC Sensing Lost Shutdown Alternator Protection Shutdown Auxiliary Input Warning Yellow Auxiliary Input Shutdown Battery Charger Fault Warning Yellow...
  • Page 45 Alarm Fault Programmed Programmed (Failure Mode Level Horn Lamp Input Output Indicator) Event ID/Parameter at Local Display Erroneous Data Generator Management (Invalid Warning Yellow Received Generator Management Enabled) High Trip To Shutdown Delay Shutdown Run Relay Coil Overload Shutdown Starter Relay Coil Overload Shutdown High System Frequency...

  • Page 46: Main Logic Circuit Board

    Water ingested into the engine may cause major engine damage that the Kohler Co. warranty does not cover. The controller operation includes several types of starting and stopping functions as detailed below. The controller buttons, lamps, and alarm horn functions are summarized in Figure 16.
  • Page 47 • AUTO-RUN (Press AUTO and RUN together for a system start signal). All generator sets in the system start and run, close to bus, synchronize, parallel, share load, etc. Some generator sets may shut down after a period of time (indicated by Generator Management) but they remain in Standby Mode ready to start and run if needed.

  • Page 48: Emergency Stop

    The engine will run until the coolant temperature is below the Engine Cooled Down parameter setting, or until the Cooldown Delay has expired. The cooldown cycle lasts for some predetermined amount of time. The cooldown delay is an adjustable parameter. The Engine Cooled Down temperature is not adjustable.

  • Page 49: System Status Lamps

    2.14.2 System Status Lamps The (OFF/RESET-AUTO-RUN) buttons indicate the status condition with an integrated lamp at the button. The lamp illuminates on the AUTO (automatic start) button indicating the system senses no faults and the unit is ready to start by remote command.
  • Page 50 Failure to Synchronize. The fault lamp illuminates yellow and the alarm horn sounds when the generator set does not successfully synchronize to the live bus within the time delay as defined in the synchronizing setup menu. The controller will continue attempting to synchronize to the bus after the time delay expires and the warning occurs. Generator Management will start another generator set if this warning occurs.
  • Page 51 Invalid Genset Voltage Phase Connection. The fault lamp illuminates yellow and the alarm horn sounds when another generator in the paralleling system has a different phase connection than this generator. The local display shows System Phase. Low Battery Voltage. The fault lamp illuminates yellow and the alarm horn sounds when the battery voltage drops below a preset level for more than 90 seconds.

  • Page 52: System Fault Shutdown Lamp With Digital Displays

    2.14.4 System Fault Shutdown Lamp with Digital Displays The system FAULT lamp glows red, the alarm horn sounds, and the unit shuts down to indicate a fault shutdown under the following conditions. See the Controller Resetting (Following System Shutdown or Warning) section, Controller Resetting procedure, for information on resetting a system shutdown.
  • Page 53 High Exhaust Temperature. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down immediately when the engine exhaust temperature exceeds the default setting. High Intake Air Temperature. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of high intake air temperature.

  • Page 54: Status And Notice Digital Displays

    Low Oil Pressure. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of low oil pressure. The shutdown occurs 5 seconds after the low pressure condition is detected. The low oil pressure shutdown does not function during first the 30 seconds after startup.

  • Page 55: Controller Resetting (Following System Shutdown Or Warning)

    Engine Cooldown (Delay) Active. This notice message indicates that the delay for engine cooldown is active where the generator set will continue to run after the OFF/RESET button is pressed. The unit will continue to run until the time delay times out.

  • Page 56: Menu Displays

    2.15 Menu Displays Use the Menu Summary List and Figure 23 after reading and understanding the features of the pushbutton/rotary selector dial. See the Graphical Display section. The Menu Summary List and Figure 23 provide a quick reference to the digital display data. Some digital display data may not be identical to your display due to generator set application differences.
  • Page 57 Menu Summary List (Legend: ● First level submenu, ○ second level submenu, ◊ third level submenu) Metering Menu Metering Menu (Continued) Generator Information Menu (Continued) • Generator Metering FUEL RATE: ###GAL/h LAST MAINTENANCE: (shown if available from ECM) ##/##/#### L1-L2 VOLTS: ###V FUEL USED LAST RUN: ###GAL OP HRS SINCE MAINT: ####hrs L2-L3 VOLTS: ###V...
  • Page 58 Generator Information Menu Generator Information Menu (Continued) Generator Information Menu (Continued) (Continued) ◊ ◊ ◊ kW RATING: ####kW CHARGER SYSTEM LOAD ENABLE: ON/OFF* ◊ ◊ kVA RATING: #####kVA VOLTAGE: 12VDC/24VDC SYSTEM LOAD CONTROL: ◊ ◊ RATED CURRENT: ###A AUTO EQUALIZE ENABLED: ON/OFF* ◊...
  • Page 59 Generator Information Menu Generator Information Menu (Continued) Controller Configuration Menu (Continued) • ◊ ◊ BUS PHASE ROTATION: UNDER FREQ DELAY: ##.#s* Controller Configuration ◊ DISABLED/A-B-C/C-B-A REVERSE VAR TRIP: ###.#%* LANGUAGE: English* ◊ ◊ GEN PHASE ROTATION: REVERSE VAR DELAY: ##.#s* UNITS: Metric/English* ◊...
  • Page 60 I/O Menu I/O Menu (Continued) Active Events Menu • • Rotate the dial to view Active Events: Resistive Input Digital Input Warnings Analog Input 0:1 Digital Input 0:1 Shutdowns Analog Input 0:2 Digital Input 0:2 Statuses Analog Input 0:3 Digital Input 0:3 Notices Analog Input 0:4 Digital Input 0:4...
  • Page 61 From Controller Power-Up From Controller Sleep/Idle Operation Alternates Alternates every every 8 seconds 8 seconds °F Changes after 3 seconds DIAL CLICK MAIN MENU 12:00 AM 12/12/12 METERING GENERATOR INFO CONTROLLER CONFIG ACTIVE EVENTS DIAL TURN DIAL PUSH at METERING. Go to the Figure 24. DIAL PUSH at GENERATOR INFO.
  • Page 62 12:00 AM GENERATOR INFO 12/12/12 GENERATOR INFO Note: EVENT HISTORY Battery Charger Configuration menu options appear but do not apply. to these models. CONFIGURATION --> VOLTAGE REGULATOR Note: VOLTAGE SELECTOR SWITCH --> Voltage Selector Switch menu options do not apply to these models. PARALLELING OPERATION Note: EMISSIONS INFO - - >...
  • Page 63 12:00 AM CONTROLLER CONFIG 12/12/12 CONFIGURATION COMMUNICATION SETUP CALIBRATION LANGUAGE: DIAL TURN ENGLISH UNITS: METRIC DIAL PUSH DIAL PUSH DIAL PUSH ENGLISH 12:00 AM TIME FORMAT: 12:00 AM 12:00 AM CALIBRATION COMM SETUP CONTROL CONFIG 12/12/12 12/12/12 12/12/12 GEN L1-L0 VOLTS: ###.#V* 12hr MODBUS BAUD RATE:...

  • Page 64: Monitoring And Programming Setup

    2.16 Monitoring and Programming Setup The user programmer can access the controller data with the controller digital display or a personal computer (PC) with optional SiteTech™ software to monitor and/or program. Access the controller system with a PC using a USB cable with a mini USB plug.
  • Page 65 Remote Single Connection A modem connects a PC to a single device. The PC communicates with the device via telephone line or an Ethernet network. See Figure 29. ®/ Ethernet Modbus Network Ethernet Network Generator Set Personal Computer Controller or with NIC Transfer Switch Control...

  • Page 66: Modbus Communications

    ® 2.16.2 Modbus Communications ® ® The controller communicates using Modbus as a slave connection with the Modbus master initiating the communication. The ® controller seeks the system and alternator parameters and diagnostic information then responds back to the Modbus master.

  • Page 67: Scheduled Maintenance

    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.
  • Page 68 WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the fuel injection system, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.

  • Page 69: Service Schedule For 14-24Ekozd/12-20.5Efkozd Models

    3.2 Service Schedule for 14-24EKOZD/12-20.5EFKOZD Models Every 50 Every Every Every Reference Hrs. 250 Hrs. 500 Hrs. 1000 Perform Service at Intervals Indicated (X) Daily Section or 1 or 3 or 6 Hrs. Month Months Months or Yearly FUEL SYSTEM Check the fuel level and fill as necessary Fuel System (Before operation)
  • Page 70 Service Schedule for 14-24EKOZD/12-20.5EFKOZD Models, continued Every 50 Every Every Every 1000 Reference Hrs. 250 Hrs. 500 Hrs. Perform Service at Intervals Indicated (X) Daily Hrs. Section or 1 or 3 or 6 or Yearly Month Months Months INTAKE/EXHAUST SYSTEM Exhaust Inspect the exhaust system components *†...

  • Page 71: Service Schedule For 32-40Ekozd/28-35Efkozd Models

    3.3 Service Schedule for 32-40EKOZD/28-35EFKOZD Models Every Every Every Every Reference 50 Hrs. 250 Hrs. 500 Hrs. Perform Service at Intervals Indicated (X) Daily 1000 Hrs. Section or Yearly 1 Month 3 Months 6 Months FUEL SYSTEM Check the fuel level and fill as necessary Fuel System (Before operation)
  • Page 72 Service Schedule for 32-40EKOZD/28-35EFKOZD Models, continued Every Every 50 Every 250 Every 1000 500 Hrs. Perform Service at Intervals Indicated (X) Reference Section Daily Hrs. or 1 Hrs. or 3 Hrs. or 6 Month Months or Yearly Months INTAKE/EXHAUST SYSTEM Inspect the exhaust system components *†...

  • Page 73: Engine Break-In Period

    3.4 Engine Break-In Period For the first 50 hours of engine operation, do not exceed 75% of the maximum power supply. 3.5 Lubrication System See the Scheduled Maintenance section for oil change and oil filter replacement intervals. See the Service Views section for the oil drain, oil check, oil fill, and oil filter locations.

  • Page 74: Oil Change

    Change the oil more frequently if the generator operates under dirty, dusty conditions. See Figure 33 for oil capacities. Model L (Qts.) 14EKOZD and 12EFKOZD (1 and 3 Phase) 8.7 (9.2) 16EKOZD and 13.5EFKOZD (1 and 3 Phase) 21EKOZD and 18/17EFKOZD (1 and 3 Phase) 11.2 (11.6)

  • Page 75: Fuel System

    Remove and replace the gaskets (qty. 3) with new gaskets. Fit and tighten the cartridge holder cover on the oil filter support and torque to 25 Nm. Fill with oil. Add new oil of the weight, grade, and quantity specified in Lubrication System section. Electric Oil Drain/Oil Fill Pump Procedure: Disconnect the pump.

  • Page 76: Fuel Filter

    3.6.2 Fuel Filter The quality and condition of the fuel largely determine the filter’s useful life. Replace the fuel filter element as listed in the service schedule. Service Views section shows the typical location of a fuel filter. Use the applicable procedure below to replace the fuel filter.

  • Page 77: Fuel System Bleed

    Fuel filter’s button location GM95722-H Fuel Filter’s Button Figure 34 3.6.3 Fuel System Bleed Bleed air from the fuel system in order to reduce rough running or vapor lock. Trapped air in the fuel system can cause difficult starting and erratic engine operation. Prime the fuel system under the following conditions: •...
  • Page 78 Fuel System Bleed Procedure (14-24EKOZD/12-20.5EFKOZD Models) Loosen the fuel filter’s air vent screw. See Figure 35. Place a suitable container underneath to collect the fuel. Initiate the auto/start sequence until fuel, free of air bubbles, flows from the vent screw at the fuel filter. Tighten the fuel filter’s air vent screw.

  • Page 79: Air Cleaner Service/Replacement (32-40Ekozd/28-35Efkozd Models)

    3.7 Air Cleaner Service/Replacement (32-40EKOZD/28-35EFKOZD Models) A dry-type air cleaner silences and filters the intake air. The air cleaner is housed inside the resonator box. At the interval specified in the service schedule, clean or replace the air filter element. Clean the filter more frequently if the generator set operates in dirty, dusty conditions.

  • Page 80: Exhaust System

    3.8 Exhaust System WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. 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.

  • Page 81: Cooling System

    The seawater then mixes with the engine exhaust and ejects out of the exhaust outlet. See Figure 37 for coolant capacities (include coolant recovery tank capacity of 0.24 L (8 oz.). Model L (Qts.) 14EKOZD and 12EFKOZD (1 and 3 Phase) 5.2 (5.5) 16EKOZD and 13.5EFKOZD (1 and 3 Phase) 21EKOZD and 18/17EFKOZD (1 and 3 Phase) 4.4 (4.6)
  • Page 82 Bleed Procedure (14-24EKOZD & 12-20.5EFKOZD Models) Remove the coolant fill cap. See the Typical (14-24EKOZD and 12-20.5EFKOZD Models) figure in the Service Views section for location. Note: For 21/24EKOZD 60 Hz models, proceed to Step 2. For all other models, proceed to Step 6. Slowly fill the coolant system until observing coolant at the first bleed point (lowest port) with the plug removed.

  • Page 83: Flushing And Cleaning

    Bleed Procedure (32/40EKOZD & 28/35EFKOZD Models) Remove the coolant fill cap. See the Typical (14-24EKOZD and 12-20.5EFKOZD Models) figure in the Service Views section for location. Slowly fill the coolant system. Figure 39 Bleed Point Location Loosen the cap screw C (shown in Figure 39) to release any air and tighten the cap screw C. Torque cap screw to 8 Nm.

  • Page 84: Pressure Cap

    3.9.4 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 85 Flattened vane Crack Broken vane TP-6053 Figure 41 Worn Impeller 10. Inspect the coverplate and gasket for corrosion and/or damage. Replace components as necessary. 11. Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing. 12.

  • Page 86: Siphon Break

    3.9.6 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 43. The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater.
  • Page 87 Waterline TP-5586-3 Silencer vertical lift 1.2 m (4 ft.) max. 10. Intake strainer Exhaust mixer elbow distance above waterline. If less 11. Engine-driven seawater pump than 23 cm (9 in.), a siphon break is required. Siphon break distance above waterline 30.5 cm 12.

  • Page 88: Anticorrosion Zinc Anode

    3.9.7 Anticorrosion Zinc Anode The heat exchanger contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion by seawater. See Figure 44. Zinc GM89507- Figure 44 Anticorrosion Zinc Anode Location 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.
  • Page 89 Anticorrosion Zinc Anode Replacement New Anode Replace When Percent of Models Dimensions mm (in.) Zinc Remaining Is: 14EKOZD/12EFKOZD 16EKOZD/13.5EFKOZD 21EKOZD/18EFKOZD 17EFKOZD 14.5 (0.57) x 40 (1.57) <50% of length/diameter 24EKOZD/20.5EFKOZD 32EKOZD/28EFKOZD 40EKOZD/35EFKOZD Figure 45 Anticorrosion Zinc Anode (Plug) Measurements Diameter: 14.5 mm (0.57 in.) Length: 40 mm (1.57 in.)

  • Page 90: Belt Tension

    3.10 Belt Tension DANGER Hazardous voltage. Moving parts. Will 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 will 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.
  • Page 91 Note: Unit shown with belt guard removed. GM95722-G Engine-driven water pump pulley Check the alternator belt deflection (tension) here Adjusting arm pivot screw Alternator adjusting screw Battery charging alternator pulley Alternator pivot screw Crankshaft pulley Figure 48 Alternator Belt Tension (32-40EKOZD/28-35EFKOZD Model Shown) Press the generator set OFF/RESET button to shut down the generator set.

  • Page 92: Battery

    Change the oil and oil filter. See the Oil Change section. Close the seacock and remove the hose at the seacock. Place the hose in a container having approximately 3.7-7.5 L (1-2 U.S. gallons) of coolant/antifreeze. Kohler Co. recommends using an environmentally friendly potable antifreeze ®...

  • Page 93: Troubleshooting

    Section 4. Troubleshooting 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.
  • Page 94 Exercise run time and/or event records inoperative Displays error message/locks up Excessive or abnormal noise High fuel consumption Low oil pressure Overheats Lacks power Stops suddenly No or low output voltage Starts hard Cranks but does not start Does not crank TP-7044 6/23...
  • Page 95 Exercise run time and/or event records inoperative Displays error message/locks up Excessive or abnormal noise High fuel consumption Low oil pressure Overheats Lacks power Stops suddenly No or low output voltage Starts hard Cranks but does not start Does not crank TP-7044 6/23...
  • Page 96 Exercise run time and/or event records inoperative Displays error message/locks Excessive or abnormal noise High fuel consumption Low oil pressure Overheats Lacks power Stops suddenly No or low output voltage Starts hard Cranks but does not start Does not crank TP-7044 6/23...
  • Page 97 Exercise run time and/or event records inoperative Displays error message/locks up Excessive or abnormal noise High fuel consumption Low oil pressure Overheats Lacks power Stops suddenly No or low output voltage Starts hard Cranks but does not start Does not crank TP-7044 6/23...
  • Page 98 Exercise run time and/or event records inoperative Displays error message/locks up Excessive or abnormal noise High fuel consumption Low oil pressure Overheats Lacks power Stops suddenly No or low output voltage Starts hard Cranks but does not start Does not crank TP-7044 6/23...

  • Page 99: Controller Display And Voltage Regulation Troubleshooting Chart

    4.1 Controller Display and Voltage Regulation Troubleshooting Chart TP-7044 6/23...
  • Page 100 Notes TP-7044 6/23...

  • Page 101: Wiring Diagrams

    Section 5. Wiring Diagrams 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.

  • Page 102: Wiring Diagram Reference

    Model Point-to-Point Figure Schematic Figure Accessory Figure Display Figure 60 Hz Models: 60 Hz Models: Figure 50 Figure 52 14EKOZD/12EFKOZD GM119901 ADV-9971 Figure 51 Figure 53 16EKOZD/13.5EFKOZD 18/17EFKOZD 50 Hz Models: 50 Hz Models: 20.5EFKOZD Figure 54 Figure 56 GM120034...
  • Page 103 Figure 50 Wiring Diagram, Point-to-Point (Sheet 1 of 2) for 14/16EKOZD Models TP-7044 6/23...
  • Page 104 Figure 51 Wiring Diagram, Point-to-Point (Sheet 2 of 2) for 14/16EKOZD Models TP-7044 6/23...
  • Page 105 Figure 52 Wiring Diagram, Schematic (Sheet 1 of 2) for 14/16EKOZD Models TP-7044 6/23...
  • Page 106 Figure 53 Wiring Diagram, Schematic (Sheet 2 of 2) for 14/16EKOZD Models TP-7044 6/23...
  • Page 107 Figure 54 Wiring Diagram, Point-to-Point (Sheet 1 of 2) for 12/13.5/17/18/20.5EFKOZD Models TP-7044 6/23...
  • Page 108 Figure 55 Wiring Diagram, Point-to-Point (Sheet 2 of 2) for 12/13.5/17/18/20.5EFKOZD Models TP-7044 6/23...
  • Page 109 Figure 56 Wiring Diagram, Schematic (Sheet 1 of 2) for 12/13.5/17/18/20.5EFKOZD Models TP-7044 6/23...
  • Page 110 Figure 57 Wiring Diagram, Schematic (Sheet 2 of 2) for 12/13.5/17/18/20.5EFKOZD Models TP-7044 6/23...
  • Page 111 Figure 58 Wiring Diagram, Point-to-Point (Sheet 1 of 2) for 21/24EKOZD 12-Volt Models TP-7044 6/23...
  • Page 112 Figure 59 Wiring Diagram, Point-to-Point (Sheet 2 of 2) for 21/24EKOZD 12-Volt Models TP-7044 6/23...
  • Page 113 Figure 60 Wiring Diagram, Schematic (Sheet 1 of 2) for 21/24EKOZD 12-Volt Models TP-7044 6/23...
  • Page 114 Figure 61 Wiring Diagram, Schematic (Sheet 2 of 2) for 21/24EKOZD 12-Volt Models TP-7044 6/23...
  • Page 115 Figure 62 Wiring Diagram, Point-to-Point (Sheet 1 of 2) for 21/24EKOZD 24-Volt Models TP-7044 6/23...
  • Page 116 Figure 63 Wiring Diagram, Point-to-Point (Sheet 2 of 2) for 21/24EKOZD 24-Volt Models TP-7044 6/23...
  • Page 117 Figure 64 Wiring Diagram, Schematic (Sheet 1 of 2) for 21/24EKOZD 24-Volt Models TP-7044 6/23...
  • Page 118 Figure 65 Wiring Diagram, Schematic (Sheet 2 of 2) for 21/24EKOZD 24-Volt Models TP-7044 6/23...
  • Page 119 Figure 66 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 120 Figure 67 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 121 Figure 68 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 122 Figure 69 Wiring Diagram, Schematic (Sheet 1 of 2) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 123 Figure 70 Wiring Diagram, Schematic (Sheet 2 of 2) for 32EKOZD/28EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 124 Figure 71 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 125 Figure 72 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 126 Figure 73 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 127 Figure 74 Wiring Diagram, Schematic (Sheet 1 of 2) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 128 Figure 75 Wiring Diagram, Schematic (Sheet 2 of 2) for 32EKOZD/28EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 129 Figure 76 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 130 Figure 77 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 131 Figure 78 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 132 Figure 79 Wiring Diagram, Schematic (Sheet 1 of 2) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 133 Figure 80 Wiring Diagram, Schematic (Sheet 2 of 2) for 32EKOZD/28EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 134 Figure 81 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 135 Figure 82 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 136 Figure 83 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 137 Figure 84 Wiring Diagram, Schematic (Sheet 1 of 2) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 138 Figure 85 Wiring Diagram, Schematic (Sheet 2 of 2) for 32EKOZD/28EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 139 Figure 86 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 140 Figure 87 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 141 Figure 88 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 142 Figure 89 Wiring Diagram, Schematic (Sheet 1 of 2) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 143 Figure 90 Wiring Diagram, Schematic (Sheet 2 of 2) for 40EKOZD/35EFKOZD 12-Volt, Standard Ground Models TP-7044 6/23...
  • Page 144 Figure 91 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 145 Figure 92 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 146 Figure 93 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 147 Figure 94 Wiring Diagram, Schematic (Sheet 1 of 2) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 148 Figure 95 Wiring Diagram, Schematic (Sheet 2 of 2) for 40EKOZD/35EFKOZD 24-Volt, Standard Ground Models TP-7044 6/23...
  • Page 149 Figure 96 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 150 Figure 97 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 151 Figure 98 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 152 Figure 99 Wiring Diagram, Schematic (Sheet 1 of 2) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 153 Figure 100 Wiring Diagram, Schematic (Sheet 2 of 2) for 40EKOZD/35EFKOZD 12-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 154 Figure 101 Wiring Diagram, Point-to-Point (Sheet 1 of 3) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 155 Figure 102 Wiring Diagram, Point-to-Point (Sheet 2 of 3) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 156 Figure 103 Wiring Diagram, Point-to-Point (Sheet 3 of 3) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 157 Figure 104 Wiring Diagram, Schematic (Sheet 1 of 2) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 158 Figure 105 Wiring Diagram, Schematic (Sheet 2 of 2) for 40EKOZD/35EFKOZD 24-Volt, Isolated Ground Models TP-7044 6/23...
  • Page 159 Figure 106 Accessory Interconnection Drawing (Sheet 1 of 2) TP-7044 6/23...
  • Page 160 Figure 107 Accessory Interconnection Drawing (Sheet 2 of 2) TP-7044 6/23...
  • Page 161 Figure 108 System Remote Display TP-7044 6/23...
  • Page 162 Notes TP-7044 6/23...

  • Page 163: Appendix A. Abbreviations

    Appendix A. Abbreviations A, amp ampere blk. htr. block heater digital to analog converter ABDC after bottom dead center BMEP brake mean effective pressure decibel alternating current bits per second dB(A) decibel (A weighted) analog to digital Brass direct current advanced digital control;...
  • Page 164 (2 bytes) megabyte (2 bytes) gallons per hour KBus Kohler communication protocol MCCB molded-case circuit breaker gallons per minute kilogram one thousand circular mils grade, gross kg/cm kilograms per square meggar megohmmeter centimeter...
  • Page 165 N, norm. normal (power source) permanent magnet generator silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) not available, not applicable potentiometer, potential s, sec. second Systeme international d’unites, nat. gas natural gas parts per million International System of Units National Bureau of Standards PROM programmable read-only...
  • Page 166 ultrahigh frequency user interface Underwriter’s Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) univ. universal uniform resource locator (web address) undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt...

  • Page 167: Appendix B. Operating Hours And Service Log

    Appendix B. Operating Hours and Service Log Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were performed. Enter hours to the nearest quarter hour. Operating Hours Service Record Total Date Run Hours Run...
  • Page 168 TP-7044 6/23e KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the Original Instructions (English) US and Canada, phone 1-800-544-2444 KOHLERPower.com © 2016 Kohler Co. All rights reserved.

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