Format: PDF (Printable Document)
File Language: English
File Pages: 79
File Size: 2.48 MB (Speed Download Link)
Brand: Kohler
Model: 15C, 20C 12.5CF, 16CF Marine
Book No: tp5983
Type of Document: Service Manual
$ 40
These Kohler 15C, 20C, 12.5CF, and 16CF marine units usually sit in tight engine rooms, backing up onboard power for lights, instruments, and hotel loads. This service manual is what I’d keep on the bench when I’m tracing a no‑start, hunting RPM, or an intermittent shutdown that only shows up under load. It walks you through checking systems in a logical order so you can prove a component is bad before you pull it, instead of just throwing parts at the genset.
Applications & Use Cases
FAQ
Q: Can I keep this manual on a tablet in the engine room?
A: Yes, it’s handy on a tablet for quick zooming on diagrams, but protect the device from heat and moisture.
Q: Is it worth printing sections of this manual?
A: Many techs print the procedures they’re using that day so they can mark notes, oily fingerprints, and test readings right on the page.
Safety Note
Always lock out power and secure the vessel before working on these units, especially in cramped or poorly ventilated spaces.
Safety Precautions and Instructions . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . i
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Operation Requirements . . . . . . . . . . . . . . . . . . . . 2
1.6 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2
1.7 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 2 Scheduled Maintenance . . . . . . . . . . . 5
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 3 Intake and Exhaust System . . . . . . . . 7
3.1 Backfire Flame Arrestor . . . . . . . . . . . . . . . . . . . . . 7
3.2 Crankcase Ventilation System . . . . . . . . . . . . . . . 7
3.3 Exhaust System Inspection . . . . . . . . . . . . . . . . . . 7
3.4 Servicing Mixing Elbow . . . . . . . . . . . . . . . . . . . . . 8
Section 4 Fuel System . . . . . . . . . . . . . . . . . . . . . 9
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Fuel Pump and Filter . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Carburetor Disassembly/ Reassembly . . . . . . . . 11
4.4.1 Cleaning and Inspection . . . . . . . . . . . . 11
4.4.2 Air Intake Reassembly . . . . . . . . . . . . . . 12
4.4.3 Fuel Bowl Assembly . . . . . . . . . . . . . . . . 12
4.5 Carburetor Troubleshooting . . . . . . . . . . . . . . . . . 14
4.5.1 Hard Starting . . . . . . . . . . . . . . . . . . . . . . 14
4.5.2 Stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5.3 Percolation . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5.4 Flooding . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5.5 Surging Above Idle . . . . . . . . . . . . . . . . . 14
4.5.6 Leaking Carburetor . . . . . . . . . . . . . . . . . 14
4.5.7 Inconsistent Idle Speed . . . . . . . . . . . . . 14
4.6 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.6.1 Governor to Carburetor Adjustment . . . 15
4.6.2 High Speed Governor Adjustment . . . . 15
Section 5 Cooling System . . . . . . . . . . . . . . . . . . 17
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Closed Heat Exchanger . . . . . . . . . . . . . . . . . . . . . 18
5.3 Check and Fill Coolant . . . . . . . . . . . . . . . . . . . . . 18
5.4 Flush and Clean Cooling System . . . . . . . . . . . . . 18
5.5 Impeller Inspection/ Replacement . . . . . . . . . . . . 19
5.6 Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.7 Anticorrosion Zinc Anode . . . . . . . . . . . . . . . . . . . 21
5.8 Generator Storage . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 6 Controller Troubleshooting . . . . . . . . 23
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Controller Sequence of Operation . . . . . . . . . . . . 23
6.2.1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.2 Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.3 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 Engine Safety Shutdown Switches . . . . . . . . . . . 25
6.3.1 Low Oil Pressure (LOP) Shutdown . . . 25
6.3.2 High Water Temperature (HWT)
and High Exhaust Temperature
(HET) Shutdown Switch . . . . . . . . . . . . . 25
6.3.3 Controller Circuit Board . . . . . . . . . . . . . 25
6.3.4 Troubleshooting Flow Chart . . . . . . . . . 26
Section 7 Generator Troubleshooting . . . . . . . . 31
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 General Troubleshooting . . . . . . . . . . . . . . . . . . . . 31
7.3 Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . 32
7.4 PowerBoost V Voltage Regulators . . . . . . . . . . . . 33
7.5 Voltage Regulator Test . . . . . . . . . . . . . . . . . . . . . 33
7.6 Voltage Regulator Adjustment . . . . . . . . . . . . . . . 34
7.7 Exciter Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.8 Exciter Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.9 Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.10 Rotor (Main Field) . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.11 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Section 8 Component Troubleshooting . . . . . . 41
8.1 Engine/Generator Components . . . . . . . . . . . . . . 41
8.2 Remote Panels (Optional) . . . . . . . . . . . . . . . . . . . 43
Section 9 Generator Disassembly/
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Section 10 Wiring Diagrams . . . . . . . . . . . . . . . . 51
10.1 Wiring Diagram—Schematic . . . . . . . . . . . . . . . . . 52
10.2 Wiring Diagram—Point-to-Point . . . . . . . . . . . . . . 53
10.3 Remote Start Panel . . . . . . . . . . . . . . . . . . . . . . . . 54
10.4 Remote Start and Two-Meter Panel . . . . . . . . . . 54
10.5 Remote Start and Four-Meter Panel . . . . . . . . . . 55
10.6 Marine Manual (Ship-to-Shore)
Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
