Format: PDF (Printable Document)
File Language: English
File Pages: 76
File Size: 3.61 MB (Speed Download Link)
Brand: Kohler
Model: 13EOZ, 11EFOZ, 14EOZ, 11.5EFOZ, 15.5EOZ, 13EFOZ, 20EOZ, 16EFOZ, 20EOZ, 17.5EFOZ, 23EOZ, 19EFOZ, 24EOZ, 20EFOZ Marine
Book No: tp6071
Type of Document: Service Manual
$ 40
These Kohler marine gensets live in tight, hot engine rooms, running hotel loads, electronics, and air conditioning while the main engines are off. This service manual is what I’d keep on the bench when I need to trace a no‑start, chase an uneven voltage issue, or pull a component without guessing. For example, if a set is shutting down after a few minutes, I’d use this book to step through fuel, cooling, and electrical checks in a logical order before blaming the controller or the alternator end.
Applications & Use Cases
FAQ
Q: Can I keep this manual on a tablet in the engine room?
A: Yes, it works well digitally; you can zoom in on diagrams and search by model or keyword while you’re at the set.
Q: Is it worth printing sections of this manual?
A: I often print the procedures I’m using that day, so greasy hands don’t ruin my device and I can mark notes as I test.
Safety Note
Always lock out power, secure the genset, and let hot components cool before opening, loosening, or testing anything.
Safety Precautions and Instructions . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . ii
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Generator, 4 Lead . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Generator, 12 Lead . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 2 Scheduled Maintenance . . . . . . . . . . . 7
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section 3 Intake and Exhaust System . . . . . . . . 9
3.1 Air Intake Silencer . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Exhaust System Inspection . . . . . . . . . . . . . . . . . . 9
3.3 Servicing Mixing Elbow . . . . . . . . . . . . . . . . . . . . . 10
3.4 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 4 Fuel System . . . . . . . . . . . . . . . . . . . . . 11
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 5 Cooling System . . . . . . . . . . . . . . . . . . 15
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Closed Heat Exchanger . . . . . . . . . . . . . . . . . . . . . 16
5.3 Check and Fill Coolant . . . . . . . . . . . . . . . . . . . . . 16
5.4 Flush and Clean Cooling System . . . . . . . . . . . . . 16
5.5 Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.6 Impeller Inspection and Replacement . . . . . . . . . 17
5.7 Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section 6 Controller Troubleshooting . . . . . . . . 19
6.1 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Controller Sequence of Operation . . . . . . . . . . . . 20
6.2.1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.2 Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.3 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Engine Safety Shutdown Switches . . . . . . . . . . . 22
6.3.1 Low Oil Pressure (LOP)
Shutdown Switch . . . . . . . . . . . . . . . . . . 22
6.3.2 High Water Temperature (HWT) and
High Exhaust Temperature (HET)
Shutdown Switch . . . . . . . . . . . . . . . . . . 22
6.3.3 Overspeed Safety Shutdown (SDR) . . 23
6.4 Controller Circuit Board . . . . . . . . . . . . . . . . . . . . . 23
6.5 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . 24
Section 7 Generator Troubleshooting . . . . . . . . 29
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2 Generator Troubleshooting . . . . . . . . . . . . . . . . . . 29
7.3 Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4 PowerBoost V Voltage Regulators . . . . . . . . . . 30
7.5 Voltage Regulator Test . . . . . . . . . . . . . . . . . . . . . 31
7.6 Voltage Regulator Adjustment . . . . . . . . . . . . . . . 32
7.7 Exciter Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.8 Exciter Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.9 Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.10 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.11 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Section 8 Component Troubleshooting . . . . . . 39
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.2 Remote Panels (Optional) . . . . . . . . . . . . . . . . . . . 41
Section 9 Generator
Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . 43
9.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Section 10 Wiring Diagrams . . . . . . . . . . . . . . . . 49
10.1 Manual Marine (Ship-to-Shore) 2 Wire and 3 Wire
Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.2 Manual Marine (Ship-to-Shore) 4 Wire Transfer
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.3 Remote Start Panel . . . . . . . . . . . . . . . . . . . . . . . . 52
10.4 Remote Start and Two-Meter Panel . . . . . . . . . . 52
10.5 Remote Start and Four-Meter Panel . . . . . . . . . . 53
10.6 Wiring Diagram 4-Lead . . . . . . . . . . . . . . . . . . . . . 55
10.7 Wiring Diagram 12-Lead . . . . . . . . . . . . . . . . . . . . 56
Appendix A Abbreviations . . . . . . . . . . . . . . . . A-1
Appendix B Common Hardware
Application Guidelines . . . . . . . . . . . . . . . . . . . . A-3
Appendix C General Torque
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Appendix D Common Hardware
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Appendix E Common Hardware List . . . . . . . A-6
