Marine Generator Sets - Kohler Power
OperationMarine Generator SetsModels:6EKOD9- 11EKOZD5EFKOD7- 9EFKOZDTP-67723/19e
WARNING: This product can exposeyou to chemicals, including carbonmonoxide and benzene, which are knownto the State of California to cause cancerand birth defects or other reproductiveharm.For more information go towww.P65warnings.ca.govWARNING: Breathing diesel engineexhaust exposes you to chemicals knownto the State of California to cause cancerand birth defects or other reproductiveharm.S Always start and operate the engine ina well-ventilated area.S If in an enclosed area, vent the exhaustto the outside.S Do not modify or tamper with theexhaust system.S Do not idle the engine except asnecessary.For more information go towww.P65warnings.ca.gov/dieselProduct Identification InformationProduct identification numbers determine service parts.Record the product identification numbers in the spacesbelow immediately after unpacking the products so thatthe numbers are readily available for future reference.Record field-installed kit numbers after installing thekits.Generator Set Identification NumbersEngine IdentificationRecord the product identification information from theengine nameplate.ManufacturerModel DesignationSerial Numberx:in:007:001Record the product identification numbers from thegenerator set nameplate(s).Model DesignationSpecification NumberSerial NumberAccessory Number2Accessory DescriptionTP-67723/19
Table of ContentsProduct Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2TP-6772Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Maintenance and Service Parts/Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Section 1 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Marine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Angular Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Operation in European Union Member Countries . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 Load Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6 Advanced Digital Control IId Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.1Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.2Starting the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.3Stopping the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.4Fault Shutdowns and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.5Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.6Controller Fault Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.7Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.8Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7 Controller Logic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.1Fault Shutdown and Warning Specifications . . . . . . . . . . . . . . . . . . . . . .2.7.2Controller Resetting (Following System Fault Shutdown) . . . . . . . . . . .2.7.3Voltage Regulator and Calibration Specifications . . . . . . . . . . . . . . . . . .2.7.4Voltage Regulator Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.5System Fault Warning Lamp with Digital Displays . . . . . . . . . . . . . . . . . .2.7.6System Fault Shutdown Lamp With Digital Displays . . . . . . . . . . . . . . . .2.7.7Status and Notice Digital Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8 Menu Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9 Monitoring and Programming Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9.1PC Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10 Reviewing Menu Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.1 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.3 Engine Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.4 Generator Metering (and Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.5 GenSet Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.6 GenSet Run Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.7 GenSet System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.8 Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.9 Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.10 Prime Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.11 Volt Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.12 USB Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53535353636373838383939404041Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Service Schedule—6- 11EKOD/EKOZD & 5- 9EFKOD/EFKOZD Models . . . . . .3.3 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.1Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.2Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.3Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .434344464646473/19Table of Contents3
3.4Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.1Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.2Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.3Fuel System Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.1Closed Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.2Checking and Filling Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.3Flushing and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.4Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.5Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.6Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.7Anticorrosion Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7.1Seawater Pump Belt Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . .Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4848484950515151515252535556565757Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5959Section 5 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Wiring Diagram Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6363Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75Appendix B Operating Hour Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77Appendix C Voltage Regulator Definitions and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .783.53.63.73.83.94Table of ContentsTP-67723/19
Safety Precautions and InstructionsIMPORTANT SAFETY INSTRUCTIONS.Electromechanicalequipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threateningdangerwhenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.This manual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.DANGERDanger indicates the presence of ahazard that will cause severepersonal injury, death, or substantialproperty damage.WARNINGWarning indicates the presence of ahazard that can cause severepersonal injury, death, or substantialproperty damage.CAUTIONCaution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition.Replace missing ordamaged decals.TP-67723/19Accidental StartingWARNINGAccidental starting.Can cause severe injury or death.Disconnect the battery cables beforeworking on the generator set.Remove the negative (- ) lead firstwhen disconnecting the battery.Reconnect the negative (- ) lead lastwhen reconnecting the battery.Disablingthegeneratorset.Accidental starting can causesevere injury or death.Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Move the generator set masterswitchtotheOFFposition.(2) Disconnect the power to the batterycharger.(3) Remove the batterycables, negative (- ) lead first.Reconnect the negative (- ) lead lastwhen reconnecting the battery. Followthese precautions to prevent starting ofthe generator set by an automatictransfer switch, remote start/stopswitch, or engine start command from aremote computer.Engine Backfire/FlashFireWARNINGRisk of fire.Can cause severe injury or death.Do not smoke or permit flames orsparks near fuels or the fuel system.Servicing the fuel system. A flashfire can cause severe injury or death.Do not smoke or permit flames orsparks near the fuel injection system,fuel line, fuel filter, fuel pump, or otherpotential sources of spilled fuels or fuelvapors. Catch fuels in an approvedcontainer when removing the fuel lineor fuel system.Servicing the air cleaner. A suddenbackfire can cause severe injury ordeath. Do not operate the generatorset with the air cleaner/silencerremoved.Combustible materials. A suddenflash fire can cause severe injury ordeath. Do not smoke or permit flamesor sparks near the generator set. Keepthe compartment and the generator setclean and free of debris to minimize therisk of fire. Catch fuels in an approvedcontainer. Wipe up spilled fuels andengine oil.Combustible materials. A fire cancause severe injury or death.Generator set engine fuels and fuelvapors are flammable and explosive.Handle these materials carefully tominimize the risk of fire or explosion.Equip the compartment or nearby areawith a fully charged fire extinguisher.Select a fire extinguisher rated ABC orBC for electrical fires or asrecommended by the local fire code oran authorized agency.Train entionprocedures.Exhaust SystemWARNINGCarbon monoxide.Cancauseseverefainting, or death.nausea,The exhaust system must beleakproof and routinely inspected.Safety Precautions and Instructions 5
Carbonmonoxidesymptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonous gas present inexhaust gases. Carbon monoxide is anodorless,colorless,tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Carbonmonoxide poisoning symptoms includebut are not limited to the following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and musclesD Sleepiness, mental fatigue,inability to concentrateor speak clearly, blurred visionD Stomachache, vomiting, nauseaIf experiencing any of these symptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyand remain active. Do not sit, lie down,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention ifthe condition of affected persons doesnot improve within minutes of breathingfresh air.Inspecting the exhaust system.Carbon monoxide can cause severenausea, fainting, or death. For thesafety of the craft’s occupants, install acarbon monoxide detector. Neveroperate the generator set without afunctioning carbon monoxide detector.Inspect the detector before eachgenerator set use.Operating the generator set. Carbonmonoxide can cause severe nausea,fainting, or death. Be especiallycareful if operating the generator setwhen moored or anchored under calmconditions because gases mayaccumulate. If operating the generatorset dockside, moor the craft so that theexhaust discharges on the lee side (theside sheltered from the wind). Alwaysbe aware of others, making sure yourexhaust is directed away from otherboats and buildings.Fuel SystemWARNINGExplosive fuel vapors.Can cause severe injury or death.Use extreme care when handling,storing, and using fuels.The fuel system. Explosive fuelvapors can cause severe injury ordeath. Vaporized fuels are highlyexplosive. Use extreme care whenhandling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe reach of children. Never add fuel tothe tank while the engine is runningbecause spilled fuel may ignite oncontact with hot parts or from sparks.Do not smoke or permit flames orsparks to occur near sources of spilledfuel or fuel vapors. Keep the fuel linesand connections tight and in goodcondition. Do not replace flexible fuellines with rigid lines. Use flexiblesections to avoid fuel line breakagecaused by vibration. Do not operate thegenerator set in the presence of fuelleaks, fuel accumulation, or sparks.Repair fuel systems before resuminggenerator set operation.Draining the fuel system. Explosivefuel vapors can cause severe injuryor death. Spilled fuel can cause anexplosion. Use a container to catch fuelwhen draining the fuel system. Wipe upspilled fuel after draining the system.Hazardous NoiseCAUTIONHazardous noise.Can cause hearing loss.Hazardous Voltage/Moving PartsDANGERHazardous voltage. Moving parts.Will cause severe injury or death.Operate the generator set only whenall guards and electrical enclosuresare in place.Servicing the generator set when itis operating. Exposed moving partswill cause severe injury or death.Keep hands, feet, hair, clothing, andtest leads away from the belts andpulleys when the generator set isrunning. Replace guards, screens, andcovers before operating the generatorset.Grounding electrical equipment.Hazardous voltage will cause severeinjury or death. Electrocution ispossible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off the maincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.Disconnecting the electrical load.Hazardous voltage will cause severeinjury or death.Disconnect thegenerator set from the load by turningoff the line circuit breaker or bydisconnecting the generator set outputleads from the transfer switch andheavily taping the ends of the leads.High voltage transferred to the loadduring testing may cause personalinjury and equipment damage. Do notuse the safeguard circuit breaker inplace of the line circuit breaker. Thesafeguard circuit breaker does notdisconnect the generator set from theload.Never operate the generator setwithout a muffler or with a faultyexhaust system.6 Safety Precautions and InstructionsTP-67723/19
Shortcircuits.Hazardousvoltage/current will cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.Electrical backfeed to the utility.Hazardous backfeed voltage cancause severe injury or death.Connect the generator set to thebuilding/marina electrical system onlythrough an approved device and afterthe building/marina main switch isturned off. Backfeed connections cancause severe injury or death to utilitypersonnel working on power linesand/or personnel near the work area.Some states and localities prohibitunauthorized connection to the utilityelectricalsystem.Installaship-to-shore transfer switch to preventinterconnection of the generator setpower and shore power.Testing live electrical circuits.Hazardous voltage or current willcause severe injury or death. Havetrained and qualified personnel takediagnostic measurements of livecircuits. Use adequately rated testequipment with electrically insulatedprobes and follow the instructions of th
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) Move the generator set master switch to the OFF position. (2) Disconnectthepowertothebattery charger. (3) Remove the battery cables, negative (-) lead .
ezo3008g 8 3000 155 800,000 25 kohler belt ezo3010g 10 3000 130 1,000,000 belt38 kohler ezo3708g 8 3700 130 800,000 belt38 kohler ezo5005g 5 5000 130 500,000 25 kohler belt ezo6004g 4 6000 160 400,000 25 kohler belt ezo6006g 6 6000 145 belt600,000 38 kohler ezo7004g 4 7000 belt160 400,000 25 kohler
Kohler Stock Coil Kohler Stock Coil Wire Kohler 10, 12, 14 hp Stock Head Gasket MSD Coil Wire Kit 12.00 60.00 22.00 10.00 18.50 Kohler Bowl Kohler Bowl Gasket Hardened Kohler Points Pin K&N Air Filter 7" OD x 9" L (4" opening) Re-cast Kohler Head with Holes (10, 12, 14 & 16 hp) 11.00 3.00 12.00 62.00 145.00 Heavy Duty Main Engine .
and pulling straight up out of the . Flush Valve A 1 Release flush valve by turning righ and pull straight up on the canister. 1 2 1 2. Kohler Co. 9 1102602-A2- I. 1102602-A2-I Kohler Co. Kohler Co. 1102602-A2- I. 1102602-A2-I CALL US FOR HELP NEW ZEALAND AUSTRALIA KOHLER NZ LTD KOHLER CO. Free Ph: 0800 564 537 (0800 KOHLER) Free Ph: 1 800 .
system is a quality KOHLER automatic transfer switch. A transfer switch that's designed by Kohler, built by Kohler and chosen specifically for your power requirements. Good news: There's more. Behind that power system is a team of dedicated Kohler engineers that focuses on every element - generator, transfer switch, switchgear and
Service Manual KT715-KT745 2 Safety 3 Maintenance 5 Specifi cations 12 Tools and Aids . ² Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To fi nd a local Kohler authorized . Year Manufactured Code Factory Code Code Year 43 2013 44 .
ONLY KOHLER ENGINES MAKES KOHLER GENUINE PARTS. KOHLER genuine parts are the key to keeping every hardworking KOHLER engine in top shape. They’re built for the long haul and designed to give peace of mind. Keep this guide handy, and use it whenever you need to find a part . EFI ECH630-ECH749, ECV630-ECV749 PART NUMBER 24 083 03-S .
KOHLER Command PRO V-Twins Model Specifications For more information, contact your KOHLER source of supply, or call toll-free in the U.S. and Canada 800-544-2444. Kohler Co., Kohler, Wisconsin 53044 Tel 920-457-4441 Fax 920-459-1570
KOHLER automatic transfer switch. A transfer switch that's designed by Kohler, built by Kohler and chosen specifically for your power requirements. Good news: There's more. Behind that power system is a team of dedicated Kohler engineers that focuses on every element— generator, transfer switch, switchgear and controller—to be sure
