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Kohler 9EFOZ

Kohler 9EFOZ
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 9EFOZ Specifications

General IconGeneral
BrandKohler
Model9EFOZ
CategoryPortable Generator
LanguageEnglish

Summary

Safety Precautions and Instructions

Accidental Starting

Warnings and procedures for preventing accidental generator startup during maintenance.

Battery Safety

Precautions regarding sulfuric acid, battery gases, and safe handling of batteries.

Engine Backfire and Flash Fire Hazards

Safety measures related to engine backfire, flash fires, and combustible materials.

Exhaust System Safety

Information on carbon monoxide hazards and exhaust system inspection.

Fuel System Safety

Precautions for handling explosive fuel vapors and preventing fuel system leaks.

Hazardous Noise and Voltage

Warnings about hearing loss from noise and electrocution risk from hazardous voltage.

Hot Parts Precautions

Safety advice for avoiding burns from hot engine and exhaust system components.

Moving Parts Hazards

Safety warnings about rotating parts, airborne particles, and servicing moving components.

Introduction

Service Assistance

Information on how to contact Kohler for professional advice and service.

Section 1 Specifications

1.1 General

Overview of the manual's scope, model coverage, and service recommendations.

1.2 Service Views

Diagrams illustrating component identification for various generator models.

1.3 Engine Specifications

Detailed specifications for the Yanmar engines used in the generator sets.

1.4 Generator Specifications

Electrical and performance specifications for the generator components.

Section 2 Scheduled Maintenance

2.1 General Maintenance Precautions

General safety warnings and notes related to scheduled maintenance procedures.

2.2 Lubrication System

Procedures and recommendations for engine oil changes and oil selection.

2.3 Battery Maintenance

Guidelines for battery care, maintenance, and safety during servicing.

2.4 Generator Storage Procedure

Steps for properly preparing the generator set for long-term storage.

Section 3 Intake and Exhaust System

3.1 Air Intake SilencerFilter

Procedure for cleaning or replacing the air intake silencer element.

3.2 Exhaust System Inspection

Checks for exhaust leaks, blockages, and component integrity.

3.3 Mixing Elbow Maintenance

Inspection and cleaning of the mixing elbow for carbon buildup and corrosion.

Section 4 Fuel System

4.1 General Fuel System

Description of typical fuel system arrangements and low fuel supply considerations.

4.2 Fuel Specifications

Recommendations for diesel fuel quality, cetane number, and cleanliness.

4.3 Fuel Filter Replacement

Procedures for replacing spin-on fuel filters and filter elements.

4.4 Bleed the Fuel System

Step-by-step guide to removing air from the fuel system to ensure proper starting.

4.5 Fuel Solenoid Operation

Explanation of the fuel solenoid's function, wiring, and resistance readings.

4.7 Governor Adjustment

Instructions for checking and adjusting engine speed and frequency control.

Section 5 Cooling System

5.1 General Cooling System

Overview of cooling system components including heat exchanger and pumps.

5.2 Water-Cooled Exhaust Manifold

Information on the exhaust manifold, thermostat location, and bolt tightening.

5.5 Flush and Clean Cooling System

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

5.7 Impeller Inspection and Replacement

Steps for inspecting and replacing the seawater pump impeller.

5.8 Belt Tension Adjustment

Procedure for checking and adjusting belt tension for optimal operation.

5.9 Siphon Break Inspection

Procedure for inspecting the siphon break to prevent seawater entry.

Section 6 Controller Troubleshooting

6.2 Controller Sequence of Operation

Description of controller logic for start, run, stop, and shutdown sequences.

6.3 Engine Safety Shutdown Switches

How low oil pressure and high temperature switches affect controller operation.

6.5 Troubleshooting Flowcharts

Diagnostic flowcharts for troubleshooting the relay controller and generator set.

Section 7 Generator Troubleshooting

7.2 General Troubleshooting

Steps and flowchart for diagnosing no or low AC output issues.

7.3 Separate Excitation Test

Procedure to test voltage regulator function by separately exciting the generator.

7.4.1 Voltage Regulator Test

Testing the voltage regulator output using a variable transformer and test lamp.

7.8 Rotor Testing

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

7.9 Stator Testing

Methods for checking stator continuity, resistance, and ground faults.

Section 8 Component Troubleshooting

8.1 General Component Testing

Overview of component testing using a multimeter and wiring harness checks.

8.2 Remote Panels Troubleshooting

Diagnostic steps for remote start panels, gauges, and senders.

Section 9 Generator DisassemblyReassembly

9.1 Disassembly Procedures

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

9.2 Reassembly Procedures

Instructions for correctly reassembling the generator set components.

Section 10 Voltage Reconnection and Wiring Diagrams

10.1 Voltage Reconnection

Guidelines for reconnecting the generator set for different voltage configurations.

10.3 Wiring Diagram, Schematic

Schematic wiring diagram illustrating the generator set's electrical connections.

10.4 Wiring Diagram, Point-to-Point

Point-to-point wiring diagram for remote panel and generator connections.

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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