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Kohler 15EKOZD - User Manual

Kohler 15EKOZD
360 pages
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Marine Generator Sets
Models:
13- 40EKOZD
11- 35EFKOZD
Controller:
Decision-Makerr 3500
TP-6953 7/19f
Service

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Kohler 15EKOZD Specifications

General IconGeneral
TypePortable Generator
Fuel TypeGasoline
Run Time at 50% Load10 hours
Voltage120/240V
Frequency60 Hz
Starting SystemElectric Start
Power Output15 kW
Rated Watts15000 watts
PhaseSingle Phase
Dimensions (L x W x H)48 x 29 x 33 in
Warranty3 years limited warranty

Summary

Safety Precautions and Instructions

Accidental Starting

Procedure and warnings for preventing accidental generator startup to avoid injury or death.

Engine Backfire;Flash Fire

Warnings and precautions related to risks of fire and explosion from engine backfire.

Exhaust System

Safety warnings regarding carbon monoxide hazards from the exhaust system.

Fuel System

Safety warnings and precautions for handling fuels and fuel vapors to prevent fires.

Hazardous Voltage;Moving Parts

Safety warnings regarding electrical hazards and dangers from moving parts.

Introduction

Service Assistance

Information on how to obtain professional advice and service for generator sets.

Section 1 Specifications

1.1 General

Overview of the manual's scope and guidance on consulting generator set nameplates.

1.2 Engine

Detailed specifications for the engine used in the generator sets.

1.3 Service Views

Illustrations and labels identifying key components and service points on the generator set.

Section 2 Operation

2.1 Prestart Checklist

A comprehensive list of checks to perform before starting the generator set.

2.5 Load Profile

Recommendations for maintaining minimum load to prevent engine wet stacking.

2.6 Controller Operation

Explanation of the Decision-Maker® 3500 controller modes and functions.

Section 3 Scheduled Maintenance

3.1 General

Guidelines for scheduling routine maintenance based on operating hours and conditions.

3.2 Alternator Service

Procedure for cleaning the alternator windings and cooling system.

3.3 Engine Service

Instructions for performing engine service at specified intervals.

Section 4 Exhaust System

4.1 Exhaust System Inspection

Procedure for inspecting the exhaust system for leaks, blockages, and corrosion.

4.2 Servicing Mixing Elbow

Procedure for checking and cleaning the mixing elbow for carbon buildup.

Section 5 Fuel System

5.1 General

Overview of the fuel system and considerations for installations.

5.1.1 Fuel Filter

Information on fuel filter replacement and its impact on system life.

5.1.2 Fuel System Bleed

Procedure to remove air from the fuel system to prevent starting issues.

Section 6 Cooling System

6.1 General

Description of the heat exchanger cooling system components.

6.3 Coolant Replacement Including Heat Exchanger Service

Procedure for replacing coolant and servicing the heat exchanger.

6.5 Flush and Clean Cooling System

Procedure for flushing and cleaning the cooling system.

Section 7 Troubleshooting

7.1 Introduction

Overview of troubleshooting procedures, diagnostics, and repair information.

7.2 Initial Checks

Common problems to check first before replacing parts.

7.3 Troubleshooting Chart

Charts to diagnose and correct common problems with probable causes and recommendations.

Section 8 Decision-Makerr 3500 Controller

8.1 General Repair Information

General guidelines for controller repair and service part replacement.

8.2 SiteTecht Software

Necessary PC requirements and software for using SiteTecht.

8.6 Controller Service Replacement Kit GM92086

Procedure for installing a replacement controller.

Section 9 Component Testing and Adjustment

9.1 Controller Handling

Guidelines for safely handling the controller and its components.

9.4 Leads;Wires;Connectors;Wiring Harnesses

Information on repairing or replacing wiring and connectors.

9.5 Crank Relay

Test procedure for crank relays, run relays, cold start, and flash relays.

Section 10 Alternator Component Testing and Adjustment (11- 32 kW Generator Sets Equipped with 4 D;4 E Alternators)

10.1 Introduction

Overview of troubleshooting and testing alternator components.

10.2 Separate Excitation

Procedure to separately excite the generator using an external voltage source.

10.3 Exciter Field

Procedure for testing the exciter field resistance and for short-to-ground conditions.

Section 11 Alternator Component Testing and Adjustment (35- 40 kW Generator Sets Equipped with 4 PX;4 QX Alternators)

11.1 Introduction

Overview of troubleshooting and testing alternator components.

11.2 Alternator Troubleshooting

Flowcharts for troubleshooting alternator output conditions.

11.3 LED Optic Board Test

Procedure for testing the LED optic board.

Section 12 Paralleling System Information

12.1 Controller Functionality

Description of Decision-Maker® 3500 controller functions for various applications.

12.1.2 External Paralleling

Requirements and considerations for external paralleling.

12.1.3 Internal Paralleling

Requirements and considerations for internal paralleling.

Section 13 Generator Management Information

13.1 Generator Management Purpose

Explains the purpose of Generator Management for optimizing generator operation.

13.2 Generator Management Basic Function

Describes the basic functions of Generator Management for starting/stopping generators.

13.4 Generator Management Setup

Parameters and considerations for configuring Generator Management.

Section 14 Load Management

14.1 Purpose

Explains the purpose of Load Management for controlling loads.

14.2 Basic Function

Describes the basic functions of Load Management in Decision-Maker® 3500.

14.2.1 Sequence of Operation-Single Generator System

Step-by-step operation of Load Management in a single generator system.

Section 15 Alternator Disassembly;Reassembly

15.1 Introduction

Introduction to the alternator disassembly and reassembly procedures.

15.2 Disassembly Procedure

Step-by-step procedure for disassembling the alternator.

15.3 Reassembly

Step-by-step procedure for reassembling the alternator.

Section 16 Additional 4 PX;4 QX Alternator Information

16.1 Disassembly

Disassembly procedures specific to 4PX/4QX alternators.

16.2 Reassembly

Reassembly procedures specific to 4PX/4QX alternators.

Section 17 Wiring Diagrams

17.1 Wiring Diagram Reference

Reference guide to locate specific wiring diagrams for various models.

Appendix A Abbreviations

Appendix B Common Hardware Application Guidelines

Bolt;Screw Length

Guidelines for determining proper bolt and screw length.

Washers and Nuts

Guidelines for selecting and using washers and nuts.

Appendix C General Torque Specifications

American Standard Fasteners Torque Specifications

Torque specifications for American standard fasteners.

Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Torque specifications for metric fasteners.

Appendix D Common Hardware Identification

Screw;Bolts;Studs Head Styles

Identification of common screw, bolt, and stud head styles.

Nuts Nut Styles

Identification of common nut styles.

Washers Washer Styles

Identification of common washer styles.

Appendix E Common Hardware List

American Standard

List of common hardware items for American standard fasteners.

Metric

List of common hardware items for metric fasteners.

Appendix F Electrical Noise and Wiring Practices

Minimize coupling by the following:

Practices to minimize signal coupling between circuits.

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