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Kohler 13EOZ Service Manual

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See also: Operating Manual , Instruction and Installation Manual
Marine Generator Sets
13EOZ/11EFOZ
14EOZ/11.5EFOZ
15.5EOZ/13EFOZ
20EOZ/16EFOZ
20EOZ/17.5EFOZ
23EOZ/19EFOZ
24EOZ/20EFOZ
Service
Models:
TP-6071 3/00

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Summary of Contents for Kohler 13EOZ

  • Page 1 Service Marine Generator Sets Models: 13EOZ/11EFOZ 14EOZ/11.5EFOZ 15.5EOZ/13EFOZ 20EOZ/16EFOZ 20EOZ/17.5EFOZ 23EOZ/19EFOZ 24EOZ/20EFOZ TP-6071 3/00...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ..6.3.2 High Water Temperature (HWT) and High Exhaust Temperature (HET) Introduction ....... Shutdown Switch .
  • Page 4 Table of Contents TP-6071 3/00...

  • 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 Carbon monoxide symptoms. 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. Carbon Short circuits can cause bodily injury vapors are flammable and explosive.

  • Page 7: Fuel System

    Operating the generator set. Carbon Installing the fuel system. Explosive Ignition-protected equipment. monoxide can cause severe nausea, fuel vapors can cause severe injury Explosive fuel vapors can cause fainting, or death. Carbon monoxide or death. Fuel leakage can cause an severe injury or death.

  • Page 8: Hot Parts

    Engine noise. Hazardous noise can Short circuits. Hazardous Heavy Equipment cause hearing loss. Generator sets voltage/current can cause severe not equipped with sound enclosures injury or death. Short circuits can WARNING can produce noise levels greater than cause bodily injury and/or equipment 105 dBA.
  • Page 9 Checking the coolant level. Tightening the hardware. Flying NOTICE coolant can cause severe injury or projectiles can cause severe injury Voltage reconnection. Affix a notice death. Allow the engine to cool. or death. Loose hardware can cause to the generator set after reconnecting Release pressure from the cooling the hardware or pulley to release from the set to a voltage different from the...
  • Page 10 Notes Safety Precautions and Instructions TP-6071 3/00...

  • Page 11: Introduction

    Information in this publication represents data available familiar with generator set operation and service. at the time of print. Kohler Co. reserves the right to change this publication and the products represented x:in:001:003 without notice and without any obligation or liability whatsoever.

  • Page 12: Service Assistance

    D Consult the Yellow Pages under the heading Product Information Generators— Electric D Visit the Kohler Generator Division web site at Product identification numbers determine service parts. www.kohlergenerators.com Record the product identification numbers in the spaces D Call 1-800-544-2444 below immediately after unpacking the products so that the numbers are readily available for future reference.

  • Page 13: Section 1 Specifications

    220--240, 11/13/16/19EFOZ 100/200--110/220 (50 Hz) an exhaust mixer. 110/190--240/416 Kohler Co. develops all Kohlerr marine generator set 11.5/17.5/20EFOZ (50 Hz broadrange) ratings using accepted reference conditions of 25_C Figure 1-1 Generator Model Coverage (77_F) and pressure of 29.2 in. Hg dry barometer. ISO...

  • Page 14: Engine

    1.2 Engine Generator Model 13EOZ 11EFOZ 14/15.5EOZ 11.5/13EFOZ Engine manufacturer Yanmar Engine model 3TNE88 3TNE84-T Number of cylinders Cylinder block material Cast iron Cylinder head material Cast iron Piston rings 2 compression/1 oil Connecting rod material Forged carbon steel Governor Centrifugal, mechanical Bore x stroke, mm (in.)

  • Page 15: Fuel

    1.3 Fuel 1.4 Cooling Fuel System All Models Cooling System 13- -15.5 kW 20- -24 kW Diesel ISO 8217DMA, 50% ethylene glycol; 50% clean, Fuel recommendation BS 2869A1 or A2 Recommended coolant softened water Fuel feed pump Electric Coolant capacity, approx. L (U.S.

  • Page 16: Generator, 4 Lead

    1.5 Generator, 4 Lead 13EOZ 15.5EOZ 20- -23EOZ 11EFOZ 13EFOZ 16- -19EFOZ Component Specification Hot exciter field voltage/amperage readings at rated voltage 4/0.7 4/0.7 6/1.0 No load (63 Hz) 12/1.8 14/2.3 16/2.4 Full load (60 Hz) Exciter field resistance (cold)

  • Page 17: Service Views

    1.7 Service Views Service Side 13/20EOZ 11/16/17.5EFOZ Non-Service Side 14/15.5/23/24EOZ 11.5/13/19/20EFOZ 1. Controller 15. Fuel return line 2. Start/stop switch 16. Fuel injection pump HX-250000 3. DC circuit breaker 17. Belt guard 4. Hourmeter 18. Oil fill 5. Optional circuit breaker location 19.
  • Page 18 Notes Section 1 Specifications TP-6071 3/00...

  • Page 19: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance 2.1 General 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 Schedule routine maintenance using the service generator set as follows: (1) Disconnect the power to the schedule located in the generator set operatation battery charger, if equipped.

  • Page 20: Lubrication System

    2.2 Lubrication System 5W20 Service The selection of engine oil is very important to a diesel Grade 20W40 engine. If an unsuitable oil is used or an oil change is neglected, it may result in damage and a shorter engine 10W30 life.

  • Page 21: Section 3 Intake And Exhaust System

    Section 3 Intake and Exhaust System 3.1 Air Intake Silencer 3.2 Exhaust System Inspection The 13--24EOZ models use a round, polyurethane, WARNING sound-absorbing-type intake silencer to silence the intake air drawn into the cylinder head from the intake port. Besides providing a silencing effect, the silencer also acts as an air cleaner.

  • Page 22: Servicing Mixing Elbow

    3.3 Servicing Mixing Elbow The mixing elbow combines high-temperature exhaust with cooling seawater. The mixture when exposed to engine vibration makes conditions conducive to rapid deterioration and failure if the elbow is not properly maintained. 1. Check the mixing elbow for carbon buildup and corrosion inside the pipe.

  • Page 23: Section 4 Fuel System

    Section 4 Fuel System 4.1 General Fuel Filter Replacement Procedure: 1. Close the fuel valve. In most installations, both the generator set and the propulsion engine operate from a common fuel tank with 2. Remove the fuel filter. a dual dip tube arrangement. The generator set’s dip tube is shorter than the propulsion engine’s dip tube.

  • Page 24: Fuel Pump

    6. Toggle the start/stop switch until fuel, free of air 3. Connect the positive (+) terminal of a 12-volt bubbles, flows from vent screw C. Tighten the vent battery to the positive terminal of the fuel pump. screw. Connect the negative terminal of the fuel pump to the negative (--) terminal of the battery.

  • Page 25: Governor

    4.5 Governor speed, turn the screw counterclockwise. Tighten the locking nut when the correct setting is reached. See The centrifugal, mechanical governor keeps the engine Figure 4-4. speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load.
  • Page 26 Notes Section 4 Fuel System TP-6071 3/00...

  • Page 27: Section 5 Cooling System

    Section 5 Cooling System 5.1 General 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 Heat exchanger cooling consists of a heat exchanger release pressure, cover the pressure cap with a thick cloth and with coolant recovery tank, thermostat, rubber impeller then slowly turn the cap counterclockwise to the first stop.

  • Page 28: Closed Heat Exchanger

    5.2 Closed Heat Exchanger 5.4 Flush and Clean Cooling System In a closed cooling system, seawater circulates through separate chambers within the heat exchanger to cool For optimum protection, drain, flush, and refill the the engine coolant. The seawater then mixes with cooling system at the interval listed in the service engine exhaust and ejects out of the exhaust outlet.

  • Page 29: Impeller Inspection And Replacement

    5.6 Impeller Inspection and Replacement 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.

  • Page 30: Siphon Break

    5.7 Siphon Break A siphon break prevents seawater entry into the engine 3. Use a light detergent to clean the reed valve to remove residue and oxidation. when the engine exhaust manifold outlet is less than 23 cm (9 in.) above the waterline of a fully-loaded, 4.

  • Page 31: Section 6 Controller Troubleshooting

    Section 6 Controller Troubleshooting 6.1 Controller This section covers the controller troubleshooting operation manual to identify the controller’s external procedure for generator sets equipped with a relay components. Refer to Figure 6-1 to identify the controller and related engine components. Refer to the controller’s internal components.

  • Page 32: Controller Sequence Of Operation

    6.2 Controller Sequence of The normally open K1 contacts close to energize the (optional) oil pressure, coolant temperature, battery Operation voltmeter, and hourmeter gauges and the generator “ON” light. Sections 6.2.1--6.3.3 describe the controller sequence of operation during generator start, run, stop, and fault The normally open K5 contacts close to permit the high shutdown modes.
  • Page 33 229938 Figure 6-2 Sequence of Operation Wiring Diagram TP-6071 3/00 Section 6 Controller Troubleshooting...

  • Page 34: Engine Safety Shutdown Switches

    6.3 Engine Safety Shutdown contacts open to deenergize the K2 relay (LED2 goes out). The normally closed K2 contacts close to ground Switches the circuit to the K4 relay until the generator set comes to a complete stop. 6.3.1 Low Oil Pressure (LOP) Shutdown Switch 6.3.2 High Water Temperature (HWT)

  • Page 35: Overspeed Safety Shutdown (Sdr)

    6.3.3 Overspeed Safety Shutdown (SDR) When the engine speed exceeds 70 Hz (2100 rpm), the shutdown relay (SDR) on the overspeed protection circuit board energizes. The normally open SDR contacts close to complete the circuit and energize the K4 relay (LED4 lights). The normally closed K4 contacts open to deenergize the K25 relay.

  • Page 36: Troubleshooting Flow Chart

    6.5 Troubleshooting Flow Chart Use the following flow chart as an aid in troubleshooting the main circuit board and the entire generator set. Press the start switch Go to B Does the engine crank? (local or remote). (next page). Is theK2 relay LED lit? Is the K3 relay LED lit? --Check the battery condition and...
  • Page 37 Go to C Does the engine start? (next page). Is voltage present at the fuel solenoid (P4--14 and P) (check wiring and connectors)? Is the 10 amp (F2) fuse functional? Engine fault (check the fuel supply, fuel feed pump, bleed fuel system, etc.).
  • Page 38 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? Go to D (next page). Is the fuel solenoid functioning? Do the local and remote start/ stop...
  • Page 39 Is there AC output Is the voltage when the start button Is AC output at the regulator is held and the unit is correct voltage fuse functional? running? (e.g. 120 volts AC)? Replace the fuse. Is there 12VDC at the exciter field? Test the voltage regulator.
  • Page 40 Replace the circuit Does the K1 board (inoperative K1 relay LED light? relay). Does the K5 relay LED light after 5--10 seconds of running time? Replace the circuit board (inoperative K5 relay). Did the K4 relay LED light? Do the local and remote start/stop switches function? Replace the circuit...

  • Page 41: Section 7 Generator Troubleshooting

    Section 7 Generator Troubleshooting 7.1 General Generator has no or Before beginning the troubleshooting procedures, read low output all the safety precautions at the beginning of this manual. The following tests include additional safety precautions; OBSERVE THESE PRECAUTIONS! Separately Generator has WARNING excite the generator output...

  • Page 42: Powerboostä V Voltage Regulators

    3. Connect a separate excitation circuit as shown in Figure 7-2. Connect an ammeter and a 10-amp — fuse in series with F1. Note and record the ammeter reading. 4. The approximate ammeter reading should equal battery voltage divided by the sum of the specified exciter resistances (cold).

  • Page 43: Voltage Regulator Test

    7.5 Voltage Regulator Test 7. Slowly increase the variac. The light should begin to illuminate at approximately 90 volts. The following components will be needed to test the 8. Adjust the variac to 240 volts. Do not exceed 300 voltage regulator: volts.

  • Page 44: Voltage Regulator Adjustment

    7.6 Voltage Regulator Adjustment The voltage regulator is factory-set and under normal circumstances requires further adjustment. However, if the voltage regulator has been replaced or Output Input tampered with, or if voltage/frequency reconnection has Green been done, readjust the voltage regulator according to STAB V/HZ VOLTS...

  • Page 45: Exciter Field

    7. Rotate the volts/Hz potentiometer clockwise until the voltage level as measured on the voltmeter begins to drop. When the regulator is set to these specifications the generator will attempt to maintain normal output until the engine speed drops below the frequency set in step 6. 8.

  • Page 46: Exciter Armature

    7.8 Exciter Armature The exciter armature supplies excitation current to the generator main field through the rectifier module. Test the exciter armature as described in the following steps. Exciter Armature Test Procedure: 1. Disassemble the alternator. Refer to Section 9. 2.

  • Page 47: Rectifier Module

    7.9 Rectifier Module 7.10 Rotor The rectifier module located between the exciter The generator rotor (magnetized by DC from the rectifier armature and the main field converts AC from the exciter module) rotating within the stator windings induces AC armature to DC, which magnetizes the generator main in the stator windings.

  • Page 48: Stator

    TP-5588-7 TP-5983-7 1. Main field (rotor) 4. Ohmmeter 1. Main field (rotor) 5. Rectifier module 2. Stator windings 5. Armature 2. Stator windings 6. Megohmmeter 3. Rectifier module 6. Exciter field 3. Frame connection 7. Armature 4. Shaft connection 8. Exciter field Figure 7-14 Stator Ohmmeter Connections Figure 7-13 Megohmmeter Connections on Main Field...
  • Page 49 Between leads Continuity 1 and 4 2 and 5 3 and 6 7 and 10 8 and 11 9 and 12 55 and 66 B1 and B2 1 and 2, 3, 7, 8, 9 1 and 55, B1, and B2 4 and B1 and B2 55 and B1 and B2 Any stator lead and...
  • Page 50 Notes Section 7 Generator Troubleshooting TP-6071 3/00...

  • Page 51: Section 8 Component Troubleshooting

    Section 8 Component Troubleshooting 8.1 General See Figure 8-1 through Figure 8-3 for component the following tables. Check each component using a testing. multimeter to verify that the switches function and that voltage is present at each component. With the generator set battery connected, check the generator wiring harness and the components listed in Component Voltmeter Connections...
  • Page 52 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 53: 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 a panel with a start/stop switch open or shorted.
  • Page 54 Refer to Figure 8-6 for troubleshooting information on the remote start panels. Component Ohmmeter Procedure Results Connections Remote start/stop switch Remote switch: yellow/red wire Place the ohmmeter on the R x 1 Continuity—the switch is terminal and black wire terminal. scale.

  • Page 55: Section 9 Generator Disassembly/Reassembly

    Section 9 Generator Disassembly/Reassembly 9.1 Disassembly 3. Disconnect the P4 (22-pin) connector from J4. 4. Remove the ground strap. Disconnect all of the external connections—battery cables at the battery (negative (--) lead first), AC-output Note: It is possible to connect the output leads in leads in the controller, remote start panel at the various positions for different voltage controller P3 connector, water line at the seawater...
  • Page 56 9. Disconnect the P7 (FP and FN) and P6 (F1 and F2) connectors. See Figure 9-3. 10. Remove the four bolts to remove the exciter field. See Figure 9-3. 1. Armature 2. Armature retaining bolt 558865 3. Rotor leads 4. Rectifier board Figure 9-4 Armature Removal 16.
  • Page 57 19. Install a sling capable of handling the weight of the stator housing 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.

  • Page 58: Reassembly

    Note: Install the fan with the flange side facing away from the flywheel. 4. Replace the O-ring in the end bracket bearing bore. Use a sling to support the stator assembly while installing the stator over the rotor. Do not damage the rotor.
  • Page 59 7. Apply antiseize compound to the keyed end of the 11. Install tie wraps to secure the wires as necessary. rotor shaft. Bring the rotor leads through the bores 12. Route the output leads 1, 2, 3, and 4 through the in the armature while installing the armature on the bottom of the controller box.
  • Page 60 Notes Section 9 Generator Disassembly/Reassembly TP-6071 3/00...

  • Page 61: Section 10 Wiring Diagrams

    Section 10 Wiring Diagrams WARNING WARNING Moving rotor. Hazardous voltage. 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 62: Manual Marine (Ship-To-Shore) 2 Wire And 3 Wire Transfer Switches

    10.1 Manual Marine (Ship-to-Shore) 2 Wire and 3 Wire Transfer Switches 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...

  • Page 63: Manual Marine (Ship-To-Shore) 4 Wire Transfer Switch

    10.2 Manual Marine (Ship-to-Shore) 4 Wire Transfer Switch Kraus Naimer/American Solenoid 4-Wire, three phase Generator Sets To Generator To Shore Power L3 L0 To Load I-940 TP-6071 3/00 Section 10 Wiring Diagrams...

  • Page 64: Remote Start Panel

    10.3 Remote Start Panel 10.4 Remote Start and Two-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 65: Remote Start And Four-Meter Panel

    10.5 Remote Start and Four-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 66 Notes Section 10 Wiring Diagrams TP-6071 3/00...

  • Page 69: 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 70 kiloampere mtg. mounting root mean square kilobyte (2 bytes) megawatt rnd. round kilogram milliwatt read only memory kg/cm kilograms per square microfarad rot. rotate, rotating centimeter N, norm. normal (power source) revolutions per minute kilogram-meter not available, not applicable right side kg/m kilograms per cubic meter nat.

  • Page 71: 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 72: 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 Cast Iron or Steel Assembled into...

  • Page 73: 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 74: 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 75 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Hex Nuts M931-06040-60 M6-1.00 x 40 M933-04006-60 M4-0.70 x 6 M934-03-50 M3-0.50 Standard...
  • Page 76 Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Kohlerr Power Systems Asia Pacific Headquarters TP-6071 3/00 7 Jurong Pier Road Singapore 619159 E Kohler Co., 2000. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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