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Kohler 10EOZ User Manual

Kohler 10EOZ
80 pages
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Marine Generator Sets
Models:
5EOZ
8EOZ
9EOZ
10EOZ
4EFOZ
6.5EFOZ
8EFOZ
9EFOZ
TP-6053 7/04a
Service

Table of Contents

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Kohler 10EOZ Specifications

General IconGeneral
Model10EOZ
TypePortable Generator
Fuel TypeGasoline
Voltage120/240 V
Frequency60 Hz
Wheel KitIncluded
AC Output Running Watts10000 watts
AC Output Starting Watts12500 watts
Rated Wattage10000 watts
Maximum Wattage12500 watts
Starting SystemElectric Start

Summary

Safety Precautions and Instructions

Accidental Starting Safety

Warnings and procedures to prevent accidental generator startup during maintenance.

Battery Handling and Safety

Hazards associated with battery acid, gases, and electrical shock.

Engine-Related Hazards

Risks of engine backfire, flash fire, and carbon monoxide exposure.

Fuel System Safety Precautions

Precautions regarding explosive fuel vapors and fire hazards.

Noise, Voltage, and Electrical Hazards

Dangers of hazardous noise, voltage, and electrical shock.

Hot Parts and Component Safety

Warnings about hot engine parts, coolant, and exhaust system.

Moving Parts Safety Precautions

Hazards associated with rotating parts and airborne particles.

Introduction to the Manual

Service Assistance and Support

Contact information and resources for professional advice and service.

Generator Set Specifications

General Generator Set Information

Overview of the manual's scope and generator set models covered.

Generator Set Service Views and Diagrams

Diagrams identifying key components of generator set models.

Engine Specifications

Detailed specifications for the engine models used in generator sets.

Generator Electrical Specifications

Electrical and performance specifications for the generator end.

Scheduled Maintenance Procedures

General Maintenance Guidelines

Essential safety and operational notes for scheduled maintenance.

Engine Lubrication System Maintenance

Guidance on engine oil selection and capacities for proper lubrication.

Battery Care and Maintenance

Procedures and precautions for battery care and maintenance.

Generator Storage Procedures

Steps for preparing the generator set for extended storage periods.

Intake and Exhaust System Maintenance

Air Intake Silencer/Filter Maintenance

Maintenance procedures for the air cleaner and silencer assembly.

Exhaust System Inspection and Safety

Guidelines for inspecting the exhaust system for leaks and blockages.

Mixing Elbow Maintenance

Procedures for cleaning and inspecting the exhaust mixing elbow.

Fuel System Maintenance and Troubleshooting

General Fuel System Overview

Overview of typical fuel system arrangements and low supply warnings.

Diesel Fuel Specifications

Recommended diesel fuel quality and standards for optimal performance.

Fuel Filter Replacement Procedures

Procedures for replacing spin-on and element-type fuel filters.

Bleeding the Fuel System

Steps to remove air from the fuel system to ensure proper starting.

Fuel Solenoid Operation and Testing

Information on the fuel solenoid's function, wiring, and readings.

Fuel Pump Testing Procedure

Procedure to test the fuel pump's operation and output.

Governor Speed Adjustment

Instructions for checking and adjusting engine speed and frequency.

Cooling System Maintenance

General Cooling System Overview

Overview of the cooling system components and their functions.

Water-Cooled Exhaust Manifold

Details on the exhaust manifold and its role in heat management.

Closed Heat Exchanger System

Explanation of the closed cooling system and heat exchanger operation.

Coolant Level Check and Fill

Guidelines for checking coolant levels and recommended coolant mixtures.

Cooling System Flush and Cleaning

Procedure for draining, flushing, and refilling the cooling system.

Pressure Cap Function

Information on the pressure cap's function in raising the boiling point.

Seawater Pump Impeller Service

Steps for inspecting and replacing the seawater pump impeller.

Belt Tension Adjustment

Procedure for checking and adjusting belt tension on the generator set.

Siphon Break Inspection

How to inspect the siphon break to prevent seawater entry.

Anticorrosion Zinc Anode Service

Information on checking and replacing the zinc anode to prevent corrosion.

Controller Troubleshooting

General Controller Troubleshooting

Introduction to controller troubleshooting procedures and component identification.

Controller Sequence of Operation

Explanation of the controller's operational sequence for start, run, and stop.

Engine Safety Shutdown Switch Integration

How safety shutdown switches (LOP, HWT, HET) affect controller operation.

Controller Circuit Board Components

Overview of the controller circuit board, LEDs, and testing methods.

Troubleshooting Flowcharts

Step-by-step troubleshooting guides for relay controller circuit board issues.

Generator Troubleshooting

General Troubleshooting Precautions

Safety precautions and essential checks before troubleshooting the generator.

General Troubleshooting Steps for Output Issues

Initial steps and flow chart for diagnosing no- or low-AC output issues.

Separate Excitation Test Procedure

Procedure for testing the generator by separately exciting the rotor.

PowerBoost IIIE Voltage Regulator

Information on the PowerBoost IIIE voltage regulator and its testing.

Voltage Regulator Output Test

Method to test the voltage regulator's output using specific components.

Voltage Regulator Adjustment Procedure

Procedure for adjusting voltage regulator settings for output control.

Exciter Field Resistance Test

How to test the exciter field for continuity and ground faults.

Exciter Armature Testing

Procedures for testing the exciter armature's continuity and ground resistance.

Rectifier Module Diode Test

Method to test the rectifier module diodes for proper function.

Rotor Main Field Testing

Procedures for testing the generator rotor's main field resistance and ground.

Stator Continuity and Resistance Tests

Steps for testing stator continuity, resistance, and ground faults.

Component Troubleshooting

General Component Testing Procedures

Overview of component testing procedures using a multimeter.

Remote Panel Troubleshooting

Troubleshooting guides for remote start panels and gauges.

Generator Disassembly and Reassembly

Disassembly Procedures

Step-by-step instructions for disassembling the generator set components.

Reassembly Procedures

Step-by-step instructions for reassembling the generator set components.

Voltage Reconnection and Wiring Diagrams

Voltage Reconnection Configurations

Guidelines for reconnecting generator set leads for different voltage configurations.

Marine Transfer Switch Wiring Diagrams

Wiring diagrams for marine ship-to-shore transfer switch installations.

Schematic Wiring Diagram

Detailed schematic of the generator set's electrical system wiring.

Point-to-Point Wiring Diagram

Point-to-point wiring diagram for component connections.

Remote Start Panel Wiring Diagram

Wiring diagram for a basic remote start panel.

Remote Start & 2-Meter Panel Wiring

Wiring diagram for remote start panel with two gauges.

Remote Start & 4-Meter Panel Wiring

Wiring diagram for remote start panel with four gauges.

Appendix A: Abbreviations

Appendix B: Common Hardware Application Guidelines

Appendix C: General Torque Specifications

Appendix D: Common Hardware Identification

Appendix E: Common Hardware List

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