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Kohler 15C/12.5CF Operation

Kohler 15C/12.5CF Operation

Marine generator sets
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Operation
Marine Generator Sets
Models:
15C/12.5CF
20C/16CF
TP-5981 11/01a

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Summary of Contents for Kohler 15C/12.5CF

  • Page 1 Operation Marine Generator Sets Models: 15C/12.5CF 20C/16CF TP-5981 11/01a...

  • 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 Battery short circuits. Explosion Combustible materials. A sudden Carbon monoxide symptoms. flash fire can cause severe injury or Carbon monoxide can cause severe can cause severe injury or death. death. Do not smoke or permit flames nausea, fainting, or death. Carbon Short circuits can cause bodily injury or sparks near the fuel system.
  • Page 7 Operating the generator set. Carbon The fuel system. Explosive fuel Ignition-protected equipment. monoxide can cause severe nausea, vapors can cause severe injury or Explosive fuel vapors can cause fainting, or death. Carbon monoxide death. Vaporized fuels are highly severe injury or death. Gasoline is an odorless, colorless, tasteless, explosive.
  • Page 8 Hazardous Voltage/ Testing voltage regulator. Hot Parts Hazardous voltage cause Electrical Shock severe injury or death. High voltage WARNING is present at the voltage regulator heat sink. To prevent electrical shock do not WARNING touch the voltage regulator heat sink when testing the voltage regulator.
  • Page 9 Moving Parts Servicing the generator set when it NOTICE is operating. Exposed moving parts Hardware damage. The engine and can cause severe injury or death. generator set may use both American WARNING Keep hands, feet, hair, clothing, and Standard and metric hardware. Use test leads away from the belts and the correct size tools to prevent pulleys when the generator set is...
  • Page 10 Notes Safety Precautions and Instructions TP-5981 11/01...

  • Page 11: Introduction

    Before installing a marine generator set, obtain the Information in this publication represents data available most current installation manual from your local at the time of print. Kohler Co. reserves the right to distributor/dealer. Only qualified persons should change this publication and the products represented install the generator set.
  • 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. Part Description Part Number Battery Charging Fuse (10 amp) 223316 Belt (Seawater Pump) 359206...

  • Page 13: Section 1 Service Views

    Section 1 Service Views SERVICE VIEW ADV-6382A-E ENGINE-END VIEW NON-SERVICE VIEW GX-250000D-D 1. Oil fill 21. Fuel feed pump (fuel inlet) 2. Coolant overflow bottle (daily coolant check/fill location) 22. Lube oil filter 23. Seawater pump (water inlet) 3. Electric choke (on carburetor) 24.
  • Page 14 Notes Section 1 Service Views TP-5981 11/01...

  • Page 15: Section 2 Operation

    Drive Belts. Check the belt condition and tension of the radiator fan, water pump, and battery charging 2.2 Marine Inspection alternator belt(s). Kohler Co. recommends that all boat owners have their Exhaust System. Check for exhaust leaks and vessels—especially the exhaust system attached to the blockages.

  • Page 16: Operation In European Union Member Countries

    This generator set is specifically intended and approved the unit fails to start after three attempts, contact for operation below the deck in the engine compartment. an authorized Kohler distributor/dealer for repair. Operation above the deck and/or outdoors would Failure to follow these guidelines may result in constitute a violation of European Union Directive starter motor burnout.

  • Page 17: Starting The Generator Set

    2.6.2 Starting the Generator Set 2.6.3 Remote Panel Gauge Operation The following table describes the actions required to If the generator set has an optional remote panel with start the generator set. gauges, observe the gauges upon engine start-up. If gauge readings are not within the ranges specified, contact an authorized service distributor/dealer.
  • Page 18 Notes Section 2 Operation TP-5981 11/01...

  • Page 19: Section 3 Scheduled Maintenance

    Hot engine and exhaust system. Can cause severe injury or death. Annual Inspection. Kohler Co. recommends that all boat owners have their vessels—especially the exhaust Do not work on the generator set until it cools.
  • Page 20 See the Safety Precautions and Instructions at the Routine Maintenance. Refer to the following generator beginning of this manual before attempting to service, set service schedule, the engine service schedule, and repair, or operate the generator set. Have an authorized the hourmeter located on the generator set controller to distributor/dealer perform generator set service.
  • Page 21 Notes TP-5981 11/01 Section 3 Scheduled Maintenance...

  • Page 22: Service Schedule

    3.2 Service Schedule After Every Every Every 50 Hrs 100 Hrs 400 Hrs 500 Hrs Reference Before Perform Service at Intervals Indicated (X) 1 Month 3 Months 6 Months Yearly Section Starting FUEL SYSTEM Check the fuel level and fill as necessary Lubricate ball-joint assembly 3.4.2 (200 hrs)
  • Page 23 Service Schedule—Continued After Every Every Every 50 Hrs 100 Hrs 400 Hrs 500 Hrs Reference Before Perform Service at Intervals Indicated (X) Section Starting 1 Month 3 Months 6 Months Yearly INTAKE/EXHAUST SYSTEM, ETC. Inspect exhaust system components [ Check the exhaust gas condition. (during operation) Service backfire flame arrestor...

  • Page 24: Lubrication System

    3.3 Lubrication System 3.3.1 Oil Specifications Use oil that meets the American Petroleum Institute (API) classification of SH or SG. Using unsuitable oil or neglecting an oil change may result in engine damage that is not covered by the engine warranty. Figure 3-1 TP-5586-3 shows the recommended Society of Automotive 1.

  • Page 25: Oil Filter Change

    Oil Change Procedure 3.3.5 Oil Filter Change 1. Stop the generator set. Replace the oil filter at the interval specified in the service schedule. Change the oil filter more frequently if 2. To drain the oil, open the oil-drain valve. See the generator set operates under dirty, dusty conditions.

  • Page 26: Fuel System

    Do not use gasoline left over from the previous season. Kohler Co. recommends unleaded fuel because it leaves fewer combustion chamber deposits. Never mix oil with fuel. 359412- 1.

  • Page 27: Backfire Flame Arrestor

    See Section 1 for location. Carbon monoxide. Replace a damaged flame arrestor. Use only cause severe nausea, USCG-approved Kohler replacement parts. Follow the fainting, or death. procedure described below. exhaust system must leakproof and routinely inspected. Backfire Flame Arrestor Cleaning Procedure 1.

  • Page 28: Cooling System

    3.7 Cooling System Do not add coolant to a hot engine. Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until engine has cooled. 3.7.1 Closed Heat Exchanger Note: Coolant solution. A coolant solution of 50% In a closed cooling system, the seawater circulates ethylene glycol provides freezing protection to through separate chambers within the heat exchanger...

  • Page 29: Seawater Pump

    3.7.3 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 30: Siphon Break

    3.7.4 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 31 Waterline TP-5586-3 1. Mounting base 12. Seawater strainer 2. Retaining cap 13. Seacock 3. Reed valve assembly 14. Intake strainer 4. Silencer vertical lift 1.2 m (4 ft.) max. 15. Engine-driven seawater pump 5. Exhaust mixer elbow distance above waterline. If less than 16.

  • Page 32: Anticorrosion Zinc Anode

    3.7.5 Anticorrosion Zinc Anode The heat exchanger on these models contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion by seawater. Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule. TP-5586-3 Depending upon operating conditions and seawater 1.

  • Page 33: Belt Tension

    3.8 Belt Tension WARNING Rotating parts. Can cause severe injury or death. Operate the generator set only when all guards, screens, and covers are in place. 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 1.

  • Page 34: Ignition System

    3.9 Ignition System 3. Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling Service the spark plugs at the interval specified in the into the combustion chamber. service schedule using the following procedure. 4.
  • Page 35 5. Clean spark plugs by wiping them with a rag. File the center electrode to keep it parallel to the side electrode. Note: Do not sandblast, wire brush, scrape, or otherwise service a spark plug in poor condition. Obtain a new plug for best results.

  • Page 36: Battery

    3.10 Battery 2. Start and run the generator set until it reaches operating temperature, or about 15 minutes. Consult battery manufacturer’s instructions 3. Stop the generator set. regarding battery care and maintenance. 4. Change the oil and oil filter; see Section 3.3.4—Oil Change and Section 3.3.5—Oil Filter Change.

  • Page 37: 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 38 Trouble Symptoms Section or Publication Probable Causes Recommended Actions Reference* Controller Controller start/stop switch in the Move the controller start/stop switch to the START position. Section 2 STOP position Controller fuse blown Replace the blown controller fuse. If the fuse blows again, Section 2, W/D troubleshoot the controller.[ Controller circuit breaker tripped...
  • Page 39 Trouble Symptoms Section or Section or Publication Publication Probable Causes Probable Causes Recommended Actions Recommended Actions Reference* Reference* Electrical System (DC circuits) Battery connections loose, corroded, Verify that the battery connections are correct, clean, and tight. Section 3 or incorrect Battery weak or dead Recharge or replace the battery.
  • Page 40 Trouble Symptoms Section or Section or Publication Publication Probable Causes Probable Causes Recommended Actions Recommended Actions Reference* Reference* Fuel System Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. — Stale or bad fuel.

  • Page 41: 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 42 359148-A Figure 5-1 Schematic Wiring Diagram Section 5 Wiring Diagrams TP-5981 11/01...
  • Page 43 359148-A Figure 5-2 Point-to-Point Wiring Diagram TP-5981 11/01 Section 5 Wiring Diagrams...
  • Page 44 Notes Section 5 Wiring Diagrams TP-5981 11/01...

  • Page 45: 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 46 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...

  • Page 47: 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 48 For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Kohler Power Systems Asia Pacific Headquarters TP-5981 11/01a 7 Jurong Pier Road Singapore 619159 E 1998 and 2001 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

This manual is also suitable for:

20c/16cf

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