Format: PDF (Printable Document)
File Language: English
File Pages: 80
File Size: 2.45 MB (Speed Download Link)
Brand: Kohler
Model: 5EOZ, 8EOZ, 9EOZ, 10EOZ, 4EFOZ, 6.5EFOZ, 8EFOZ, 9EFOZ Marine
Book No: tp6053
Type of Document: Service Manual
$ 40
These Kohler EOZ and EFOZ marine sets usually sit in tight engine rooms, running hotel loads, electronics, and air-con while the main engines are off. This service manual is what I pull out when I need to prove what’s actually wrong before hanging parts. If a unit is slow to pick up load or trips on shutdown, I use this book to trace fuel, air, and electrical systems in a logical order, then disassemble only what’s needed and set it back up to spec.
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 diagrams and use search to jump straight to the system you’re working on.
Q: Is it worth printing sections of this manual?
A: Many techs print the pages for the job they’re doing so they can mark notes, oily fingerprints, and torque reminders right at the generator.
Safety Note
Always lock out power sources and verify the set cannot start automatically before opening, testing, or adjusting any component.
Safety Precautions and Instructions . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . i
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 2 Scheduled Maintenance . . . . . . . . . . . 7
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Generator Storage . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section 3 Intake and Exhaust System . . . . . . . . 11
3.1 Air Intake Silencer/Filter . . . . . . . . . . . . . . . . . . . . 11
3.2 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Mixing Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section 4 Fuel System . . . . . . . . . . . . . . . . . . . . . 13
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Bleed the Fuel System . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.6 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.7 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 5 Cooling System . . . . . . . . . . . . . . . . . . 19
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Water-Cooled Exhaust Manifold . . . . . . . . . . . . . . 20
5.3 Closed Heat Exchanger . . . . . . . . . . . . . . . . . . . . . 20
5.4 Fill Check and Coolant . . . . . . . . . . . . . . . . . . . . . 20
5.5 Flush and Clean Cooling System . . . . . . . . . . . . . 20
5.6 Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.7 Impeller Inspection and Replacement . . . . . . . . . 21
5.8 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.9 Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.10 Anticorrosion Zinc Anode . . . . . . . . . . . . . . . . . . . 24
Section 6 Controller Troubleshooting . . . . . . . . 25
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 Controller Sequence of Operation . . . . . . . . . . . . 25
6.2.1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.2 Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.3 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3 Engine Safety Shutdown Switches . . . . . . . . . . . 26
6.3.1 Low Oil Pressure (LOP) Shutdown . . . 26
6.3.2 High Water Temperature and
High Exhaust Temperature
Shutdown Switch . . . . . . . . . . . . . . . . . . 26
6.4 Controller Circuit Board . . . . . . . . . . . . . . . . . . . . . 27
6.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Section 7 Generator Troubleshooting . . . . . . . . 33
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.2 General Troubleshooting . . . . . . . . . . . . . . . . . . . . 33
7.3 Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . 34
7.4 PowerBoost IIIE Voltage Regulators . . . . . . . . . . 34
7.4.1 Voltage Regulator Test . . . . . . . . . . . . . . 35
7.4.2 Voltage Regulator Adjustment . . . . . . . 35
7.5 Exciter Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.6 Exciter Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.7 Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.8 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.9 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Section 8 Component Troubleshooting . . . . . . 41
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2 Remote Panels (Optional) . . . . . . . . . . . . . . . . . . . 43
Section 9 Generator Disassembly/
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Section 10 Voltage Reconnection and
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.1 Voltage Reconnection . . . . . . . . . . . . . . . . . . . . . . 51
10.1.1 100–120-Volt Configurations . . . . . . . . . 51
10.1.2 100–120/200–240-Volt
Configurations . . . . . . . . . . . . . . . . . . . . . 52
10.1.3 200–240-Volt Configurations . . . . . . . . . 52
10.2 Marine Manual (Ship-to-Shore)
Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.3 Wiring Diagram, Schematic . . . . . . . . . . . . . . . . . 54
10.4 Wiring Diagram, Point-to-Point . . . . . . . . . . . . . . . 55
10.5 Remote Start Panel . . . . . . . . . . . . . . . . . . . . . . . . 56
10.6 Remote Start and 2-Meter Panel . . . . . . . . . . . . . 56
10.7 Remote Start and 4-Meter Panel . . . . . . . . . . . . . 57
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
