Kohler 9EFOZ, 10EOZ, 8.5EFOZ, 11EFOZ, 13EOZ Operation Manual

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Page 1

Operation

Marine Generator Sets

Models:

4EFOZ/5EOZ, 6.5EFOZ/8EOZ

9EFOZ/10EOZ, 8.5EFOZ, 11EFOZ/13EOZ

11.5EFOZ/14EOZ, 13EFOZ/15.5EOZ 16EFOZ/20EOZ, 17.5EFOZ/20EOZ

19EFOZ/23EOZ, 20EFOZ/24EOZ 23EFOZ/28EOZ, 27EFOZ/32EOZ

TP-6068 10/02b

Page 2

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

Record the product identification numbers from the generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

x:in:007:001

Page 3

Table of Contents

Product Identification Information Inside front cover............................................

Safety Precautions and Instructions I........................................................

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

Service Assistance i........................................................................

Maintenance and Service Parts/Related Literature ii............................................

Section 1. Service Views 1..................................................................

Section 2. Operation 3......................................................................

2.1 Prestart Checklist 3.....................................................

2.2 Marine Inspection 4.....................................................

2.3 Angular Operation 4.....................................................

2.4 Operation in European Union Member Countries 4..........................

2.5 Exercising the Generator Set 4...........................................

2.6 Starting and Stopping Procedure 4........................................

2.6.1 Controls and Indicators 5........................................

2.6.2 Starting the Generator Set 5......................................

2.6.3 Remote Panel Gauge Operation 5.................................

2.6.4 Stopping the Generator Set 5.....................................

Section 3. Scheduled Maintenance 7.........................................................

3.1 General Maintenance 7..................................................

3.2 Service Schedule—4--20EFOZ and 5--24EOZ Models 8......................

3.3 Service Schedule—23/27EFOZ and 28/32EOZ Models 10.....................

3.4 Lubrication System 12....................................................

3.4.1 Oil Specifications 12..............................................

3.4.2 Oil Check 12....................................................

3.4.3 Oil Change 13...................................................

3.5 Fuel System 14..........................................................

3.5.1 Fuel Specifications 14............................................

3.5.2 Fuel Filter 14....................................................

3.5.3 Bleeding the Fuel System 15......................................

3.6 Air Intake Silencer/Cleaner 16.............................................

3.7 Exhaust System 17......................................................

3.8 Cooling System 18.......................................................

3.8.1 Closed Heat Exchanger 18........................................

3.8.2 Checking and Filling Coolant 18....................................

3.8.3 Flushing and Cleaning 18.........................................

3.8.4 Pressure Cap 18.................................................

3.8.5 Seawater Pump 19...............................................

3.8.6 Siphon Break 20.................................................

3.8.7 Anticorrosion Zinc Anode 22.......................................

3.9 Belt Tension 23..........................................................

3.9.1 Seawater Pump Belt Tensioning Procedure 23.......................

3.9.2 Battery Charging Alternator Belt Tensioning Procedure 23.............

3.10 Battery 24...............................................................

3.11 Generator Storage Procedure 24...........................................

Section 4. Troubleshooting 25................................................................

Section 5. Wiring Diagrams 29................................................................

Appendix A. Abbreviations A-1...............................................................

Appendix B. Operating Hour Service Log A-3..................................................

Table of Contents TP-6068 10/02

Page 4

Page 5

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe

personal injury, death,orsubstantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe

personal injury, death,or substantial property damage.

CAUTION

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 safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals.

Accidental Starting

WARNING

Accidental starting. Can cause severe injury or death.

Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set. Accidental starting can cause severe injury or death. Before

working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Place the generator set start/stop switch in the STOP position. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

Battery

WARNING

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

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

Battery electrolyte is a diluted sulfuric acid. Battery acidcan cause severe injury or death. Battery acid

can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid inthe case of eye contact. Never add acid to a battery after placing the battery in service, asthis mayresult inhazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a containerwith4L(1gal.)ofwaterand mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

Battery gases. Explosion can cause severe injury or death. Battery gases

can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove alljewelry beforeservicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

TP-6068 10/02 Safety Precautions and Instructions I

Page 6

Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash Fire

WARNING

Fire. Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the fuel system. A flash fire can cause severe injury or death.

Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor.

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

set with the air cleaner/silencer removed.

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

or sparks near the fuel system. Keep the compartment and the generator set clean and free of debris to minimize the risk of fire. Wipe up spilled fuels and engine oil.

Combustible materials. A fire can cause severe injury or death.

Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.

Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon

monoxide is a poisonous gas present in exhaust gases. Carbon monoxide 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, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improvewithin minutesof breathing fresh air.

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 the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the

safety of the craft’s occupants, install a carbon monoxidedetector. Consult the boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.

Operating thegenerator set. Carbon monoxide cancause severenausea, fainting, or death. Carbon monoxide

is an odorless, colorless, tasteless, nonirritating gasthat cancause death if inhaled for even a short time. Use the following precautions when installing and operating the generator set. Do not install the exhaustoutlet where exhaust can be drawn in through portholes, vents, or air conditioners. 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. Never operate the generator set without a functioning carbon monoxide detector. Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate. If operating the generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always be aware of others, making sure your exhaust is directed away from other boats and buildings. Avoidoverloading the craft.

TP-6068 10/02II Safety Precautions and Instructions

Page 7

Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

WARNING

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

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

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly

explosive. Use extreme care when handling and storing fuels. Store fuels inawell-ventilatedareaawayfrom spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do notoperate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation.

Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an

explosion. Use acontainer tocatch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.

Installing the fuel system. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an

explosion. Do not modify the tank or the propulsion engine fuel system. Equip the craft with a tank that allows one of the two pickup arrangements described in the installation section. The tank and installation must conform to USCG Regulations.

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

Fuel leakage can cause an explosion. Use pipesealant onall threadedfittings to prevent fuel leakage. Use pipe sealant that resists gasoline, grease, lubrication oil, common bilge solvents, salt deposits, and water.

Ignition-protected equipment. Explosive fuel vapors can cause severe injury or death. Gasoline

vapors can cause an explosion. USCG Regulation 33CFR183 requires that all electrical devices (ship-to-shore transfer switch, remote start panel, etc.) must be ignition protected when used in a gasoline and gaseous-fueled environment. The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous-fueled environment such as an engineroom or near fuel tanks. Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash.

Hazardous Noise

CAUTION

Hazardous noise. Can cause hearing loss.

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

Engine noise. Hazardous noise can cause hearing loss. Generator sets

not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposureto noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/ Electrical Shock

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution

is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing theequipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to complywith applicablecodes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Disconnecting the electrical load. Hazardous voltage can cause severe injury or death. Disconnect

the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads. High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load.

Moving rotor.

TP-6068 10/02 Safety Precautions and Instructions III

Page 8

Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can

cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove alljewelry beforeservicing the equipment.

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

is present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator.

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

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

Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is opened. Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near the work area. Some states and localities prohibit unauthorized connection to the utility electrical system. Install a ship-to-shore transfer switch to prevent interconnection of the generator set power and shore power.

Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have

trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and followthe instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approvedelectrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically.

(600 volts and under)

Hot Parts

WARNING

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

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

WARNING

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

Do not work on the generator set until it cools.

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

Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure capwith a thick cloth and then slowly turn the cap counterclockwiseto the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check thecoolant levelat thetank ifthe generator set has a coolant recovery tank.

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

The engine and exhaust system components become extremely hot during operation.

Moving Parts

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

WARNING

Rotating parts. Can cause severe injury or death.

Operate the generator set only when all guards, screens, and coversare in place.

WARNING

Airborne particles. Can cause severe injury or blindness.

Wear protective goggles andclothing when using power tools, hand tools, or compressed air.

Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause

the hardware or pulley to release from the generator setengine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.

Moving rotor.

TP-6068 10/02IV Safety Precautions and Instructions

Page 9

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

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

Sound shield removal. Exposed moving parts can cause severe injury or death. The generator set

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

(Sound-shield-equipped models only)

Notice

NOTICE

This generator set has been rewired fromits nameplate voltage to

246242

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.

NOTICE

Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE

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

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

NOTICE

Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic). Do not substitute clear glass-type fuses for ceramic fuses. Refer to the wiring diagram when the ampere rating is unknown or questionable.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

TP-6068 10/02 Safety Precautions and Instructions V

Page 10

Notes

TP-6068 10/02VI Safety Precautions and Instructions

Page 11

Introduction

This manual provides operation instructions for 4--27EFOZ/5--32EOZ model generator sets.

Refer to the engine operation manual for generator set engine scheduled maintenance information.

This manual may be used for models not listed on the front cover.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the

For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric

Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Obtain service from an authorized service distributor/dealer to keep equipment in top condition.

Before installing a marine generator set, obtain the most current installation manual from your local distributor/dealer. Only qualified persons should install the generator set.

x:in:001:002:a

Service Assistance

China

North China Regional Office, Beijing Phone: (86) 10 6518 7950

(86) 10 6518 7951 (86) 10 6518 7952

Fax: (86) 10 6518 7955

D Visit the Kohler Power Systems website at

KohlerPowerSystems.com

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents included with the product

D Call toll free in the US and Canada 1-800-544-2444

D Outside the US and Canada, call the nearest regional

office

Africa, Europe, Middle East

London Regional Office Langley, Slough, England Phone: (44) 1753-580-771 Fax: (44) 1753-580-036

Asia Pacific

Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 264-6422 Fax: (65) 264-6455

East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office Bangalore, India Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727

Latin America

Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131

X:in:008:001a

TP-6068 10/02 Introduction i

Page 12

Maintenance and Service Parts/Related Literature

Maintenance and Service Parts

Figure 1 identifies maintenance and service parts for your generator set. Obtain a complete list of maintenance and service parts from your authorized generator distributor/dealer.

Models

8.5EFOZ,

4EFOZ/

Part Description

Air Cleaner

Air Filter Element 278612 278858 278858 250902

Battery Charging Fuse (10 amp)

DC Circuit Breaker (10 amp) 250719 250719 250719 250719 250719

Fuel Filter Element 229715 229715 252898 252898 363418

Oil Filter 229678 229678 252834 252834 252834

Seawater Pump Impeller Kit 229826 229826 229826 229955 229826

Spray Paint (White) 221335 221335 221335 221335 221335

Touch-Up Paint (White) GM19490 GM19490 GM19490 GM19490 GM19490

V-Belt (Alternator)

V-Belt (Seawater Pump) GM13660 GM13660 229125 256503 249989

Voltage Regulator Fuse (8 amp)

Zinc Anode 267928 267928 267928 N/A 267928

5EOZ

N/A N/A N/A N/A

223316 223316 223316 223316 223316

229553 363064

258405 258405 258405 258405 258405

6.5EFOZ/ 8EOZ

9EFOZ/

10EOZ

225428

(12-volt models)

344920

(24-volt models)

11--20EFOZ/

13--24EOZ

13/20EOZ and

11/16/17.5EFOZ

models with serial numbers after 0723548,

use air filter

element number

GM24456

GM11551

(12-volt models)

344829

(24-volt models)

23/27EFOZ/

28/32EOZ

A-344931

(w/sound shield)

A-344930

(w/o sound shield)

for Specs: PA-126212 PA-126213 PA-126214 PA-126215 PA-126177 PA-126178 PA-126185 PA-126186

GM16944

for Specs:

GM24459-GA1 GM24459-GA2 GM24459-GA3 GM24459-GA4 GM24459-GA5 GM24459-GA6 GM24459-GA7 GM24459-GA8

363205

(12-volt models)

258955

(24-volt models)

Figure 1 Maintenance and Service Parts

x:in:001:004

TP-6068 10/02ii Introduction

Page 13

List of Related Literature

Figure 2 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set.

Models

8.5EFOZ, 4/9EFOZ,

and

Literature Type

Installation Manual TP-6069 TP-6069 TP-6069 TP-6069 Operation Manual TP-6068 TP-6068 TP-6068 TP-6068 Parts Catalog* TP-5616

Service Manual (Engine) TP-5876 TP-5876 TP-5876 TP-6054 Service Manual (Generator) TP-6053 TP-6053 TP-6071 TP-5936

* Includes the generator and engine information.

5/10EOZ

(4EFOZ/5EOZ)

TP-5587

(8.5EFOZ,

9EFOZ/ 10EOZ)

6.5EFOZ and

8EOZ

TP-5616

Figure 2 Generator Set Literature

11--20EFOZ

and

13--24EOZ

TP-5591

(11--13EFOZ/

13--15.5EOZ)

TP-5593

(16--20EFOZ/

20--24EOZ)

23/27EFOZ

and

28/32EOZ

TP-5998

x:in:001:005

TP-6068 10/02 Introduction iii

Page 14

Notes

TP-6068 10/02iv Introduction

Page 15

Section 1 Service Views

START

DC--CIRCUIT BREAKER

STOP/

PREHEAT

HOUR METER

AC--CIRCUIT

BREAKER

DRAIN

WATER

1. Controller

2. Start/Stop switch

3. Hourmeter

4. DC circuit breaker

5. AC load lead connector (rear)

6. Nameplate (top)

7. Remote start connector (rear)

8. AC circuit breaker

9. Air intake silencer

10. Lifting eye

11. Fuel filter

12. Oil fill

13. Pressure cap

14. Overflow tube

15. Oil fill

16. Seawater pump (water inlet)

17. Lube oil filter

NOTICE

CHECKZINCANODE EVERY100 HOURS OR3 MONTHS.

11--20EFOZ and 13--24EOZ Models Only

18. Oil check

19. Oil drain valve and hose

20. Fuel feed pump

21. Mixing elbow (water outlet/exhaust outlet)

22. Cooling air inlet

23. Coolant overflow bottle (location varies by model)

24. Heat exchanger (all models except 11--20EFOZ & 13--24EOZ)

25. V-belts

26. Coolant (freshwater) drain (all models except 11--20EFOZ & 13--24EOZ)

27. Anticorrosion zinc anode (seawater drain) (all models except 11--20EFOZ & 13 --24EOZ)

28. Belt guard

29. Heat exchanger (located on nonservice side of unit for 11--20EFOZ & 13 --24EOZ models)

30. Coolant (freshwater) drain (11--20EFOZ & 13--24EOZ models)

31. Seawater drain (11 --20EFOZ & 13--24EOZ models)

Figure 1-1 Service Views—Typical

Consult installation drawings in the spec sheet or installation manual for fuel and battery connection points. Consult an authorized

Note:

distributor/dealer or the service manual for items not shown.

ADV-6285A-A GB-250000-A

DA-250000

TP-6068 10/02 1Section 1 Service Views

Page 16

Notes

TP-6068 10/022 Section 1 Service Views

Page 17

Section 2 Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.

Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine.

Air Inlets. Check for clean and unobstructed air inlets.

Air Shrouding. Check for securely installed and

positioned air shrouding.

Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.

Coolant Level. Check the coolant level according to the cooling system maintenance information.

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

D Ensure that the carbon monoxide detector(s) is (1) in

the craft, (2) functional, and (3) energized whenever the generator set operates.

Note: Never operate the generator set without a

functioning carbon monoxide detector.

Fuel Level. Check the fuel level and keep the tank(s)

full to ensure adequate fuel supply.

Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.

Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.

Seawater Pump Priming. Prime the seawater pump before initial startup. To prime the pump: (1) close the seacock, (2) remove the hose from the water-filter outlet, (3) fill the hose and seawater pump with clean water, (4) reconnect the hose to the water filter outlet, and (5) open the seacock. Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet.

Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections.

Inspect the the exhaust system components (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and outlet flapper) for cracks, leaks, and corrosion.

D Check the hoses for softness, cracks, leaks, or dents.

Replace the hoses as needed.

D Check for corroded or broken metalparts and replace

them as needed.

D Check for loose, corroded, or missing clamps.

Tighten or replace the hose clamps and/or hangers as needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). Check

for carbon or soot residue on exhaust components. Carbon and soot residue indicates an exhaust leak. Seal leaks as needed.

TP-6068 10/02 3Section 2 Operation

Page 18

2.2 Marine Inspection

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

m:op:001:003

2.3 Angular Operation

See Figure 2-1 for angular operation limits for units covered in this manual.

Continuous

25_ 30_

Maximum value for all directions

Intermittent—

3 minutes or less

Figure 2-1 Angular Operation

m:op:001:004

2.4 Operation in European Union Member Countries

This generator set is specifically intended and approved for operation below the deck in the enginecompartment. Operation above the deck and/or outdoors would constitute a violation of European Union Directive 2000/14/EC noise emission standard.

2.6 Starting and Stopping Procedure

Note: Opening seacock. Before starting the generator

set, open the seacock to allow cooling water passage. Failure to do so could damage the seawater pump impeller and cause serious engine overheating damage.

Note: Transfer switch. Check that the marine

ship-to-shore transfer switch, if equipped, is in the ship position.

Note: Close seacock if engine fails to start. If the

engine fails to start after the first attempt, close the seacock before the next starting attempt. Failure to close the seacock may cause seawater to enter the exhaust piping, silencer, and/or engine. A water-filled exhaust piping and silencer may further hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valve. Water ingested into the engine may cause major engine damage that the Kohler Co. warranty does not cover.

Note: Close seacock if water enters the exhaust

system. If water enters the exhaust system,

close the seacock and drain the water from the exhaust system at the silencer’s drain plugbefore attempting to start the generator set. If excessive cranking is a chronic problem, have the unit, including the exhaust system, serviced by an authorized Kohlerr distributor/dealer.

2.5 Exercising the Generator Set

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

The operator should perform all of the prestart checks before starting the exercise procedure. Start the generator set according to the starting procedure in the controller section of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks.

x:op:001:005

Note: Starter motor cooldown. Do not crank the

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 3 attempts, contact an authorized Kohlerr distributor/ dealer for repair. Failure to follow these guidelines may result in starter motor burnout.

The following table describes the allowable cranking time:

Cranking Attempts

1 Open up to 10 seconds

2 Close up to 10 seconds

3 Close up to 10 seconds

Allow a 60-second cooldown period between cranking attempts.

If the units fails to start after 3 attempts, contact an authorized Kohler

Once unit is running, immediately open the seacock.

Seacock

Position

Cranking

r distributor/dealer for repair.

Time

TP-6068 10/024 Section 2 Operation

Page 19

2.6.1 Controls and Indicators

2.6.3 Remote Panel Gauge Operation

The following table describes the controls and indicators located at the controller:

Name Description

Start/Stop Switch Use this switch to start and stopthe

AC Circuit Breaker (optional)

DC Circuit Breaker The circuit breaker trips when a

Remote Start Connector

Hourmeter The meter records total generator

generator set. Press the switch to theSTARTpositiontostartthe generator set. Press the switch to theSTOPpositiontostopthe generator set.

The circuit breaker trips when a fault occurs in the output circuit. During maintenance of craft or generator set wiring, the circuit breaker disconnects the generator set. Place the circuit breaker(s) in the ON position to close the circuit breaker.

fault occurs in the controller circuit. After afault correction,depress the circuit breaker’s center button to reset the circuit breaker.

A 6-pin connector on the controller’s back panel allows the connection of (optional) remote start kits

set operating hours for reference in maintenance scheduling.

2.6.2 Starting the Generator Set

If the generator set has an optional remote panel with gauges, observe the gauges upon engine startup. If gauge readings are not within the ranges specified, contact an authorized service distributor/dealer.

Gauge Normal Operating Range

Oil pressure 276--414 kPa (40--60 psi )*

Water temperature

DC voltmeter 12--14 volts

*50 Hz models show a slightly lower pressure range.

77--91°C (170--195°F)

2.6.4 Stopping the Generator Set

The following table describes the actions required to stop the generator set.

Step

1 Cooldown

Run the generator set at no load for 5 minutes to ensure adequate engine cooldown.

2 Stopping

Place the controller start/stop switch or remote start/stop switch in the STOP position.

NOTE: Do not place the start/stop-preheat switch, if equipped, in the STOP-PREHEAT position for more than 30 seconds or damage to the preheat feature may occur.

3 Fuel shutoff valve

Close the manual fuel shutoff valve, if equipped.

ction

The following table describes the actions required to start the generator set.

Step

1 Preheat/cold weather starts

During cold weather starts** place the controller’s start/stop switch in the STOP/PREHEAT position for 15--20 seconds before attempting to start the generator set to energize the air heater coil (8.5--27EFOZ and 10--32EOZ) or glow plugs (4--6.5EFOZ and 5--8EOZ). Do not energize the preheat feature for more than 30 seconds or damage to the preheat feature may occur.

NOTE: All controller start/stop switches indicate preheat; however, an optional preheat kit is required to make the preheat feature functional.

2 Fuel shutoff valve

Open the manual fuel shutoff valve, if equipped.

3 Starting

Hold the generator set controllerstart/stop switch or the remote start/stop switch in the START position until the generator set starts.

**Below --5_C(23_F) 4/8.5/9/23/27EFOZ and 5/10/28/32EOZ

Below 5_C(41_F) 6.5EFOZ/8EOZ Below 4_C(40_F) 11--20EFOZ and 13--24EOZ

ction

TP-6068 10/02 5Section 2 Operation

Page 20

Notes

TP-6068 10/026 Section 2 Operation

Page 21

Section 3 Scheduled Maintenance

3.1 General Maintenance

WARNING

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

generator set or equipment connected to the set, disable the generator set asfollows: (1) Place the generator set start/stop switch in the STOP position. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

NOTICE

Hardware damage. The engine and generator set may use both American Standardand metrichardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized distributor/dealer perform generator set service.

Engine Service. Perform generator set engine service at the intervals specified by the engine operation manual.

Generator Set Service. Perform generator set service at the intervals specified by the generator set operation manual.

If the generator set operates under dusty or dirty conditions, use dry compressed air to blow dust out of the alternator. With the generator set running, direct the stream of air in through the cooling slots at the alternator end.

WARNING

Rotating parts. Can cause severe injury or death.

Operate the generator set only when all guards, screens, and coversare in place.

Servicing the generator set when it isoperating. Exposed moving parts can cause severe injury or death. Keep

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

Sound shield removal. Exposed moving parts can cause severe injury or death. The generator set must be operating

in orderto performsome scheduled maintenance procedures. Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

(Sound-shield-equipped models only)

Routine Maintenance. Refer to the following generator set service schedule, the engine service schedule, and the hourmeter located on the generator set controller to determine when to schedule routine maintenance. Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions.

Service Log. Use the Operating Hour Service Log located in the back of this manual to document performed services.

Service Schedule. Perform maintenance on each item in the service schedule at the designated intervals 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, and so on.

x:sm:004:001

TP-6068 10/02 7Section 3 Scheduled Maintenance

Page 22

3.2 Service Schedule—4--20EFOZ and 5--24EOZ Models

Perform Service at Intervals

Indicated (X)

Reference

Section

Daily

Every

50 Hrs.

or 1

Month

Every

200 Hrs.

or 3

Months

400 Hrs.

Months

FUEL SYSTEM

Check the fuel level and fill as necessary 3.5

(Before

operation)

Check for any abnormal fuel injection sound [

(During

operation)

Remove the sediment from the fuel tank and drain the fuel tank [w Clean the fuel filter *

(4/6.5EFOZ and 5/8EOZ models only)

3.5.2 X

Replace the fuel filter element * 3.5.2 X Check the fuel injection nozzles/check the injection

spray condition *[] Check the fuel injection timing *[] Check the fuel injection pump *[]

LUBRICATION SYSTEM

Check the crankcase oil level and add oil as necessary

3.4.2

(Before

operation)

Replace the oil in the crankcase * 3.4.3

(Break-in

period)

Replace the lube oil filter element * 3.4.3

(Break-in

period)

COOLING SYSTEM

Check the coolant level and fill as necessary * 3.8.2

(Before

operation)

Check the seawater outlet and clean as necessary 3.7 X

Adjust the seawater pump belt tension * 3.9.1

(Break-in

period) Check the function of the siphon break, if equipped 3.8.6 X Check the heat exchanger anticorrosion zinc

condition, if equipped *

Check/replace the seawater pump impeller *[

Replace the coolant *[ Replace the heat exchanger anticorrosion zinc anode, if equipped *[

* Requires removal of the sound shield door, if installed

[ Consult your local distributor/dealer for service ] Read the WARNING found at the beginning of the manual regarding moving parts w Consult the operating instructions supplied with the craft

3.8.7 X

3.8.5 (Check)X(Replace)

3.8.3 X

3.8.7 X

Every

or 6

Every 1000 Hrs. or Yearly

TP-6068 10/028 Section 3 Scheduled Maintenance

Page 23

Service Schedule—4--20EFOZ and 5--24EOZ Models, continued

Perform Service at Intervals

Indicated (X)

Reference

Section

Daily

Every

50 Hrs.

or 1

Month

Every

200 Hrs.

or 3

Months

Every

400 Hrs.

or 6

Months

1000 Hrs. or Yearly

INTAKE/EXHAUST SYSTEM

Inspect the exhaust system components *[

3.7

(Before

operation)

Check the exhaust gas condition. If the exhaust is blue or black, contact your local distributor/dealer

Clean the intake silencer element * (11--20EFOZ and 13--24EOZ models) Clean the intake silencer element * (4--9EFOZ and 5--10EOZ models)

3.7

3.6 X

(During

operation)

Replace the intake silencer element * 3.6 X Clean the exhaust/water mixing elbow *[ Check the breather pipe for obstructions *[ Inspect the turbocharger compressor, if equipped *[ Check for abnormal turbocharger rotor noise during

operation, if equipped *[

3.7 X X

Check the turbo rotor shaft for wear, if equipped *[ Inspect the complete exhaust system k 2.2 X

ELECTRICAL SYSTEM

Keep the battery charged and in good condition w 3.10

(Before

operation)

Adjust the alternator driving belt tension * 3.9.2

(Break-in

period)

Check and tighten the electrical connections * X Clean the battery cables [

ENGINE AND MOUNTING

Check for water, fuel, coolant, and oil leakage *[]

(After

operation)

Retighten any loose nuts and bolts *

(Before

operation)

Check the mounting bolts/vibromounts and tighten if necessary *

Adjust the intake/exhaust valve clearance *[ X

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

(Before

operation)

REMOTE CONTROL SYSTEM

Check the remote control operation 2.6.3

(Break-in-

period)

GENERATOR

Test run the generator set 2.5

Blow dust out of the generator *[

* Requires removal of the sound shield door, if installed

[ Consult your local distributor/dealer for service ] Read the WARNING found at the beginning of the manual regarding moving parts w Consult the battery manufacturer’s instructions

k Should be performed by your local distributor/dealer

3.1 X

(Weekly)

Every

TP-6068 10/02 9Section 3 Scheduled Maintenance

Page 24

3.3 Service Schedule—23/27EFOZ, 28/32EOZ Models

Perform Service at Intervals

Indicated (X)

Reference

Section

Before

Starting

Every

50 Hrs.

or 1

Month

Every

200 Hrs.

or 3

Months

400 Hrs.

Months

FUEL SYSTEM

Check the fuel level and fill as necessary 3.5 X Remove the sediment from the fuel tank [w

Check for any abnormal fuel-injection sound [

During

operation Clean the fuel filter * 3.5.2 X Replace the fuel filter element * 3.5.2 X Check the fuel injection nozzles/check the injection

spray condition *[] Check the fuel injection timing *[] Check the fuel injection pump *[] Check the governor operation and adjust as

necessary *[]

LUBRICATION SYSTEM

Check the crankcase oil level and add oil as necessary

3.4.2 X

Replace the oil in the crankcase * 3.4.3

(Break-in

period)

Replace the lube oil filter element * 3.4.3

(Break-in

period)

COOLING SYSTEM

Check the coolant level and fill as necessary * 3.8.2 X Check the seawater outlet and clean as necessary 3.7 X Check the function of the siphon break, if equipped 3.8.6 X

Adjust the seawater pump belt tension * 3.9.1

(Break-in

period)

Check the heat exchanger anticorrosion zinc condition *

Replace the seawater pump impeller *[

3.8.7 X

3.8.5

Check the thermostat function *[ Flush the cooling system *[ Replace the heat exchanger anticorrosion zinc

anode *[

* Requires removal of the sound shield door, if installed

[ Consult your local distributor/dealer for service ] Read the WARNING found at the beginning of the manual regarding moving parts w Consult the operating instructions supplied with the craft

3.8.7 X

Every

or 6

Check

Every 1000 Hrs. or Yearly

X X

TP-6068 10/0210 Section 3 Scheduled Maintenance

Page 25

Service Schedule—23/27EFOZ, 28/32EOZ Models, continued

Perform Service at Intervals

Indicated (X)

Reference

Section

Before

Starting

Every

50 Hrs.

or 1

Month

Every

200 Hrs.

or 3

Months

Every

400 Hrs.

or 6

Months

1000 Hrs. or Yearly

INTAKE/EXHAUST SYSTEM

Inspect the exhaust system components *[

Check the exhaust gas condition. If the exhaust is blue or black, contact your local distributor/dealer

3.7 X

3.7

During

operation

Replace the intake silencer * 3.6 X Clean the exhaust/water mixing elbow *[ Check the breather pipe for obstructions *[

3.7 X X

Inspect the complete exhaust system k 2.2 X

ELECTRICAL SYSTEM

Keep the battery charged and in good condition w 3.10 X

Adjust the alternator driving belt tension * 3.9.2

(Break-in

period)

Check and tighten the electrical connections * X Clean the battery cables [

ENGINE AND MOUNTING

Check for water, fuel, coolant, and oil leakage *[]

X X Retighten all major nuts and bolts * X X Check the mounting bolts/vibromounts and tighten if

necessary *

Adjust the intake/exhaust valve clearance *[ X Check the compartment condition (fuel, oil, or water

leaks)

REMOTE CONTROL SYSTEM

Check the remote control operation 2.6.3

(Break-in

period)

GENERATOR

Test run the generator set 2.5

Blow dust out of the generator *[

* Requires removal of the sound shield door, if installed

[ Consult your local distributor/dealer for service ] Read the WARNING found at the beginning of the manual regarding moving parts

w Consult the battery manufacturer’s instructions

k Have performed by the your local distributor/dealer

3.1 X

(Weekly)

Every

TP-6068 10/02 11Section 3 Scheduled Maintenance

Page 26

3.4 Lubrication System

3.4.2 Oil Check

See the Scheduled Maintenance section for oil change and oil filter replacement intervals. See Section 1 for the oil drain, oil check, oil fill, and oil filter locations.

x:sm:001:002:

3.4.1 Oil Specifications

Use oil that meets the American Petroleum Institute (API) classification of CD, CC/CD, or CC. Using an unsuitable oil or neglecting an oil change may result in damage and a shorter engine life. Figure 3-1 shows the recommended Society of Automotive Engineers (SAE) viscosity designation for given operating temperature ranges.

SAE

Service

Grade

5W20

20W40

10W30

20W20

20W30

Check the oil level in the crankcase daily or before each startup to ensure that the level is in the safe range. To check the oil level, remove the dipstick and wipe the end clean, reinsert as far as possible, and remove. Maintain the oil level between the Min and Max marks on the dipstick, as shown in Figure 3-2. See Section 1 for dipstick location.

1. Min mark

2. Max mark

TP-5586-3

Figure 3-2 Oil Level Check Marks

Note: Do not operate the set if the oil level is below the

Min mark or above the Max mark.

20W40

°C°F-- 30 -- 2 0 -- 10 0 1 0 2 0 3 0 4 0

0204060 80 100°C°F

Operating Temperature

TP-5856-1

Figure 3-1 Engine Oil Selection

Note: Failure to observe the oil specifications may

cause inadequate lubrication/oil pressure and cold-starting difficulties.

TP-6068 10/0212 Section 3 Scheduled Maintenance

Page 27

3.4.3 Oil Change

g. Close the oil drain valve.

Change the oil more frequently if the generator operates under dirty, dusty conditions. See Figure 3-3 for oil capacities.

Model L (Qts.)

4EFOZ and 5EOZ 3.0 (3.2)

6.5EFOZ and 8EOZ 2.3 (2.4)

8.5EFOZ, 9EFOZ and 10EOZ 5.2 (5.5)

1 1/11.5/13EFOZ and 13/14/15.5EOZ 4.7 (5.0)

16/17.5/19/20EFOZ and 20/23/24EOZ 5.8 (6.1)

23/27EFOZ and 28/32EOZ 10.2 (10.8)

Figure 3-3 Oil Capacities

Oil Change Procedure

Whenever possible, drain the oil while it is still warm.

1. Drain the oil.

a. Place the generator set start/stop switch in the

STOP position.

b. Disconnect the power to the battery charger, if

equipped.

h. Replace the cap on the oil drain hose. Replace

theoildrainhoseinitsretainingclip.

2. Replace the oil filter.

a. Remove the oil filter by rotating it

counterclockwise with an oil filter wrench.

b. Apply a light coat of clean oil to the rubber seal

of the new oil filter.

c. Install the new oil filter following the instructions

provided with the filter.

Note: Dispose of all waste materials (engine

oil, fuel, filter, etc.) in an environmentally safe manner.

3. Fill with oil. Add new oil of the weight, grade, and quantity specified in Section 3.4.

Electric Oil Drain/Oil Fill Pump Procedure:

Disconnect the pump. Close the oil drain valve. Replace the cap on the oil drain hose.

4. Check for leaks.

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

d. Remove the oil drain hose from its retaining

clip. Remove the cap from the oil drain hose and lower the hose into an oil collection container.

Electric Oil Drain/Oil Fill Pump Procedure: Connect the pump to the end of the oil drain hose. Place the outlet of the pump into an oil collection container. Remove the oil fill cap(s).

e. Open the oil drain valve on the engine.

f. Allow time for the engine oil to drain completely.

Electric Oil Drain/Oil Fill Pump Procedure:

Activate the pump until all of the oil is removed. Go to step 2.

a. Check that the generator set start/stop switch is

in the STOP position.

b. Reconnect the generator set engine starting

battery, negative (--) lead last.

c. Reconnect the power to the battery charger, if

equipped.

d. Start the generator set and check for leaks

around the oil filter.

e. Stop the generator set and tighten the oil filter to

stop any leaks.

x:sm:001:003:

TP-6068 10/02 13Section 3 Scheduled Maintenance

Page 28

3.5 Fuel System

3.5.1 Fuel Specifications

Use a clean, good quality diesel fuel oil with a cetane number of 45 or greater. Clean fuel prevents the diesel fuel injectors and pumps from clogging.

Fuel Recommendations

United States ISO 8217 DMA, BS 2869 Part 1 Class A1

or Part 2 Class A2 United Kingdom BS 2869-1983, Part 2 Class A2

Germany DIN 51 601-1978

Note: Never store diesel fuel in galvanized containers;

diesel fuel and the galvanized coating react chemically to produce flaking that quickly clogs filters or causes fuel pump or injector failure.

Note: Avoid storing fuel for more than one month. Take

special precautions to keep all dirt, water, and other contaminants out of fuel to prevent the growth of microbes. Microbes form slime that clogs the fuel filter and lines.

3. Remove the filter bowl and fuel filter. Clean the fuel filter with fresh fuel oil and blow compressed air from the inside outward. Replace a damaged fuel filter. Dispose of the fuel filter in an approved manner.

4. Wipe off all parts with a clean rag. Inspect all mating surfaces and threads for damage; replace as necessary.

5. Place the fuel filter into the filter bowl and lubricate the rubber seal with fresh fuel oil. Wash hands after any contact with fuel oil.

6. With the collar against the filter bowl flange, position the fuel filter against the adapter and hand-tighten the collar.

7. Open the fuel supply valve.

8. Bleed the system. See Section 3.5.3, Bleeding the Fuel System.

8.5--27EFOZ and 10--32EOZ Models:

1. Close the fuel supply valve.

Note: Do not run the generator set out of fuel because

the fuel lines will draw in air and necessitate bleeding the fuel system before restarting the unit.

3.5.2 Fuel Filter

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. Section 1 shows the typical location of a fuel filter. Use the applicable procedure below to replace the fuel filter.

Fuel Filter Cleaning/Replacement Procedure

4/6.5EFOZ and 5/8EOZ Models:

1. Close the fuel supply valve.

2. Remove the collar from the fuel filter adapter while holding the filter bowl in place.

2. Loosen the fuel filter by turning it counterclockwise. Remove the fuel filter and use rags to clean up spilled fuel oil. Dispose of the fuel filter in an approved manner.

3. Clean the contact surface of the fuel oil filter adapter.

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

5. Open the fuel supply valve.

6. Bleed the system. See Section 3.5.3, Bleeding the Fuel System.

TP-6068 10/0214 Section 3 Scheduled Maintenance

Page 29

3.5.3 Bleeding the Fuel System

Bleed air from the fuel system to prevent startingfailures and/or erratic operation. One or more of the following causes air to collect in the fuel system:

D Operating the generator set until the fuel supply is

emptied.

D Developing air leaks in the suction side of the fuel

system.

Note: Wipe up all spilled diesel fuel after bleeding

the system. Wash hands after any contact with fuel oil.

4/6.5EFOZ and 5/8EOZ Models

D Replacing the fuel filter.

Note: Connect the battery during the priming procedure

to allow engine cranking. Do not allow the engine/generator to start. To prevent starting, toggle the start/stop switch by momentarily placing the start/stop switch in the START position for a few seconds and then placing the switch in the STOP position. Close the seacock during bleeding.

Procedure to Bleed the Fuel System

1. Loosen the fuel filter screw at position 1. See Figure 3-4.

2. Toggle the start/stop switch until fuel, free of air bubbles, flows from the vent screw at position 1. Tighten the screw.

3. Loosen the fuel filter screw at position 2.

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

8.5--27EFOZ and 10--32EOZ Models

TP-5586-3

5. Loosen the fuel injection pump screw at position 5.

6. Toggle the start/stop switch until fuel, free of air bubbles, flows from the vent screw at position 5. Tighten the screw.

1. Vent screw, position 1

2. Vent screw, position 2

3. Fuel filter

4. Fuel injection pump

5. Vent screw, position 5

TP-5592-3

Figure 3-4 Fuel System (Typical)

TP-6068 10/02 15Section 3 Scheduled Maintenance

Page 30

3.6 Air Intake Silencer/Cleaner

At the interval specified in the service schedule, clean or replace the air intake silencer. Clean the silencer more

frequently if the generator set operates in dirty, dusty conditions. Follow one of the procedures described below.

3. Wash the element in mild detergent and water solution. Rinse and air dry the element. See Figure 3-5.

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

Air Cleaner Service/Replacement

4/6.5/8.5/9/11/16/17EFOZ, 5/8/10/13/20EOZ Models & 23/27EFOZ, 28/32EOZ Models, Spec Numbers:

GM24459-GA1 GM24459-GA2 GM24459-GA3 GM24459-GA4 GM24459-GA5 GM24459-GA6 GM24459-GA7 GM24459-GA8

A dry-type air cleaner silences and filters the intake air. The air intake silencer assembly connects to the intake manifold via a flexible hose.

1. Release the spring clips to open the housing and remove the air silencer element.

2. Tap the element lightly against a flat surface to dislodge loose surface dirt. Do not clean in any liquid or use compressed air as these will damage the filter element.

3. Examine the element and housing for damage and wear. Replace the element or housing if necessary.

1. Element

Figure 3-5 Element Washing

(11.5/13EFOZ and 14/15.5EOZ Models)

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

23/27EFOZ, 28/32EOZ Models, Spec Numbers:

PA-126212 PA-126213 PA-126214 PA-126215 PA-126177 PA-126178 PA-126185 PA-126186

1-776

4. Wipe the cover and base with a clean rag to remove any dirt. Make sure that the sealing surfaces fit correctly, and reattach the spring clips.

11.5/13EFOZ and 14/15.5EOZ Models:

A round air cleaner silences and filters the intake air. Replace a damaged or dirt-contaminated air silencer. See Section 1 and refer to the following procedure:

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

2. Remove the element from the cover and inspect. If the element is not damaged, continue with step 3. If the element is damaged, replace it, skip step 3, and go to step 4.

The air cleaner silences and filters the intake air. The air intake silencer assembly connects to the air intake manifold.

1. Release the clamp (two clamps if equipped with a sound shield).

2. Remove the air intake silencer assembly.

3. Replace with a new air intake silencer assembly.

4. Wipe the cover and base with a clean rag to remove any dirt. Make sure that the sealing surfaces fit correctly and reattach the clamp(s).

TP-6068 10/0216 Section 3 Scheduled Maintenance

Page 31

3.7 Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of

the craft’s occupants, install a carbon monoxide detector. Consult the boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.

At the interval specified in the service schedule, inspect the exhaust system. See Section 1 for the exhaust outlet location.

Inspection Points

Inspect the the exhaust system components (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and outlet flapper) for cracks, leaks, and corrosion.

D Check the hoses for softness, cracks, leaks, or dents.

Replace the hoses as needed.

D Check for corroded or broken metalparts and replace

them as needed.

D Check for loose, corroded, or missing clamps.

Tighten or replace the hose clamps and/or hangers as needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). Check

for carbon or soot residue on exhaust components. Carbon and soot residue indicates an exhaust leak. Seal leaks as needed.

D Ensure that the carbon monoxide detector is (1) in the

craft, (2) functional, and (3) energized whenever the generator set operates.

x:op:001:002

TP-6068 10/02 17Section 3 Scheduled Maintenance

Page 32

3.8 Cooling System

3.8.1 Closed Heat Exchanger

In a closed cooling system, the seawater circulates through separate chambers within the heat exchanger or manifold to cool the engine water . The seawater then mixes with the engine exhaust and ejects out of the exhaust outlet. See Figure 3-6 for coolant capacities (include coolant recovery tank capacity of 0.24 L (8 oz.).

Model L (Qts.)

4EFOZ and 5EOZ 1.8 (1.9)

6.5EFOZ and 8EOZ 3.9 (4.1)

8.5EFOZ, 9EFOZ and 10EOZ 2.5 (2.6)

1 1/11.5/13EFOZ and 13/14/15.5EOZ 4.4 (4.6)

16/17.5/19/20EFOZ and 20/23/24EOZ 6.0 (6.3)

23/27EFOZ and 28/32EOZ 7.6 (8.0)

Figure 3-6 Coolant Capacities

coolant level on closed systems by removing the pressure cap. Do not rely solely on the level in the coolant recovery tank. Add fresh coolant until the level is just below the overflow tube opening.

Note: A coolant solution of 50% ethylene glycol

provides freezing protection to --37°C(--34°F) and overheating protection to 129°C (265°F). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can cause engine or component damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant. Consult the engine manufacturer’s operation manual for engine coolant specifications.

Note: Do not add coolant to a hot engine. Adding

coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until the engine has cooled.

3.8.2 Checking and Filling Coolant

WARNING

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

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

Checking the coolant level. Hot coolantcan cause severe injury or death. Allow the engine to cool. Release pressure

from thecooling systembefore removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and theengine hascooled. Check thecoolant level at the tank if the generator set has a coolant recovery tank.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

Maintain the coolant level in the coolant recovery tank at approximately 1/4 full. Before filling the cooling system, close all petcocks and tighten all hose clamps. Use a solution of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion and prevent freezing. Add additional coolant solution, as necessary, to the coolant recovery tank. Periodically check the

Note: Pay special attention to the coolant level. After

the coolant drains, allow time when re-filling the coolant for a complete refill of the engine water jacket. Check the coolant level as prescribed in the Prestart Checklist.

3.8.3 Flushing and Cleaning

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

Flushing and Cleaning Procedure

1. Open the pressure cap and open petcocks located at the 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 simplify draining.

2. Drain, clean, and flush the coolant recovery tank.

3. Flush the system with clean water.

4. Fill the system with recommended coolant.

3.8.4 Pressure Cap

Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant, enabling higher operating temperatures. If the cap leaks, replace it with a cap of the same rating. The pressure cap typically has the pressure rating stamped on the cap body.

TP-6068 10/0218 Section 3 Scheduled Maintenance

Page 33

3.8.5 Seawater Pump

The belt-driven seawater pump is located on the service side of the generator set. Check and change the seawater pump impeller at the interval specified in the service schedule. Follow the instructions included with the impeller kit. If the instructions are not included with the kit, use the following procedure:

Impeller Inspection and Replacement Procedure:

1. Close the seacock.

2. Remove the seawater pump coverplate. See Figure 3-7.

3. Remove the impeller.

4. Inspect the impeller for damaged, cracked, broken, missing or flattened vanes. The impeller vanes should be straight and flexible. See Figure 3-8. Replace the impeller if it is damaged.

1. Seawater pump

2. Coverplate

3. Gasket

4. Impeller

5. Bearing

6. Housing

7. Pulley

8. Drive shaft

9. Washer

10. Nut

11. Mechanical seal,

TP-6053

if equipped

1. Flattened vane

TP-6053

2. Crack

3. Broken vane

Figure 3-8 Worn Impeller

5. Lubricate the impeller with soapy water before installation.

6. Install the impeller.

Note: During installation push and rotate the

impeller in the same direction as the engine rotation until it is thoroughly seated in the impeller housing.

7. Inspect the coverplate and gasket for corrosion and/or damage. Replace components as necessary.

8. Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing.

9. Open the seacock.

10. Start the generator set and check for leaks.

11. Stop the generator set and repair leaks or replace damaged or worn components.

m:sm:003:008

Figure 3-7 Seawater Pump, Typical

TP-6068 10/02 19Section 3 Scheduled Maintenance

Page 34

3.8.6 Siphon Break

A siphon break prevents seawater entry into the generator set’s engine when the engine exhaust manifold outlet is less than 230 mm (9 in.) above the waterline of a fully loaded, docked or stationary craft. See Figure 3-10. The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater. Use the following procedure to inspect the siphon break at the intervals listed in the service schedule.

Siphon Break Inspection

6. Install the reed valve into the mounting base with the valve downward. See Figure 3-9, item 3.

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

1. Stop the generator set.

2. Remove the retaining cap and remove the reed valve for inspection. See Figure 3-9.

3. Use a mild detergent to remove residue and oxidation from the reed valve.

4. Clear blockage from the reed valve opening.

5. Replace the siphon break if the reed valve is cracked or if the reed valve material has hardened or deteriorated.

1. Mounting base

2. Retaining cap

3. Reed valve

Figure 3-9 Siphon Break

TP-5856-3

m:sm:003:007

TP-6068 10/0220 Section 3 Scheduled Maintenance

Page 35

Waterline

1. Silencer vertical lift 1.2 m (4 ft.) max.

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

3. Siphon break distance above waterline 30.5 cm (1 ft.) min.

4. Siphon break

5. Exhaust mixer elbow

6. Heat exchanger (locations vary by model)

7. Coolant recovery tank

8. Locate coolant recovery tank at the same height as the heat exchanger

Figure 3-10 Siphon Break (Plastic “U” Type) Installation

9. Seawater strainer

10. Seacock

11. Intake strainer

12. Engine-driven seawater pump

13. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

14. Water lock (optional)

15. Silencer distance from exhaust mixer elbow 3 m (10 ft.) max.

16. Silencer (customer supplied)

17. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

18. Exhaust outlet distance above the waterline 10 cm (4 in.) min.

TP-5586-3

Note: Consult the installation manual for complete

explanation of dimensions and other installation considerations.

TP-6068 10/02 21Section 3 Scheduled Maintenance

Page 36

3.8.7 Anticorrosion Zinc Anode

The heat exchanger on models 4--9EFOZ, 5--10EOZ, 23/27EFOZ, and 28/32EOZ contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion by seawater.

Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule. Depending upon operating conditions and seawater properties, the anticorrosion zinc anode may require more frequent replacement. See Section 1 for the location and use the following procedure.

Anticorrosion Zinc Anode Replacement

1. With the generator set cooled, close the seacock, open the petcock on the engine, and drain the coolant into a suitable container.

TP-5586-3

1. Diameter: 9 mm (0.34 in.)

2. Length: 43 mm (1.7 in.) for 4-9EFOZ/EOZ models or 19 mm (0.75 in.) for 23/27EFOZ, 28/32EOZ models

Figure 3-12 Anticorrosion Zinc Anode (Plug)

4. Clean the threaded hole of the heat exchanger and coat the threads of the anticorrosion zinc anode (plug) with pipe sealant suitable for marine applications. Cut the anticorrosion zinc to the correct length. Install the anticorrosion zinc anode into the heat exchanger.

2. Remove the anticorrosion zinc anode (plug) from the heat exchanger.

3. Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode. Replace the anode according to Figure 3-11 and Figure 3-12.

Anticorrosion Zinc Anode Replacement

Replace When

Percent of Zinc

Remaining Is:

<50% of

length/diameter

<50% of

length/diameter

Models

4--9EFOZ 5--10EOZ

23/27EFOZ

28/32EOZ

New Anode

Dimensions mm (in.)

9 (0.34) x 43 (1.7)

9 (0.34) x 19 (0.75)

Figure 3-11 Anticorrosion Zinc Anode (Plug)

Measurements

5. Close the petcock on the engine and open the seacock. Refill the cooling system.

6. Start the generator set and check for leaks at the anticorrosion zinc anode location. The pump is operating if the cooling water flows from the exhaust outlet. If water is not discharging at the exhaust outlet, see Section 2.1, Prestart Checklist—Seawater Pump Priming.

TP-6068 10/0222 Section 3 Scheduled Maintenance

Page 37

3.9 Belt Tension

WARNING

Rotating parts. Can cause severe injury or death.

Operate the generator set only when all guards, screens, and coversare in place.

Servicing the generator set when it isoperating. Exposed moving parts can cause severe injury or death. Keep

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

3.9.1 Seawater Pump Belt Tensioning Procedure

1. Remove the belt guard.

2. Check the belt tension at the midpoint of the longest span of the belt using a belt-tensioning tool set to 55 ft. lbs. See Figure 3-13. Recheck a new belt tension after 10 minutes of operation.

Note: If the belt tension is not within specifications,

go to step 3. If the belt tension is within specifications, go to step 7.

3. Loosen the pivot and adjusting screws.

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

5. Tighten the pivot screw.

6. Recheck and adjust as necessary.

Check the belt tensions at the interval specified in the service schedule. If tensions are not within the specifications, adjust as necessary using the following procedures.

1. Engine-driven water pump pulley

2. Adjusting arm pivot screw

3. Battery charging alternator pulley

4. Alternator adjusting screw

5. Alternator pivot screw

6. Check the alternator belt tension here

7. Crankshaft pulley

8. Check the seawater pump belt tension here

9. Seawater pump adjusting screw

10. Seawater pump pulley

11. Pivot screw

TP-5586-3

7. Replace the belt guard.

3.9.2 Battery Charging Alternator Belt Tensioning Procedure

1. Remove the belt guard.

2. Check the belt tension at the midpoint of the longest span of the belt by pressing with your finger. See Figure 3-13 and Figure 3-14. If the belt is not within the specifications, go to step 3. If the belt is within the specifications, go to step 7.

Belt Type Deflection mm (in.)

New 7--9 (0.3--0.4)

Used 10--15 (0.4--0.6)

Figure 3-14 Belt Specifications

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

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

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

6. Recheck and adjust as necessary.

7. Replace the belt guard.

Figure 3-13 Belt Tension (Typical)

TP-6068 10/02 23Section 3 Scheduled Maintenance

Page 38

3.10 Battery

3.11 Generator Storage Procedure

Consult the battery manufacturer’s instructions regarding battery care and maintenance.

WARNING

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

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause

blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a batteryafter placing the battery in service, as this may result in hazardous spattering of battery acid.

Keep the craft afloat for generator operation during the storage procedure. Follow the procedure below when storing your generator set for 3 months or more.

Generator Set Storage Procedure

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

2. Stop the generator set.

3. Change the oil and oil filter. See Section 3.4.3.

4. Close the seacock and remove the hose at the seacock. Place the hose in a container having approximately 3.7--7.5 L (1--2 U.S. gallons) of coolant/antifreeze. Kohler Co. recommends using an environmentally friendly potable antifreeze such as PeakR RV/marine propylene glycol/water mix or equivalent.

5. With a suitable container at the exhaust outlet, run the generator set until coolant discharges at the exhaust outlet or until the coolant mixture is depleted. Do not allow coolant mixture to flow into waterways.

6. Stop the generator set.

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke

or permit flames or sparks to occur near a battery at any time, particularly whenit ischarging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

7. Connect a hose to the seacock. Leave theseacock closed.

8. Check the coolant level of the heat exchanger and add coolant if necessary.

Note: Use antifreeze capable of withstanding the

lowest possible temperatures.

9. Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion.

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

11. Select a well-ventilated (not humid or dusty) location to store the generator.

12. Cover the entire unit with a dust cover.

Note: Run the generator set once a month

whenever possible.

TP-6068 10/0224 Section 3 Scheduled Maintenance

Page 39

Section 4 Troubleshooting

This section contains generator set troubleshooting, diagnostic, and repair information.

Use the following chart as a quick troubleshooting reference. The table groups generator set faults and suggests likely causes and remedies. The table also refers you to more detailed information including sections of this manual, the generator set service manual (S/M), the generator set installation manual (I/M), and the engine service manual (Engine S/M) to correct the indicated problem.

Corrective action and testing often require knowledge of electrical and electronic circuits. To avoid additional problems caused by incorrect repairs, have an authorized service distributor/dealer perform service.

NOTICE

Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/dealer. Use the record to help describe the problem and repairs or adjustments made to the equipment.

x:gt:001:002a:

TP-6068 10/02 25Section 4 Troubleshooting

Page 40

Section or

Reference*

Publication

Section 2, W/D

Gen. S/M

Sec. 3, Eng. O/M

Trouble Symptoms

Probable Causes Recommended Actions

abnormal noise Excessive or

consumption High fuel

pressure Low oil

Overheats

Lacks power

suddenly Stops

output voltage No or low

Move the controller start/stop switch to the START position. Section 2

Controller start/stop switch in the

STOP position

troubleshoot the controller.[

Controller fuse blown Replace the blown controller fuse. If the fuse blows again,

Replace the controller master or start/stop switch. —

Troubleshoot the controller.[

Controller master or start/stop switch

inoperative

x Controller fault

x x Air openings clogged Clean the air openings. —

system.

Restore the coolant to normal operating level. Section 3

High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling

Low coolant level shutdown, if

equipped

x Impeller inoperative Replace the impeller Section 3

x x Seawater strainer clogged or restricted Clean the strainer. Section 3

x Coolant level low Restore the coolant to normal operating level. Section 3

x Thermostat inoperative Replace the thermostat. Eng. S/M

x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M

Starts hard

does not start Cranks but

crank Does not

26 Section 4 Troubleshooting

Controller

x x x

x x Controller circuit breaker tripped Reset the controller circuit breaker. Section 2

x x Controller circuit board(s) inoperative Replace the controller circuit board. Gen. S/M

Cooling System

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

TP-6068 10/02

Page 41

Section or

Reference*

Publication

Recommended ActionsProbable Causes

Section 3, S/S

W/D

Eng. S/M

I/M

Section 3, I/M

Gen. S/M

Eng. S/M

Trouble Symptoms

abnormal noise Excessive or

consumption High fuel

pressure Low oil

Overheats

Lacks power

suddenly Stops

output voltage No or low

Verify that the battery connections are correct, clean, and tight. Section 3

Battery connections loose, corroded,

or incorrect

Battery weak or dead Recharge or replace the battery. The spec sheet provides

recommended battery CCA rating.

Disconnect the engine harness connector(s) then reconnect it to

Engine harness connector(s) not

the controller.

locked tight

TP-6068 10/02

x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2

Replace the inoperative switch. Gen. S/M or W/D

High exhaust temperature switch

inoperative

Replace the inoperative switch. Gen. S/M

High water temperature switch

inoperative

Clean or replace the filter element. Section 2

Air cleaner/backfire flame arrestor

clogged

Check the compression.[

manual for wattage specifications.

Engine overload Reduce the electrical load. See the generator set installation

x x x x x

system components.[

Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust

components.[

Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system

Adjust the governor.[

Adjust the valves.[

x Vibration excessive Tighten all loose hardware. —

x x Valve clearance incorrect

Starts hard

does not start Cranks but

crank Does not

x x

Electrical System (DC circuits)

x x

x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M

x x x x

Engine

x x x x x Compression weak

x x x x Governor inoperative

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

27Section 4 TroubleshootingTP-6068 10/02

Page 42

Section or

Reference*

Publication

Recommended ActionsProbable Causes

Eng. S/M

Troubleshoot the fuel solenoid.[

Eng. S/M

Clean, test, and/or replace the inoperative fuel injector.[

Eng. S/M

Adjust the fuel injection timing.[

Eng. S/M

Rebuild or replace the injection pump.[

—

Gen. S/M

—

Gen. S/M

side of the circuit breaker.

Move the transfer switch test switch to the AUTO position. ATS O/ M

Check for continuity. Gen. S/M, W/D

Test and/or replace the rotor.[

Test and/or replace the stator.[

Tighten loose components.[

troubleshoot the voltage regulator.

Eng. O/M

Change the oil. Use oil with a viscosity suitable for the operating

climate.

abnormal noise Excessive or

consumption High fuel

pressure Low oil

Overheats

Lacks power

suddenly Stops

output voltage

Trouble Symptoms

28 Section 4 Troubleshooting

No or low

Starts hard

does not start Cranks but

crank Does not

x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —

Fuel System

x x x x Fuel filter restriction Clean or replace the fuel filter. Eng. O/M

x Fuel solenoid inoperative

x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M

Fuel or fuel injectors dirty or faulty

(diesel only)

x x x

Fuel injection timing out of adjustment

(diesel only)

Fuel feed or injection pump inoperative

(diesel only)

x x x x

x x x

AC output circuit breaker open Reset the breaker and check for AC voltage at the generator

Generator

Transfer switch test switch in the OFF

position

Wiring, terminals, or pin in the exciter

field open

Main field (rotor) inoperative (open or

grounded)

x Vibration excessive

x Stator inoperative (open or grounded)

x x Voltage regulator out of adjustment Adjust the voltage regulator. Gen. S/M

Voltage regulator inoperative Replace the voltage regulator fuse, If the fuse blows again,

x x

x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M

Lube System

Crankcase oil type incorrect for

x Low oil pressure shutdown Check the oil level. Eng. O/M

ambient temperature

x x x x

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

TP-6068 10/02

[ Have an authorized service distributor/dealer perform this service.

Page 43

Section 5 Wiring Diagrams

WARNING

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible

whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits tocomply withapplicable codesand standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Moving rotor.

TP-6068 10/02 29Section 5 Wiring Diagrams

Page 44

Figure 5-1 Schematic Wiring Diagram—4/6.5/9EFOZ and 5/8/10EOZ (1-Phase Models)

229294-L

TP-6068 10/0230 Section 5 Wiring Diagrams

Page 45

Figure 5-2 Point-to-Point Wiring Diagram—4/6.5/9EFOZ and 5/8/10EOZ (1-Phase Models)

TP-6068 10/02 31Section 5 Wiring Diagrams

229294-L

Page 46

Figure 5-3 Schematic Wiring Diagram—8.5EFOZ (3-Phase Models)

GM22515-

TP-6068 10/0232 Section 5 Wiring Diagrams

Page 47

Figure 5-4 Point-to-Point Wiring Diagram—8.5EFOZ (3-Phase Models)

TP-6068 10/02 33Section 5 Wiring Diagrams

GM22515-

Page 48

Figure 5-5 Schematic Wiring Diagram—11/13/16/19/23/27EFOZ and 13/15.5/20/23/28/32EOZ

(1-Phase Models)

229937-D

TP-6068 10/0234 Section 5 Wiring Diagrams

Page 49

Figure 5-6 Point-to-Point Wiring Diagram—11/13/16/19/23/27EFOZ and 13/15.5/20/23/28/32EOZ

(1-Phase Models)

TP-6068 10/02 35Section 5 Wiring Diagrams

229937-D

Page 50

Figure 5-7 Schematic Wiring Diagram—11.5/17.5/20/23/27EFOZ and 14/20/24/28/32EOZ

(3-Phase Models)

229938-B

TP-6068 10/0236 Section 5 Wiring Diagrams

Page 51

Figure 5-8 Point-to-Point Wiring Diagram—11.5/17.5/20/23/27EFOZ and 14/20/24/28/32EOZ

(3-Phase Models)

TP-6068 10/02 37Section 5 Wiring Diagrams

229938-B

Page 52

Notes

TP-6068 10/0238 Section 5 Wiring Diagrams

Page 53

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimensional

AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards

AO anticipatory only API American Petroleum Institute approx. approximate, approximately AR as required, as requested AS as supplied, as stated, as

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary A/V audiovisual avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery

BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block

blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CARB California Air Resources Board CB circuit breaker cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide

cogen. cogeneration Com communications (port) conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards

CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., ° degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung

DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection

EPS emergency power system ER emergency relay ES engineering special,

ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust ext. external F Fahrenheit, female

substrate (semiconductor)

Association

e. V. (also Deutsche Industrie Normenausschuss)

Association

Agency

engineered special

fglass. fiberglass FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lbs. foot pounds (torque) ft./min. feet per minute ggram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter

GND, gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temperature hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air

HWT high water temperature Hz hertz (cycles per second) IC integrated circuit ID inside diameter, identification IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting in. inch in. H in. Hg inches of mercury in. lbs. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe ISO International Organization for

J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (2

ground

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

bytes)

TP-6068 10/02 Appendix A-1

Page 54

kg kilogram

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kW kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound, pounds

lbm/ft

pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side L

sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (10

units), male

cubic meter

/min. cubic meters per minute

when used with SI

mA milliampere man. manual max. maximum MB megabyte (2

bytes) MCM one thousand circular mils MCCB molded-case circuit breaker meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, mW

milliohm

MOhm, MW

megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second MTBF mean time between failure MTBO mean time between overhauls mtg. mounting

MW megawatt mW milliwatt mF microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical

Manufacturers Association

NFPA National Fire Protection

Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe

thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment

manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health

Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor

ph.,

Æ phase

PHC Phillips head crimptite (screw) PHH Phillips hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent-magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only

memory psi pounds per square inch pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart qty. quantity R replacement (emergency)

power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote RFI radio frequency interference RH round head RHM round head machine (screw) rly. relay

rms root mean square rnd. round ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive

Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites,

International System of Units SI/EO side in/end out sil. silencer SN serial number SPDT single--pole, double--throw SPST single--pole, single--throw spec, specs

specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to

normal TDES time delay engine start TDNE time delay normal to

emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple

locations) UF underfrequency UHF ultrahigh frequency UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer

TP-6068 10/02A-2 Appendix

Page 55

Appendix B Operating Hour Service Log

Use the log below to keep a cumulative record of operating hours on your generator set and the dates

OPERATING HOURS SERVICE RECORD

DATE

RUN

HOURS

RUN

TOTAL

HOURS

SERVICE

DATE

required services were performed. Enter hours to the nearest quarter hour.

SERVICE

TP-6068 10/02 Appendix A-3

Page 56

Page 57

Page 58

Page 59

Page 60

TP-6068 10/02b

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455

Kohler 9EFOZ, 10EOZ, 8.5EFOZ, 11EFOZ, 13EOZ Operation Manual

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Frequently Asked Questions

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