Kohler 6EOD Operation
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Kohler 6EOD Operation

Kohler 6EOD Operation

Marine generator sets
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Operation
Marine Generator Sets
Models:
6EOD
4.5EFOD
8- -32EOZD
6.5- -27EFOZD
TP-6252
2/08c

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Summary of Contents for Kohler 6EOD

  • Page 1 Operation Marine Generator Sets Models: 6EOD 4.5EFOD 8- -32EOZD 6.5- -27EFOZD TP-6252 2/08c...

  • 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

    ..........Service Schedule—6EOD and 4.5EFOD Models .
  • Page 4 Section 4 Troubleshooting ..............Fault Codes .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Engine Backfire/Flash Safety decals affixed to the equipment IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, in prominent places alert the operator Fire including generator sets, transfer or service technician to potential switches, switchgear, and accessories, hazards and explain how to act safely. can cause bodily harm and pose The decals are shown throughout this WARNING...
  • Page 6 Exhaust System Fuel System Hazardous Noise WARNING CAUTION WARNING Carbon monoxide. Hazardous noise. Explosive fuel vapors. cause severe nausea, Can cause hearing loss. Can cause severe injury or death. fainting, or death. Never operate the generator set Use extreme care when handling, exhaust system must...
  • Page 7 Hot Parts Notice Disconnecting the electrical load. Hazardous voltage cause severe injury or death. Disconnect NOTICE WARNING the generator set from the load by Fuse replacement. Replace fuses turning off the line circuit breaker or by with fuses of the same ampere rating disconnecting the generator set output and type (for example: 3AB or 314, leads from the transfer switch and...
  • Page 8 Notes 8 Safety Precautions and Instructions TP-6252 2/08...

  • 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

    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 14EOZD/ 15.5EOZD/ 13EOZD/ 23EOZD/ 28EOZD/ 20EOZD 24EOZD 32EOZD 6EOD 8EOZD 9EOZD 10EOZD 11EFOZD/ 11.5EFOZD/ 13EFOZD/ 23EFOZD/ 17EFOZD/ Part 4.5EFOD 6.5EFOZD...
  • Page 12 List of Related Literature Figure 2 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set. Models 6EOD 8EOZD 9EOZD 10EOZD 13- -15.5EOZD 20- -24EOZD 28/32EOZD Literature 4.5EFOD...

  • Page 13: Section 1 Service Views

    Section 1 Service Views ADV-6843- 13- -24EOZD & 11- -20EFOZD Models Non Service-Side View GM30645D- 1. ADC 2100 Control 17. Oil drain valve and hose 2. Run-Off/Reset-Auto switch 18. Strain relief for the load lead cable 3. Nameplate 19. Alternator cooling air inlet 4.
  • Page 14 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 15: Section 2 Operation

    Section 2 Operation 2.1 Prestart Checklist Check the hoses for softness, cracks, leaks, or dents. Replace the hoses as needed. WARNING Check for corroded or broken metal parts and replace them as needed. Check for loose, corroded, or missing clamps. Tighten or replace the hose clamps and/or hangers 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 Operation

    The controller is factory-set and should not require configuration or adjustment under normal operating conditions. If the generator set is reconnected to a different voltage and/or frequency, refer to an authorized Kohler distributor/dealer system configuration adjustment instructions.

  • Page 18: Starting The Generator Set

    Kohler Co. warranty does not cover. Operating the generator set. Carbon monoxide can cause The following procedures describe the actions required severe nausea, fainting, or death. Be especially careful if to start the generator set.

  • Page 19: Stopping The Generator Set

    2.6.3 Stopping the Generator Set 2.6.4 Fault Shutdowns The following procedures describe the actions required The generator set shuts down automatically under the to stop the generator set. fault conditions listed in Figure 2-5 and the controller displays a fault code. The generator set cannot be Local Stopping.
  • Page 20 Code Fault Description Check Auxiliary fault Input from a customer-supplied switch that closes Check the cause of the auxiliary fault. input shutdown when the fault is active. Shutdown occurs 0.3 seconds after the fault is detected and will not start when the fault is active (input is grounded).

  • Page 21: Resetting The Controller After A Fault Shutdown

    2. Disconnect the generator set from the load using Kohler recommends moving the master switch to the line circuit breaker or ATS. See the safety the OFF/RESET position (complete power down, precautions at the beginning of this manual before 0 mA draw).

  • Page 22: Circuit Protection

    Section 4, Troubleshooting, for possible Controller Lead PF1 causes. * See Figure 2-8 for the fuse location on 6EOD/4.5EFOD models or See Figure 2-9 for the fuse location on 9EOZD/7EFOZD models. 2.7.1 Line Circuit Breaker Figure 2-7 Fuses...

  • Page 23: 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 24: Service Schedule-6Eod And 4.5Efod Models

    3.2 Service Schedule—6EOD and 4.5EFOD 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...
  • Page 25 Service Schedule—6EOD and 4.5EFOD Models, continued Every Every Every Every 50 Hrs. 250 Hrs. 500 Hrs. Perform Service at Intervals or 1 or 3 or 6 1000 Hrs. Reference Daily or Yearly Indicated (X) Section Month Months Months INTAKE/EXHAUST SYSTEM...

  • Page 26: Service Schedule-8Eozd And 6.5Efozd Models

    3.3 Service Schedule—8EOZD and 6.5EFOZD Models Every Every Every Every 50 Hrs. 200 Hrs. 400 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 operation)
  • Page 27 Service Schedule—8EOZD and 6.5EFOZD Models, continued Every Every Every Every 50 Hrs. 200 Hrs. 400 Hrs. Perform Service at Intervals or 1 or 3 or 6 1000 Hrs. Reference Daily or Yearly Indicated (X) Section Month Months Months INTAKE/EXHAUST SYSTEM Inspect the exhaust system components *[ (Before operation)

  • Page 28: Service Schedule-9--32Eozd And 7--27Efozd Models

    3.4 Service Schedule—9- -32EOZD and 7- -27EFOZD 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 29 Service Schedule—9- -32EOZD and 7- -27EFOZD Models, continued Every Every Every 50 Hrs. 250 Hrs. 500 Hrs. Every or 1 or 3 or 6 1000 Hrs. Perform Service at Intervals Reference Daily Month Months Months or Yearly Indicated (X) Section INTAKE/EXHAUST SYSTEM (Before Inspect the exhaust system components *[...

  • Page 30: Lubrication System

    15W40 --10_C (14_F) 50_C (122_F) shorter engine life. Figure 3-1 shows the recommended Figure 3-2 Engine Oil Selection for Models 6EOD Society of Automotive Engineers (SAE) viscosity and 4.5EFOD designation for given operating temperature ranges. 3.5.2...

  • Page 31: Oil Change

    2. Replace the oil filter. Model L (Qts.) a. Remove filter rotating 6EOD and 4.5EFOD 3.1 (3.2) counterclockwise with an oil filter wrench. 8EOZD and 6.5EFOZD 2.3 (2.4) b. Apply a light coat of clean oil to the rubber seal 9EOZD and 7EFOZD 3.6 (3.8)

  • Page 32: Fuel System

    Note: Avoid storing fuel for more than one month. Take Fuel System. special precautions to keep all dirt, water, and other contaminants out of fuel to prevent the 6EOD, 10- -32EOZD, 4.5EFOD, and 9- -27EFOZD growth of microbes. Microbes form slime that Models: clogs the fuel filter and lines.

  • Page 33: Bleeding The Fuel System

    5. Loosen the fuel injection pump screw at position 5. 6. Initiate the auto/start sequence until fuel, free of air bubbles, flows from the vent screw at position 5. Tighten the screw. 6EOD, 10- -32EOZD, 4.5EFOD, and 9- -27EFOZD Models: 1. Loosen the fuel injection pump screw. Figure 3-5.

  • Page 34: Air Intake Silencer/Cleaner

    Air Cleaner Service/Replacement 2. Remove the filter element and inspect. If the element is not damaged, continue with step 3. If 6EOD, 8/9/10/13/20/28/32EOZD, the element is damaged, replace it, skip step 3, and 4.5EFOD, and 6.5/7/9/11/17/17.5/23/27EFOZD go to step 4.

  • Page 35: Exhaust System

    3.8 Exhaust System At the interval specified in the service schedule, inspect the exhaust system components (exhaust manifold, mixing elbow, exhaust hose, hose clamps, silencer, and WARNING outlet flapper) for cracks, leaks, and corrosion. See Section 1 for the exhaust outlet location. Ensure that the carbon monoxide detector(s) is (1) in the craft, (2) functional, and (3) energized whenever the Carbon monoxide.

  • Page 36: Cooling System

    (include coolant recovery tank capacity of 0.24 L (8 oz.). just below the overflow tube opening. Model L (Qts.) Note: A coolant solution of 50% ethylene glycol is 6EOD and 4.5EFOD 2.0 (2.1) required. This mix provides freezing protection to --37°C (--34°F) and overheating protection to 8EOZD and 6.5EFOZD 3.9 (4.1)

  • Page 37: Pressure Cap

    3. Flush the system with clean water. 4. Fill the system with recommended coolant. 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.

  • Page 38: Siphon Break

    3.9.6 Siphon Break 6. Install the reed valve into the mounting base with the valve downward. See Figure 3-11, item 2. A siphon break prevents seawater entry into the generator set’s engine when the engine exhaust 7. Install and only finger tighten the retaining cap. Do not overtighten it.
  • Page 39 Waterline 1. Silencer vertical lift 1.2 m (4 ft.) max. 10. Seacock TP-5586-3 2. Exhaust mixer elbow distance above waterline. If less than 11. Intake strainer 23 cm (9 in.), a siphon break is required. 12. Engine-driven seawater pump 3. Siphon break distance above waterline 30.5 cm (1 ft.) min. 13.

  • Page 40: Anticorrosion Zinc Anode

    3.9.7 Anticorrosion Zinc Anode heat exchanger models 8/9/10EOZD, 6.5/7/9EFOZD, 28/32EOZD, 23/27EFOZD contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion by seawater. Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule. TP-5586-3 Depending upon operating conditions and seawater 1.

  • Page 41: Belt Tension

    3.10 Belt Tension 3.10.1 Seawater Pump Belt Tensioning Procedure, If Equipped WARNING 1. Remove the belt guard. 2. Check the belt tension at the midpoint of the longest span of the belt using a belt-tensioning tool set to 55 ft. lbs. See Figure 3-15. Recheck a new belt tension after 10 minutes of operation.

  • Page 42: 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 43: Section 4 Troubleshooting

    Section 4 Troubleshooting 4.1 Fault Codes This section contains generator set troubleshooting, diagnostic, and repair information. The Advanced Digital Control displays fault codes to aid Use the following charts as a quick troubleshooting in troubleshooting. Fault codes, descriptions, and reference. The table groups generator set faults and recommended actions are listed in Figure 2-5.
  • Page 44 TP-6252 2/08 Section 4 Troubleshooting...
  • Page 45 TP-6252 2/08 Section 4 Troubleshooting...
  • Page 46 TP-6252 2/08 Section 4 Troubleshooting...

  • Page 47: Section 5 Wiring Diagrams

    5.1 Wiring Diagram Reference Figure 5-1 lists the wiring diagram numbers and locations. Wiring Model Figure Schematic Figure Diagram 6EOD ADV-7095A-D Figure 5-3 GM42202-E Figure 5-2 4.5EFOD ADV-7095B-D Figure 5-4 9EOZD GM50490-B Figure 5-5...
  • Page 48 GM42202-E Figure 5-2 Wiring Diagram for Model 6EOD/4.5EFOD Section 5 Wiring Diagrams TP-6252 2/08...
  • Page 49 ADV7095A-D Figure 5-3 Schematic for Model 6EOD/4.5EFOD (Sheet 1 of 2) TP-6252 2/08 Section 5 Wiring Diagrams...
  • Page 50 ADV7095B-D Figure 5-4 Schematic for Model 6EOD/4.5EFOD (Sheet 2 of 2) Section 5 Wiring Diagrams TP-6252 2/08...
  • Page 51 GM50490-B Figure 5-5 Wiring Diagram for Model 9EOZD/7EFOZD TP-6252 2/08 Section 5 Wiring Diagrams...
  • Page 52 GM50488-A Figure 5-6 Wiring Diagram for Models 8, 10--32EOZD/6.5, 8.5--27EFOZD Section 5 Wiring Diagrams TP-6252 2/08...
  • Page 53 ADV7283A-A Figure 5-7 Schematic for Models 8--32EOZD/6.5--27EFOZD (Sheet 1 of 2) TP-6252 2/08 Section 5 Wiring Diagrams...
  • Page 54 ADV7283B-A Figure 5-8 Schematic for Models 8--32EOZD/6.5--27EFOZD (Sheet 2 of 2) Section 5 Wiring Diagrams TP-6252 2/08...

  • Page 55: 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 56 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter µF microfarad read only memory 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 57: 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 58 TP-6252 2/08...
  • Page 59 TP-6252 2/08...
  • Page 60 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-6252 2/08c 7 Jurong Pier Road Singapore 619159 Phone (65)6264-6422, Fax (65)6264-6455 E 2004, 2006, 2007, and 2008 by Kohler Co. All rights reserved.

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