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Kohler 80EFOZ User Manual

Kohler 80EFOZ
68 pages
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Marine Generator Sets
TP-6109 6/03c
Operation
Models:
33EFOZ/40EOZ
40EFOZ/50EOZ
55EFOZ/65EOZ
70EFOZ/80EOZ
80EFOZ/99EOZ
100EFOZ/125EOZ
125EFOZ/150EOZ

Other manuals for Kohler 80EFOZ

Questions and Answers:

Kohler 80EFOZ Specifications

General IconGeneral
BrandKohler
Model80EFOZ
CategoryMarine Equipment
LanguageEnglish

Summary

Product Identification Information

Generator Set Identification Numbers

Record product identification numbers from the generator set nameplate.

Engine Identification

Record product identification information from the engine nameplate.

Safety Precautions and Instructions

Accidental Starting

Warning about accidental starting and how to prevent it.

Battery Safety

Safety precautions related to battery acid, gases, and short circuits.

Safety Precautions and Instructions

Battery Short Circuits

Warning about explosion risk from battery short circuits.

Engine Backfire and Fire Hazards

Precautions regarding fuel system fire and engine backfire hazards.

Exhaust System Safety

Warnings and precautions concerning the exhaust system and carbon monoxide.

Safety Precautions and Instructions

Combustible Materials and Fire Prevention

Advice on handling combustible materials and preventing fires.

Exhaust System Inspection and Operation

Guidelines for inspecting and operating the exhaust system safely.

Safety Precautions and Instructions

Fuel System Safety

Precautions for handling explosive fuel vapors and maintaining the fuel system.

Hazardous Noise

Warnings about noise levels and the need for hearing protection.

Hazardous Voltage and Electrical Shock

Warnings about electrical hazards and precautions to prevent shock.

Safety Precautions and Instructions

Moving Parts Safety

Warnings about hazards associated with moving parts on the generator set.

Hot Parts Safety

Warnings about hot engine and exhaust system components.

Safety Precautions and Instructions

Airborne Particles Safety

Precautions against airborne particles during tool use.

Hardware and Maintenance Notices

Notices regarding hardware, ESD damage, fuse replacement, and saltwater damage.

Introduction

Service Assistance

Contact information for obtaining professional advice and service.

Maintenance and Service Parts/Related Literature

Maintenance and Service Parts

Lists parts and their part numbers for various generator models.

Related Literature

Lists available literature such as installation and service manuals for generator sets.

Section 1 Specifications

1.1 Introduction

Overview of specification sheets and other manuals for detailed information.

1.2 Specifications

Describes the alternator, excitation system, and PMG advantages.

Section 1 Specifications

1.3 Service Views

Identifies key components of the generator set with a diagram.

1.4 Remote Annunciator Kit

Provides convenient monitoring of generator set condition from a remote location.

1.5 Safeguard Breaker

Senses output current and shuts off AC voltage regulator if overload occurs.

1.6 Line Circuit Breaker

Interrupts generator output during overload or short circuit.

1.7 Run Relay Kit

Includes contacts that energize during operation to control external devices.

Section 2 Operation

2.1 Prestart Checklist

Procedures for checking the generator set before starting operation.

2.2 Marine Inspection

Recommendation for annual inspection by Coast Guard Auxiliary or dealer.

2.3 Angular Operation

Specifies angular operation limits for generator set units.

2.4 Operation in European Union Member Countries

Notes on compliance with EU directive regarding noise emissions.

2.5 Exercising the Generator Set

Procedure for operating the generator set under load weekly for one hour.

Section 2 Operation

2.6 Decision-Maker™ 3+, 16-Light Microprocessor Controller Operation

Details operation of the Decision-Maker 3+ controller.

2.6.1 Controls and Indicators

Describes the controls and indicators on the Decision-Maker 3+ controller.

2.6.2 Fuses and Terminal Strips

Identifies fuses and terminal strips on the controller circuit board.

2.6.3 Auxiliary Fault Lamp Conditions

Explains possible auxiliary fault lamp conditions and their meanings.

2.6.4 Starting the Generator Set

Procedures for starting the generator set locally or automatically.

2.6.5 Stopping the Generator Set

Procedures for normal and emergency stopping of the generator set.

2.6.6 Prime Power Mode Operation

Explains how to enable, disable, and operate in prime power mode.

2.6.7 Fault Shutdowns

Lists automatic shutdown conditions and their causes.

2.6.8 Controller Resetting Procedure (Following Fault Shutdown)

Steps to restart the generator set after a fault shutdown.

2.6.9 Resetting the Emergency Stop Switch

Procedure to restart the generator set after an emergency stop shutdown.

Section 2 Operation

2.7 Expanded Decision-Maker™ 1 Controller Operation

Details operation of the Expanded Decision-Maker 1 controller.

2.7.1 Controls and Indicators

Describes the controls and indicators on the Expanded Decision-Maker 1 controller.

2.7.2 Starting the Generator Set

Procedures for starting the Expanded Decision-Maker 1 generator set.

2.7.3 Stopping the Generator Set

Procedures for stopping the Expanded Decision-Maker 1 generator set.

2.7.4 Fault Shutdowns

Lists fault conditions for the Expanded Decision-Maker 1 controller.

2.7.5 Controller Resetting Procedure (Following Fault Shutdown)

Steps to restart after fault shutdown for the Expanded Decision-Maker 1.

Section 2 Operation

2.8 Standard Decision-Maker™ 1 Controller Operation

Details operation of the Standard Decision-Maker 1 controller.

2.8.1 Controls and Indicators

Describes controls and indicators on the Standard Decision-Maker 1 controller.

2.8.2 Starting the Generator Set

Procedures for starting the Standard Decision-Maker 1 generator set.

2.8.3 Stopping the Generator Set

Procedures for stopping the Standard Decision-Maker 1 generator set.

2.8.4 Fault Shutdowns

Lists fault conditions for the Standard Decision-Maker 1 controller.

2.8.5 Controller Resetting Procedure (Following Fault Shutdown)

Steps to restart after fault shutdown for the Standard Decision-Maker 1.

Section 3 Scheduled Maintenance

3.1 General Maintenance

Provides general maintenance warnings and procedures.

Section 3 Scheduled Maintenance

3.2 Generator Set Service Schedule

Outlines routine maintenance intervals for various systems.

Section 3 Scheduled Maintenance

3.3 Cooling System

Details maintenance for the generator set's cooling system.

3.3.1 Siphon Break

Procedure for inspecting the siphon break to prevent seawater entry.

Section 3 Scheduled Maintenance

3.3 Cooling System

Details maintenance for the generator set's cooling system.

3.3.2 Impeller Inspection and Replacement Procedure

Steps for inspecting and replacing the seawater pump impeller.

Section 3 Scheduled Maintenance

3.4 Exhaust System

Inspection points and safety warnings for the exhaust system.

Section 3 Scheduled Maintenance

3.5 Storage Procedure

Procedures for preparing the generator set for storage for three months or longer.

3.5.1 Lubricating System

Steps to prepare the engine lubricating system for storage.

3.5.2 Cooling System

Steps to prepare the cooling system for storage.

3.5.3 Fuel System

Steps to prepare the fuel system for storage.

3.5.4 Exterior

Steps to prepare the exterior of the generator set for storage.

3.5.5 Battery

Procedure for storing the battery after other storage steps.

Section 4 Troubleshooting

Troubleshooting Chart

Quick reference for common generator set faults, causes, and remedies.

Fuse Replacement Notice

Notice regarding proper fuse replacement procedures.

Section 4 Troubleshooting

Cooling System Troubleshooting

Details troubleshooting for cooling system issues like no crank, starts hard, overheats.

Section 4 Troubleshooting

Electrical System (DC Circuits) Troubleshooting

Troubleshooting for DC circuit issues like no crank, starts hard, low voltage.

Engine Troubleshooting

Troubleshooting for engine issues like no crank, starts hard, overheats, power loss.

Section 4 Troubleshooting

Fuel System Troubleshooting

Troubleshooting for fuel system issues like no crank, starts hard, low voltage, fuel consumption.

Generator Troubleshooting

Troubleshooting for generator issues like no crank, starts hard, low voltage, stops suddenly.

Section 4 Troubleshooting

Lube System Troubleshooting

Troubleshooting for lube system issues like no crank, overheats, fuel consumption.

Section 5 Wiring Diagrams

Wiring Diagram Safety Warnings

General safety warnings applicable to wiring diagrams and electrical work.

Section 5 Wiring Diagrams

Figure 5-1 Wiring Diagram—Standard Controller

Detailed wiring diagram for the standard controller.

Wiring Diagram Legend

Explains the symbols and abbreviations used in the wiring diagrams.

Section 5 Wiring Diagrams

Figure 5-2 Wiring Diagram—Standard Controller, Remote Panel Options

Wiring diagram for standard controller with remote panel options.

Section 5 Wiring Diagrams

Figure 5-3 Wiring Diagram—Standard Controller, Remote Panel Options

Wiring diagram for standard controller with remote panel options.

Section 5 Wiring Diagrams

Figure 5-4 Wiring Diagram—Schematic, Standard Controller

Schematic wiring diagram for the standard controller.

Section 5 Wiring Diagrams

Figure 5-5 Wiring Diagram—Expanded Controller

Wiring diagram for the expanded controller.

Section 5 Wiring Diagrams

Figure 5-6 Wiring Diagram—Expanded Controller, Engine and Fuel System

Wiring diagram for expanded controller, engine and fuel system.

Section 5 Wiring Diagrams

Figure 5-7 Wiring Diagram—Expanded Controller, Remote Panel Options

Wiring diagram for expanded controller with remote panel options.

Section 5 Wiring Diagrams

Figure 5-8 Wiring Diagram—Expanded Controller, Remote Panel Options

Wiring diagram for expanded controller with remote panel options.

Section 5 Wiring Diagrams

Figure 5-9 Wiring Diagram—Expanded Controller, Remote Panel Options

Wiring diagram for expanded controller with remote panel options.

Section 5 Wiring Diagrams

Figure 5-10 Wiring Diagram—Expanded Controller, Remote Panel Options

Wiring diagram for expanded controller with remote panel options.

Section 5 Wiring Diagrams

Figure 5-11 Wiring Diagram—Schematic, Expanded Controller

Schematic wiring diagram for the expanded controller.

Section 5 Wiring Diagrams

Figure 5-12 Wiring Diagram—Decision-Maker™ 3+ Controller

Wiring diagram for the Decision-Maker 3+ controller.

Section 5 Wiring Diagrams

Figure 5-13 Wiring Diagram—Decision-Maker™ 3+ Controller, Remote Panel Options

Wiring diagram for Decision-Maker 3+ controller with remote panel options.

Section 5 Wiring Diagrams

Figure 5-14 Wiring Diagram—Decision-Maker™ 3+ Controller, Remote Panel Options

Wiring diagram for Decision-Maker 3+ controller with remote panel options.

Section 5 Wiring Diagrams

Figure 5-15 Wiring Diagram—Decision-Maker™ 3+ Controller, Remote Panel Options

Wiring diagram for Decision-Maker 3+ controller with remote panel options.

Section 5 Wiring Diagrams

Figure 5-16 Wiring Diagram—Decision-Maker™ 3+ Controller, Remote Panel/Annunciator Options

Wiring diagram for Decision-Maker 3+ controller with remote panel/annunciator options.

Section 5 Wiring Diagrams

Figure 5-17 Wiring Diagram—Decision-Maker™ 3+ Controller, Remote Annunciator Options

Wiring diagram for Decision-Maker 3+ controller with remote annunciator options.

Section 5 Wiring Diagrams

Figure 5-18 Wiring Diagram—Decision-Maker™ 3+ Controller, Remote Annunciator Options

Wiring diagram for Decision-Maker 3+ controller with remote annunciator options.

Section 5 Wiring Diagrams

Controller TB1 Terminal Strip (Decision-Maker™ 3+ Controller)

Details the terminals and their purposes on the TB1 strip.

Controller TB2 Terminal Strip (Decision-Maker™ 3+ Controller)

Details terminals for crank mode and prime power on TB2 strip.

Appendix A Abbreviations

Appendix B Operating Hour Service Log

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