Kohler 5EOZ User manual

Marine Generator Sets
Models:
5EOZ
8EOZ
9EOZ
10EOZ
4EFOZ
6.5EFOZ
8EFOZ
9EFOZ
TP-6053 7/04a
Service

TP-6053 7/04 Table of Contents
Table of Contents
Safety Precautions and Instructions I.........
Introduction i...............................
Service Assistance i.........................
Section 1 Specifications 1....................
1.1 General 1..................................
1.2 Service Views 2.............................
1.3 Engine 5...................................
1.4 Generator 6.................................
Section 2 Scheduled Maintenance 7...........
2.1 General 7..................................
2.2 Lubrication System 7.........................
2.3 Battery 8...................................
2.4 Generator Storage 9.........................
Section 3 Intake and Exhaust System 11........
3.1 Air Intake Silencer/Filter 11....................
3.2 Exhaust System 11...........................
3.3 Mixing Elbow 11..............................
Section 4 Fuel System 13.....................
4.1 General 13..................................
4.2 Fuel Specifications 13.........................
4.3 Fuel Filter 13.................................
4.4 Bleed the Fuel System 14......................
4.5 Fuel Solenoid 15.............................
4.6 Fuel Pump 16................................
4.7 Governor 17.................................
Section 5 Cooling System 19..................
5.1 General 19..................................
5.2 Water-Cooled Exhaust Manifold 20..............
5.3 Closed Heat Exchanger 20.....................
5.4 Fill Check and Coolant 20.....................
5.5 Flush and Clean Cooling System 20.............
5.6 Pressure Cap 21.............................
5.7 Impeller Inspection and Replacement 21.........
5.8 Belt Tension 22...............................
5.9 Siphon Break 23..............................
5.10 Anticorrosion Zinc Anode 24...................
Section 6 Controller Troubleshooting 25........
6.1 General 25..................................
6.2 Controller Sequence of Operation 25............
6.2.1 Start 25.............................
6.2.2 Run 25..............................
6.2.3 Stop 26..............................
6.3 Engine Safety Shutdown Switches 26...........
6.3.1 Low Oil Pressure (LOP) Shutdown 26...
6.3.2 High Water Temperature and
High Exhaust Temperature
Shutdown Switch 26..................
6.4 Controller Circuit Board 27.....................
6.5 Troubleshooting 28...........................
Section 7 Generator Troubleshooting 33........
7.1 General 33..................................
7.2 General Troubleshooting 33....................
7.3 Separate Excitation 34........................
7.4 PowerBoost IIIE Voltage Regulators 34..........
7.4.1 Voltage Regulator Test 35..............
7.4.2 Voltage Regulator Adjustment 35.......
7.5 Exciter Field 36...............................
7.6 Exciter Armature 37...........................
7.7 Rectifier Module 38...........................
7.8 Rotor 38.....................................
7.9 Stator 39....................................
Section 8 Component Troubleshooting 41......
8.1 General 41..................................
8.2 Remote Panels (Optional) 43...................
Section 9 Generator Disassembly/
Reassembly 45...............................
9.1 Disassembly 45..............................
9.2 Reassembly 47...............................
Section 10 Voltage Reconnection and
Wiring Diagrams 51...........................
10.1 Voltage Reconnection 51......................
10.1.1 100--120-Volt Configurations 51.........
10.1.2 100--120/200--240-Volt
Configurations 52.....................
10.1.3 200--240-Volt Configurations 52.........
10.2 Marine Manual (Ship-to-Shore)
Transfer Switch 53............................
10.3 Wiring Diagram, Schematic 54.................
10.4 Wiring Diagram, Point-to-Point 55...............
10.5 Remote Start Panel 56........................
10.6 Remote Start and 2-Meter Panel 56.............
10.7 Remote Start and 4-Meter Panel 57.............
Appendix A Abbreviations A-1................
Appendix B Common Hardware Application
Guidelines A-3...............................
Appendix C General Torque
Specifications A-4............................
Appendix D Common Hardware
Identification A-5.............................
Appendix E Common Hardware List A-6.......

TP-6053 7/04Table of Contents
Notes

TP-6053 7/04 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
equipment connected to the set,
disable the generator set as follows:
(1) Place the generator set start/stop
switch in the STOP position.
(2) Disconnect the power to the battery
charger, if equipped. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.
Battery
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.