Kohler 40EFOZ User manual

Marine Generator Sets
TP-6109 6/03c
Operation
Models:
33EFOZ/40EOZ
40EFOZ/50EOZ
55EFOZ/65EOZ
70EFOZ/80EOZ
80EFOZ/99EOZ
100EFOZ/125EOZ
125EFOZ/150EOZ

Engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
California Proposition 65
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Number
x:in:007:001

Table of ContentsTP-6109 6/03
Table of Contents
Product Information inside front cover.........................................................
Safety Precautions and Instructions I........................................................
Introduction 1...............................................................................
Service Assistance 1........................................................................
Maintenance and Service Parts/Related Literature 2............................................
Section 1 Specifications 3...................................................................
1.1 Introduction 3..........................................................
1.2 Specifications 3.........................................................
1.3 Service Views 4........................................................
1.4 Remote Annunciator Kit 5................................................
1.5 Safeguard Breaker 5....................................................
1.6 Line Circuit Breaker 5...................................................
1.7 Run Relay Kit 5.........................................................
Section 2 Operation 7.......................................................................
2.1 Prestart Checklist 7.....................................................
2.2 Marine Inspection 7.....................................................
2.3 Angular Operation 7.....................................................
2.4 Operation in European Union Member Countries 7..........................
2.5 Exercising the Generator Set 8...........................................
2.6 Decision-Makert3+, 16-Light Microprocessor Controller Operation 8.........
2.6.1 Controls and Indicators 9........................................
2.6.2 Fuses and Terminal Strips 10......................................
2.6.3 Auxiliary Fault Lamp Conditions 11.................................
2.6.4 Starting the Generator Set 12......................................
2.6.5 Stopping the Generator Set 12.....................................
2.6.6 Prime Power Mode Operation 13...................................
2.6.7 Fault Shutdowns 13..............................................
2.6.8 Controller Resetting Procedure 14..................................
2.6.9 Resetting the Emergency Stop Switch 14............................
2.7 Expanded Decision-Makert1 Controller Operation 15........................
2.7.1 Controls and Indicators 15........................................
2.7.2 Starting the Generator Set 16......................................
2.7.3 Stopping the Generator Set 16.....................................
2.7.4 Fault Shutdowns 16..............................................
2.7.5 Controller Resetting Procedure 16.................................
2.8 Standard Decision-Makert1 Controller Operation 17........................
2.8.1 Controls and Indicators 17........................................
2.8.2 Starting the Generator Set 17......................................
2.8.3 Stopping the Generator Set 17.....................................
2.8.4 Fault Shutdowns 18..............................................
2.8.5 Controller Resetting Procedure 18.................................
Section 3 Scheduled Maintenance 19..........................................................
3.1 General Maintenance 19..................................................
3.2 Generator Set Service Schedule 20........................................
3.3 Cooling System 21.......................................................
3.3.1 Siphon Break 21.................................................
3.3.2 Impeller Inspection and Replacement Procedure 22..................
3.4 Exhaust System 23......................................................
3.5 Storage Procedure 24....................................................
3.5.1 Lubricating System 24............................................
3.5.2 Cooling System 24...............................................
3.5.3 Fuel System 24..................................................

TP-6109 6/03Table of Contents
3.5.4 Exterior 24......................................................
3.5.5 Battery 24.......................................................
Section 4 General Troubleshooting 25.........................................................
Section 5 Wiring Diagrams 31................................................................
Appendix A Abbreviations A-1..................................................................
Appendix B Operating Hour Service Log A-3.....................................................

TP-6109 6/03 ISafety Precautions and Instructions
Safety Precautions and Instructions
IMPORTANT SAFETY
INSTRUCTIONS. Electromechanical
equipment, including generator sets,
transfer switches, switchgear, and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,orsubstantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
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.
WARNING
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Battery
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
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 lb.) of
bicarbonate of soda (baking soda) to a
containerwith4L(1gal.)ofwaterand
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove 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.

TP-6109 6/03II Safety Precautions and Instructions
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner/silencer
removed.
Combustible materials. A sudden
flash fire can cause severe injury or
death. Do not smoke or permit flames
or sparks near the fuel system. Keep
the compartment and the generator set
clean and free of debris to minimize the
risk of fire. Wipe up spilled fuels and
engine oil.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide
poisoning symptoms include but are
not limited to the following:
DLight-headedness, dizziness
DPhysical fatigue, weakness in
joints and muscles
DSleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
DStomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Copper tubing exhaust systems.
Carbon monoxide can cause severe
nausea, fainting, or death. Do not
use copper tubing in diesel exhaust
systems. Sulfur in diesel exhaust
causes rapid deterioration of copper
tubing exhaust systems, resulting in
exhaust/water leakage.
Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the
safety of the craft’s occupants, install a
carbon 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. Do not
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 your
exhaust is directed away from other
boats and buildings. Avoid overloading
the craft.

TP-6109 6/03 IIISafety Precautions and Instructions
Fuel System
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
WARNING
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
inawell-ventilatedareaawayfrom
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do 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. Do not modify the tank or
the propulsion engine fuel system.
Equip the craft with a tank that allows
one of the two pickup arrangements
described in the installation section.
The tank and installation must conform
to USCG Regulations.
Pipe sealant. Explosive fuel vapors
can cause severe injury or death.
Fuel leakage can cause an explosion.
Use 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
environment such 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
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
CAUTION
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous Voltage/
Electrical Shock
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
WARNING
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
CAUTION
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.

TP-6109 6/03IV Safety Precautions and Instructions
Disconnecting the electrical load.
Hazardous voltage can cause
severe injury or death. Disconnect
the generator set from the load by
opening the line circuit breaker or by
disconnecting the generator set output
leads from the transfer switch and
heavily taping the ends of the leads.
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.
Welding the generator set. Can
cause severe electrical equipment
damage. Before welding the generator
set perform the following steps:
(1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine battery-
charging alternator connections.
(5) Attach the weld ground connection
close to the weld location.
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.
Testing the voltage regulator.
Hazardous voltage can cause
severe injury or death. High voltage
is present at the voltage regulator heat
sink. To prevent electrical shock do not
touch the voltage regulator heat sink
when testing the voltage regulator.
(PowerBoostt, PowerBoosttIII, and
PowerBoosttV voltage regulator
models only)
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death.
Connect the generator set to the
building/marina electrical system only
through an approved device and after
the building/marina main switch is
opened. Backfeed connections can
cause severe injury or death to utility
personnel working on power lines
and/or personnel near the work area.
Some states and localities prohibit
unauthorized connection to the utility
electrical system. Install a
ship-to-shore transfer switch to prevent
interconnection of the generator set
power and shore power.
Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and follow the instructions of the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)
Hot Parts
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
Checking the coolant level. Hot
coolant can cause severe injury or
death. Allow the engine to cool.
Release pressure from the cooling
system before removing the pressure
cap. To release pressure, cover the
pressure cap with a thick cloth and then
slowly turn the cap counterclockwise to
the first stop. Remove the cap after
pressure has been completely
released and the engine has cooled.
Check the coolant level at the tank if the
generator set has a coolant recovery
tank.
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.
Moving Parts
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
WARNING

TP-6109 6/03 VSafety Precautions and Instructions
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
WARNING
Tightening the hardware. Flying
projectiles can cause severe injury
or death. Loose hardware can cause
the hardware or pulley to release from
the generator set engine and can cause
personal injury. Retorque all
crankshaft and rotor hardware after
servicing. Do not loosen the crankshaft
hardware or rotor thrubolt when making
adjustments or servicing the generator
set. Rotate the crankshaft manually in
a clockwise direction only. Turning the
crankshaft bolt or rotor thrubolt
counterclockwise can loosen the
hardware.
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 if the
sound shield has been removed,
leaving the belts and pulleys exposed.
(Sound-shield-equipped models only)
Notice
NOTICE
This generator set has been
rewired from its nameplate voltage
to
246242
NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
NOTICE
Hardware damage. The engine and
generator set may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads and nuts.
NOTICE
When replacing hardware, do not
substitute with inferior grade
hardware. Screws and nuts are
available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of
markings, and metric hardware uses a
numeric system. Check the markings
on the bolt heads and nuts for
identification.
NOTICE
Electrostatic discharge damage.
Electrostatic discharge (ESD)
damages electronic circuit boards.
Prevent electrostatic discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short,to
ground.
NOTICE
Fuse replacement. Replace fuses
with fuses of the same ampere rating
and type (for example: 3AB or 314,
ceramic). Do not substitute clear
glass-type fuses for ceramic fuses.
Refer to the wiring diagram when the
ampere rating is unknown or
questionable.
NOTICE
Saltwater damage. Saltwater quickly
deteriorates metals. Wipe up saltwater
on and around the generator set and
remove salt deposits from metal
surfaces.

TP-6109 6/03VI Safety Precautions and Instructions
Notes

TP-6109 6/03 1Introduction
Introduction
This manual provides operation instructions for
40/50/65/80/99/125/150EOZ and 33/40/55/70/80/100/
125EFOZ model generator sets equipped with the
following controllers:
DDecision-Makert3+ 16-Light
DDecision-Makert1 Expanded
DDecision-Makert1 Standard
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.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Obtain service from an authorized service
distributor/dealer to keep equipment in top condition.
Before installing a marine generator set, obtain the
most current installation manual from your local
distributor/dealer. Only qualified persons should
install the generator set.
x:in:001:002:a
Service Assistance
For professional advice on generator power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
DConsult the Yellow Pages under the heading
Generators—Electric
DVisit the Kohler Power Systems website at
KohlerPowerSystems.com
DLook at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product
DCall toll free in the US and Canada 1-800-544-2444
DOutside the US and Canada, call the nearest regional
office
Africa, Europe, Middle East
London Regional Office
Langley, Slough, England
Phone: [phone]
Fax: [phone]
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]
X:in:008:001a

TP-6109 6/032 Maintenance and Service Parts/Related Literature
Maintenance and Service Parts/Related Literature
Maintenance and Service Parts
Figure 1 identifies maintenance and service parts for
your generator set. Obtain a complete list of
maintenance and service parts from your authorized
generator distributor/dealer.
Models
Part Description
40EOZ/
33EFOZ
50EOZ/
40EFOZ
65EOZ/
55EFOZ
80EOZ/
70EFOZ
99EOZ/
80EFOZ
125EOZ/
100EFOZ
150EOZ/
125EFOZ
Air Filter Element GM15397 GM15397 GM15397 GM15398 GM15398 324134 324134
Belt (Alternator and Seawater
Pump) GM15402 GM15402 GM15402 GM15402 GM15402 GM18704 GM18704
Dec I Standard Controller:
Input Fuse (10 amp) 223316 223316 223316 223316 223316 223316 223316
Dec I Expanded Controller:
Input Fuse (10 amp) 223316 223316 223316 223316 223316 223316 223316
Dec 3+ Controller:
Remote Annunciator Fuse
(3 amp) 243273 243273 243273 243273 243273 243273 243273
Controller Fuse
(3 amp) 243273 243273 243273 243273 243273 243273 243273
Engine & Accessory Fuse
(15 amp) 283645 283645 283645 283645 283645 283645 283645
Fuel Filter Element GM15399 GM15399 GM15399 GM15399 GM15399 GM18808 GM18808
Oil Filter GM15400 GM15400 GM15400 GM15400 GM15400 223673 223673
Seawater Pump Impeller Kit GM15401 GM15401 GM15401 GM15401 GM15401 GM18793 GM18793
Spray Paint (White) 221335 221335 221335 221335 221335 221335 221335
Touch-Up Paint (White) GM19490 GM19490 GM19490 GM19490 GM19490 GM19490 GM19490
Zinc Anode GM15403 GM15403 GM15403 GM15404 GM15404 GM15404 GM15404
Figure 1 Maintenance and Service Parts
Related Literature
Figure 2 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.
Models
Literature Type
40EOZ/
33EFOZ
50EOZ/
40EFOZ
65EOZ/
55EFOZ
80EOZ/
70EFOZ
99EOZ/
80EFOZ
125EOZ/
100EFOZ
150EOZ/
125EFOZ
Installation Manual TP-6069 TP-6069 TP-6069 TP-6069 TP-6069 TP-6069 TP-6069
Parts Catalog* TP-5738 TP-5738 TP-5738 TP-5738 TP-5738 TP-5738 TP-5738
Operation & Service Manual
(Engine) TP-6084 TP-6084 TP-6084 TP-6084 TP-6084 N/A N/A
Service Manual (Generator) TP-5737 TP-5737 TP-5737 TP-5737 TP-5737 TP-5737 TP-5737
* Includes the generator and engine information.
Figure 2 Generator Set Literature
x:in:001:005

TP-6109 6/03 3Section 1 Specifications
Section 1 Specifications
1.1 Introduction
The specification sheets for each generator set provide
specific generator and engine information. Refer to the
respective specification sheet for data not supplied in
this manual. Consult the generator set service manual,
installation manual, engine operation manual, and
engine service manual for additional specifications.
1.2 Specifications
The alternator is a 4-pole, rotating-field unit with a
brushless, permanent-magnet-generator (PMG)
excitation system. The generator set excitation system
uses a permanent-magnet exciter with a
silicon-controlled rectifier (SCR) assembly that controls
the amount of DC current supplied to the generator field.
The voltage regulator sends a signal to the SCR
assembly through an optical coupling. The voltage
regulator bases the signal on engine speed and
generator output voltage. The signal turns a stationary
light-emitting diode (LED) on or off. The LED is mounted
on the end bracket opposite a photo transistor board
that rotates on the shaft. The photo transistor receives
the signal from the LED and signals the SCR assembly
to turn on or off. See Figure 1-1.
PMG, Fast-ResponsetII generator sets offer the
following advantages:
DThe voltage recovery period of this type of generator
is several times faster than the conventional PMG
generators because the generator set does not have
to contend with the inductance of the 2nd exciter field.
DBetter recovery characteristics than static-excited
generators because the system doesn’t draw
excitation power from the generator output voltage.
DThe inherent ability to support short-circuit current
and allow system coordination for tripping
downstream branch circuit breakers.
The PMG exciter system changes the level of exciter
current to the main field within 0.05 seconds of a load
change.
For the duration of a short circuit in the load circuit(s), the
output voltage drops and the amperage momentarily
rises to 200--300% of the generator set’s rated current,
and 200--300% for the duration of the short circuit. The
SCR assembly sends full exciter power to the main field
and the generator sustains up to 300% of rated current.
The sustained high current causes the correspondingly
rated load circuit fuses/breakers to trip. The safeguard
breaker kit collapses the generator set’s main field
during a sustained heavy overload or short circuit.
1
2
3
4
6
7
8
9
10
11
12
13
5
TP-5353-1
1. Field
2. Main generator/alternator
3. SCR assembly
4. Exciter generator/alternator
5. Exciter field magnets
6. Exciter armature
7. Optical coupling
8. Starting battery
9. Safegaurd breaker (optional)
10. AC voltage regulator
11. LED board
12. Photo transistor board
13. Stator
Figure 1-1 Alternator Schematic

TP-6109 6/034 Section 1 Specifications
1.3 Service Views
1
ADV-6581A-
1. Nameplate
2. Controller (Decision-MakertI expanded controller shown)
3. Generator set master switch
4. Hourmeter
5. Air cleaner
6. Exhaust outlet (nonservice side)
7. Fuel return
8. Lifting eye
9. Fuel filter
10. Fuel inlet
11. Fuel pump
12. Seawater pump
13. Oil fill
14. Coolant overflow bottle
15. Pressure cap
16. Overflow tube
17. Heat exchanger
18. Anticorrosion zinc anode
19. Fuel injection pump
20. Oil drain (optional location)
21. Seawater inlet (drain)
22. Coolant drain
23. Belt guard
24. Oil dipstick (check)
25. Oil filter
26. Oil drain valve and hose
27. Cooling air inlets (generator)
2345 8
911 12 13 14 15 16 17
19
212324252627
18
22
6107
20
Figure 1-2 Service Views (Typical)

TP-6109 6/03 5Section 1 Specifications
1.4 Remote Annunciator Kit
A remote annunciator provides convenient monitoring
of the generator set’s condition from a remote location.
See Figure 1-3. The remote annunciator includes an
alarm horn, alarm silence switch, lamp test, and the
same lamp indicators (except air damper and auxiliary
prealarm) as the microprocessor controller, plus the
following lamps:
Line Power lamp illuminates to indicate that the
commercial utility is the power source.
Generator Power lamp illuminates to indicate that the
generator set is the power source.
Remote Annunciator
14-Relay Dry Contact Box A-293983
A-258782
NO C CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14
INPUTCONTACT RATINGS: 10A @120VAC RES. LOAD
.01A @28VDC MIN.
10A @28VDC MAX.
PCB ASSY A-- 320639
LOT NO.
42A 2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10K11 K13K14K12
10 AMP
42B
FBA--1
P
Figure 1-3 Remote Annunciator with 14-Relay Dry
Contact Box
1.5 Safeguard Breaker
The safeguard breaker senses output current on each
generator phase and shuts off the AC voltage regulator if
a sustained overload or short circuit occurs. It is not a
line circuit breaker and does not disconnect the
generator set from the load. See Figure 1-4.
X-796
Figure 1-4 Safeguard Breaker
1.6 Line Circuit Breaker
The line circuit breaker interrupts generator output if an
overload or short circuit occurs. Use the line circuit
breaker to manually disconnect the generator set from
the load during generator set service. See Figure 1-5.
TP-5352-1
Figure 1-5 Line Circuit Breaker
1.7 Run Relay Kit
The run relay kit includes three sets of contacts that
energize only during generator set operation. The run
relay kit can control air intake louvers, radiator louvers,
alarms, and other signaling devices. See Figure 1-6.
273705
Figure 1-6 Run Relay Kit

TP-6109 6/036 Section 1 Specifications
Notes

TP-6109 6/03 7Section 2 Operation
Section 2 Operation
2.1 Prestart Checklist
To ensure continued satisfactory operation perform the
following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks require
verification after the unit starts.
Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering the
engine.
Air Inlets. Check for clean and unobstructed air inlets.
Air Shrouding. Check for securely installed and
positioned air shrouding.
Battery. Check for tight battery connections. Consult
the battery manufacturer’s instructions regarding
battery care and maintenance.
Coolant Level. Check the coolant level according to
the cooling system maintenance information.
Drive Belts. Check the belt condition and tension of the
water pump and battery charging alternator belt.
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components (exhaust
manifold, mixing elbow, exhaust line, hose clamps,
silencer, and exhaust outlet) for cracks, leaks, and
corrosion.
DCheck the hoses for softness, cracks, leaks, or dents.
Replace the hoses as needed.
DCheck for corroded or broken metal parts and replace
them as needed.
DCheck for loose, corroded, or missing clamps.
Tighten or replace the hose clamps as needed.
DCheck that the exhaust outlet is unobstructed.
DVisually 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.
DEnsure that the carbon monoxide detector(s) is (1) in
the craft, (2) functional, and (3) energized whenever
the generator set operates.
Note: Never operate the generator set without a
functioning carbon monoxide detector.
Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.
Lamp Test. Press the lamp test button, if equipped to
verify that all controller LEDs illuminate.
Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
generator set.
Seawater Pump Priming. Prime the seawater pump
before initial startup. To prime the pump: (1) close the
seacock, (2) remove the hose from the water-filter
outlet, (3) fill the hose and seawater pump with clean
water, (4) reconnect the hose to the water filter outlet,
and (5) open the seacock. Confirm seawater pump
operation on startup as indicated by water discharge
from the exhaust outlet.
2.2 Marine Inspection
Kohler Co. recommends that all boat owners have their
vessels—especially the exhaust system attached to 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.
Continuous
Intermittent—
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.

TP-6109 6/038 Section 2 Operation
2.5 Exercising the Generator Set
Operate the generator set under load once each week
for one hour with an operator present.
The operator should perform all of the prestart checks
before starting the exercise procedure. Start the
generator set according to the starting procedure in the
controller section of this manual. While the generator
set is operating, listen for a smooth-running engine and
visually inspect the generator set for fluid or exhaust
leaks.
x:op:001:005
2.6 Decision-Maker3+, 16-Light
Microprocessor Controller
Operation
The Decision-Makert3+, 16-light microprocessor
controller has a prime power mode of operation. See
Section 2.6.6 for prime power mode operation.
Figure 2-2 identifies the relay controller’s indicators and
controls and their functions.
ADV-5849 P1
12 34 5 6
8
9
1011121314151617
18
1. Fuses (inside controller)
2. Frequency meter
3. AC voltmeter
4. Controller TB1 and TB2 terminal strips (on circuit board)
5. AC ammeter
6. Scale lamps (upper/lower)
7. Selector switch
8. Annunciator panel lamps
9. Alarm silence switch
10. Lamp test
11. Generator set master switch
12. Alarm horn
13. DC voltmeter
14. Emergency stop switch (if equipped)
15. Water temperature gauge
16. Voltage adjustment
17. Oil pressure gauge
18. Hourmeter
7
Figure 2-2 Decision-Makert3+, 16-Light Microprocessor Controller

TP-6109 6/03 9Section 2 Operation
2.6.1 Controls and Indicators
The following table describes the controls and indicators
located on the controller.
Name Description
AC ammeter Meter displays the AC output
amperage. Use the selector
switch to choose the phase
current.
AC voltmeter Meter displays the AC output
voltage. Use the selector switch to
choose the output lead circuits.
DC voltmeter Meter displays the voltage of the
starting battery(ies).
Alarm horn Horn sounds if any fault or
anticipatory condition exists.
Place the generator set master
switch in the AUTO position before
silencing the horn. See the
Controller Resetting Procedure
later in this section.
Alarm silence switch Switch disconnects the alarm
during service (place the generator
set master switch in the AUTO
position before silencing the alarm
horn). Restore the alarm horn
switches at all locations (controller,
remote annunciator, and
audio/visual alarm) to normal
positions after correcting the fault
shutdown to avoid reactivating the
alarm horn. See the Controller
Resetting Procedure later in this
section.
Auxiliary fault lamp Lamp flashes or lights when the
controller detects a fault. See the
lamp conditions section following.
Frequency meter Meter displays the frequency (Hz)
of the generator set output
voltage.
Generator set master
switch
Switch functions as the controller
reset and generator set operation
switch.
High engine
temperature lamp
Lamp illuminates if the generator
set shuts down because of high
engine temperature. Shutdown
occurs 5 seconds after the engine
reaches temperature shutdown
range.
Hourmeter Hourmeter records the generator
set total operating hours for
reference in maintenance
scheduling.
Lamp test switch Switch tests the controller indicator
lamps.
Low oil pressure
lamp
Lamp illuminates if the generator
set shuts down because of low oil
pressure. Shutdown occurs
5 seconds after the engine
reaches oil pressure shutdown
range.
Overcrank lamp Lamp illuminates and cranking
stops if the engine does not start
after 45 seconds of continuous
cranking or 75 seconds of cyclic
cranking.
Cranking stops and overcrank
lamp lights after 15 seconds if the
starter or engine does not turn
(locked rotor).
Overcrank lamp flashes if speed
sensor signal is absent longer than
one second.
NOTE: The generator set
controller’s automatic restart
function attempts to restart the
generator set if the engine speed
drops below 13 Hz (390 rpm).
Continued decreased engine
speed causes an overcrank
condition.
Overspeed lamp Lamp illuminates if the generator
set shuts down because governed
frequency on 50 and 60 Hz
models exceeds 70 Hz.
Water temperature
gauge
Gauge displays the engine coolant
temperature.
Oil pressure gauge Gauge displays the engine oil
pressure.
Scale lamps
(upper/lower)
Lamps indicate which AC
voltmeter and/or ammeter scales
to read.
Selector switch Switch selects which generator set
output circuits to measure. When
switched to a position with two
circuit labels, measures amperage
on the lead shown in the upper
label and measures voltage
between the two leads shown in
the lower label. The AC ammeter
and voltmeter function only with
the switch in the ON position.
Voltage adjustment
potentiometer
Potentiometer fine-tunes (±5%)
the generator set output voltage.
Fine adjustment (5%) of generator
output voltage level.

TP-6109 6/0310 Section 2 Operation
Name Description
Auxiliary prealarm
lamp
Lamp illuminates when
customer-provided sensing
devices activate the pump.
Emergency stop
lamp
Lamp illuminates and the
generator set shuts down when
the operator energizes the optional
emergency stop switch. The lamp
needs the optional emergency
stop switch to function.
Generator switch not
in auto lamp
Lamp illuminates when the
generator set master switch is in
the RUN or OFF/RESET position.
Low fuel lamp Lamp illuminates when the fuel
level in the tank approaches
empty. The lamp needs a low fuel
sensor in the fuel tank to function.
High water
temperature lamp
Lamp illuminates when the water
temperature approaches shutdown
range. The lamp needs an
optional prealarm sender kit to
function.
Prealarm high engine
temperature lamp
Lamp illuminates when the engine
coolant temperature approaches
shutdown range. The lamp needs
an optional prealarm sender kit to
function.
Prealarm low oil
pressure lamp
Lamp illuminates when the engine
oil pressure approaches shutdown
range. The lamp needs an
optional prealarm sender kit to
function.
System ready lamp Lamp illuminates when the
generator set master switch is in
AUTO position and the system
senses no faults.
Emergency stop
switch
Switch, if activated, instantly shuts
down the generator set in
emergency situations. Use the
emergency stop switch for
emergency shutdowns only. Use
the generator set master switch for
normal shutdowns.
2.6.2 Fuses and Terminal Strips
The following table describes the controller circuit board
fuses and controller terminal strips.
Name Description
3-amp remote
annunciator fuse
Fuse protects the remote
annunciator circuit, A/V alarm, and
isolated alarm kit, if equipped.
3-amp controller fuse Fuse protects the controller circuit
board, speed sensor, and lamp
circuit board.
15-amp engine and
accessories fuse
Fuse protects the engine/starting
circuitry and accessories.
Controller TB1
terminal strip
Terminal strip provides connection
points for customer-supplied
sensing devices and generator set
accessories such as the
emergency stop switch, remote
start stop/switch, audio/visual
alarms, etc., to the controller.
Figure 2-3 shows the location of
the TB1 terminal strip on the
controller circuit board. Refer to
the wiring diagrams for information
on connecting accessories to the
TB1 terminal strip.
Controller TB2
terminal strip
Terminal strip provides connection
points for crank mode selection
(cyclic or continuous) and remote
start/stop switch inputs of
operation. Figure 2-3 shows the
location of the TB2 terminal strip
on the controller circuit board.
Refer to the wiring diagrams for
connection information.
P1
P2
A-336415-A
R41
LED4
12
3
1. TB1 terminal strip
2. TB2 terminal strip
3. Fuses
Figure 2-3 TB1 and TB2 Terminal Strips on
Decision-Makert3+ Controller Circuit
Board