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Service Manual, 4EOZ/3.5EFOZ (TP-6137)

1. 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 Service Views Section 1 Specifications Circuit Breaker Panel Engine End View ADV6652 High engine water temperature safety shutdown switch Air cleaner Fuel feed pump Governor Battery connection Oil check Battery connection Starter solenoid starter motor Lifting eye Mixing elbow High exhaust temperature safety shutdown switch Low oil pressure safety shutdown switch Control panel connector Seawater inlet Ground lug equipment ground Seawater pump water inlet Anticorrosion zinc anode Controller Nameplate TP 6137 5 03 1 4 Engine Generator Model 4EOZ 3 5EFOZ Engine manufacturer Farymann Diesel Engine model 18W Number of cylinders 1 Cylinder block material Cast iron Cylinder head material Cast iron Piston rings 2 compression 1 oil Crankshaft material Stamped forgin
2. Uuuu AAA IIA PITA CAPACITOR MAIN ALTERNATOR 1 GROUND Ka GRD Lo NEUTRAL CT WATT ey E Ca RED Es WHITE E E Ta RED 8 5 EFOZ 220 VOLT 50 HZ 2 WIRE WHITE CAPACITOR C1 02 GROUND RED NEUTRAL Lo 2 1 ATT UL TOOT 3 4 uuu JUL Lu VITIITIM MAIN ALTERNATOR 1 2 WHITE RED GROUND GRD Lt IAN Lo NEUTRAL TP 6137 5 03 GM20645 B Section 11 Wiring Diagrams 93 Notes 94 Section 11 Wiring Diagrams TP 6137 5 03 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 cow 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 Ame
3. 0 0 cect t eens 15 3 5 2 FUCLSYSTOM cdi enere tada ara ean aged ard ro ind 15 3 5 3 Cooling System Lesere aeaea aaa a a a ae a aaia 15 3 5 4 EXE NOT e a che a a aa da tear aa eA meee bo a a 15 3 5 5 A O E NRTA 15 Section 4 Intake and Exhaust System 0 cc cece eee eee eee eens 17 4 1 Air Intake Silencer Filter 00 0 ccc cect tte 17 4 2 Exhaust System 2 ccc 20saiee nek tienes a la 18 4 3 MIXING EIDOW iw bias deen dear a a A a a bee eee bie kee 18 Section 5 Fuel System vc 0200 sve ceieie dese tee a a cee ee ee eee eileen 19 Bede O ikke tate hoe cites at So Saleh te ttl Se tee EEE ee Les 19 5 2 Fuel Specifications ressidar anion Saw ed ieee ee baie eld 19 535 Fuel IMG set sey techies eae tee det ha died ar ed WES da debe bem eed tt ban a E 20 5 4 Fuel Injector Nozzle 0 c cc tenets 21 5 5 Excess Fuel Start Device iae ea nien rar 23 5 6 The Injection Pump s Fuel Starting Delivery Point 00 eee ee 24 5 7 Fuel Pump Adjustment Timing occcccoccoccoccc eee 25 TP 6137 5 03 Table of Contents 5 8 Fuel Pump and Gear Cover Installation 0 cece eee 25 5 9 Bleeding the Fuel System 00 cece eee tenets 26 5 10 COVE irrita es fain a eae Ee ea a ee eee a 27 Section 6 Cooling System 2 2 i ieee eee cee ee eee eee eee eee eee eee ees 31 6 1 Direct Water Cooled 0 cr 31 6 2 TOMOS iii it A eds a ane ey 32 6 3 Se
4. A 4 Appendix TP 6137 5 03 Appendix D Common Hardware Identification Screw Bolts Studs Hex Head or Machine Head Hex Head W Grade 2 Hex Head or Machine Head i with Washer Lock or Elastic Grade 5 Flat Head FHM Square Grade 8 Grade 8 9 Hex Socket Head Metric Round Head RHM Cap or Acorn Pan Head Wing Number stamped on Hex Socket Head Cap or Washers hardware 5 8 shown Allen Head Cap Washer Styles Hex Socket Head or Allen Head Shoulder Bolt Plain Sheet Metal Screw Split Lock or Spring Stud Spring or Wave Drive Styles External Tooth Lock Hex Internal Tooth Lock Hex and Slotted Internal External Tooth Lock Phillips Slotted Hex Socket Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company Sample Dimensions American Standard Screws Bolts Studs and Nuts Plain Washers 1 4 20 x 1 L Length In Inches Screws and Bolts 9 32 x 5 8 x 198 Thickness Threads Per Inch External Dimension Major Thread Diameter In Fractional Inches Or Screw Number Size ______________ Internal Dimension Metric Screws Bolts Studs and Nuts M8 1 25 x 20 Lock Washers Length In Millimeters Screws and Bolts 5 8 Distance Between Threads In Millimeters LAA Internal Dimension Major Thread Diameter In Millimeters TP
5. 1 Carefully remove the crankshaft from the crankcase Note Avoid touching scratching the main bearing bushing 2 Use a puller to release the gear wheel from the crankshaft See Figure 10 57 TE Figure 10 57 Crankshaft 3 For ball bearing replacement EDEN AEA Figure 10 55 Main Bearing TP 6137 5 03 Section 10 Generator and Engine Disassembly Reassembly 73 a Place the main bearing cover under a press and support its outer side with two mountings b Press out the crankshaft See Figure 10 58 Wo Figure 10 58 Crankshaft c Remove the snap ring of the bearing s outer race d With a socket press on the inner race until the bearing is out from its seat Note The engine is completely disassembled Clean all parts with suitable cleaning solution After the parts are dried check for any damage wear or tear Replace any parts that are questionable 10 4 Generator Engine Reassembly Crankcase Bushing 1 Using a driver press the crankshaft s bush bearing on the crankcase Ensure that its edge is inside the crankcase as indicated in Figure 10 59 Also ensure that its oil holes are horizontal and aligned with the crankcase groove 74 Section 10 Generator and Engine Disassembly Reassembly Figure 10 59 Crankcase Bushing Crankshaft Gear 1 Toinstall the crankshaft gear heat itin an oil bath or on an electrical heater plate at a temperature of 90 100 C 195 210 F See Figure 1
6. TP 6137 5 03 11 2 Wiring Diagram Point to Point ENGINE START PANEL CONTROL BOX WIRING DIAGRAM CONTROL BOX HIGH CYL HEAD TEMP LOW OIL PRESSURE o HIGH EXHAUST TEMP FUEL SOLENOID RELAY 3 5877 FARKAS i STD CONTROL Hour Meter PANEL On Off D Oilpress T Engine 4 PIN REMOTE CONTROL PANEL CONNECTOR 25 PIN REMOTE PLUS PANEL CONNECTOR NOTE FOR REMOTE PANEL OPTIONS SEE ADV 6652 SHEET 2 LEGEND BCA BATTERY CHARGING ALTERNATOR BCR BATTERY CHARGING REGULATOR BR1 BRIDGE RECTIFIER C t CAPACITOR D DIODE EBG ENGINE BLOCK GROUND F FUSE FP FUEL PUMP FS FUEL SOLENOID GND CONTROLLER BOX GROUND HCHT HIGH CYLINDER HEAD TEMPERATURE HET HIGH EXHAUST TEMPERATURE J JACK Ki START RELAY K2 FUEL SOLENOID RELAY K3 AC CRANK DISCONNECT RELAY LOP LOW OIL PRESSURE P PLUG SM STARTER MOTOR SS STARTER SOLENOID TB TERMINAL BLOCK TW PIN WHITE GROUND 4EOZ 120 VOLT 60 HZ 2 WIRE y GRO r 2 NEUTRAL e
7. 7 Install and only finger tighten the retaining cap Do not overtighten it 1 Mounting base 2 Retaining cap 3 Reed valve Figure 6 5 Siphon Break m sm 003 007 Section 6 Cooling System 33 Waterline 14 Silencer vertical lift 1 2 m 4 ft max 2 Exhaust outlet distance from the waterline Use a siphon break if the exhaust mixer outletis located less than 23 cm 9 in above the waterline Siphon break distance above waterline 30 5 cm 1 ft min Siphon break Exhaust outlet Seawater strainer Seacock Intake strainer Gear driven seawater pump Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Water lock optional Silencer distance from exhaust outlet 3 m 10 ft max Silencer customer supplied Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Exhaust outlet distance above the waterline 10 cm 4 in min Figure 6 6 Siphon Break Plastic U Type Note Do not locate the siphon break directly above the generator set 34 Section 6 Cooling System TP 6137 5 03 6 5 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 requir
8. Starting Hold the generator set controller start button until the generator set starts Green LEDs indicate good water engine and exhaust temperature performance Note If the start button is pressed before a normal start procedure an electrical device disconnects the starter pinion 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 2 6 4 Engine Safety Shutdown Switches The engine is protected by 3 shutdown switches which automatically reset when the engine failure is corrected The engine safety shutdown switches become functional when the unit comes up to speed AC voltage is available and after a 3 5 second time delay The engine will shut down when e The engine oil pressure is 0 3 0 7 bar 30 70 kPa or less e The engine water temperature is 78 83 C 172 181 F or higher e The water temperature in the mixer elbow is 94 100 C 201 212 F or higher Note The low oil pressure switch is not a low oil level shutdown Check the oil level regularly to protect against engine damage from low
9. Before installing the rotocap check for proper operation by spinning the cap washer and releasing it Replace the rotocap if it produces a an ununiform rattling sound or if it is hard to move 4 Fit the cylinder head gasket See Figure 10 85 he ate rr Figure 10 86 Flywheel and Crankcase Marks 5 Slide the head onto the cylinder TP 6137 5 03 Section 10 Generator and Engine Disassembly Reassembly 83 2 Set the governor pin into the governor hole using grease to keep it in place 3 Align the mark on the camshaft gear with the mark on the gear cover See Figure 10 87 4 Put the cover gasket in place Slowly guide the gear cover towards the crankcase without moving the camshaft 5 Check that the distance between the flywheel mark and the crankcase mark is within 2 mm 0 0787 in If within this range the timing gear operation is correct Figure 10 87 Camshaft Gear and Gear Cover Marks 6 The crankshaft could stop in a position that causes difficulty installing the gear cover because the governor touches its lower side If this happens follow this procedure to install the cover a Move the flywheel until its mark aligns with the threaded hole on the crankcase at the 1 o clock position See Figure 10 88 b Move the camshaft gear until its mark is exactly three teeth to the left of the gear cover mark Figure 10 89 Camshaft and Gear Cover Mark See Figure 10 89 7 When installing the gear cover screws
10. The following tests include additional safety precautions OBSERVE THESE PRECAUTIONS 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 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 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 High voltage test Hazardous voltage can cause severe injury or death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment dama
11. 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 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 Section 3 Scheduled Maintenance 9 3 2 Service Schedule 3 5EFOZ and 4EOZ Models Every Every 100 Hrs 200 Hrs Perform Service at Intervals or 3 or6 Indicated X Months Months FUEL SYSTEM Check the fuel level and fill as necessary Before operation x Check for any abnormal fuel injection sound During operation Remove the sediment from the fuel tank and drain the fuel tank 8 Xx Drain water from the fuel filter and strainer f Break in period Clean the filter inserts of the fuel transfer pump F Replace the fuel filter Check the fuel injection nozzles check the injection spray cond
12. 10070 60 M931 10080 60 M931 10090 60 M931 10100 60 M931 12045 60 M931 12050 60 M931 12055 60 M931 12060 60 M931 12065 60 M931 12080 60 M931 12090 60 M931 12100 60 M931 12110 60 M931 16090 60 M931 20065 60 M931 20120 60 M931 20160 60 M931 22090 60 M931 22120 60 M931 22160 60 M931 24090 60 M931 24120 60 M931 24160 60 This metric hex bolt s hardness is grade 10 9 TP 6137 5 03 Dimensions M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M8 1 25 x 35 M8 1 25 x 40 M8 1 25 x 40 M8 1 25 x 45 M8 1 25 x 50 M8 1 25 x 55 M8 1 25 x 60 M8 1 25 x 70 M8 1 25 x 70 M8 1 25 x 75 M8 1 25 x 80 M8 1 25 x 90 M8 1 25 x 95 M8 1 25 x 100 M10 1 50 x 40 M10 1 50 x 45 M10 1 50 x 50 M10 1 50 x 55 M10 1 50 x 60 M10 1 50 x 65 M10 1 50 x 70 M10 1 50 x 80 M10 1 50 x 90 M10 1 50 x 100 M12 1 75 x 45 M12 1 75 x 50 M12 1 75 x 55 M12 1 75 x 60 M12 1 75 x 65 M12 1 75 x 80 M12 1 75 x 90 M12 1 75 x 100 M12 1 75 x 110 M16 2 00 x 90 M20 2 50 x 65 M20 2 50 x 120 M20 2 50 x 160 M22 2 50 x 90 M22 2 50 x 120 M22 2 50 x 160 M24 3 00 x 90 M24 3 00 x 120 M24 3 00 x 160 Part No Dimensions Hex Head Bolts full thread M933 04006 60 M933 05050 60 M933 06010 60 M933 0601 4 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06040 60 M933 06050 60 M933 08016 60 M933 08020 60 M933 08025 60 M933 08030 60 M933 10012 60 M961 10020 60 M933 10020 60 M933
13. 20 80 M934 22 80 M982 22 80 M934 24 80 M982 24 80 Washers Part No M125A 03 80 M125A 04 80 M125A 05 80 M125A 06 80 M125A 08 80 M125A 10 80 M125A 12 80 M125A 14 80 M125A 16 80 M125A 18 80 M125A 20 80 M125A 24 80 Dimensions M3 0 50 M4 0 70 M5 0 80 M5 0 80 M6 1 00 M6 1 00 M6 1 00 M8 1 25 M8 1 25 M8 1 25 M10 1 50 M10 1 50 M12 1 75 M12 1 75 M14 2 00 M16 2 00 M16 2 00 M18 2 50 M20 2 50 M20 2 50 M22 2 50 M22 2 50 M24 3 00 M24 3 00 ID 3 2 4 3 5 3 6 4 8 4 10 5 13 0 15 0 17 0 19 0 21 0 25 0 OD 7 0 9 0 10 0 12 0 16 0 20 0 24 0 28 0 30 0 34 0 37 0 44 0 Type Standard Standard Standard Elastic Stop Spiralock Std green Elastic Stop Spiralock Standard Elastic Stop Spiralock Elastic Stop Spiralock Elastic Stop Elastic Stop Spiralock Elastic Stop Elastic Stop Standard Elastic Stop Standard Elastic Stop Standard Elastic Stop Bolt Thick Screw 0 5 M3 0 8 M4 1 0 M5 1 6 M6 1 6 M8 2 0 M10 2 5 M12 2 5 M14 3 0 M16 3 0 M18 3 0 M20 4 0 M24 Appendix A 7 TP 6137 5 03 2003 by Kohler Co All rights reserved KOHLER POWER SYSTEMS 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
14. 65 264 6422 Fax 65 264 6455
15. Clean the residual carbon buildup with a wire brush Inspect the exhaust manifold flange for cracking and corrosion The mixing elbow combines high temperature exhaust and cooling seawater The mixture when exposed to engine vibration makes conditions conducive to rapid deterioration and failure if not correctly maintained If any damage is detected with the mixing elbow or other exhaust components replace the damaged components to prevent engine exhaust carbon monoxide leakage 1 Mixing Elbow Figure 4 3 Mixing Elbow Location TP 6137 5 03 5 1 General A WARNING Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 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 In most installations both the generator set and the propulsion engine operate from a common fuel tank with a dual dip tube arrangement The generator set dip tube is shorter than the propulsion engine s dip tube With this arrangement fuel may not be available to the generator set when the fuel supply is low Description An electric fuel pump draws fuel from the tank The fuel flows in the fuel supply line through
16. 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 TP 6137 5 03 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 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 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 tha
17. 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 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 5 2 5 Exercising the Generator Set Ope
18. and Engine Disassembly Reassembly TP 6137 5 03 3 Repeat this procedure on the nut that connects the Remove the cylinder head high pressure line to the injector body See Figure 10 29 1 Remove the two locknuts and washers that hold the protective tube retaining spring 2 Loosen and remove the four cylinder head nuts See Figure 10 31 Figure 10 29 High Pressure Fuel Line on the Fuel Injector Remove ihe tuetinjector Figure 10 31 Cylinder Head 1 Remove the two nuts from the injector clamp See Figure 10 30 Remove the rocker arms _ 2 Remove the injector from its seat If it s locked tap Using a chisel and hammer drive out the rocker the injector lightly and carefully with a soft faced arm shaft See Figure 10 32 hammer Be careful not to damage the injector 2 Remove the rocker arms and push rods Note Remove the copper washer located between the head and the injector 3 The cup shaped cover holds the arm s shaft in its bracket Remove any snap rings during this disassembly 4 Hold the protective tube and remove the cylinder head See Figure 10 33 Figure 10 30 Fuel Injector Figure 10 32 Rocker Arms TP 6137 5 03 Section 10 Generator and Engine Disassembly Reassembly 65 Figure 10 33 Protective Tube Disassembly the valves 1 Use the special tool shown in Figure 10 34 to disassemble the valves Consult the engine service manual Note Be aware of the two thin steel washers locate
19. appropriate torque See Section 1 5 9 Install on the outside of the main bearing cover the O ring the angle ring and the two elastic washers as shown in Figure 10 62 Note The cover installs correctly on the crankcase by turning it in the correct position aid Figure 10 63 Main Bearing Cover Section 10 Generator and Engine Disassembly Reassembly 75 Flywheel 1 Remove any oil or grease from the flywheel and the tapered side of the crankshaft 2 Place the flywheel key in its groove 3 Install the flywheel on the tapered side of the crankshaft and tighten the nut at the specified torque See Section 1 5 See Figure 10 64 a gt Figure 10 64 Flywheel Oil Pump 1 Assemble the oil pump together with the thin covering plate valve and gasket to the crankcase See Figure 10 65 and Figure 10 66 2 Pull the pump downwards before tightening the screws at the specified torque See Section 1 5 3 The clearance on the pump screw holes allows Figure 10 66 Oil Pump enough backlash between the crankshaft gear and the pump gear Note The 4EOZ 3 5EFOZ model s engine have a counterclockwise rotation as viewed from the engine flywheel Also the oil pump is located on the crankcase s left side 76 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 Governor 1 Install the holding device so that all of its teeth are engaged with the teeth of the crankshaft gear See Figure 10 67 2 R
20. at the specified torque in three steps after the retaining spring nuts See Section 1 5 See Figure 10 93 Figure 10 91 Block Tappets Push Rods and Protective Tube 1 Install the O rings and push down the protective tube of the push rods towards the gear cover TP 6137 5 03 Section 10 Generator and Engine Disassembly Reassembly 85 Valve Adjustment 1 Move the piston in the compression stroke until it s at Top Dead Center TDC 2 Loosen the locknuts of the valve adjustment screws and drive a 0 2 mm 0 78 in feeler gage between the upper surface of the valve stem and the rocker arm See Figure 10 94 3 Adjust the clearance until a slight drag is felt on the feeler gage when turning the valve adjustment screws with a screwdriver 4 Hold the valve adjustment screws and tighten the locknuts 5 Recheck the clearance Figure 10 95 Adjustment 86 Section 10 Generator and Engine Disassembly Reassembly Fuel Injector 1 Replace the washer located under the injector and in the seat of the cylinder head Note Use only a gasket under the injector and ensure that the old gasket is removed 2 Install the injector and the clamp 3 Tighten the injector nuts at the specified torque See Section 1 5 Injection Pump and Speed Conirol Shaft Connection 1 Keep the accelerator lever in the higher position 2 Pull down the fuel excess start device s button Note As the inner return spring pushes the co
21. atomizes the fuel in the cylinder under high pressure As it is located in the A WARNING combustion chamber it operates at high temperatures p and strong mechanical stress Clean and adjust the H injector as described below W Injector Cleaning Explosive fuel vapors Can cause severe injury or death 1 Use a brass wire brush to remove residual combustion products on the nozzle s surface Use extreme care when handling storing and using fuels 2 A special tool needle is required to clean the injector nozzle s spray hole Consult the engine i 1 Connect the injector to a tester to check the service manual for more information injection pressure value See Figure 5 6 2 Using the hand pump lever of the tester pump fuel in the injector until it ejects at the specified pressure 3 During this operation the ejected fuel must be evenly atomized without leakage or dripping Figure 5 5 Injector Figure 5 6 Tester TP 6137 5 03 Section 5 Fuel System 21 Injector Adjustment 1 If during the injector pressure test the pressure values are not correct replace the shims in the injector a Unscrew the injector nut b Remove the nozzle assembly pressure piece spring seat s conical stop spring and shims See Figure 5 7 Note A change of 0 1 mm 004 in shim size can modify the pressure value of the injector of 10 bar 145 psi The thicker shim increases the pressure value of the inject
22. crafts 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 e Check the hoses for softness cracks leaks or dents Replace the hoses as needed e Check for 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 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 is 1 inthe craft 2 functional and 8 energized whenever the generator set operates x 0p 001 002 18 Section 4 Intake and Exhaust System 4 3 Mixing Elbow Check the mixing elbow for carbon buildup and corrosion inside the pipe
23. fuse blown Replace the fuse If the fuse blows again contact your local Kohler generator set distributor for service Starter does not work properly Loosened or corroded connections Clean and tighten the loose connections Low battery output power Check the electrolyte level and specific gravity batteries with filler caps only Check battery voltage Inoperative starter solenoid Replace the starter solenoid Inoperative start stop switch Replace the switch Inoperative wiring Check the wiring Starter cranks slowly 40 Section 7 Troubleshooting Low battery output Check the electrolyte level and specific gravity batteries with filler caps only Too heavy viscosity lube oil Use proper viscosity oil Loosened or corroded wiring Clean and tighten loose connections High starter current draw Rebuild or replace the starter Battery cable undersized See the installation manual TP 6137 5 03 Section 8 Controller Troubleshooting CL Hour Meter FEF ie On off Start ag Oilpress N A Engine S Z Exhaust N Starter motor K1 relay protects the starter motor in the event of an improper engine start d K2 relay energizes OAK the fuel pump FP gt and the fuel solenoid FS ae If the fuel solenoid FS is energized fuel
24. growth See the engine operation manual 3 Change the fuel filter and bleed the fuel system See Section 5 x sm 002 004 3 5 3 Cooling System Prepare the cooling system for storage as follows TP 6137 5 03 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 3 5 4 Exterior Prepare the exterior for storage as follows 1 Clean the exterior surface of the generator set 2 Seal all engine openings except for the air intake with nonabsorbent adhesive tape 3 To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake 4 Mask electrical connections 5 Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion x sm 002 006a 3 5 5 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the battery ies negative lead first 3 Clean the battery 4 Place the battery in a cool dry location 5 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 15 Notes 16 Section 3 Sched
25. 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 6137 5 03 6 4 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 intervals 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 6 5 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 TP 6137 5 03 6 Install the reed valve into the mounting base with the valve downward See Figure 6 5 item 3
26. injectors Contact your local Kohler generator set distributor for service Incorrect fuel injection timing Contact your local Kohler generator set distributor for service Incorrect valve clearance Contact your local Kohler generator set distributor for service Lube oil level too high Drain out surplus Incorrect lube oil Use correct viscosity oil Low lube oil pressure Low lube oil level Add lube oil Incorrect lube oil viscosity Drain fill with correct lube oil Inoperative lube oil pump Contact your local Kohler generator set distributor for service Inoperative oil pressure switch Replace the shutdown switch High lube oil consumption TP 6137 5 03 Too light viscosity oil Use correct viscosity lube oil Oil leaks Check for leaks in lines around gasket and drain plug Incorrect oil type Use correct viscosity lube oil Clogged breather system Clean the breather system Inoperative piston ring piston cylinder block valve guide and seat Contact your local Kohler generator set distributor for service Section 7 Troubleshooting 39 Problem Possible Cause Corrective Action High fuel consumption Incorrect fuel type Use correct fuel Clogged or dirty air intake screen Service the air intake screen Engine overloaded Reduce the load Incorrect valve clearance Conta
27. inlet and exhaust line at the mixing elbow Observe all the safety precautions listed at the beginning of this manual during the disassembly reassembly procedures 1 Standard controller panel 2 Harness outlet hole to the remote control panel 3 AC harness inlet holes to the control panel 1 Controller box 2 Circuit breaker 3 Controller fuse Figure 10 2 Controller Components TP 6137 5 03 KOHLER N ae d Standard controller panel Hourmeter On Off switch Start switch Engine low oil pressure LEDs Engine water overheating temperature LEDs Exhaust gas overheating temperature LEDs Connection between the standard controller panel and the controller box ANOaABRWN Figure 10 3 Controller Components Controller Removal 1 Using a 10 mm socket wrench loosen the four M6 nuts that hold the controller box on the stator housing See Figure 10 4 ea al gt Figure 10 4 Controller Box Removal 2 Disconnect all of the controller box wires that do not permit its removal Section 10 Generator and Engine Disassembly Reassembly 57 Note It is possible to connect the output leads in various positions for different volt configurations Marks the leads for correct reconnection 3 Carefully lift the controller box See Figure 10 5 Figure 10 7 Seawater Pump Impeller Seawater Pump Housing Removal Figure 10 5 Controller Box Removal 1 After disconnecting the inlet
28. 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 Section 5 Fuel System 19 5 3 Fuel Filter 5 Remove and discard the fuel filter The fuel filter prevents the entry of dirt into the fuel Note Dispose of all waste materials engine oil system and preserves the injector and fuel injection fuel filter etc in an environmentally safe pump The quality and condition of the fuel largely manner determine the filter s useful life Replace the fuel filter as listed in the service schedule See Figure 5 2 6 Replace the fuel filter with the arrow on the fuel filter housing indicating the direction of fuel flow See Figure 5 4 1 Fuel filter Figure 5 2 Fuel Filter Location Fuel Filter Cleaning Replacement Procedure 1 Close the fuel supply valve 2 Using a rag clean the fuel line 7 Reconnect the pipes to the fuel filter 3 To avoid fuel leakage clamp off the fuel supply line near the filter 8 Remove the clamp from the fuel supply line 4 Disconnect the inlet and outlet lines to the fuel filter 9 Open the fuel supply valve Ensure that dirt does not enter the fuel system See Figure 5 3 10 Bleed the system See Section 5 9 Bleeding the Fuel System Figure 5 3 Disconnect the Fuel Line 20 Section 5 Fuel System TP 6137 5 03 5 4 Fuel Injector Nozzle Injector Pressure Test The fuel injector nozzle ejects and
29. oil level Section 2 Operation 7 2 6 5 Circuit Protection The AC circuit breaker trips when a fault is detected in the output circuit After correcting the fault reset the AC circuit breaker by placing in the ON position See Figure 1 1 for circuit breaker location Note Replace the 25 amp fuse installed in the control box after a fault See Figure 1 1 for the fuse location Unit is now ready for restart 2 7 Remote Panel Kits Remote start stop panels allow starting or stopping the generator set from a remote location 2 7 1 Remote Start Stop Panel Kit The remote start stop panel includes an hourmeter and start stop switch The generator set includes a 4 pin connector for connection of the remote start stop panel Order a 4 to 6 pin harness kit to connect the panel to the 4 pin connector located at the controller See Figure 2 4 and Figure 2 5 ie e oJo o o o TOTAL HOURS All START STOP KOHLER GENERATORS gt WS l A 226965 A 1 Hourmeter 2 Start Stop switch 3 6 pin connector 1 Start Stop switch connection Figure 2 5 Remote Start Stop Panel Connection 8 Section 2 Operation 2 7 2 Remote Panel Kit The remote panel kit includes a start button an on off button an hourmeter to record total generator set operating hours an engine oil pressure light an engine water temperature light and an exhaust gas light Order additional extension harnesses for panel connection
30. set from the load Safety Precautions and Instructions III 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 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 inst
31. speed controller shaft has been removed or tampered with they need to be readjusted Figure 5 19 Taplet Bolt Position 9 Hold the taplet bolt in this position and tighten the nut See Figure 5 19 10 Bend the lock plate and reassemble the cover plate on the gear cover Note It is essential for adequate engine operation to obtain the correct adjustment between the taplet Figure 5 18 Cover Plate 1 28 Remove the governor cover plate on the gear cover See Figure 5 18 Move the engine until the governor flyweights are in the vertical position Keep the accelerator lever in the higher engine speed position Open the lock plate of the taplet bolt and loosen the nut Section 5 Fuel System bolt and the governor pin The engine will go into overspeed if a clearance exists between the taplet bolt and the governor pin while a forced contact produces an engine speed drop 11 With the engine stopped adjust both the cross slotted nuts so that their upper surfaces are at the same height as the governor bolt See Figure 5 20 12 Start the engine and check its speed TP 6137 5 03 13 If the engine speed needs modification turn the cross slotted nuts 43 Y A i Mi i s kets 83 Figure 5 20 Engine Speed Adjustment a y Note Tightening both cross slot nuts increases engine speed because the axial movement of the governor pin does not permit the control lever to push the fu
32. stops TP 6137 5 03 8 2 Engine Safety Shutdown Switches 8 2 1 Low Oil Pressure LOP Shutdown If the oil pressure drops while operating the engine the normally closed low oil pressure LOP switch contacts close DC travels to connection 5 on the control panel and the K2 relay is deenergized DC does not travel to the fuel solenoid FS or to the fuel pump FP and the engine stops The red oil pressure LED on the control panel lights immediately while the green oil pressure LED cuts off Check and correct the generator set fault TP 6137 5 03 8 2 2 High Water Temperature and High Exhaust Temperature Shutdown Switch If high engine water temperature or exhaust gas temperature is encountered the normally open contacts of the HCHT and HET switch close DC travels to connection 3 or 4 on the control panel deenergizing the K2 relay DC does not travel to the fuel solenoid FS or to the fuel pump FP and the engine stops The red LED of the high water temperature and or high exhaust gas temperature light immediately while the corresponding green LED cuts off Check and correct the generator set fault Section 8 Controller Troubleshooting 43 Control panel Connector to STD control panel connector 0 63 amp fuse J3 connector to control panel P5 connector to remote panel harness P6 connector to remote start stop switch connector J6 remote start stop switch connector ees
33. the electric pump the filter the engine stop solenoid and then reaches the fuel injection mechanical pump The injection pump pushes the fuel from the nipple valve to the injector The injector ejects and atomizes the required fuel at high pressure before the piston reaches TDC Any excess fuel returns to the tank The rubber pipe located between the mechanical pump and the injector s banjo return bolt allows for bleeding air from the fuel system TP 6137 5 03 Section 5 Fuel System Fuel tank Electric fuel pump Fuel supply line Fuel filter Stop solenoid Air bleeding pipe Injector assembly High pressure fuel line Fuel injection pump mechanical Fuel return line SCOMNODTAWNH Figure 5 1 Fuel System Schematic Typical 5 2 Fuel Specifications Use a clean good quality diesel fuel oil with a cetane number of 45 or greater Clean fuel prevents 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 failure 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
34. the gasket located between the housing and the engine head Figure 10 25 Antiresonator Housing Remove the exhaust elbow mixer 1 Disconnect the water pipe located between the thermostat and the exhaust elbow See Figure 10 26 2 Loosen the upper clamp on the outlet water pipe 3 Remove the two hex socket screws that attach the exhaust elbow to the engine head 4 Remove the exhaust elbow without damaging the high exhaust temperature switch or its electrical connection Section 10 Generator and Engine Disassembly Reassembly 63 5 Discard the gasket located between the exhaust elbow and the engine head Figure 10 27 Rocker Cover Disconnect the high pressure fuel line 1 Hold a 14 mm wrench on the fuel injector pump s nipple valve See Figure 10 28 Figure 10 26 Exhaust Elbow Mixer 2 Loosen the high pressure line using a 17 mm wrench Disconnect the fuel supply and return lines 1 To remove the fuel supply line and prevent fuel spills close the fuel supply line using a clamp or a flat nose pliers located between the filter and the electric fuel pump 2 Close the fuel return line to the tank using another clamp located after the injector s banjo fitting Remove the rocker cover 1 Remove the two rocker cover nuts washer cover and gasket See Figure 10 27 Note If the cover is difficult to remove tap it lightly with a soft faced hammer Delivery Valve 64 Section 10 Generator
35. the numbers face Tighten the connecting rod nuts at the specified torque See Section 1 5 Section 10 Generator and Engine Disassembly Reassembly 77 Camshaft Gear 1 Put the camshaft gear wheel in an oil bath or an electric heater plate at a temperature of 90 100 C 95 210 F See Figure 10 70 2 Using a socket and hydraulic press push the gear in its seat on the camshaft Note For a correct gear adjustment timing the chisel mark on the gear must face the camshaft side Figure 10 68 Connecting Rod Figure 10 69 Connecting Rod 8 Install the oil cooler and screws torqued to the specified value See Section 1 5 Figure 10 70 Camshaft Gear 78 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 Camshaft Bearing Injection Pump Camfollower 1 Using a socket install the camshaft bearing on the 1 Assemble the injection pump camfollower and gear cover until it is against its seat See tighten its fixing nut through the oil fill hole Figure 10 71 Speed Control Shaft 1 Set the inner torsion return spring in the control lever s fuel pump lever s hole See Figure 10 73 2 Insert the end leg of the spring in the inner control lever hole 3 Put the control lever on the bench 4 Install the ratchet plate and the accelerator lever on the pin of the eccentric speed shaft It will engage with the ratchet plate s slot and the accelerator lever hole 5 Install the outer torsio
36. x 2 00 3 8 16 x 2 25 3 8 16 x 2 50 3 8 16 x 2 75 3 8 16 x 3 00 3 8 16 x 3 25 3 8 16 x 3 50 3 8 16 x 3 75 3 8 16 x 4 50 3 8 16 x 5 50 3 8 16 x 6 50 A 6 Appendix Part No Dimensions Hex Head Bolts cont X 6238 14 X 6238 16 X 6238 21 X 6238 22 X 6024 5 X 6024 2 X 6024 8 X 6024 3 X 6024 4 X 6024 11 X 6024 12 X 129 15 X 129 17 X 129 18 X 129 19 X 129 20 X 129 21 X 129 22 X 129 23 X 129 24 X 129 25 X 129 27 X 129 29 X 129 30 X 463 9 X 129 44 X 129 51 X 129 45 X 129 52 X 6021 3 X 6021 4 X 6021 2 X 6021 1 273049 X 6021 5 X 6021 6 X 6021 7 X 6021 12 X 6021 11 X 6021 10 X 6021 9 X 6239 1 X 6239 8 X 6239 2 X 6239 3 X 6239 4 X 6239 5 X 6239 6 X 792 1 X 792 5 X 792 8 3 8 24 x 75 3 8 24 x 1 25 3 8 24 x 4 00 3 8 24 x 4 50 7 16 14 x 75 7 16 14 x 1 00 7 16 14 x 1 25 7 16 14 x 1 50 7 16 14 x 2 00 7 16 14 x 2 75 7 16 14 x 6 50 1 2 13 x 75 1 2 13 x 1 00 1 2 13 x 1 25 1 2 13 x 1 50 1 2 13x 1 75 1 2 13 x 2 00 1 2 13 x 2 25 1 2 13 x 2 50 1 2 13 x 2 75 1 2 13 x 3 00 1 2 13 x 3 50 1 2 13 x 4 00 1 2 13 x 4 50 1 2 13 x 5 50 1 2 13 x 6 00 1 2 20 x 75 1 2 20 x 1 25 1 2 20 x 1 50 5 8 11 x 1 00 5 8 11 x 1 25 5 8 11 x 1 50 5 8 11 x 1 75 5 8 11 x 2 00 5 8 11 x 2 25 5 8 11 x 2 50 5 8 11 x 2 75 5 8 11 x 3 75 5 8 11 x 4 50 5 8 11 x 6 00 5 8 18 x 2 50 3 4 10 x 1 00 3 4 10 x 1 25 3 4 10 x 1 50 3 4 10 x 2 00 3 4 10 x 2 50 3 4 10 x 3 00 3 4 10 x 3 50 1 8
37. 0 0 8661 21 970 0 8650 21 930 0 8634 22 022 0 8670 21 980 0 8654 21 960 0 8645 21 910 0 8626 21 990 0 8657 21 860 0 8606 Cylinder Head Inner guide diameter Outer guide diameter Head protrusion of the intake valve guide Head protrusion of the exhaust valve guide Clearance between the guide and stem valve Valve face angle Valve guide in the head hole diameter Valve head recessing Press down until the lower guide edge is at the level of the flat surface TP 6137 5 03 7 014 0 2761 10 019 0 3944 5 700 0 2244 6 200 0 2441 0 049 0 0019 45 9 988 0 3932 0 200 0 0079 Section 10 Generator and Engine Disassembly Reassembly 89 7 005 0 2758 10 010 0 3941 E 0 025 0 0009 9 979 0 3929 0 100 0 0039 0 15 0 0059 0 600 0 0236 Notes 90 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 Section 11 Wiring Diagrams Electroswitch 2 Wire Generator Sets LI lt To Generator Set L2 O gt To Shore Power YY To Load 3 Wire Generator Sets L1 0 9 7 Q 2 1 3 4 oe n 8 To Shore Power L2 _ To Generator 6 5 7 Set Lo lt 10 To Load Kraus Naimler American Solenoid Early Rectangular Design 2 Wire Generator Sets L1 lt O 9 0 7 0 gt To Generator 1 5 To Shore Power 3 Wire Generator Sets LI lt 1 Set L2 L a O To Generator 3 To Shore Se
38. 0 60 Figure 10 60 Crankshaft Gear 2 Using a socket and a hydraulic press push it down on the shaft 3 Lubricate the bush bearing and slide the crankshaft into the housing without damaging the bush bearing with the gear teeth See Figure 10 61 TP 6137 5 03 Figure 10 61 Bush Bearing Main Bearing Cover 1 Using a hydraulic press and socket install the ball bearing in the main bearing cover until the outer race is against its seat See Figure 10 62 We mn I Ten p or a va Z VEL AN haw TS O Ring between the crankcase and cover Bearing snap ring Oil seal Angle ring Elastic washers O Ring under the angle ring Bearing Figure 10 62 Main Bearing Cover Assembly TP 6137 5 03 2 Lock the bearing s outer race with the snap ring in the cover 3 Set the crankshaft on the board of a press and carefully clean the tapered surface of the bearing seat 4 Put the main bearing cover on the crankshaft so that the snap ring is towards the flywheel side 5 Using a socket press the main bearing cover on the crankshaft until the inner race bearing is in its seat against the shoulder of the crankshaft 6 Lubricate the oil seal lip and the tapered surface of the crankshaft and assemble the oil seal on the cover Do not use grease 7 Put the O ring between the crankcase and cover and tap lightly with a soft faced hammer to seat the cover 8 Tighten the nuts to the
39. 0 6518 7950 86 10 6518 7951 86 10 6518 7952 86 10 6518 7955 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 Fax X in 008 001a Introduction i Notes ii Service Assistance TP 6137 5 03 1 1 General This manual covers the operation maintenance troubleshooting and repair of the alternating current marine generator sets Have an authorized service dealer distributor perform required servicing to assure your unit continues to meet USCG requirements Please take a few moments to read this manual then carefully follow all service recommendations Keep this manual aboard your craft for future reference See Figure 1 1 for identification and location of components Your craft is equipped with a dependable 120 volt 60 Hz or 230 volt 50 Hz single phase alternating current generator set 1 2 Generator Section 1 Specifications The 4EO7 3 5EFOZ models are powered by a Farymann one cylinder direct water cooled four cycle diesel engine Kohler Co develops all Kohler marine generator set ratings using accepted reference con
40. 10025 60 M933 10030 60 M933 10030 82 M961 10035 60 M933 10035 60 M933 12016 60 M933 12020 60 M933 12025 60 M933 12025 82 M933 12030 60 M933 12040 60 M933 12040 82 M961 14025 60 M933 1 4025 60 M961 16025 60 M933 16025 60 M933 16030 82 M933 16035 60 M933 16040 60 M933 16050 60 M933 16050 82 M933 16060 60 M933 18050 60 M933 18060 60 M4 0 70 x 6 M5 0 80 x 50 M6 1 00 x 10 M6 1 00 x 14 M6 1 00 x 16 M6 1 00 x 20 M6 1 00 x 25 M6 1 00 x 40 M6 1 00 x 50 M8 1 25 x 16 M8 1 25 x 20 M8 1 25 x 25 M8 1 25 x 30 M10 1 50 x 12 M10 1 25 x 20 M10 1 50 x 20 M10 1 50 x 25 M10 1 50 x 30 M10 1 50 x 30 M10 1 25 x 35 M10 1 50 x 35 M12 1 75x 16 M12 1 75 x 20 M12 1 75 x 25 M12 1 75 x 25 M12 1 75 x 30 M12 1 75 x 40 M12 1 75 x 40 M14 1 50 x 25 M14 2 00 x 25 M16 1 50 x 25 M16 2 00 x 25 M16 2 00 x 30 M16 2 00 x 35 M16 2 00 x 40 M16 2 00 x 50 M16 2 00 x 50 M16 2 00 x 60 M18 2 50 x 50 M18 2 50 x 60 Pan Head Machine Screws M7985A 03010 20 M7985A 0301 2 20 M7985A 04020 20 M7985A 05010 20 M7985A 0501 2 20 M3 0 50 x 10 M3 0 50 x 12 M4 0 70 x 20 M5 0 80 x 10 M5 0 80 x 12 Flat Head Machine Screws M965A 05016 20 M5 0 80 x 16 Part No Hex Nuts M934 03 50 M934 04 50 M934 05 50 M982 05 80 M6923 06 80 M934 06 64 M982 06 80 M6923 08 80 M934 08 60 M982 08 80 M6923 10 80 M982 10 80 M6923 12 80 M982 12 80 M982 14 80 M6923 16 80 M982 16 80 M982 18 80 M934 20 80 M982
41. 6137 5 03 Appendix A 5 Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Hex Head Bolts Grade 5 X 465 17 X 465 6 X 465 2 X 465 16 X 465 18 X 465 7 X 465 8 X 465 9 X 465 10 X 465 11 X 465 12 X 465 14 X 465 21 X 465 25 X 465 20 X 125 33 X 125 23 X 125 3 X 125 31 X 125 5 X 125 24 X 125 34 X 125 25 X 125 26 230578 X 125 29 X 125 27 X 125 28 X 125 22 X 125 32 X 125 35 X 125 36 X 125 40 X 125 43 X 125 44 X 125 30 X 125 39 X 125 38 X 6238 2 X 6238 10 X 6238 3 X 6238 11 X 6238 4 X 6238 5 X 6238 1 X 6238 6 X 6238 17 X 6238 7 X 6238 8 X 6238 9 X 6238 19 X 6238 12 X 6238 20 X 6238 13 X 6238 18 X 6238 25 Dimensions 1 4 20 x 38 1 4 20 x 50 1 4 20 x 62 1 4 20 x 75 1 4 20 x 88 1 4 20 x 1 00 1 4 20 x 1 25 1 4 20 x 1 50 1 4 20 x 1 75 1 4 20 x 2 00 1 4 20 x 2 25 1 4 20 x 2 75 1 4 20 x 5 00 1 4 28 x 38 1 4 28 x 1 00 5 16 18 x 50 5 16 18 x 62 5 16 18 x 75 5 16 18 x 88 5 16 18 x 1 00 5 16 18 x 1 25 5 16 18 x 1 50 5 16 18 x 1 75 5 16 18 x 2 00 5 16 18 x 2 25 5 16 18 x 2 50 5 16 18 x 2 75 5 16 18 x 3 00 5 16 18 x 4 50 5 16 18 x 5 00 5 16 18 x 5 50 5 16 18 x 6 00 5 16 18 x 6 50 5 16 24 x 1 75 5 16 24 x 2 50 5 16 24 x 75 5 16 24 x 2 00 5 16 24 x 2 75 3 8 16 x 62 3 8 16 x 75 3 8 16 x 88 3 8 16 x 1 00 3 8 16 x 1 25 3 8 16 x 1 50 3 8 16 x 1 75 3 8 16
42. 7 5 03 10 2 Generator Alternator Reassembly Note See Section 1 5 for specified torque values Engine and Rotor Hub Installation 1 To reinstall the engine rotor hub at the flywheel tighten the four M8 x 35 screws at the specified torque see section 1 5 with a 13 mm socket wrench See Figure 10 17 Figure 10 17 Engine Rotor Hub Rotor Installation 1 Apply antiseize compound to the keyed end of the rotor shaft 2 Guide the rotor on the alternator through stud and push it towards the flywheel See Figure 10 18 Note To prevent the rotor from falling screw without tightening the 27 mm nut of the seawater pump shaft on the rotor through stud TP 6137 5 03 Figure 10 18 Rotor Replacement Stator Housing Installation 1 Guide the stator housing towards the engine flywheel housing as far as possible An O ring in the bearing seat hole stops it Ensure that the holes of the fixing stator housing screws M10 x 140 are aligned with the screws of the engine flywheel housing Using a light uphand hammer turn the stator housing towards the engine flywheel until it enters and the stator housing rear side supports the rotor bearing See Figure 10 19 Figure 10 19 Stator Housing Replacement 4 Screw without tightening the four M10 x 140 stator housing screws with a 17 mm socket wrench See Figure 10 20 Section 10 Generator and Engine Disassembly Reassembly 61 Figure 10 20 Stator Housi
43. 8 da dd ld dd E he 3 1 5 Torque Specifications dorioci dica Sede ii ia 4 Section 2 Operation ai a odia 5 2 1 Prestar Checklist vomita ds 5 2 2 Marine Inspection oooccccocccccncconcc tte nee 5 2 3 Angular Operation seren iis Sande ado ido 5 2 4 Operation in European Union Member Countries 0c eee 5 25 Exercising the Generator Set 0 00 cece eect cette eens 6 2 6 Starting and Stopping Procedure 0 0 cece eee eee teens 6 2 6 1 Controls and Indicators 0 0 ccc eet eet teens 6 2 6 2 Starting the Generator Set 0 00 ccc eect eee 7 2 6 3 Stopping the Generator Set 00 cece 7 2 6 4 Engine Safety Shutdown Switches 0 eee eee 7 2 6 5 Circuit Protection 0 emee ia n a eens 8 27 Remote Panel Kits toc coi a 8 2 7 1 Remote Start Stop Panel Kit 0 eee eee eee eee 8 2 7 2 Remote Panel Kit nosiris asrida eka cece teas 8 Section 3 Scheduled Maintenance ccc cece eee eee eens 9 Sel O A RR 9 3 2 Service Schedule 3 5EFOZ and 4EOZ Models ooocccccccccccoo 10 3 3 Lubrication System o ooooooccoooocono rr 12 3 3 1 Oil Specifications ooooooooooocoror aaa aaa EE 12 33 2 OMGheck arta dias lc tilda 12 33 39 A dike Leet ad Uae dddh Whee decries 12 3 4 Battery succor kei dai a eda a4 14 3 5 Generator Storage Procedure 0 00 cece rnanan 15 3 5 1 Lubricating System
44. A The electric fuel flows to the injection S pump FP refills the Pump fuel supply line Engine battery charger regulator The generator set starts The starting R cycle is completed The low oil pressure switch LOP contacts open The generator set starts Figure 8 1 Generator Set Starting Cycle TP 6137 5 03 Section 8 Controller Troubleshooting 41 8 1 General The following section covers the controller troubleshooting procedure Refer to Figure 8 2 to identify the controller components EY Hour Meter On Off Z Oilpress N 2 Engine N 2 Exhaust S 15 Control panel Hourmeter On off switch Start switch K2 relay Green red oil pressure K3 relay LEDs Engine voltage regulator Green red engine water Electrical connection plate temperature LEDs Harness control box to Green red exhaust engine connector temperature LEDs Harness control box to STD Control box panel connector 25 amp fuse 10 amp fuse Bridge rectifier K1 relay Figure 8 2 Controller Internal Components 42 Section 8 Controller Troubleshooting 8 1 1 On Off Switch After pressing the On Off switch on the control panel local or remote two green LEDs and one red LED oil engine light This operation energizes the control panel and permits DC to the K2
45. 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 Check for 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 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 thatthe carbon monoxide detector s is 1 in the craft 2 functional and 8 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 TP 6137 5 03 Section 2 Operation 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
46. G Remote start stop switch On Off 777 7 OANOOBRWN Figure 8 3 Control Panel 44 Section 8 Controller Troubleshooting TP 6137 5 03 8 3 Operation Sequence Use the following controller operation sequence to help repair is needed be sure to disconnect the battery localize and control possible inconveniences Follow Consult the safety precautions in the beginning of this the wiring diagram sequence shown in Section 10 Ifa manual 3 5EFOZ 4EOZ Kohler generator starting operation By the operator E By the separate control Push the ON OFF switch The panel control energizes Push the START switch The relay K1 is energized The relay K2 is energized The starter motor solenoid S is The battery charging voltage energized regulator VR is excited The electric fuel pump FP is The stop solenoid FS is energized energized and opens Fuel flows to the pump AC is supplied for the load and for the static exiting circuit The unit operates AC energizes the relay K3 that The engine alternator charges disconnects the starter the battery The engine speed opens the low The relay K1 is deenergized oil pressure switch LOP contacts and avoids stopping the engine The unit operates because the Release the START switch The High Cylinder Head Temperature gener
47. Service Marine Generator Sets Includes Engine Maintenance Models NATIONALLY REGISTERED KOHLER POWER SYSTEMS war ses 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 001a Table of Contents Product Identification Information 0 cece eee eee eee eee eee Inside front cover Safety Precautions and Instructions 0c c cece eee eee eee eee eens l Introd ctioi ii ices acisre rd tie aeni aT AAA AA DEEA i Service ASSISTANCE A aaa eaa a e dives crete E ENE E Aaa Ea EEA tes i Section 1 Specifications 2 ssswrrissus sia sawi eee et ee ee eee eee dee eee eee ew ees 1 Mali General o a e Mea er Ns Micah sa ane Se ee 1 112 Generator it A ee ee A da 1 123 Service VIEWS a Ad is 2 AAS HENQING 22
48. The governor is installed at the crankshaft and turns with similar speed If the engine operates with a decreasing load the engine speed will increase The centrifugal force spreads the governor weights and its pin pushes the tappet bolt of the inner control lever It pivots on the eccentric shaft so that the injection pump pin moves towards the position for lower fuel supply rate During conditions with less fuel the engine speed decreases the governor pin returns to its hole and the inner control lever moves the injection pump pin towards the position for higher fuel supply rate to increase the engine speed Consequently the engine speed has permanent oscillations but these are so small that only a very sensitive revolution meter could detect them Section 5 Fuel System 27 5 Screw the taplet bolt completely until it rests on the inner control lever 6 Insert a screwdriver between the flyweights and force them apart to the maximum opening See Figure 5 19 7 Turn the taplet bolt until it contacts the governor pin Note No play should be felt when pushing the inner control lever with the hand 8 Release the flyweights and turn the taplet bolt a half turn further Injection pump Control lever Taplet bolt Inner retainer ring Ratchet plate Accelerator lever Eccentric shaft Figure 5 17 Speed Controller Shaft Assembly Components Governor and Speed Controller Shaft Adjustment If the governor or the
49. and outer water tubes from the seawater pump housing loosen the three Seawater Pump Cover Removal M5 x 40 socket screws with a 4 mm setscrew wrench 1 Using a 7 mm socket wrench release the four M4 x 8 screws from the seawater pump cover See 2 Remove the housing from the alternator Figure 10 6 Note Remove the entire seawater pump every time alternator disassembly is required in order to check electrical components 1 Seawater pump housing Figure 10 6 Seawater Pump Cover Removal Figure 10 8 Seawater Pump Housing Seawater Pump Impeller Removal 1 Carefully remove the seawater pump impeller from its housing See Figure 10 7 58 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 1 M10 x 140 Screws qty 4 Figure 10 11 Disconnect the Alternator 3 Release the two M8 nuts from the vibromounts 1 Cover for field diode and rotor inspection using a 13 mm socket wrench 2 Stator housing alternator Seawater puMpetial 4 Using a hoist hook the stator bracket and lift the 4 Vibromount nut 5 Alternator bracket alternator to release the vibromount bolts from the alternator bracket Figure 10 9 Alternator Components 5 Install a jawpuller with three M5 threaded screws Engine and Stator Housing Disconnection into the seawater pump housing holes See Figure 10 12 1 Using a 27 mm socket wrench unscrew the seawater pump shaft nut See Figure 10 10 Figure 10 12 Jawpuller Installatio
50. at holds the camshaft in the gear cover 2 Using a driver press out the camshaft See Figure 10 46 Figure 10 46 Camshaft Camshaft Gear 1 Remove the gear from the camshaft using a puller or by pressing it off from the shaft See Figure 10 47 Figure 10 47 Camshaft 70 Section 10 Generator and Engine Disassembly Reassembly Camshaft Bearing 1 Remove the camshaft s ball bearing from inside of the gear cover by using a socket pushed with a hydraulic press See Figure 10 48 Figure 10 48 Camshaft Bearing TP 6137 5 03 Speed Control Shaft Governor 1 Put the gear cover on the work bench 1 Install a holding device and remove the governor pin See Figure 10 50 2 Using a pliers remove the inner retainer ring from the eccentric shaft 2 Spread the flyweights with a sturdy driver 3 Pull the eccentric shaft towards the outer side of the 3 Use a socket wrench to unscrew the governor gear cover so that the fuel pump pin is released Note The governor has a left hand thread Unscrew A WARNING the governor in a clockwise direction Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place 4 Carefully using a pliers unhook the outer torsional return spring from its boss 5 Hold the inner control lever and turn down the accelerator lever until the inner torsional return Figure 10 50 Governor spring releases i
51. ator set is operating HCHT and High Exhaust because the relay K2 is Temperature HET contacts that energized by the control panel are normally opened are still opened together with the low oil pressure switch LOP contacts Figure 8 4 Starting Operation TP 6137 5 03 Section 8 Controller Troubleshooting 45 4EOZ 3 5EFOZ Kohler generator stopping operation The unit stops due to High l Cylinder Head Temperature The operator stops the unit local The unit stops due to a Low Oil HCHT or High Exhaust or remote Pressure LOP condition Temperature HET condition The high temperature contacts The low oil pressure deenergizes the relay K2 Push the ON OLR switch deenergizes the relay K2 The electric fuel pump FP and The electric fuel pump FP and z the stop solenoid FS are The relay K2 is deenergized the stop solenoid FS are deenergized and the unit stops deenergized and the unit stops Check the unit for causes of the pc a gt Check the unit for causes of the high temperature failure deenergized low oil pressure failure The unit stops Release the ON OFF switch Figure 8 5 Stopping Operation 46 Section 8 Controller Troubleshooting TP 6137 5 03 8 4 Troubleshooting Use the following flowcharts as an aid in troubleshooting replace the control panel Consult the saf
52. ault shutdown Check the shutdown switches Out of fuel Replenish fuel supply Fuel shut off valve closed Open the fuel shut off valve Inoperative fuel feed pump Replace the fuel feed pump Clogged fuel filter Service the fuel filter element Air in the fuel system Bleed the air Water or dirt in the fuel system Drain and flush the fuel system Dirty or faulty fuel injectors Contact your local Kohler generator set distributor for service Incorrect compression Contact your local Kohler generator set distributor for service Incorrect fuel type Use the correct fuel type Consult the fuel supplier temperature Incorrect lube oil type for ambient Use the correct lube oil Faulty fuel solenoid Replace the solenoid Air intake screen clogged Clean or replace Faulty ground connection Clean and retighten Weak or dead battery Recharge or replace Engine malfunction Contact your local Kohler generator set distributor for service Engine starts but does not continue to run after start switch is released switch es Inoperative high exhaust temperature HET low oil pressure LOP and or high shutdown switch es water temperature HWT shutdown Check the HET LOP and or HWT No low oil pressure Check the oil pressure and pump TP 6137 5 03 No generator output voltage Ch
53. awater Pump and Impeller 0000 cece cece eee 32 6 4 Siphom Break ici a dd 33 6 5 Anticorrosion Zinc Anode 0 eee eet tte 35 Section 7 Troubleshooting vicio aaa 37 FA General Siete iti hadi den baled oo idl eo ok fo eo he elo dle add 37 Section 8 Controller Troubleshooting oooccccccoccnnnnn eee eee eee eens 41 8 General aa td et ead as ae le Le cae e he Ro alg Dd reg a 42 8 1 1 On Off Switch isra men eea denara ence eee teen enna 42 Silke E 42 8 1 3 FRU Sivan e ek Shree a ne teat eisai tent a il abe 42 8 1 4 On Off Switch Stop 0 0 eee eee nes 42 8 2 Engine Safety Shutdown Switches 0 00 c eee 43 8 2 1 Low Oil Pressure LOP Shutdown 00 cece eee eee eee 43 8 2 2 High Water Temperature and High Exhaust Temperature Shutdown Switch 0 0 eects 43 8 3 Operation Sequence i oara a eee e et et nn eens 45 8 4 Troubleshooting 0 00 cece ett tee eens 47 Section 9 Generator Troubleshooting 0c cece cece eee eee eee eee eens 51 G4 General inmi Seite Hud ee tee eos eae leeds 51 9 2 Theory of Operation Brushless Generator Sets 0 0 cece cece eens 52 9 3 Output Voltage and Frequency 000 cece ccc eet eens 52 9 3 1 Voltage Rating and Rotation Speed 000 c eee eee 52 9 3 2 Bearing fk he eee bd o eed ij ee eae 52 94 Rotor lest iccch nina a a ee a 53 9 54 Fleld DIOdCHESt cue ss et ia ghee ee rd a
54. 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 Safety Precautions and Instructions V Notes VI Safety Precautions and Instructions TP 6137 5 03 This manual provides troubleshooting and repair instructions for 4EOZ 3 5EFOZ model generator sets Refer to the engine service manual for generator set engine service information x in 001 001 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 Introduction Read this manual and carefully follow all procedures and sa
55. button pulled down The engine s output power is dependant upon the position of the upper conical surface of the excess fuel button in the gear cover The shorter its insertion in the gear cover the more fuel arrives at the injector The longer its insertion in the gear cover the less fuel arrives at the injector Note The units output power with the correct adjustment of the excess fuel device is factory set Do not alter its setting However if the excess fuel device and or gear cover are removed or replaced the high rate of supplied fuel at the injector must be readjusted on the test bench 1 Conical surface of the excess fuel starting device 2 Yoke of the inner control lever 3 Pin of the fuel injection pump Figure 5 9 Excess Fuel Start Device Button Section 5 Fuel System 23 5 6 The Injection Pump s Fuel 4 To locate the injection pump s fuel starting delivery z point put the accelerator lever in the higher speed Starting Delivery Point position and keep the inner control lever in the For proper engine operation ensure the correct higher fuel rate position adjustment of the fuel starting delivery point As the fuel Note In order for fuel to reach the injection pump pump timing is fixed check or readjust it only when perform this check with the fuel solenoid valve altering engine speed installing a new injection pump and the electric fuel pump energized or replacing the camshaft or gear cover 5 En
56. cal L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft8 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 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 ms cubic 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 NPTF NR ns oc OD OEM OF opt OS OSHA OV oz p Pp PC 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 micr
57. cifications Nm ft Ibs 4E0Z 3 5EFOZ Cylinder head nuts 30 33 22 24 5 Connecting rod nuts 30 33 22 24 5 Valve cover nuts 8 12 6 9 Main bearing plate nuts 30 33 22 24 5 Fuel pump nuts 30 33 22 24 5 Delivery valve holder fuel pump 34 39 25 29 High pressure fuel pipe nut fuel pump 18 22 13 5 16 High pressure fuel pipe nut injector 25 30 18 5 22 Injector clamp nuts 8 12 6 9 Governor on crankshaft 55 60 40 5 44 5 Flywheel nut 216 226 159 5 166 5 Gear cover screws 34 38 25 28 Tappet block screws 8 10 6 7 5 Oil pump screws 16 20 12 15 Oil cooler screws 9 11 6 5 8 Banjo bolt on fuel pump 25 35 18 5 26 Body injector nut 25 30 18 5 22 Starter screws 20 15 Flywheel rotor hub nuts 25 18 5 Nut fixing the rotor 25 18 5 Stator screws 30 22 Alternator bracket screws 50 37 Engine bracket screws 50 37 4 Section 1 Specifications TP 6137 5 03 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 Inlets Check for clean and unobstructed air inlets Air Shrouding Check for securely installed and positioned air shrouding
58. ct your local Kohler generator set distributor for service Incorrect fuel injection timing Contact your local Kohler generator set distributor for service Low engine temperature Check the thermostat Incorrect compression Contact your local Kohler generator set distributor for service Fuel leakage Check for leaks at the fuel tank lines and engine fuel system Unit is noisy Exhaust system leak Check the exhaust system Exhaust system not securely installed Check for loose parts Broken or damaged vibromounts Check the vibromounts No installation clearance Units hits the craft structure or compartment Check the clearance No compartment sound insulation Install approved insulation Excessive vibration Contact your local Kohler generator set distributor for service Loose or vibrating sheet metal Tighten all bolts Abnormal noise Worn or inoperative bearing or gear Contact your local Kohler generator set distributor for service Loose bolt or screw Tighten the hardware Low lube oil level Add lube oil Battery will not charge Loose or corroded connections Clean and tighten connections Sulfated or worn battery connections Check the electrolyte level and specific gravity batteries with filler caps only Inoperative battery charging system Check the charging system Battery charging
59. d under the intake valve spring Figure 10 34 Valve 66 Section 10 Generator and Engine Disassembly Reassembly Replacing the valve guides 1 If valve guide replacement is necessary use the proper driver and press out the old guides from the head See Figure 10 35 Figure 10 35 Valve Guide Replacing the seats The cylinder head is equipped with two valve ring seats of wear resistant steel Consult the engine service manual and the following procedure if the head seats are so worn that a grinding valve rework will not ensure a good gas proof Use a valve seat cutter if a surface rework is needed 1 Insert the guide pin into the valve guide 2 Rotate the cutting surface of the T handled tool applying light pressure to touch the ring seat See Figure 10 36 Note Do not cut too deep or use grinding compound Observe the allowable valve recess To check the sealing valves 1 Put the sealing valves in their guides 2 Install the springs and fill the intake exhaust openings on the head with a small amount of diesel fuel oil 3 A good valve seal occurs when the diesel fuel oil leaks about 2 drops per minute TP 6137 5 03 Figure 10 36 T Handle Tool Tappets block 1 Release the two push rods by loosening the two hex cap screws and removing them from the upper surface of the gear case See Figure 10 37 Figure 10 37 Gear Case TP 6137 5 03 Cylinder 1 Rotate the flywheel until the piston reaches th
60. d Wear Part Description Dimensions Original Max Limit Max mm in Min mm in mm in Cylinder Liner Bore upper diameter below diameter Note It is not possible to rehone the liner because of the conical shape We always suggest to exchange the cylinder together with the piston and rings 81 900 3 2244 82 030 3 2295 81 880 3 2236 82 010 3 2287 82 000 3 2283 82 130 3 2335 Piston Crown diameter 18t compression ring groove height 2nd compression ring groove height Oil scrapper ring groove height Diameter of the piston pin hole Clearance between groove 1t comp ring height groove 2 comp ring height groove oil scrapper ring height 18t and 29 compression ring gaps oil scrapper ring gap Note The excessive clearances or gaps are because of the abnormal wears of the cylinder liner piston and rings We always suggest to exchange the cylinder together with the piston and rings 81 967 3 2270 2 120 0 0835 2 070 0 0815 4 040 0 1591 22 010 0 8665 0 145 0 0057 0 092 0 0036 0 065 0 0026 0 500 0 0197 0 500 0 0197 81 953 3 2265 2 100 0 0827 2 050 0 0807 4 020 0 1583 22 04 0 8663 0 110 0 0043 0 060 0 0024 0 030 0 0012 0 300 0 0118 0 250 0 0098 0 170 0 0067 0 140 0 0055 0 110 0 0043 1 000 0 0394 1 000 0 0394 Crankshaft Journal diameter D1 Journal diameter D3 Journal diameter D2 Jour
61. d the capacitor As current in the stator main winding increases with the load additional current is induced in the rotor field to supplement the current being supplied by the stator auxiliary winding The generator cannot be disconnected or removed from the engine as a single unit 9 3 Output Voltage and Frequency The 3 5EFOZ model generator set supplies 230 volts at 50 Hz while the 4EOZ model supplies 120 240 volts at 60 Hz in accordance with the preselected winding connection and engine speed 52 Section 9 Generator Troubleshooting 9 3 1 Voltage Rating and Rotation Speed Always check the generator set s output voltage at the nominal speed rotation The alternators are preset at the factory to supply voltage slightly higher 5 6 than the voltage at the nominal engine speed rotation The difference between the engine rotation and the nominal one can cause slight deviation of output voltage Keep in mind that the output voltage varies proportionally to the rotation speed If requiring output voltage correction of the generator set at a defined rotation vary the capacity of the excitation capacitor By increasing or decreasing the capacity value of the capacitor voltage changes Note Do not operate the generator set with voltages that deviate more than 10 of the nominal speed rotation 9 3 2 Bearing The alternator s rear bearings are self lubricating and do not require maintenance for 10 000 operating hours Re
62. ditions of 25 C 77 F and pressure of 98 9 kPa 29 2 in Hg dry barometer ISO 3046 and ISO 8528 1 include reference conditions and output calculations Obtain technical information bulletin TIB 101 on ratings guidelines for complete ratings definitions Generator Model 4EOZ 3 5EFOZ Dimensions mm in Length 560 22 05 Width 390 15 35 Height 490 19 29 Weight kg Ibs 209 5 95 0 Air requirements combustion L min cfm 436 15 4 363 12 8 Fuel consumption Lph gph at load 25 0 64 0 17 0 60 0 16 50 1 02 0 27 0 96 0 25 75 1 36 0 36 1 28 0 34 100 1 70 0 45 1 60 0 42 Generator type 2 pole rotating field Coupling type Tapered hub Excitation type Brushless exciter Shaft RPM 3600 3000 Number of output leads 4 2 Voltage regulation model Capacitor type Voltage regulation 5 Frequency regulation 3 Voltage 120 230 Amps 25 C 77 F 29 2 14 6 13 9 kW kVA 25 C 77 F 3 5 3 2 Phase Hz 1 60 Hz 1 50 Hz Cold main field rotor resistance ohms 2 57 Cold stator resistance ohms 1 2 0 96 1 23 3 4 0 96 C1 C2 2 32 2 87 10 11 0 068 0 091 TP 6137 5 03 Section 1 Specifications 1 1 3 Service Views Figure 1 1 2 OMNOTARWN Service Side View Shown without sound shield doors and panels
63. e Bottom Dead Center BDC so that the studs are a guideline to remove the cylinder from the crankcase See Figure 10 38 Note If the repair does not require replacing the piston or liner keep the liner on the piston Lift up the liner enough so that the piston pin hole is free Continue with the following step Figure 10 38 Cylinder Section 10 Generator and Engine Disassembly Reassembly 67 Piston 2 Move the flywheel until the piston reaches the Bottom Dead Center BDC of its stroke 1 Rotate the flywheel until the piston reaches Top Dead Center TDC 3 Loosen the six hex cap head screws of the oil R cooler housing and remove it from the engine If 2 Using a needle nose pliers remove the piston pin the screws are tight tap them with ahammer anda retainer from the groove in the piston See flat faced punch to loosen them See Figure 10 39 Figure 10 41 4 Using a 13 mm socket wrench unscrew the two connecting rod nuts Pull the connecting rod cap downwards while pushing the connecting rod upwards See Figure 10 42 5 If the two half shells of the connecting rod need to be reinstalled mark them so that proper repositioning occurs during reassembly Figure 10 39 Piston 3 Gently push the piston pin out of the piston from the flywheel side See Figure 10 40 Note If the piston pin sticks in the piston remove the piston together with the connecting rod Remove the assembly from the engine and hamm
64. e 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 6 Section 2 Operation 2 6 1 Controls and Indicators The following table describes the controls and indicators located at the controller See Figure 2 2 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 b
65. e more frequent replacement See Figure 6 7 for the location and use the following procedure 1 Seawater pump 2 Water cooled alternator 3 Anticorrosion zinc anode seawater drain Figure 6 7 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 6 8 and Figure 6 9 TP 6137 5 03 Anticorrosion Zinc Anode Replacement New Anode Dimensions mm in Replace When Percent of Zinc Remaining Is lt 50 of length diameter Figure 6 8 Anticorrosion Zinc Anode Plug Measurements i 10 0 39 x 20 0 79 AX gt 1 Diameter 9 5 mm 0 375 in 2 Length 19 05 mm 0 75 in Figure 6 9 Anticorrosion Zinc Anode Plug 4 lf 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 Refill the seawater cooling system 7 Start the generator set and check for leaks at the anticorrosion zinc anode location The pump is operat
66. e use a Wheatstone bridge See Figure 9 5 See Figure 9 6 for resistance values Figure 9 5 Rotor Resistance Test Model Resistance in Ohms at 20 C 68 F 2 57 10 2 57 10 4EOZ 60 Hz 3 5EFOZ 50 Hz Figure 9 6 Rotor Resistance Values 9 5 Field Diode Test Check the rotor s field diodes using a multimeter Disconnect the field diodes from the rotor and check the forward and reverse resistance A good diode performance is indicated with a very high resistance in the reverse direction and a low resistance in the forward direction See Figure 9 7 A failed diode gives a full deflection reading in both directions with the ohmmeter on 10 000 Ohms or an infinity reading in both directions 54 Section 9 Generator Troubleshooting Figure 9 7 Field Diodes and Varistors Test Failed Diodes Replacement The rectifier assemblies are two sets of diodes and two varistors one for each rotor winding Take care to ensure that each diode is installed with the correct polarity 1 Check that the arrow on the diode surface direct towards the fixing plate 2 Check that the wire end with the eye terminal is located between the diode and the fixing plate The other winding end must be welded at the upper part of the diode 3 While fitting the diodes at the plate carefully tighten the nuts to ensure good mechanical and electrical contacts Surge Suppressor The surge suppressor is a metal oxide varistor
67. e the diagram below 3 Follow these SAE washer rules after determining exit hole type a Always use a washer between hardware and a slot b Always use a washer under a nut see 2 above for exception c Use a washer under a bolt when the female thread is fixed weld nut 4 Refer to the diagram below which depicts the preceding hardware configuration possibilities L l 9 Ag a 4 Cap screw Entry hole types Standard nut and SAE washer Whiz nut or spiralock up to 1 2 in dia hardware Weld nuts above 1 2 in dia hardware Exit hole types Figure 2 Acceptable Hardware Combinations Appendix A 3 Appendix C General Torque Specifications Use the following torque specifications when service oiled threads Increase values by 15 for nonplated literature instructions give no specific torque values threads All torque values are 0 10 The charts list values for new plated zinc phosphate or American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel assembled into Torque Aluminum Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5 Z Z 2 Z zZ 2 z 33533353 o DAA 2222 333333333333333 Z 3 108 138 154 191 216 338 378 Zz 33 DE A E A 3 23 3 333 nee a ipaa XT OY Assembled into Aluminum Size mm Grade 5 8 Grade 8 8 Grade 10 9 Grade 5 8 or 8 8 Assembled into Cast Iron or Steel
68. eck the AC voltage Section 7 Troubleshooting 37 Problem Possible Cause Corrective Action Stops suddenly Out of fuel Replenish fuel supply Air intake clogged Service the air intake screen Circuit breaker tripped in the controller Reset the circuit breaker Inoperative seawater pump impeller Replace the impeller Clogged seawater strainer Clean the strainer Fuel line restricted Check the fuel lines and the fuel tank Dirty fuel filter Clean the fuel filter No low oil pressure Check the oil pressure and pump High temperature Check the engine cooling system Inoperative high exhaust temperature HET low oil pressure LOP and or high water temperature HWT shutdown switch es Check the HET LOP and HWT shutdown switch es Loss of AC output Contact your local Kohler generator set distributor for service Operates erratically Air intake clogged Service the air intake screen Stale or bad fuel Replace the fuel Clogged fuel filter Service the fuel filter Vent in fuel tank cap obstructed Clean the cap in solvent blow dry Water dirt or air in the fuel system Drain flush fill and bleed air in the system Dirty or faulty injectors Contact your local Kohler generator set distributor for service Faulty governor link Contact your local Kohler generator set distributo
69. el pump pin in a position for lower fuel supply Loosening both cross slot nuts decrease engine speed because the governor pin pushes the control lever towards the position for lower fuel supply A half turn 180 of both cross slot nuts generally change the engine speed 50 RPM Note Keep the cross slotted nuts at least on the flat end of the stud bolt Otherwise the nuts self securing effect will not work Normally the stud bolt protrudes out of the cross slotted nuts For larger speed variations replace the governor springs Replace the cross slotted nuts whenever unscrewing a nut Check every engine speed modification in a controlled environment on a test bench or with a revolution counter TP 6137 5 03 Accelerator Lever The accelerator lever is fixed by its hole at the pin of the eccentric shaft The ratchet plate is installed with its slot at the eccentric shaft pin and kept in place with an 8 mm nut As the ratchet plate spring is used as a buffer for engine deceleration it holds the accelerator lever in the higher engine speed position the correct adjustment between the accelerator lever and the ratchet plate is very important Perform this adjustment leaving a half notch of the plate visible See Figure 5 21 If an incorrect adjustment is achieved and more notches are visible a manual engine stop operation may be obstructed because the accelerator lever touches the lower stop notch on the crankcase without cut
70. emove any oil or grease from the threaded hole of the crankshaft and governor screw Apply a thin film of Loctite No 270 or equivalent on the governor screw threads Note The governor screw has left hand threads To correctly install the governor ensure that the governor flyweights have spread entirely and that the socket wrench holds the entire head of the governor screw Tighten the screw at the specified torque value and remove the holding device See Section 1 5 Figure 10 67 Governor TP 6137 5 03 Connecting Rod 4 To install new bearing shells take a half shell and place it about 3 4 into the connecting rod cap Using a sliding movement press the shell in its seat until the lip goes into its relief Note Avoid touching scratching the connecting rod bushing Repeat this procedure for the other half shell to be placed in the connecting rod trunk Find the casting numbers located on the connecting rod trunk and cap surfaces See Figure 10 68 Similar numbers identify connecting rod parts that are matched together The connecting rod assembly must contain the two parts with similar numbers Lubricate the bearing shells Drive the connecting rod trunk and its cap in the crankcase around the crankshaft journal See Figure 10 69 Note The stamped numbers must be aligned on the 7 same side of the connecting rod but it is not important which engine side flywheel or gear cover
71. er out the piston pin Figure 10 40 Piston Figure 10 42 Connecting Rod Nuts Connecting Rod 1 Lay the engine on its flywheel side on a work bench 68 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 Gear Cover 1 Remove the six hex cap head screws to remove the gear cover If necessary tap the cover with a soft faced hammer to remove it See Figure 10 43 2 If during cover removal the cover catches on the governor move the flywheel to release the governor s cover Do not disassemble or remove the gear cover any further unless necessary Otherwise modifications to the delivery start of the fuel pump gear timing adjustment and the engine speed values may be required Figure 10 43 Gear Cover 3 If disassembly of the injection pump camfollower camshaft camshaft gear or camshaft bearing is necessary proceed to the following sections Injection Pump 1 Remove the two hex nuts of the injection pump and remove the pump from the gear cover Note To avoid losing the shims or the gasket reinstall them on the cover and reinstall the washers and nuts See Figure 10 44 TP 6137 5 03 Figure 10 44 Injection Pump Removal Camfollower 1 To remove the camfollower unscrew the screw shown in Figure 10 45 through the oil filling hole 1 Screw Figure 10 45 Camfollower Section 10 Generator and Engine Disassembly Reassembly 69 Camshaft 1 Release the snap ring th
72. eration 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 package 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 ge
73. ety the main control panel and the entire generator set If precautions in the beginning of this manual the prescribed remedy does not correct the problem Push the on off switch local or remote y Are the two green LEDs and Does the the red LED oil pressure lit Push the start switch local engine or remote on the control panel crank No v Is the 12 DC voltage present on the coil of the K1 relay Change the fuse Y Y Yes Y Is current present on the terminals of the solenoid S of the starter engine ii No y Check the 0 63 amp fuse on the control panel Check the conditions ofthe battery connections Check the conditions ofthe P1 connections 7 GND Check the conditions ofthe TB1 connections 7 GND Check the conditions ofthe P3 connections 7 GND Check the conditions ofthe 1 2 connections on the terminal board of the control panel Are these checks okay Check the conditions ofthe K1 connections 5 GND Check the conditions ofthe K3 connections 5 Check the conditions ofthe TB1 connections 5 GND Check the conditions ofthe P3 connections 5 GND Check the conditions ofthe 2 6 connections on the terminal board of the control panel Reset the failed connections to energize the coil of the K1 relay Check the conditions ofthe S connections 9 GND Check the co
74. fety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are important for safe and efficient operation Inspect the parts often and perform required service at the prescribed intervals Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service x in 001 003 Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPowerSystems com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e 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 TP 6137 5 03 China North China Regional Office Beijing Phone 86 1
75. g Connecting rod material Aluminum Governor Centrifugal mechanical Bore x stroke mm in 82 x 55 3 23 x 2 17 Displacement L cu in 0 29 17 7 Compression ratio 20 1 Horsepower 60 50 Hz 5 9 5 6 RPM 60 50 Hz 3600 3000 Direction of rotation as viewed from generator end Counterclockwise Lubrication system Pressure trochoid pump Lube oil capacity w filter L qts 1 25 1 32 Oil recommendation API CD CD CC or CC Fuel injection timing BTDC 22 22 5 17 18 5 Fuel injection pressure bar psi 200 2900 Combustion system Direct injection Battery voltage 12 volt negative ground Battery recommendation min 500 CCA 100 amp hr Battery charging alternator 15 amps 12 volts Fuel recommendation Diesel DIN 51601 ASTM D 975 67 ID 2D BS 2869 1967 A1 A2 Fuel shutoff solenoid system Electric Fuel feed pump Electric solenoid type Fuel pump priming Electric Max recommended fuel pump lift m ft 0 9 3 Thermostat freshwater seawater 75 C 167 F 50 C 122 F Starter motor 12 volt Intake exhaust valve clearance cold mm in 0 2 0 008 Inlet water line hose ID CEE pump inlet mm in 16 5 8 a ean 51 20 Fuel inlet fuel pump inlet 1 4 NPT Fuel return size type 1 4 NPT TP 6137 5 03 Section 1 Specifications 3 1 5 Torque Specifications Torque Spe
76. ge Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment AC Output a lt Residual magnetism of the rotor starts the process Automatic Exciter Figure 9 1 Alternator and Exciter Diagram TP 6137 5 03 Section 9 Generator Troubleshooting 51 9 2 Theory of Operation Brushless Generator Sets These generator sets use a two pole revolving field alternator The generator set s alternator is a brushless design utilizing capacitor excitation This system does not use brushes slip rings or a voltage regulator In order to obtain generator output the rotor field must be energized and moving The rotor is directly connected to the flywheel by a tapered coupling A ball bearing located in the stator frame holds the rear portion of the rotor The engine moves the rotor field past the stator main winding which induces an AC voltage across the stator leads The rotor core holds enough residual magnetism to produce low AC output from the stator during start up As the generator speed increases the stator auxiliary winding connected to the capacitor leads C1 and C2 induces a voltage on the rotor field winding A diode on the rotor rectifies the voltage to produce DC field current in the rotor AC output is drawn from the stator winding that supplied 12 VDC to the K3 relay start protection and fee
77. gear cover s surface Every thickness of 1 10 mm 0 0040 in under the injection pump increases or decreases the distance between the marks on the flywheel and crankcase by 2 mm 0 78 in Adding or removing shims between the gear cover and the fuel pump s body decreases or increases the distance between the fuel pump flange and the cam of the camshaft Adjust the starting delivery point so that its value is within the above mentioned value Figure 5 12 Flywheel Mark TP 6137 5 03 5 8 Fuel Pump and Gear Cover Installation 1 If replacing one of these parts check the distance between the fuel pump surface on the gear cover and the roller tappet cam follower edge 2 Measure the distance between the parts and add the shim thickness Total distance should be between 57 5 59 1 mm 2 263 2 327 in See Figure 5 13 ra ALIEN AT NII ii and Figure 5 13 Acceptable Distance Note The thickness of the fitted shims under the injection pump is stamped on the front surface of the pump in 1 10 mm 0 004 in e g 15 indicates 1 5 mm 0 0600 in thickness Note The value stamped on the pump is for factory installed fuel pumps Fuel pump or injection timing modifications alter the thickness values Figure 5 14 Stamp Section 5 Fuel System 25 5 9 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 co
78. generator set as follows 1 Press the generator set on off button to shut down the generator set Allindicator 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 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 to a container with 4 L 1 gal of water and mix the neutralizing sol
79. gine stop condition Move the engine in the 1 Move the engine towards the compression stroke counterclockwise direction as viewed from the flywheel and check the drip tube Fuel will flow 2 Puta mark on the flywheel at the 5 o clock position freely and then cease with the piston that is before Top Dead Center TDC 6 Obtain the correct fuel starting delivery point when fob ods A the plunger has reached and closed the injection 3 Remove the injection pump s allen head screw and pump s allen head screw s hole and only a drop of sealing washer from the fuel pump body and install fuel comes out from the tube every second See inits place a drip tube with a sealing washer located Figure 5 11 between the pump and the tube See Figure 5 10 Note Fuel will flow from the pump immediately after loosening the allen screw Figure 5 11 Fuel Drop Figure 5 10 Drip Tube 24 Section 5 Fuel System TP 6137 5 03 5 7 Fuel Pump Adjustment Timing To obtain the correct adjustment timing of the fuel pump use aruler and measure the distance between the mark on the flywheel and the mark on the crankcase when the plunger is in the fuel starting delivery point See Figure 5 12 Acceptable values are between 40 2 mm 1 5748 0 0394 in for 3000 RPM units and 50 1 mm 1 968 0 0394 in for 3600 RPM unit If this value is not obtained readjust the fuel starting delivery point by adding or removing shims between the pump and the
80. he carbon from the cylinder head Improper cooling Inspect the cooling system Fuel line restricted Check the fuel lines Engine overloaded Reduce the load Dirty fuel filter Service the fuel filter Improper valve clearance Contact your local Kohler generator set distributor for service Dirty or faulty injectors Contact your local Kohler generator set distributor for service Incorrect fuel injection timing Contact your local Kohler generator set distributor for service Improper engine compression Contact your local Kohler generator set distributor for service Vent in fuel tank obstructed Clean the cap in solvent blow dry Overheats Improper cooling Check the intake and outlet openings Check the raw water strainer Inoperative thermostat Replace the thermostat Air intake clogged Service the air intake screen Engine overloaded Reduce the load Cooling system need flushing Flush the cooling system Inoperative temperature switches Replace shutdown switches Cooling water leaks from the water passage Check the water passage Engine emits black or gray exhaust smoke Incorrect fuel type Use correct fuel Clogged or dirty air intake screen Service the air intake screen Inoperative injection pump Contact your local Kohler generator set distributor for service Faulty
81. ing if the cooling water flows from the exhaust outlet If water is not discharging at the exhaust outlet see Section 2 Prestart Checklist Seawater Pump Priming in the operation manual Section 6 Cooling System 35 Notes 36 Section 6 Cooling System TP 6137 5 03 Section 7 Troubleshooting 7 1 General When troubles occur do not overlook simple causes Improper fuel or an empty fuel tank could cause a starting problem The following charts indicates some common problems Consult the safety precaution section of this manual before servicing the generator set If the procedures in this manual do not explain how Problem Unit will not crank Weak or dead battery Possible Cause to correct the problem bring the generator set to an authorized Kohler distributor or dealer Tell the distributor or dealer exactly what happened when the problem occurred and any adjustments made to the generator set Corrective Action Recharge or replace the battery Poor ground Reversed or poor battery connections Check the connections Circuit breaker tripped in the controller Reset the circuit breaker Inoperative start stop switch Check function replace as necessary Inoperative starter solenoid Check the starter solenoid and wiring Replace as necessary Inoperative starter Attempt starting by direct connection to the battery Repair replace as necessary Unit cranks but will not start F
82. 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 N ES y STA ra A AY 1 Oil drain hose Figure 3 4 Oil Drain Hose e 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 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 filter 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 6137 5 03 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 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 star
83. iston rings so that the Top Marks are towards the piston crown See Figure 10 80 Figure 10 78 Inner Spring Figure 10 80 Piston and Ring Expander Tool 11 Check the speed control shaft performance and a Lubricate Ihgnings and Me PISTON SKIN check its springs The inner spring is correctly set if it rejects the push of the governor pin See Figure 10 78 4 Put the cylinder on the bench with its upper side touching the bench 3 Check that the piston ring gaps are at 120 offset 12 The outer spring is correctly set when the accelerator lever is held in position during a higher Note Never tap on the piston crown engine speed rate Increase its tension by changing the position on the ratchet plate Also Note Never install the piston from the upper side of the check its reaction in the opposite direction See cylinder because the liner is narrower and lightly Figure 10 79 tapered in this position 5 Compress all of the rings with a ring compressor tool and drive the piston in the cylinder Figure 10 79 Ratchet Plate Figure 10 81 Ring Compressor TP 6137 5 03 Section 10 Generator and Engine Disassembly Reassembly 81 6 Guide the piston into the cylinder liner until the Valve Guides piston hole is slightly to the upper edge of the cylinder This will allow for the connection between 1 Press the valve guides in the proper head holes the piston assembly and the connecting rod Carefully ensure that they are i
84. ition Xx Check the crankcase oil level and add oil as necessary Before operation Xx Replace the oil in the crankcase 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 x Replace Check replace the seawater pump impeller Replace the anticorrosion zinc anode Requires removal of the sound shield if installed Consult your local distributor dealer for service 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 10 Section 3 Scheduled Maintenance TP 6137 5 03 Perform Service at Intervals Indicated X INTAKE EXHAUST SYSTEM Inspect the exhaust system components Xx Before operation Every 100 Hrs or3 Months Every 200 Hrs or 6 Months Every 400 Hrs or 12 Months Every 600 Hrs or 18 Months Check the exhaust gas condition If the exhaust is blue or black contact your local distributor dealer x During 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 Xx Before
85. itions ofthe P1 connections 8 GND Check the conditions ofthe TB1 connections 8 GND Check the continuity of the K2 connections 7 8 Reset the failed connections to energize the fuel pump FP and the cut off solenoid FS Figure 8 7 Troubleshooting Relay Controller Control Panel 2 of 4 48 Section 8 Controller Troubleshooting TP 6137 5 03 After the start switch is release is the engine operating Yes gt No Y Is 12 DC voltage present on the K2 relay coil No y Can you stop the engine using the on off switch Generator set checks out m Yes gt okay No y Are the 30 87 terminals of the K2 relay open L No Change the K2 relay Is any red LEDs LOP HET HCHT lit Change the control panel LOP Check the oil level the oil pressure and the alarm switch e HET and HCHT Check if water flows out of the exhaust manifold and if the two alarm switches work e Are these checks okay Change the control panel Figure 8 8 Troubleshooting Relay Controller Control Panel 3 of 4 TP 6137 5 03 Section 8 Controller Troubleshooting 49 y If there AC output when the on off switch is held and the unit is running No Y Is AC output at the correct voltage e g 120 volts AC Yes gt No Y Is 12 volts DC present on the coil of
86. l Specifications SAE Service Grade 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 Section 1 Figure 1 1 for dipstick location 12 Section 3 Scheduled Maintenance TP 5586 3 1 Min mark 2 Max mark 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 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 L Qts 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 6137 5 03 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
87. l 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 TP 6137 5 03 3 5 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 5 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 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 5 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
88. llect in the fuel system e Operating the generator set until the fuel supply is emptied e Developing air leaks in the suction side of the fuel system e Replacing the fuel filter 26 Section 5 Fuel System Procedure to Bleed the Fuel System 1 Loosen the vent screw See Figure 5 15 ADV 6652 1 Vent screw Figure 5 15 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 6137 5 03 5 10 Governor Governor body Pin Spacer Bridge Spring retainer Full speed spring Idle speed spring Cross slot nut 1 2 3 4 5 6 7 8 Figure 5 16 Governor Components The centrifugal mechanical governor keeps the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load No regular service is required on the governor The factory adjusts the governor during run in and further adjustment should not be needed unless poor governor control develops after extended generator usage Governor Construction and Function The governor consists of two flyweights and a set of springs that balance the centrifugal forces of the governor flyweights TP 6137 5 03
89. lving speed Correct no load voltage but low voltage at load Rotating diode s damage Check and replace the diode s Low speed at full load Operate on the speed governor Load too high Reduce the voltage supplied Unstable voltage Uneven rotation Check the engine Poor connection contacts Check the wiring diagram and reset the connections Uneven load Check the load and eliminate the uneven loads Unit is noisy 9 7 Alternator Excitation As a result of disassembling the generator set the alternator can get deenergized It is then necessary to excite the alternator after reassembly to the engine by applying 12 volts DC to the line terminals Connect in series a 10 amp 250 volt fuse to the positive wire going to the battery See Figure 9 10 56 Section 9 Generator Troubleshooting Poor coupling Check and correct the coupling Short circuit in winding or load Check windings and loads and replace the damaged parts Bearing breakage Replace the broken bearing Figure 9 10 Alternator Excitation TP 6137 5 03 Section 10 Generator and Engine Disassembly Reassembly 10 1 Generator Alternator Disassembly Disconnect all the external connections battery cables at the battery negative lead first AC output leads in the controller remote start panel at the controller connector water line at the seawater pump fuel line at the fuel pump filter
90. mation below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance po si F EJ E E Unacceptable Nut Bolt Clearance i E 1 1 2 of bolt diameter 2 Minimum 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths TP 6137 5 03 Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nut and SAE washer Hardware 1 2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut Se
91. mpartment 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 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 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 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 i
92. n 6 Slowly turn the jawpuller bolt to free the alternator Figure 10 10 Seawater Pump Shaft Nut from the engine 2 Using a 17 mm socket wrench loosen the four 7 As the puller bolt turns on the head of the alternator M10 x 140 screws to disconnect the alternator from through stud ensure no damage occurs the engine flywheel housing See Figure 10 11 TP 6137 5 03 Section 10 Generator and Engine Disassembly Reassembly 59 Note With a suitable puller it is possible to reuse the original seawater pump screws 8 Remove the stator housing from the rotor See Figure 10 13 Figure 10 13 Remove the Stator Housing Rotor and Alternator Through Stud Disconnection 1 With an uphand hammer tap the outer surface of the rotor and release the connection between the rotor and the alternator through stud See Figure 10 14 Figure 10 14 Rotor Removal 60 Section 10 Generator and Engine Disassembly Reassembly Engine and Rotor Hub Disconnection 1 Using a 13 mm socket wrench loosen the four M8 x 35 screws and remove the alternator engine hub from the engine flywheel See Figure 10 15 Figure 10 15 Engine Rotor Hub Stator Removal 1 The moveable and permanent magnet rotor is connected at the engine flywheel with five M6 x 30 socket screws The stator is installed with three M6 x 16 bolts on the engine flywheel housing See Figure 10 16 1 Permanent magnet 2 Stator Figure 10 16 Stator and Flywheel TP 613
93. n 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating 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
94. n 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 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 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 Donot install the exhaust outlet 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 yo
95. n return spring on the eccentric shaft and hook its end leg in the middle notch of the ratchet plate See Figure 10 74 Figure 10 71 Camshaft Bearing Camshaft 1 Install the O ring 2 From inside the gear cover use a socket to push the camshaft into the bearing hole See Figure 10 72 3 Put a fitted socket under the outer bearing race to avoid an improper installation of the camshaft 4 Set the camshaft s snap ring in its groove to lock it Figure 10 73 Control Lever Figure 10 74 Ratchet Plate and Accelerator Lever Figure 10 72 Camshaft TP 6137 5 03 Section 10 Generator and Engine Disassembly Reassembly 79 6 Guide the eccentric shaft through the bushing housing until it meets the inner control lever See Figure 10 75 Figure 10 75 Eccentric Shaft 7 Turn the ratchet plate towards the lower position until the inner spring can be hooked with the other Figure 10 76 Gear Housing Boss end leg at the groove of the eccentric shaft 10 Push the eccentric speed shaft further until it locks 8 Move the ratchet plate between its two stop with the inner retainer ring See Figure 10 77 notches on the gear housing 9 Use a looping wire to move and to hook the other end leg of the outer spring at the gear housing boss See Figure 10 76 Figure 10 77 Inner Retainer Ring 80 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 Piston 1 Using a ring expander tool install the p
96. nal diameter undersize of 0 25 mm 0 010 in D1 D2 Journal diameter undersize of 0 50 mm 0 020 in D1 D2 Crankshaft gear diameter Diameter of crankshaft gear journal Clearance Con rod bearing and crankshaft journal diameter Bushing and crankshaft journal diameter 88 Section 10 Generator and Engine Disassembly Reassembly 40 080 1 5780 35 023 1 3789 40 030 1 5760 39 830 1 5681 39 780 1 5661 39 580 1 5583 39 530 1 5563 22 000 0 8661 22 029 0 8673 0 060 0 0024 0 050 0 0020 40 060 1 5772 35 015 1 3785 40 020 1 5756 39 810 1 5673 39 770 1 5657 39 560 1 5575 39 520 1 5559 21 970 0 8650 22 008 0 8665 0 030 0 0012 0 020 0 0008 0 110 0 0043 0 080 0 0031 TP 6137 5 03 10 6 Engine Component Dimensions and Wear Continued Part Description Dimensions Original Max Limit Max mm in Min mm in mm in Connecting Rod Large bore diameter without bearing Small bore diameter without bearing Outer bushing diameter Inner bushing diameter 43 666 1 7191 24 986 0 9837 25 075 0 9872 22 050 0 8681 43 650 1 7185 24 974 0 9832 25 035 0 9856 22 030 0 8673 Piston Pin Outer diameter 22 000 0 8661 21 996 0 8660 Camshaft Camshaft gear journal diameter Camshaft gear hole diameter Crankcase hole diameter Camshaft journal in the crankcase diameter 22 031 0 8674 22 00
97. nd the cylinder and through the cylinder head A thermostat controls the cooling water circuit temperature See Figure 6 2 for thermostat settings Consult the engine operation manual for the thermostat cleaning and checking procedures Thermostat Settings Max Temp Seawater 50 C 122 F Freshwater 75 C 167 F Figure 6 2 Thermostat Settings 6 3 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 6 3 E ae SA 1 Seawater pump 2 Coverplate 3 Gasket 4 Impeller 5 Bearing 6 Housing Figure 6 3 Seawater Pump Typical 32 Section 6 Cooling System 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 6 4 Replace the impeller if it is damaged 1 Flattened vane 2 Crack 3 Broken vane Figure 6 4 Worn Impeller 5 Lubricate the impeller with soapy water before installation 6 Install the impeller Note During installation push and rotate the impeller
98. nditions ofthe P1 connections 9 GND Check the conditions ofthe TB1 connections 9 GND Check the conditions ofthe K1 connections 7 9 Check the conditions ofthe TB1 connections 7 GND Reset the failed connections to energize the coil of the solenoid S on the starter motor Yes y Change the control panel Change the control panel Y Is the current present on the contacts of the S solenoid starter motor side Yes Y Change the starter motor Figure 8 6 Troubleshooting Relay Controller Control Panel 1 of 4 TP 6137 5 03 Section 8 Controller Troubleshooting 47 Does the engine crank No Y Is the 12 DC voltage present on the K2 relay coil No y Checkthe conditions ofthe K2 connections 6 GND Checkthe conditions ofthe TB1 connections 6 GND Checkthe conditions ofthe P3 connections 6 GND Checkthe conditions ofthe 2 7 connections on the terminal board of the control panel Reset the failed connections to energize the K2 relay Yes Is current present on the coils of the fuel pump FP and the cut off solenoid FS No Y Y Check the conditions ofthe FP connections 8 GND Change the fuel pump FP or the cut off solenoid FS if these are inoperative Check the conditions ofthe FS connections 8 GND Check the cond
99. nerator 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 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 210 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 mechani
100. ng Figure 10 22 Seawater Pump Shaft 5 Tighten the four M10 x 140 screws at the specified torque See section 1 5 See Figure 10 21 Seawater Pump Installation 1 Assemble on the rear side of the stator housing the seawater pump housing Tighten the three M5 x 40 screws at the specified torque see section 1 5 with a 4 mm setscrew wrench 2 Push the impeller in the housing turning it slowly until it is on the shaft See Figure 10 23 Figure 10 21 Alternator Connection 6 Put the holes of the alternator bracket on the two vibromount mounting bolts and screw the two M8 nuts at the specified torque see section 1 5 with a 13 mm socket wrench 7 Tighten the 27 mm nut of the seawater pump shaft at the specified torque see section 1 5 to strengthen the tapered connection between the rotor and the alternator through stud See Figure 10 22 Figure 10 23 Seawater Pump Impeller 3 Set the O ring and install the seawater pump cover Tighten the four M4 x 8 screws at the specified torque see section 1 5 with a 6 mm socket wrench Note Check the generator set s nameplate to verify the original voltage configuration See Section 10 for more information regarding voltage reconnection 4 Reconnect all external connections the exhaust line to the mixing elbow the fuel lines the water line to the seawater pump the remote panel the AC output leads and the battery cable to the battery negative lead last 5 O
101. note that c Install the gear cover and turn the flywheel until the upper two screws and the one screw located in the camshaft mark aligns with the one on the the middle left position are longer than the other gear cover three screws d Check the distances between the flywheel 8 Place anew gasket under the front plate of the gear mark and the crankcase mark located in the cover and tighten the two screws 3 o clock position is within 2 mm 0 0787 in of each other If it is the valve timing adjustment is acceptable 84 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 2 Putthe retainer spring in the upper side of the head as shown in Figure 10 92 3 Do not tighten the nuts 4 Guide the push rods in the tube until they touch the tappets Note Both rods look alike However place the intake valve s push rod in the hole closer to the crankcase Figure 10 90 Gear Cover Screws Block Tappets Figure 10 92 Retainer Spring In Cylinder Head 1 Check that the tappets movement in their block is not forced Check the surface wear that touches the camshaft See Figure 10 91 Hecker Arms 1 Ensure that the piston is in the Top Dead Center TDC position 2 Lubricate and then drive the rocker arm shaft into its support 3 Align the push rods with the correct rocker arms 4 Ensure aclearance between these parts to prevent damaging the head nuts after tightening 5 Tighten the head nuts
102. nstalled in an upright position at the head surface See 7 Carefully slide the cylinder towards the crankcase Figure 10 83 until its lower part is inserted into the block f Note Assemble the rotocap valve s retainer ring before 8 Align the piston and connecting rod holes and pressing the exhaust valve guide install the pin with its retainers See Figure 10 82 Note If the piston has to be reinstalled on the engine mark it before its removal Figure 10 83 Valve Guides Figure 10 82 Piston Assembled 82 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 Valve Note The exhaust valve has a larger counterbore than the intake valve when viewing the head from the upper surface The exhaust valve has a smaller hole when viewing the head from the opposite side Note The rotocap and conical shaped spring belong to the exhaust valve See Figure 10 84 Figure 10 85 Cylinder Head and Gasket 6 On the shorter stud put the engine lifting bracket 7 Tighten the nuts at the specified torque See Section 1 5 Gear Cover 1 Move the piston to Top Dead Center TDC and check the alignment between the mark on the flywheel and the mark on the crankcase at the 3 o clock position See Figure 10 86 Figure 10 84 Intake and Exhaust Valve Components 1 Install the two thin steel washers under the intake valve spring 2 Grind the valves and set new cup seals on the valve guide s head 3
103. ntrol lever it goes towards the timing gear cover and stops against it 3 Set the pin of the fuel injection pump in the higher fuel supply position towards the right front fuel pump view 4 Guide the injection pump in the timing gear cover and ensure that its pin is in the yoke of the control lever s arm 5 Reinstall the injection pump using the same number and type of shims Note Before installing the shims put the paper gasket on the cover because a direct contact does not permit adequate sealing Figure 10 96 Injection Pump TP 6137 5 03 High Pressure Line 1 Install the high pressure line and tighten the nuts at the injector nipple and at the nonreturn valve nipple located on the fuel injection pump body Note Perform step 1 while holding the injector and nonreturn valve nipples with a 14 mm wrench See Figure 10 97 2 Tighten the fuel line nuts with a 17 mm wrench Figure 10 97 High Pressure Line TP 6137 5 03 Valve Cover 1 Install the valve cover gasket on the upper surface of the head See Figure 10 98 2 Reinstall the valve cover 3 Put the synthetic rubber washers under the cover nuts and tighten at the specified torque See Section 1 5 Note To avoid oil leaks check and hold the right side of the gasket on the head during this operation A Figure 10 98 Valve Cover Gasket Section 10 Generator and Engine Disassembly Reassembly 87 10 5 Engine Component Dimensions an
104. ofarad 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 oversize 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 Aut
105. omotive 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 WwW watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6137 5 03 Appendix B Common Hardware Application Guidelines Use the infor
106. operation X Check and tighten the electrical connections Clean the battery cables ENGINE AND MOUNTING Check for water fuel and oil leakage Xx After operation X Retighten any loose nuts and bolts x Before operation Check the mounting bolts vibromounts and tighten if necessary Adjust the intake exhaust valve clearance Head bolt retightening REMOTE CONTROL SYSTEM Check the remote control operation GENERATOR Test run the generator set Xx Break in period X X Blow dust out of the generator Requires removal of the sound shield if installed Consult your local distributor dealer for service 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 6137 5 03 Section 3 Scheduled Maintenance 11 3 3 Lubrication System See the Service Schedule for oil change and oil filter replacement intervals See Section 1 for the oil drain oil check and oil fill locations 3 3 1 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 Oi
107. or while the thinner shim decreases the pressure value of the injector Add or remove shims to obtain the correct pressure value Injector nut Nozzle assembly Pressure piece Spring seat s conical stop Spring Figure 5 7 Injector Components 22 Section 5 Fuel System Injector Overhaul 1 Inspect the injector assembly to ensure that the nozzle s needle is in the hole of the pressure piece 2 Ifthe nozzle leaks or does not atomize replace the entire nozzle 3 Lapping of the nozzle needle is not recommended TP 6137 5 03 5 5 Excess Fuel Start Device The engine is equipped with a device that supplies extra fuel to facilitate engine starting See Figure 5 8 When the device s button is pulled down its upper conical surface releases the fuel control lever and the fuel injection pump pin performs a longer movement thus increasing the fuel rate at the injector a Figure 5 8 Excess Fuel Start Device Button If the excess fuel start device is activated the engine without load reaches the higher speed The governor pushes the injection pump s control lever towards the lower value of supplying fuel and the excess fuel start device button returns to its initial position TP 6137 5 03 Before pulling down the device s button start the engine without load to allow it to reach it s highest engine speed Note To avoid heavy engine damage and engine overload never operate with the device s
108. pen the seacock and the fuel valve 62 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 10 3 Generator Engine Disassembly Disconnect all the external connections battery cables at the battery negative lead first AC output leads in the controller remote start panel at the controller P3 connector water line at the seawater pump fuel line at the fuel pump filter inlet and exhaust line at the mixing elbow Observe all the safety precautions listed at the beginning of this manual during the disassembly reassembly procedures Note This section includes engine disassembly reassembly procedures unique to the marine generator set Consult the engine service manual for engine torque specs special tool requirements and further engine service information Oil Drain 1 Place a container under the oil drain hole 2 Remove the oval flange of the oil drain See Figure 10 24 3 Drain the oil Allow time for a complete oil drain Note If necessary slightly tip the engine to ensure a complete oil drain Figure 10 24 Oil Drain Remove the air intake s antiresonator device 1 Remove the air cleaner cover s four flat screws TP 6137 5 03 2 Before removing the electric fuel pump clean the inside of the antiresonator housing with a rag 3 Ensure that dirt or debris does not enter the cylinder 4 Remove the antiresonator housing by removing the two screws See Figure 10 25 5 Discard
109. place the rear bearings during a complete engine overhaul TP 6137 5 03 9 4 Rotor Test Procedure to test the rotor s continuity The two pole rotor creates the magnetic field needed to 1 Using an Ohmmeter test check if the rotor winding raise the alternating current in the stator windings 19 opened See Figure 9 3 If an accurate ohmmeter is not available check the circuits Before testing inspect the rotor for visible damage to the continuity using a 12 VDC battery and a suitable pole shoes insulation and exposed coil windings lamp See Figure 9 4 Replace the rotor if it is Check the rotor bearings for noisy operation excessive grounded has an opened or short circuit wear and heat discoloration Replace or repair these components if any of the above conditions exist Procedure to test the rotor s insulation 1 Disconnect the two rotor field diodes D4 and D5 See the wiring diagrams in Section 11 2 Using a Megger set at 500 volts DC check the winding insulation resistance value to ground Check every part isolated from the others See Figure 9 2 Normally windings with a resistance value to ground greater than 1 MOhm are considered good If resistance is lower than 1 MOhm replace the rotor Figure 9 2 Rotor Insulation Test Figure 9 4 Rotor Continuity Test with AC Test Lamp TP 6137 5 03 Section 9 Generator Troubleshooting 53 Procedure to test the rotor s resistance 1 To test the rotor resistanc
110. r for service Inoperative fuel feed pump Replace the fuel feed pump Incorrect valve clearance Contact your local Kohler generator set distributor for service Inoperative valve spring Contact your local Kohler generator set distributor for service Incorrect compression Contact your local Kohler generator set distributor for service Engine knocks Improper fuel type Use proper fuel type consult fuel supplier Improper fuel injection timing Contact your local Kohler generator set distributor for service Improper cylinder top clearance Contact your local Kohler generator set distributor for service Inoperative piston or piston ring Contact your local Kohler generator set distributor for service Inoperative crankshaft bearing or piston pin bearing Contact your local Kohler generator set distributor for service Improper valve clearance piston pin bearing Contact your local Kohler generator set distributor for service Air in injectors Bleed air Loses power 38 Section 7 Troubleshooting Air intake clogged Service the air intake screen Bad or stale fuel Replace the fuel Engine not operating at rated RPM Check the governor Governor adjustments incorrect Adjust the governor TP 6137 5 03 Problem Possible Cause Corrective Action Loses power continued Carbon build up Clean t
111. rate 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 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 cylinder 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 th
112. reaker s in the ON position to close the circuit breaker See Figure 1 1 Oil Pressure The lamp illuminates red if the Lamp generator set shuts down because of low oil pressure Engine Lamp The lamp illuminates red if the generator set shuts down because of high engine temperature Exhaust Lamp The lamp illuminates red 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 See Figure 2 3 A 25 pin connector underneath the controller allows the connection of the optional remote start stop switch hourmeter and indicator panel kit See Figure 2 3 TP 6137 5 03 2 Ss 0000080 TR Sy Hourmeter On Off button Oil pressure lights Engine temperature lights Exhaust temperature lights Start button Figure 2 2 Controls and Indicators 1 4 pin connector 2 25 pin connector Figure 2 3 Remote Panel Connections TP 6137 5 03 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
113. relay This in turn energizes the fuel solenoid FS and the fuel pump FP because the normally open contacts of the K2 relay close 8 1 2 Start Press the START switch local or remote the K1 relay energizes The normally open K1 contacts close allowing DC to the normally open contacts of the starter motor s solenoid S The energized starter starts the generator set s engine 8 1 3 Run After reaching correct engine and generator set performance the two generator set wires marked 10 and 11 energize the K3 relay AC crank disconnect that opens its normally closed contacts DC supplied to the starter is interrupted every starting operation is eliminated The generator set wires marked C1 and C2 connect at the capacitor supplying AC As it gives or receives current in accordance with variable loads its capacity changes to hold the correct AC voltage value When good engine oil pressure operation is reached the normally closed contacts of the low oil pressure LOP switch close The red LED on the control panel cuts off and the green LED lights If all three green LEDs on the control panel are lit at the same time good engine performance is achieved and AC is supplied to the windings L1 L2 L3 and L4 8 1 4 On Off Switch Stop If the On Off switch local or remote is repressed the K2 relay deenergizes The fuel solenoid FS and fuel pump FP do not receive DC the normally open K2 contacts reopen and the engine
114. rican 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 charging 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 6137 5 03 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 El 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 cogen
115. rst 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 A 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 Il 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 co
116. ructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under 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 inj
117. s RR 54 9 07 Stator Test oss caver tanta nthe pedal ha E ia 55 9 7 Alternator Excitation viii ao a 56 Section 10 Generator and Engine Disassembly Reassembly oocccoocccnn o 57 10 1 Generator Alternator Disassembly 0 00 57 10 2 Generator Alternator Reassembly 0 00 cece ees 61 10 3 Generator Engine Disassembly 000 cece eee eee es 63 10 4 Generator Engine Reassembly 0 00 cece eee eee eens 74 10 5 Engine Component Dimensions and Wear 0 00 cee eens 88 Section 11 Wiring Diagrams 0 00 cece eee eee eee eens 91 11 1 Wiring Diagram Schematic 0000 c cece eens 92 11 2 Wiring Diagram Point to Point 0 0 ccc cee 93 Appendix A Abbreviations se cuore dt a Sakti as A 1 Appendix B Common Hardware Application Guidelines 6 ces A 3 Appendix C General Torque Specifications 0 0 c ccc eee eens A 4 Appendix D Common Hardware Identification 0 tee e eee A 5 Appendix E Common Hardware List 0 6 cece tnt A 6 Table of Contents TP 6137 5 03 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
118. safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning 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 6137 5 03 Accidental Starting A WARNING FAS 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
119. shunted to the field diodes to prevent high transient reverse voltages in the field windings thus damaging the diodes The varistor is not polarized and shows on a standard ohmmeter a virtually infinitive reading in both directions See Figure 9 7 If it is defective normally a visible inspection shows burning signs it gives a full deflection reading short circuit TP 6137 5 03 9 6 Stator Test Stator Insulation Continuity and Winding Resistance Test 1 Disconnect the generator set s AC output leads from the control box Note Refer to the Wiring Diagrams in Section 11 and Figure 9 8 for output lead coding 2 Check the windings insulation resistance to ground Note Remember that while checking isolate each part from the others 3 Use a Megger set at 500 volts DC If winding resistance values to ground is 1 MOhm consider the insulation good If the resistance is lower than 1 MOhm replace the stator 4 Using an ohmmeter test for an open circuit in the stator winding Note If an accurate ohmmeter is unavailable check the circuit s continuity using a 12 volt DC battery and a suitable lamp 5 Replace the stator ifithas an open or short circuitin the windings Note Some generators have ground connections to the frame to ground check the Wiring Diagrams in Section 11 6 Using a Kelvin bridge or an accurate microhmmeter test the resistance of each stator windings and compare the resistances ob
120. t Power LO lt Y y 9 To Load Kraus Naimler American Solenoid Newer Round Design 2 Wire Generator Sets 3 Wire Generator Sets LI lt To Generator 3 Set To Shore Power 5 To Shore To Generator Power Set LO lt 11 Figure 11 1 Marine Manual Ship to Shore Transfer Switch TP 6137 5 03 Section 11 Wiring Diagrams 91 11 1 Wiring Diagram Schematic SCHEMATIC STD CONTROL PANEL os FUEL SOLENOID RELAY Y HIGH CYLINDER HEAD TEMP HIGH EXHAUST TEMP LOW OIL PRESSURE 9 N p TB1 10 12VAC 10 o 10 FROM TB1 11 MAIN 11 ALT G GR YT GREEN BCA o RED MS GREEN TB1 8 P1 2 8 o 8 gt B 7 L 99000 Cc 8 LEGEND BCA BATTERY CHARGING ALTERNATOR BCR BATTERY CHARGING REGULATOR BR1 BRIDGE RECTIFIER C CAPACITOR eee NA D DIODE EBG ENGINE BLOCK GROUND F FUSE FP FUEL PUMP FS FUEL SOLENOID GND CONTROLLER BOX GROUND HCHT HIGH CYLINDER HEAD TEMPERATURE HET HIGH EXHAUST TEMPERATURE J JACK K1 START RELAY K2 FUEL SOLENOID RELAY K3 AC CRANK DISCONNECT RELAY LOP LOW OIL PRESSURE P PLUG SM STARTER MOTOR SS STARTER SOLENOID TB TERMINAL BLOCK TW PIN 92 Section 11 Wiring Diagrams 12VDC BATTERY GM20645 B
121. tained See Figure 9 9 All windings of equal output voltage should indicate about the same resistance An unusually low reading indicates a short circuit while a high reading indicates an open circuit 7 If an open or short circuit exists replace the stator TP 6137 5 03 1011 C1 C2 Figure 9 8 Stator Windings Resistance in Ohms at 20 C 68 F Stator Leads 1 2 Model 3 4 C1 C2 0 96 2 32 10 10 4EOZ 60 Hz 2 87 3 5EFOZ 50 Hz 10 Figure 9 9 Resistance Values Section 9 Generator Troubleshooting 55 Alternator Troubleshooting and Corrective Action Problem Possible Cause Corrective Action No output Low revolving speed Check and adjust the revolving speed Incorrect connections Check the wiring diagram and reset the connections Inoperative capacitor Replace the capacitor Winding breakage Check the winding resistance and replace the damaged parts Rotating diode s damage Check and replace the diode s Low no load voltage Low revolving speed Check and adjust the revolving speed Rotating diode s damage Check and replace the diode s Capacitor with low capacity Increase the capacitor capacity Winding breakage Check the winding resistance and replace the damaged parts High no load voltage Capacitor with high capacity Reduce the capacitor capacity High speed Adjust the revo
122. the K3 relay Is AC voltage present on the capacitor CAP connections C1 C2 See Section 11 No Y Check the stator and the Are the K3 relay contacts rotor See Section 9 Yes opened 30 87a ha Change the K3 relay Check the stator winding connections See Section 9 and Section 11 Are the CAP connections C1 C2 okay Is the 10 amp fuse F2 2 No okay Y Reset the connections Change the fuse F2 Is the bridge rectifier BR1 Y okay Charge the capacitor to reset the magnetic retentivity Check the performance of the capacitor Check if the diodes D4 D5 work correctly Check if the rotor works correctly Check if the stator works correctly Note Followthe procedures included in the Engine Service Manual and Section 9 of this manual Yes Y Change the bridge rectifier Figure 8 9 Troubleshooting Relay Controller Control Panel 4 of 4 50 Section 8 Controller Troubleshooting Check the K3 connection condition Check the BRI connection condition 10 11 Check the TB1 connection condition 10 11 Are these checks okay Yes Y Check the stator winding 10 11 Note See Section 9 TP 6137 5 03 Section 9 Generator Troubleshooting 9 1 General Before beginning the following troubleshooting procedures read all the safety precautions at the beginning of this manual
123. ting battery negative lead last Reconnect the power to the battery charger if equipped x sm 001 003 Section 3 Scheduled Maintenance 13 3 4 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 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 14 Section 3 Scheduled Maintenance 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 al
124. ting off the fuel supply at the engine If no notch is visible damage to the speed controller shaft linkage may occur To relocate the ratchet plate and accelerator lever on the speed controller shaft hold the accelerator lever and move the ratchet plate until its slot is against the speed shaft pin At this position tighten the 8 mm nut Figure 5 21 Ratchet Plate Notches Section 5 Fuel System 29 Notes 30 Section 5 Fuel System TP 6137 5 03 Section 6 Cooling System 6 1 Direct Water Cooled In a direct seawater cooling system the impeller pump NOTICE circulates the seawater around the cylinder and through Saltwater damage Saltwater quickly deteriorates metals the cylinder head A thermostat controls the cooling water Wipe up saltwater on and around the generator set and circuit temperature Consult Figure 6 1 and the engine remove salt deposits from metal surfaces operation manual for the cooling water circuit diagrams BAS ES e a E TP 6134 Intake strainer Zinc plug Seacock Exhaust manifold elbow Seawater strainer Exhaust hose Engine driven seawater pump Silencer customer supplied Oil exchanger Outlet flapper exhaust water discharge Alternator water cooler Figure 6 1 Direct Water Cooled Cooling System 3 5EFOZ and 4EOZ Models TP 6137 5 03 Section 6 Cooling System 31 6 2 Thermostat In a direct seawater cooling system the impeller pump circulates the seawater arou
125. to the 25 pin connector Hour Meter On Off Start Z Oilpress Ea N GM20768 Hourmeter On Off button Oil pressure lights Engine temperature lights Exhaust temperature lights Start button Figure 2 6 Remote Panel Features TP 6137 5 03 3 1 General A WARNING T ass 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 prevent the starting of the 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 injur
126. ts tension 6 Release the inner control lever from the eccentric shaft Figure 10 49 Speed Control Shaft TP 6137 5 03 Section 10 Generator and Engine Disassembly Reassembly 71 Oil Pump 1 Loosen the three hex cap screws to remove the oil pump from the crankcase See Figure 10 51 Figure 10 51 Oil Pump Flywheel 1 Use a socket wrench and striker tool to loosen the flywheel nut two turns Keep the flywheel nut on the shaft See Figure 10 52 Note If removing the flywheel from the engine without removing the governor place the accelerator lever in the higher speed full load position Otherwise damage may occur to the regulation linkage Figure 10 53 Flywheel 2 Install the flywheel puller 3 Turn the two screws until the flywheel breaks loose from the tapered side of the engine crankshaft See Figure 10 53 4 Remove the nut and the flywheel 72 Section 10 Generator and Engine Disassembly Reassembly TP 6137 5 03 Main Bearing Cover 1 Put the engine crankcase on the work bench so that the flywheel side is in the upper position 2 Remove the four main bearing cover nuts and washers 3 Install two screws M6 x 30 in the threaded holes of the cover and turn them until the cover is released from the crankcase See Figure 10 54 4 Remove the key O ring two angle rings and two elastic washers See Figure 10 55 and Figure 10 56 Hates ES Figure 10 56 Main Bearing Crankshaft
127. uled Maintenance TP 6137 5 03 Section 4 Intake and Exhaust System 4 1 Air Intake Silencer Filter At the interval specified in the service schedule clean the air intake screen Clean the silencer more frequently if the generator set operates in dirty dusty conditions Figure 4 1 Air Cleaner 1 Air cleaner screen Figure 4 2 Air Cleaner Screen TP 6137 5 03 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 Remove the four screws to remove the air cleaner cover Remove the air cleaner screen Tap the screen 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 screen Examine the screen and housing for damage and wear Replace the screen or housing if necessary Wipe the air cleaner cover and base with a clean rag to remove any dirt Ensure that dirt does not enter the intake port Make sure that the sealing surfaces fit correctly and replace the four screws Section 4 Intake and Exhaust System 17 4 2 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
128. ur exhaust is directed away from other boats and buildings Avoid overloading the craft TP 6137 5 03 Fuel System A WARNING j 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 Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Installing the fuel system Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion
129. ury Retorque all crankshaft and rotor hardware after servicing Do notloosen 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 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 6137 5 03 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 6137 5 03 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
130. ution 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 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 l 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 fi
131. x 2 25 1 8 x 3 00 1 8 x 5 00 Part No Hex Nuts X 6009 1 X 6210 3 X 6210 4 X 6210 5 X 6210 1 X 6210 2 X 6210 6 X 6210 7 X 6210 8 X 6210 9 X 6210 10 X 6210 11 X 6210 12 X 6210 15 X 6210 14 X 85 3 X 88 12 X 89 2 Washers Part No X 25 46 X 25 9 X 25 48 X 25 36 X 25 40 X 25 85 X 25 37 X 25 34 X 25 26 X 25 15 X 25 29 X 25 127 1 062 Dimensions Type 1 8 Standard 6 32 Whiz 8 32 Whiz 10 24 Whiz 10 32 Whiz 1 4 20 Spiralock 1 4 28 Spiralock 5 16 18 Spiralock 5 16 24 Spiralock 3 8 16 Spiralock 3 8 24 Spiralock 7 16 14 Spiralock 1 2 13 Spiralock 7 16 20 Spiralock Spiralock 5 8 11 Standard 3 4 10 Standard 1 2 20 Standard Bolt ID OD Thick Screw 125 250 022 4 156 375 049 6 188 438 049 8 219 500 049 10 281 625 065 1 4 344 687 065 5 16 406 812 065 3 8 469 922 065 7 16 531 1 062 095 1 2 656 1 312 095 5 8 812 1 469 134 3 4 2 000 134 1 TP 6137 5 03 Metric Hex head bolts are hardness grade 8 8 unless noted Part No Hex Head Bolts partial thread M931 06040 60 M931 06055 60 M931 06060 60 M931 06070 60 M931 06075 60 M931 06090 60 M931 08035 60 M931 08040 60 M931 08040 82 M931 08045 60 M931 08050 60 M931 08055 82 M931 08060 60 M931 08070 60 M931 08070 82 M931 08075 60 M931 08080 60 M931 08090 60 M931 08095 60 M931 08100 60 M931 10040 60 M931 10045 60 M931 10050 60 M931 10055 60 M931 10060 60 M931 10065 60 M931
132. y 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 if the sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only TP 6137 5 03 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 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 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

Service Manual, 4EOZ/3.5EFOZ (TP-6137)

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