Kohler 8E Operation And Installation Manual
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Kohler 8E Operation And Installation Manual

Kohler 8E Operation And Installation Manual

Marine generator sets
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Operation and
Installation Manual
Marine Generator Sets
Models:
8E
10E
12.5E
TP-6277 10/03

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  • Page 1 Operation and Installation Manual Marine Generator Sets Models: 12.5E TP-6277 10/03...

  • 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 4 3.7.3 Universal Electronic Spark Control Module (UESC) ....3.7.4 DIS Coil Assembly ..........Backfire Flame Arrestor .
  • Page 5 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: Safety Precautions And Instructions

    Battery gases. Explosion can cause Engine Backfire/Flash Exhaust System severe injury or death. Battery gases Fire can cause an explosion. Do not smoke WARNING or permit flames or sparks to occur near WARNING a battery at any time, particularly when it is charging.
  • 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 Welding the generator set. Testing live electrical circuits. CAUTION cause severe electrical equipment Hazardous voltage or current can damage. Before welding the generator cause severe injury or death. Have set perform the following steps: trained and qualified personnel take (1) Remove battery cables, diagnostic...
  • Page 9 Checking the coolant level. Notice WARNING coolant can cause severe injury or death. Allow the engine to cool. NOTICE Release pressure from the cooling system before removing the pressure This generator set has been cap. To release pressure, cover the rewired from its nameplate voltage pressure cap with a thick cloth and then slowly turn the cap counterclockwise to...
  • Page 10 Notes VI Safety Precautions and Instructions TP-6277 10/03...

  • Page 11: Introduction

    This manual may be used for models not listed on the front cover. 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 without notice and without any obligation or liability whatsoever.

  • Page 12: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPowerSystems.com Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product...

  • Page 13: Section 1 Specifications

    Section 1 Specifications 1.1 General Specifications 12.5E Dimensions—mm (in.) Length 859 (33.82) 913 (35.94) Width 509 (20.04) 509 (20.04) Height 620 (24.41) 620 (24.41) Weight—(dry), kg (lbs.) 203 (447) 227 (500) Air Requirements—L/min. (cfm) Combustion 60 Hz 742 (26.2) 875 (30.9) Cooling 60 Hz 15516 (548) 19310 (682)

  • Page 14: Engine

    1.3 Engine Some general engine specifications are listed below. Refer to the appropriate service section and the engine service manual for specific service details. 12.5E Manufacturer Ford Model VSG-413 DIS Cycle Number Cylinders Compression Ratio 9.5:1 Displacement—L (cu. in.) 1.3 (79) Rated Horsepower 60 Hz RPM 60Hz 1800...
  • Page 15 1.4 Engine (Continued) 12.5E Intake Manifold Bolt Torque—Nm (ft. lbs.) 19 (14) Belt Tension—kg (lbs.) New: 36-46 (79-101) Used: 25-34 (56-75) (A used belt has been operational for 10 minutes or more.) Main Bearing Cap—Nm (ft. lbs.) 88-102 (64-75) Connecting Rod Bolts—Nm (ft. lbs.) Step 1: 4 (2.9) Step 2: Turn 90 deg.
  • Page 16 ADV--5661-C 1. Controller 19. Starter solenoid 2. Nameplate 20. Lifting eye 3. Electronic governor actuator 21. Cooling system pressure cap (coolant check/fill) 4. Anti-dieseling solenoid 22. Oil drain 5. Carburetor 23. Spark plugs/spark plug wires 6. Electric choke 24. PCV crankcase breather (oil fill) 7.

  • Page 17: Section 2 Operation

    2.2 Marine Inspection blockages. Check the silencer and piping condition and check for tight exhaust system connections. Kohler Co. recommends that all boat owners have their vessels—especially the exhaust system attached to the Inspect the exhaust system components (exhaust generator set—inspected at the start of each boating manifold, mixing elbow, exhaust line, hose clamps, season by the local Coast Guard Auxiliary.

  • Page 18: Exercising The Generator Set

    A water-filled exhaust piping and silencer may further hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valve. Water ingested into the engine may cause major engine damage that the Kohler Co. warranty does not cover. 6 Operation TP-6277 10/03...

  • Page 19: Starting The Generator Set

    If explosion and severe injury or the unit fails to start after three attempts, contact death. an authorized Kohler distributor/dealer for repair. Failure to follow these guidelines may result in Before starting the generator set, starter motor burnout.

  • Page 20: Circuit Protection

    2.7 Circuit Protection 2.9 Remote Panels (Optional) AC Circuit Breaker (8E: 33 amp, 10E: 42 amp, or 2.9.1 Remote Start Panel 12.5E: 50 amp) trips when a fault is detected in the AC output circuit. See Section 4—Troubleshooting to The remote start panel allows starting and stopping from determine cause of fault.

  • Page 21: Remote Start And Four-Meter Panel Kit

    Water Temperature Gauge measures engine coolant temperature. Normal engine operating range is 66-77_ C (150-170_ F). Hourmeter records total generator set operating hours for reference in maintenance scheduling. 1-762 1. Engine oil pressure 1-830 1. Engine oil pressure 2. Water temperature 2.
  • Page 22 Notes 10 Operation TP-6277 10/03...

  • Page 23: 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 24: Service Schedule

    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 25 Service Schedule (Continued) Every Every Every After 50 100 Hrs. 200 Hrs. 400 Hrs. Every Hrs. or 1 500 Hrs. Before or 3 or 3 or 6 Month or Yearly Perform Service at Intervals Indicated (X) Starting Months Months Months BACKFIRE FLAME ARRESTOR Service the backfire flame arrestor Check and clean the PCV valve...

  • Page 26: Lubrication System

    3.3 Lubrication System SAE Viscosity Grade (Single Outside Temperature Viscosity Oils) 3.3.1 Specifications --23_C (--10_F) to 15_C (60_F) Use high quality detergent oil of American Petroleum --12_C (10_F) to 32_C (90_F) 20W-20 Institute (API) service class SG, SG/CC, or SG/CD. Above 0_C (32_F) Most oil containers display this information.

  • Page 27: Oil Check

    3.3.2 Oil Check 3.3.3 Adding Oil Check the oil level in the crankcase daily or before each Adding some oil between oil changes is normal. The start-up to ensure that the level is in the safe range. If the amount will vary with generator set usage. Open the oil generator set has just been run, allow a few minutes for fill cap and pour in a small amount of oil using a funnel or the oil to return to the oil pan before checking the level.

  • Page 28: Oil Change

    3.3.4 Oil Change If an automatic oil drain/oil fill pump is not used: Change oil as listed in the service schedule. Change oil 1. Place the oil drain hose in a container and open the more frequently under dirty, dusty conditions. Change oil drain petcock.

  • Page 29: Oil Filter Change

    3.3.5 Oil Filter Change 2. Clean the contact surface of the oil filter adapter. Change the oil filter as listed in the service schedule. 3. Lightly lubricate the gasket surface of a new filter Change the oil filter more frequently if the unit operates with fresh engine oil.

  • Page 30: Fuel System

    Number and Motor Octane Number) 3.4.2 Fuel Filter Kohler Co. recommends unleaded fuel because it The in-line filter connects to the inlet side of the electric leaves fewer combustion chamber deposits. Never mix fuel pump. The fuel filter has a sealed housing. The oil with fuel.

  • Page 31: Cooling Systems-Closed/Heat Exchanger

    All models use a thermostat and coolant recovery tank. coolant recovery tank markings to check the coolant Kohler Co. recommends a solution of 50% ethylene level is acceptable, but Kohler Co. recommends glycol and 50% clean, softened water to inhibit...

  • Page 32: Anticorrosion Zinc

    3.5.3 Anticorrosion Zinc An anticorrosion zinc anode in the heat exchanger prevents electrolytic corrosion by seawater. When metals such as iron and copper are exposed to a highly conductive liquid (seawater), the iron gradually rusts. The anticorrosion zinc anode has chemical properties which cause the seawater to react to it rather than to the engine components.

  • Page 33: Seawater Pump

    3.5.5 Seawater Pump The seawater pump is located on the engine end 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:...

  • Page 34: Siphon Break

    3.5.7 Siphon Break 6. Install the reed valve into the mounting base with the valve downward. See Figure 3-13, 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 NOTE Numbers in illustrations refer to callouts below and not to dimensions. Waterline TP-5811--11 1. Mounting Base 12. Seawater strainer 13. Seacock 2. Retaining Cap 14. Intake strainer 3. Reed valve assembly 15. Engine-driven seawater pump 4. Silencer vertical lift 1.2 m (4 ft.) max. 16.

  • Page 36: Seawater Pump Belt Tension

    3. If a belt tension gauge is not available, use the WARNING following procedure as a guide. Perform the test at the midpoint of the longest span of the belt. At this point, the belt should deflect about 10 mm (3/8 in.) using a force of 9 kg (10 lbs.).

  • Page 37: Ignition System

    3.6 Ignition System 3. Clean spark plugs by wiping them with a rag. File the center electrode so that it is parallel to the side electrode. Should replacement be necessary, see 3.6.1 Spark Plugs Specifications for spark plug type. Service spark plugs at the interval recommended in the Note: Do not sandblast, wire brush, scrape, or Service Schedule.
  • Page 38 6. Reinstall the spark plug. Do not bump the electrode against the cylinder head. Rotate the spark plug clockwise until resistance is felt. 7. Use a torque wrench to torque each spark plug to 15-20 Nm (11-15 ft. lbs.). Otherwise, hand-tighten spark plug until there is resistance.

  • Page 39: Distributorless Ignition System (Dis)

    3.7 Distributorless Ignition System 3.7.4 DIS Coil Assembly (DIS) Internally, the DIS coils have two primary windings and two high-voltage secondary windings. One secondary The engine firing order is 1-2-4-3. The No. 1 cylinder is coil supplies high tension voltage to cylinders 1 and 4. located nearest to the front of the engine (pulley end).

  • Page 40: Backfire Flame Arrestor

    See Figure 3-21. If flame arrestor is damaged, replace it to ensure that the unit functions as a flame arrestor. Use USCG-approved Kohler replacement parts for proper fit and safety. 1. Remove the three wing nuts and cover. 2. Loosen the hose clamp of the breather hose at the air silencer fitting and remove the hose.

  • Page 41: Exhaust System

    3.9 Exhaust System 3.10 Battery Consult battery manufacturer’s instructions WARNING regarding battery care and maintenance. WARNING Carbon monoxide. cause severe nausea, fainting, or death. exhaust system must Sulfuric acid in batteries. leakproof and routinely inspected. Can cause severe injury or death. Inspecting the exhaust system.

  • Page 42: Generator Service

    If poor or insufficient AC output indicates brush antifreeze. replacement, contact an authorized Kohler service 6. With a suitable container at the exhaust outlet, run distributor/dealer to replace the brushes. the generator set until coolant discharges at the...

  • Page 43: Section 4 Troubleshooting

    Flooded carburetor Wait a few minutes and attempt restart Choke out of adjustment Readjust the choke/linkage Engine malfunction See an authorized Kohler service distributor/dealer Hard starting Stale or bad fuel Replace fuel Fuel vapor lock See an authorized Kohler service distributor/dealer...
  • Page 44 Engine starts, but does not continue to run Troubleshooting—Generator (No AC output) after start switch is No/low oil pressure See an authorized Kohler service distributor/dealer released released Inoperative low oil pressure (LOP) safety Replace the LOP shutdown switch shutdown switch High temperature shutdown Check the cooling system’s coolant level...

  • Page 45: Electrical System

    Check the electrolyte level and specific gravity (batteries with filler caps only). Replace if necessary Inoperative battery charging system See an authorized Kohler service distributor/dealer Battery charging fuse blown Replace the fuse. If fuse blows again see an authorized Kohler service distributor/dealer...

  • Page 46: Generator

    Engine in poor condition If routine services are performed and condition persists, see an authorized Kohler distributor/dealer Faulty voltage regulator See an authorized Kohler service distributor/dealer Inoperative voltage regulator and/or poor wiring See an authorized Kohler service distributor/dealer High generator output connections...

  • Page 47: Section 5 Wiring Diagrams

    Section 5 Wiring Diagrams 5.1 Four-Lead Reconnectable 5.1.2 120/240-Volt Configuration (Single-Phase) Generator Sets The 120/240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 120 volt, The following information illustrates the reconnection of remove the jumper lead (see Figure 5-1 for location). four-lead generator sets.
  • Page 48 GM17838B-A Figure 5-3 Schematic Wiring Diagram—8E, 10E, and 12.5E 36 Wiring Diagrams TP-6277 10/03...
  • Page 49 GM17838A-A Figure 5-4 Point-to-Point Wiring Diagram—8E, 10E, and 12.5E TP-6277 10/03 Wiring Diagrams 37...
  • Page 50 Electroswitch 2-Wire Generator Sets 3-Wire Generator Sets To Shore To Generator 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 Generator To Shore Power To Shore To Generator Power To Load...

  • Page 51: Section 6 Installation

    Section 6 Installation 6.1 Introduction Marine generator set installations must comply with all applicable regulations and standards. The safe and successful operation of a marine power The installer is responsible for improper installations system depends primarily on the installation. resulting in penalties from noncompliance with CARB or Figure 6-1.

  • Page 52: General Considerations

    6.2 General Considerations Allow clearance for vibration and cooling during operation. Allow a minimum of 38 mm (1.5 in.) The key to installation is location. Before making final clearance on all sides (top, front, rear, and sides). plans for locating a generator set, consider the following subsections on this page concerning the set and the 6.2.2 Mounting...

  • Page 53: Ventilation

    6.3 Ventilation For generator sets mounted in the engine compartment, increase the air flow to allow for the generator set’s requirements. Install UL-listed, ignition-protected WARNING blowers in the outlet vents and wire them to operate before starting the engine(s). Install optional detection devices to cause alarm, warning, or engine shutdown should dangerous...

  • Page 54: Fuel Systems

    6.4 Fuel Systems WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. 1-788 1. Fuel line to propulsion engine Installing the fuel system. Explosive fuel vapors can 2. Fuel line to generator set cause severe injury or death.

  • Page 55: Antisiphon Device Installation

    6.4.2 Antisiphon Device Installation Install antisiphon devices when a fuel line section lies below the highest point of the fuel tank. Install an antisiphon device as follows: Use a spring-loaded check valve (tested to function with the installation’s siphon head) or an electrically operated shutoff valve (UL ignition-protected tested to USCG regulations) that can operate manually as the antisiphon device.

  • Page 56: Cooling System

    See Figure 6-10 for a typical installation. through-hull strainer. Install slotted-hole design strainers with the slots parallel to the direction of the The optional Kohler seawater strainer is threaded for 1/2 NPT fittings. vessel’s movement. 44 Installation TP-6277 10/03...

  • Page 57: Waterlines

    Note: Some seawater strainers include a seacock and an intake through-hull strainer. ADV-5661-C 1. Seawater pump inlet Figure 6-13 Seawater Pump Inlet 1-789 1. Seawater pump 2. Seawater strainer 6.5.5 Closed/Heat Exchanger 3. Seacock Figure 6-10 Seawater Strainer Closed heat exchanger cooling is the best alternative for most applications.
  • Page 58 Arrow Description Seawater Freshwater (Coolant/Antifreeze) TP-5586-6 1. Engine block 8. Thermostat closed 2. Exhaust manifold 9. Heat exchanger 3. Exhaust mixer elbow 10. Engine-driven seawater pump 4. Outlet flapper (exhaust/water discharge) 11. Seawater strainer 5. Silencer (customer-supplied) 12. Seacock 6. Thermostat open 13.

  • Page 59: Exhaust Systems

    13 mm (1/2 in.) on each end of the flexible cause severe nausea, exhaust hose connections. Kohler Co. requires a fainting, or death. downward pitch of at least 13 mm per 30.5 cm (0.5 in. per running foot). Use a flexible exhaust hose that exhaust...

  • Page 60: Above Waterline Installation

    Exhaust system guidelines for various generator set 6.6.3 Above Waterline Installation locations follow. Information and illustrations of stern- In addition to considerations described earlier, install a (rear) exhaust installations also apply to side-exhaust customer-supplied silencer with the silencer’s outlet at a installations.

  • Page 61: Mid/Below Waterline Installation

    6.6.4 Mid/Below Waterline Installation Follow USCG regulations for installing an antisiphon provision to prevent raw water entry into the engine. Use the siphon break if the exhaust manifold outlet is located less than 23 cm (9 in.) above the waterline when the craft is loaded to maximum capacity.
  • Page 62 Waterline 1. Mounting base 12. Seawater strainer 2. Retaining cap 13. Seacock 14. Intake strainer 3. Reed valve assembly 4. Maximum silencer vertical lift of 1.2 m (4 ft.) 15. Engine-driven seawater pump 16. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm 5.

  • Page 63: Electrical Systems

    6.7 Electrical Systems 6.7.1 AC Voltage Connections Make AC connections to the generator set inside the WARNING controller box. Typically, the generator set connects to a ship-to-shore transfer switch that allows the use of shore/utility power when docked or generator set power when docked or at sea.

  • Page 64: Circuit Breaker Considerations

    Circuit Breaker Considerations WARNING Mounting location. Mount the circuit breakers in the generator set controller. Sizing. Use the generator set voltage/frequency configuration determine circuit breaker Moving rotor. Hazardous voltage. Can cause severe injury or death. amperage. If the circuit breaker was sized for one voltage configuration and later the generator set is Operate the generator set only when reconnected to a different voltage, change the circuit...

  • Page 65: Installation In Steel Or Aluminum Vessels

    6.7.3 Installation in Steel or Aluminum 6.7.4 Installation Regulations Vessels The U.S. Coast Guard governs generator set installation in U.S. pleasurecraft and commercial Installation of a generator set in a vessel constructed of vessels. Refer to the applicable regulations below: a material capable of conducting current (e.g., steel or aluminum) is subject to considerations not normally encountered in fiberglass or wood vessels.

  • Page 66: Battery

    Alternative electrical paths include metallic fuel lines that can pose a fire hazard. See Figure 6-25 for battery connections to generator set. Kohler Co. recommends using one 12-volt battery to start the generator. See Figure 6-24 for minimum cold cranking amps (CCA) recommendations.

  • Page 67: Remote Start Switch Connection

    Kohler service Figure 6-26 for remote start panel connection to the distributors/dealers. generator set controller. Kohler Co. also offers a wiring harness with a connector keyed to the controller box connector. The other end of this harness has pigtails that...
  • Page 68 Notes 56 Installation TP-6277 10/03...

  • Page 69: Section 7 Installation Drawings

    Section 7 Installation Drawings ADV-5661-C Figure 7-1 Dimension Drawing—8/10/12.5E TP-6277 10/03 Installation Drawings 57...
  • Page 70 Notes 58 Installation Drawings TP-6277 10/03...

  • Page 71: 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 72 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter µF 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.

  • Page 73: 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 74: Appendix C Generator Selection And Wattage Requirements

    Appendix C Generator Selection and Wattage Requirements General Wattage Requirements Appliance Loads Generator sets often furnish AC for appliances such as Consider total wattage requirements (lights, motors, TVs, stereos, and electric water heaters. Except for appliances) when selecting a generator set, or when resistance-type loads such as the water heater, sizing wattage usage in which available space and requirements for appliances are usually low.

  • Page 75: Appendix D Generator Set Output Ratings Procedure

    General genset installation. Figure 5 outlines the calculations. Kohler Co. develops the kilowatt output rating of a Figure 6 contains examples of how heat variables affect Kohler marine genset based upon the calculations genset ratings.
  • Page 80 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 Kohler Power Systems Asia Pacific Headquarters TP-6277 10/03 7 Jurong Pier Road Singapore 619159 E 2003 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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