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Kohler 11EFOZ Service Manual

Kohler 11EFOZ
76 pages
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Marine Generator Sets
Models:
13EOZ/11EFOZ
14EOZ/11.5EFOZ
15.5EOZ/13EFOZ
20EOZ/16EFOZ
20EOZ/17.5EFOZ
23EOZ/19EFOZ
24EOZ/20EFOZ
TP-6071 3/00
Service

Table of Contents

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Kohler 11EFOZ Specifications

General IconGeneral
Model11EFOZ
Fuel TypeGasoline
Starting SystemRecoil
Frequency60 Hz
TypePortable
Rated Voltage120V
Outlet Types(2) 120V 20A

Summary

Safety Precautions and Instructions

Accidental Starting Hazards

Procedures to prevent accidental starting and associated dangers.

Battery Safety Precautions

Hazards related to battery acid, gases, and short circuits.

Safety Precautions and Instructions (Continued)

Engine Fire and Exhaust Hazards

Warnings regarding fuel, sparks, fire, and carbon monoxide.

Safety Precautions and Instructions (Continued)

Fuel System Safety and Handling

Precautions for handling fuel, vapors, and preventing explosions.

Hazardous Noise Exposure

Risks of hearing loss from generator noise and necessary precautions.

Safety Precautions and Instructions (Continued)

Electrical and Mechanical Hazards

Dangers of hazardous voltage, moving rotors, and heavy equipment lifting.

Hot Component Warnings

Warnings about hot parts like coolant and engine components.

Safety Precautions and Instructions (Continued)

Rotating Parts and General Notices

Safety regarding rotating parts, voltage reconnection, hardware, fuses, and saltwater.

Introduction to the Manual

Service Assistance and Information

Service Contacts and Dealer Locations

How to find authorized dealers and contact Kohler service.

Product Identification and Records

Recording generator and engine identification numbers for parts.

Generator Set Specifications

General Model Coverage and Cooling System

Overview of generator models, engine types, and cooling system components.

Generator Set Specifications (Continued)

Engine Specifications by Model

Detailed engine parameters for various generator models.

Generator Set Specifications (Continued)

Fuel and Cooling System Details

Specifications for fuel system components and cooling system parameters.

Generator Set Specifications (Continued)

Generator Electrical Specifications

Electrical performance data for 4-lead and 12-lead generator configurations.

Generator Set Specifications (Continued)

Service Views and Component Identification

Diagrams identifying key components of the generator set.

Scheduled Maintenance Procedures

General Maintenance and Safety

Guidelines for routine maintenance and critical safety warnings.

Scheduled Maintenance Procedures (Continued)

Lubrication System Service

Guidance on selecting and maintaining engine oil for diesel engines.

Intake and Exhaust System Service

Air Intake Silencer and Exhaust Inspection

Procedures for servicing the air intake silencer and inspecting the exhaust system.

Intake and Exhaust System Service (Continued)

Mixing Elbow and Turbocharger Maintenance

Maintenance of the mixing elbow and inspection of the turbocharger.

Fuel System Service and Maintenance

Fuel System Overview and Filter Replacement

Fuel system description, availability, and fuel filter replacement.

Fuel System Service and Maintenance (Continued)

Fuel System Bleeding and Pump Testing

Procedures for bleeding air from the fuel system and testing the fuel pump.

Fuel System Service and Maintenance (Continued)

Governor Adjustment and Speed Control

How to adjust the governor for engine speed and frequency control.

Cooling System Service and Components

Cooling System Overview and Component Identification

Description of the cooling system and identification of its parts.

Cooling System Service and Components (Continued)

Heat Exchanger, Coolant, and Flushing Procedures

Operation of the heat exchanger, coolant checks, and system flushing.

Cooling System Service and Components (Continued)

Seawater Pump Impeller Service

Steps for inspecting and replacing the seawater pump impeller.

Cooling System Service and Components (Continued)

Siphon Break Inspection and Function

Procedure to inspect the siphon break for proper function against seawater entry.

Controller Troubleshooting Procedures

Controller Identification and Basic Checks

Identification of controller components and initial troubleshooting steps.

Controller Troubleshooting Procedures (Continued)

Controller Sequence of Operation (Start, Run, Stop)

Detailed description of the controller's start, run, and stop sequences.

Controller Troubleshooting Procedures (Continued)

Sequence of Operation Wiring Diagram

Wiring diagram illustrating the controller's sequence of operations.

Controller Troubleshooting Procedures (Continued)

Engine Safety Shutdown Switch Functions

Explanation of low oil pressure and high temperature shutdown switch operations.

Controller Troubleshooting Procedures (Continued)

Overspeed Shutdown and Circuit Board Testing

Overspeed shutdown logic and procedures for testing controller circuit board components.

Controller Troubleshooting Procedures (Continued)

Troubleshooting Flow Chart - Part 1

Step-by-step troubleshooting guide for controller circuit board issues.

Controller Troubleshooting Procedures (Continued)

Troubleshooting Flow Chart - Part 2

Continuation of troubleshooting guide for engine starting failures.

Controller Troubleshooting Procedures (Continued)

Troubleshooting Flow Chart - Part 3

Continuation of troubleshooting guide for engine run and stop issues.

Controller Troubleshooting Procedures (Continued)

Troubleshooting Flow Chart - Part 4

Continuation of troubleshooting guide for AC output and regulator issues.

Controller Troubleshooting Procedures (Continued)

Troubleshooting Flow Chart - Part 5

Final part of troubleshooting guide for LED status and safety switch functions.

Generator Troubleshooting Guide

General Troubleshooting Safety and Overview

General procedures and safety precautions for generator troubleshooting.

Generator Troubleshooting Guide (Continued)

Generator Output and Separate Excitation

Checks for output issues and procedure for separate excitation testing.

Generator Troubleshooting Guide (Continued)

PowerBoost™ V Voltage Regulator Overview

Information on the PowerBoost™ V voltage regulator and its V/Hz feature.

Generator Troubleshooting Guide (Continued)

Voltage Regulator Test Procedure

Detailed procedure for testing the voltage regulator using specific components.

Generator Troubleshooting Guide (Continued)

Voltage Regulator Adjustment and Exciter Field Test

How to adjust the voltage regulator and test the exciter field.

Generator Troubleshooting Guide (Continued)

Exciter Armature and Rectifier Module Tests

Methods for testing the exciter armature and rectifier module.

Generator Troubleshooting Guide (Continued)

Rotor (Main Field) and Rectifier Module Tests

Procedures for testing the generator rotor's resistance and the rectifier module.

Generator Troubleshooting Guide (Continued)

Rotor and Stator Testing

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

Generator Troubleshooting Guide (Continued)

Stator Continuity and Resistance Testing

Procedures for testing stator continuity and resistance to ground.

Generator Troubleshooting Guide (Continued)

Stator Continuity and Ground Tests

Details on checking stator continuity and ground resistance for single/three-phase.

Component Troubleshooting Procedures

General Component Testing and Hourmeter/Stator

General guidance and tests for hourmeter and stator auxiliary windings.

Component Troubleshooting Procedures (Continued)

Testing Switches, Relays, and Fields

Testing procedures for switches, relays, exciter fields, and armatures using an ohmmeter.

Component Troubleshooting Procedures (Continued)

Rotor, Safety Switches, and Remote Panel Senders

Testing rotor, safety switches, and remote panel sender resistance values.

Component Troubleshooting Procedures (Continued)

Remote Start Panel Switch and Gauge Testing

Troubleshooting guide for remote start panel switches, lights, and gauges.

Generator Disassembly and Reassembly

Initial Disassembly Steps and Component Removal

Steps for disconnecting connections and removing covers and controller.

Generator Disassembly and Reassembly (Continued)

Exciter Field, Armature, and Rotor Removal

Detailed steps for removing the exciter field, armature, and rotor.

Generator Disassembly and Reassembly (Continued)

Stator and Rotor Assembly Removal Procedures

Procedures for removing the stator assembly and the rotor/drive disc assembly.

Generator Disassembly and Reassembly (Continued)

Generator Reassembly Steps and Alignment

Steps for installing the drive disc, rotor assembly, and stator, including alignment.

Generator Disassembly and Reassembly (Continued)

Final Reassembly and External Connections

Installing the exciter field, rectifier board, and reconnecting external components.

Wiring Diagrams and Electrical Safety

Electrical Safety Precautions for Diagrams

Safety precautions related to electrical work and interpreting wiring diagrams.

Wiring Diagrams and Electrical Safety (Continued)

Manual Marine Transfer Switch Diagrams (2/3 Wire)

Wiring diagrams for manual marine transfer switches with generator sets.

Wiring Diagrams and Electrical Safety (Continued)

Manual Marine Transfer Switch Diagram (4 Wire)

Wiring diagram for manual marine transfer switches with 4-wire generator sets.

Wiring Diagrams and Electrical Safety (Continued)

Remote Start Panel Wiring Diagrams

Wiring diagrams for basic remote start panels and panels with gauges.

Wiring Diagrams and Electrical Safety (Continued)

Remote Start and Four-Meter Panel Wiring

Wiring diagram for a remote start panel with four gauges.

Wiring Diagrams and Electrical Safety (Continued)

4-Lead Generator Wiring Diagram

Comprehensive wiring diagram for 4-lead generator sets.

Wiring Diagrams and Electrical Safety (Continued)

12-Lead Generator Wiring Diagram

Comprehensive wiring diagram for 12-lead generator sets.

Appendix A: Abbreviations Glossary

Appendix B: Hardware Application Guidelines

Bolt Length and Nut/Bolt Clearance Rules

Guidance on selecting appropriate bolt lengths and nut clearances for fasteners.

Appendix C: General Torque Specifications

Appendix D: Hardware Identification Guide

Appendix E: Common Hardware List (American Standard)

Appendix E: Common Hardware List (Metric)

Metric Hardware Part Numbers and Dimensions

A list of common hardware part numbers and dimensions for metric items.

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