Kohler 14EKOZD Instruction Manual

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

2 TP-7044 6/23
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.
•Always start and operate the engine in a well-ventilated area.
•If in an enclosed area, vent the exhaust to the outside.
•Do not modify or tamper with the exhaust system.
•Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel
Product Identification Information
Product identification numbers determine service parts. Record the product identification numbers in the spaces below
immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed
kit numbers after installing the kits.
Generator Set Identification Numbers
Record the product identification numbers from the engine nameplate(s).
Model Designation _________________________________________________________
Specification Number _______________________________________________________
Serial Number: ____________________________________________________________
Engine Identification
Record the product identification information from the engine nameplate.
Mufacturer_________________________________________________________________
Model Designation___________________________________________________________
Serial Number_______________________________________________________________
Accessory Number
Accessory Description
Accessory Number
Accessory Description

TP-7044 6/23 3
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
2.1 Prestart Checklist...................................................................................................................................................17
2.2 Marine Inspection...................................................................................................................................................18
2.3 Angular Operation..................................................................................................................................................18
2.4 Operation in European Union Member Countries ..................................................................................................19
2.5 Load Profile............................................................................................................................................................19
2.6 Introduction ............................................................................................................................................................19
2.7 Controller Specifications.........................................................................................................................................19
2.8 Decision-Maker 3500®Controller Information........................................................................................................20
2.9 Controller Features.................................................................................................................................................21
2.9.1 Switches and Controls .............................................................................................................................22
2.9.2 Exhaust Gas Recirculation (EGR) Lamp..................................................................................................23
2.9.3 Annunciator Lamps..................................................................................................................................23
2.9.4 Graphical Display.....................................................................................................................................24
2.10 Metering Menu .......................................................................................................................................................24
2.10.1 Generator Metering Submenu..................................................................................................................24
2.10.2 Engine Metering Submenu.......................................................................................................................25
2.10.3 Overview Submenu..................................................................................................................................25
2.10.4 Paralleling Metering Submenu.................................................................................................................26
2.11 Generator Information Menu..................................................................................................................................26
2.11.1 Generator Information Submenu..............................................................................................................26
2.11.2 Event History Submenu ...........................................................................................................................27
2.11.3 Configuration Submenu ...........................................................................................................................27
2.11.4 Voltage Regulation Submenu ..................................................................................................................29
2.11.5 Voltage Selector Switch...........................................................................................................................30
2.11.6 Paralleling Operation ...............................................................................................................................30
2.12 Controller Configuration Menu ...............................................................................................................................38
2.12.1 Controller Configuration Submenu...........................................................................................................38
2.12.2 Communication Setup Submenu .............................................................................................................39
2.12.3 Calibration Submenu ...............................................................................................................................40
2.13 I/O Setup Menu......................................................................................................................................................41
2.13.1 Controller Fault Diagnostics.....................................................................................................................42
2.13.2 Main Logic Circuit Board..........................................................................................................................46
2.14 Controller Operation...............................................................................................................................................46
2.14.1 Emergency Stop ......................................................................................................................................48
2.14.2 System Status Lamps..............................................................................................................................49
2.14.3 System Fault Warning Lamp with Digital Displays...................................................................................49
2.14.4 System Fault Shutdown Lamp with Digital Displays ................................................................................52
2.14.5 Status and Notice Digital Displays...........................................................................................................54
2.14.6 Controller Resetting (Following System Shutdown or Warning)...............................................................55
2.15 Menu Displays........................................................................................................................................................56
2.16 Monitoring and Programming Setup.......................................................................................................................64
2.16.1 PC Communications ................................................................................................................................64
2.16.2 Modbus®Communications.......................................................................................................................66

4 TP-7044 6/23
Section 3. Scheduled Maintenance........................................................................................................................67
3.1 General Maintenance.............................................................................................................................................67
3.2 Service Schedule for 14-24EKOZD/12-20.5EFKOZD Models................................................................................69
3.3 Service Schedule for 32-40EKOZD/28-35EFKOZD Models...................................................................................71
3.4 Engine Break-In Period..........................................................................................................................................73
3.5 Lubrication System.................................................................................................................................................73
3.5.1 Oil Specifications .....................................................................................................................................73
3.5.2 Oil Check .................................................................................................................................................73
3.5.3 Oil Change...............................................................................................................................................74
3.6 Fuel System...........................................................................................................................................................75
3.6.1 Fuel Specifications...................................................................................................................................75
3.6.2 Fuel Filter.................................................................................................................................................76
3.6.3 Fuel System Bleed...................................................................................................................................77
3.7 Air Cleaner Service/Replacement (32-40EKOZD/28-35EFKOZD Models) ............................................................79
3.8 Exhaust System .....................................................................................................................................................80
3.9 Cooling System......................................................................................................................................................81
3.9.1 Closed Heat Exchanger...........................................................................................................................81
3.9.2 Checking and Filling Coolant ...................................................................................................................81
3.9.3 Flushing and Cleaning .............................................................................................................................83
3.9.4 Pressure Cap...........................................................................................................................................84
3.9.5 Seawater Pump .......................................................................................................................................84
3.9.6 Siphon Break ...........................................................................................................................................86
3.9.7 Anticorrosion Zinc Anode.........................................................................................................................88
3.10 Belt Tension...........................................................................................................................................................90
3.10.1 Belt Tensioning Procedure.......................................................................................................................90
3.11 Battery....................................................................................................................................................................92
3.12 Generator Storage Procedure................................................................................................................................92
Section 4. Troubleshooting.....................................................................................................................................93
4.1 Controller Display and Voltage Regulation Troubleshooting Chart ........................................................................99
Section 5. Wiring Diagrams ..................................................................................................................................101
5.1 Wiring Diagram Reference...................................................................................................................................102
Appendix A. Abbreviations.......................................................................................................................................163
Appendix B. Operating Hours and Service Log......................................................................................................167

TP-7044 6/23 5
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.
This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.
Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and
explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or
damaged decals.
Accidental Starting
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. 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) Press the generator set off/reset button to shut down
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (–) lead
first. Reconnect the negative (–) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the
generator set by the remote start/stop switch.

6 TP-7044 6/23
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. Catch fuels in an
approved container when removing the fuel line or fuel system.
Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the
air cleaner/silencer removed.
Combustible materials. A sudden flash fire can cause severe injury or death. Do not smoke or permit flames or sparks
near the generator set. Keep the compartment and the generator set clean and free of debris to minimize the risk of fire. Catch
fuels in an approved container. Wipe up spilled fuels and engine oil.
Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable
and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area
with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the
local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a
poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause
death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
•Light-headedness, dizziness
•Physical fatigue, weakness in joints and muscles
•Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
•Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active.
Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the
condition of affected persons does not improve within minutes of breathing fresh air.
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. Never operate the generator set without a functioning carbon monoxide detector.
Inspect the detector before each generator set use.
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. If operating the
generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always
be aware of others, making sure your exhaust is directed away from other boats and buildings.

TP-7044 6/23 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. Store fuels in a well-ventilated area away from spark-producing equipment and out of the
reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts
or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines
and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel
line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming generator set operation.
Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion.
Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.
Hazardous Voltage/Moving Parts
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. Replace guards, screens,
and covers before operating the generator set.
Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever
electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer
switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the
equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions
increase the risk of electrocution.
Disconnecting the electrical load. Hazardous voltage will cause severe injury or death. Disconnect the generator set from
the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and
heavily taping the ends of the leads. High voltage transferred to the load during testing may cause personal injury and equipment
damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not
disconnect the generator set from the load.

8 TP-7044 6/23
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. Hazardous backfeed voltage can cause severe injury or death. Connect the generator
set to the building/marina electrical system only through an approved device and after the building/marina main switch is turned
off. Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near
the work area. Some states and localities prohibit unauthorized connection to the utility electrical system. Install a ship-to-shore
transfer switch to prevent interconnection of the generator set power and shore power.
Testing live electrical circuits. Hazardous voltage or current will cause severe injury or death. Have trained and qualified
personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes
and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions
when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch
the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under)
Hot Parts
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap, stop the engine and allow it to cool. Then loosen the
pressure cap to relieve pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and
exhaust system components become extremely hot during operation.
Notice
NOTICE
Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic). Do not
substitute clear glass-type fuses for ceramic fuses. Refer to the wiring diagram when the ampere rating is unknown or
questionable.
NOTICE
Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt
deposits from metal surfaces.

TP-7044 6/23 9
Introduction
This manual provides operation instructions for the following marine model generator sets:
14/16/21/24/32/40EKOZD (60 Hz) and 12.5/13.5/17/18/20.5/28/35EFKOZD (50 Hz)
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.
Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid
bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual
with the equipment for future reference.
The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not
supplied in this manual. Consult the generator set service manual, engine operation manual, and engine service manual for
additional specifications. Obtain copies of the latest spec sheets, manuals, diagrams, and drawings from your local
distributor/dealer.
The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform
required service at the prescribed intervals. Obtain service from an authorized service distributor/dealer to keep equipment in
top condition.
Before installing a marine generator set, obtain the most current installation manual from your local distributor/dealer.
Only qualified persons should install the generator set.

10 TP-7044 6/23
Service Assistance
For professional advice and conscientious service, please
contact your nearest Kohler distributor or dealer.
•Visit the Kohler Co. website at KOHLERPower.com.
•Look at the labels and decals on your Kohler product
or review the appropriate literature or documents
included with the product.
•Call toll free in the US and Canada 1-800-544-2444.
•Outside the US and Canada, call the nearest
regional office.
Headquarters Europe, Middle East, Africa (EMEA)
Kohler EMEA Headquarters
Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]
Asia Pacific
Kohler Asia Pacific Headquarters
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

TP-7044 6/23 11
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.
Part Description
Models
14EKOZD and
12EFKOZD
(1 and 3 Phase)
16EKOZD and
13.5EFKOZD
(1 and 3 Phase)
21EKOZD,
18EFKOZD,
and 17EFKOZD
(1 and 3 Phase)
24EKOZD,
and 20.5EFKOZD
(1 and 3 Phase)
Fuel Filter Element
ED0021753200-S
ED0021753200-S
ED0021753200-S
ED0021753200-S
Oil Filter
ED0021752800-S
ED0021752800-S
ED0021752800-S
ED0021752800-S
Seawater Pump Impeller Kit
229826
229826
229826
229826
V-Belt (Seawater Pump)
GM90645
GM90645
GM90645
GM90645
Zinc Anode
ED0090802840-S
ED0090802840-S
ED0090802840-S
ED0090802840-S
Part Description
Models
32EKOZD and 28EFKOZD (1 and 3 Phase)
40EKOZD and 35EFKOZD (1 and 3 Phase)
Air Intake Filter
GM101994
GM101994
Fuel Filter Element (Primary)
GM41014
GM41014
Fuel Filter Element (Secondary)
ED0021753180-S
ED0021753180-S
Oil Filter Element
ED0021750010-S
ED0021750010-S
Seawater Pump Impeller Kit
GM50644
GM50644
V-Belt (Alternator)
GM102586
GM102586
Zinc Anode
ED0090802840-S
ED0090802840-S
Figure 1 Maintenance and Service Parts

12 TP-7044 6/23
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.
Literature Type
Models
14EKOZD
and
12EFKOZD
(1 Phase)
14EKOZD
and
12EFKOZD
(3 Phase)
16EKOZD
and
13.5EFKOZD
(1 Phase)
16EKOZD
and
13.5EFKOZD
(3 Phase)
Specification Sheet
G2-185
G2-186
G2-187
G2-188
Installation Manual
TP-7045
Operation Manual
TP-7044
Parts Catalog*
TP-6954
Service Manual (Engine)
TP-6939
Service Manual (Generator)
TP-6953
Kohler KDI Special Tools Manual
TP-7105
SiteTech™ Software Operation Manual
TP-6701
Modbus®Communications Protocol Operation Manual
TP-6113
Literature Type
21EKOZD
and
18EFKOZD
(1 Phase)
21EKOZD
and
17EFKOZD
(3 Phase)
24EKOZD
and
20.5EFKOZD
(1 Phase)
24EKOZD
and
20.5EFKOZD
(3 Phase)
Specification Sheet
G2-189
G2-190
G2-191
G2-192
Installation Manual
TP-7045
Operation Manual
TP-7044
Parts Catalog*
TP-6954
Service Manual (Engine)
TP-6939
Service Manual (Generator)
TP-6953
Kohler KDI Special Tools Manual
TP-7105
SiteTech™Software Operation Manual
TP-6701
Modbus®Communications Protocol Operation Manual
TP-6113
Literature Type
32EKOZD
and
28EFKOZD
(1 Phase)
32EKOZD
and
28EFKOZD
(3 Phase)
40EKOZD
and
35EFKOZD
(1 Phase)
40EKOZD
and 35EFKOZD
(3 Phase)
Specification Sheet
G2-194
G2-195
G2-196
G2-197
Installation Manual
TP-7045
Operation Manual
TP-7044
Parts Catalog*
TP-6954
Service Manual (Engine)
TP-6916
Service Manual (Generator)
TP-6953
Kohler KDI Special Tools Manuals
TP-7105, TP-7083, and TP-7084
SiteTech™ Software Operation Manual
TP-6701
Modbus®Communications Protocol Operation Manual
TP-6113
* Includes generator and engine information.
Figure 2 Generator Set Literature

TP-7044 6/23 13
Section 1. Service Views
1. Emergency stop
17. Customer load lead connection
2. Decision-Maker®3500 controller
18. Oil drain
3. Nameplate (on front of controller)
19. Optional circuit breaker location (opposite side of junction box)
4. Lifting eye
20. Fuel supply and return (fuel lines are coiled and tied to unit when shipped)
5. USB port
21. Heat exchanger internal to exhaust manifold
6. EGR lamp (on side of junction box)
(21/24EKOZD (60 Hz) models only)
22. Anticorrosion zinc anode
7. Oil filter
23. Mixing elbow (water outlet/exhaust outlet)
8. Coolant overflow bottle
24. Alternator cooling air inlet
9. Seawater inlet
25. Engine coolant drain
10. Seawater pump
26. Battery positive (+) connection
11. V-belt (Seawater pump)
27. Battery negative (-) connection
12. Belt guard
28. Air outlet
13. Oil check/dipstick
29. Seawater drain (remove hose clamp)
14. Oil drain valve
30. Oil fill
15. Fuel filter
16. Fuel pump
31. Coolant fill/coolant overflow tube
Figure 3 Service Views—Typical (14-24EKOZD and 12-20.5EFKOZD Models)
Note:
Consult installation drawings in the spec sheet or installation manual for more details. Consult an authorized distributor/dealer
or the service manual for items not shown.
ADV8880-
3
4
5
6
7
1
2
29
28
27
26
25
Service-Side View
30
31
19
20
13
14
18
17
16
15
Non Service-Side View
21
22
23
24
Top View
Side View
8
9
10
11
12

14 TP-7044 6/23
1. Emergency stop
18. Oil drain
2. Decision-Maker®3500 controller
19. Customer load lead connection
3. Nameplate (on front of controller)
20. Optional circuit breaker location
4. USB port
21. Fuel return connection
5. Air filter element
22. Fuel supply connection
6. Lifting eye
23. Heat exchanger internal to exhaust manifold
7. Oil filter cartridge cover
24. Anticorrosion zinc anode
8. Oil filter cartridge
25. Water cooled exhaust outlet
9. Coolant overflow bottle
26. Alternator cooling air inlet
10. Seawater inlet
27. Engine coolant drain
11. Seawater pump
28. Battery positive (+) connection
12. V-belt (battery charging alternator)
29. Battery negative (-) connection
13. Belt guard
30. Air outlet
14. Fuel pump
31. Seawater drain (remove hose clamp)
15. Oil check/dipstick
32. Coolant fill/coolant overflow tube
16. Oil drain valve (on engine)
33. Oil fill
17. Fuel filter
Figure 4 Service Views,Typical (32-40EKOZD and 28-35EFKOZD Models)
Note:
Consult installation drawings in the spec sheet or installation manual for more details. Consult an authorized distributor/dealer
or the service manual for items not shown.
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Service-Side View
21
End View
22
25
23
24
28
26
31
30
29
33
32
Non Service-Side View
Top View
ADV-9908
19
20
27
1
2

TP-7044 6/23 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.
Sound Shield Roof and Door Removal
1. Open the service doors by releasing the latches, if equipped, or by using a flat-head screwdriver to turn the 1/4-turn
fasteners. See Figure 5.
2. Lift up the roof by using a flat-head screwdriver to turn the 1/4-turn fasteners. See Figure 5.
3. Slide the roof towards the service side of the unit for removal.
4. Open the front, rear, and non-service side doors as needed.
1. Sound shield roof
2. 1/4-turn fastener
3. Service door
4. Latch
Figure 5 Sound Shield Door and Roof Removal, Typical
3
4
GM102977
1
2
2

16 TP-7044 6/23
Notes

TP-7044 6/23 17
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. If operating the
generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always
be aware of others, making sure your exhaust is directed away from other boats and buildings.
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. Replace guards, screens,
and covers before operating the generator set.
To ensure continued satisfactory operation perform the following checks or inspections before or at each startup, as designated,
and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.
Air Inlets. Check for clean and unobstructed air inlets.
Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and
maintenance.
Coolant Level. Check the coolant level according to the cooling system maintenance information.
Drive Belts if equipped. Check the belt condition and tension of the water pump belt.
Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust
system connections.
Inspect the exhaust system components (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and exhaust
outlet) for cracks, leaks, and corrosion.
•Check the hoses for softness, cracks, leaks, or dents. Replace the hoses as needed.
•Check for corroded or broken metal parts and replace them as needed.
•Check for loose, corroded, or missing clamps. Tighten or replace the hose clamps as needed.
•Check that the exhaust outlet is unobstructed.
•Visually inspect for exhaust leaks (blow by). Check for carbon or soot residue on exhaust components. Carbon and
soot residue indicates an exhaust leak. Seal leaks as needed.
•Ensure that the carbon monoxide detector(s) is (1) in the craft, (2) functional, and (3) energized whenever the generator
set operates.
For your safety: Never operate the generator set without a functioning carbon monoxide detector(s) for your safety and
the safety of others on your vessel.
Fuel Level. Check the fuel level and keep the tank(s) full to ensure adequate fuel supply.

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Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.
Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave
rags, tools, or debris on or near the generator set.
Seawater Pump Priming. Prime the seawater pump before initial startup. To prime the pump: (1) close the seacock, (2) remove
the hose from the water-filter outlet, (3) fill the hose and seawater pump with clean water, (4) reconnect the hose to the water
filter outlet, and (5) open the seacock. Confirm seawater pump operation on startup as indicated by water discharge from the
exhaust outlet.
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
authorized Kohler®distributor/dealer. Repair any problems identified before operating the generator set.
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a
poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause
death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
•Light-headedness, dizziness
•Physical fatigue, weakness in joints and muscles
•Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
•Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active.
Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the
condition of affected persons does not improve within minutes of breathing fresh air.
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. Never operate the generator set without a functioning carbon monoxide detector.
Inspect the detector before each generator set use.
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. If operating the
generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always
be aware of others, making sure your exhaust is directed away from other boats and buildings.
2.3 Angular Operation
See Figure 6 for angular operation limits.
14-24EKOZD/12-20.5EFKOZD Models
Instant Operation (up to1 min.)
Intermittent Operation (up to 30 min.)
35°
25°
32-40EKOZD/28-35EFKOZD Models
Intermittent Operation (up to1 min.)
Continuous Operation
35°
25°
Figure 6 Angular Operation

TP-7044 6/23 19
2.4 Operation in European Union Member Countries
This generator set is specifically intended and approved for operation below the deck in the engine compartment. Operation
above the deck and/or outdoors would constitute a violation of 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. Extended light loading may result in engine “wet stacking.”
Minimum Load Requirement
Ideal Load Requirement
30% load
70% load or more
Figure 7 Load Profile
Unburned Fuel (Wet Stacking) occurs when water/fuel vapor condenses in the exhaust system. At normal combustion
temperatures, water stays vaporized but at low combustion temperatures, it condenses back to a liquid. When running the
generator set under normal loads (30% load or more) for long periods of time, diesel exhaust stays hot enough to prevent
water/fuel vapor from condensing. Conversely, if the generator set is subjected to light loads (30% or less) for long periods of
time, water/fuel vapors accumulate and may result in the following conditions to develop:
•Cylinder wall glazing
•Fuel on water
•Crankcase oil dilution
•Wet stacking
Note:
Consult the engine manufacturer’s guidelines for more details on unburned fuel and wet stacking.
The operator should perform all of the prestart checks. Start the generator set according to the starting procedure in the controller
section of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator
set for fluid or exhaust leaks.
2.6 Introduction
The spec sheets for each generator set provide model-specific generator and engine information. Refer to the respective spec
sheet for data not supplied in this manual. Refer to the generator set service manual, installation manual, engine operation
manual, and engine service manual for additional specifications.
2.7 Controller Specifications
Decision-Maker®3500
Power source with circuit protection
12- or 24-volt DC
Power drain
400 milliamps at 12V
200 milliamps at 24V
Humidity range
5-95%
Operating temperature
-40° to 70°C (-40° to 158°F)
Storage temperature
-40° to 85°C (-40° to 185°F)
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.

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2.8 Decision-Maker 3500®Controller Information
The following data must be resident for the controller to function.
•Application program contains the software that controls system operation. The application file was preprogrammed
in the original controller at the factory.
•Personality profile is specific to the engine and alternator and was preprogrammed in the original controller at the
factory.
Typically, the Kohler authorized distributor/dealer creates a backup of the personality profile and passes this information
onto the owner. Inform the owner to store this information for possible future use such as controller replacement or
other circumstances requiring a backup.
Note:
If the personality profile is NOT available, request a replacement from Kohler Aftermarket Parts Department.
Enter an aftermarket parts order for part number PROFILE. Include in the order notes the generator set model,
specification number, serial number, generator set modifications, and email of recipient.
•User parameters unique to an installation include timer values, setpoints, generator set data such as voltage and
input/output selections. These parameters are typically set up for or by the installer at the time of installation. User
parameters are typically recorded on the personality profile disk, a separate backup disk/drive, or written on a paper
form.
Note:
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.
Note:
Controller service replacement kits do not include the three files. The service technician must install the three files into
the replacement controller.