1. Manuals
  2. Brands
  3. Kohler Manuals
  4. Marine Equipment
  5. 5EOZ
  6. Manual

Kohler 5EOZ Manual

Marine generator sets
Hide thumbs Also See for 5EOZ:
Table of Contents

Advertisement

Quick Links

See also: Operating Manual , Instruction and Installation Manual
Marine Generator Sets
Service
Models:
5EOZ
8EOZ
9EOZ
10EOZ
4EFOZ
6.5EFOZ
8EFOZ
9EFOZ
TP-6053 7/04a

Advertisement

Table of Contents
loading

Related Manuals for Kohler 5EOZ

Summary of Contents for Kohler 5EOZ

  • Page 1 Service Marine Generator Sets Models: 5EOZ 8EOZ 9EOZ 10EOZ 4EFOZ 6.5EFOZ 8EFOZ 9EFOZ TP-6053 7/04a...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ..6.3.2 High Water Temperature and High Exhaust Temperature Introduction ....... Shutdown Switch .
  • Page 4 Notes Table of Contents TP-6053 7/04...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting Battery electrolyte is a diluted INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear...
  • Page 6 Battery short circuits. Explosion Combustible materials. A fire can Copper tubing exhaust systems. cause severe injury or death. Carbon monoxide can cause severe can cause severe injury or death. Generator set engine fuels and fuel nausea, fainting, or death. Do not Short circuits can cause bodily injury vapors are flammable and explosive.
  • Page 7 Fuel System Pipe sealant. Explosive fuel vapors Hazardous Voltage can cause severe injury or death. Fuel leakage can cause an explosion. WARNING Use pipe sealant on all threaded fittings WARNING to prevent fuel leakage. Use pipe sealant that resists gasoline, grease, lubrication oil, common bilge solvents, salt deposits, and water.
  • Page 8 Disconnecting the electrical load. Electrical backfeed to the utility. Hot Parts Hazardous voltage cause Hazardous backfeed voltage can severe injury or death. Disconnect cause severe injury or death. WARNING the generator set from the load by Connect the generator set to the opening the line circuit breaker or by building/marina electrical system only disconnecting the generator set output...
  • Page 9 Moving Parts Tightening the hardware. Flying NOTICE projectiles can cause severe injury Voltage reconnection. Affix a notice or death. Loose hardware can cause to the generator set after reconnecting WARNING the hardware or pulley to release from the set to a voltage different from the the generator set engine and can cause voltage on the nameplate.
  • Page 10 Notes Safety Precautions and Instructions TP-6053 7/04...

  • Page 11: Introduction

    Maintenance work must be performed by appropriately Information in this publication represents data available skilled and suitably-trained maintenance personnel at the time of print. Kohler Co. reserves the right to familiar with generator set operation and service. change this publication and the products represented...
  • Page 12 Product Information Engine Identification Record the product identification information from the Product identification numbers determine service parts. engine nameplate. Record the product identification numbers in the spaces Manufacturer below immediately after unpacking the products so that Model Number the numbers are readily available for future reference. Serial Number Record field-installed kit numbers after installing the kits.

  • Page 13: Section 1 Specifications

    ISO 3046 and ISO 8528-1 include reference location of components. conditions and output calculations. Obtain technical The 5EOZ/4EFOZ models are powered by a Yanmar information bulletin (TIB-101) on ratings guidelines for three-cylinder, water-cooled, four-cycle diesel engine. complete ratings definitions.

  • Page 14: Service Views

    14. Seawater pump (water inlet) 31. Mixing elbow 15. Coolant (fresh water) drain 32. Water temperature sender 16. Heat exchanger 33. Engine starter 17. Coolant drain (fresh water) 34. Battery charging alternator Figure 1-1 Generator Set Service View (5EOZ/4EFOZ) Section 1 Specifications TP-6053 7/04...
  • Page 15 A-358000A-A 18. Fuel filter 1. Start/stop switch 2. Controller 19. Oil filter 3. Nameplate 20. Oil drain valve and hose 4. Hourmeter 21. Fuel feed pump 5. DC circuit breaker 22. Oil check 6. AC circuit breaker 23. Fuel inlet connection 7.
  • Page 16 A-358000A-A 1. Start/stop switch 18. Fuel feed pump 2. Controller 19. Fuel inlet connection 3. Nameplate 20. Oil check 4. Hourmeter 21. Coolant drain (fresh water) 5. DC circuit breaker 22. Fuel return 6. AC circuit breaker 23. Wet exhaust manifold 7.

  • Page 17: Engine

    1.3 Engine Generator Model 5EOZ/4EFOZ 8EOZ/6.5EFOZ 9EOZ/8EFOZ 10EOZ/9EFOZ Engine manufacturer Yanmar Engine model 3TNE68 3TNE74 3TNE78A 3TNE82A Number of cylinders Cylinder block material Cast iron Cylinder head material Cast iron Piston rings 2 compression/1 oil Crankshaft material Stamped forging Connecting rod material...

  • Page 18: Generator

    Engine (continued) Generator Model 5EOZ/4EFOZ 8EOZ/6.5EFOZ 9EOZ/8EFOZ 10EOZ/9EFOZ Intake/exhaust valve clearance 0.15--0.25 (0.006--0.010) (cold), mm (in.) Belt tension (force) @ 10 kg 10--15 (0.4--0.6) (22 lbs.), mm (in.) Flex plate to rotor bolt torque 45 (35) 36.6 (27) 45 (35) 38 (28) (3/8-16), Nm (ft.

  • Page 19: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance 2.1 General 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. WARNING Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

  • Page 20: Battery

    Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in Model L (Qts.) service, as this may result in hazardous spattering of battery 5EOZ and 4EFOZ 3.0 (3.2) acid. 8EOZ and 6.5EFOZ 2.3 (2.4) Battery gases.

  • Page 21: Generator Storage

    2.4 Generator Storage 7. Stop the generator set. 8. Connect the hose to the seacock. Leave the Perform the generator storage procedure while the craft seacock closed. is afloat. Follow the procedure below when storing your generator set for 3 months or more. 9.
  • Page 22 Notes Section 2 Scheduled Maintenance TP-6053 7/04...

  • Page 23: Section 3 Intake And Exhaust System

    Section 3 Intake and Exhaust System 3.1 Air Intake Silencer/Filter Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust A dry-type air cleaner silences and filters the intake air. system connections. The air intake silencer assembly connects to the intake Inspect the exhaust system components (exhaust manifold via a flexible hose.
  • Page 24 Notes Section 3 Intake and Exhaust System TP-6053 7/04...

  • Page 25: Section 4 Fuel System

    Section 4 Fuel System 4.1 General 4.3 Fuel Filter In most installations, both the generator set and the The quality and condition of the fuel largely determine propulsion engine operate from a common fuel tank with the filter’s useful life. Replace the fuel filter element a dual dip tube arrangement.

  • Page 26: Bleed The Fuel System

    Fuel Filter Element Replacement Procedure 4.4 Bleed the Fuel System 1. Place the generator set start/stop switch in the Bleed the air from the fuel system to prevent starting STOP position. failures and/or erratic operation. One or more of the following causes air to collect in the fuel system: 2.

  • Page 27: Fuel Solenoid

    4.5 Fuel Solenoid 5/8EOZ and 4/6.5EFOZ Models The fuel solenoid serves to pull the injector pump lever to the fuel-on position when energized. The fuel solenoid is spring loaded to return the injector-pump lever to the fuel-off position when deenergized. The generators in this manual use a 3-lead fuel solenoid.

  • Page 28: Fuel Pump

    In addition to the ohmmeter test, check for smooth, 4.6 Fuel Pump non-binding movement of the plunger. It is important The fuel pump transfers fuel from a source to the fuel that the linkage between the fuel solenoid and the fuel injection pump.

  • Page 29: Governor

    Turn the screw counterclockwise to decrease the speed. Tighten the locknut at the new setting. See Figure 4-8 or Figure 4-9. DK-250000B-D 1. Locknut 2. Speed adjusting screw Figure 4-8 Governor, 5EOZ/4EFOZ TP-6053 7/04 Section 4 Fuel System...
  • Page 30 Notes Section 4 Fuel System TP-6053 7/04...

  • Page 31: Section 5 Cooling System

    Section 5 Cooling System 5.1 General The heat exchanger cooling system consists of a heat Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool. Release pressure exchanger with a coolant recovery tank, a thermostat, a from the cooling system before removing the pressure cap.

  • Page 32: Water-Cooled Exhaust Manifold

    129°C (265°F). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can 5EOZ/4EFOZ 8EOZ/6.5EFOZ cause engine or component damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant.

  • Page 33: Pressure Cap

    5.6 Pressure Cap 9. Open the seacock. 10. Start the generator set and check for leaks. Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant, enabling higher 11. Stop the generator set and repair leaks or replace operating temperatures.

  • Page 34: Belt Tension

    5.8 Belt Tension 7. Tighten the adjusting arm pivot screw and alternator pivot screw. WARNING 8. Recheck and adjust the belt tension as necessary. 9. Replace the belt guard. 10. Reconnect the generator set engine starting battery, negative (--) lead last. Rotating parts.

  • Page 35: Siphon Break

    5.9 Siphon Break 3. Use a light detergent to clean the reed valve. 4. Check that the reed valve opening is clear. A siphon break prevents seawater entry into the engine when the engine exhaust manifold outlet is less than 5.

  • Page 36: Anticorrosion Zinc Anode

    The pump is operating if cooling water flows from the exhaust outlet. If water is not discharging at the exhaust outlet stop the 5EOZ/4EFOZ generator set. For seawater pump priming see the Prestart Checklist in the operation manual.

  • Page 37: Section 6 Controller Troubleshooting

    Section 6 Controller Troubleshooting 6.1 General shutdown modes. Use this as a starting point for controller fault identification. Use the LEDs on the following section covers controller controller circuit board to assist in the troubleshooting troubleshooting procedure for generator sets equipped process.

  • Page 38: Stop

    The normally open K1 contacts close to energize the 6.3 Engine Safety Shutdown (optional) oil pressure, coolant temperature, battery Switches voltmeter, and hourmeter gauges and the generator ON light. 6.3.1 Low Oil Pressure (LOP) Shutdown The normally open K5 contacts close to permit the high When low oil pressure occurs, the LOP shutdown switch water temperature (HWT), high exhaust temperature contacts close and energize the K4 relay (LED4 lights).

  • Page 39: Controller Circuit Board

    Component Ohmmeter Connections Procedure Results K1 Relay Coil K1 coil terminals Ohmmeter on R x 10 If functional, approximately 270 ohms. (see relay schematic) scale Low resistance (continuity), shorted coil. High resistance, open coil. K2 Relay Coil K2 coil terminals Ohmmeter on R x 10 If functional, approximately 270 ohms.

  • Page 40: Troubleshooting

    6.5 Troubleshooting Use the following flow chart as an aid in troubleshooting prescribed remedy does not correct the problem, the the main circuit board and the entire generator set. If the circuit board may have to be replaced. Press the start switch Go to A Does the engine crank? (local or remote).
  • Page 41 Go to B Does the engine start? (next page). Is 12 volts DC present at the fuel solenoid? (check wiring)? Is the 10-amp fuse okay? Is the K4 relay LED lit? Replace the fuse. Engine fault: check the fuel Do the local and remote Is the K25 relay functioning supply, fuel feed pump, fuel start/stop switches...
  • Page 42 Does the engine continue Can the engine be stopped to run after the start by using the stop switch? switch is released? Generator set checks out okay. Did the K4 relay LED light? Does the K1 relay LED light? Is the fuel solenoid functioning correctly? Do the local and...
  • Page 43 Is there AC output Is the voltage when the start button Is AC output at the regulator is HELD and the unit correct voltage fuse okay? is running? (e.g. 120 volts AC)? Replace the fuse. Is there 12VDC at the exciter field? Test the voltage Test the stator,...
  • Page 44 Notes Section 6 Controller Troubleshooting TP-6053 7/04...

  • Page 45: Section 7 Generator Troubleshooting

    Section 7 Generator Troubleshooting 7.1 General 7.2 General Troubleshooting Before beginning following troubleshooting To determine the cause of no- or low-AC output , refer to procedures, read all the safety precautions at the the following steps and the troubleshooting flow chart beginning of this manual.

  • Page 46: Separate Excitation

    7.3 Separate Excitation 5. Start the engine and check that the ammeter remains stable. An increasing meter reading By separately exciting the generator to determine the indicates a shorted rotor. A decreasing meter reading to zero or unstable reading, suggests a presence of a faulty voltage regulator, it is possible to running open in the rotor.

  • Page 47: Voltage Regulator Test

    3. Turn the variable transformer on. Slowly increase the variable transformer voltage to 100 volts. The Kohler Co. sets the voltage regulator and, under normal test lamp should light. If the lamp does not light, circumstances, the regulator requires no further turn the voltage adjustment potentiometer (pot) adjustment.

  • Page 48: Exciter Field

    Voltage Regulator Adjustment Procedure 8. Use the remote rheostat, if equipped, to make final voltage adjustments. 1. Stop the generator set. 9. Stop the generator set. 2. Turn the remote rheostat, if equipped, to the midpoint. Turn the voltage and stability pots fully 7.5 Exciter Field counterclockwise.

  • Page 49: Exciter Armature

    5. Check the exciter field for a grounded condition. Use a megohmmeter to apply 500 volts DC to the FP or FN lead and the exciter field frame. Follow the instructions of the megohmmeter manufacturer when performing this test. A reading of approximately 500 kOhms (1/2 megohm) and higher indicates the field winding is functional.

  • Page 50: Rectifier Module

    7.7 Rectifier Module 7.8 Rotor The rectifier module, located between the exciter The generator rotor (magnetized by DC current from the armature and the main field, converts the AC from the rectifier module) rotating within the stator windings exciter armature to DC which magnetizes the generator induces AC voltage in the stator windings.

  • Page 51: Stator

    5. Check the main field for a grounded condition by Stator Test Procedure using a megohmmeter. Apply 500 volts DC to 1. Check the generator output lead connections. See either field lead and the main field frame. Follow Section 10, Voltage Reconnection and Wiring instructions megohmmeter’s Diagrams.
  • Page 52 4. Perform a megohmmeter test on the stator as described in the next step. Consider the stator good if the resistance reading (continuity) is low and there is no evidence of shorted windings (heat discoloration). Note: When taking an ohmmeter reading using lead 55, make the connection prior to the in-line fuse.

  • Page 53: Section 8 Component Troubleshooting

    Section 8 Component Troubleshooting 8.1 General See Figure 8-1 through Figure 8-3 for component Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury testing. With the generator set battery connected, and/or equipment damage. Do not contact electrical check generator...
  • Page 54 To further check the generator set components, Note: Before performing ohmmeter checks, disconnect the generator set battery to prevent damage to disconnect the battery and remove the wiring harness the ohmmeter. plugs from the controller circuit board. Use an ohmmeter to check the continuity of the components and to isolate inoperative components.

  • Page 55: Remote Panels (Optional)

    8.2 Remote Panels (Optional) Troubleshooting Remote Start Panels Generally, if the sender changes its resistance values as Kohler Co. offers three remote panels for connection to its respective pressure/temperature changes, it is the generator set: working correctly. An inoperative sender will either be open or shorted.
  • Page 56 Refer to Figure 8-6 for troubleshooting information on the remote start panels. Component Ohmmeter Connections Procedure Results Remote switch: yellow/red Place the ohmmeter on the Continuity, the switch is Remote start/stop switch wire terminal and black wire R x 1 scale. functional.

  • Page 57: Section 9 Generator Disassembly/Reassembly

    Section 9 Generator Disassembly/Reassembly 9.1 Disassembly 8. Remove the tie wraps from the wire harness as necessary. Disconnect the F1 connectors from the Disconnect all the external connections—battery cables resistor leads. 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...
  • Page 58 9. Disconnect the P7 (FP and FN) and P6 (F1 and F2) 12. Disconnect the main field rotor leads from the connectors. See Figure 9-3. rectifier board positive/negative terminals. Remove the bolt and washer. 10. Remove the four bolts to remove the exciter field. See Figure 9-3.

  • Page 59: Reassembly

    19. Install a sling on the stator housing. Figure 9-6. 20. Use a two-jaw puller to pull the end bracket/stator assembly from the bearing on the rotor shaft. See Figure 9-6. 21. Remove the stator assembly from the rotor. Remove or rotate the fan guard, if necessary, to clear the vibromounts.
  • Page 60 4. Inspect the O-ring in the end bracket bearing bore 6. Use the hoist to raise the alternator end. Remove and replace the O-ring if damaged. Use a sling to the wood block from under the locator plate. Lower support the stator assembly while installing the the generator set and install a bolt, a large washer, stator over the rotor.
  • Page 61 11. Install tie wraps to secure the wires as necessary. 13. Connect the P4 (22-pin) connector. Connect the ground strap using a bolt, washer, and lock washer 12. Route output leads 1, 2, 3, and 4 through the (install the lock washer against the ground strap). bottom of the controller box.
  • Page 62 Notes Section 9 Generator Disassembly/Reassembly TP-6053 7/04...

  • Page 63: Section 10 Voltage Reconnection And Wiring Diagrams

    Section 10 Voltage Reconnection and Wiring Diagrams 10.1 Voltage Reconnection Do not connect the load-side terminals of the circuit breaker together when using a factory 2-pole circuit The following information illustrates the proper breaker. See Figure 10-1. If the installation requires a reconnection of 4-lead generator sets.

  • Page 64: Configurations

    10.1.2 100- -120/200- -240-Volt 10.1.3 200- -240-Volt Configurations Configurations This configuration does not use a jumper lead. If the unit was originally wired for straight 100--200 volt, 3 wire, This configuration does not use a jumper lead. If the unit remove the jumper lead (see Figure 10-1 and was originally wired for straight 100--120 volt, 3 wire, Figure 10-2 for location).

  • Page 65: Marine Manual (Ship-To-Shore) Transfer Switch

    10.2 Marine Manual (Ship-to-Shore) Transfer Switch Electro Switch 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load To Load Kraus Naimler/American Solenoid (Early Rectangular Design) 2-Wire Generator Sets 3-Wire Generator Sets To Shore To Generator Power...

  • Page 66: Wiring Diagram, Schematic

    10.3 Wiring Diagram, Schematic 229294-N Section 10 Voltage Reconnection and Wiring Diagrams TP-6053 7/04...

  • Page 67: Wiring Diagram, Point-To-Point

    10.4 Wiring Diagram, Point-to-Point 229294-N TP-6053 7/04 Section 10 Voltage Reconnection and Wiring Diagrams...

  • Page 68: Remote Start Panel

    10.5 Remote Start Panel 10.6 Remote Start and 2-Meter Panel Stop Local 10-amp P1-9 Stop switch fuse Local P1-9 10-amp switch fuse Start Start P1-14 P2-4 P2-5 P2-6 W.T. O.P. sender sender P1-14 P2-4 P2-5 P2-6 Relay circuit Relay board circuit board P2-3...

  • Page 69: Remote Start And 4-Meter Panel

    10.7 Remote Start and 4-Meter Panel Stop Local P1-9 10-amp switch fuse Start O.P. W.T. P1-14 P2-4 P2-5 P2-6 sender sender Relay circuit board P2-3 P4-2 P4-3 P2-8 P2-9 P2-7 Grey/ P3-4 P3-5 P3-1 P3-2 P3-3 P3-6 Black J3-4 J3-5 J3-1 J3-2 J3-3...
  • Page 70 Notes Section 10 Voltage Reconnection and Wiring Diagrams TP-6053 7/04...

  • Page 71: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute exh. exhaust ABDC after bottom dead center center of gravity ext. external alternating current cubic inch displacement Fahrenheit, female analog to digital centerline fglass.
  • Page 72 kilo (1000) MTBF mean time between failure round head machine (screw) kelvin MTBO mean time between overhauls rly. relay kiloampere mtg. mounting root mean square kilobyte (2 bytes) megawatt rnd. round kilogram milliwatt read only memory µF kg/cm kilograms per square microfarad rot.

  • Page 73: Appendix B Common Hardware Application Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 74: Appendix C General Torque Specifications

    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 Assembled into Cast Iron or Steel...

  • Page 75: Appendix D Common Hardware Identification

    Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)

  • Page 76: Appendix E Common Hardware List

    Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
  • Page 77 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Full Thread), Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), continued continued M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M933-12016-60...
  • Page 78 Metric, continued Part No. Dimensions Type Hex Nuts M934-03-50 M3-0.50 Standard M934-04-50 M4-0.70 Standard M934-04-B M4-0.70 Brass M934-05-50 M5-0.80 Standard M934-06-60 M6-1.00 Standard M934-06-64 M6-1.00 Std. (green) M6923-06-80 M6-1.00 Spiralock M982-06-80 M6-1.00 Elastic Stop M934-08-60 M8-1.25 Standard M6923-08-80 M8-1.25 Spiralock M982-08-80 M8-1.25 Elastic Stop...
  • Page 80 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-6053 7/04a 7 Jurong Pier Road Singapore 619159 E 2000 and 2004 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...

This manual is also suitable for:

8eoz10eoz4efoz6.5efoz8efoz9efoz ... Show all

Table of Contents