Kohler 40EFOZ Operation Manual
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Kohler 40EFOZ Operation Manual

Kohler 40EFOZ Operation Manual

Marine generator sets
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See also: Instruction and Installation Manual
Operation
Marine Generator Sets
33EFOZ/40EOZ
40EFOZ/50EOZ
55EFOZ/65EOZ
70EFOZ/80EOZ
80EFOZ/99EOZ
100EFOZ/125EOZ
125EFOZ/150EOZ
Models:
TP-6109 6/03c

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Summary of Contents for Kohler 40EFOZ

  • Page 1 Operation Marine Generator Sets Models: 33EFOZ/40EOZ 40EFOZ/50EOZ 55EFOZ/65EOZ 70EFOZ/80EOZ 80EFOZ/99EOZ 100EFOZ/125EOZ 125EFOZ/150EOZ TP-6109 6/03c...
  • Page 2 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 Information ............inside front cover Safety Precautions and Instructions .
  • Page 4 3.5.4 Exterior ............3.5.5 Battery .

  • 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. nausea, fainting, or death. Do not Generator set engine fuels and fuel Short circuits can cause bodily injury use copper tubing in diesel exhaust vapors are flammable and explosive.
  • Page 7 Fuel System Pipe sealant. Explosive fuel vapors Hazardous Voltage/ can cause severe injury or death. Electrical Shock 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. WARNING Hazardous voltage cause Hazardous backfeed voltage can cause severe injury or death. severe injury or death. Disconnect Connect the generator set to the the generator set from the load by building/marina electrical system only opening the line circuit breaker or by through an approved device and after...
  • Page 9 Sound shield removal. Exposed NOTICE WARNING moving parts can cause severe When replacing hardware, do not injury or death. The generator set substitute with inferior grade must be operating in order to perform hardware. Screws and nuts are some scheduled maintenance available in different hardness ratings.
  • Page 10 Notes Safety Precautions and Instructions TP-6109 6/03...

  • 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

    Obtain a complete list of maintenance and service parts from your authorized generator distributor/dealer. Models 40EOZ/ 50EOZ/ 65EOZ/ 80EOZ/ 99EOZ/ 125EOZ/ 150EOZ/ 33EFOZ 40EFOZ 55EFOZ 70EFOZ 80EFOZ 100EFOZ 125EFOZ Part Description Air Filter Element GM15397 GM15397 GM15397 GM15398 GM15398...

  • Page 13: Section 1 Specifications

    Section 1 Specifications 1.1 Introduction and 200--300% for the duration of the short circuit. The SCR assembly sends full exciter power to the main field The specification sheets for each generator set provide and the generator sustains up to 300% of rated current. specific generator and engine information.

  • Page 14: Service Views

    1.3 Service Views ADV-6581A- 1. Nameplate 15. Pressure cap 2. Controller (Decision-Makert I expanded controller shown) 16. Overflow tube 17. Heat exchanger 3. Generator set master switch 4. Hourmeter 18. Anticorrosion zinc anode 5. Air cleaner 19. Fuel injection pump 6.

  • Page 15: Remote Annunciator Kit

    1.4 Remote Annunciator Kit A remote annunciator provides convenient monitoring of the generator set’s condition from a remote location. See Figure 1-3. The remote annunciator includes an alarm horn, alarm silence switch, lamp test, and the same lamp indicators (except air damper and auxiliary X-796 prealarm) as the microprocessor controller, plus the Figure 1-4 Safeguard Breaker...
  • Page 16 Notes Section 1 Specifications TP-6109 6/03...

  • Page 17: Section 2 Operation

    Drive Belts. Check the belt condition and tension of the 2.2 Marine Inspection water pump and battery charging alternator belt. 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 18: Exercising The Generator Set

    2.5 Exercising the Generator Set 2.6 Decision-Maker 3+, 16-Light Microprocessor Controller Operate the generator set under load once each week Operation for one hour with an operator present. The Decision-Makert 3+, 16-light microprocessor The operator should perform all of the prestart checks controller has a prime power mode of operation.

  • Page 19: Controls And Indicators

    2.6.1 Controls and Indicators Lamp test switch Switch tests the controller indicator lamps. The following table describes the controls and indicators Low oil pressure Lamp illuminates if the generator located on the controller. lamp set shuts down because of low oil pressure.

  • Page 20: Fuses And Terminal Strips

    2.6.2 Fuses and Terminal Strips Name Description Auxiliary prealarm Lamp illuminates when The following table describes the controller circuit board lamp customer-provided sensing fuses and controller terminal strips. devices activate the pump. Emergency stop Lamp illuminates and the Name Description lamp generator set shuts down when 3-amp remote...

  • Page 21: Auxiliary Fault Lamp Conditions

    2.6.3 Auxiliary Fault Lamp Conditions Emergency Stop Switch Reset. Resetting the optional emergency stop switch while the generator set The following descriptions define the possible auxiliary master switch is in the AUTO or RUN position causes fault lamp conditions. the auxiliary lamp to light. Place the generator set master switch in the OFF/RESET position to clear the auxiliary lamp ON condition.

  • Page 22: Starting The Generator Set

    2.6.4 Starting the Generator Set 2.6.5 Stopping the Generator Set The following procedures describe starting the The following procedures describe stopping the generator set. generator set. Local Starting (Nonautomatic). Move the generator Normal Stopping set master switch to the RUN position to start the 1.

  • Page 23: Prime Power Mode Operation

    2.6.6 Prime Power Mode Operation 2.6.7 Fault Shutdowns The Decision-Makert 3+ controller operates in either The generator set shuts down automatically under the the normal mode or the prime power mode. In prime following fault conditions and cannot be restarted until power mode, the controller draws less current, the fault condition is corrected.

  • Page 24: Controller Resetting Procedure

    2.6.8 Controller Resetting Procedure 2.6.9 Resetting the Emergency Stop (Following Fault Shutdown) Switch Use the following procedure to restart the generator set Use the following procedure to restart the generator set after a fault shutdown. Refer to Resetting the after an emergency stop switch shutdown. Refer to the Emergency Stop Switch in this section to reset the Controller Resetting Procedure in this section to restart generator set after an emergency stop.

  • Page 25: Controller Operation

    2.7 Expanded Decision-Makert 1 Controller Operation For identification of the expanded controller’s indicators and controls and their functions, refer to Figure 2-4. ADV-5849E-B 1. Frequency meter 8. Voltage adjustment potentiometer 2. AC voltmeter 9. Fault lamp 3. AC ammeter 10. 10-amp controller fuse 4.

  • Page 26: Starting The Generator Set

    2.7.2 Starting the Generator Set Fault Description High engine Shutdown occurs 5 seconds after the The following procedures describe starting the temperature fault. The high engine temperature generator set. shutdown does not function during the first 5 seconds after startup. Local Starting.

  • Page 27: T 1 Controller Operation

    2.8 Standard Decision-Makert 1 2.8.2 Starting the Generator Set Controller Operation The following procedures describe starting the generator set. For identification of the standard basic controller’s indicators and controls and their functions, refer to Local Starting. Move the generator set master switch Figure 2-5.

  • Page 28: Fault Shutdowns

    2.8.4 Fault Shutdowns 2.8.5 Controller Resetting Procedure (Following Fault Shutdown) The generator set shuts down automatically under the following fault conditions and cannot be restarted until Use the following procedure to restart the generator set the fault condition is corrected. The system automatically after a fault shutdown.

  • Page 29: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance 3.1 General Maintenance Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely WARNING hot during operation. WARNING Accidental starting. Can cause severe injury or death.

  • Page 30: Generator Set 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 31: Cooling System

    3.3 Cooling System Siphon Break Inspection 1. Stop the generator set. WARNING 2. Remove the retaining cap and remove the reed valve for inspection. See Figure 3-1. 3. Use a mild detergent to remove residue and oxidation from the reed valve. Hot coolant and steam.

  • Page 32: Impeller Inspection And Replacement Procedure

    3.3.2 Impeller Inspection and Replacement Procedure The gear 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.

  • Page 33: Exhaust System

    3.4 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 34: Storage Procedure

    3.5 Storage Procedure 3.5.3 Fuel System Prepare the fuel system for storage as follows: Perform the following storage procedure before taking a generator set out of service for three months or longer. Diesel-Fueled Engines Follow the engine manufacturer’s recommendations, if available, for fuel system and internal engine 1.

  • Page 35: Section 4 General 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 36 TP-6109 6/03 Section 4 Troubleshooting...
  • Page 37 TP-6109 6/03 Section 4 Troubleshooting...
  • Page 38 TP-6109 6/03 Section 4 Troubleshooting...
  • Page 39 TP-6109 6/03 Section 4 Troubleshooting...
  • Page 40 Notes Troubleshooting TP-6109 6/03...

  • 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 GM24452A-A Figure 5-1 Wiring Diagram, Decision-Makert 1 Standard Controller (Sheet 1 of 3) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 43 GM24452B-A Figure 5-2 Wiring Diagram, Decision-Makert 1 Standard Controller, Remote Panel Options (Sheet 2 of 3) TP-6109 6/03 Section 5 Wiring Diagrams...
  • Page 44 GM24452C-A Figure 5-3 Wiring Diagram, Decision-Makert 1 Standard Controller, Remote Panel Options (Sheet 3 of 3) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 45 ADV6740-A Figure 5-4 Wiring Diagram—Schematic, Decision-Makert 1 Standard Controller (Sheet 1 of 1) TP-6109 6/03 Section 5 Wiring Diagrams...
  • Page 46 GM24453A-A Figure 5-5 Wiring Diagram, Decision-Makert 1 Expanded Controller (Sheet 1 of 6) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 47 GM24453B-A Figure 5-6 Wiring Diagram, Decision-Makert 1 Expanded Controller (Sheet 2 of 6) TP-6109 6/03 Section 5 Wiring Diagrams...
  • Page 48 GM24453C-A Figure 5-7 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 3 of 6) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 49 GM24453D-A Figure 5-8 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 4 of 6) TP-6109 6/03 Section 5 Wiring Diagrams...
  • Page 50 GM24453E-A Figure 5-9 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 5 of 6) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 51 GM24453F-A Figure 5-10 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 6 of 6) TP-6109 6/03 Section 5 Wiring Diagrams...
  • Page 52 ADV6741-A Figure 5-11 Wiring Diagram—Schematic, Decision-Makert 1 Expanded Controller (Sheet 1 of 1) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 53 GM24454A-B Figure 5-12 Wiring Diagram, Decision-Makert 3+ Controller (Sheet 1 of 7) TP-6109 6/03 Section 5 Wiring Diagrams...
  • Page 54 GM24454B-B Figure 5-13 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 2 of 7) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 55 GM24454C-B Figure 5-14 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 3 of 7) TP-6109 6/03 Section 5 Wiring Diagrams...
  • Page 56 GM24454D-B Figure 5-15 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 4 of 7) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 57 GM24454E-B Figure 5-16 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel/Annunciator Options (Sheet 5 of 7) TP-6109 6/03 Section 5 Wiring Diagrams...
  • Page 58 GM24454F-B Figure 5-17 Wiring Diagram, Decision-Makert 3+ Controller, Remote Annunciator Options (Sheet 6 of 7) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 59 GM24454G-B Figure 5-18 Wiring Diagram, Decision-Makert 3+ Controller, Remote Annunciator Options (Sheet 7 of 7) TP-6109 6/03 Section 5 Wiring Diagrams...
  • Page 60 ADV6742-A Figure 5-19 Wiring Diagram—Schematic, Decision-Makert 3+ Controller (Sheet 1 of 1) Section 5 Wiring Diagrams TP-6109 6/03...
  • Page 61 Terminal Purpose Terminal Purpose Ground—emergency stop relay (K4)—connect Prime power operation emergency stop across terminals TB1-1 and Prime power operation 1A * Remote start ground—connect transfer Emergency stop relay (K4) coil; negative switch or remote start switch to TB2--3 and side—connect emergency stop across TB2--4 terminals TB1-1 and 1A *...
  • Page 62 Notes Section 5 Wiring Diagrams TP-6109 6/03...

  • Page 63: 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 64 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 65: 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 68 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-6109 6/03c 7 Jurong Pier Road Singapore 619159 E 2000, 2001, 2002, and 2003 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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