Kohler 13.5CCOZ, 11CCFOZ, 15CCFOZ, 21CCOZ, 16.5CCFOZ Installation Manual

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Page 1

Operation and

Installation Manual

Marine Generator Sets

Models:

13.5CCOZ/11CCFOZ

18.5 CCOZ/15CCFOZ 21CCOZ/16.5CCFOZ

18CCFOZ

14CCOZ/11.5CCFOZ

20CCOZ/17.5CCFOZ

24CCOZ/20CCFOZ

1 Phase

and 3 Phase

TP-5592 7/96a

Page 2

California Proposition 65

WARNING

Engine exhaust from this product contains chemicalsknowntotheState of Californiato cause cancer, birth defects, or other reproductive harm.

Page 3

Table of Contents

SUBJECT PAGE SUBJECT PAGE

Safety Precautions and Instructions I. . . . . .

Reference Material IX. . . . . . . . . . . . . . . . . . . . . .

Introduction i. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance ii. . . . . . . . . . . . . . . . . . . . . .

Routine Service Parts iv. . . . . . . . . . . . . . . . . . .

Section 1. Specifications 1-1. . . . . . . . . . . . . . . .

General Specifications—1-Phase Models 1-1. . . .

General Specifications—3-Phase Models 1-2. . . .

Generator 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Ratings—1-Phase Models 1-4. . . . . . . .

Generator Ratings—3-Phase Models 1-5. . . . . . . .

Engine 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Data 1-6.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Specifications—1-Phase Models 1-7. . . . .

Engine Specifications—3-Phase Models 1-9. . . . .

Controller 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Features 1-10.. . . . . . . . . . . . . . . . . . . . . .

Accessories 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Views 1-13.. . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2. Operation 2-1. . . . . . . . . . . . . . . . . . . .

Prestart Checklist 2-1. . . . . . . . . . . . . . . . . . . . . . . .

Exercising the Generator Set 2-2. . . . . . . . . . . . . .

Controller 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Procedure 2-3. . . . . . . . . . . . . . . . . . . . . . .

Preheat Feature 2-3. . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Generator 2-3. . . . . . . . . . . . . . . . . . . . . . . .

Stopping Procedure 2-3.. . . . . . . . . . . . . . . . . . . . .

Circuit Protection 2-4.. . . . . . . . . . . . . . . . . . . . . . . .

Engine Safety Shutdown Switches 2-4. . . . . . . . . .

Remote Panels (Optional) 2-5. . . . . . . . . . . . . . . . .

Section 3. Scheduled Maintenance 3-1.. . . . . .

General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Schedule 3-3. . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Syst em 3-6.. . . . . . . . . . . . . . . . . . . . . .

Specifications 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Check 3-6.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Change 3-7.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Filter Change 3-8.. . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 3-9.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleeding Fuel System 3-10.. . . . . . . . . . . . . . . . . . . .

Air Intake Silencer/Cleaner 3-11. . . . . . . . . . . . . . . .

Turbocharger 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Mixing Elbow 3-12.. . . . . . . . . . . . . . . . . . .

Governor 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling Syst ems 3-14. . . . . . . . . . . . . . . . . . . . . . . . .

Closed/Heat Exchanger 3-14. . . . . . . . . . . . . . . . . . .

Siphon Break 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt Tension 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seawater Pump Belt 3-17. . . . . . . . . . . . . . . . . . . . . .

Battery Charging Alternator/

Engine-Driven Water Pump Belt 3-18. . . . . . . . . . .

Battery 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning 3-19.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charging 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Electrolyte Level 3-20. . . . . . . . . . . . . . . . .

Checking Specific Gravity 3-21. . . . . . . . . . . . . . . . . .

Generator Service 3-22. . . . . . . . . . . . . . . . . . . . . . . .

General 3-22.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wattage Requirement s 3-22.. . . . . . . . . . . . . . . . . . .

Storage Procedure 3-23. . . . . . . . . . . . . . . . . . . . . . .

Section 4. Troubleshooting 4-1. . . . . . . . . . . . . .

Section 5. Wiring Diagrams 5-1. . . . . . . . . . . . . .

Section 6. Installation 6-1. . . . . . . . . . . . . . . . . . .

Introduction 6-1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 6-3.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Space 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent ilation 6-4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Systems 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Supply 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti-Siphon Provisions 6-6.. . . . . . . . . . . . . . . . . . .

Fuel Lines And Filters 6-6.. . . . . . . . . . . . . . . . . . . .

Fuel Pump Lift Capabilities

And Fuel Consumption 6-6.. . . . . . . . . . . . . . . . .

Cooling Syst ems 6-8. . . . . . . . . . . . . . . . . . . . . . . . .

General 6-8.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Closed/Heat Exchanger 6-10. . . . . . . . . . . . . . . . . . .

Exhaust Systems 6-12. . . . . . . . . . . . . . . . . . . . . . . . .

General 6-12.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Above Waterline 6-13. . . . . . . . . . . . . . . . . . . . . . . . . .

Mid/Below Waterline 6-15. . . . . . . . . . . . . . . . . . . . . .

Electrical Systems 6-17. . . . . . . . . . . . . . . . . . . . . . . .

AC Volt age Connections 6-17.. . . . . . . . . . . . . . . . . .

Installation In Steel Or Aluminum Vessels 6-18. . . .

Installation Regulations 6-18.. . . . . . . . . . . . . . . . . . .

Battery 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Start Switch Connection 6-20. . . . . . . . . . . .

Section 7. Installation Drawings 7-1. . . . . . . . . .

Appendix A. Generator Selection

and Wattage Requirements A-1. . . . . . . . . . . . .

Appendix B. Glossary of Abbreviations B-1. . . Appendix C. Operating Hour Service Log C-1.

TP-5592 7/96 Table of Contents

Page 4

Safety Precautions and Instructions

A generator set, like any other electromechanical device, can pose potential dangers to life and limb if improperly maintained or operated. The best way to prevent accidents is to be aware of potential dangers and act safely. Please read and follow the safety precautions and instructions below to prevent harm to yourselfandothers. This manualcontains severaltypes of safety precautions and instructions which are explained below. SAVE THESE INSTRUCTIONS.

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

CAUTION

Safety decals affixed to the generator set in prominent places advise the operator or service technician of potential hazards and how to act safely. The decals are reproduced in this publication to improve operator recognition. Replace missing or damaged decals.

Accidental Starting

WARNING

Accidental starting. Can cause severe injury or death.

Disconnect battery cables before working on generator set (disconnect negative lead first and reconnect it last).

Disabling generator set. Accidental starting can cause severe injury or death. Disconnect battery

cables (remove negative lead first and reconnect it last) todisable generatorsetbefore workingonthe generator set or connected equipment. The generator set can be started by the remote start/stop switch unless this precaution is followed.

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is important but not hazard related.

TP-5592 7/96

Safety Precautions and Instructions I

Page 5

Battery

Engine Backfire/Flash Fire

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Use protective goggles and clothes. Battery acid can cause permanent damage to eyes, burn skin, and eat holes in clothing.

Battery acid. Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can

cause permanent damage to eyes, burn skin, and eat holes in clothing. Always wear splash-proof safety goggleswhen working near the battery. If battery acid is splashed in the eyes or on skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eyecontact. Neveradd acidto abatteryafterplacingthe battery in service, as this may result in hazardous spattering of battery acid.

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do

not smoke or permit flame or spark to occur near a battery at any time, particularly when it is charging. Avoid touching terminals with tools, etc., to prevent burns and sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling battery. Never connect negative (--) battery cable to positive (+) connection terminal of starter solenoid. Do not test battery condition by shorting terminalstogether. Sparkscould ignite battery gases or fuel vapors. Ventilate any compartment containing batteries to prevent accumulation of explosive gases. To avoid sparks, do not disturb battery charger connectionswhile battery isbeingcharged. Alwaysturn battery charger off before disconnecting battery connections. Remove negative lead first and reconnect it last when disconnecting battery.

WARNING

Fire. Can cause severe injury or death.

Do not smoke or permit flame or spark to occur near fuel or fuel system.

Servicingfuel system. A flash firecan cause severe injuryor death. Do notsmoke orpermit flameor spark

to occur near carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuel or fuel vapors. Catch all fuel in a suitable containerwhen removing fuel line or carburetor.

Servicing backfire flame arrestor. A sudden backfire can cause severe injury or death. Do not

operate with backfire flame arrestor removed.

Servicing air cleaner. A sudden backfire can cause severe injury or death. Do not operate with air

cleaner/silencer removed.

Combustible materials. A sudden flash fire can cause severe injury or death. Do not smoke or permit

flame or spark to occur near fuel system. Keep the compartmentandgeneratorsetclean and free of debris to minimize chances of fire. Wipe up all spilled fuel and engine oil.

II Safety Precautions and Instructions

TP-5592 7/96

Page 6

Exhaust System

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Copper tubing exhaust systems. Carbon monoxide can cause severe nausea, fainting, or death. Do not

use copper tubing in diesel exhaust systems. Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems resulting in exhaust/water leakage.

Inspecting exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. In addition

to routine exhaust system inspection, install a carbon monoxide detector. Consult your boat builder or dealer forapproved detector installation. Inspect yourdetector before each generator set use.

Carbon monoxide symptoms. Carbon monoxide cancause severe nausea, fainting, or death. Carbon

monoxide is a poisonous gas which is present in exhaustgases. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness D Physical fatigue, weakness in joints and muscles D Sleepiness, mental fatigue, inability to concentrate

or speak clearly, blurred vision

D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, affected persons should seek fresh air immediately. They should remain active. They should notsit,lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. If the condition of affected persons does not improve within minutes of breathing fresh air, they should seek medical attention.

Operating generator set. Carbon monoxide can cause severe nausea, fainting, or death. Use the

following precautions when installing and operating generator set. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas. Be especially careful if operating the generator set when moored or anchored under calm conditions as 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—make sure your exhaust is directed away from other boats and buildings. Do not install exhaust outlet where exhaust can be drawn in through portholes,vents,orairconditioners. If the generator set exhaust discharge outlet is near the waterline water could enter the exhaust discharge outlet and close or restrict the flow of exhaust. Avoid overloading the craft.

TP-5592 7/96

Safety Precautions and Instructions III

Page 7

Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Useextreme care when handling, storing, and using fuels.

Fuel system. Explosive fuel vapors can cause severe injury or death. All fuels arehighly explosive in

a vapor state. Use extreme care when handling and storing fuels. Store fuel in a well-ventilated area away fromspark-producingequipmentandout of the reach of children. Never add fuel to the tank while the engine is running since spilled fuel may ignite on contact with hot parts or from ignition spark. Do not smoke or permit flame or spark to occur near sources of spilled fuel or fuelvapors. Keep fuellinesand connections tight andin good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid breakage causedby vibration. Donotoperate generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair systems before resuming generator set operation

Draining 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 fuel system. Wipe up all spilled fuel after draining system.

Installing fuel system. Explosive fuel vapors can causesevere injury or death. Fuel leakage cancause

an explosion. Do not modify the tank or propulsion enginefuelsystem. Equip craftwith a tank allowing one of the two pickup arrangements described in the installation section. Tank and installation must conform to U.S.C.G. Regulations.

Pipe sealant. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an

explosion. Use pipe sealant on all threaded fittings to prevent fuel leakage. Use pipe sealant which resists gasoline,grease, lubricationoil,common bilgesolvents, and salt or fresh water.

IV Safety Precautions and Instructions

TP-5592 7/96

Page 8

Hazardous Noise

CAUTION

Hazardous noise. Can cause loss of hearing.

Never operate generator set without a muffler or with a faulty exhaust system.

Hazardous Voltage/ Electrical Shock

WARNING

Hazardous voltage. Can cause severe injury or death.

Moving rotor.

Shortcircuits. Hazardous voltagecan 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 adjustments are made. Remove wristwatch, rings, and jewelry before servicing equipment.

Testing voltage regulator. Hazardous voltage can cause severe injury or death. High voltage is present

at the voltage regulator heat sink. Do not touch voltage regulator heat sink when testing or electrical shock will occur.

(PowerBoostt, PowerBoostt III, and PowerBoostt V voltage regulator models only.)

Electrical backfeed to utility. Hazardous backfeed voltage can cause severe injury or death. Connect

generator set to building/marina electrical system only through an approved device and after building/marina main switch is open. Backfeed connections can cause serious injury or death to utility personnel working on power lines and/or personnel in the vicinity of the work area. Unauthorized connection to utility electrical systemmay beunlawfulin somestatesand/or localities. Install a ship-to-shore transfer switch to prevent interconnection of generator set power and shore power.

Operate generator set only with all guards and electrical enclosures in place.

Grounding generator set. Hazardous voltage can cause severe injury or death. Electrocution is

possible whenever electricity is present. Open main circuit breakers of all power sources before servicing equipment. Configure the installation to electrically ground the generator set and electrical circuits when in use. Never contact electrical leads or appliances when standing in water or on wet ground, as the chance of electrocution is increased under such conditions.

TP-5592 7/96

Safety Precautions and Instructions V

Page 9

Heavy Equipment

Hot Parts

WARNING

Unbalanced weight. Improper lift can cause severe injury or death and/or equipment damage.

Do not use lifting eyes. Use slings under skid to balance and lift generator set.

WARNING

Hot coolant and steam. Can cause severe injury or death.

Before removing pressure cap, stop generator set and allow it to cool. Then loosen pressure cap to relieve pressure.

WARNING

Hot engine and exhaust system. Can cause severe injury or death.

Do not work on generator set until it is allowed to cool.

Checking coolant level. Hot coolant can cause severe injury or death. Allow engine to cool. Release

pressure from cooling system before opening pressure cap. Torelease pressure, coverthepressurecap with a thick cloth; then slowly turn it counterclockwise to the first stop. Remove cap after pressure has been completely released and the engine has cooled. Check coolant level at tank if generator set is equipped with a coolant recovery tank.

Servicing exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.

An engine becomes hot while running and exhaust system components become extremely hot.

VI Safety Precautions and Instructions

TP-5592 7/96

Page 10

Moving Parts

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate generator set only with all guards and electrical enclosures in place.

Moving rotor.

WARNING

Rotating parts. Can cause severe injury or death.

Do not operate generator set without all guards, screens, and covers in place.

Tightening hardware. Flying projectiles can cause severe injury or death. Retorque all crankshaft and

rotorhardware afterservicing. Donot loosencrankshaft hardware or rotor thrubolt when making adjustments or servicinggeneratorset. Rotate crankshaftmanuallyin a clockwisedirection only. Turningcrankshaft bolt orrotor thrubolt counterclockwise can loosen hardware. Loose hardware can cause hardware or pulley to release from engine of generator set and can cause personal injury.

Servicing generator set when operating. Exposed moving parts can cause severe injury or death.

Keep hands, feet, hair, clothing, and test leads away from belts and pulleys when generator set is running. Replace guards, screens, and covers before operating generator set.

Sound shield removal. Exposed moving parts can cause severe injury or death. Additional precautions

for sound shield-equipped models:

The generator set must be operating in order to perform some scheduled maintenance procedures. Be especially careful if the sound shield has been removed leaving belts and pulleys exposed.

TP-5592 7/96

Safety Precautions and Instructions VII

Page 11

Notice

NOTICE

This generator set has been rewired from its nameplate voltage to:

246242

NOTICE

Voltage reconnection! Affix notice to generator set

after reconnecting to a voltage different than the nameplate. Order voltage reconnection decal 246242 from authorized service distributors/dealers.

NOTICE

Hardwaredamage! Engine andgeneratorset may use

both American Standard and metric hardware. Usethe correct size tools to prevent rounding of bolt heads and nuts.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are

available in different hardness ratings. American Standard hardware uses a series of markings and metric hardware uses a numeric system to indicate hardness. Check markings on bolt head and nuts for identification.

NOTICE

Fuse replacement! Replace fuses with fuses of the

sameampereratingandtype(forexample:ABCor3AC, ceramic). Do not substitute clear glass-type fuses for ceramic fuses. If ampere rating is unknown or questionable, see wiring diagram.

NOTICE

Seawater damage! High-mineral content seawater

(saltwater) causes rapid deterioration of all metals. Wipe up all saltwater spillage on and around generator set and keep metal surfaces free from accumulated salt deposits.

VIII Safety Precautions and Instructions

TP-5592 7/96

Page 12

Reference Material

Observe the regulations and standards below when installing marine generator sets.

Pleasurecraft

U.S. Coast Guard Code of Federal Regulations

Title 33, Part 183

Subpart I—Electrical Systems Subpart J—Fuel Systems

Order the above publication from:

Superintendent of Documents U.S. Government Printing Office Washington, DC 20402 Phone: 1-202-783-3238

Boating Safety Circular Commandant (G-BC) Boating Statistics (G-BP-1)

Order the above documents from:

U.S. Coast Guard Headquarters 2100 Second Street, S.W. Washington, DC 20593-0001 Boating Safety Hotline: 1-800-368-5647

Underwriters Laboratories, Inc. (UL)

Publications Stock 333 Pfingsten Road Northbrook, IL 60062 Marine Department Phone: 1-919-549-1400

NFPA 302

National Fire Protection Association Batterymarch Park Quincy, MA 02269

Society of Automotive Engineers (SAE)

Customer Service 400 Commonwealth Drive Warrendale, PA 15086 Phone: 1-412-776-4970

American Boat and Yacht Council, Inc. (ABYC)

3069 Solomon’s Island Rd. Edgewater, MD 21037 Phone: 1-410-956-1050 Phone: 1-410-974-8112 Fax: 1-410-956-2737

IEEE 45

TheInstitute of Electrical and ElectronicsEngineersInc. 345 East 47th Street New York, NY 10017

Reference Material IXTP-5592 7/96

Page 13

Commercial Vessels

In order to use generator sets listed in this manual for commercial applications where U.S. Coast Guard Title 46Certificate isrequired,additional modifications willbe necessary.

U.S. Coast Guard Code of Federal Regulations

Title 46

Subchapter F—Marine Engineering

Part 58—Main and Auxiliary Machinery and

Related Systems

Subchapter J—Electrical Engineering

Part 111—Electrical Systems—

General Requirements

Part 112—Emergency Lighting and Power Systems

Subchapter T—Small Passenger Vessels

(Under 100 Gross Tons) Part 182—Machinery Installation Part 183—Electrical Installation

Order the above publications from the following address:

Superintendent of Documents U.S. Government Printing Office Washington, DC 20402 Phone: 1-202-783-3238

American Bureau of Shipping (ABS)

65 Broadway New York, NY 10006

Order ABS publications from:

American Bureau of Shipping Book Order Section 45 Eisenhower Drive P.O. Box 910 Paramus, NJ 97653-0910

Lloyd’s Register of Shipping

71 Fenchurch Street London, EC3M 4BS England

Midwest Office:

Lloyd’s Register of Shipping 100 South York Street, Room 226 Elmhurst, IL 60126 Phone: 1-312-279-5414

Additional References

The following organizations provide a service which may be useful to the generator set installer. These organizations do not regulate but rather provide guidelines and assistance. They are listed only as a source for additional information. Kohler Co. hereby gives no solicitation or representation.

Yacht Corrosion Consultants, Inc.

2970 Seaborg Ave. Ventura, CA 93003 Phone: 1-805-644-1886

Ward’s Marine Electric, Inc.

630 S.W. Flagler Ave. Ft. Lauderdale, FL 33301 Phone: 1-305-523-2815 Phone: 1-800-545-9273 Fax: 1-305-523-1967

X Reference Material TP-5592 7/96

Page 14

Introduction

This manual covers the general operation, maintenance, and installation of the following Kohler marine generator sets:

D 13.5CCOZ/11CCFOZ

D 18.5CCOZ/15CCFOZ

D 21CCOZ/16.5CCFOZ

D 18CCFOZ

D 14CCOZ/11.5CCFOZ

D 20CCOZ/17.5CCFOZ

D 24CCOZ/20CCFOZ

All information in this publication represents data available at time of printing. Kohler Co. reserves the right to change this literature and the products represented without incurring obligation.

Read through 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 equipment for future reference.

Equipment service requirements are minimal but are very important to safe and efficient operation; therefore, inspect parts often and perform required service at the prescribed intervals. An authorized service distributor/dealer should perform required service to keep equipment in top condition.

See Figure 1-1 and Figure 1-2 to identify and locate major components.

TP-5592 7/96 Introduction i

Page 15

Service Assistance

For sales and service in the U.S.A. and Canada check the yellow pages of the telephone directory under the headingGENERATORS—ELECTRICfor anauthorized service distributor/dealer or call 1-800-544-2444.

For sales and service outside the U.S.A. and Canada, contact your local distributor.

For further information or questions, contact the company directly at:

KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone: 414-565-3381 Fax: 414-459-1646 (U.S.A. Sales)

414-459-1614 (International)

To ensure supply of correct parts or information, make note of the following identification numbers in the spaces provided:

GENERATOR SET

MODEL, SPEC, and SERIAL numbers are found on the nameplate attached to the generator set.

Model No.

Specification No. Serial No.

GENERATOR SET ACCESSORIES

An alternate nameplate inside the junction box identifies factory-installed generator set accessories.

Accessory Nos.

ENGINE

The engine serial number is found on the engine nameplate.

Engine Serial No.

TP-5592 7/96ii Service Assistance

Page 16

At the time of print, this manual applied to the model numbers and specification (spec.) numbers listed on this page. On occasion this manual may be used for specifications not listed such as when similar new specifications are created after the printing of this manual and prior to the updated reprint or in cases where the manual is deemed an acceptable substitute for a manual under development.

Model No. Spec. No. Wiring Diagram

13.5CCOZ/ 11CCFOZ

18.5CCOZ/ 15CCFOZ

21CCOZ/

16.5CCFOZ

126147 126148

126151 126152

126154 126155

229937 229991

229937

229991 18CCFOZ 126150 229937 14CCOZ/

11.5CCFOZ 20CCOZ/

17.5CCFOZ 24CCOZ

20CCFOZ

126149 229938

126153 229938

126156 229938

TP-5592 7/96 Service Assistance iii

Page 17

Routine Service Parts

Contact your Kohler generator distributor/dealer for a complete list of service parts for your generator set.

Part Description Kohler Part No.

Air Filter Element 250902 Oil Filter 252834 Fuel Filter Element 225021 Seawater Pump Impeller 229955 V-Belt (Seawater Pump) 256503 V-Belt (Alternator)

11/11.5CCFOZ and

13.5/14CCOZ V-Belt (Alternator)

18.5/20/21/24CCOZ and 18CCFOZ White Spray Paint 221318

276141

229880

iv Routine Service Parts TP-5592 7/96

Page 18

Section 1. Specifications

General Specifications—1-Phase Models

21CCOZ

13.5CCOZ 11CCFOZ

Dimensions—in. (mm)

Length 36.62 (930) 41.35 (1050) Width 22.31 (567) 22.31 (567) Height 26.01 (661) 26.42 (671) Length w/sound shield 41.24 (1047) 44.75 (1137) Wisth w/sound shield 25.75 (654) 25.75 (654)

Height w/sound shield 28.25 (718) 28.75 (730) Weight (wet)—lbs. (kg) 680 (308) 765 (347) 790 (358) w/sound shield (wet)—lbs. (kg) 775 (352) 870 (395) 895 (405) Air Requirements—CFM (L/min.)

Combustion 60 Hz/50 Hz

Cooling 60 Hz/50 Hz Angular Operation (max.)

(in all directions) Minimum clearances for vibration and

cooling (top, front, rear, and sides) (without sound shield)—in. (mm)

Fuel Consumption 60 Hz—U.S. Gal./Hr. (L/Hr.) (Fuel consumption based on CCOZ120/240 voltage configuration)

LOAD

25% 0.48 (1.8) 0.63 (2.4) 0.67 (2.5)

50% 0.71 (2.7) 0.90 (3.4) 0.98 (3.7)

75% 0.93 (3.5) 1.24 (4.7) 1.37 (5.2)

100% 1.19 (4.5) 1.63 (6.2) 1.77 (6.7) Fuel Consumption 50 Hz—U.S. Gal./Hr. (L/Hr.)

(Fuel consumption based on CCFOZ110/220 voltage configuration) LOAD

25% 0.38 (1.4) 0.50 (1.9) 0.53 (2.0)

50% 0.54 (1.9) 0.72 (2.7) 0.77 (2.9)

75% 0.72 (2.7) 1.00 (3.8) 1.05 (4.0)

100% 0.93 (3.5) 1.38 (5.2) 1.40 (5.3)

* 18CCFOZ -- 50 Hz only

86.78/72.32 (1422/1185)

25_ continuous, 30_ intermittent

18.5CCOZ 15CCFOZ

115.91/96.59 (1899/1582)

210/175

(5946/4955)

(three minutes or less)

1.5 (38)

16.5CCFOZ 18CCFOZ *

TP-5592 7/96 Specifications 1-1

Page 19

General Specifications—3-Phase Models

14CCOZ

11.5CCFOZ

Dimensions—in. (mm)

Length 36.62 (930) 41.35 (1050) Width 22.31 (567) 22.31 (567) Height 26.01 (661) 26.42 (671) Length w/sound shield 41.24 (1047) 44.75 (1137) Width w/sound shield 25.75 (654) 25.75 (654)

Height w/sound shield 28.25 (718) 28.75 (730) Weight (wet)—lbs. (kg) 690 (313) 775 (352) 800 (363) w/sound shield (wet)—lbs. (kg) 785 (356) 880 (399) 905 (411) Air Requirements—CFM (L/min.)

Combustion 60 Hz/50 Hz

Cooling 60 Hz/50 Hz Angular Operation (max.) (in all direc-

tions) Minimum clearances for vibration and

cooling (top, front, rear, and sides) (without sound shield)—in. (mm)

Fuel Consumption 60 Hz—U.S. Gal./Hr. (L/Hr.) (Fuel consumption based on CCOZ120/240 voltage configuration)

LOAD

25% 0.48 (1.8) 0.63 (2.4) 0.67 (2.5)

50% 0.71 (2.7) 0.90 (3.4) 0.98 (3.7)

75% 0.93 (3.5) 1.24 (4.7) 1.37 (5.2)

100% 1.19 (4.5) 1.63 (6.2) 1.77 (6.7) Fuel Consumption 50 Hz—U.S. Gal./Hr. (L/Hr.)

(Fuel consumption based on CCFOZ110/220 voltage configuration) LOAD

25% 0.38 (1.4) 0.50 (1.9) 0.53 (2.0)

50% 0.54 (1.9) 0.72 (2.7) 0.77 (2.9)

75% 0.72 (2.7) 1.00 (3.8) 1.05 (4.0)

100% 0.93 (3.5) 1.38 (5.2) 1.40 (5.3)

86.78/72.32 (1422/1185)

25_ continuous, 30_ intermittent

20CCOZ

17.5CCFOZ

115.91/96.59 (1899/1582)

210/175

(5946/4955)

(three minutes or less)

1.5 (38)

24CCOZ

20CCFOZ

115.91/96.59 (1899/1582)

TP-5592 7/961-2 Specifications

Page 20

Generator

The generator is direct mounted to the engine for permanent alignment. The unit uses a static excited, rotating-field construction with a four-pole rotor.

Generator Features

D Brushless, rotating field design permits power to

be obtained from stationary leads.

D Rotor and stator are vacuum impregnated with

high-bond epoxy varnish. Varnish helps prevent corrosion in high-humidity areas.

D Rotors are dynamically balanced to minimize

vibration.

D Copper windings ensure minimal heat buildup.

Insulation meets NEMA standards for Class F insulation.

D Direct connected to the engine, generator has

sealed precision ball bearing with precision machined steel sleeve in end bracket to prevent shaft misalignment and to extend bearing life.

D Generator is mounted on a drip-proof constructed

tray.

Alternator Features

Generator Type four pole, rotating field Coupling Type flexible disc Excitation Type brushless exciter Shaft RPM (50/60 Hz) 1500/1800 Number of Output Leads 4—1-phase models

12—3-phase models Voltage Regulator Model PowerBoostÔ V Voltage Regulation ±2% Frequency Regulation ±5%

NOTE

All one-phase and three-phase units are rated 1.0 power factor. Ratings are based onan altitude of 500 ft. (150 m) above sea level.

D One-phase models feature a four-lead

reconnectable stator; three-phase models have a twelve-lead reconnectable stator.

TP-5592 7/96 Specifications 1-3

Page 21

Generator Ratings—1-Phase Models

13.5CCO

11CCFOZ

18.5CCO

15CCFOZ

21CCO

16.5CCFOZ

18CCFOZ

77_F (25_C)

Model Series Voltage

13.5CCOZ 100/200 125/62.5 12.5/12.5 1 60 120/240 112.5/56.3 13.5/13.5 1 60

11CCFOZ 100/200 110/55 11/11 1 50

110/220 100/50 11/11 1 50

220 50 11/11 1 50 240 45.8 11/11 1 50

18.5CCOZ 100/200 165/82.5 16.5/16.5 1 60 120/240 154/77.1 18.5/18.5 1 60

15CCFOZ 100/200 150/75 15/15 1 50

110/220 136.4/68.2 15/15 1 50

220 68.2 15/15 1 50 240 54.2 13/13 1 50

21CCOZ 100/200 165/82.5 16.5/16.5 1 60

120/240 175/87.5 21/21 1 60

16.5CCFOZ 100/200 170/85 17/17 1 50 110/220 150/75 16.5/16.5 1 50

220 75 16.5/16.5 1 50 240 54.2 13/13 1 50

Amps

77_F (25_C)

kW/kVA

Phase Hz

Continuous 77_F (25_C)

Model Series Voltage

18CCFOZ 100/200 180/90 18/18 185/92.5 18.5/18.5 1 50

110/220 159.1/79.5 17.5/17.5 168.2/84.1 18.5/18.5 1 50

220 79.5 17.5/17.5 84.1 18.5/18.5 1 50 240 62.5 15/15 72.9 17.5/17.5 1 50

Amps

Continuous 77_F (25_C)

kW/kVA

Peak Rating

Amps

Peak Rating

kW/kVa

Phase Hz

TP-5592 7/961-4 Specifications

Page 22

Generator Ratings—3-Phase Models

14CCO

11.5CCFOZ

20CCO

17.5CCFOZ

24CCO

20CCFOZ

77_F (25_C)

Model Series Voltage

14CCOZ 120/208 38.9 14/14 3 60

120/240 33.7 14/14 3 60 120/240 58.3 14/14 1 60 127/220 36.8 14/14 3 60 139/240 33.7 14/14 3 60 220/380 21.3 14/14 3 60 227/480 16.9 14/14 3 60

11.5CCFOZ 110/190 35.0 11.5/11.5 3 50 110/220 52.3 11.5/11.5 1 50 120/208 31.9 11.5/11.5 3 50 220/380 17.5 11.5/11.5 3 50 230/400 16.6 11.5/11.5 3 50 240/416 16.0 11.5/11.5 3 50

20CCOZ 120/208 55.6 20/20 3 60

120/240 48.2 20/20 3 60 120/240 70.8 17/17 1 60 127/220 52.5 20/20 3 60 139/240 48.2 20/20 3 60 220/380 30.4 20/20 3 60 277/480 24.1 20/20 3 60

17.5CCFOZ 110/190 53.2 17.5/17.5 3 50 110/220 65.9 14.5/14.5 1 50 120/208 48.6 17.5/17.5 3 50 220/380 26.6 17.5/17.5 3 50 230/400 25.3 17.5/17.5 3 50 240/416 24.3 17.5/17.5 3 50

24CCOZ 120/208 66.7 24/24 3 60

120/240 57.8 24/24 3 60 127/220 63.1 24/24 3 60 139/240 57.8 24/24 3 60 220/380 36.5 24/24 3 60 277/480 28.9 24/24 3 60

20CCFOZ 110/190 60.8 20/20 3 50

110/220 52.5 20/20 3 50 120/208 55.6 20/20 3 50 220/380 30.4 20/20 3 50 230/400 28.9 20/20 3 50 240/416 27.8 20/20 3 50

Amps

77_F (25_C)

kW/kVA

Phase Hz

TP-5592 7/96 Specifications 1-5

Page 23

Engine

Engine Data

Number

Generator

Model

13.5CCOZ

11CCFOZ

18.5CCOZ

15CCFOZ 18CCFOZ 4JH2LHT-K 4 4 21CCOZ

16.5CCFOZ

14CCOZ

11.5CFOZ

20CCOZ

17.5CCFOZ

24CCOZ 20CCFOZ

Engine

Model

3JH2LT-K 3 4

4JH2LT-K 4 4

4JH2LHT-K 4 4

3JH2LT-K 3 4

4JH2LT-K 4 4

4JH2LHT-K 4 4

Cylinders

Number

Cycles

These Yanmar engines feature the following:

D One side serviceability of fuel system, lubrication

Cooling

System

Heat Exchanger

system, seawater pump, and air cleaner

D Low oil pressure cutout D High water and high exhaust temperature cutouts D Focused vibromounts D Belt guard D Disposable oil filter D Oil drain valve and hose D Water-cooled turbocharger D Air intake heater circuit for cold starting (optional

on models 13.5CCOZ/11CCFOZ, 18.5CCOZ/ 15CCOZ, 14CCOZ/11.5CCFOZ, and 20CCOZ/

17.5CCFOZ)

D Electric rotary vane fuel pump with 1/4 NPT fuel

inlet

D Battery charging alternator D Overspeed safety shutdown (optional)

TP-5592 7/961-6 Specifications

Page 24

Engine Specifications—1-Phase Models

13.5CCOZ/ 11CCFOZ

Engine Manufacturer Yanmar Engine Model 3JH2LT-K 4JH2LT-K 4JH2LHT-K Number of cylinders 3 4 Cylinder Block Material cast iron Cylinder Head Material cast iron Piston Rings 2 compression/1 oil Crankshaft stamped forging Connecting Rod Material forged carbon steel Governor centrifugal, mechanical Bore x Stroke—in. (mm) 3.23 (82) x 3.39 (86) Displacement—CID (cc) 87.26 (1.43) 116.6 (1.91) Compression Ratio 17.79:1 16.99:1 Horsepower 60/50 Hz 25.2/16.5 27.5/22.5 27.5 * 35/27.5 RPM 60/50 Hz 1800/1500 1500 * 1800/1500 Direction of Rotation

(as viewed from generator end) Lubrication System pressure, trochoid pump Lube Oil Capacity—

U.S. qts. (L) (w/filter) Oil Recommendation (API) CD Engine Firing Order

(#1 cylinder nearest to flywheel) Fuel Injection Timing (B.T.D.C.) 17° 17° ±1 Fuel Injection Pressure

psi (kg/cm sq.) Combustion System direct injection Battery Voltage 12 volt, negative ground Battery Recommendation (min.) 500 CCA, 100 amp. hr. Battery Charging (alternator) 50 amps. @ 12 volts Fuel Recommendation Diesel, ASTM/D975-66T, No. 1-D or No. 2-D Fuel System electric solenoid fuel shutoff Fuel Pump Prime Pump electric Fuel Pump Lift (max.)—ft. (m) 4 (1.2) Coolant Capacity—U.S. qts. (L) 2.36 (2.23) 3.15 (3.0) Coolant Recovery Tank—qts. (L) 0.85 (.8) Recommended Coolant 50% ethylene glycol 50% clean, softened water Thermostat 195°F (90°C) Pressure Cap Rating 12.8 psi (88.3 kPa) Starter Motor 1.8 kW bendix, gear-reduction automotive type Intake/Exhaust Valve Clearance—in. (mm.)

(cold)

Belt Tension (force)—in. (mm) @ 22 lbs. (10 kg)

* 18CCFOZ -- 50 Hz only

5.0 (4.7) 6.1 (5.8)

1-3-2 1-3-4-2

18.5CCOZ/ 15CCFOZ

counterclockwise

2844 ±71 (200 ±5)

0.0079 (0.2)

0.38 (10)

18CCFOZ

21CCOZ/

16.5CCFOZ

TP-5592 7/96 Specifications 1-7

Page 25

Engine Specifications—1-Phase Models (Continued)

13.5CCOZ/ 11CCFOZ

Flex Plate to Rotor Bolt Torque —ft. lbs. (Nm)

Cylinder Head Torque—ft. lbs. (Nm)

Initial ft. lbs (Nm) 29 (39) Final ft. lbs (Nm) (2-step intervals) 58 (79)

Flex Plate to Flywheel Bolt Torque —ft. lbs. (Nm)

Generator Adapter Plate to Flywheel Housing Bolt Torque —ft. lbs. (Nm)

Overbolt Torque—ft. lbs. (Nm) 30 (41) Inlet Water Line Hose ID—in. (mm)

(seawater pump inlet) Outlet Water Line Hose ID

—in. (mm) (mixing elbow outlet) Fuel Inlet—(fuel pump inlet) 3/8 ID—1/4 NPT Fuel Return Size—Type 3/8 ID—1/4 NPT

18.5CCOZ/ 15CCFOZ

18CCFOZ

30 (41)

20 (27)

30 (41)

1.0 (25)

3 (76)

21CCOZ/

16.5CCFOZ

TP-5592 7/961-8 Specifications

Page 26

Engine Specifications—3-Phase Models

14CCOZ/

11.5CCFOZ

Engine Manufacturer Yanmar Engine Model 3JH2LT-K 4JH2LT-K 4JH2LHT-K Number of cylinders 3 4 Cylinder Block Material cast iron Cylinder Head Material cast iron Piston Rings 2 compression/1 oil Crankshaft stamped forging Connecting Rod Material forged carbon steel Governor centrifugal, mechanical Bore x Stroke—in. (mm) 3.23 (82) x 3.39 (86) Displacement—CID (cc) 87.26 (1.43) 116.6 (1.91) Compression Ratio 17.79:1 16.99:1 Horsepower 60/50 Hz 25.2/16.5 27.5/22.5 35/27.5 RPM 60/50 Hz 1800/1500 Direction of Rotation

(as viewed from generator end) Lubrication System pressure, trochoid pump Lube Oil Capacity—

U.S. qts. (L) (w/filter) Oil Recommendation (API) CD Engine Firing Order

(#1 cylinder nearest to flywheel) Fuel Injection Timing (B.T.D.C.) 17° 17° ±1 Fuel Injection Pressure

Clearance—in. (mm) (cold) Belt Tension (force)—in. (mm)

@ 22 lbs. (10 kg)

5.0 (4.7) 6.1 (5.8)

1-3-2 1-3-4-2

20CCOZ/

17.5CCFOZ

counterclockwise

2844 ±71 (200 ±5)

0.0079 (0.2)

0.38 (10)

24CCOZ

20CCFOZ

TP-5592 7/96 Specifications 1-9

Page 27

Engine Specifications—3-Phase Models (Continued)

14CCOZ/

11.5CCFOZ

Flex Plate to Rotor Bolt Torque —ft. lbs. (Nm)

Cylinder Head Torque—ft. lbs. (Nm)

Initial ft. lbs (Nm) 29 (39) Final ft. lbs (Nm) (2-step

intervals) Flex Plate to Flywheel Bolt Torque

—ft. lbs. (Nm) Generator Adapter Plate to

Flywheel Housing Bolt Torque —ft. lbs. (Nm)

Overbolt Torque—ft. lbs. (Nm) 30 (41) Inlet Water Line Hose I.D.—in.

(mm) (seawater pump inlet) Outlet Water Line Hose I.D.

—in. (mm) (mixing elbow outlet) Fuel Inlet—(fuel pump inlet) 3/8 ID—1/4 NPT Fuel Return Size—Type 3/8 ID—1/4 NPT

20CCOZ/

17.5CCFOZ

30 (41)

58 (79)

20 (27)

30 (41)

1.0 (25)

3 (76)

Controller

24CCOZ

20CCFOZ

The generator set has a relay controller with hourmeter. For a description of the controller, see Section 2—Operation.

Controller Features

D Electricstarting with a start/stop switch located on

the controller or by (optional) remote start

D Rubber mounted to minimize vibration D Safety shutdowns for overheating, low oil

pressure, and overspeed (optional)

D Starter interlock to prevent reengagement of

starter whenever engine is running

D Controller connections by plugs/receptacles and

clearly identified corrosion-resistant terminals to eliminate the possibility of misconnection

D Quick disconnect on 22-pin wiring harness D External6-pin connector for remote panel harness D Hourmeter for scheduling maintenance D Voltage/frequency adjustable PowerBoostä

voltage regulator

TP-5592 7/961-10 Specifications

Page 28

Accessories

Kohler Co. offers several accessories to finalize the installation or to add convenience to operation and service. Contact a local Kohler distributor/dealer to obtain the most current information. The following list includes accessories available at the time of print of this publication.

Seawater strainer available for inline installation between seacock and seawater pump.

Siphon break mandatory kit on generators installed at or below the waterline. Prevents the siphoning of floatation water into the engine.

Sound shield provides for highly effective silencing, ease of access for engine/generator servicing, low maintenance, excellent durability, and safety.

The Kohler Ship-to-Shore Transfer Switch allows immediate switching to Kohler generator set power or shore power protecting the electrical system from the possibility of simultaneous connection of both power sources.

Line circuit breakers protect the generator from extreme overload and provide protection for the output cabling. Determine circuit breaker ampere rating bythe voltage configuration.

Remote start panel allows starting, stopping from a locationremote of thegeneratorset. Suppliedwith 15 ft. (4.6 m) connection harness. Overall mounting dimensions are 4 1/16 in. (103 mm) by 2 1/8 in. (54mm) with a minimum mounting depth of 2 1/4 in. (57 mm).

Remote start and two-meter panel kit allows starting/stopping from a location remote of the generator set. The illuminated gauges include an engine oil pressure gauge and a water temperature gauge. Overall dimensions are 6 in. (152 mm) by 6 in. (152mm)withaminimummountingdepthof 23/4 in.(70 mm). RequiresRemote Connection/ExtensionHarness for hook-up. Requires Sender Kit.

Remote start and four-meter panel kit allows starting/stopping from a location remote of the generatorset. The illuminated meters/gauges include a DC voltmeter, engine oil pressure gauge, water temperature gauge, and an hourmeter which records totalgeneratorsetoperatinghours. Overalldimensions are 9 in. (229 mm) by 6 in. (152 mm) with a minimum depth of 4 in. (102 mm). Requires Remote Connection/Extension Harness for hook-up. Requires Sender Kit.

Sender kit provides the necessary senders for making remote meter panel gauges functional.

Preheat kit provides improved starting in cold climates. Available for the following models only:

D 13.5CCOZ/11CCFOZ D 14CCOZ/11.5CCFOZ D 18.5CCOZ/15CCFOZ D 20CCOZ/17.5CCFOZ

Twelve-inch (0.3 m) remote wiring harness has a 6-pin connector on one end which is keyed to the controller box connector. The other end has pigtails for connectionto customer-supplied start switch, generator ON light, hourmeter, etc.

Remote connection/extension harness provides additional wiring between all remote panels and controller connector in 15 ft. (4.6 m) or 25 ft. (7.6 m) increments. One harness is required for each Remote Meter Panel Kit. Extension limited to a total of four kits and 75 ft.

Overspeed shutdown kit provides additional protection from overspeed/voltage damage.

Heavy-duty battery cables are available for these marine generator sets.

Flexible fuel lines connect the generator set to the main fuel tank.

TP-5592 7/96 Specifications 1-11

Fuel attachment block allows connection to the fuel inlet and return from one point.

Coolant overflow extension hose allows remote mounting of the coolant overflow bottle, 10.8 ft. (3.3m).

Page 29

ADV-5852-A

2021

Figure 1-1. Service Views—13.5CCOZ/11CCFOZ and 14CCOZ/11.5CCFOZ

DA-250000-H

TP-5592 7/961-12 Specifications

Page 30

Service Views

1. Controller

2. Air intake silencer

3. Fuel solenoid

4. Lifting eye

5. Lifting eye

6. Fuel injectors

7. Oil fill

8. Water temperature sender (optional)

9. Fuel filter

10. Fuel return connector

11. Fuel injection pump

12. Oil fill

13. Governor

14. Seawater pump (drain point) (water inlet)

15. Oil pressure sender (optional)

16. Lube oil filter

17. Oil drain valve and hose

18. Oil check

19. Fuel feed pump (fuel inlet)

20. Low oil pressure safety shutdown switch

21. Coolant (freshwater) drain

22. High water temperature safety shutdown switch

23. Overflow tube

24. Pressure cap

25. Heat exchanger

26. Coolant (freshwater) drain

27. Seawater drain

28. High exhaust temperature safety shutdown switch

29. AC load lead connector

30. Nameplate

31. Remote start connector

32. Mixing elbow (water outlet/exhaust outlet)

33. Starter solenoid

34. Battery positive (+) connection

35. Starter motor

36. Ground lug (equipment ground)

37. Battery negative (--) connection

38. Seawater (drain point) petcock

39. Belt guard

40. Coolant (freshwater) drain

41. Battery charging alternator

42. V-belts

43. Engine-driven water pump

Not Shown

Air Intake Heater (Optional Preheat Kit required to make air

intake heater functional).

TP-5592 7/96 Specifications 1-13

Page 31

ADV-5853-A

Figure 1-2. Service Views—18CCFOZ, 18.5CCOZ/15CCFOZ, 20CCOZ/17.5CCFOZ, 21CCOZ/16.5CCFOZ, and

24CCOZ/20CCFOZ

DA-250000-H

TP-5592 7/961-14 Specifications

Page 32

Service Views

1. Controller

2. Air intake silencer

3. Fuel solenoid

4. Lifting eye

5. Lifting eye

6. Fuel injectors

7. Oil fill

8. Water temperature sender (optional)

9. Fuel filter

10. Fuel return connector

11. Fuel injection pump

12. Oil fill

13. Governor

14. Seawater pump (drain point) (water inlet)

15. Oil pressure sender (optional)

16. Lube oil filter

17. Oil drain valve and hose

18. Oil check

19. Fuel feed pump (fuel inlet)

20. Low oil pressure safety shutdown switch

21. Coolant (freshwater) drain

22. High water temperature safety shutdown switch

23. Overflow tube

24. Pressure cap

25. Heat exchanger

26. Coolant (freshwater) drain

27. Seawater drain

28. High exhaust temperature safety shutdown switch

29. AC load lead connector

30. Nameplate

31. Remote start connector

32. Mixing elbow (water outlet/exhaust outlet)

33. Starter solenoid

34. Battery positive (+) connection

35. Starter motor

36. Ground lug (equipment ground)

37. Battery negative (--) connection

38. Seawater (drain point) petcock

39. Belt guard

40. Coolant (freshwater) drain

41. Battery charging alternator

42. V-belts

43. Engine-driven water pump

Not Shown

Air Intake Heater (Optional Preheat Kit required to make air

intake heater functional).

TP-5592 7/96 Specifications 1-15

Page 33

Section 2. Operation

Prestart Checklist

To ensure continued satisfactory operation, check the following items before each startup and at regular intervals.

AIr Cleaner. Keep air cleaner element clean. Install element to keep unfiltered air from entering engine.

Air Shrouding. Keep tight and in position. AIr Inlets. Keep clean and unobstructed. Backfire Flame Arrestor. Clean and install air cleaner

to prevent unfiltered air from entering engine. Battery. Ensuretight battery connections. Maintain full

battery electrolyte level. Coolant Level. For cooling systems equipped with a

coolant recovery tank, check coolant level at tank after the engine has cooled.

Maintain coolant level just below the filler neck, approximately 3/4 to 1 1/2 in. (19 to 33 mm).

A coolant solution of 50% ethylene glycol provides freezing protection of --34°F (--37°C) and overheating protectionto 265°F(129°C). Acoolant solutionwithless than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution withmore than50%ethylene glycolcancause engineor component damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant. Consultthe engine manufacturer’s operationmanualfor engine coolant specifications.

Do not add coolant to an overheated engine. Wait until engine has cooled. Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack.

Drive Belts. Check belt condition and tension of radiator fan, water pump, and battery charging alternator belt(s).

ExhaustSystem. Keep exhaustoutletclear and free of debris. Keep silencer and piping tight and in good condition. Check hoses for leaks. V erify that each exhaust hose connection has two clamps and that all connections are tight.

Fuel Level. Keep tank(s) full to ensure adequate fuel supply.

Oil Level. Maintain oil level at or near full mark on dipstickbutnotover. Keeptheoillevelin themechanical governor (if equipped) at or near the full level.

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 beforeinitial startup. Toprimepump, close seacockand remove the hose from the water filter outlet. Fill hose and pump with clean water. Replace hose and open seacock. Check for pump operation on startup by observing water discharge from exhaust outlet.

Kohler Co. recommends that all boat owners have their vessels—especiallytheexhaustsystemattached to the generator set—inspected at the start of each boating season by their local Coast Guard Auxiliary. If there is no Coast Guard Auxiliary in the area, contact an authorized Kohler distributor or dealer for the inspection.

Cooling. Check the coolant level on closed-type heat exchanger systems using the coolant recovery tank. The MIN mark indicates full when cold and the MAX mark indicates full when hot. Maintain the coolant level between these marks. Periodically check the coolant level on closed systems by removing the pressure cap. Do not rely solely on level in coolant recovery tank.

Add fresh coolant until level is just below overflow tube opening. See Maintenance—Cooling Systems.

TP-5592 7/96 Operation 2-1

Page 34

Exercising the Generator Set

Run the generator set under load once each week for one hour with an operator present.

Perform all prestart checks before starting the exercise procedure. With the generator set operating, listen for a smooth-running engine, and visually inspect the

Controller

For identification of controller components, see Figure 2-1.

1. Start/StopSwitch. Useswitch tostart andstop the generator set. Refer to Starting and Stopping following.

2. DC Circuit Breaker. The generator set will shut down automatically after fault. See Circuit Protection following.

3. ACCircuit Breaker(optional). Thecircuit breaker trips when a fault is detected in the output circuit. During maintenance of craft wiring, the circuit breaker disconnects the generator set . To close circuit breaker(s), place breaker in ON position.

4. Remote Start Connector. A 6-pin connector on controller back panel allows connection of (optional) remote start kits.

5. Hourmeter. Records total generator set operating hours for reference in maintenance scheduling.

generator set to ensure there are no fluid or exhaust leaks.

Start the generator set according to the starting procedure in the controller section of this manual.

1. Start/Stop switch

2. DC circuit breaker

3. AC circuit breaker (optional)

4. Remote start connector

5. Hourmeter

ADV-5852-A

Figure 2-1. Controller

2-2 Operation TP-5592 7/96

Page 35

Starting Procedure

Preheat Feature (optional)

13.5CCOZ/11CCFOZ,

18.5CCOZ/15CCFOZ,

14CCOZ/11.5CCFOZ, and

20CCOZ/17.5CCFOZ models only

During cold weather starts (below 40°F [4°C]), place controller start switch in stop-preheat position for 15-20 seconds before attempting to start generator set to energize the air heater coil. Toprevent damage, do not energize preheat feature for more than 30 seconds.

NOTE

The start/stop switches of all controllers indicate preheat. However,an optional preheat kit is required to make the air intake coil (preheat) functional.

Starting Generator

Open manual fuel shut-off valve (if equipped). Start generatorsetby placing controller master switch in start position or use remote start/stop switch.

NOTE

If engine fails to start after the first attempt, close the seacock before next starting attempt. Failure to close the seacock may cause seawater to enter the exhaust piping and silencer. Water-filled exhaust piping and silencermayfurtherhinder generatorstarting andcause

seawater entry into the engine cylinders through the exhaust valve.

If water enters the exhaust system, close seacock and drain water from the exhaust system at silencer drain plug before attempting to start generator set. If excessive cranking is a chronic problem, have the unit (including the exhaust system) serviced by an authorized Kohler distributor/dealer.

NOTE

Do not crank engine continuously for more than 10 seconds at a time. Allow a 60-second cooldown period between cranking attempts if the engine does not start. If the unit fails to start after three attempts, contact an authorizedKohler distributor/dealer forrepair. Failure to follow these guidelines may result in starter motor burnout.

NOTE

After starting the generator set, open the seacock to allow cooling water passage.

NOTE

Failure to open seacock after generator set is running could damage the seawater pump impeller and cause serious engine overheating damage.

NOTE

Check that the marine ship-to-shore transfer switch, if equipped, is in the proper position.

Stopping Procedure

Run generator set at no load for five minutes to ensure adequate engine cooldown. To stop the generator set, place controller start/stop switch or remote start/stop switch in the STOP position and wait until generator set comes to a complete stop.

TP-5592 7/96 Operation 2-3

Do not place start/stop--preheat switch (if equipped) in stop--preheat position for more than 30 seconds or damage to the preheat feature may occur.

NOTE

Page 36

Circuit Protection

AC circuit breakers (optional) trip when a fault is

detected in the output circuit. Correct the fault and then place the AC circuit breaker(s) in the ON position to reset. Restart the unit. See Figure 2-2 for AC circuit breaker ratings. Base circuit breaker selection on voltage configuration for each model.

Voltage

(max.)

250 1 50 250 1 70 250 1 80 240 2 50 240 2 60 240 2 70 240 2 80 240 2 90 600 3 20 600 3 30 600 3 40 480 3 50 600 3 60 600 3 70

Number of

Poles

AC Circuit

Breaker (Amps)

DC Circuit Breaker (10 amp) will trip when a fault

occurs in the controller circuit. See Section 4—Troubleshooting. Correct the fault and then depress the center button of the DC circuit breaker to reset. Restart the unit.

Voltage regulator fuse (8 amp) protects in case of fault inthe voltage regulatorand/orgenerator circuit. Correct thefaultandthenreplacethefuse with a new fuse of the same rating. Voltage regulator circuit is then functional.

Battery charging fuse is a 10 amp fuse that protects the battery charging alternator, battery charging regulator, and circuitry. Correct the fault and then replace the fuse with a new fuse of the same rating. Battery charging circuit is then functional.

Figure 2-2. AC Circuit Breakers

Engine Safety Shutdown Switches

Four shutdown switches protect the engine. These switches automatically reset after correcting the problemorcoolingdowntheunit(ifoverheating was the problem). The following conditions will cause a generator set shutdown: Low Oil Pressure (LOP) High Water Temperature (HWT) High Exhaust Temperature (HET) Overspeed

Engine safety shutdown switches become functional when unit comes up to speed and AC voltage is available.

High Exhaust Temperature (HET) of215°F (102°C) or greater will shut down the unit.

Low Oil Pressure (LOP) of 6.8 psi (47 kPa) or less will shut down the unit.

NOTE

TheLowOilPressure(LOP)switchdoesnotactasalow oil level switch. Check oil level regularly to protect against damage from low oil level.

High Water Temperature (HWT) of 203°F (95°C) or above will shut down the unit.

Overspeed (overfrequency) will immediately shut down the unit at 70 Hz or greater.

2-4 Operation TP-5592 7/96

Page 37

Remote Panels (Optional)

Remote Start Panel

Remote start panel allows starting/stopping from a location remote of the generator set. Standard generator sets have a 6-pin connector on the controller for connecting the panel kit. See Figure 2-3.

1-656

1. ON light

2. Start/stop switch

Figure 2-3. Remote Start Panel Features

Engine Oil Pressure Gauge. Measures engine oil

pressure. Normal engine operating range is 40-60 psi (276-414 kPa) for 60 Hz models. 50 Hz models may show a slightly lower pressure range.

NOTE

During the engine break-in period, the engine sometimes produces higher oil pressure readings.

WaterTemperature Gauge. Measures engine coolant temperature. Normal engine operating range is 170-195°F (77-91°C).

Remote Start and

Two-Meter Panel Kit

Allows starting/stopping from a location remote of the generator set. The illuminated gauges include an engine oil pressure gauge and a water temperature gauge. Standard generator setshavea 6-pin connector on the controller for connecting the panel kit. See Figure 2-4 for remote start and two-meter panel kit.

NOTE

Remote start panels require a sender kit. Start/Stop Switch. A rocker-type switch with ON light

starts and stops the generator set.

1. Engine oil pressure gauge

2. Water temperature gauge

3. Start/stop switch

4. ON light

Figure 2-4. Remote Start and

Two-Meter Panel Features

1-762

TP-5592 7/96 Operation 2-5

Page 38

Remote Start and

Four-Meter Panel Kit

Allows starting/stopping from a location remote of the generator set. The illuminated gauges include a DC voltmeter, an engine oil pressure gauge, a water temperature gauge, and a generator running time hourmeter. Standard generator sets have a 6-pin connector on the controller back panel for connecting the panel kit. See Figure 2-5 for remote start and four-meter panel features.

NOTE

Remote start meter panel requires a sender kit. Start/Stop Switch. A rocker-type switch with ON light

starts and stops the generator set.

WaterTemperature Gauge. Measures engine coolant temperature. Normal engine operating range is 170-195° F (77-91° C).

Hourmeter. Records total generator set operating hours for reference in maintenance scheduling.

DC Voltmeter. Measures voltage of starting battery(ies). Normal battery operating range is 12-14 volts.

Engine Oil Pressure Gauge. Measures engine oil pressure. Normal engine operating range is 40-60 psi (276-414 kPa) for 60 Hz models. 50 Hz models may show a slightly lower pressure range.

NOTE

During the engine break-in period, the engine sometimes produces higher oil pressure readings.

1-830

1. Engine oil pressure gauge

2. Hourmeter

3. Voltmeter

4. Water temperature gauge

5. Start/stop switch

6. ON light

Figure 2-5. Remote Start and Four-Meter Panel

Features

2-6 Operation TP-5592 7/96

Page 39

Section 3. Scheduled Maintenance

General

Servicing generator set when operating. Exposed

WARNING

moving parts can cause severe injury or death.

Keep hands, feet, hair, clothing, and test leads away from belts and pulleys when generator set is running. Replace guards, screens, and covers before operating generator set.

Accidental starting. Can cause severe injury or death.

Disconnect battery cables before working on generator set (disconnect negative lead first and reconnect it last).

Disabling generator set. Accidental starting can cause severe injury or death. Disconnect battery

WARNING

Rotating parts. Can cause severe injury or death.

Sound shield removal. Exposed moving parts can cause severe injury or death. Additional precautions

for sound shield-equipped models:

The generator set must be operating in order to perform some scheduled maintenance procedures. Be especially careful if the sound shield has been removed leaving belts and pulleys exposed.

NOTICE

Seawater damage! High-mineral content seawater

(saltwater) causes rapid deterioration of all metals. Wipe up all saltwater spillage on and around generator set and keep metal surfaces free from accumulated salt deposits.

NOTICE

Hardwaredamage! Engine andgeneratorset may use

both American Standard and metric hardware. Usethe correct size tools to prevent rounding of bolt heads and nuts.

Do not operate generator set without all guards, screens, and covers in place.

TP-5592 7/96 Scheduled Maintenance 3-1

Page 40

Under normal operating conditions the generator set alternator does not require scheduled service. Refer to the prestart checklist for items that require maintenance.

Periodically take the generator set to an authorized distributor/dealer for tune-up. Tune-ups improve performance and ensure continuous satisfactory operation during a long, trouble-free service life.

If the generator set is operated under dusty or dirty conditions, use dry compressed air to blow dust out of the generator. Blow dust out with the generator set running. Direct the streamofair through openings inthe generator end bracket.

See Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair,oroperate thegeneratorset. Havean authorized Kohler service distributor/dealer perform all generator service. Perform generator set engine service at the intervals specified by the engine service literature. Contact an authorized Kohler service distributor/dealer to obtain service literature.

Refer to the service schedule following and the hourmeter located on the generator set controller to schedule routine maintenance. If the generator set is subjected to extreme weather, long operating hours, or dusty or dirty conditions, service the unit more frequently.

Perform maintenance on each item in the service schedule at the designated interval for the life of the generator set. For example, an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months, 300 hours or 9 months, etc.

Tools and instruments to perform some maintenance items are not generally available to the generator set owner.

UsetheOperatingHour Service Log located in the back of this manual to document performed services.

The generator set will eventually require a complete overhaul. Rough operation, lack of power, metallic noises, and excessive oil consumption indicate serious generator set problems or a need for an overhaul. Service the generator set promptly.

3-2 Scheduled Maintenance TP-5592 7/96

Page 41

Service Schedule

After

Before

Perform Service at Intervals Indicated (X)

FUEL SYSTEM

Check the fuel oil level X Fill the fuel tank X Remove sediment from fuel tank X

Check for any abnormal fuel injection sound

Replace the fuel filter element *

Check the injection timing *#& X Check governor operation and adjust

as necessary *& Check the fuel injection nozzles *#& X

LUBRICATION SYSTEM

Check the oil level in crankcase X

Replace the oil in crankcase *

Replace the lube oil filter element *

COOLING SYSTEM

Check coolant level X

Check seawater outlet

Adjust engine water pump belt tension*

Adjust seawater pump belt tension*

Check function of siphon break (if equipped) X Flush cooling system * X Replace seawater pump impeller* X (Check) X Check the thermostat function * X

* Requires removal of sound shield (if installed). # Reference engine service manual for procedure. & Read WARNING found at the beginning of Section 3 regarding moving parts.

Starting

(During

operation)

(During

operation)

50 Hrs./

1 Month

(Break-in

period)

(Break-in

period)

(Break-in

period)

(Break-in

period)

Every

100 Hrs./

3 Months

(Break-in

period)

(150 Hours)

Every

300 Hrs./

6 Months

500 Hrs./

Yearly

Every

TP-5592 7/96 Scheduled Maintenance 3-3

Page 42

Service Schedule (Continued)

After

Before

Perform Service at Intervals Indicated (X)

AIR CLEANER, etc.

Check the exhaust gas condition *

Inspect turbocharger compressor * # X Check for abnormal turbocharger

rotor noise during operation *#& Clean the intake silencer element * X (Clean) X (Replace) Clean the exhaust/water mixing elbow * X Check the breather pipe * X Check turbo rotor shaft for wear (end play and radial

tolerances) *#

ELECTRICAL SYSTEM

Check electrolyte level in the battery (batteries with filler caps only) Check the electrical connections * X

Adjust alternator driving belt tension*

Check the battery specific gravity (batteries with filler caps only)

ENGINE AND MOUNTING

Check for water and oil leakage*& X

Retighten cylinder head bolts * #

Adjust intake/exhaust valve clearance * #

Check tightness of mounting bolts/vibromounts * X Retighten all major nuts and bolts * X

* Requires removal of sound shield (if installed). # Reference engine service manual for procedure. & Read WARNING found at the beginning of Section 3 regarding moving parts.

Starting

(During

operation)

50 Hrs./

1 Month

(Break-in

period)

(Break-in

period)

(Break-in

period)

Every

100 Hrs./

3 Months

(1500 Hrs.)

Every

300 Hrs./

6 Months

Every

500 Hrs./

Yearly

(6000 Hrs.)

(Two Years)

3-4 Scheduled Maintenance TP-5592 7/96

Page 43

Service Schedule (Continued)

After

Before

Perform Service at Intervals Indicated (X)

REMOTE CONTROL SYSTEM, etc.

Check compartment condition (fuel, oil, or water leaks)

Test run generator set

Check remote control operation

EXHAUST SYSTEM

Inspect exhaust system components for cracks and corrosion (exhaust line, hose clamps, silencer, and outlet flapper) *&

Check that exhaust outlet is clear X Check that hose clamps are tight X Check for hose leaks X Inspect the complete exhaust system *** X

GENERATOR

Blow dust out of generator *& X

* Requires removal of sound shield (if installed). *** Should be performed by the Coast Guard Auxiliary. # Reference engine service manual for procedure.

& Read WARNING found at the beginning of Section 3 regarding moving parts.

Starting

50 Hrs./

1 Month

(Monthly)

(Break-in

period)

Every

100 Hrs./

3 Months

Every

300 Hrs./

6 Months

500 Hrs./

Yearly

Every

TP-5592 7/96 Scheduled Maintenance 3-5

Page 44

Lubrication System

Specifications

Engine oil selection is very important to a diesel engine. Use of an unsuitable oil or neglecting an oil change may result in damage and a shorter engine life. Oil must meet the American Petroleum Institute (API) classification of CD, CC/CD, or CC. Figure 3-1 shows the recommended Society of Automotive Engineers (SAE) viscosity designation for given temperature ranges.

S.A.E. Service Grade

5W20

20W40

10W30

10W

20W

SAE 20

SAE 30

SAE 40

Oil Check

Check the oil level in the crankcase daily or before each start-up to ensure that the level is in the safe range. To check the oil level, remove dipstick and wipe the end clean, reinsert as far as possible, and remove. Level should be between min and max marks on the dipstick (Figure 3-2).

1. Min mark

2. Max mark

Figure 3-2. Oil Level Check

°C°F--30 --20 --10 0 10 20 30 40

0 20 40 60 80 100

Operating Temperature

°C °F

Recommended Value Usable Limit

Figure 3-1. Engine Oil Selection

NOTE

Failure to observe these standards may cause inadequate lubrication/oil pressure and cold-starting difficulties.

NOTE

Do not operate the set if the oil level is below the min mark or above the max mark.

3-6 Scheduled Maintenance TP-5592 7/96

Page 45

Oil Change

Change oil according to the service schedule. Change oil more frequently under dirty, dusty conditions. Changeoilwhiletheengineisstillwarm. Use one of the following procedures. If engine oil filter needs replacement, see Oil Filter Change following.

If using an automatic oil drain/oil fill pump:

7. Disconnect pump and replace the oil drain hose end cap and turn the valve at the base of the oil drain hose.

8. Start generator set and check for oil leaks.

9. Stop generator set. Remove dipstick and wipe clean, reinsert as far as possible, and remove to checkoillevel. Add oil, as necessary,to bring level up to max mark.

1. Connect the pump to the end of the oil drain hose. See Figure 3-3 for location.

1. Oil drain hose

ADV-5853-A

Figure 3-3. Oil Drain Hose (Typical)

2. Place the pump outlet hose into a container.

3. Remove the oil fill cap. One cap is near the top of the engine on the valve cover. The other cap is near the governor. See Figure 3-4.

NOTE

Too highanoil level will causehighoil consumption and engine carbonization. Too low a level will cause engine damage.

NOTE

Do not pollute the environment. Dispose of used engine oil and other contaminants in a safe and an approved manner.

4. Start the pump and remove all oil.

5. Fillcrankcasewith specifiedamount andtype ofoil. See Section 1—Specifications.

6. Replace oil fill cap.

TP-5592 7/96 Scheduled Maintenance 3-7

1. Oil fill at valve cover

2. Oil fill at governor

Figure 3-4. Oil Fill Locations (Typical)

ADV-5853-A

Page 46

If not using an automatic oil drain/oil fill pump:

1. To drain oil, turn valve (if equipped) at the base of the oil drain hose. See Figure 3-3 for location. Remove oil drain hose end cap and place oil drain hosein acontainer. Donotpollute the environment or waterways.

2. Allow ample time for oil to drain. After completing theoil draining process, replace the end cap on the hose and turn the valve at the base of the oil drain hose.

3. Remove oil fill cap. One cap is near the top of the engine on the valve cover. The other cap is near the governor. See Figure 3-4.

4. Fillcrankcasewith specifiedamount andtype ofoil. See Section 1—Specifications.

Oil Filter Change

Replace the oil filter as listed in the service schedule. Change more frequently if operating in dirty, dusty conditions. See Figure 3-5 and refer to the following procedure.

1. Loosen the oil filter by turning it counterclockwise. Removeoilfilteranduseragstocleanupspilled oil. Dispose of oil filter in a safe and approved manner.

2. Clean contact surface on the oil filter adapter.

3. Lightly lubricate the gasket surface of the new filter with fresh engine oil. Thread filter on adapter until gasket makes contact, hand-tighten an additional one-half turn. Wash hands after any contact with engine oil.

5. Replace oil fill cap.

6. Start generator set and check for oil leaks.

7. Stop generator set. Remove dipstick and wipe clean, reinsert as far as possible, and remove to checkoillevel. Add oil, as necessary,to bring level up to max mark.

To perform an oil change skip Steps 4-5 and go back to Oil Change procedure preceding.

4. Start generator set and check for oil leaks.

5. Stop generator set. Remove dipstick and wipe clean. Reinsert as far as possible and remove to checkoillevel. Add oil, as necessary,to bring level up to max mark.

3-8 Scheduled Maintenance TP-5592 7/96

ADV-5853-A

1. Lube oil filter

Figure 3-5. Lube Oil Filter (Typical)

Page 47

Fuel System

Specifications

Use a clean, good quality No. 1-D or No. 2-D diesel fuel oil with a cetane number of 45 or greater. The fuel must meet the requirements of the American Society of Testing and Materials (ASTM) diesel fuel classification D975.

Useclean fuelsince dieselengineshave easilyclogged, precision fuel injectors and pumps.

Recommended fuel: United States ASTM/D975-66T, No. 1-D or No. 2-D diesel oil. United Kingdom BS2869 Class A1.

NOTE

Never store diesel fuel in galvanized containers; diesel fuel and the galvanized coating react chemically to produceflakingwhich quickly clogs filters or causes fuel pump or injector failure.

NOTE

Do not run the generator set out of fuel since the fuel lines will draw in air and necessitate bleeding the fuel system before restarting the unit.

Fuel Filter

Clean the fuel filter with fresh fuel oil and compressed air. The quality and condition of the fuel largely determine the filter’s useful life. Replace the fuel filter element as listed in the service schedule. Use the following procedure to replace the fuel filter.

1. Close the fuel valve.

2. Loosenthefuel filterbyturning it counterclockwise. Remove fuel filter and use rags to clean up spilled fueloil. Dispose offuelfilter in asafeand approved manner. See Figure 3-6.

NOTE

Avoidstoringfuel formore thanone month. Takespecial precautions to keep all dirt, water, and other contaminants out of the fuel. Diesel fuel storage tanks containing contaminants and water may cause the growth of microbes. Microbes form slime which clogs the fuel filter and lines.

ADV-5853-A

Figure 3-6. Fuel Filter Location (Typical)

3. Clean contact surface on fuel oil filter adapter.

4. Lightly lubricate the gasket surface of the new fuel filterwith freshfueloil. Thread filter onadapteruntil gasket makes contact, hand-tighten an additional one-half turn. Wash hands after any contact with fuel oil.

5. Open fuel valve.

6. Bleed the system. Follow the procedures in Bleeding Fuel System following.

TP-5592 7/96 Scheduled Maintenance 3-9

Page 48

Bleeding Fuel System

If the generator set engine runs out of fuel, if air leaks develop in the suction side of the fuel system, or when replacing the fuel filter, bleed the entire system to prevent starting failures and/or erratic operation.

NOTE

Connect the battery during the priming procedure to allowengine cranking. Do not allowengine/generatorto start. To prevent actual starting, toggle the start/stop switch. (Momentarily place the start/stop switch in the START position for a few seconds and then place the switch in the STOP position.)

Use the following procedure to bleed the fuel system.

1. Loosen vent screw A at fuel filter. See Figure 3-7.

2. Toggle the start/stop switch until fuel, free of air bubbles, flows from vent screw A. Tighten connection.

3. Loosen vent screw B at fuel filter.

4. Toggle the start/stop switch until fuel, free of air bubbles, flows from vent screw B. Tighten connection.

5. Loosen vent screw C at fuel injection pump.

6. Toggle the start/stop switch until fuel, free of air bubbles, flows from vent screw C. Tighten connection.

TP-5592-3

1. Vent screw A

2. Vent screw B

3. Fuel filter

4. Fuel injection pump

5. Vent screw C

Figure 3-7. Fuel System Bleeding (Typical)

NOTE

Wipe up all spilled diesel fuel after bleeding system. Wash hands after any contact with fuel oil.

3-10 Scheduled Maintenance TP-5592 7/96

Page 49

Air Intake Silencer/Cleaner

A round polyurethane sound-absorbing type intake silencer silences the intake air drawn into the cylinder headfromtheintake port. Besides providing a silencing effect,the silencer also actsasan air cleaner. Cleanthe airsilenceraslistedintheserviceschedule. Cleanmore frequentlyifoperatingindirty, dustyconditions. Replace a damaged or dirt-contaminated air silencer. See Figure 3-8 and refer to the following procedure.

1. Spring clip

2. Air intake silencer/cleaner

Figure 3-8. Air Intake Silencer (Typical)

ADV-5853-A

1--776

1. Element

Figure 3-9. Element Washing

1. Release the two spring clips and remove intake silencer cover.

2. Remove theelementfrom the cover and inspect. If theelementisinreasonableconditionforcleaning, continue with Step 3.

If the element is damaged or in poor condition, replace the element. Skip Step 3 and go to Step 4.

3. Wash the element in mild detergent and water solution. Rinse and allow to air dry. See Figure 3-9.

4. Wipe intake silencer cover and base with a clean rag to remove any dirt. Check base for damage; replace as necessary.

TP-5592 7/96 Scheduled Maintenance 3-11

5. Reassemble element and cover assembly to intake silencer base. Make sure sealing surfaces fit correctly and reattach spring clips. Air intake silencer duct should be at the 5 o’clock position as viewed from the generator end.

Page 50

Turbocharger

Inspect the compressor (blower) as listed in the service schedule for buildup of carbon residue. An authorized service dealer, using Yanmar Service Manuals, must perform all other turbocharger inspection and service describedin theserviceschedule . SeeFigure 3-10and use the following procedure to inspect the compressor.

DA-250000-H

1. Remove breather hose from air intake silencer connector, if equipped.

2. Loosen hose clamp on air intake silencer and remove air intake silencer.

3. Inspect compressor (blower) housing and impeller (blower wheel) for buildup of carbon residue. If the compressor requires cleaning, contact an authorized Kohler service distributor/dealer, who should use a Yanmar approved turbocharger cleaner.

4. Place air intake silencer over turbocharger compressor housing inlet and tighten clamp. Direct the air intake silencer duct down and away from the engine.

5. Attach breather hose to air intake silencer connector, if equipped.

1. Turbocharger

Figure 3-10. Turbocharger Inspection

Servicing Mixing Elbow

1. Check inside mixing elbow for carbon buildup and corrosion.

2. Remove carbon buildup with a wire brush.

3. Inspect exhaust manifold mounting threads for cracking and corrosion. The mixing elbow combines high temperature exhaust and cooling seawater. When exposed to engine vibration, the

mixture of exhaust and seawater can cause rapid deterioration and failure in an improperly maintained exhaust system.

4. Replace damaged mixing elbow or other exhaust components to prevent engine exhaust (carbon monoxide) leakage.

3-12 Scheduled Maintenance TP-5592 7/96

Page 51

Governor

The centrifugal, mechanical governor keeps engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in theload. Thegovernor requires no regularservice. The governoris adjustedduringrun-in at thefactory. Further adjustments are unnecessary except under greatly varying load conditions or if poor governor control develops after extended usage.

60 Hz generator sets are designed to operate at 57-63 Hz, 1800 RPM under full load and 1890 RPM under no load.

50 Hz generator sets are designed to operate at 47-53 Hz, 1500 RPM under full load and 1590 RPM under no load.

To checkspeed,use frequency meter connectedtoload leads or use hand tachometer.

1. Loosen locking nut on speed adjusting screw.

2. To increase speed (and frequency), turnscrew in a clockwise direction. Turn screw counterclockwise to decrease speed.

3. Tighten locking nut at new setting. See Figure 3-11.

1. Speed adjusting screw

2. Locking nut

Figure 3-11. Governor (Typical)

TP-5592-3

TP-5592 7/96 Scheduled Maintenance 3-13

Page 52

Cooling Systems

Closed/Heat Exchanger

In a closed cooling system, the seawater does not circulate through the engine. Rather, the seawater circulates through the separate chambers within the manifold to cool the engine water. The seawater then mixes with engine exhaust and ejects out the exhaust outlet. See Section 1—Specifications for coolant capacity (including coolant recovery tank), thermostat rating, and pressure cap rating. Use a solution of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion and prevent freezing.

WARNING

Hot coolant and steam. Can cause severe injury or death.

Before removing pressure cap, stop generator set and allow it to cool. Then loosen pressure cap to relieve pressure.

Filling and Checking

Before filling the cooling system, close all petcocks and tighten all hose clamps. If the cooling system requires filling, open pressure cap on heat exchanger and add fresh coolant until level is just below overflow tube opening. Add additional coolant, as necessary, to coolant recovery tank. Fill to just below the HOT (full) mark. Maintain proper coolant level in coolant recovery tank. TheCOLD (add) markindicates fullwhen coldand the HOT (full) mark indicates full when hot. Maintain coolant level between these marks.

NOTE

Pay special attention to the coolant level. After the coolant drains, allow time for complete refill of the engine water jacket. Check coolant level as prescribed in the Prestart Checklist.

Checking coolant level. Hot coolant can cause severe injury or death. Allow engine to cool. Release

3-14 Scheduled Maintenance TP-5592 7/96

Page 53

NOTICE

Seawater damage! High-mineral content seawater

(saltwater) causes rapid deterioration of all metals. Wipe up all saltwater spillage on and around generator set and keep metal surfaces free from accumulated salt deposits.

Seawater Pump

These models use a belt-driven seawater pump located on the service side. Check and change the seawater pump as listed in the service schedule.

Siphon Break

Cleaning

For optimum protection, drain the cooling system at the interval listed in the service schedule.

1. Open petcocks located at heat exchanger, engine block, and cooling system and let the system drain completely. Some models may have petcocks located behind the belt guard. Remove the pressure cap to make draining easier.

2. Drain, clean, and flush coolant recoverytank. Use chemical cleaners for badly rusted or corroded coolingsystem;follow manufacturer’sinstructions.

3. Flush system with clean water before filling with recommended coolant.

Pressure Cap

Closed/heat exchanger systems incorporate a pressurized cap to raise the boiling point of the coolant enabling higher operating temperatures. If the cap leaks, replace the cap with one of the same type and rating. Find the pressure cap rating in Section 1—Specifications.

A siphon break provision prevents seawater entry into the engine when the engine exhaust manifold outlet is less than 9 in. (23 cm) above waterline of a fully-loaded, shut-downcraft. When the craft isused in contaminated waters or saltwater, the formation of corrosion may not allow the siphon break to function correctly. Check the siphon break as listed in the service schedule. Use the following procedure to ensure correct functioning of the siphon break.

1. Stop the generator set.

2. Remove retaining cap to inspect reed valve assembly. See Figure 3-12.

3. Clean reed valve to remove residue and oxidation.

4. Check that reed valve (opening) is clear.

5. Replace siphonbreak if it iscracked or if reedvalve material has hardened or deteriorated.

6. Install reed valve into mounting base with valve downward.

7. Install retaining cap and finger-tighten only. Do not overtighten.

TP-5592 7/96 Scheduled Maintenance 3-15

Page 54

NOTE

Numbers in illustration refer to callouts be-

low and not to dimensions.

Waterline

1. Mounting base

2. Retaining cap

3. Reed valve assembly

4. Maximum silencer vertical lift of 4 ft. (1.2 m)

5. Exhaust mixer elbow distance above waterline. If less than 9 in. (23 cm), siphon break is required.

6. Minimumsiphonbreakdistanceabovewaterlineof1 ft. (30.5 cm)

7. Siphon break

8. Exhaust mixer elbow

9. Heat exchanger (locations vary by model)

10. Coolant recovery tank

11. Indicates coolant recovery tank at same height as heat exchanger

Figure 3-12. Siphon Break (plastic “U” type)

NOTE

Read text for complete explanation of dimensions and other installation considerations.

NOTE

Usetwohoseclampsoneachendofall flexible exhaust hose connections.

12. Seawater strainer

13. Seacock

14. Intake strainer

15. Engine-driven seawater pump

16. Minimumexhausthosepitchof0.5in.perft.(1.3cmper30.5cm)

17. Water lock (optional)

18. Maximumdistancebetweensilencerandexhaustmixerelbowof 10 ft. (3 m)

19. Silencer (customer supplied)

20. Minimumexhausthosepitchof 0.5in.perft.(1.3cmper 30.5 cm)

21. Minimumexhaustoutletdistanceabovewaterlineof4in.(10cm)

NOTE

Data given also applies to side-exhaust installations.

3-16 Scheduled Maintenance TP-5592 7/96

Page 55

Belt Tension

WARNING

Accidental starting. Can cause severe injury or death.

Disconnect battery cables before working on generator set (disconnect negative lead first and reconnect it last).

Disabling generator set. Accidental starting can cause severe injury or death. Disconnect battery

WARNING

Seawater Pump Belt

1. Remove the belt guard.

2. Check belt tension at the midpoint of the longest spanof thebelt. Atmidpoint, the beltshoulddeflect about 0.4-0.6 in. (10-15 mm) with about 22 lbs. (10 kg) of force. See Figure 3-13.

If belt is not within specifications, go to Step 3. If belt is within specifications, go to Step 7.

3. Loosen pivot and adjusting screws.

Rotating parts. Can cause severe injury or death.

Do not operate generator set without all guards, screens, and covers in place.

Servicing generator set when operating. Exposed moving parts can cause severe injury or death.

Keep hands, feet, hair, clothing, and test leads away from belts and pulleys when generator set is running. Replace guards, screens, and covers before operating generator set.

Check the belt tension as listed in the service schedule. If the tension is not within specifications, adjust as necessary using the following procedure.

1. Engine-driven water pump pulley

2. Adjusting arm pivot screw

3. Battery charging alternator pulley

4. Adjusting screw

5. Alternator pivot screw

6. Check alternator belt tension here

7. Crankshaft pulley

8. Check seawater pump belt tension here

9. Adjusting screw

10. Seawater pump pulley

11. Pivot screw

TP--5592--3

Figure 3-13. Belt Tension (Typical)

4. While prying seawater pump outward, tighten adjusting screw.

5. Tighten pivot screw.

6. Recheck and adjust as necessary.

7. Replace the belt guard.

TP-5592 7/96 Scheduled Maintenance 3-17

Page 56

Battery Charging Alternator/

Engine-Driven Water Pump Belt

1. Remove belt guard.

2. Check belt tension at the midpoint of the longest spanof thebelt. Atmidpoint, the beltshoulddeflect about 0.4-0.6 in. (10-15 mm) with about 22 lbs. (10 kg) of force, see Figure 3-13.

If belt is not within specifications, go to Step 3. If belt is within specifications, go to Step 7.

3. Loosen adjusting arm pivot screw, alternator pivot screw, and alternator adjusting screw.

4. While prying alternator outward, tighten alternator adjusting screw.

5. Tighten adjusting arm pivot screw and alternator pivot screw.

6. Recheck and adjust as necessary.

7. Replace the belt guard.

3-18 Scheduled Maintenance TP-5592 7/96

Page 57

Battery

Kohler Co. recommends using one 12-volt battery as the starting battery. It must have a minimum of 500 cold cranking amps (CCA) at 0°F (--18°C) or 100 amp. hr. A maintenance-free battery does not require checking the specific gravity or electrolyte level. Otherwise, perform these procedures at the interval recommended in the service schedule.

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Use protective goggles and clothes. Battery acid can cause permanent damage to eyes, burn skin, and eat holes in clothing.

Battery acid. Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do

Cleaning

Clean battery by wiping it with a damp cloth. Keep all electrical connections dry and tight. If the battery is corroded, disconnect cables from battery and remove corrosion with a wire brush. Clean battery and cables with a solution of baking soda and water. Do not allow the cleaning solution to enter battery cells. After cleaning the battery, flush the battery and the cables with clean water and wipe the battery with a dry cloth. After reconnecting the battery cables, coat terminals with petroleum jelly, silicon grease, or other nonconductive grease.

TP-5592 7/96 Scheduled Maintenance 3-19

Page 58

Charging

Theenginealternatorwillprovideacharge of 12 volts at up to 50 amps. To adjust belt tension, see Belt Tension.

NOTE

Operation of on-board electrical equipment, such as auxiliarylights andradios,off ofbattery power drainsthe batteries. Batteries must maintain a charge sufficient to start the generator. To maintain battery charge while docked, charge battery using shore power. To maintain battery power while underway, operate generator set.

Checking Electrolyte Level

Check the electrolyte level before each start--up. Remove filler caps and check to see that electrolyte level is up to bottoms of filler holes. See Figure 3-14. Refill as necessary with distilled water or clean tap water. Do not add fresh electrolyte! Tightenfiller caps. After adding water during freezing temperatures, run generator set for 20-30 minutes to allow electrolyte and added water to mix. This will prevent battery damage caused by freezing.

TP--5592--3

1. Filter caps

2. Electrolyte level

Figure 3-14. Electrolyte Level Inspection

3-20 Scheduled Maintenance TP-5592 7/96

Page 59

Checking Specific Gravity

Usea battery hydrometertocheck the specificgravityof the electrolyte in each battery cell. While holding the hydrometervertically,readthenumber ontheglass bulb atthe top of the electrolytelevel(or the numberadjacent to the pointer). If the hydrometer does not have a correction table, use the table in Figure 3-16. Determine specific gravity and electrolyte temperature of battery cells. Locate temperature in Figure 3-16 and adjust gravity by amount shown. The battery is fully charged if the specific gravity is 1.260 at an electrolyte temperature of 80°F (26.7°C). The difference between specific gravities of each cell should not exceed ±0.01. Charge the battery if the specific gravity is below 1.215 at an electrolyte temperature of 80°F (26.7°C).

NOTE

Some battery testers have four or five beads in the test tube. Draw electrolyte into the tube as done with the hydrometer described previously. Use the manufacturer’s instructions. Figure 3-15 interprets the test results.

Number of Beads

Five floating beads Overcharged

Four floating beads Fully charged

Three floating beads A good charge

One or two floating beads A low charge

No floating beads A dead battery

Battery

Condition

°C °F

71.1

65.6

60.0

54.4

48.9

43.3

37.8

32.2

26.7

21.1

15.6

4.4

-- 1.1

-- 6.7

-- 12.2

160

150

140

130

120

110

100

Correction + .032 + .030 + .028

EXAMPLE NO. 1—

+ .026

Temperature below 80°F (26.7°C)

+ .024 + .022

Hydrometer Reading 1.250

+ .020

Acid Temperature 20°F (--6.7°C)

+ .018 + .016

Subtract .024 Specific Gravity Corrected Specific Gravityis 1.226

+ .014 + .012 + .010 + .008 + .006

EXAMPLE NO. 2—

+ .004

Temperature above 80°F (26.7°C)

+ .002

Hydrometer Reading 1.235

-- .002

Acid Temperature 100°F (37.8°C)

-- .004

Add .008 Specific Gravity

--. 006

Corrected Specific Gravity is

-- .008

1.243

-- .010

-- .012

-- .014

-- .016

-- .018

-- .020

-- .022

-- .024

-- .026

-- .028

Figure 3-15. Bead Test

The temperature correction amountsto about .004 (4 “points”) ofspecificgravityforeach10°F(5.5°C)changeintemperature.

1-787

Figure 3-16. Specific Gravity

Temperature Correction

TP-5592 7/96 Scheduled Maintenance 3-21

Page 60

Generator Service

General

Undernormal conditions,the generatordoesnot require regular service. If operating under dusty and dirty conditions, use dry compressed air to blowdust and dirt out of the generator while the generator set is running. Directthe stream of air inthroughthe cooling slots at the end of the generator.

Wattage Requirements

Iftheratedcapacityofthegenerator setis exceeded,the circuit breaker located on the controller trips to protect the generator against damage. A short circuit in the AC circuitof the craft or simultaneousoperationof too many on-board appliances could cause the generator set’s controller circuit breaker to trip. If the circuit breaker trips,the set may continue torun,butthere will be no AC output to the protected circuit.

Replace the end bracket bearing every 10,000 hours of operation. Service the end bracket bearing more frequently if bearing inspection indicates excessive rotorend play or bearing damage from corrosion orheat buildup. The sealed end bracket bearing requires no additional lubrication. Have an authorized Kohler service distributor/dealer perform all generator service.

Before resetting the circuit breaker, turn off some of the appliances and lights inside the craft to bring the load down within the rated limits of the set. If the circuit breaker trips after the load reduction, there is a short circuit. Turn off the set and have a qualified electrician locate and correct the cause of the short circuit.

For more information regarding generator set capacity, see Section 1—Specifications.

3-22 Scheduled Maintenance TP-5592 7/96

Page 61

Storage Procedure

Keep the craft afloat until completing generator set storagesince theunitmust bestartedduring thestorage procedure.

1. Start and run generator set until it reaches operating temperature, or about 15 minutes.

2. Stop generator set. Drainoil from crankcase while engineis still warm. Refillcrankcasewithspecified weight oil.

NOTE

Follow steps a.-e. or f.-i..

a. Close seacock and remove hose at seacock.

Place hose in a container of coolant/antifreeze. Container should have approximately 1-2 U.S. gallons (3.7-7.5 L) of antifreeze. Use a mixture of50% ethyleneglycoland 50%clean, softened water.

b. With a suitable container at exhaust outlet, run

generator set until coolant discharges at exhaust outlet or until coolant mixture is used up. Do not allow coolant mixture to flow into

waterways. c. Stop generator set. d. Connect hose to seacock. Leave seacock

closed. e. Check coolant level of heat exchanger and add

if necessary.

-- Or --

f. Close seacock and drain all seawater out of

cooling system.

g. Drain seawater from strainer and seawater

pump.

h. Open petcock on heat exchanger to drain only

seawater. Use an air hose to blow out any remaining seawater, if necessary. Check coolant level of heat exchanger and add if necessary.

i. Drain seawater from exhaust water line.

NOTE

Ifthe craft is stored infreezingtemperatures,be sure anti-freeze can withstand the lowest possible temperatures. Generally, a mixture of 50% ethylene glycol and 50% clean, softened water is sufficient.

3. Diesel fuel can be stored inthefueltank for several months.

4. Clean exterior of generator set and spread a light film of oil or silicon spray over any exposed surfaceswhichmaybesubjecttorust or corrosion.

5. Seal air inlet, exhaust pipe, and fuel tank cap with tape.

6. Disconnect and remove battery. Place battery in a warm, dry location for storage period. Recharge once a month to maintain full charge.

7. Cover entire unit with a dust cover.

TP-5592 7/96 Scheduled Maintenance 3-23

Page 62

Section 4. Troubleshooting

Unitwillnotcran

Unitcranksbutwillno

notcontinuetoru

release

When troubles occur, do not overlook simple causes. A starting problem, for example, could be caused by incorrectfuel oranempty fueltank. The followingcharts list some common problems. If procedures in this manual do not explain how to correct the problem, take

Engine

Problem Possible Cause Corrective Action

Unit will not crank

Unit cranks but will not start

Engine starts, but does not continue to run after start switch is

Weak or dead battery Recharge or replace battery Reversed or poor battery connections. Poor

ground. Circuit breaker tripped in controller Reset circuit breaker Defective start/stop switch Check switch, replace as necessary Defective starter solenoid Check starter solenoid and wiring. Replace as

Defective starter Replace/repair as necessary Out of fuel Replenish fuel Fault shutdown Check shutdown switches Fuel shut-off valve closed Open shut-off valve Defective fuel feed pump Replace fuel feed pump Clogged fuel filter Service fuel filter element Air in fuel system Bleed air from system Water, dirt in fuel system Drain, flush fuel system Dirty or faulty injectors See authorized Kohler service distributor/dealer Incorrect compression See authorized Kohler service distributor/dealer Incorrect type of fuel Use correct type of fuel; consult fuel supplier Incorrect type of crankcase lube oil for ambient

temperature Faulty fuel solenoid Replace solenoid Air intake clogged Clean or replace air intake Faulty ground (-) connection Clean and retighten Weak or dead battery Recharge or replace battery Engine malfunction See authorized Kohler service distributor/dealer No generator output voltage Check AC voltage. See

No/low oil pressure See authorized Kohler service distributor/dealer Defective low oil pressure (LOP) safety

shutdown switch High temperature shutdown Check cooling system for coolant level Defective high exhaust temp. (HET) and/or high

water temp. (HWT) safety shutdown switch(es)

the generator set to an authorized Kohler service distributor/dealer.Tell thedealerexactly what happened when the problem occurred and of any adjustments made to the set.

Check and correct connections

necessary.

Use correct lube oil

Troubleshooting—Generator (No AC output)

Replace LOP shutdown switch

Replace HET and/or HWT shutdown switch(es)

TP-5592 7/96 Troubleshooting 4-1

Page 63

Problem Possible Cause Corrective Action

Stopssuddenly

Operateserratically

Engineknock

Engineoverheats

Stops suddenly

Operates erratically

Engine knocks

Engine overheats

Engine (Continued)

Out of fuel Replenish fuel Air intake clogged Service air intake silencer Circuit breaker tripped in controller Reset circuit breaker Defective seawater pump impeller Replace seawater pump impeller Clogged seawater strainer Clean strainer Fuel line restriction Check fuel lines and tank Dirty fuel filter Service fuel filter No/low oil pressure See authorized Kohler service distributor/dealer Defective low oil pressure (LOP) safety

shutdown switch High temperature shutdown Check engine coolant system for coolant level Defective high exhaust temp. (HET) and/or high

water temp. (HWT) safety shutdown switch(es) Loss of AC output See authorized Kohler service distributor/dealer Air intake clogged Service air intake silencer Stale or bad fuel Replace fuel Clogged fuel filter Replace fuel filter Vent in fuel tank cap obstructed Clean cap in solvent; blow dry Water, dirt, or air in fuel system Drain, flush, fill, and bleed air in the system Dirty or faulty injectors See authorized Kohler service distributor/dealer Faulty governor linkage See authorized Kohler service distributor/dealer Defective fuel feed pump Replace fuel feed pump Incorrect valve clearance See authorized Kohler service distributor/dealer Defective valve spring See authorized Kohler service distributor/dealer Incorrect compression See authorized Kohler service distributor/dealer Incorrect type of fuel Use correct type of fuel; consult fuel supplier Incorrect fuel injection timing See authorized Kohler service distributor/dealer Incorrect cylinder top clearance See authorized Kohler service distributor/dealer Defective piston or piston ring See authorized Kohler service distributor/dealer Defective crankshaft bearing or piston pin

bearing Incorrect valve clearance See authorized Kohler service distributor/dealer Air in injectors Bleed air Inadequate cooling Check engine coolant level Thermostat defective Replace thermostat Air intake clogged Service air intake silencer Engine overloaded Reduce load Loose or defective cooling water pump belt Adjust belt tension or replace belt Cooling system needs flushing Flush cooling system Defective temperature switch Replace shutdown switch Cooling water leaks from water passage Check water passage

Replace LOP shutdown switch

Replace HET and HWT shutdown switch(es)

See authorized Kohler service distributor/dealer

TP-5592 7/964-2 Troubleshooting

Page 64

Problem Possible Cause Corrective Action

Lackspowe

Engineemitsblacko

Lowlubeoilpressur

Highlubeoil

Highfuelconsumption

Lacks power

Engine emits black or gray exhaust smoke

Low lube oil pressure

High lube oil consumption

High fuel consumption

Engine (Continued)

Air intake clogged Service air intake silencer Bad or stale fuel Replace fuel Engine not operating at rated RPM See authorized Kohler service distributor/dealer Governor adjustments incorrect See authorized Kohler service distributor/dealer Carbon build-up Clean carbon from cylinder heads Inadequate cooling Inspect cooling system Fuel line restricted Check fuel lines Dirty fuel filter Service fuel filter Engine overloaded Reduce load Incorrect valve clearance See authorized Kohler service distributor/dealer Dirty or faulty injectors See authorized Kohler service distributor/dealer Incorrect fuel injection timing See authorized Kohler service distributor/dealer Incorrect engine compression See authorized Kohler service distributor/dealer Vent in fuel tank cap obstructed Clean cap in solvent; blow dry Incorrect type of fuel Use correct fuel Clogged or dirty air intake silencer Service air intake silencer Defective injection pump See authorized Kohler service distributor/dealer Faulty injectors See authorized Kohler service distributor/dealer Incorrect fuel injection timing See authorized Kohler service distributor/dealer Incorrect valve clearance See authorized Kohler service distributor/dealer Lube oil level too high Drain out surplus lube oil Incorrect lube oil Use correct viscosity oil Low lube oil level Add lube oil Incorrect lube oil viscosity Drain, fill correct lube oil Defective lube oil pump See authorized Kohler service distributor/dealer Defective oil pressure switch Replace safety shutdown switch Too light viscosity oil Use correct viscosity oil Oil leaks Check for leaks in lines, around gasket, and

drain plug Incorrect type of oil Use oil of correct viscosity Clogged breather system Clean breather system Defective piston ring, piston, cylinder liner,

valve guide, and seat Incorrect type of fuel Use correct fuel Clogged or dirty air intake silencer Service air intake silencer Engine overloaded Reduce load Incorrect valve clearance See authorized Kohler service distributor/dealer Incorrect fuel injection timing See authorized Kohler service distributor/dealer Low engine temperature Check thermostat Incorrect compression See authorized Kohler service distributor/dealer Fuel leakage Check for leaks at fuel tank, lines, and engine

See authorized Kohler service distributor/dealer

fuel system

TP-5592 7/96 Troubleshooting 4-3

Page 65

Problem Possible Cause Corrective Action

Abnormalnoise

Batterywillnotcharg

Starterdoesnotwor

Unit is noisy

Abnormal noise

Problem Possible Cause Corrective Action

Battery will not charge

Starter does not work correctly

Starter cranks slowly

Engine (Continued)

Exhaust system leak Inspect exhaust system for leaks and repair

them Exhaust system not securely installed Check for loose parts and tighten them Broken or damaged vibromounts Check vibromounts for cracks No installation clearance (unit hits craft

structure or compartment) No compartment sound insulation Install approved insulation Excessive vibration engine/ generator (internal

imbalance) Worn or defective bearing or gear See authorized Kohler service distributor/dealer Loose bolt or screw Tighten hardware Low lube oil level Add lube oil

Check and increase clearances

See authorized Kohler service distributor/dealer

Electrical System

Loose or corroded connections Clean and tighten connections Sulfated or worn-out battery Check electrolyte level and specific gravity

(batteries with filler caps only) Defective battery charging system Check charging system Battery charging fuse blown Replace fuse. If fuse blows again see

authorized Kohler service distributor/dealer Loose or corroded connections Clean and tighten loose connections Low battery output Check electrolyte level and specific gravity

(batteries with filler caps only). Check battery

voltage. Defective starter solenoid Replace starter solenoid Defective start/stop switch Replace switch Defective wiring Check wiring Low battery output Check electrolyte level and specific gravity

(batteries with filler caps only) Too heavy viscosity lube oil Use correct viscosity oil Loose or corroded wiring Clean and tighten loose connections High starter current draw Rebuild or replace starter

TP-5592 7/964-4 Troubleshooting

Page 66

Problem Possible Cause Corrective Action

NoACoutpu

Lowoutputor

voltage

No AC output

Low output or excessive drop in

High generator output voltage

Generator

Circuit breaker in OFF position Reset breaker to ON position Circuit breaker tripped due to overload on

generator set Ship-to-shore transfer switch in OFF or SHORE

position Controller circuit breaker tripped Reset circuit breaker Generator malfunction such as defective rotor,

faulty voltage regulator, or other internal fault Engine speed too low Adjust governor Generator overloaded Reduce load. See Wattage Requirements. Engine in poor condition If routine services are performed and condition

Faulty voltage regulator See authorized Kohler service distributor/dealer Defective voltage regulator and/or poor wiring

connections Rotor grounded See authorized Kohler service distributor/dealer

Reduce load. See Wattage Requirements.

Reset breaker to ON position.

Turn switch to generator power

See authorized Kohler service distributor/dealer

persists, see authorized Kohler

distributor/dealer

See authorized Kohler service distributor/dealer

TP-5592 7/96 Troubleshooting 4-5

Page 67

Section 5. Wiring Diagrams

Voltage Reconnection (4-lead)

The following information illustrates the correct reconnection of 4-lead generator sets. In all cases, follow the National Electrical Code (NEC).

NOTE

When connecting a generator set to a voltage different from nameplate voltage, place a notice on the unit indicatingthe voltagechange. Adecal (part no.246242) is available for this purpose from authorized Kohler distributors/dealers.

Jumper lead not used. Circuit breaker MUST be a circuit breaker manufacturer two-pole circuit breaker. Two single-pole circuit breakers do not conform to NEC requirements when supplying a 200-240 volt load. This is true even if they are mechanically attached together. Since Leads L1 and L2 are of different phases, never connect them together.

L0 (Neutral)

Ground

Load Side

Line Side

100-120 Volt

4 3 2 1

Stator Leads

60 Hz 50 Hz

L0-L1 100-120 Volt 100-120 Volt L0-L2 100-120 Volt 100-120 Volt

2 Wire

L0 GRD.

Single-Pole Circuit Breaker

Figure 5-1. 100-120 Volt Configuration*

TP-5592 7/96 Wiring Diagrams 5-1

Page 68

Load Side

Line Side

L0 (Neutral)

Ground

L0 GRD.

L2 L1

Factory Two-Pole Circuit Breaker

Load Side

Line Side

L0 (Neutral)

Ground

Tape to insulate from ground

L0 GRD.

Single-Pole Circuit Breaker

4 3 2 1

Stator Leads

100-120/200-240 Volt,

3 Wire

60 Hz 50 Hz

L0-L1 100-120 Volt 100-120 Volt L0-L2 100-120 Volt 100-120 Volt L0-L2 200--240 Volt 200--240 Volt

Figure 5-2. 100-120/200-240 Volt Configuration

4 3 2 1

Stator Leads

200-220-240 Volt

2 Wire

60 Hz 50 Hz

L0-L1 not used 200-220-240 Volt

Figure 5-3. 200-220-240 Volt Configuration*

TP-5592 7/965-2 Wiring Diagrams

Page 69

NOTES

TP-5592 7/96 Wiring Diagrams 5-3

Page 70

Voltage Reconnection (12-lead)

This reconnection procedure details voltage reconnections only. If the generator set requires frequency changes, the governor and voltage regulator will need adjustment. See the generator service manual for information regarding frequency adjustment.

The following information illustrates the reconnection of 12-lead generator sets In all cases, follow the National Electrical Code (NEC) guidelines.

Reconnect the stator leads of the generator set if desiring a different output phase or voltage. Refer to the following procedure and the connection schematics following. Followall safetyprecautionsat thefrontof thismanualand in the text during this procedure.

NOTE

Voltage reconnection! Affix notice to generator set after

reconnecting to a voltage different than the nameplate. Ordervoltage reconnection decal 246242 from authorized service distributors/dealers.

1. Move generator set master switch to OFF/RESET position.

2. Disconnect engine starting battery,negative (--) lead first. Disconnect power to battery charger (if equipped).

3. Use Figure 5-4 to determine generator set voltage configuration. Noteoriginal voltageandreconnect as needed.

TP-5592 7/965-4 Wiring Diagrams

Page 71

TP-5592 7/96 Wiring Diagrams 5-5

EM-250000-

Figure 5-4. Generator Reconnection

Page 72

Electro Switch

To Generator

Set

To Generator

Set

2-Wire Generator Sets

2 1 3 4

6 5 7 8

To Load

Kraus Naimler/American Solenoid

(Early Rectangular Design)

2-Wire Generator Sets

1 2 6 5

3 4 8 7

To Shore

Power

To Shore

Power

To Generator

Set L0

To Generator

Set

3-Wire Generator Sets

2 1 3 4

6 5 7 8

10 9 11 12

To Load

3-Wire Generator Sets

1 2 6 5

3 4 8 7

9 10 14 13

To Shore

Power

To Shore

Power

To Generator

Set

To Load

Kraus Naimler/American Solenoid

2-Wire Generator Sets

3 2 4 1

7 6 8 5

To Load

(Newer Round Design)

To Shore

Power

To Generator

Set L0

To Load

3-Wire Generator Sets

3 2 4 1

7 6 8 5

11 10 12 9

To Load

To Shore

Power

TP-5399-5

Figure 5-5. Marine Manual (Ship-to-Shore) Transfer Switch

TP-5592 7/965-6 Wiring Diagrams

Page 73

Kraus Naimer/American Solenoid

4-Wire, three phase

Generator Sets

To Generator

Set

Figure 5-6. Marine Manual (Ship-to-Shore) Transfer Switch

3 2 4 1

7 6 8 5

11 10 12 9

15 14 16 13

L2 L3 L0L1

To Load

To Shore

Power

I-940

TP-5592 7/96 Wiring Diagrams 5-7

Page 74

Figure 5-7. Schematic Wiring Diagram—13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ

229937-A

(1-Phase Models)

TP-5592 7/965-8 Wiring Diagrams

Page 75

Figure 5-8. Point-to-Point Wiring Diagram—13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ

TP-5592 7/96 Wiring Diagrams 5-9

229937-A

(1-Phase Models)

Page 76

Figure 5-9. Schematic Wiring Diagram—14/20/24CCOZ and 11.5/17.5/20CCFOZ

229938-

(3-Phase Models)

TP-5592 7/965-10 Wiring Diagrams

Page 77

Figure 5-10. Point-to-Point Wiring Diagram—14/20/24CCOZ and 11.5/17.5/20CCFOZ

TP-5592 7/96 Wiring Diagrams 5-11

229938-

(3-Phase Models)

Page 78

Figure 5-11. Schematic Wiring Diagram—13.5/18.5/21CCOZ

(Specs: PA-126148, PA-126152, and PA-126155 1-Phase Models)

229991-B

TP-5592 7/965-12 Wiring Diagrams

Page 79

Figure 5-12. Point-to-Point Wiring Diagram—13.5/18.5/21CCOZ

(Specs: PA-126148, PA-126152, and PA-126155 1-Phase Models)

TP-5592 7/96 WiringDiagrams 5-13

229991-B

Page 80

Section 6. Installation

Introduction

Use this section as a guide when installing the marine generator set, then refer to the operation section for specific service instructions. Reliable and safe generator set operation depends largely upon correct installation. Remember that the generator set will probably be the craft’s sole source of electrical power.

Marine generator set installations must comply with all applicable regulations and standards. See Reference Material section of this manual for governing agencies. Follow information presented here in planning and making installations. Use specifications given only in initial planning. Use current dimension drawings and wiring diagrams.

NOTE

Thereis awoodblock located undersome generator set end brackets to prevent damage during shipment. For the same reason, there are metal brackets attaching some generator sets to their wood shipping bases. Remove the wood block and the metal brackets prior to installation to provide adequate vibration clearance during generator set operation. Remove all packing material, literature, and loose accessories from generator set prior to operation.

TP-5592 7/96 Installation 6-1

Page 81

KOHLER

1. Exhaust mixer elbow (exhaust/water outlet) (not shown)

2. Heat exchanger (not shown)

3. Coolant recovery tank

4. Seawater strainer *

5. Seawater pump (seawater inlet)

6. Seawater line *

7. Seacock *

8. Mounting base

9. Fuel feed pump (fuel inlet) *

10. Fuel return line *

Figure 6-1. Typical Location and Mounting

NOTE

Usetwohoseclampsoneachendofall flexible exhaust hose connections.

11. Hose clamps

12. Fuel supply line *

13. Mounting tray

14. Battery/battery storage box

15. Battery cables

16. Exhaust/waterline *

17. Electrical leads (AC output leads/remote start panel leads)

* Indicated components must conform to USCG Regulations.

6-2 Installation TP-5592 7/96

Page 82

Location

General

Consider the following when selecting or constructing a generator set location.

D Allow adequate space for ventilation, cooling and

exhaust system installation, service access to set (engine and generator), and correct fuel system installation.

D Engine stringers or other available structural

members must provide adequate support for generator set weight.

D Generator set compartment must be sealed to

prevent exhaust gases and fuel vapors from entering cabins.

D Generator sets located above deck must have a

protective cover to prevent damage from rain and watersplash. This covermustnot affect coolingair flow and serviceability.

See Section 1—Specifications for dimensions and weights. See Figure 6-1 for a typical installation.

Space

Locationshouldalloweasyaccesstothe generatorset’s engine,controller,cooling, and fuel system components forroutineservice. Theengine compartmentis oftenthe ideal generator set location if propulsion engine(s) do not obstruct access to generator and controller.

Allow clearance for vibration and cooling during operation. See Section 1—Specifications for minimum recommended clearances for vibration and cooling. If the unit has a sound shield, maintain clearances per sound shield instructions.

These generator sets are not ignition protected. According to USCG Regulation 183.410, gasoline/gaseous-fueled environments require ignition-protected devices.

Mounting

Enginestringers generally providethebest support fora generatorset. Besure structural membersformounting can support generator set weight and withstand engine vibration. The generator sets include vibration mounts and mounting tray; install additional vibration isolating pads between tray and bases.

Mount the generator set as high as possible to avoid bilge splash and lower lying vapors and to allow for a downward pitch of the exhaust line.

For angular installation considerations, see Section 1—Specifications.

TP-5592 7/96 Installation 6-3

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Ventilation

WARNING

Explosion. Gasoline vapors can cause explosion and severe injury or death.

Before starting generator set, operate blower 4 minutes and check engine compartment for gasoline vapors.

Enginecombustion,generator cooling, and expulsion of flammable and lethal fumes require ventilation. Ventilation provisions must comply with USCG Regulations governing sizing of vents and operator requirements.

As a rule, size each inlet- and outlet-vent area to a minimumof2sq.in. per ft. (13 sq. cm/30.5 cm) of craft’s beam. Should this rule in any instance conflict with USCG Regulations, follow Regulations. If using any screen in inlets, double the size of hull/deck openings. Extend vent ducts to bilges to expel heavier-than-air fumes. For generator sets mounted in the engine compartment, increase air flow to allow for generator set’s requirements. Install optional sniffer devices to cause alarm, warning, or engine shutdown should dangerous fumes accumulate in the compartment.

Figure 6-2 lists air requirements for various models. The air intake silencer/cleaner provides combustion air to the engine. Do not compromise the recommended minimum clearance of 1.5 in. (38mm) between duct opening and any enclosure wall. Not following these guidelines will adversely affect engine/generator performance.

Air Requirements CFM (L/min.)

Model

13.5/14CCOZ

11/11.5CCFOZ

18.5/20/21/24CCOZ

15/17.5/16.5/18/20CCFOZ

Combustion

60Hz/50Hz

86.78/72.32 (1422/1185)

115.91/96.59 (1899/1582)

Cooling

60Hz/50Hz

210/175 (5946/4955)

210/175 (5946/4955

Figure 6-2. Air Requirements

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Fuel Systems

Fuel Supply

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Useextreme care when handling, storing, and using fuels.

Installing fuel system. Explosive fuel vapors can causesevere injury or death. Fuel leakage cancause

Generator sets, in most cases, draw fuel from the same tank as the propulsion engines. If the tank’s fuel pickup opening allows, use a multiple dip tube arrangement (Figure 6-3). The alternate tank should have a smaller separate pickup opening allowing a single dip tube (Figure 6-4). Equipthe fueltank withaprecipitation tank anda drain petcock to removeanyaccumulated dirt and water. See Figure 6-5.

1-788

1. Fuel line to propulsion engine

2. Fuel line to generator set

Figure 6-3. Dual Dip Tubes

NOTE

Fuel systems must conform to USCG Regulations and tests.

1-788

1. Fuel line to generator set

Figure 6-4. Single Dip Tube

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Locatethe fuelreturnline asfaras practicalfrom thefuel pickup to allow tank fuel to cool return fuel before delivery back to the fuel injectors. Incoming fuel cools the injectors and achieves maximum engine efficiency by supplying cool fuel to the engine. Fuel tank capacity and amount of fuel will affect cooling capability.

1-788

1. Precipitation tank

2. Drain petcock

Figure 6-5. Precipitation Tank (typical)

Under no circumstances should the propulsion engine and generator set share mutual pickup or return lines (tee arrangement) which would allow the larger engine tostarvefuelfromthesmaller engine. It is also possible that the operation of either engine could completely drain the fuel line of the other engine and make starting difficult.

Anti-Siphon Provisions

USCG Regulations do not require anti-siphoning devices with diesel-powered applications. Therefore, Kohler Co. does not recommend using anti-siphoning devices.

Fuel Lines And Filters

Usemetallic linesfromthe tanktoa flexiblehosesection to connect a metallic line to the engine fuel pump inlet connection point. Use metallic lines from the tank to a flexible hose section connecting metallic line to the fuel return line connection point. The flexible hose section allows vibrational motion of the generator set during operation. Use 3/8 in. ID size customer-supplied fuel lines to connect to the fuel pump and fuel return. Fuel lines and fuel line supports must comply with USCG Regulations 33CFR183.

See Figure 6-6 for fuel feed pump inlet connection and fuel return line connection.

Anyin-linefuelfiltersorstrainersmustconformto USCG Regulations.

Fuel Pump Lift Capabilities And

Fuel Consumption

Locate the fuel pump lift capabilities, fuel line size/type, and generator set fuel consumption rates in Section 1—Specifications.

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Page 86

1. Fuel Return Connection

2. Fuel Feed Pump

Figure 6-6. Fuel Feed Pump (Inlet Connection) and Fuel Return Connection (Typical)

3. Inlet Connection

ADV-5853-A

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General

Cooling Systems

The following features are necessary in any marine cooling system.

Intake through-hull strainer (seacock cover) Install a screened strainer to prevent entry of foreign objects. Acceptedtypes of through-hullstrainers are those ofthe perforated, slotted-hole, or unrestricted-hole design. See Figure 6-8 for examples of typical strainers. The selected strainer must have oopening(s) that are equal to or greater than the inside diameter of the waterline hosetotheseawaterpump. Donot align the strainer (in relation to direction of travel) with the propulsion engine intake. See Figure 6-7. Flushmount the recommended through-hull strainer. If the selected strainer is of the slotted-hole design, install it with the slots parallel to the direction of vessel movement.

An intake through-hull strainer must not be of the speed scoop or cup design which can cause a ramming effect and force water upward, past the seawater pump, and into engine cylinders when the vessel is moving and the generator set is shut down. Hull designs incorporating sea chests are also not suitable for intake through-hull strainers. A sea chest is a concave molded-in-the-hull chamber that is also aligned to the direction of travel. A sea chest configuration applies a positive pressure similar to a scoop-type through-hull strainer.

4 3

NOTE

Position intakes in relation to vessel travel so neither is in the wake of the other.

1. Generator set intake

2. Propulsion engine intake

3. Aft

4. Fore

Figure 6-7. Intake Strainer

1-789

Mount seacock to hull, assemble it to intake, and ensureit isaccessiblefor operation. Figure 6-8shows a typical installation. Install the canvas on the outside of the hull and the canvas or rubber packing on the inside of the hull. Tighten the seacock.

If using caulking to seal seacock, do not apply an excessive amount. Excess caulk causes incorrect waterflowand,insomecases,developsa barrier which can force water upward, past the seawater pump, and into the engine cylinders when the vessel is moving and the generator set is shut down.

1. Inside packing

2. Outside packing

3. Seacock cover

4. Direction of vessel movement

5. Typical intake through-hull strainers

Figure 6-8. Seacock Installation

1-789

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Mount seawater strainer of sufficient capacity to seacock or permanent structure at a point not higher than seawater pump. Ensure that the strainer is accessible for servicing. See Figure 6-9 for a typical installation.

NOTE

Some seawater strainers include seacock and intake through-hull strainer.

1-789

1. Seawater pump

2. Seawater strainer

3. Seacock

Figure 6-9. Seawater Strainer

Waterlines from seacock to engine-driven seawater

pump are usually flexible hose. Reference ABYC Standard P-1 for acceptable exhaust hose materials. If using a non-flexible waterline, a flexible section of hose isnecessaryto allow vibrational motion of the generator set during operation. Support a nonflexible waterline within 4 in. (102 mm) of its connection to the flexible section.

Keep pipes as straight and as short as possible. If the pipe is too long, water draw problems may occur. To remedy some problems with long pipe runs (usually over 15 ft [4.6 m]), increase the hose size to the next standard pipe diameter. Example: substitute 3/4 in. hose for 5/8 in. See Section 1—Specifications for inlet water line hose size. See Figure 6-10 for seawater connectionto seawater pump inlet. Theseawateroutlet combines with engine exhaust gases.

ADV-5853-A

1. Seawater pump inlet

Figure 6-10. Seawater Inlet Connection (Typical)

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Closed/Heat Exchanger

Closedheat exchangercoolingis thebestalternative for most applications. Kohler Co. recommends using closed heat exchanger cooling if the craft is operated in saltwater or water with high silt content.

Provide service accessibility for the water-cooled exhaust manifold pressure cap. Mount the coolant recovery tank either to engine or craft stringer. Mount the coolant recovery tank so that its surface level is the same height or 2 in. (5 cm) max. below the level of the pressure cap. See Figure 6-12 for a typical installation. See Figure 6-11 for coolant recovery tank connections. Use supplied hose to connect to coolant recovery tank.

NOTE

If not using a coolant recovery tank, be sure that the overflow hose is not immersed in the bilge water to prevent bilge water from siphoning back into the cooling system.

DA-250000-H

1. Overflow tube

2. Cooling system pressure cap

Figure 6-11. Coolant Recovery Tank Connections

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1. Oil cooler

2. Engine block

3. Thermostat

4. Water-cooled manifold

5. Heat exchanger

6. Exhaust mixer elbow

7. Water-cooled turbocharger

Seawater Freshwater (Coolant/Antifreeze)

TP-5592-6

8. Silencer (customer supplied)

9. Exhaust outlet

10. Intake strainer

11. Seacock

12. Seawater strainer

13. Engine-driven seawater pump

14. Engine-driven water pump

Figure 6-12. Closed/Heat Exchanger Cooling System

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Exhaust Systems

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Inspecting exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. In addition

to routine exhaust system inspection, install a carbon monoxide detector. Consult your boat builder or dealer forapproved detector installation. Inspect yourdetector before each generator set use.

General

Use water-cooled exhaust lines in all marine installations. Keep the lines as short and straight as possible. ABYC SafetyStandards P-1.6.i. recommends using two corrosion-resistant hose clamps, with a minimumwidthof1/2in.(13mm),on eachend offlexible exhaust hose connections A pitch of at least 1/2 in. (13 mm)per runningfoot(30.5 cm)is preferred. Useflexible exhaust hose conforming to U.L. Standard 1129 for engine wet exhaust components between mixing elbow andexhaust outlet. Independentlymountthe silencer to eliminate any stress on exhaust system and exhaust manifold/mixer elbow. See Section 1—Specifications for mixing elbow water line hose size. See Figure 6-13 for exhaust connection to mixer elbow.

Operating generator set. Carbon monoxide can cause severe nausea, fainting, or death. Use the

DA-250000-H

1. Water/exhaust outlet

Figure 6-13. Mixer Elbow/Exhaust Connection

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Locatethe exhaustoutletat least4in. (10cm)above the waterline when craft is loaded to maximum capacity. Typically, install a flapper at exhaust (transom) outlet to prevent water backup in following seas or when moving astern (backward).

Exhaust system guidelines for various generator set locations follow. Information and illustrations of stern (rear) exhaust installations also apply to side-exhaust installations. Where exhaust lines would require passage through bulkheads, it may be more practical to use port- (left) or starboard- (right) side exhaust outlets. This would be especially true where long exhaust lines to the transom (rear) could cause excessive back pressure. Should any information regarding installation conflict with USCG Regulations, follow regulations.

Above Waterline

In addition to considerations described earlier, install a customer-supplied silencer with silencer outlet at a maximum of 10 horizontal ft. (3 m) from center of engine’s exhaust outlet. See Figure 6-14. Mount a typical silencer with inlet and outlet horizontal and with drain plug down. A pitch of at least 1/2 in. (13 mm) per running foot (30.5 cm) is preferred. Some silencers require two supporting brackets or hanger straps for installation to stringers or other suitable structure. Any liftin theexhaustline toimprove silencingmust bebelow engine exhaust manifold outlet.

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NOTE

Numbers in Illustrations refer to callouts below and not to dimensions.

Waterline

1. Slight lift improves silencing (keep below level of exhaust manifold outlet)

2. Silencer (customer-supplied)

3. Exhaust mixer elbow

4. Heat exchanger (locations vary by model)

5. Coolant recovery tank

6. Locate coolant recovery tank at same height as heat exchanger

7. Maximum seawater pump lift of 3 ft. (1 m)

8. Seawater strainer

Figure 6-14. Typical Above Water Line Installation

NOTE

Usetwohoseclampsoneachendofall flexible exhaust hose connections.

9. Seacock

10. Intake strainer

11. Engine-driven seawater pump

12. Minimumexhausthosepitchof0.5in.perft.(1.3cmper30.5cm)

13. Maximumdistancebetweensilencerandexhaustmixerelbowof 10 ft. (3 m)

14. Minimumexhausthosepitchof0.5in.perft.(1.3cmper30.5cm)

15. Minimumexhaustoutletdistanceabovewaterlineof4in.(10cm)

NOTE

Data applies to both rear- and side-exhaust installations.

NOTE

Read text for complete explanation of dimensions and other installation considerations.

6-14 Installation TP-5592 7/96

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Mid/Below Waterline

FollowABYCP-1.8.c recommendations for installing an anti-siphoning provision to prevent raw water entry into the engine. Use the siphon break if exhaust manifold outlet is located less than 9 in. (23 cm) above waterline when craft is loaded to maximum capacity. Install siphon break, see Figure 6-15, at least 1 ft. (31 cm) above waterline.

Locate siphon break above highest point in exhaust line between the heat exchanger and the exhaust mixer. See Figure 6-15 for siphon break connection. Support the siphon break and hoses to maintain proper position andfunction. Mount the siphon break directly vertical of its connection to generator set where possible. Otherwise,allow a slight offsettoclear stringers or other permanent structures. Protect the siphon break air inlet from dirt and debris.

NOTE

Failure to properly install a siphon break will cause engine damage and may void warranty.

DA-250000-H

1. Cut hose and connect siphon break and hardware

Figure 6-15. Siphon Break Connection

Mounta typicalsilencer’sbaseno morethan4 ft.(1.2m) below highest point in exhaust line. Attach a separate wood mounting base to hull stringers or other suitable structure. Secure silencer to hull using silencer manufacturer’s recommendation. Mount silencer with outlet not more than 10 horizontal ft. (3 m) from engine exhaust manifold outlet. Use UL-listed marine exhaust hose.

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NOTE

Numbers in Illustrations refer to callouts below and not to dimensions.

2 3

Waterline

1. Mounting base

2. Retaining cap

3. Reed valve assembly

4. Maximum silencer vertical lift of 4 ft. (1.2 m)

5. Exhaust mixer elbow distance above waterline. If less than 9 in. (23 cm), siphon break is required.

6. Minimumsiphonbreakdistanceabovewaterlineof1 ft. (30.5 cm)

7. Siphon break

8. Exhaust mixer elbow

9. Heat exchanger (locations vary by model)

10. Coolant recovery tank

11. Indicates coolant recovery tank at same height as heat exchanger

12. Seawater strainer

Figure 6-16. Typical Mid- and Below-Waterline Installation

NOTE

Usetwohoseclampsoneachendofall flexible exhaust hose connections.

13. Seacock

14. Intake strainer

15. Engine-driven seawater pump

16. Minimumexhausthosepitchof0.5in.perft.(1.3cmper30.5cm)

17. Water lock (optional)

18. Maximumdistancebetweensilencerandexhaustmixerelbowof 10 ft. (3 m)

19. Silencer (customer supplied)

20. Minimumexhausthosepitchof0.5in.perft.(1.3cmper30.5cm)

21. Minimumexhaustoutletdistanceabovewaterlineof4in.(10cm)

NOTE: Read text for complete explanation of dimensions

and other installation considerations.

NOTE

Data applies to both rear- and side-exhaust installations.

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Electrical Systems

AC Voltage Connections

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate generator set only with all guards and electrical enclosures in place.

Electrical backfeed to utility. Hazardous backfeed voltage can cause severe injury or death. Connect

Moving rotor.

Make AC connections to generator set inside the controller box. Typically, the generator set isconnected toaship-to-shoretransferswitchwhichallowsthe useof shore/utility power when docked or generator set power when docked or at sea. Thewiring is then connected to a main circuit breaker box (panel board) which distributes branch circuits throughout the craft. See Figure 6-17 for AC voltage connections to generator set. See Section 5—Wiring Diagrams for reconnection of generator set.

1. Line side

2. AC circuit breaker

3. Load side

4. L1/L2 phase (black) leads

5. GRD. ground (green) lead

6. L0 neutral (white) lead

Figure 6-17. AC Voltage Connections in

Controller Box

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Page 97

Installation In Steel Or Aluminum

Vessels

Installation of a generator set in a vessel constructed of a material capable of conducting current (e.g.: steel or aluminum) is subject to considerations not normally encountered in fiberglass or wood vessels. These differences include equipment grounding, grounding of neutral conductors, ground-fault protection, and isolation of galvanic currents.

While the scope of these topics is too extensive to be fully discussed here, this manual makes references to the appropriate governing bodies for further investigation.

The information provided here is a guideline to boat manufacturers and generator set installers. This information is not intended or implied to be limited to these sources and is subject to revision by the appropriate governing bodies.

Installation Regulations

Pleasurecraft Generator Installation:

TheU.S. CoastGuard andtheAmerican Boatand Yacht Council, Inc. govern generator sets installed in pleasurecrafts.

General

U.S. Coast Guard Title 33CFR, Part 183

Grounded Neutral Systems (required for generator sets installed in pleasurecrafts)

American Boat and Yacht Council (ABYC) E-8.4.b

Wiring Configurations

ABYC E-8.22 through E-8.29

Grounding of appliances and equipment

ABYC E-8.12

Galvanic corrosion prevention by means of galvanic isolator or isolation transformer

ABYC E-8.20 and E-8.11

Before installing the generator set, check the available wiring diagrams in Section 5 to become familiar with the electrical system.

Commercial Craft Generator Installation :

The U.S. Coast Guard (Title 46CFR), the American Bureau of Shipping, and Lloyd’s Register of Shipping govern generator sets installed in commercial vessels.

General

U.S. Coast Guard Title 46CFR

Equipment grounding

American Bureau of Shipping (ABS) 35.9.6 Lloyd’s Register of Shipping, Part 6, Chapter 2-1, Section 1.3

Types of permissible neutral grounding of generating equipment

ABS 35.125 and 35.95.1 Lloyd’s Register of Shipping, Part 6, Chapter 2-1, Section 14.4

Ground-fault protection

Lloyd’s Register of Shipping, Part 6, Chapter 2-1, Section 14.5 Lloyd’s Register of Shipping, Part 6, Chapter 2-2, Section 13.6

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Battery

Batteries and their installation must conform to USCG Regulations183.420(a)through(g). Providegenerator setswith batteriesseparatefrom the propulsionengines whenever possible. The starting/charging systems of both the generator set and the engine must have a common negative (--) ground.

USCG Regulation 183.415, Grounding, requires connection of a common conductor to each grounded cranking motor circuit. Sizethis conductor to match the larger of the engine’s two battery cables. Figure 6-18 lists cable sizes for generator set battery connections at various ambient temperatures. Connecting a common conductor to each grounded cranking motor circuit prevents the starting motor current from using alternative electrical paths should the cranking motor ground circuit be restricted or open due to oxidation or loose hardware. Alternative electrical paths include metallic fuel lines which can pose a fire hazard. See Figure 6-19 for battery connections to generator set.

Cable

Size

Distance between

Generator Set

and Battery ft. (m)

40 (12.2) 00 0 1 30 (9.1) 0 1 2 25 (7.6) 1 2 4 20 (6.1) 2 2 6 15 (4.6) 2 4 6 10 (3.0) 4 6 8

5 (1.5) 6 6 8

2.5 (0.8) 8 8 8

At 0°F

(-18°C)

(AWG) At

32°F

(0°C)

75°F

(24°C)

1. Starter solenoid

2. Battery positive (+) connection

3. Equipment ground

4. Engine block mount

5. Battery negative (--) connection

Figure 6-19. Battery Connections

DA-250000-H

Figure 6-18. Battery Cable Sizes

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Wiring

Remote Start Switch Connection

Use only stranded copper wire. Wire gauges and insulation, conductor temperature ratings, sheath stripping, conductor support and protection, conductor terminals and splices, and over-current protection (circuit breakers, fuses) must conform to USCG Regulations 183.425 through 183.460. Use rubber grommets and cable ties as necessary to protect and secure wire from sharp objects, exhaust system, and any moving parts. See Figure 6-20 for remote start panel connection to generator set controller.

Kohler Co. offers several remote panels for connection to the generator set. See Accessories for further detailed descriptions. Also available is a wiring harness with a connector keyed to the controller box connector. The other end of this harness has pigtails which can be used if the installer elects to use a (customer-supplied) start/stop switch or separate lights and hourmeter. See Figure 6-21.

NOTE

Senders are available for most generator sets. If using gauges, be sure they are compatible with generator set senders. Gauges/senders are available as a service item from authorized Kohler service distributors/dealers. If gauges are not used, tape harness leads to insulate.

DA-250000-H

1. Controller remote connector

Figure 6-20. Controller Remote Connector

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536

1. Use insulink or solder connection (tape to insulate)

2. Hourmeter

3. Stop

4. ON light

5. Rocker switch

6 3

45 12

Figure 6-21. Remote Control Panel Wiring

NOTE

All wire is 16 gauge. Tape to insulate all unused lead ends.

Lead

(older

1 Black N Ground (--) 2 Tan 5 Water temperature

3 Lt. Blue 7C Oil pressure gauge 4 Violet 70 Generator ON (+) 5 Yellow/Red 47 Start 6 Grey/Black 43 Stop

models)

Lead

(newer

models)

Function

gauge 3

6. Start

7. Generator set

8. Senders

9. Controller socket

10. Wiring harness plug

Figure 6-22. Lead Designations

TP-5592 7/96 Installation 6-21

Kohler 13.5CCOZ, 11CCFOZ, 15CCFOZ, 21CCOZ, 16.5CCFOZ Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual