Related Manuals for Kohler 4EFOZ
Summary of Contents for Kohler 4EFOZ
- Page 1 Operation Marine Generator Sets Models: 4EFOZ/5EOZ, 6.5EFOZ/8EOZ 9EFOZ/10EOZ, 8.5EFOZ, 11EFOZ/13EOZ 11.5EFOZ/14EOZ, 13EFOZ/15.5EOZ 16EFOZ/20EOZ, 17.5EFOZ/20EOZ 19EFOZ/23EOZ, 20EFOZ/24EOZ 23EFOZ/28EOZ, 27EFOZ/32EOZ TP-6068 10/02b...
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Page 2: Product Identification Information
California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service parts. Engine Identification Record the product identification numbers in the spaces Record the product identification information from the below immediately after unpacking the products so that engine nameplate. -
Page 3: Table Of Contents
Table of Contents Product Identification Information ..........Inside front cover Safety Precautions and Instructions . -
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: Exhaust System
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
Fuel System Installing the fuel system. Explosive Engine noise. Hazardous noise can fuel vapors can cause severe injury cause hearing loss. Generator sets or death. Fuel leakage can cause an not equipped with sound enclosures explosion. Do not modify the tank or can produce noise levels greater than WARNING the propulsion engine fuel system. - Page 8 Short circuits. Hazardous Hot Parts Moving Parts voltage/current can cause severe injury or death. Short circuits can WARNING WARNING cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments repairs. Remove all jewelry before servicing the equipment.
- Page 9 Servicing the generator set when it Notice NOTICE is operating. Exposed moving parts When replacing hardware, do not can cause severe injury or death. substitute with inferior grade NOTICE Keep hands, feet, hair, clothing, and hardware. Screws and nuts are test leads away from the belts and available in different hardness ratings.
- Page 10 Notes VI Safety Precautions and Instructions TP-6068 10/02...
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Page 11: Introduction
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 Before installing a marine generator set, obtain the... -
Page 12: 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 8.5EFOZ, 9EFOZ/ 4EFOZ/ 6.5EFOZ/ 11- -20EFOZ/ 23/27EFOZ/ 10EOZ 5EOZ 8EOZ... - Page 13 5/10EOZ 8EOZ 13- -24EOZ 28/32EOZ Installation Manual TP-6069 TP-6069 TP-6069 TP-6069 Operation Manual TP-6068 TP-6068 TP-6068 TP-6068 Parts Catalog* TP-5616 TP-5591 (4EFOZ/5EOZ) (11--13EFOZ/ TP-5587 13--15.5EOZ) TP-5616 TP-5998 (8.5EFOZ, TP-5593 9EFOZ/ (16--20EFOZ/ 10EOZ) 20--24EOZ) Service Manual (Engine) TP-5876 TP-5876 TP-5876 TP-6054...
- Page 14 Notes iv Introduction TP-6068 10/02...
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Page 15: Section 1 Service Views
Section 1 Service Views START DC- - CIRCUIT BREAKER STOP/ PREHEAT HOUR METER AC- - CIRCUIT BREAKER NOTICE CHECK ZINC ANODE EVERY 100 HOURS OR 3 MONTHS. ADV-6285A-A GB-250000-A 11- -20EFOZ and 13- -24EOZ Models Only DA-250000 1. Controller 18. Oil check 2. - Page 16 Notes Section 1 Service Views TP-6068 10/02...
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Page 17: Section 2 Operation
Section 2 Operation 2.1 Prestart Checklist Ensure that the carbon monoxide detector(s) is (1) in the craft, (2) functional, and (3) energized whenever To ensure continued satisfactory operation perform the the generator set operates. following checks or inspections before or at each Note: Never operate the generator set without a startup, as designated, and at the intervals specified in functioning carbon monoxide detector. -
Page 18: Marine Inspection
2.2 Marine Inspection 2.6 Starting and Stopping Procedure Kohler Co. recommends that all boat owners have their vessels—especially the exhaust system attached to the Note: Opening seacock. Before starting the generator generator set—inspected at the start of each boating set, open the seacock to allow cooling water season by the local Coast Guard Auxiliary. -
Page 19: Controls And Indicators
2.6.1 Controls and Indicators 2.6.3 Remote Panel Gauge Operation The following table describes the controls and indicators If the generator set has an optional remote panel with located at the controller: gauges, observe the gauges upon engine startup. If gauge readings are not within the ranges specified, Name Description contact an authorized service distributor/dealer. - Page 20 Notes Section 2 Operation TP-6068 10/02...
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Page 21: Section 3 Scheduled Maintenance
Section 3 Scheduled Maintenance 3.1 General Maintenance NOTICE Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and WARNING remove salt deposits from metal surfaces. NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware. -
Page 22: Service Schedule-4--20Efoz And 5--24Eoz Models
3.2 Service Schedule—4- -20EFOZ and 5- -24EOZ Models Every Every Every Every 50 Hrs. 200 Hrs. 400 Hrs. Perform Service at Intervals Reference 1000 Hrs. or 1 or 3 or 6 Indicated (X) Section Daily or Yearly Month Months Months FUEL SYSTEM Check the fuel level and fill as necessary (Before... - Page 23 Service Schedule—4- -20EFOZ and 5- -24EOZ Models, continued Every Every Every Every 50 Hrs. 200 Hrs. 400 Hrs. Perform Service at Intervals 1000 Hrs. Reference or 1 or 3 or 6 or Yearly Indicated (X) Daily Month Months Months Section INTAKE/EXHAUST SYSTEM Inspect the exhaust system components *[ (Before...
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Page 24: Service Schedule-23/27Efoz And 28/32Eoz Models
3.3 Service Schedule—23/27EFOZ, 28/32EOZ Models Every Every Every Every 50 Hrs. 200 Hrs. 400 Hrs. Perform Service at Intervals 1000 Hrs. Reference Before or 1 or 3 or 6 or Yearly Indicated (X) Month Months Months Section Starting FUEL SYSTEM Check the fuel level and fill as necessary Remove the sediment from the fuel tank [ Check for any abnormal fuel-injection sound [... - Page 25 Service Schedule—23/27EFOZ, 28/32EOZ Models, continued Every Every Every Every 50 Hrs. 200 Hrs. 400 Hrs. Perform Service at Intervals 1000 Hrs. Reference Before or 1 or 3 or 6 or Yearly Indicated (X) Month Months Months Section Starting INTAKE/EXHAUST SYSTEM Inspect the exhaust system components *[ Check the exhaust gas condition.
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Page 26: Lubrication System
3.4 Lubrication System 3.4.2 Oil Check Check the oil level in the crankcase daily or before each See the Scheduled Maintenance section for oil change startup to ensure that the level is in the safe range. To and oil filter replacement intervals. See Section 1 for the check the oil level, remove the dipstick and wipe the end oil drain, oil check, oil fill, and oil filter locations. -
Page 27: Oil Change
2. Replace the oil filter. Model L (Qts.) a. Remove filter rotating 4EFOZ and 5EOZ 3.0 (3.2) counterclockwise with an oil filter wrench. 6.5EFOZ and 8EOZ 2.3 (2.4) 8.5EFOZ, 9EFOZ and 10EOZ 5.2 (5.5) b. Apply a light coat of clean oil to the rubber seal of the new oil filter. -
Page 28: Fuel System
3.5 Fuel System 3. Remove the filter bowl and fuel filter. Clean the fuel filter with fresh fuel oil and blow compressed air from the inside outward. Replace a damaged fuel 3.5.1 Fuel Specifications filter. Dispose of the fuel filter in an approved manner. -
Page 29: Bleeding The Fuel System
3.5.3 Bleeding the Fuel System Note: Wipe up all spilled diesel fuel after bleeding the system. Wash hands after any contact Bleed air from the fuel system to prevent starting failures with fuel oil. and/or erratic operation. One or more of the following causes air to collect in the fuel system: 4/6.5EFOZ and 5/8EOZ Models Operating the generator set until the fuel supply is... -
Page 30: Air Intake Silencer/Cleaner
3.6 Air Intake Silencer/Cleaner 3. Wash the element in mild detergent and water solution. Rinse and air dry the element. See At the interval specified in the service schedule, clean or Figure 3-5. replace the air intake silencer. Clean the silencer more 4. -
Page 31: Exhaust System
3.7 Exhaust System Inspection Points Inspect the the exhaust system components (exhaust WARNING manifold, mixing elbow, exhaust line, hose clamps, silencer, and outlet flapper) for cracks, leaks, and corrosion. Check the hoses for softness, cracks, leaks, or dents. Replace the hoses as needed. Carbon monoxide. -
Page 32: Cooling System
A coolant solution with more than 50% ethylene glycol can cause engine Model L (Qts.) or component damage. Do not use alcohol or 4EFOZ and 5EOZ 1.8 (1.9) methanol antifreeze or mix them with the 6.5EFOZ and 8EOZ 3.9 (4.1) specified coolant. -
Page 33: Seawater Pump
3.8.5 Seawater Pump The belt-driven seawater pump is located on the service 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. -
Page 34: Siphon Break
3.8.6 Siphon Break 6. Install the reed valve into the mounting base with the valve downward. See Figure 3-9, item 3. A siphon break prevents seawater entry into the generator set’s engine when the engine exhaust 7. Install and only finger tighten the retaining cap. Do not overtighten it. - Page 35 Waterline TP-5586-3 1. Silencer vertical lift 1.2 m (4 ft.) max. 9. Seawater strainer 2. Exhaust mixer elbow distance above waterline. If less than 10. Seacock 23 cm (9 in.), a siphon break is required. 11. Intake strainer 3. Siphon break distance above waterline 30.5 cm (1 ft.) min. 12.
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Page 36: Anticorrosion Zinc Anode
3.8.7 Anticorrosion Zinc Anode The heat exchanger on models 4--9EFOZ, 5--10EOZ, 23/27EFOZ, and 28/32EOZ contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion by seawater. Check and replace the anticorrosion zinc anode at TP-5586-3 intervals recommended in the service schedule. 1. -
Page 37: Belt Tension
3.9 Belt Tension 3.9.1 Seawater Pump Belt Tensioning Procedure WARNING 1. Remove the belt guard. 2. Check the belt tension at the midpoint of the longest span of the belt using a belt-tensioning tool set to 55 ft. lbs. See Figure 3-13. Recheck a new belt tension after 10 minutes of operation. -
Page 38: Battery
Place the hose in a container having blindness and burn skin. approximately 3.7--7.5 L (1--2 U.S. gallons) of coolant/antifreeze. Kohler Co. recommends using an environmentally friendly potable antifreeze Battery electrolyte is a diluted sulfuric acid. Battery acid such as PeakR RV/marine propylene glycol/water can cause severe injury or death. -
Page 39: Section 4 Troubleshooting
Section 4 Troubleshooting This section contains generator set troubleshooting, NOTICE diagnostic, and repair information. Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic). Use the following chart as a quick troubleshooting Do not substitute clear glass-type fuses for ceramic fuses. - Page 40 TP-6068 10/02 Section 4 Troubleshooting...
- Page 41 TP-6068 10/02 Section 4 Troubleshooting...
- Page 42 TP-6068 10/02 Section 4 Troubleshooting...
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Page 43: Section 5 Wiring Diagrams
Section 5 Wiring Diagrams WARNING WARNING Hazardous voltage. Moving rotor. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working on the generator set. - Page 44 229294-L Figure 5-1 Schematic Wiring Diagram—4/6.5/9EFOZ and 5/8/10EOZ (1-Phase Models) Section 5 Wiring Diagrams TP-6068 10/02...
- Page 45 229294-L Figure 5-2 Point-to-Point Wiring Diagram—4/6.5/9EFOZ and 5/8/10EOZ (1-Phase Models) TP-6068 10/02 Section 5 Wiring Diagrams...
- Page 46 GM22515- Figure 5-3 Schematic Wiring Diagram—8.5EFOZ (3-Phase Models) Section 5 Wiring Diagrams TP-6068 10/02...
- Page 47 GM22515- Figure 5-4 Point-to-Point Wiring Diagram—8.5EFOZ (3-Phase Models) TP-6068 10/02 Section 5 Wiring Diagrams...
- Page 48 229937-D Figure 5-5 Schematic Wiring Diagram—11/13/16/19/23/27EFOZ and 13/15.5/20/23/28/32EOZ (1-Phase Models) Section 5 Wiring Diagrams TP-6068 10/02...
- Page 49 229937-D Figure 5-6 Point-to-Point Wiring Diagram—11/13/16/19/23/27EFOZ and 13/15.5/20/23/28/32EOZ (1-Phase Models) TP-6068 10/02 Section 5 Wiring Diagrams...
- Page 50 229938-B Figure 5-7 Schematic Wiring Diagram—11.5/17.5/20/23/27EFOZ and 14/20/24/28/32EOZ (3-Phase Models) Section 5 Wiring Diagrams TP-6068 10/02...
- Page 51 229938-B Figure 5-8 Point-to-Point Wiring Diagram—11.5/17.5/20/23/27EFOZ and 14/20/24/28/32EOZ (3-Phase Models) TP-6068 10/02 Section 5 Wiring Diagrams...
- Page 52 Notes Section 5 Wiring Diagrams TP-6068 10/02...
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Page 53: Appendix A Abbreviations
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex. - Page 54 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat. gas natural gas right side kilojoule...
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Page 55: Appendix B Operating Hour Service Log
Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed. Enter hours to the operating hours on your generator set and the dates nearest quarter hour. OPERATING HOURS SERVICE RECORD DATE HOURS TOTAL... - Page 60 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-6068 10/02b 7 Jurong Pier Road Singapore 619159 E 2000, 2001, and 2002 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...