Operation Manual, 3.5EFOZ/4EOZ (TP
Contents
1. Literature Type Installation Manual Operation Manual Operation Manual Engine Parts Catalog Service Manual Engine Service Manual Generator Figure 2 Generator Set Literature x in 001 005 TP 6134 11 01 OMANDABRWN 11 10 Service Side View Shown without sound shield doors and panels 25 Cooling air inlet On off button Hourmeter Start button Circuit breaker panel Remote panel connector Fuel inlet Fuel return Water outlet exhaust outlet Siphon break connection Customer load lead access Remote panel harness access AC circuit breaker Input fuse Customer load lead access connection Fuel injection pump Oil fill Oil drain valve and hose Fuel filter Figure 1 1 Service Views Typical Section 1 Service Views Circuit Breaker Panel 14 Engine End View ADV6652 High engine water temperature safety shutdown switch Air cleaner Fuel feed pump Battery connection Oil check Battery connection Starter solenoid starter motor Lifting eye Mixing elbow High exhaust temperature safety shutdown switch Nameplate Low oil pressure safety shutdown switch Control panel connector2. Seawater inlet Ground lug equipment ground Seawater pump water inlet Zinc plug Controller Note Consult an authorized distributor dealer or the service manual for items not shown TP 6134 11 01 Section 1 Service Views 1 Notes 2 Section1 Service Views TP 6134 11 01 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 Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper for cracks leaks and corrosion e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded
3. v 4 W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donot operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Usea containerto catch 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 de
4. Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A 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 TP 6134 11 01 Accidental Starting A WARNING KS x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set on off button to shut down the generator set All indicator lamps dim 2 Disconnect the pow
5. Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Handling the capacitor Hazardous voltage can cause severe injury or death Electrical shock results from touching the charged capacitor terminals Discharge the capacitor by shorting the terminals together Capacitor excited 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 andfollowthe instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests
6. or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e 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 e 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 TP 6134 11 01 Section 2 Operation 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 2 2 Marine Inspection Kohler Co recommends that all boat owners have their vessels especially the exhaust system attached to
7. 01 3 9 5 Battery Perform battery storage after all other storage procedures 1 Clean the battery Place the generator set master switch in the OFF RESET position Disconnect the battery ies negative lead first Refer to 3 2 Scheduled Maintenance for the battery cleaning procedure Place the battery in a cool dry location Connect the battery to a float equalize battery charger or charge it monthly with a trickle battery charger Refer to the battery charger manufacturer s recommendations Maintain a full charge to extend battery life x sm 002 007 Section 3 Scheduled Maintenance 19 Notes 20 Section 3 Scheduled Maintenance TP 6134 11 01 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 TP 6134 11 01 Section 4 Troubleshooting NOTICE Fuse
8. 1 Remove all jewelry 2 Stand on adry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under IV Safety Precautions and Instructions Hot Parts A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Moving Parts A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place A WARNING A Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing 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 set engine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen the crankshaft hardware or rotor thrubolt when making adjustme
9. Do not operate the set if the oil level is below the Min mark or above the Max mark 3 3 3 Oil Change Change the oil more frequently if the generator operates under dirty dusty conditions See Figure 3 3 for oil capacities Model Lats 1 25 1 32 Figure 3 3 Oil Capacities Oil Change Procedure Whenever possible drain the oil while it is still warm 1 Drain the oil a Press the generator set on off button to stop the generator set b Disconnect the power to the battery charger if equipped c Disconnect the generator set engine starting battery negative lead first TP 6134 11 01 Remove the oil drain hose from its retaining clip See Figure 3 4 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 y S S L 5 SETA ra E E 1 Oil drain hose Figure 3 4 Oil Drain Hose e f Open the oil drain valve on the engine 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 Close the oil drain valve Replace the cap on the oil drain hose Replace the oil drain hose in its retaining clip Note Dispose of all waste materials engine oil fuel filte
10. Gasket 4 Impeller 5 Bearing 6 Housing Figure 3 11 Seawater Pump Typical 3 Remove the impeller 4 Inspectthe impeller for damaged cracked broken missing or flattened vanes The impeller vanes should be straight and flexible See Figure 3 12 Replace the impeller if it is damaged TP 6134 11 01 1 Flattened vane 2 Crack 3 Broken vane Figure 3 12 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 TP 6134 11 01 3 7 8 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 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 inte
11. Read the WARNING found at the beginning of the manual Consult the operating instructions supplied with the craft Should be performed by your local distributor dealer TP 6134 11 01 Section 3 Scheduled Maintenance 9 3 3 Lubrication System See Section 3 2 Service Schedule for oil change and oil filter replacement intervals See Section 1 for the oil drain oil check and oil fill locations x sm 001 002 3 3 1 Oil Specifications Use HD 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 5W20 5W30 Figure 3 1 Engine Oil Selection Note Failure to observe the oil specifications may cause inadequate lubrication oil pressure and cold starting difficulties 3 3 2 Oil Check 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 See Section 1 Figure 1 1 for dipstick location 10 Section 3 Scheduled Maintenance TP 5586 3 1 Min mark 2 Max mark Figure 3 2 Oil Level Check Marks Note
12. 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 Safety Precautions and Instructions V Notes VI Safety Precautions and Instructions TP 6134 11 01 This manual provides operation instructions for 3 5EFOZ AEOZ 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 Safety Precautions and Instructions section at the beginning of t
13. it to normal operating temperature 2 Stop the generator set 3 With the engine still warm drain the oil from the crankcase 4 Refill the crankcase with oil suited to the climate 5 Run the generator set for two minutes to distribute the clean oil 6 Stop the generator set 7 Check the oil level and adjust if needed x sm 002 002 3 9 2 Fuel System Prepare the fuel system for storage as follows Diesel Fueled Engines 1 Fill the fuel tank with 2 diesel fuel 2 Condition the fuel system with compatible additives to control microbial growth See the engine operation manual 3 Change the fuel filter and bleed the fuel system See Section 3 4 x sm 002 004 3 9 3 Cooling System Prepare the cooling system for storage as follows 1 Unscrew the seawater pump cover to drain the cooling water from the engine 2 Remove the hose from the fitting to drain the cooling water from the alternator TP 6134 11 01 3 9 4 Exterior Prepare the exterior for storage as follows 1 2 Clean the exterior surface of the generator set Seal all engine openings except for the air intake with nonabsorbent adhesive tape To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake Mask electrical connections Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion x sm 002 006a TP 6134 11
14. metal surfaces 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 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 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 exa
15. meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 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 MQ milliohm MOhm MQ 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 A 2 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT p pp PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional over
16. recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea 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 presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of 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 sa
17. 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 Kohler distributor dealer for the inspection 2 3 Angular Operation See Figure 2 1 for angular operation limits for units covered in this manual Intermittent Continuous 3 minutes or less 25 30 Maximum value for all directions 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 engine compartment Operation above the deck and or outdoors would constitute a violation of European Union Directive 2000 14 EC noise emission standard Section 2 Operation 3 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 0p 001 005 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 p
18. 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
19. 75 in 2 Length 19 05 mm 0 75 in Figure 3 17 Anticorrosion Zinc Anode Plug 4 If necessary cut the anticorrosion zinc to the correct length Clean the threaded hole of the engine and coat the threads of the anticorrosion zinc anode plug with pipe sealant suitable for marine applications Install the anticorrosion zinc anode into the threaded hole 5 Close the petcock on the engine and open the seacock 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 Section 3 Scheduled Maintenance 17 3 8 Battery Consult the battery manufacturer s regarding battery care and maintenance instructions A 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 medi
20. OZ and 4EOZ TP 6134 11 01 Section 5 Wiring Diagrams 29 Notes 30 Section 5 Wiring Diagrams TP 6134 11 01 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cc CCA ccw CEC cfh cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery chargin
21. Operation Marine Generator Sets Models 3 5EFOZ 4EOZ KOHLER GENERATORS P 9001 INTERNATIONALLY REGISTERED KOHLER POWER SYSTEMS ces 100 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 Table of Contents Product Identification Information s eese Inside front cover Safety Precautions and Instructions sseeeeeeeeeeee nn nnn nnn I Intr duction ei o 20 Euch era RR GR EUR RACER UR A A RUE i Service Assistance vo 1 u au 0 iuc re Alu ler Rack Ra pu waa xu rm mem wea rx xa ep gu mis a mnia i Maintenance and Service Parts Related Literature usee
22. S 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 WwW watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6134 11 01 Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed Enter hours to the operating hours on your generator set and the dates nearest quarter hour OPERATING HOURS SERVICE RECORD DATE TOTAL SERVICE RUN HOURS DATE SERVICE TP 6134 11 01 Appendix A 3 TP 6134 11 01 2001 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Web site www kohlergenerators com Fax 920 459 1646 U S A Sales Fax 920
23. ackage double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft ft Ibs ft min g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext 1 0 IP ISO J JIS k K kA KB hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex
24. cal aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina 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 18 Section 3 Scheduled Maintenance 3 9 Generator Storage Procedure Perform the following storage procedure before taking a generator set out of service for three months or longer Follow the engine manufacturer s recommendations if available for fuel system and internal engine component storage x sm 002 001 3 9 1 Lubricating System Prepare the engine lubricating system for storage as follows 1 Run the generator set for a minimum of 30 minutes to bring
25. d the WARNING found at the beginning of the manual 8 Consult the operating instructions supplied with the craft Should be performed by your local distributor dealer 8 Section 3 Scheduled Maintenance TP 6134 11 01 Every Every 100 Hrs 200 Hrs Perform Service at Intervals Reference or 3 or 6 Indicated X Section i Months Months INTAKE EXHAUST SYSTEM X Inspect the exhaust system components Before operation Check the exhaust gas condition If the X exhaust is blue or black contact your local During distributor dealer operation Clean the intake silencer element Clean the exhaust water mixing elbow Replace the intake silencer element Inspect the complete exhaust system ELECTRICAL SYSTEM Keep the battery charged and in good condition Bde operation Check and tighten the electrical connections Clean the battery cables ENGINE AND MOUNTING Check for water fuel and oil leakage T ee operation X Retighten any loose nuts and bolts Before operation Check the mounting bolts vibromounts and tighten if necessary Adjust the intake exhaust valve clearance REMOTE CONTROL SYSTEM Check the remote control operation Bode X inperiod GENERATOR Test run the generator set Blow dust out of the generator Requires removal of the sound shield if installed Consult your local distributor dealer for service
26. dealer perform this service Notes 26 Troubleshooting TP 6134 11 01 A WARNING D KS E x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set on off button to shut down the generator set All indicator lamps dim 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 preventthe starting ofthe generator set by the remote start stop switch TP 6134 11 01 Section 5 Wiring Diagrams A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place 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 transfe
27. e to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING 7 d 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 l Safety Precautions and Instructions 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
28. ector s then reconnect itto W D locked tight the controller Fault shutdown Reset the fault switches and troubleshoot the controller High exhaust temperature switch Replace the inoperative switch Gen S M or W D inoperative Starter starter solenoid inoperative Replace the starter or starter solenoid Eng S M High cylinder head temperature switch Replace the inoperative switch Gen S M inoperative Air cleaner clogged Clean or replace the filter element Section 2 Compression weak Check the compression y Eng S M Engine overload Reduce the electrical load See the generator set installation I M manual for wattage specifications Exhaust system leak Inspect the exhaust system Replace the inoperative exhaust Section 3 I M system components Exhaust system not securely installed Inspect the exhaust system Tighten the loose exhaust system Section 3 I M components Governor inoperative Adjust the governor t Gen S M Valve clearance incorrect Adjust the valves Eng O M Vibration excessive Tighten all loose hardware E 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 S S Spec Sheet W D Wiring Diagram Have an authorized service distributor dealer perform this service Bunooysa qno y uon
29. eeeeeeeeeeeennnnnnn ii Section 1 Service VIeWS 3 er a HE 1 Section 2 Operation per Il ivle a e ee as 3 2 4 Prestart Checklist socie Ie e ee et Cov bie RU a 3 22 Marine Inspection 00 ccc s nennen nennen 3 23 Angular Operation ise libel bee bie e REIR Inka ei 3 2 4 Operation in European Union Member Countries 000000 eee ee 3 2 5 Exercising the Generator Set annarr ernaar eer 4 2 6 Starting and Stopping Procedure 00 cece cece eee 4 2 6 1 Controls and Indicators 0 0 cece cece eee eee eae 4 2 6 2 Starting the Generator Set 000 eiie 5 2 6 8 Stopping the Generator Set 00 cece cece eee eee 5 Section 3 Scheduled Maintenance oooooocccccncnncnr eee eee n nnn nnn 7 3 1 General Maintenance 0 0 cece n 7 3 2 Service Schedule 3 5EFOZ and 4EOZ Models 2 00 eee eee 8 3 3 Lubrication System ici oboe da a EIL 10 3 3 1 Oil Specifications RII LIED DEI et oS 10 332 OIGHeCk nern Hann es de ERAS 10 339 DI Changer soc eR MEE MEM 10 34 F ueliSystem issus rer werk ee det ure abt vetant 12 3 4 1 Fuel Specifications sig oensdag d a a y ai apaia esses 12 3 4 2 Fieltro ee ee sie a tai 12 3 43 Bleeding the Fuel System 0 cece cee eens 12 3 5 Air Intake Silencer Cleaner 0 cece cece cece e 13 3 6 Exhaust System esci an aR Gs Ri oh A eR NC 14 3 7 Coo
30. er 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 A 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 battery after placing the battery in service as this may result in hazardous 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 Ib of bicarbonate of soda baking soda toa container with 4 L 1 gal of water and 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 a
31. erating generator set Hazardous Voltage Electrical Shock A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place 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 to comply with applicable codes 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 Safety Precautions and Instructions Ill Short circuits Hazardous voltage current can cause severe injury or death
32. erative Replace the controller circuit board Gen S M Air openings clogged Clean the air openings Impeller inoperative Replace the impeller Section 3 Seawater strainer clogged or restricted Clean the strainer Section 3 High temperature shutdown Allow the engine to cool down Then troubleshoot the cooling system Sec 3 Eng O M Thermostat inoperative Replace the thermostat Eng O M 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 S S Spec Sheet W D Wiring Diagram Have an authorized service distributor dealer perform this service LO LL vELO dL ez Bunooysejqnos y uonoes Trouble Symptoms Section or Publication Probable Causes Recommended Actions Reference Does not Cranks but does not start Starts hard No or low output voltage Stops suddenly Lacks power Overheats pressure High fuel consumption Excessive or abnormal noise Electrical System x Battery connections loose corroded Verify that the battery connections are correct clean and tight Section 3 or incorrect Battery weak or dead Recharge or replace the battery The spec sheet provides Section 3 S S recommended battery CCA rating Engine harness connector s not Disconnect the engine harness conn
33. erator set until the fuel supply is emptied e Developing air leaks in the suction side of the fuel system e Replacing the fuel filter Procedure to Bleed the Fuel System 1 Loosen the vent screw See Figure 3 7 ADV 6652 1 Vent screw Figure 3 7 Vent Screw Location 2 Operate the generator set until fuel free of air bubbles flows from the vent screw 3 Tighten the screw Note Wipe up all spilled diesel fuel after bleeding the system Wash hands after any contact with fuel oil TP 6134 11 01 3 5 Air Intake Silencer Cleaner Atthe 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 1 Air cleaner element Figure 3 9 Air Cleaner Element TP 6134 11 01 Air Cleaner Service Replacement 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 Remove the four screws to remove the air cleaner cover 2 Remove the air silencer element 3 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 4 Examine the element and housing for damage and wear Replace the element or housing if necessar
34. ers as needed e Check that the exhaust outlet is unobstructed e 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 e Ensure that the carbon monoxide detector is 1 in the craft 2 functional and 3 energized whenever the generator set operates x 0p 001 002 14 Section 3 Scheduled Maintenance 3 7 Cooling System 3 7 1 Thermostat In a direct seawater cooling system the impeller pump circulates the seawater around the cylinder and through the cylinder head A thermostat controls the cooling water circuit temperature See Figure 3 10 for thermostat settings Consult the engine operation manual for the thermostat cleaning and checking procedures Thermosiat Settings Max Temp Seawater 50 C 122 F Freshwater 75 C 167 F Figure 3 10 Thermostat Settings 3 7 2 Seawater Pump and Impeller The gear driven seawater pump is located on the alternator 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 11 S 1 Seawater pump 2 Coverplate 3
35. fety of the craft s occupants installa carbon monoxide detector Consultthe 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 the generator set Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Use the following precautions when installing and operating the generator set Do not installthe 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 Avoid overloading the craft TP 6134 11 01 Fuel System A WARNING A
36. g alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute TP 6134 11 01 CG CID CL cm CMOS cogen Com conn cont CPVC crit CRT CSA CT Cu Cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline p
37. head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 21 bytes Appendix A 1 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m8 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm KQ 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 LxWxH length by width by height Ib pound pounds Ibm ft pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display Id 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 Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male m3 cubic
38. his manual Keep this manual with the equipment for future reference Introduction The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe 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 Please contact a local authorized distributor dealer for sales service or other information about Kohler Co Generator Division products e Look on the product or in the information included with the product e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Co Generator Division web site at www kohlergenerators com e Inside the U S A and Canada call 1 800 544 2444 e Outside the U S A 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 Australia Australia Regional Office Queensland Australia Phone 617 3893 0061 Fax 617 3893 0072 China China Regional Office Shanghai People s Republic of China Phone 86 21 6482 1252 Fax 86 21 6482 1255 TP 6134 11 01 India Bangladesh Sri Lanka Ind
39. ia Regional Office Bangalore India Phone 91 80 2284270 91 80 2284279 Fax 91 80 2284286 Japan Japan Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida U S A Phone 941 619 7568 Fax 941 701 7131 South East Asia Singapore Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 X in 008 001 Introduction i 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 3 5EFOZ 4EOZ GM20848 GM20849 GM20850 GM20851 GM20852 221335 GM19490 GM20853 Part Description Air Filter Element Battery Charging Fuse 10A Fuel Filter Input Fuse 25 A Seawater Pump Impeller Kit Spray Paint White Touch Up Paint White Zinc Anode Figure 1 Maintenance and Service Parts x in 001 004 ii Maintenance and Service Parts Related Literature 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 3 5EFOZ 4EOZ TP 6069 TP 6134 TP 6143 TP 6138 TP 6163 TP 6137 Includes the generator and engine information
40. in Seacock Figure 3 14 Siphon Break Plastic U Type Note Do notlocate the siphon break directly above the generator set 16 Section 3 Scheduled Maintenance TP 6134 11 01 3 7 4 Anticorrosion Zinc Anode The generator set includes 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 See Section 1 Figure 1 1 and Figure 3 15 for the location and use the following procedure 1 Seawater pump 2 Water cooled alternator 3 Anticorrosion zinc anode seawater drain Figure 3 15 Anticorrosion Zinc Anode 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 2 Remove the anticorrosion zinc anode plug 3 Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode Replace the anode according to Figure 3 16 and Figure 3 17 TP 6134 11 01 Anticorrosion Zinc Anode Replacement New Anode Dimensions mm in Replace When Percent of Zinc Remaining Is lt 50 of length diameter Figure 3 16 Anticorrosion Zinc Anode Plug Measurements i 10 0 39 x 20 0 79 BE EE 1 Diameter 9 5 mm 0 3
41. ling System iod se buc ge ete ome pee s ra d Y e a at 14 3 7 1 Thermostat scs breit op Re Yt 14 3 7 2 Seawater Pump and Impeller 000 c eee eee eens 14 3 73 Siphon Break use e ved rx E GR AR 15 3 7 4 Anticorrosion Zinc Anode ooccccccccocccc 17 3 85 Battery ii oos ee A A ee a Ie M eg 18 3 9 Generator Storage Procedure 00 cee cece esee 18 3 9 1 Lubricating System 0c ccc eee 18 B 9 2 E el System idus Ask dd y ld kot ge dete 18 3 9 8 Cooling System asi see goaie o aiai b a ia eee 18 3 9 4 EXterioE s cast a et 19 3 9 5 Battery i nter deest ri A Bch be malato ota 19 Section 4 Troubleshooting cece eee ence eee eee nnn n n nnn 21 Section 5 Wiring Diagrams sagan e RR ee ge 27 Appendix A Abbreviations 00 cece REESE DEERE e ee eee eee hh hn nn A 1 Appendix B Operating Hour Service Log ooccooococnccccn A 3 TP 6134 11 01 Table of Contents 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
42. ll 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 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 Safety Precautions and Instructions I 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 cabl
43. mple 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 Section 3 Scheduled Maintenance 7 3 2 Service Schedule 3 5EFOZ and 4EOZ Models Every Every Every Every 100 Hrs 200 Hrs 400 Hrs 600 Hrs Perform Service at Intervals Reference or 3 or 6 or 12 or 18 Indicated X Section Months Months Months Months FUEL SYSTEM Check the fuel level and fill as necessary A Before operation X During operation Check for any abnormal fuel injection sound t Remove the sediment from the fuel tank and drain the fuel tank 8 Clean the filter inserts of the fuel transfer pump Replace the fuel filter Check the fuel injection nozzles check the injection spray condition T3 LUBRICATION SYSTEM Check the crankcase oil level and add oil as X Before necessary operation X Replace the oil in the crankcase 3 Break in period Clean the oil strainer y Check the seawater outlet and clean as necessary Check the function of the siphon break if equipped Check the anticorrosion zinc anode s condition Check replace the seawater pump seal amp X impeller Replace Replace the anticorrosion zinc anode Requires removal of the sound shield if installed Consult your local distributor dealer for service Rea
44. n 2 6 1 Controls and Indicators Thefollowing table describes the controls and indicators located at the controller Name Description On Off Button Use this button to initiate the start procedure or to stop the generator set Press the button to the ON position before starting the generator set Press the button to the OFF position to stop the generator set Start Button Use this button to start the generator set Press the start button to start the generator set Hourmeter The meter records total generator set operating hours for reference in maintenance scheduling AC Circuit Breaker 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 Oil Pressure The lamp illuminates if the generator Lamp set shuts down because of low oil pressure Engine Lamp The lamp illuminates if the generator setshuts down because of high engine temperature Exhaust Lamp The lamp illuminates if the generator set shuts down because of high exhaust temperature Remote Start Connectors A 4 pin connector on the controller s side allows the connection of the optional remote start stop switch and hourmeter panel kit A 25 pin connector underneath the controller allows the connection of the optional remote star
45. nts 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 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 TP 6134 11 01 Notice NOTICE This generator set has been rewired from its nameplate voltage to 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 TP 6134 11 01 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
46. oes pz LO LL VELO dL Trouble Symptoms Does not Fuel System Cranks but does not start Starts hard No or low output voltage Stops suddenly Lacks power Overheats pressure High fuel consumption Excessive or abnormal noise Probable Causes Recommended Actions Section or Publication Reference Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position Fuel filter restriction Replace the fuel filter Section 3 or Eng O M Air in fuel system diesel only Bleed the diesel fuel system Section 3 Fuel or fuel injectors dirty or faulty diesel only Clean test and or replace the inoperative fuel injector Eng S M Fuel injection timing out of adjustment diesel only Adjust the fuel injection timing Eng S M Fuel feed or injection pump inoperative diesel only Rebuild or replace the injection pump Eng S M Generator AC output circuit breaker open Reset the breaker and check for AC voltage at the generator side of the circuit breaker Transfer switch test switch in the OFF position Move the transfer switch test switch to the AUTO position Inoperative capacitor See an authorized service distributor dealer Wiring terminals or pin in the exciter field open Check for continuity Gen S M W D Main field rotor inoperative open or grounded Test and or replace the ro
47. r etc in an environmentally safe manner 2 Oil Strainer Service Clean the oil strainer at the interval listed in the Service Schedule a Remove the flange on the crankcase See Figure 3 5 for location Remove the end of the oil drain hose Remove the metallic screen oil strainer Clean the oil stainer using diesel oil but no gasoline Consult the engine operation manual TP 6134 11 01 1 Oil fill cap 2 Flange Figure 3 5 Oil Strainer 3 Fill with oil Add new oil of the weight grade and quantity specified in Section 3 3 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 a Check that the generator set on off button is in the OFF position Reconnect the generator set engine starting battery negative lead last Reconnect the power to the battery charger if equipped x sm 001 003 Section 3 Scheduled Maintenance 11 3 4 Fuel System 3 4 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 Recommendation DIN 51601 ASTM D 975 67 ID 2D BS 2869 1967 A1 A2 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 failu
48. r switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Section 5 Wiring Diagrams 27 STD Control Panel mt High Ex Temp a Low dil Press Figure 5 1 Schematic Wiring Diagram 3 5EFOZ and 4EOZ 28 Section 5 Wiring Diagrams LEGEND BATTERY CHARGING ALTERNATOR STAR BAT 12V 80 100 Ah BRIOGE RECTIFIER DIODE DIODE DIDDE FUSE 25A FUSE 11A FUEL PUMP FUEL SALENDID HIGH CYLINDER HEAD TEMPERATURE HIGH EXHAUST TEMPERATURE START RELAY FUEL SOLENDIO RELAY AC CRANK DISCONNECT RELAY LOW DIL PRESSURE WIRING HARNESS CONNECTOR STD CONTROL PANEL CONNECTOR REMATE CONTROL PANEL CONNECTOR REMOTE START STQP SWITCH CONNECTOR STARTER MOTOR OC TERMINAL BLOCK PIN VOLTAGE REGULATOR TP 6134 11 01 WIRING DIAGRAM WIRING DIAGRAM STD CONTROL PANEL ICONTROL BOXI CU D LU ND z Fuel Sole maid Relay Q gt High Cyl Head Temp High Exhaust Temp Lew Uil Pressure Start 1234567 STD Control Panel 2n m ALTERNATOR I Remote Sl rt Stop 1234 Switch WIRING DIAGRAM ENGINE BATTERY 12V On OFF Remote Stari Stop Switch 7 Optional Equivalent wire numbers for Kohler Remote Start Stop Switch Not Shown 4 Pin Kohler Connector Wire No Figure 5 2 Point to Point Wiring Diagram 3 5EF
49. re 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 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 4 2 FuelFilter 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 See Figure 3 6 1 Fuel filter Figure 3 6 Fuel Filter Fuel Filter Cleaning Replacement Procedure 1 Close the fuel supply valve 2 Clamp off the fuel supply line 3 Remove the pipes from the filter filter 4 Remove and discard the fuel filter 12 Section 3 Scheduled Maintenance Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner 5 Replace the fuel filter with the arrow on the fuel filter housing indicating the direction of fuel flow 6 Reconnect the pipes to the fuel filter 7 Remove the clamp from the fuel supply line 8 Open the fuel supply valve 9 Bleed the system See Section 3 4 3 Bleeding the Fuel System 3 4 3 Bleeding the Fuel System Bleed air from the fuel system to prevent starting failures and or erratic operation One or more of the following causes air to collect in the fuel system e Operating the gen
50. 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 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 Section 4 Troubleshooting 21 Bunoouse qnoj y uonoes ZZ LO LL VELO dL Trouble Symptoms Does not crank Cranks but does not start Starts hard No or low output voltage Stops suddenly Lacks power Overheats pressure High fuel consumption Excessive or abnormal noise Controller Probable Causes Recommended Actions Section or Publication Reference Controller on off button in the OFF position Press the controller on off button to the ON position Section 2 Controller fuse blown Replace the blown controller fuse If the fuse blows again troubleshoot the controller Section 2 W D Controller circuit breaker tripped Reset the controller circuit breaker Section 2 Controller on off button inoperative Replace the controller on off button Controller fault Troubleshoot the controller Gen S M Controller circuit board s inop
51. rvals listed in the service schedule Siphon Break Inspection 1 Stop the generator set 2 Remove the retaining cap and remove the reed valve for inspection See Figure 3 13 3 Use a mild detergent to remove residue and oxidation from the reed valve 4 Clear blockages 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 6 Install the reed valve into the mounting base with the valve downward See Figure 3 13 item 3 7 Install and only finger tighten the retaining cap Do not overtighten it 1 Mounting base 2 Retaining cap 3 Reed valve Figure 3 13 Siphon Break m sm 003 007 Section 3 Scheduled Maintenance 15 Waterline 14 gt Silencer vertical lift 1 2 m 4 ft max Intake strainer 2 Exhaust outlet distance from the waterline Use asiphon break if Gear driven seawater pump the exhaust mixer outlet is located less than 23 cm 9 in above Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min the waterline Water lock optional Siphon break distance above waterline 30 5 cm 1 ft min Silencer distance from exhaust outlet 3 m 10 ft max Siphon break Silencer customer supplied Exhaust outlet Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Seawater strainer Exhaust outlet distance above the waterline 10 cm 4 in m
52. scribed in the installation section The tank and installation must conform to USCG Regulations TP 6134 11 01 Pipe sealant Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Use pipe sealant on all threaded fittings to prevent fuel leakage Use pipe sealant 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 thatall 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 environmentsuch as an engine room or near fuel tanks Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash Hazardous Noise A 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 exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an op
53. size overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw 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 TDE
54. t stop switch hourmeter and indicator panel kit TP 6134 11 01 2 6 2 Starting the Generator Set The following table describes the actions required to start the generator set Action Fuel shutoff valve Open the manual fuel shutoff valve if equipped Initiate Starting Press the controller on off button to the ON position Note The controller s oil pressure engine and exhaust lamps illuminate Starting Holdthe generator set controller start button until the generator set starts TP 6134 11 01 2 6 3 Stopping the Generator Set The following table describes the actions required to stop the generator set Step Action Cooldown Run the generator set at no load for 5 minutes to ensure adequate engine cooldown Stopping Press the controller on off button to the OFF position to stop the generator set Note The controller s oil pressure engine and exhaust lamps darken Fuel shutoff valve Close the manual fuel shutoff valve if equipped Section 2 Operation 5 Notes 6 Section 2 Operation TP 6134 11 01 3 1 General Maintenance A WARNING kaS KS x 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 se
55. tor Gen S M Stator inoperative open or grounded Test and or replace the stator t Gen S M Vibration excessive Tighten loose components 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 S S Spec Sheet W D Wiring Diagram Have an authorized service distributor dealer perform this service LO LL vELO dL Sz Bunoouse qnoj y uonoes Trouble Symptoms Does not Cranks but does not start Starts hard No or low output voltage Stops suddenly Lacks power Overheats pressure High fuel consumption Excessive or abnormal noise Probable Causes Recommended Actions Section or Publication Reference Oil level low Restore the oil level Inspect the generator set for oil leaks Section 3 Low oil pressure shutdown Check the oil level Section 3 or Eng O M Crankcase oil type incorrect for ambient temperature Change the oil Use oil with a viscosity suitable for the operating climate Section 3 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 S S Spec Sheet W D Wiring Diagram Have an authorized service distributor
56. ump 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 f water enters the exhaust system close the seacock and drain the water from the exhaust system at the silencer s drain plug before attempting to start the generator set If excessive cranking is a chronic problem have the unit including the exhaust system serviced by an authorized Kohler distributor dealer 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 Kohler distributor dealer for repair Failure to follow these guidelines may result in starter motor burnout 4 Section 2 Operatio
57. vere injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set on off button to shut down the generator set All indicator lamps dim 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 preventthe starting ofthe generator set by the remote start stop switch A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place 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 orderto perform some scheduled maintenance procedures Be especially careful if the sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only TP 6134 11 01 Section 3 Scheduled Maintenance NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from
58. y 5 Wipe the air cleaner cover and base with a clean rag to remove any dirt Ensure that dirt does not enter the intake port 6 Make sure that the sealing surfaces fit correctly and replace the four screws Section 3 Scheduled Maintenance 13 3 6 Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea 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 n addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times Atthe 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 e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hang
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