135ccoz 2

Operation and
Installation Manual
Marine Generator Sets
Models:
13.5CCOZ/11CCFOZ
18.5 CCOZ/15CCFOZ
21CCOZ/16.5CCFOZ
18CCFOZ
14CCOZ/11.5CCFOZ
20CCOZ/17.5CCFOZ
24CCOZ/20CCFOZ
1 Phase
and 3 Phase
TP-5592 7/96a
Downloaded from www.Manualslib.com manuals search engine

California Proposition 65
WARNING
Engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

Table of Contents
SUBJECT PAGE SUBJECT PAGE
Safety Precautions and Instructions . . . . . . I Seawater Pump Belt . . . . . . . . . . . . . . . . . . . . . . 3-17

Reference Material . . . . . . . . . . . . . . . . . . . . . . IX Battery Charging Alternator/
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Engine-Driven Water Pump Belt . . . . . . . . . . . 3-18
Service Assistance . . . . . . . . . . . . . . . . . . . . . . ii Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Routine Service Parts . . . . . . . . . . . . . . . . . . . iv Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Section 1. Specifications . . . . . . . . . . . . . . . . 1-1 Checking Electrolyte Level . . . . . . . . . . . . . . . . . 3-20
General Specifications— 1-Phase Models . . . . 1-1 Checking Specific Gravity . . . . . . . . . . . . . . . . . . 3-21
General Specifications— 3-Phase Models . . . . 1-2 Generator Service . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Generator Ratings— 1-Phase Models . . . . . . . . 1-4 Wattage Requirements . . . . . . . . . . . . . . . . . . . . 3-22
Generator Ratings— 3-Phase Models . . . . . . . . 1-5 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . 3-23
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Section 4. Troubleshooting . . . . . . . . . . . . . . 4-1
Engine Specifications— 1-Phase Models . . . . . 1-7
Engine Specifications— 3-Phase Models . . . . . 1-9 Section 5. Wiring Diagrams . . . . . . . . . . . . . . 5-1
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Section 6. Installation . . . . . . . . . . . . . . . . . . . 6-1
Controller Features . . . . . . . . . . . . . . . . . . . . . . . 1-10
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Section 2. Operation . . . . . . . . . . . . . . . . . . . . 2-1 Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Exercising the Generator Set . . . . . . . . . . . . . . 2-2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 2-3 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Preheat Feature . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Anti-Siphon Provisions . . . . . . . . . . . . . . . . . . . . 6-6
Starting Generator . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Fuel Lines And Filters . . . . . . . . . . . . . . . . . . . . . 6-6
Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . 2-3 Fuel Pump Lift Capabilities
And Fuel Consumption . . . . . . . . . . . . . . . . . . 6-6
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Engine Safety Shutdown Switches . . . . . . . . . . 2-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Remote Panels (Optional) . . . . . . . . . . . . . . . . . 2-5
Closed/Heat Exchanger . . . . . . . . . . . . . . . . . . . 6-10
Section 3. Scheduled Maintenance . . . . . . . 3-1 Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Above Waterline . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . 3-6 Mid/Below Waterline . . . . . . . . . . . . . . . . . . . . . . 6-15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 AC Voltage Connections . . . . . . . . . . . . . . . . . . . 6-17
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Installation In Steel Or Aluminum Vessels . . . . 6-18
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Installation Regulations . . . . . . . . . . . . . . . . . . . . 6-18
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Remote Start Switch Connection . . . . . . . . . . . . 6-20
Bleeding Fuel System . . . . . . . . . . . . . . . . . . . . . 3-10
Section 7. Installation Drawings . . . . . . . . . . 7-1
Air Intake Silencer/Cleaner . . . . . . . . . . . . . . . . 3-11
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Appendix A. Generator Selection
Servicing Mixing Elbow . . . . . . . . . . . . . . . . . . . . 3-12 and Wattage Requirements . . . . . . . . . . . . . A-1
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Appendix B. Glossary of Abbreviations . . . B-1
Closed/Heat Exchanger . . . . . . . . . . . . . . . . . . . 3-14
Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Appendix C. Operating Hour Service Log . C-1
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
TP-5592 7/96 Table of Contents

Safety Precautions and Instructions
A generator set, like any other electromechanical Safety decals affixed to the generator set in prominent
device, can pose potential dangers to life and limb if places advise the operator or service technician of
improperly maintained or operated. The best way to potential hazards and how to act safely. The decals are
prevent accidents is to be aware of potential dangers reproduced in this publication to improve operator
and act safely. Please read and follow the safety recognition. Replace missing or damaged decals.
precautions and instructions below to prevent harm to
yourself and others. This manual contains several types Accidental Starting
of safety precautions and instructions which are
explained below. SAVE THESE INSTRUCTIONS. WARNING
DANGER
Danger indicates the presence of a hazard that will

Accidental starting.
cause severe personal injury, death, or substantial
Can cause severe injury or death.
property damage.
Disconnect battery cables before working on
generator set (disconnect negative lead first and
WARNING reconnect it last).
Disabling generator set. Accidental starting can

Warning indicates the presence of a hazard that can
cause severe injury or death. Disconnect battery
cause severe personal injury, death, or substantial
cables (remove negative lead first and reconnect it last)
property damage.
to disable generator set before working on the generator
set or connected equipment. The generator set can be
started by the remote start/stop switch unless this
CAUTION
precaution is followed.
Caution indicates the presence of a hazard that will or

can cause minor personal injury or property damage.
NOTICE
Notice communicates installation, operation, or
maintenance information that is important but not
hazard related.
TP-5592 7/96 Safety Precautions and Instructions I

Battery Engine Backfire/Flash Fire
WARNING WARNING
Fire.
Sulfuric acid in batteries. Can cause severe injury or death.
Do not smoke or permit flame or spark to occur
Use protective goggles and clothes. Battery acid can near fuel or fuel system.
cause permanent damage to eyes, burn skin, and eat
holes in clothing.
Servicing fuel system. A flash fire can cause severe
Battery acid. Sulfuric acid in batteries can cause injury or death. Do not smoke or permit flame or spark
severe injury or death. Sulfuric acid in battery can to occur near carburetor, fuel line, fuel filter, fuel pump,
cause permanent damage to eyes, burn skin, and eat or other potential sources of spilled fuel or fuel vapors.
holes in clothing. Always wear splash-proof safety Catch all fuel in a suitable container when removing fuel
goggles when working near the battery. If battery acid is line or carburetor.
splashed in the eyes or on skin, immediately flush the Servicing backfire flame arrestor. A sudden
affected area for 15 minutes with large quantities of backfire can cause severe injury or death. Do not
clean water. Seek immediate medical aid in the case of operate with backfire flame arrestor removed.
eye contact. Never add acid to a battery after placing the
battery in service, as this may result in hazardous Servicing air cleaner. A sudden backfire can cause
spattering of battery acid. severe injury or death. Do not operate with air
cleaner/silencer removed.
Battery gases. Explosion can cause severe injury
or death. Battery gases can cause an explosion. Do Combustible materials. A sudden flash fire can
not smoke or permit flame or spark to occur near a cause severe injury or death. Do not smoke or permit
battery at any time, particularly when it is charging. flame or spark to occur near fuel system. Keep the
Avoid touching terminals with tools, etc., to prevent compartment and generator set clean and free of debris
burns and sparks that could cause an explosion. to minimize chances of fire. Wipe up all spilled fuel and
Remove wristwatch, rings, and any other jewelry before engine oil.
handling battery. Never connect negative (--) battery
cable to positive (+) connection terminal of starter
solenoid. Do not test battery condition by shorting
terminals together. Sparks could ignite battery gases or
fuel vapors. Ventilate any compartment containing
batteries to prevent accumulation of explosive gases.
To avoid sparks, do not disturb battery charger
connections while battery is being charged. Always turn
battery charger off before disconnecting battery
connections. Remove negative lead first and reconnect
it last when disconnecting battery.
II Safety Precautions and Instructions TP-5592 7/96

Exhaust System Copper tubing exhaust systems. Carbon monoxide
can cause severe nausea, fainting, or death. Do not
WARNING use copper tubing in diesel exhaust systems. Sulfur in
diesel exhaust causes rapid deterioration of copper
tubing exhaust systems resulting in exhaust/water
leakage.
Inspecting exhaust system. Carbon monoxide can

cause severe nausea, fainting, or death. In addition
Carbon monoxide.
to routine exhaust system inspection, install a carbon
Can cause severe nausea, fainting, or death.
monoxide detector. Consult your boat builder or dealer
The exhaust system must be leakproof and for approved detector installation. Inspect your detector
routinely inspected. before each generator set use.
Carbon monoxide symptoms. Carbon monoxide Operating generator set. Carbon monoxide can
can cause severe nausea, fainting, or death. Carbon cause severe nausea, fainting, or death. Use the
monoxide is a poisonous gas which is present in following precautions when installing and operating
exhaust gases. Carbon monoxide poisoning symptoms generator set. Carbon monoxide is an odorless,
include but are not limited to the following: colorless, tasteless, nonirritating gas. Be especially
D Light-headedness, dizziness careful if operating the generator set when moored or
D Physical fatigue, weakness in joints and muscles anchored under calm conditions as gases may
D Sleepiness, mental fatigue, inability to concentrate accumulate. If operating the generator set dockside,
or speak clearly, blurred vision moor the craft so that the exhaust discharges on the lee
D Stomachache, vomiting, nausea side (the side sheltered from the wind). Always be
If experiencing any of these symptoms and carbon aware of others— make sure your exhaust is directed
monoxide poisoning is possible, affected persons away from other boats and buildings. Do not install
should seek fresh air immediately. They should remain exhaust outlet where exhaust can be drawn in through
active. They should not sit, lie down, or fall asleep. Alert portholes, vents, or air conditioners. If the generator set
others to the possibility of carbon monoxide poisoning. exhaust discharge outlet is near the waterline water
If the condition of affected persons does not improve could enter the exhaust discharge outlet and close or
within minutes of breathing fresh air, they should seek restrict the flow of exhaust. Avoid overloading the craft.
medical attention.
TP-5592 7/96 Safety Precautions and Instructions III

Fuel System Draining fuel system. Explosive fuel vapors can
cause severe injury or death. Spilled fuel can cause
WARNING an explosion. Use a container to catch fuel when
draining fuel system. Wipe up all spilled fuel after
draining system.
Installing fuel system. Explosive fuel vapors can

cause severe injury or death. Fuel leakage can cause
an explosion. Do not modify the tank or propulsion
engine fuel system. Equip craft with a tank allowing one
Explosive fuel vapors.
of the two pickup arrangements described in the
installation section. Tank and installation must conform
Use extreme care when handling, storing, to U.S.C.G. Regulations.
and using fuels.
Pipe sealant. Explosive fuel vapors can cause
Fuel system. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an
severe injury or death. All fuels are highly explosive in explosion. Use pipe sealant on all threaded fittings to
a vapor state. Use extreme care when handling and prevent fuel leakage. Use pipe sealant which resists
storing fuels. Store fuel in a well-ventilated area away gasoline, grease, lubrication oil, common bilge solvents,
from spark-producing equipment and out of the reach of and salt or fresh water.
children. Never add fuel to the tank while the engine is
running since spilled fuel may ignite on contact with hot
parts or from ignition spark. Do not smoke or permit
flame or spark to occur near sources of spilled fuel or
fuel vapors. Keep fuel lines and connections tight and in
good condition. Do not replace flexible fuel lines with
rigid lines. Use flexible sections to avoid breakage
caused by vibration. Do not operate generator set in the
presence of fuel leaks, fuel accumulation, or sparks.
Repair systems before resuming generator set
operation
IV Safety Precautions and Instructions TP-5592 7/96

Hazardous Noise Short circuits. Hazardous voltage can cause severe
injury or death. Short circuits can cause bodily injury
CAUTION and/or equipment damage. Do not contact electrical
connections with tools or jewelry while adjustments are
made. Remove wristwatch, rings, and jewelry before
servicing equipment.
Testing voltage regulator. Hazardous voltage can

cause severe injury or death. High voltage is present
Hazardous noise. at the voltage regulator heat sink. Do not touch voltage
Can cause loss of hearing. regulator heat sink when testing or electrical shock will
Never operate generator set without a muffler or occur.
with a faulty exhaust system. (PowerBoostt , PowerBoostt III, and PowerBoostt V
voltage regulator models only.)
Hazardous Voltage/ Electrical backfeed to utility. Hazardous backfeed
Electrical Shock voltage can cause severe injury or death. Connect
generator set to building/marina electrical system only
through an approved device and after building/marina
WARNING main switch is open. Backfeed connections can cause
serious injury or death to utility personnel working on
power lines and/or personnel in the vicinity of the work
area. Unauthorized connection to utility electrical
system may be unlawful in some states and/or localities.
Install a ship-to-shore transfer switch to prevent
Hazardous voltage. Moving rotor. interconnection of generator set power and shore
Can cause severe injury or death. power.
Operate generator set only with all guards and

electrical enclosures in place.
Grounding generator set. Hazardous voltage can

cause severe injury or death. Electrocution is
possible whenever electricity is present. Open main
circuit breakers of all power sources before servicing
equipment. Configure the installation to electrically
ground the generator set and electrical circuits when in
use. Never contact electrical leads or appliances when
standing in water or on wet ground, as the chance of
electrocution is increased under such conditions.
TP-5592 7/96 Safety Precautions and Instructions V

Heavy Equipment Hot Parts
WARNING WARNING
Hot coolant and steam.

Unbalanced weight.
Improper lift can cause severe injury or death Before removing pressure cap, stop generator set
and/or equipment damage. and allow it to cool. Then loosen pressure cap to
relieve pressure.
Do not use lifting eyes.
Use slings under skid to balance and lift generator
set. WARNING
Hot engine and exhaust system.

Do not work on generator set until it is allowed to
cool.
Checking coolant level. Hot coolant can cause

severe injury or death. Allow engine to cool. Release
pressure from cooling system before opening pressure
cap. To release pressure, cover the pressure cap with a
thick cloth; then slowly turn it counterclockwise to the
first stop. Remove cap after pressure has been
completely released and the engine has cooled. Check
coolant level at tank if generator set is equipped with a
coolant recovery tank.
Servicing exhaust system. Hot parts can cause

severe injury or death. Do not touch hot engine parts.
An engine becomes hot while running and exhaust
system components become extremely hot.
VI Safety Precautions and Instructions TP-5592 7/96

Moving Parts Tightening hardware. Flying projectiles can cause
severe injury or death. Retorque all crankshaft and
WARNING rotor hardware after servicing. Do not loosen crankshaft
hardware or rotor thrubolt when making adjustments or
servicing generator set. Rotate crankshaft manually in a
clockwise direction only. Turning crankshaft bolt or rotor
thrubolt counterclockwise can loosen hardware. Loose
hardware can cause hardware or pulley to release from
Hazardous voltage. Moving rotor. engine of generator set and can cause personal injury.
Can cause severe injury or death. Servicing generator set when operating. Exposed
moving parts can cause severe injury or death.
Operate generator set only with all guards and
Keep hands, feet, hair, clothing, and test leads away
electrical enclosures in place.
from belts and pulleys when generator set is running.
Replace guards, screens, and covers before operating
generator set.
WARNING
Sound shield removal. Exposed moving parts can
cause severe injury or death. Additional precautions
for sound shield-equipped models:
The generator set must be operating in order to perform
some scheduled maintenance procedures. Be
Rotating parts. especially careful if the sound shield has been removed
Can cause severe injury or death. leaving belts and pulleys exposed.
Do not operate generator set without all guards,
screens, and covers in place.
TP-5592 7/96 Safety Precautions and Instructions VII

Notice NOTICE
When replacing hardware, do not substitute with
NOTICE inferior grade hardware. Screws and nuts are
available in different hardness ratings. American
This generator set has been rewired from its Standard hardware uses a series of markings and
nameplate voltage to: metric hardware uses a numeric system to indicate
hardness. Check markings on bolt head and nuts for
identification.
NOTICE
Fuse replacement! Replace fuses with fuses of the
246242
same ampere rating and type (for example: ABC or 3AC,
NOTICE ceramic). Do not substitute clear glass-type fuses for
Voltage reconnection! Affix notice to generator set ceramic fuses. If ampere rating is unknown or
after reconnecting to a voltage different than the questionable, see wiring diagram.
nameplate. Order voltage reconnection decal 246242 NOTICE
from authorized service distributors/dealers. Seawater damage! High-mineral content seawater
NOTICE (saltwater) causes rapid deterioration of all metals.
Hardware damage! Engine and generator set may use Wipe up all saltwater spillage on and around generator
both American Standard and metric hardware. Use the set and keep metal surfaces free from accumulated salt
correct size tools to prevent rounding of bolt heads and deposits.
nuts.
VIII Safety Precautions and Instructions TP-5592 7/96

Reference Material
Observe the regulations and standards below when
installing marine generator sets.
Pleasurecraft
U.S. Coast Guard Code of Federal Regulations Underwriters Laboratories, Inc. (UL)
Title 33, Part 183 Publications Stock
Subpart I— Electrical Systems 333 Pfingsten Road
Subpart J— Fuel Systems Northbrook, IL 60062
Marine Department Phone: 1-919-549-1400
Order the above publication from:
Superintendent of Documents NFPA 302
U.S. Government Printing Office National Fire Protection Association
Washington, DC 20402 Batterymarch Park
Phone: 1-202-783-3238 Quincy, MA 02269
Boating Safety Circular Commandant (G-BC) Society of Automotive Engineers (SAE)
Boating Statistics (G-BP-1) Customer Service
400 Commonwealth Drive
Order the above documents from:
Warrendale, PA 15086
U.S. Coast Guard Headquarters
Phone: 1-412-776-4970
2100 Second Street, S.W.
Washington, DC 20593-0001 American Boat and Yacht Council, Inc. (ABYC)
Boating Safety Hotline: 1-800-368-5647 3069 Solomon’s Island Rd.
Edgewater, MD 21037
Phone: 1-410-956-1050
Phone: 1-410-974-8112
Fax: 1-410-956-2737
IEEE 45
The Institute of Electrical and Electronics Engineers Inc.
345 East 47th Street
New York, NY 10017
TP-5592 7/96 Reference Material IX

Commercial Vessels
In order to use generator sets listed in this manual for American Bureau of Shipping (ABS)
commercial applications where U.S. Coast Guard Title 65 Broadway
46 Certificate is required, additional modifications will be New York, NY 10006
necessary.
Order ABS publications from:
U.S. Coast Guard Code of Federal Regulations American Bureau of Shipping
Title 46 Book Order Section
Subchapter F— Marine Engineering 45 Eisenhower Drive
Part 58— Main and Auxiliary Machinery and P.O. Box 910
Related Systems Paramus, NJ 97653-0910
Subchapter J— Electrical Engineering
Lloyd’s Register of Shipping
Part 111— Electrical Systems—
71 Fenchurch Street
General Requirements
London, EC3M 4BS England
Part 112— Emergency Lighting and Power Systems
Subchapter T— Small Passenger Vessels Midwest Office:
(Under 100 Gross Tons) Lloyd’s Register of Shipping
Part 182— Machinery Installation 100 South York Street, Room 226
Part 183— Electrical Installation Elmhurst, IL 60126
Phone: 1-312-279-5414
Order the above publications from the following
address:
Superintendent of Documents
U.S. Government Printing Office
Washington, DC 20402
Phone: 1-202-783-3238
Additional References
The following organizations provide a service which Ward’s Marine Electric, Inc.
may be useful to the generator set installer. These 630 S.W. Flagler Ave.
organizations do not regulate but rather provide Ft. Lauderdale, FL 33301
guidelines and assistance. They are listed only as a Phone: 1-305-523-2815
source for additional information. Kohler Co. hereby Phone: 1-800-545-9273
gives no solicitation or representation. Fax: 1-305-523-1967
Yacht Corrosion Consultants, Inc.
2970 Seaborg Ave.
Ventura, CA 93003
Phone: 1-805-644-1886
X Reference Material TP-5592 7/96

Introduction
This manual covers the general operation, Read through this manual and carefully follow all
maintenance, and installation of the following Kohler procedures and safety precautions to ensure proper
marine generator sets: equipment operation and to avoid bodily injury. Read
and follow the Safety Precautions and Instructions
D 13.5CCOZ/11CCFOZ
section at the beginning of this manual. Keep this
D 18.5CCOZ/15CCFOZ manual with equipment for future reference.
D 21CCOZ/16.5CCFOZ
Equipment service requirements are minimal but are
D 18CCFOZ
very important to safe and efficient operation; therefore,
D 14CCOZ/11.5CCFOZ inspect parts often and perform required service at the
D 20CCOZ/17.5CCFOZ prescribed intervals. An authorized service
distributor/dealer should perform required service to
D 24CCOZ/20CCFOZ
keep equipment in top condition.
All information in this publication represents data
See Figure 1-1 and Figure 1-2 to identify and locate
available at time of printing. Kohler Co. reserves the
major components.
right to change this literature and the products
represented without incurring obligation.
TP-5592 7/96 Introduction i

Service Assistance
For sales and service in the U.S.A. and Canada check GENERATOR SET ACCESSORIES
the yellow pages of the telephone directory under the An alternate nameplate inside the junction box identifies
heading GENERATORS— ELECTRIC for an authorized factory-installed generator set accessories.
service distributor/dealer or call 1-800-544-2444.
Accessory Nos.
For sales and service outside the U.S.A. and Canada,
contact your local distributor.
For further information or questions, contact the
company directly at:
KOHLER CO., Kohler, Wisconsin 53044 U.S.A.
Phone: 414-565-3381
Fax: 414-459-1646 (U.S.A. Sales)
414-459-1614 (International)
To ensure supply of correct parts or information, make
note of the following identification numbers in the
spaces provided:
GENERATOR SET
MODEL, SPEC, and SERIAL numbers are found on
the nameplate attached to the generator set.
ENGINE
Model No. The engine serial number is found on the engine
nameplate.
Specification No.
Engine Serial No.
Serial No.
ii Service Assistance TP-5592 7/96

At the time of print, this manual applied to the model Model No. Spec. No. Wiring Diagram
numbers and specification (spec.) numbers listed on
13.5CCOZ/ 126147 229937
this page. On occasion this manual may be used for 11CCFOZ 126148 229991
specifications not listed such as when similar new
18.5CCOZ/ 126151 229937
specifications are created after the printing of this 15CCFOZ 126152 229991
manual and prior to the updated reprint or in cases
21CCOZ/ 126154 229937
where the manual is deemed an acceptable substitute
16.5CCFOZ 126155 229991
for a manual under development.
18CCFOZ 126150 229937
14CCOZ/
126149 229938
11.5CCFOZ
20CCOZ/
126153 229938
17.5CCFOZ
24CCOZ
126156 229938
20CCFOZ
TP-5592 7/96 Service Assistance iii

Routine Service Parts
Contact your Kohler generator distributor/dealer for a
complete list of service parts for your generator set.
Part Description Kohler Part No.

Air Filter Element 250902
Oil Filter 252834
Fuel Filter Element 225021
Seawater Pump Impeller 229955
V-Belt (Seawater Pump) 256503
V-Belt (Alternator)
11/11.5CCFOZ and
13.5/14CCOZ 276141
V-Belt (Alternator)
18.5/20/21/24CCOZ and
18CCFOZ 229880
White Spray Paint 221318
iv Routine Service Parts TP-5592 7/96

Section 1. Specifications
General Specifications— 1-Phase Models

21CCOZ
13.5CCOZ 18.5CCOZ 16.5CCFOZ
11CCFOZ 15CCFOZ 18CCFOZ *
Dimensions— in. (mm)
Length 36.62 (930) 41.35 (1050)
Width 22.31 (567) 22.31 (567)
Height 26.01 (661) 26.42 (671)
Length w/sound shield 41.24 (1047) 44.75 (1137)
Wisth w/sound shield 25.75 (654) 25.75 (654)
Height w/sound shield 28.25 (718) 28.75 (730)
Weight (wet)— lbs. (kg) 680 (308) 765 (347) 790 (358)
w/sound shield (wet)— lbs. (kg) 775 (352) 870 (395) 895 (405)
Air Requirements— CFM (L/min.)
86.78/72.32 115.91/96.59
Combustion 60 Hz/50 Hz
(1422/1185) (1899/1582)
210/175
Cooling 60 Hz/50 Hz
(5946/4955)
Angular Operation (max.) 25_continuous, 30_intermittent
(in all directions) (three minutes or less)
Minimum clearances for vibration and
cooling (top, front, rear, and sides) 1.5 (38)
(without sound shield)— in. (mm)
Fuel Consumption 60 Hz— U.S. Gal./Hr. (L/Hr.)
(Fuel consumption based on CCOZ120/240 voltage configuration)
LOAD
25% 0.48 (1.8) 0.63 (2.4) 0.67 (2.5)
50% 0.71 (2.7) 0.90 (3.4) 0.98 (3.7)
75% 0.93 (3.5) 1.24 (4.7) 1.37 (5.2)
100% 1.19 (4.5) 1.63 (6.2) 1.77 (6.7)
(Fuel consumption based on CCFOZ110/220 voltage configuration)
LOAD
25% 0.38 (1.4) 0.50 (1.9) 0.53 (2.0)
50% 0.54 (1.9) 0.72 (2.7) 0.77 (2.9)
75% 0.72 (2.7) 1.00 (3.8) 1.05 (4.0)
100% 0.93 (3.5) 1.38 (5.2) 1.40 (5.3)
* 18CCFOZ -- 50 Hz only
TP-5592 7/96 Specifications 1-1

General Specifications— 3-Phase Models
14CCOZ 20CCOZ 24CCOZ
11.5CCFOZ 17.5CCFOZ 20CCFOZ
Dimensions— in. (mm)
Length 36.62 (930) 41.35 (1050)
Width 22.31 (567) 22.31 (567)
Height 26.01 (661) 26.42 (671)
Length w/sound shield 41.24 (1047) 44.75 (1137)
Width w/sound shield 25.75 (654) 25.75 (654)
Height w/sound shield 28.25 (718) 28.75 (730)
Weight (wet)— lbs. (kg) 690 (313) 775 (352) 800 (363)
w/sound shield (wet)— lbs. (kg) 785 (356) 880 (399) 905 (411)
Air Requirements— CFM (L/min.)
86.78/72.32 115.91/96.59 115.91/96.59
Combustion 60 Hz/50 Hz
(1422/1185) (1899/1582) (1899/1582)
210/175
Cooling 60 Hz/50 Hz
(5946/4955)
Angular Operation (max.) (in all direc- 25_continuous, 30_intermittent
tions) (three minutes or less)
Minimum clearances for vibration and
cooling (top, front, rear, and sides) 1.5 (38)
(without sound shield)— in. (mm)
(Fuel consumption based on CCOZ120/240 voltage configuration)
LOAD
25% 0.48 (1.8) 0.63 (2.4) 0.67 (2.5)
50% 0.71 (2.7) 0.90 (3.4) 0.98 (3.7)
75% 0.93 (3.5) 1.24 (4.7) 1.37 (5.2)
100% 1.19 (4.5) 1.63 (6.2) 1.77 (6.7)
(Fuel consumption based on CCFOZ110/220 voltage configuration)
LOAD
25% 0.38 (1.4) 0.50 (1.9) 0.53 (2.0)
50% 0.54 (1.9) 0.72 (2.7) 0.77 (2.9)
75% 0.72 (2.7) 1.00 (3.8) 1.05 (4.0)
100% 0.93 (3.5) 1.38 (5.2) 1.40 (5.3)
1-2 Specifications TP-5592 7/96

Generator
The generator is direct mounted to the engine for Alternator Features
permanent alignment. The unit uses a static excited,
rotating-field construction with a four-pole rotor. Generator Type four pole, rotating field
Coupling Type flexible disc
Generator Features
Excitation Type brushless exciter
D Brushless, rotating field design permits power to Shaft RPM (50/60 Hz) 1500/1800
be obtained from stationary leads.
Number of Output Leads 4— 1-phase models
D Rotor and stator are vacuum impregnated with 12— 3-phase models
high-bond epoxy varnish. Varnish helps prevent Voltage Regulator Model PowerBoostÔ V
corrosion in high-humidity areas. Voltage Regulation ±2%
D Rotors are dynamically balanced to minimize Frequency Regulation ±5%
vibration.
D Copper windings ensure minimal heat buildup. NOTE
Insulation meets NEMA standards for Class F All one-phase and three-phase units are rated 1.0
insulation. power factor. Ratings are based on an altitude of 500 ft.
D Direct connected to the engine, generator has (150 m) above sea level.
sealed precision ball bearing with precision
machined steel sleeve in end bracket to prevent
shaft misalignment and to extend bearing life.
D Generator is mounted on a drip-proof constructed
tray.
D One-phase models feature a four-lead
reconnectable stator; three-phase models have a
twelve-lead reconnectable stator.

Generator Ratings— 1-Phase Models
77_F (25_C) 77_F (25_C)
Model Series Voltage Amps kW/kVA Phase Hz
13.5CCOZ 100/200 125/62.5 12.5/12.5 1 60
120/240 112.5/56.3 13.5/13.5 1 60
11CCFOZ 100/200 110/55 11/11 1 50
110/220 100/50 11/11 1 50
220 50 11/11 1 50
240 45.8 11/11 1 50
18.5CCOZ 100/200 165/82.5 16.5/16.5 1 60
120/240 154/77.1 18.5/18.5 1 60
15CCFOZ 100/200 150/75 15/15 1 50
110/220 136.4/68.2 15/15 1 50
220 68.2 15/15 1 50
240 54.2 13/13 1 50
21CCOZ 100/200 165/82.5 16.5/16.5 1 60
120/240 175/87.5 21/21 1 60
16.5CCFOZ 100/200 170/85 17/17 1 50
110/220 150/75 16.5/16.5 1 50
220 75 16.5/16.5 1 50
240 54.2 13/13 1 50
Continuous Continuous
77_F (25_C) 77_F (25_C) Peak Rating Peak Rating
Model Series Voltage Amps kW/kVA Amps kW/kVa Phase Hz
18CCFOZ 100/200 180/90 18/18 185/92.5 18.5/18.5 1 50
110/220 159.1/79.5 17.5/17.5 168.2/84.1 18.5/18.5 1 50
220 79.5 17.5/17.5 84.1 18.5/18.5 1 50
240 62.5 15/15 72.9 17.5/17.5 1 50

Generator Ratings— 3-Phase Models
77_F (25_C) 77_F (25_C)
Model Series Voltage Amps kW/kVA Phase Hz
14CCOZ 120/208 38.9 14/14 3 60
120/240 33.7 14/14 3 60
120/240 58.3 14/14 1 60
127/220 36.8 14/14 3 60
139/240 33.7 14/14 3 60
220/380 21.3 14/14 3 60
227/480 16.9 14/14 3 60
11.5CCFOZ 110/190 35.0 11.5/11.5 3 50
110/220 52.3 11.5/11.5 1 50
120/208 31.9 11.5/11.5 3 50
220/380 17.5 11.5/11.5 3 50
230/400 16.6 11.5/11.5 3 50
240/416 16.0 11.5/11.5 3 50
20CCOZ 120/208 55.6 20/20 3 60
120/240 48.2 20/20 3 60
120/240 70.8 17/17 1 60
127/220 52.5 20/20 3 60
139/240 48.2 20/20 3 60
220/380 30.4 20/20 3 60
277/480 24.1 20/20 3 60
17.5CCFOZ 110/190 53.2 17.5/17.5 3 50
110/220 65.9 14.5/14.5 1 50
120/208 48.6 17.5/17.5 3 50
220/380 26.6 17.5/17.5 3 50
230/400 25.3 17.5/17.5 3 50
240/416 24.3 17.5/17.5 3 50
24CCOZ 120/208 66.7 24/24 3 60
120/240 57.8 24/24 3 60
127/220 63.1 24/24 3 60
139/240 57.8 24/24 3 60
220/380 36.5 24/24 3 60
277/480 28.9 24/24 3 60
20CCFOZ 110/190 60.8 20/20 3 50
110/220 52.5 20/20 3 50
120/208 55.6 20/20 3 50
220/380 30.4 20/20 3 50
230/400 28.9 20/20 3 50
240/416 27.8 20/20 3 50

Engine
Engine Data These Yanmar engines feature the following:
D One side serviceability of fuel system, lubrication
Number Number system, seawater pump, and air cleaner
Generator Engine of of Cooling
Model Model Cylinders Cycles System D Low oil pressure cutout
13.5CCOZ Heat
11CCFOZ
3JH2LT-K 3 4
Exchanger D High water and high exhaust temperature cutouts
18.5CCOZ
4JH2LT-K 4 4
Heat D Focused vibromounts
15CCFOZ Exchanger
Heat
D Belt guard
18CCFOZ 4JH2LHT-K 4 4
Exchanger
D Disposable oil filter
21CCOZ Heat
4JH2LHT-K 4 4 D Oil drain valve and hose
16.5CCFOZ Exchanger
14CCOZ Heat D Water-cooled turbocharger
3JH2LT-K 3 4
11.5CFOZ Exchanger
20CCOZ Heat D Air intake heater circuit for cold starting (optional
4JH2LT-K 4 4
17.5CCFOZ Exchanger on models 13.5CCOZ/11CCFOZ, 18.5CCOZ/
24CCOZ Heat 15CCOZ, 14CCOZ/11.5CCFOZ, and 20CCOZ/
4JH2LHT-K 4 4
20CCFOZ Exchanger 17.5CCFOZ)
D Electric rotary vane fuel pump with 1/4 NPT fuel
inlet
D Battery charging alternator
D Overspeed safety shutdown (optional)

Engine Specifications— 1-Phase Models
13.5CCOZ/ 18.5CCOZ/ 21CCOZ/
11CCFOZ 15CCFOZ 18CCFOZ 16.5CCFOZ
Engine Manufacturer Yanmar
Engine Model 3JH2LT-K 4JH2LT-K 4JH2LHT-K
Number of cylinders 3 4
Cylinder Block Material cast iron
Cylinder Head Material cast iron
Piston Rings 2 compression/1 oil
Crankshaft stamped forging
Connecting Rod Material forged carbon steel
Governor centrifugal, mechanical
Bore x Stroke— in. (mm) 3.23 (82) x 3.39 (86)
Displacement— CID (cc) 87.26 (1.43) 116.6 (1.91)
Compression Ratio 17.79:1 16.99:1
Horsepower 60/50 Hz 25.2/16.5 27.5/22.5 27.5 * 35/27.5
RPM 60/50 Hz 1800/1500 1500 * 1800/1500
Direction of Rotation
counterclockwise
(as viewed from generator end)
Lubrication System pressure, trochoid pump
Lube Oil Capacity—
5.0 (4.7) 6.1 (5.8)
U.S. qts. (L) (w/filter)
Oil Recommendation (API) CD
Engine Firing Order
1-3-2 1-3-4-2
(#1 cylinder nearest to flywheel)
Fuel Injection Timing (B.T.D.C.) 17° 17°±1
Fuel Injection Pressure
2844 ±71 (200 ±5)
psi (kg/cm sq.)
Combustion System direct injection
Battery Voltage 12 volt, negative ground
Battery Recommendation (min.) 500 CCA, 100 amp. hr.
Battery Charging (alternator) 50 amps. @ 12 volts
Fuel Recommendation Diesel, ASTM/D975-66T, No. 1-D or No. 2-D
Fuel System electric solenoid fuel shutoff
Fuel Pump Prime Pump electric
Fuel Pump Lift (max.)— ft. (m) 4 (1.2)
Coolant Capacity— U.S. qts. (L) 2.36 (2.23) 3.15 (3.0)
Coolant Recovery Tank— qts. (L) 0.85 (.8)
Recommended Coolant 50% ethylene glycol 50% clean, softened water
Thermostat 195°F (90°C)
Pressure Cap Rating 12.8 psi (88.3 kPa)
Starter Motor 1.8 kW bendix, gear-reduction automotive type
Intake/Exhaust Valve Clearance— in. (mm.)
0.0079 (0.2)
(cold)
Belt Tension (force)— in. (mm)
0.38 (10)
@ 22 lbs. (10 kg)
* 18CCFOZ -- 50 Hz only

Engine Specifications— 1-Phase Models (Continued)
13.5CCOZ/ 18.5CCOZ/ 21CCOZ/
11CCFOZ 15CCFOZ 18CCFOZ 16.5CCFOZ
Flex Plate to Rotor Bolt Torque
30 (41)
— ft. lbs. (Nm)
Cylinder Head Torque— ft. lbs. (Nm)
Initial ft. lbs (Nm) 29 (39)
Final ft. lbs (Nm) (2-step intervals) 58 (79)
Flex Plate to Flywheel Bolt Torque
20 (27)
— ft. lbs. (Nm)
Generator Adapter Plate
to Flywheel Housing Bolt Torque 30 (41)
— ft. lbs. (Nm)
Overbolt Torque— ft. lbs. (Nm) 30 (41)
Inlet Water Line Hose ID— in. (mm)
1.0 (25)
(seawater pump inlet)
Outlet Water Line Hose ID
3 (76)
— in. (mm) (mixing elbow outlet)
Fuel Inlet— (fuel pump inlet) 3/8 ID— 1/4 NPT
Fuel Return Size— Type 3/8 ID— 1/4 NPT

Engine Specifications— 3-Phase Models
14CCOZ/ 20CCOZ/ 24CCOZ
Engine Manufacturer Yanmar
Engine Model 3JH2LT-K 4JH2LT-K 4JH2LHT-K
Number of cylinders 3 4
Cylinder Block Material cast iron
Cylinder Head Material cast iron
Piston Rings 2 compression/1 oil
Crankshaft stamped forging
Connecting Rod Material forged carbon steel
Governor centrifugal, mechanical
Bore x Stroke— in. (mm) 3.23 (82) x 3.39 (86)
Displacement— CID (cc) 87.26 (1.43) 116.6 (1.91)
Compression Ratio 17.79:1 16.99:1
Horsepower 60/50 Hz 25.2/16.5 27.5/22.5 35/27.5
RPM 60/50 Hz 1800/1500
Direction of Rotation
counterclockwise
(as viewed from generator end)
Lubrication System pressure, trochoid pump
Lube Oil Capacity—
5.0 (4.7) 6.1 (5.8)
U.S. qts. (L) (w/filter)
Oil Recommendation (API) CD
Engine Firing Order
1-3-2 1-3-4-2
(#1 cylinder nearest to flywheel)
Fuel Injection Timing (B.T.D.C.) 17° 17°±1
Fuel Injection Pressure
2844 ±71 (200 ±5)
psi (kg/cm sq.)
Combustion System direct injection
Battery Voltage 12 volt, negative ground
Battery Recommendation (min.) 500 CCA, 100 amp. hr.
Battery Charging (alternator) 50 amps. @ 12 volts
Fuel Recommendation Diesel, ASTM/D975-66T, No. 1-D or No. 2-D
Fuel System electric solenoid fuel shutoff
Fuel Pump Prime Pump electric
Fuel Pump Lift (max.)— ft. (m) 4 (1.2)
Coolant Capacity— U.S. qts. (L) 2.36 (2.23) 3.15 (3.0)
Coolant Recovery Tank— qts. (L) 0.85 (.8)
Recommended Coolant 50% ethylene glycol 50% clean, softened water
Thermostat 195°F (90°C)
Pressure Cap Rating 12.8 psi (88.3 kPa)
Starter Motor 1.8 kW bendix, gear-reduction automotive type
Intake/Exhaust Valve
0.0079 (0.2)
Clearance— in. (mm) (cold)
Belt Tension (force)— in. (mm)
0.38 (10)
@ 22 lbs. (10 kg)

Engine Specifications— 3-Phase Models (Continued)
14CCOZ/ 20CCOZ/ 24CCOZ
Flex Plate to Rotor Bolt Torque
30 (41)
— ft. lbs. (Nm)
Cylinder Head Torque— ft. lbs. (Nm)
Initial ft. lbs (Nm) 29 (39)
Final ft. lbs (Nm) (2-step
58 (79)
intervals)
Flex Plate to Flywheel Bolt Torque
20 (27)
— ft. lbs. (Nm)
Generator Adapter Plate to
Flywheel Housing Bolt Torque 30 (41)
— ft. lbs. (Nm)
Overbolt Torque— ft. lbs. (Nm) 30 (41)
Inlet Water Line Hose I.D.— in.
1.0 (25)
(mm) (seawater pump inlet)
Outlet Water Line Hose I.D.
3 (76)
— in. (mm) (mixing elbow outlet)
Fuel Inlet— (fuel pump inlet) 3/8 ID— 1/4 NPT
Fuel Return Size— Type 3/8 ID— 1/4 NPT
Controller
The generator set has a relay controller with hourmeter. D Starter interlock to prevent reengagement of
For a description of the controller, see Section starter whenever engine is running
2— Operation. D Controller connections by plugs/receptacles and
clearly identified corrosion-resistant terminals to
Controller Features eliminate the possibility of misconnection
D Electric starting with a start/stop switch located on D Quick disconnect on 22-pin wiring harness
the controller or by (optional) remote start D External 6-pin connector for remote panel harness
D Rubber mounted to minimize vibration D Hourmeter for scheduling maintenance
D Safety shutdowns for overheating, low oil D Voltage/frequency adjustable PowerBoostä
pressure, and overspeed (optional) voltage regulator

Accessories
Kohler Co. offers several accessories to finalize the Remote start and four-meter panel kit allows
installation or to add convenience to operation and starting/stopping from a location remote of the
service. Contact a local Kohler distributor/dealer to generator set. The illuminated meters/gauges include a
obtain the most current information. The following list DC voltmeter, engine oil pressure gauge, water
includes accessories available at the time of print of this temperature gauge, and an hourmeter which records
publication. total generator set operating hours. Overall dimensions
are 9 in. (229 mm) by 6 in. (152 mm) with a minimum
Seawater strainer available for inline installation
depth of 4 in. (102 mm). Requires Remote
between seacock and seawater pump.
Connection/Extension Harness for hook-up. Requires
Siphon break mandatory kit on generators installed at Sender Kit.
or below the waterline. Prevents the siphoning of
Sender kit provides the necessary senders for making
floatation water into the engine.
remote meter panel gauges functional.
Sound shield provides for highly effective silencing,
Preheat kit provides improved starting in cold climates.
ease of access for engine/generator servicing, low
Available for the following models only:
maintenance, excellent durability, and safety.
D 13.5CCOZ/11CCFOZ
The Kohler Ship-to-Shore Transfer Switch allows
immediate switching to Kohler generator set power or D 14CCOZ/11.5CCFOZ
shore power protecting the electrical system from the D 18.5CCOZ/15CCFOZ
possibility of simultaneous connection of both power
sources. D 20CCOZ/17.5CCFOZ
Twelve-inch (0.3 m) remote wiring harness has a
Line circuit breakers protect the generator from
6-pin connector on one end which is keyed to the
extreme overload and provide protection for the output
controller box connector. The other end has pigtails for
cabling. Determine circuit breaker ampere rating by the
connection to customer-supplied start switch, generator
voltage configuration.
ON light, hourmeter, etc.
Remote start panel allows starting, stopping from a
location remote of the generator set. Supplied with 15 ft. Remote connection/extension harness provides
(4.6 m) connection harness. Overall mounting additional wiring between all remote panels and
dimensions are 4 1/16 in. (103 mm) by 2 1/8 in. (54mm) controller connector in 15 ft. (4.6 m) or 25 ft. (7.6 m)
with a minimum mounting depth of 2 1/4 in. (57 mm). increments. One harness is required for each Remote
Meter Panel Kit. Extension limited to a total of four kits
Remote start and two-meter panel kit allows
and 75 ft.
starting/stopping from a location remote of the
generator set. The illuminated gauges include an Overspeed shutdown kit provides additional
engine oil pressure gauge and a water temperature protection from overspeed/voltage damage.
gauge. Overall dimensions are 6 in. (152 mm) by 6 in. Heavy-duty battery cables are available for these
(152 mm) with a minimum mounting depth of 2 3/4 in. (70 marine generator sets.
mm). Requires Remote Connection/Extension Harness
for hook-up. Requires Sender Kit. Flexible fuel lines connect the generator set to the
main fuel tank.
Fuel attachment block allows connection to the fuel
inlet and return from one point.
Coolant overflow extension hose allows remote
mounting of the coolant overflow bottle, 10.8 ft. (3.3m).

2 4
1 5 8
3 6 7
10
11
12
13
14
15
16
21 20 19 18
17
ADV-5852-A
24
26 27 28
23 25
22 29
43 30
42 31
41
32
40
39
38
37
35 33
36 34
DA-250000-H
Figure 1-1. Service Views— 13.5CCOZ/11CCFOZ and 14CCOZ/11.5CCFOZ


Service Views
1. Controller 25. Heat exchanger
2. Air intake silencer 26. Coolant (freshwater) drain
3. Fuel solenoid 27. Seawater drain
4. Lifting eye 28. High exhaust temperature safety shutdown switch
5. Lifting eye 29. AC load lead connector
6. Fuel injectors 30. Nameplate
7. Oil fill 31. Remote start connector
8. Water temperature sender (optional) 32. Mixing elbow (water outlet/exhaust outlet)
9. Fuel filter 33. Starter solenoid
10. Fuel return connector 34. Battery positive (+) connection
11. Fuel injection pump 35. Starter motor
12. Oil fill 36. Ground lug (equipment ground)
13. Governor 37. Battery negative (--) connection
14. Seawater pump (drain point) (water inlet) 38. Seawater (drain point) petcock
15. Oil pressure sender (optional) 39. Belt guard
16. Lube oil filter 40. Coolant (freshwater) drain
17. Oil drain valve and hose 41. Battery charging alternator
18. Oil check 42. V-belts
19. Fuel feed pump (fuel inlet) 43. Engine-driven water pump
20. Low oil pressure safety shutdown switch
21.
22.
Coolant (freshwater) drain
High water temperature safety shutdown switch
Not Shown
23. Overflow tube Air Intake Heater (Optional Preheat Kit required to make air
24. Pressure cap intake heater functional).

3 6
8
4 5
2 7 9
1
10
11
12
13
14
15
16
21 17
20 19 18
ADV-5853-A
24
26 27 28
23 25
22 29 30
43
42 31
41
32
40
39
38
37
35 34 33
36
DA-250000-H
Figure 1-2. Service Views— 18CCFOZ, 18.5CCOZ/15CCFOZ, 20CCOZ/17.5CCFOZ, 21CCOZ/16.5CCFOZ, and

24CCOZ/20CCFOZ

Service Views
1. Controller 25. Heat exchanger
2. Air intake silencer 26. Coolant (freshwater) drain
3. Fuel solenoid 27. Seawater drain
4. Lifting eye 28. High exhaust temperature safety shutdown switch
5. Lifting eye 29. AC load lead connector
6. Fuel injectors 30. Nameplate
7. Oil fill 31. Remote start connector
8. Water temperature sender (optional) 32. Mixing elbow (water outlet/exhaust outlet)
9. Fuel filter 33. Starter solenoid
10. Fuel return connector 34. Battery positive (+) connection
11. Fuel injection pump 35. Starter motor
12. Oil fill 36. Ground lug (equipment ground)
13. Governor 37. Battery negative (--) connection
14. Seawater pump (drain point) (water inlet) 38. Seawater (drain point) petcock
15. Oil pressure sender (optional) 39. Belt guard
16. Lube oil filter 40. Coolant (freshwater) drain
17. Oil drain valve and hose 41. Battery charging alternator
18. Oil check 42. V-belts
19. Fuel feed pump (fuel inlet) 43. Engine-driven water pump
20. Low oil pressure safety shutdown switch
21.
22.
Coolant (freshwater) drain
High water temperature safety shutdown switch
Not Shown
23. Overflow tube Air Intake Heater (Optional Preheat Kit required to make air
24. Pressure cap intake heater functional).

Section 2. Operation
Prestart Checklist
To ensure continued satisfactory operation, check the Drive Belts. Check belt condition and tension of
following items before each startup and at regular radiator fan, water pump, and battery charging
intervals. alternator belt(s).
AIr Cleaner. Keep air cleaner element clean. Install Exhaust System. Keep exhaust outlet clear and free of
element to keep unfiltered air from entering engine. debris. Keep silencer and piping tight and in good
condition. Check hoses for leaks. Verify that each
Air Shrouding. Keep tight and in position.
exhaust hose connection has two clamps and that all
AIr Inlets. Keep clean and unobstructed. connections are tight.
Backfire Flame Arrestor. Clean and install air cleaner Fuel Level. Keep tank(s) full to ensure adequate fuel
to prevent unfiltered air from entering engine. supply.
Battery. Ensure tight battery connections. Maintain full Oil Level. Maintain oil level at or near full mark on
battery electrolyte level. dipstick but not over. Keep the oil level in the mechanical
Coolant Level. For cooling systems equipped with a governor (if equipped) at or near the full level.
coolant recovery tank, check coolant level at tank after Operating Area. Check for obstructions that could
the engine has cooled. block the flow of cooling air. Keep the air intake area
Maintain coolant level just below the filler neck, clean. Do not leave rags, tools, or debris on or near the
approximately 3/4 to 1 1/2 in. (19 to 33 mm). generator set.
A coolant solution of 50% ethylene glycol provides Seawater Pump Priming. Prime the seawater pump
freezing protection of --34°F (--37°C) and overheating before initial startup. To prime pump, close seacock and
protection to 265°F (129°C). A coolant solution with less remove the hose from the water filter outlet. Fill hose
than 50% ethylene glycol may not provide adequate and pump with clean water. Replace hose and open
freezing and overheating protection. A coolant solution seacock. Check for pump operation on startup by
with more than 50% ethylene glycol can cause engine or observing water discharge from exhaust outlet.
component damage. Do not use alcohol or methanol Kohler Co. recommends that all boat owners have their
antifreeze or mix them with the specified coolant. vessels— especially the exhaust system attached to the
Consult the engine manufacturer’s operation manual for generator set— inspected at the start of each boating
engine coolant specifications. season by their local Coast Guard Auxiliary. If there is
Do not add coolant to an overheated engine. Wait until no Coast Guard Auxiliary in the area, contact an
engine has cooled. Adding coolant to a hot engine can authorized Kohler distributor or dealer for the
cause the cylinder block or cylinder head to crack. inspection.
Cooling. Check the coolant level on closed-type heat

exchanger systems using the coolant recovery tank.
The MIN mark indicates full when cold and the MAX
mark indicates full when hot. Maintain the coolant level
between these marks. Periodically check the coolant
level on closed systems by removing the pressure cap.
Do not rely solely on level in coolant recovery tank.
Add fresh coolant until level is just below overflow tube

opening. See Maintenance— Cooling Systems.
TP-5592 7/96 Operation 2-1

Exercising the Generator Set
Run the generator set under load once each week for generator set to ensure there are no fluid or exhaust
one hour with an operator present. leaks.
Perform all prestart checks before starting the exercise Start the generator set according to the starting
procedure. With the generator set operating, listen for a procedure in the controller section of this manual.
smooth-running engine, and visually inspect the
Controller
For identification of controller components, see
2
Figure 2-1.
1 3
1. Start/Stop Switch. Use switch to start and stop the
generator set. Refer to Starting and Stopping
following.
2. DC Circuit Breaker. The generator set will shut 4
down automatically after fault. See Circuit
Protection following.
3. AC Circuit Breaker (optional). The circuit breaker
trips when a fault is detected in the output circuit.
During maintenance of craft wiring, the circuit
5
breaker disconnects the generator set . To close ADV-5852-A
circuit breaker(s), place breaker in ON position.
1. Start/Stop switch
4. Remote Start Connector. A 6-pin connector on 2. DC circuit breaker
3. AC circuit breaker (optional)
controller back panel allows connection of 4. Remote start connector
(optional) remote start kits. 5. Hourmeter
Figure 2-1. Controller
5. Hourmeter. Records total generator set operating
hours for reference in maintenance scheduling.
2-2 Operation TP-5592 7/96

Starting Procedure
Preheat Feature (optional) seawater entry into the engine cylinders through the
exhaust valve.
13.5CCOZ/11CCFOZ,
18.5CCOZ/15CCFOZ, If water enters the exhaust system, close seacock and
drain water from the exhaust system at silencer drain
14CCOZ/11.5CCFOZ, and
plug before attempting to start generator set. If
20CCOZ/17.5CCFOZ models only excessive cranking is a chronic problem, have the unit
During cold weather starts (below 40°F [4°C]), place (including the exhaust system) serviced by an
controller start switch in stop-preheat position for 15-20 authorized Kohler distributor/dealer.
seconds before attempting to start generator set to NOTE
energize the air heater coil. To prevent damage, do not
Do not crank engine continuously for more than 10
energize preheat feature for more than 30 seconds.
seconds at a time. Allow a 60-second cooldown period
NOTE between cranking attempts if the engine does not start.
The start/stop switches of all controllers indicate If the unit fails to start after three attempts, contact an
preheat. However, an optional preheat kit is required to authorized Kohler distributor/dealer for repair. Failure to
make the air intake coil (preheat) functional. follow these guidelines may result in starter motor
burnout.
Starting Generator NOTE
Open manual fuel shut-off valve (if equipped). Start After starting the generator set, open the seacock to
generator set by placing controller master switch in start allow cooling water passage.
position or use remote start/stop switch.
NOTE
NOTE Failure to open seacock after generator set is running
If engine fails to start after the first attempt, close the could damage the seawater pump impeller and cause
seacock before next starting attempt. Failure to close serious engine overheating damage.
the seacock may cause seawater to enter the exhaust
NOTE
piping and silencer. Water-filled exhaust piping and
silencer may further hinder generator starting and cause Check that the marine ship-to-shore transfer switch, if
equipped, is in the proper position.
Stopping Procedure
Run generator set at no load for five minutes to ensure NOTE
adequate engine cooldown. To stop the generator set, Do not place start/stop--preheat switch (if equipped) in
place controller start/stop switch or remote start/stop stop--preheat position for more than 30 seconds or
switch in the STOP position and wait until generator set damage to the preheat feature may occur.
comes to a complete stop.

Circuit Protection
AC circuit breakers (optional) trip when a fault is DC Circuit Breaker (10 amp) will trip when a fault
detected in the output circuit. Correct the fault and then occurs in the controller circuit. See Section
place the AC circuit breaker(s) in the ON position to 4— Troubleshooting. Correct the fault and then depress
reset. Restart the unit. See Figure 2-2 for AC circuit the center button of the DC circuit breaker to reset.
breaker ratings. Base circuit breaker selection on Restart the unit.
voltage configuration for each model.
Voltage regulator fuse (8 amp) protects in case of fault
in the voltage regulator and/or generator circuit. Correct
Voltage Number of AC Circuit
(max.) Poles Breaker (Amps) the fault and then replace the fuse with a new fuse of the
250 1 50 same rating. Voltage regulator circuit is then functional.
250 1 70 Battery charging fuse is a 10 amp fuse that protects
250 1 80 the battery charging alternator, battery charging
regulator, and circuitry. Correct the fault and then
240 2 50
replace the fuse with a new fuse of the same rating.
240 2 60
Battery charging circuit is then functional.
240 2 70
240 2 80
240 2 90
600 3 20
600 3 30
600 3 40
480 3 50
600 3 60
600 3 70
Figure 2-2. AC Circuit Breakers
Engine Safety Shutdown Switches

Four shutdown switches protect the engine. These NOTE
switches automatically reset after correcting the The Low Oil Pressure (LOP) switch does not act as a low
problem or cooling down the unit (if overheating was the oil level switch. Check oil level regularly to protect
problem). The following conditions will cause a against damage from low oil level.
generator set shutdown:
Low Oil Pressure (LOP) High Water Temperature (HWT) of 203°F (95°C) or
High Water Temperature (HWT) above will shut down the unit.
High Exhaust Temperature (HET) Overspeed (overfrequency) will immediately shut
Overspeed down the unit at 70 Hz or greater.
Engine safety shutdown switches become functional
when unit comes up to speed and AC voltage is
available.
High Exhaust Temperature (HET) of 215°F (102°C) or
greater will shut down the unit.
Low Oil Pressure (LOP) of 6.8 psi (47 kPa) or less will
shut down the unit.

Remote Panels (Optional)
Remote Start Panel Engine Oil Pressure Gauge. Measures engine oil
pressure. Normal engine operating range is 40-60 psi
Remote start panel allows starting/stopping from a (276-414 kPa) for 60 Hz models. 50 Hz models may
location remote of the generator set. Standard show a slightly lower pressure range.
generator sets have a 6-pin connector on the controller
for connecting the panel kit. See Figure 2-3. NOTE
During the engine break-in period, the engine
sometimes produces higher oil pressure readings.
Water Temperature Gauge. Measures engine coolant
temperature. Normal engine operating range is
2 170-195°F (77-91°C).
1-656
1. ON light
2. Start/stop switch
Figure 2-3. Remote Start Panel Features
Remote Start and

Two-Meter Panel Kit
Allows starting/stopping from a location remote of the
generator set. The illuminated gauges include an
engine oil pressure gauge and a water temperature
4 3 2
gauge. Standard generator sets have a 6-pin connector 1-762
on the controller for connecting the panel kit. See
1. Engine oil pressure gauge
Figure 2-4 for remote start and two-meter panel kit. 2. Water temperature gauge
NOTE 4. ON light
Remote start panels require a sender kit. Figure 2-4. Remote Start and
Two-Meter Panel Features
Start/Stop Switch. A rocker-type switch with ON light
starts and stops the generator set.

Remote Start and Water Temperature Gauge. Measures engine coolant
temperature. Normal engine operating range is
Four-Meter Panel Kit
170-195°F (77-91°C).
Allows starting/stopping from a location remote of the
Hourmeter. Records total generator set operating
generator set. The illuminated gauges include a DC
hours for reference in maintenance scheduling.
voltmeter, an engine oil pressure gauge, a water
temperature gauge, and a generator running time 2
1
hourmeter. Standard generator sets have a 6-pin
connector on the controller back panel for connecting
the panel kit. See Figure 2-5 for remote start and
four-meter panel features.
NOTE
Remote start meter panel requires a sender kit.
Start/Stop Switch. A rocker-type switch with ON light 6
starts and stops the generator set.
DC Voltmeter. Measures voltage of starting
5
battery(ies). Normal battery operating range is 12-14 3
volts.
4
Engine Oil Pressure Gauge. Measures engine oil 1-830
pressure. Normal engine operating range is 40-60 psi 1. Engine oil pressure gauge
2. Hourmeter
(276-414 kPa) for 60 Hz models. 50 Hz models may 3. Voltmeter
show a slightly lower pressure range. 4. Water temperature gauge
NOTE 6. ON light
Figure 2-5. Remote Start and Four-Meter Panel
During the engine break-in period, the engine
Features
sometimes produces higher oil pressure readings.

Section 3. Scheduled Maintenance
General
Servicing generator set when operating. Exposed
WARNING moving parts can cause severe injury or death.
Keep hands, feet, hair, clothing, and test leads away
from belts and pulleys when generator set is running.
Replace guards, screens, and covers before operating
generator set.
Accidental starting. Sound shield removal. Exposed moving parts can

Can cause severe injury or death. cause severe injury or death. Additional precautions
for sound shield-equipped models:
The generator set must be operating in order to perform
generator set (disconnect negative lead first and
reconnect it last). some scheduled maintenance procedures. Be
especially careful if the sound shield has been removed
Disabling generator set. Accidental starting can leaving belts and pulleys exposed.
cause severe injury or death. Disconnect battery
NOTICE
to disable generator set before working on the generator Seawater damage! High-mineral content seawater
set or connected equipment. The generator set can be (saltwater) causes rapid deterioration of all metals.
started by the remote start/stop switch unless this Wipe up all saltwater spillage on and around generator
precaution is followed. set and keep metal surfaces free from accumulated salt
deposits.
WARNING NOTICE
Hardware damage! Engine and generator set may use
both American Standard and metric hardware. Use the
correct size tools to prevent rounding of bolt heads and
nuts.
Rotating parts.
Do not operate generator set without all guards,
screens, and covers in place.
TP-5592 7/96 Scheduled Maintenance 3-1

Under normal operating conditions the generator set Periodically take the generator set to an authorized
alternator does not require scheduled service. Refer to distributor/dealer for tune-up. Tune-ups improve
the prestart checklist for items that require performance and ensure continuous satisfactory
maintenance. operation during a long, trouble-free service life.
If the generator set is operated under dusty or dirty Tools and instruments to perform some maintenance
conditions, use dry compressed air to blow dust out of items are not generally available to the generator set
the generator. Blow dust out with the generator set owner.
running. Direct the stream of air through openings in the
Kohler Co. recommends that all boat owners have their
generator end bracket.
vessels— especially the exhaust system attached to the
See Safety Precautions and Instructions at the generator set— inspected at the start of each boating
beginning of this manual before attempting to service, season by their local Coast Guard Auxiliary. If there is
repair, or operate the generator set. Have an authorized no Coast Guard Auxiliary in the area, contact an
Kohler service distributor/dealer perform all generator authorized Kohler distributor or dealer for the
service. Perform generator set engine service at the inspection.
intervals specified by the engine service literature.
Use the Operating Hour Service Log located in the back
Contact an authorized Kohler service distributor/dealer
of this manual to document performed services.
to obtain service literature.
The generator set will eventually require a complete
Refer to the service schedule following and the
overhaul. Rough operation, lack of power, metallic
hourmeter located on the generator set controller to
noises, and excessive oil consumption indicate serious
schedule routine maintenance. If the generator set is
generator set problems or a need for an overhaul.
subjected to extreme weather, long operating hours, or
Service the generator set promptly.
dusty or dirty conditions, service the unit more
frequently.
Perform maintenance on each item in the service
schedule at the designated interval for the life of the
generator set. For example, an item requiring service
every 100 hours or 3 months also requires service after
200 hours or 6 months, 300 hours or 9 months, etc.
3-2 Scheduled Maintenance TP-5592 7/96

Service Schedule
After Every Every Every
Before 50 Hrs./ 100 Hrs./ 300 Hrs./ 500 Hrs./
Perform Service at Intervals Indicated (X) Starting 1 Month 3 Months 6 Months Yearly
FUEL SYSTEM
Check the fuel oil level X
Fill the fuel tank X
Remove sediment from fuel tank X
X
Check for any abnormal fuel injection sound (During
operation)
X
Replace the fuel filter element * (Break-in X
period)
Check the injection timing *#& X
Check governor operation and adjust
X
as necessary *&
Check the fuel injection nozzles *#& X
LUBRICATION SYSTEM
Check the oil level in crankcase X
X
X
Replace the oil in crankcase * (Break-in
(150 Hours)
period)
X
Replace the lube oil filter element * (Break-in X
period)
COOLING SYSTEM
Check coolant level X
X
Check seawater outlet (During
operation)
X
Adjust engine water pump belt tension* (Break-in X
period)
X
Adjust seawater pump belt tension* (Break-in X
period)
Check function of siphon break (if equipped) X
Flush cooling system * X
Replace seawater pump impeller* X (Check) X
Check the thermostat function * X
* Requires removal of sound shield (if installed).
# Reference engine service manual for procedure.
& Read WARNING found at the beginning of Section 3 regarding moving parts.

Service Schedule (Continued)
AIR CLEANER, etc.
X
Check the exhaust gas condition * (During
operation)
Inspect turbocharger compressor * # X
Check for abnormal turbocharger X
rotor noise during operation *#& (1500 Hrs.)
Clean the intake silencer element * X (Clean) X (Replace)
Clean the exhaust/water mixing elbow * X
Check the breather pipe * X
Check turbo rotor shaft for wear (end play and radial X
tolerances) *# (6000 Hrs.)
ELECTRICAL SYSTEM
Check electrolyte level in the battery
X
(batteries with filler caps only)
Check the electrical connections * X
X
Adjust alternator driving belt tension* (Break-in X
period)
Check the battery specific gravity
X
ENGINE AND MOUNTING
Check for water and oil leakage*& X
X
X
Retighten cylinder head bolts * # (Break-in
(Two Years)
period)
X
Adjust intake/exhaust valve clearance * # (Break-in X
period)
Check tightness of mounting bolts/vibromounts * X
Retighten all major nuts and bolts * X

Service Schedule (Continued)
REMOTE CONTROL SYSTEM, etc.
Check compartment condition X
(fuel, oil, or water leaks)
X
Test run generator set
(Monthly)
X X
Check remote control operation (Break-in
period)
EXHAUST SYSTEM
Inspect exhaust system components for X
cracks and corrosion (exhaust line, hose clamps,
silencer, and outlet flapper) *&
Check that exhaust outlet is clear X
Check that hose clamps are tight X
Check for hose leaks X
Inspect the complete exhaust system *** X
GENERATOR
Blow dust out of generator *& X
*** Should be performed by the Coast Guard Auxiliary.

Lubrication System
Specifications Oil Check
Engine oil selection is very important to a diesel engine. Check the oil level in the crankcase daily or before each
Use of an unsuitable oil or neglecting an oil change may start-up to ensure that the level is in the safe range. To
result in damage and a shorter engine life. Oil must check the oil level, remove dipstick and wipe the end
meet the American Petroleum Institute (API) clean, reinsert as far as possible, and remove. Level
classification of CD, CC/CD, or CC. Figure 3-1 shows should be between min and max marks on the dipstick
the recommended Society of Automotive Engineers (Figure 3-2).
(SAE) viscosity designation for given temperature
ranges.
S.A.E. 5W20
Service
Grade
20W40
10W30 2
10W
20W
SAE 20
1
SAE 30 1. Min mark
2. Max mark
SAE 40 Figure 3-2. Oil Level Check
NOTE
°C --30 --20 --10 0 10 20 30 40 °C Do not operate the set if the oil level is below the min
mark or above the max mark.
°F 0 20 40 60 80 100 °F
Operating Temperature
Recommended Value
Usable Limit
Figure 3-1. Engine Oil Selection
NOTE
Failure to observe these standards may cause
inadequate lubrication/oil pressure and cold-starting
difficulties.

Oil Change 7. Disconnect pump and replace the oil drain hose
end cap and turn the valve at the base of the oil
Change oil according to the service schedule. Change drain hose.
oil more frequently under dirty, dusty conditions. 8. Start generator set and check for oil leaks.
Change oil while the engine is still warm. Use one of the
following procedures. If engine oil filter needs 9. Stop generator set. Remove dipstick and wipe
clean, reinsert as far as possible, and remove to
replacement, see Oil Filter Change following.
check oil level. Add oil, as necessary, to bring level
If using an automatic oil drain/oil fill pump: up to max mark.
1. Connect the pump to the end of the oil drain hose. NOTE
See Figure 3-3 for location.
Too high an oil level will cause high oil consumption
and engine carbonization. Too low a level will
cause engine damage.
NOTE
Do not pollute the environment. Dispose of used
engine oil and other contaminants in a safe and an
approved manner.
1 ADV-5853-A
1. Oil drain hose

Figure 3-3. Oil Drain Hose (Typical)
2. Place the pump outlet hose into a container.
3. Remove the oil fill cap. One cap is near the top of
the engine on the valve cover. The other cap is 2
near the governor. See Figure 3-4.
4. Start the pump and remove all oil. ADV-5853-A
5. Fill crankcase with specified amount and type of oil. 1. Oil fill at valve cover
See Section 1— Specifications. 2. Oil fill at governor
Figure 3-4. Oil Fill Locations (Typical)
6. Replace oil fill cap.

If not using an automatic oil drain/oil fill pump: Oil Filter Change
1. To drain oil, turn valve (if equipped) at the base of
Replace the oil filter as listed in the service schedule.
the oil drain hose. See Figure 3-3 for location.
Change more frequently if operating in dirty, dusty
Remove oil drain hose end cap and place oil drain
hose in a container. Do not pollute the environment conditions. See Figure 3-5 and refer to the following
or waterways. procedure.
2. Allow ample time for oil to drain. After completing 1. Loosen the oil filter by turning it counterclockwise.
the oil draining process, replace the end cap on the Remove oil filter and use rags to clean up spilled oil.
hose and turn the valve at the base of the oil drain Dispose of oil filter in a safe and approved manner.
hose. 2. Clean contact surface on the oil filter adapter.
3. Remove oil fill cap. One cap is near the top of the 3. Lightly lubricate the gasket surface of the new filter
engine on the valve cover. The other cap is near with fresh engine oil. Thread filter on adapter until
the governor. See Figure 3-4. gasket makes contact, hand-tighten an additional
4. Fill crankcase with specified amount and type of oil. one-half turn. Wash hands after any contact with
See Section 1— Specifications. engine oil.
5. Replace oil fill cap. To perform an oil change skip Steps 4-5 and go
6. Start generator set and check for oil leaks. back to Oil Change procedure preceding.
7. Stop generator set. Remove dipstick and wipe 4. Start generator set and check for oil leaks.
clean, reinsert as far as possible, and remove to 5. Stop generator set. Remove dipstick and wipe
check oil level. Add oil, as necessary, to bring level clean. Reinsert as far as possible and remove to
up to max mark. check oil level. Add oil, as necessary, to bring level
up to max mark.
ADV-5853-A
1. Lube oil filter

Figure 3-5. Lube Oil Filter (Typical)

Fuel System
Specifications Fuel Filter
Use a clean, good quality No. 1-D or No. 2-D diesel fuel Clean the fuel filter with fresh fuel oil and compressed
oil with a cetane number of 45 or greater. The fuel must air. The quality and condition of the fuel largely
meet the requirements of the American Society of determine the filter’s useful life. Replace the fuel filter
Testing and Materials (ASTM) diesel fuel classification element as listed in the service schedule. Use the
D975. following procedure to replace the fuel filter.
Use clean fuel since diesel engines have easily clogged, 1. Close the fuel valve.
precision fuel injectors and pumps. 2. Loosen the fuel filter by turning it counterclockwise.
Recommended fuel: Remove fuel filter and use rags to clean up spilled
United States ASTM/D975-66T, No. 1-D or No. 2-D fuel oil. Dispose of fuel filter in a safe and approved
diesel oil. manner. See Figure 3-6.
United Kingdom BS2869 Class A1.
1
NOTE
Never store diesel fuel in galvanized containers; diesel
fuel and the galvanized coating react chemically to
produce flaking which quickly clogs filters or causes fuel
pump or injector failure.
NOTE
Do not run the generator set out of fuel since the fuel
lines will draw in air and necessitate bleeding the fuel
system before restarting the unit.
NOTE
Avoid storing fuel for more than one month. Take special
precautions to keep all dirt, water, and other
contaminants out of the fuel. Diesel fuel storage tanks ADV-5853-A
containing contaminants and water may cause the

growth of microbes. Microbes form slime which clogs Figure 3-6. Fuel Filter Location (Typical)
the fuel filter and lines. 3. Clean contact surface on fuel oil filter adapter.
4. Lightly lubricate the gasket surface of the new fuel
filter with fresh fuel oil. Thread filter on adapter until
gasket makes contact, hand-tighten an additional
one-half turn. Wash hands after any contact with
fuel oil.
5. Open fuel valve.
6. Bleed the system. Follow the procedures in
Bleeding Fuel System following.

Bleeding Fuel System
1 2
If the generator set engine runs out of fuel, if air leaks
develop in the suction side of the fuel system, or when
replacing the fuel filter, bleed the entire system to
prevent starting failures and/or erratic operation.
NOTE
Connect the battery during the priming procedure to
allow engine cranking. Do not allow engine/generator to
start. To prevent actual starting, toggle the start/stop 3
switch. (Momentarily place the start/stop switch in the
START position for a few seconds and then place the
switch in the STOP position.)
Use the following procedure to bleed the fuel system.
1. Loosen vent screw A at fuel filter. See Figure 3-7.
2. Toggle the start/stop switch until fuel, free of air 5 4
bubbles, flows from vent screw A. Tighten
connection. TP-5592-3
3. Loosen vent screw B at fuel filter. 1. Vent screw A

2. Vent screw B
4. Toggle the start/stop switch until fuel, free of air 3. Fuel filter
4. Fuel injection pump
bubbles, flows from vent screw B. Tighten 5. Vent screw C
connection. Figure 3-7. Fuel System Bleeding (Typical)
5. Loosen vent screw C at fuel injection pump.
NOTE
6. Toggle the start/stop switch until fuel, free of air Wipe up all spilled diesel fuel after bleeding system.
bubbles, flows from vent screw C. Tighten
Wash hands after any contact with fuel oil.
connection.

Air Intake Silencer/Cleaner
A round polyurethane sound-absorbing type intake
silencer silences the intake air drawn into the cylinder
head from the intake port. Besides providing a silencing
effect, the silencer also acts as an air cleaner. Clean the 1
air silencer as listed in the service schedule. Clean more
frequently if operating in dirty, dusty conditions. Replace
a damaged or dirt-contaminated air silencer. See
Figure 3-8 and refer to the following procedure.
2
1
1--776
1. Element
Figure 3-9. Element Washing
1. Release the two spring clips and remove intake
silencer cover.
2. Remove the element from the cover and inspect. If
the element is in reasonable condition for cleaning,
ADV-5853-A
continue with Step 3.
1. Spring clip If the element is damaged or in poor condition,

2. Air intake silencer/cleaner replace the element. Skip Step 3 and go to Step 4.
Figure 3-8. Air Intake Silencer (Typical)
3. Wash the element in mild detergent and water
solution. Rinse and allow to air dry. See
Figure 3-9.
4. Wipe intake silencer cover and base with a clean
rag to remove any dirt. Check base for damage;
replace as necessary.
5. Reassemble element and cover assembly to
intake silencer base. Make sure sealing surfaces
fit correctly and reattach spring clips. Air intake
silencer duct should be at the 5 o’clock position as
viewed from the generator end.

Turbocharger
Inspect the compressor (blower) as listed in the service 1. Remove breather hose from air intake silencer
schedule for buildup of carbon residue. An authorized connector, if equipped.
service dealer, using Yanmar Service Manuals, must 2. Loosen hose clamp on air intake silencer and
perform all other turbocharger inspection and service remove air intake silencer.
described in the service schedule . See Figure 3-10 and
3. Inspect compressor (blower) housing and impeller
use the following procedure to inspect the compressor.
(blower wheel) for buildup of carbon residue. If the
compressor requires cleaning, contact an
authorized Kohler service distributor/dealer, who
1 should use a Yanmar approved turbocharger
cleaner.
4. Place air intake silencer over turbocharger
compressor housing inlet and tighten clamp.
Direct the air intake silencer duct down and away
from the engine.
5. Attach breather hose to air intake silencer
connector, if equipped.
DA-250000-H
1. Turbocharger
Figure 3-10. Turbocharger Inspection
Servicing Mixing Elbow

1. Check inside mixing elbow for carbon buildup and mixture of exhaust and seawater can cause rapid
corrosion. deterioration and failure in an improperly
maintained exhaust system.
2. Remove carbon buildup with a wire brush.
4. Replace damaged mixing elbow or other exhaust
3. Inspect exhaust manifold mounting threads for
components to prevent engine exhaust (carbon
cracking and corrosion. The mixing elbow
monoxide) leakage.
combines high temperature exhaust and cooling
seawater. When exposed to engine vibration, the

Governor
The centrifugal, mechanical governor keeps engine
speed constant by automatically adjusting the amount
of fuel supplied to the engine according to changes in 1 2
the load. The governor requires no regular service. The
governor is adjusted during run-in at the factory. Further
adjustments are unnecessary except under greatly
varying load conditions or if poor governor control
develops after extended usage.
60 Hz generator sets are designed to operate at 57-63
Hz, 1800 RPM under full load and 1890 RPM under no
load.
50 Hz generator sets are designed to operate at 47-53
Hz, 1500 RPM under full load and 1590 RPM under no
load.
To check speed, use frequency meter connected to load
leads or use hand tachometer.
1. Loosen locking nut on speed adjusting screw.
2. To increase speed (and frequency), turn screw in a
clockwise direction. Turn screw counterclockwise TP-5592-3
to decrease speed. 1. Speed adjusting screw
2. Locking nut
3. Tighten locking nut at new setting. See
Figure 3-11. Figure 3-11. Governor (Typical)

Cooling Systems
Closed/Heat Exchanger
WARNING
In a closed cooling system, the seawater does not
circulate through the engine. Rather, the seawater
circulates through the separate chambers within the
manifold to cool the engine water. The seawater then
mixes with engine exhaust and ejects out the exhaust
outlet. See Section 1— Specifications for coolant Hot coolant and steam.
capacity (including coolant recovery tank), thermostat Can cause severe injury or death.
rating, and pressure cap rating. Use a solution of 50% Before removing pressure cap, stop generator set
ethylene glycol and 50% clean, softened water to inhibit and allow it to cool. Then loosen pressure cap to
rust/corrosion and prevent freezing. relieve pressure.
Filling and Checking Checking coolant level. Hot coolant can cause
Before filling the cooling system, close all petcocks and severe injury or death. Allow engine to cool. Release
tighten all hose clamps. If the cooling system requires pressure from cooling system before opening pressure
filling, open pressure cap on heat exchanger and add cap. To release pressure, cover the pressure cap with a
fresh coolant until level is just below overflow tube thick cloth; then slowly turn it counterclockwise to the
opening. Add additional coolant, as necessary, to first stop. Remove cap after pressure has been
coolant recovery tank. Fill to just below the HOT (full) completely released and the engine has cooled. Check
mark. Maintain proper coolant level in coolant recovery coolant level at tank if generator set is equipped with a
tank. The COLD (add) mark indicates full when cold and coolant recovery tank.
the HOT (full) mark indicates full when hot. Maintain
coolant level between these marks.
NOTE
Pay special attention to the coolant level. After the
coolant drains, allow time for complete refill of the
engine water jacket. Check coolant level as prescribed
in the Prestart Checklist.

NOTICE Seawater Pump
Seawater damage! High-mineral content seawater These models use a belt-driven seawater pump located
(saltwater) causes rapid deterioration of all metals. on the service side. Check and change the seawater
Wipe up all saltwater spillage on and around generator pump as listed in the service schedule.
set and keep metal surfaces free from accumulated salt
deposits. Siphon Break
Cleaning A siphon break provision prevents seawater entry into
the engine when the engine exhaust manifold outlet is
For optimum protection, drain the cooling system at the less than 9 in. (23 cm) above waterline of a fully-loaded,
interval listed in the service schedule. shut-down craft. When the craft is used in contaminated
1. Open petcocks located at heat exchanger, engine waters or saltwater, the formation of corrosion may not
block, and cooling system and let the system drain allow the siphon break to function correctly. Check the
completely. Some models may have petcocks siphon break as listed in the service schedule. Use the
located behind the belt guard. Remove the following procedure to ensure correct functioning of the
pressure cap to make draining easier. siphon break.
2. Drain, clean, and flush coolant recovery tank. Use 1. Stop the generator set.
chemical cleaners for badly rusted or corroded
cooling system; follow manufacturer’s instructions. 2. Remove retaining cap to inspect reed valve
assembly. See Figure 3-12.
3. Flush system with clean water before filling with
recommended coolant. 3. Clean reed valve to remove residue and oxidation.
4. Check that reed valve (opening) is clear.
Pressure Cap
5. Replace siphon break if it is cracked or if reed valve
Closed/heat exchanger systems incorporate a material has hardened or deteriorated.
pressurized cap to raise the boiling point of the coolant
enabling higher operating temperatures. If the cap 6. Install reed valve into mounting base with valve
downward.
leaks, replace the cap with one of the same type and
rating. Find the pressure cap rating in Section 7. Install retaining cap and finger-tighten only. Do not
1— Specifications. overtighten.

NOTE
Numbers in illustration refer to callouts be-
low and not to dimensions.
2
3
7 8
9
10
1
20 4 11
Waterline
21
16
12
19
15
17
13
18
14
1. Mounting base 12. Seawater strainer

2. Retaining cap 13. Seacock
3. Reed valve assembly 14. Intake strainer
4. Maximum silencer vertical lift of 4 ft. (1.2 m) 15. Engine-driven seawater pump
5. Exhaust mixer elbow distance above waterline. If less than 9 in. 16. Minimum exhaust hose pitch of 0.5 in. per ft. (1.3 cm per 30.5 cm)
(23 cm), siphon break is required. 17. Water lock (optional)
6. Minimum siphon break distance above waterline of 1 ft. (30.5 cm) 18. Maximum distance between silencer and exhaust mixer elbow of
7. Siphon break 10 ft. (3 m)
8. Exhaust mixer elbow 19. Silencer (customer supplied)
9. Heat exchanger (locations vary by model) 20. Minimum exhaust hose pitch of 0.5 in. per ft. (1.3 cm per 30.5 cm)
10. Coolant recovery tank 21. Minimum exhaust outlet distance above waterline of 4 in. (10 cm)
11. Indicates coolant recovery tank at same height as heat
exchanger
Figure 3-12. Siphon Break (plastic “U” type)
NOTE NOTE
Read text for complete explanation of dimensions and Data given also applies to side-exhaust installations.
other installation considerations.
NOTE
Use two hose clamps on each end of all flexible exhaust
hose connections.

Belt Tension
Seawater Pump Belt
WARNING
1. Remove the belt guard.
2. Check belt tension at the midpoint of the longest
span of the belt. At midpoint, the belt should deflect
about 0.4-0.6 in. (10-15 mm) with about 22 lbs. (10
kg) of force. See Figure 3-13.
Accidental starting.
Can cause severe injury or death. If belt is not within specifications, go to Step 3. If
belt is within specifications, go to Step 7.
generator set (disconnect negative lead first and 3. Loosen pivot and adjusting screws.
reconnect it last).
4
Disabling generator set. Accidental starting can
cause severe injury or death. Disconnect battery 1
to disable generator set before working on the generator
set or connected equipment. The generator set can be
2 3
started by the remote start/stop switch unless this
precaution is followed. 5
11
6
WARNING
10
9 8 TP--5592--3
Rotating parts.
1. Engine-driven water pump pulley
Do not operate generator set without all guards, 2. Adjusting arm pivot screw
screens, and covers in place. 3. Battery charging alternator pulley
4. Adjusting screw
5. Alternator pivot screw
Servicing generator set when operating. Exposed 6. Check alternator belt tension here
7. Crankshaft pulley
moving parts can cause severe injury or death. 8. Check seawater pump belt tension here
Keep hands, feet, hair, clothing, and test leads away 9. Adjusting screw
10. Seawater pump pulley
from belts and pulleys when generator set is running. 11. Pivot screw
Replace guards, screens, and covers before operating Figure 3-13. Belt Tension (Typical)
generator set.
4. While prying seawater pump outward, tighten
Check the belt tension as listed in the service schedule. adjusting screw.
If the tension is not within specifications, adjust as 5. Tighten pivot screw.
necessary using the following procedure.
6. Recheck and adjust as necessary.
7. Replace the belt guard.

Battery Charging Alternator/ 3. Loosen adjusting arm pivot screw, alternator pivot
screw, and alternator adjusting screw.
Engine-Driven Water Pump Belt
4. While prying alternator outward, tighten alternator
1. Remove belt guard. adjusting screw.
2. Check belt tension at the midpoint of the longest 5. Tighten adjusting arm pivot screw and alternator
span of the belt. At midpoint, the belt should deflect pivot screw.
about 0.4-0.6 in. (10-15 mm) with about 22 lbs. (10
kg) of force, see Figure 3-13. 6. Recheck and adjust as necessary.
7. Replace the belt guard.
If belt is not within specifications, go to Step 3. If
belt is within specifications, go to Step 7.

Battery
Kohler Co. recommends using one 12-volt battery as Battery gases. Explosion can cause severe injury
the starting battery. It must have a minimum of 500 cold or death. Battery gases can cause an explosion. Do
cranking amps (CCA) at 0°F (--18°C) or 100 amp. hr. A not smoke or permit flame or spark to occur near a
maintenance-free battery does not require checking the battery at any time, particularly when it is charging.
specific gravity or electrolyte level. Otherwise, perform Avoid touching terminals with tools, etc., to prevent
these procedures at the interval recommended in the burns and sparks that could cause an explosion.
service schedule. Remove wristwatch, rings, and any other jewelry before
handling battery. Never connect negative (--) battery
WARNING cable to positive (+) connection terminal of starter
solenoid. Do not test battery condition by shorting
terminals together. Sparks could ignite battery gases or
fuel vapors. Ventilate any compartment containing
batteries to prevent accumulation of explosive gases.
To avoid sparks, do not disturb battery charger
connections while battery is being charged. Always turn
Sulfuric acid in batteries. battery charger off before disconnecting battery
connections. Remove negative lead first and reconnect
Use protective goggles and clothes. Battery acid can it last when disconnecting battery.
cause permanent damage to eyes, burn skin, and eat
holes in clothing.
Cleaning
Battery acid. Sulfuric acid in batteries can cause Clean battery by wiping it with a damp cloth. Keep all
severe injury or death. Sulfuric acid in battery can electrical connections dry and tight. If the battery is
cause permanent damage to eyes, burn skin, and eat corroded, disconnect cables from battery and remove
holes in clothing. Always wear splash-proof safety
corrosion with a wire brush. Clean battery and cables
goggles when working near the battery. If battery acid is
with a solution of baking soda and water. Do not allow
splashed in the eyes or on skin, immediately flush the
the cleaning solution to enter battery cells. After
affected area for 15 minutes with large quantities of
cleaning the battery, flush the battery and the cables
clean water. Seek immediate medical aid in the case of
with clean water and wipe the battery with a dry cloth.
eye contact. Never add acid to a battery after placing the
After reconnecting the battery cables, coat terminals
battery in service, as this may result in hazardous
with petroleum jelly, silicon grease, or other
spattering of battery acid.
nonconductive grease.

Charging
The engine alternator will provide a charge of 12 volts at
1
up to 50 amps. To adjust belt tension, see Belt Tension.
NOTE
Operation of on-board electrical equipment, such as
auxiliary lights and radios, off of battery power drains the
batteries. Batteries must maintain a charge sufficient to
start the generator. To maintain battery charge while
docked, charge battery using shore power. To maintain
battery power while underway, operate generator set.
Checking Electrolyte Level

2
Check the electrolyte level before each start--up.
Remove filler caps and check to see that electrolyte
level is up to bottoms of filler holes. See Figure 3-14. TP--5592--3
Refill as necessary with distilled water or clean tap
1. Filter caps
water. Do not add fresh electrolyte! Tighten filler caps. 2. Electrolyte level
After adding water during freezing temperatures, run Figure 3-14. Electrolyte Level Inspection
generator set for 20-30 minutes to allow electrolyte and
added water to mix. This will prevent battery damage
caused by freezing.

Checking Specific Gravity Correction
°C °F
71.1 160 + .032
Use a battery hydrometer to check the specific gravity of
+ .030
the electrolyte in each battery cell. While holding the
65.6 150 + .028
hydrometer vertically, read the number on the glass bulb EXAMPLE NO. 1—
+ .026
at the top of the electrolyte level (or the number adjacent 60.0 140 + .024
Temperature below 80°F (26.7°C)
to the pointer). If the hydrometer does not have a + .022 Hydrometer Reading 1.250
correction table, use the table in Figure 3-16. 54.4 130 + .020
Determine specific gravity and electrolyte temperature Acid Temperature 20°F (--6.7°C)
+ .018
of battery cells. Locate temperature in Figure 3-16 and 48.9 120 + .016 Subtract .024 Specific Gravity
adjust gravity by amount shown. The battery is fully + .014 Corrected Specific Gravity is 1.226
charged if the specific gravity is 1.260 at an electrolyte 43.3 110 + .012
temperature of 80°F (26.7°C). The difference between + .010
37.8 100 + .008

specific gravities of each cell should not exceed ±0.01.
+ .006 EXAMPLE NO. 2—
Charge the battery if the specific gravity is below 1.215
32.2 90 + .004
at an electrolyte temperature of 80°F (26.7°C). Temperature above 80°F (26.7°C)
+ .002
NOTE 26.7 80 0 Hydrometer Reading 1.235

-- .002
Some battery testers have four or five beads in the test Acid Temperature 100°F (37.8°C)
21.1 70 -- .004
tube. Draw electrolyte into the tube as done with the --. 006 Add .008 Specific Gravity
hydrometer described previously. Use the 15.6 60 -- .008
Corrected Specific Gravity is
manufacturer’s instructions. Figure 3-15 interprets the 1.243
-- .010
test results. 10 50 -- .012
-- .014
Battery 4.4 40 -- .016
Number of Beads Condition
-- .018
Five floating beads Overcharged -- 1.1 30 -- .020
Four floating beads Fully charged -- .022
Three floating beads A good charge -- 6.7 20 -- .024
-- .026
One or two floating beads A low charge
-- 12.2 10 -- .028
No floating beads A dead battery
Figure 3-15. Bead Test
The temperature correction amounts to about .004 (4 “points”)

of specific gravity for each 10°F (5.5°C) change in temperature.
1-787
Figure 3-16. Specific Gravity

Temperature Correction

Generator Service
General Replace the end bracket bearing every 10,000 hours of
operation. Service the end bracket bearing more
Under normal conditions, the generator does not require frequently if bearing inspection indicates excessive
regular service. If operating under dusty and dirty rotor end play or bearing damage from corrosion or heat
conditions, use dry compressed air to blow dust and dirt buildup. The sealed end bracket bearing requires no
out of the generator while the generator set is running. additional lubrication. Have an authorized Kohler
Direct the stream of air in through the cooling slots at the service distributor/dealer perform all generator service.
end of the generator.
Wattage Requirements
If the rated capacity of the generator set is exceeded, the Before resetting the circuit breaker, turn off some of the
circuit breaker located on the controller trips to protect appliances and lights inside the craft to bring the load
the generator against damage. A short circuit in the AC down within the rated limits of the set. If the circuit
circuit of the craft or simultaneous operation of too many breaker trips after the load reduction, there is a short
on-board appliances could cause the generator set’s circuit. Turn off the set and have a qualified electrician
controller circuit breaker to trip. If the circuit breaker locate and correct the cause of the short circuit.
trips, the set may continue to run, but there will be no AC
For more information regarding generator set capacity,
output to the protected circuit.
see Section 1— Specifications.

Storage Procedure
Keep the craft afloat until completing generator set -- Or --
storage since the unit must be started during the storage
procedure.
f. Close seacock and drain all seawater out of
1. Start and run generator set until it reaches cooling system.
operating temperature, or about 15 minutes.
g. Drain seawater from strainer and seawater
2. Stop generator set. Drain oil from crankcase while pump.
engine is still warm. Refill crankcase with specified
h. Open petcock on heat exchanger to drain only
weight oil.
seawater. Use an air hose to blow out any
NOTE remaining seawater, if necessary. Check
coolant level of heat exchanger and add if
Follow steps a.-e. or f.-i..
necessary.
a. Close seacock and remove hose at seacock. i. Drain seawater from exhaust water line.
Place hose in a container of coolant/antifreeze.
Container should have approximately 1-2 U.S. NOTE
gallons (3.7-7.5 L) of antifreeze. Use a mixture If the craft is stored in freezing temperatures, be
of 50% ethylene glycol and 50% clean, softened sure anti-freeze can withstand the lowest
water. possible temperatures. Generally, a mixture of
b. With a suitable container at exhaust outlet, run 50% ethylene glycol and 50% clean, softened
generator set until coolant discharges at water is sufficient.
exhaust outlet or until coolant mixture is used
up. Do not allow coolant mixture to flow into 3. Diesel fuel can be stored in the fuel tank for several
waterways. months.
c. Stop generator set. 4. Clean exterior of generator set and spread a light
film of oil or silicon spray over any exposed
d. Connect hose to seacock. Leave seacock surfaces which may be subject to rust or corrosion.
closed.
5. Seal air inlet, exhaust pipe, and fuel tank cap with
e. Check coolant level of heat exchanger and add tape.
if necessary.
6. Disconnect and remove battery. Place battery in a
warm, dry location for storage period. Recharge
once a month to maintain full charge.
7. Cover entire unit with a dust cover.

Section 4. Troubleshooting
When troubles occur, do not overlook simple causes. A the generator set to an authorized Kohler service
starting problem, for example, could be caused by distributor/dealer. Tell the dealer exactly what happened
incorrect fuel or an empty fuel tank. The following charts when the problem occurred and of any adjustments
list some common problems. If procedures in this made to the set.
manual do not explain how to correct the problem, take
Engine
Problem Possible Cause Corrective Action
Unit will not crank Weak or dead battery Recharge or replace battery
Reversed or poor battery connections. Poor Check and correct connections
ground.
Circuit breaker tripped in controller Reset circuit breaker
Defective start/stop switch Check switch, replace as necessary
Defective starter solenoid Check starter solenoid and wiring. Replace as
necessary.
Defective starter Replace/repair as necessary
Unit cranks but will not Out of fuel Replenish fuel
start Fault shutdown Check shutdown switches
Fuel shut-off valve closed Open shut-off valve
Defective fuel feed pump Replace fuel feed pump
Clogged fuel filter Service fuel filter element
Air in fuel system Bleed air from system
Water, dirt in fuel system Drain, flush fuel system
Dirty or faulty injectors See authorized Kohler service distributor/dealer
Incorrect compression See authorized Kohler service distributor/dealer
Incorrect type of fuel Use correct type of fuel; consult fuel supplier
Incorrect type of crankcase lube oil for ambient Use correct lube oil
temperature
Faulty fuel solenoid Replace solenoid
Air intake clogged Clean or replace air intake
Faulty ground (-) connection Clean and retighten
Weak or dead battery Recharge or replace battery
Engine malfunction See authorized Kohler service distributor/dealer
Engine starts, but does No generator output voltage Check AC voltage. See
not continue to run Troubleshooting— Generator (No AC output)
after start switch is No/low oil pressure See authorized Kohler service distributor/dealer
released
Defective low oil pressure (LOP) safety Replace LOP shutdown switch
shutdown switch
High temperature shutdown Check cooling system for coolant level
Defective high exhaust temp. (HET) and/or high Replace HET and/or HWT shutdown switch(es)
water temp. (HWT) safety shutdown switch(es)
TP-5592 7/96 Troubleshooting 4-1

Engine (Continued)
Stops suddenly Out of fuel Replenish fuel
Air intake clogged Service air intake silencer
Circuit breaker tripped in controller Reset circuit breaker
Defective seawater pump impeller Replace seawater pump impeller
Clogged seawater strainer Clean strainer
Fuel line restriction Check fuel lines and tank
Dirty fuel filter Service fuel filter
No/low oil pressure See authorized Kohler service distributor/dealer
Defective low oil pressure (LOP) safety Replace LOP shutdown switch
shutdown switch
High temperature shutdown Check engine coolant system for coolant level
Defective high exhaust temp. (HET) and/or high Replace HET and HWT shutdown switch(es)
water temp. (HWT) safety shutdown switch(es)
Loss of AC output See authorized Kohler service distributor/dealer
Operates erratically Air intake clogged Service air intake silencer
Stale or bad fuel Replace fuel
Clogged fuel filter Replace fuel filter
Vent in fuel tank cap obstructed Clean cap in solvent; blow dry
Water, dirt, or air in fuel system Drain, flush, fill, and bleed air in the system
Faulty governor linkage See authorized Kohler service distributor/dealer
Defective fuel feed pump Replace fuel feed pump
Incorrect valve clearance See authorized Kohler service distributor/dealer
Defective valve spring See authorized Kohler service distributor/dealer
Engine knocks Incorrect type of fuel Use correct type of fuel; consult fuel supplier
Incorrect fuel injection timing See authorized Kohler service distributor/dealer
Incorrect cylinder top clearance See authorized Kohler service distributor/dealer
Defective piston or piston ring See authorized Kohler service distributor/dealer
Defective crankshaft bearing or piston pin See authorized Kohler service distributor/dealer
bearing
Air in injectors Bleed air
Engine overheats Inadequate cooling Check engine coolant level
Thermostat defective Replace thermostat
Air intake clogged Service air intake silencer
Engine overloaded Reduce load
Loose or defective cooling water pump belt Adjust belt tension or replace belt
Cooling system needs flushing Flush cooling system
Defective temperature switch Replace shutdown switch
Cooling water leaks from water passage Check water passage
4-2 Troubleshooting TP-5592 7/96

Engine (Continued)
Lacks power Air intake clogged Service air intake silencer
Bad or stale fuel Replace fuel
Engine not operating at rated RPM See authorized Kohler service distributor/dealer
Governor adjustments incorrect See authorized Kohler service distributor/dealer
Carbon build-up Clean carbon from cylinder heads
Inadequate cooling Inspect cooling system
Fuel line restricted Check fuel lines
Dirty fuel filter Service fuel filter
Incorrect engine compression See authorized Kohler service distributor/dealer
Vent in fuel tank cap obstructed Clean cap in solvent; blow dry
Engine emits black or Incorrect type of fuel Use correct fuel
gray exhaust smoke Clogged or dirty air intake silencer Service air intake silencer
Defective injection pump See authorized Kohler service distributor/dealer
Faulty injectors See authorized Kohler service distributor/dealer
Lube oil level too high Drain out surplus lube oil
Incorrect lube oil Use correct viscosity oil
Low lube oil pressure Low lube oil level Add lube oil
Incorrect lube oil viscosity Drain, fill correct lube oil
Defective lube oil pump See authorized Kohler service distributor/dealer
Defective oil pressure switch Replace safety shutdown switch
High lube oil Too light viscosity oil Use correct viscosity oil
consumption Oil leaks Check for leaks in lines, around gasket, and
drain plug
Incorrect type of oil Use oil of correct viscosity
Clogged breather system Clean breather system
Defective piston ring, piston, cylinder liner, See authorized Kohler service distributor/dealer
valve guide, and seat
High fuel consumption Incorrect type of fuel Use correct fuel
Clogged or dirty air intake silencer Service air intake silencer
Low engine temperature Check thermostat
Fuel leakage Check for leaks at fuel tank, lines, and engine
fuel system

Engine (Continued)
Unit is noisy Exhaust system leak Inspect exhaust system for leaks and repair
them
Exhaust system not securely installed Check for loose parts and tighten them
Broken or damaged vibromounts Check vibromounts for cracks
No installation clearance (unit hits craft Check and increase clearances
structure or compartment)
No compartment sound insulation Install approved insulation
Excessive vibration engine/ generator (internal See authorized Kohler service distributor/dealer
imbalance)
Abnormal noise Worn or defective bearing or gear See authorized Kohler service distributor/dealer
Loose bolt or screw Tighten hardware
Low lube oil level Add lube oil
Electrical System
Battery will not charge Loose or corroded connections Clean and tighten connections
Sulfated or worn-out battery Check electrolyte level and specific gravity
Defective battery charging system Check charging system
Battery charging fuse blown Replace fuse. If fuse blows again see
authorized Kohler service distributor/dealer
Starter does not work Loose or corroded connections Clean and tighten loose connections
correctly Low battery output Check electrolyte level and specific gravity
(batteries with filler caps only). Check battery
voltage.
Defective starter solenoid Replace starter solenoid
Defective start/stop switch Replace switch
Defective wiring Check wiring
Starter cranks slowly Low battery output Check electrolyte level and specific gravity
Too heavy viscosity lube oil Use correct viscosity oil
Loose or corroded wiring Clean and tighten loose connections
High starter current draw Rebuild or replace starter
4-4 Troubleshooting TP-5592 7/96

Generator
No AC output Circuit breaker in OFF position Reset breaker to ON position
Circuit breaker tripped due to overload on Reduce load. See Wattage Requirements.
generator set Reset breaker to ON position.
Ship-to-shore transfer switch in OFF or SHORE Turn switch to generator power
position
Controller circuit breaker tripped Reset circuit breaker
Generator malfunction such as defective rotor, See authorized Kohler service distributor/dealer
faulty voltage regulator, or other internal fault
Low output or Engine speed too low Adjust governor
excessive drop in Generator overloaded Reduce load. See Wattage Requirements.
voltage
Engine in poor condition If routine services are performed and condition
persists, see authorized Kohler
distributor/dealer
Faulty voltage regulator See authorized Kohler service distributor/dealer
High generator output Defective voltage regulator and/or poor wiring See authorized Kohler service distributor/dealer
voltage connections
Rotor grounded See authorized Kohler service distributor/dealer

Section 5. Wiring Diagrams
Voltage Reconnection (4-lead)

The following information illustrates the correct
L0 (Neutral)
reconnection of 4-lead generator sets. In all cases, follow L0
the National Electrical Code (NEC). GRD.
Ground
NOTE
When connecting a generator set to a voltage different Load L1
from nameplate voltage, place a notice on the unit Side
indicating the voltage change. A decal (part no. 246242) is
Single-Pole
available for this purpose from authorized Kohler Circuit
distributors/dealers. Breaker
Jumper lead not used. Circuit breaker MUST be a circuit Line

Side
breaker manufacturer two-pole circuit breaker. Two
single-pole circuit breakers do not conform to NEC
requirements when supplying a 200-240 volt load. This is
true even if they are mechanically attached together.
Since Leads L1 and L2 are of different phases, never
connect them together.
100-120 Volt
4 3 2 1 2 Wire
Stator Leads
60 Hz 50 Hz
L0-L1 100-120 Volt 100-120 Volt
L0-L2 100-120 Volt 100-120 Volt
Figure 5-1. 100-120 Volt Configuration*
TP-5592 7/96 Wiring Diagrams 5-1

L0 (Neutral) L0 (Neutral)
L0 L0
GRD. GRD.
Ground Ground
L2 L1
Load L1 Load
Side Side Single-Pole
Circuit
Factory Breaker
Two-Pole Line
Circuit Side
Breaker
Line
Side
Tape to insulate
from ground
4 3 2 1
100-120/200-240 Volt,
Stator Leads 4 3 2 1 200-220-240 Volt
3 Wire
Stator Leads 2 Wire
60 Hz 50 Hz 60 Hz 50 Hz
L0-L1 100-120 Volt 100-120 Volt L0-L1 not used 200-220-240 Volt
L0-L2 100-120 Volt 100-120 Volt Figure 5-3. 200-220-240 Volt Configuration*
L0-L2 200--240 Volt 200--240 Volt
Figure 5-2. 100-120/200-240 Volt Configuration
5-2 Wiring Diagrams TP-5592 7/96

NOTES

Voltage Reconnection (12-lead)
This reconnection procedure details voltage NOTE
reconnections only. If the generator set requires Voltage reconnection! Affix notice to generator set after
frequency changes, the governor and voltage regulator reconnecting to a voltage different than the nameplate.
will need adjustment. See the generator service manual Order voltage reconnection decal 246242 from authorized
for information regarding frequency adjustment. service distributors/dealers.
The following information illustrates the reconnection of 1. Move generator set master switch to OFF/RESET
12-lead generator sets In all cases, follow the National position.
Electrical Code (NEC) guidelines.
2. Disconnect engine starting battery, negative (--) lead
Reconnect the stator leads of the generator set if desiring first. Disconnect power to battery charger (if
a different output phase or voltage. Refer to the following equipped).
procedure and the connection schematics following. 3. Use Figure 5-4 to determine generator set voltage
Follow all safety precautions at the front of this manual and configuration. Note original voltage and reconnect as
in the text during this procedure. needed.

EM-250000-
Figure 5-4. Generator Reconnection

Electro Switch
2-Wire Generator Sets 3-Wire Generator Sets
L1 L1
To Generator 2 1 3 4 To Shore 2 1 3 4
Set Power
L2 L2
6 5 7 8 To Generator 6 5 7 8 To Shore
Set Power
L0
10 9 11 12
To Load
To Load
Kraus Naimler/American Solenoid

(Early Rectangular Design)
L1 L1
To Generator 1 2 6 5 To Shore 1 2 6 5
Set Power
L2 L2
Set Power
L0
9 10 14 13
To Load
To Load
Kraus Naimler/American Solenoid

(Newer Round Design)
L1 L1
3 2 4 1 To Shore 3 2 4 1
To Generator
Set Power
L2 L2
Set Power
L0
11 10 12 9
To Load
To Load
TP-5399-5
Figure 5-5. Marine Manual (Ship-to-Shore) Transfer Switch

Kraus Naimer/American Solenoid
4-Wire, three phase
Generator Sets
L1 L1
3 2 4 1
L2 L2
To Generator 7 6 8 5 To Shore
Set Power
L3 L3
11 10 12 9
L0 L0
15 14 16 13
L1 L2 L3 L0
To Load
I-940
Figure 5-6. Marine Manual (Ship-to-Shore) Transfer Switch

229937-A
Figure 5-7. Schematic Wiring Diagram— 13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ

(1-Phase Models)

229937-A
Figure 5-8. Point-to-Point Wiring Diagram— 13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ

(1-Phase Models)

229938-
Figure 5-9. Schematic Wiring Diagram— 14/20/24CCOZ and 11.5/17.5/20CCFOZ

(3-Phase Models)

229938-
Figure 5-10. Point-to-Point Wiring Diagram— 14/20/24CCOZ and 11.5/17.5/20CCFOZ

(3-Phase Models)

229991-B
Figure 5-11. Schematic Wiring Diagram— 13.5/18.5/21CCOZ

(Specs: PA-126148, PA-126152, and PA-126155 1-Phase Models)

229991-B
Figure 5-12. Point-to-Point Wiring Diagram— 13.5/18.5/21CCOZ

(Specs: PA-126148, PA-126152, and PA-126155 1-Phase Models)

Section 6. Installation
Introduction
Use this section as a guide when installing the marine NOTE
generator set, then refer to the operation section for There is a wood block located under some generator set
specific service instructions. Reliable and safe end brackets to prevent damage during shipment. For
generator set operation depends largely upon correct the same reason, there are metal brackets attaching
installation. Remember that the generator set will some generator sets to their wood shipping bases.
probably be the craft’s sole source of electrical power. Remove the wood block and the metal brackets prior to
Marine generator set installations must comply with all installation to provide adequate vibration clearance
applicable regulations and standards. See Reference during generator set operation. Remove all packing
Material section of this manual for governing agencies. material, literature, and loose accessories from
Follow information presented here in planning and generator set prior to operation.
making installations. Use specifications given only in
initial planning. Use current dimension drawings and
wiring diagrams.
TP-5592 7/96 Installation 6-1

1 2
17
16
KOHLER
15 4
14
5
13
9
8
12 6
11 7
10
1. Exhaust mixer elbow (exhaust/water outlet) (not shown) 11. Hose clamps
2. Heat exchanger (not shown) 12. Fuel supply line *
3. Coolant recovery tank 13. Mounting tray
4. Seawater strainer * 14. Battery/battery storage box
5. Seawater pump (seawater inlet) 15. Battery cables
6. Seawater line * 16. Exhaust/waterline *
7. Seacock * 17. Electrical leads (AC output leads/remote start panel leads)
8. Mounting base * Indicated components must conform to USCG Regulations.
9. Fuel feed pump (fuel inlet) *
10. Fuel return line *
Figure 6-1. Typical Location and Mounting
NOTE
Use two hose clamps on each end of all flexible exhaust
hose connections.
6-2 Installation TP-5592 7/96

Location
General Space
Consider the following when selecting or constructing a Location should allow easy access to the generator set’s
generator set location. engine, controller, cooling, and fuel system components
for routine service. The engine compartment is often the
D Allow adequate space for ventilation, cooling and
exhaust system installation, service access to set ideal generator set location if propulsion engine(s) do
(engine and generator), and correct fuel system not obstruct access to generator and controller.
installation. Allow clearance for vibration and cooling during
D Engine stringers or other available structural operation. See Section 1— Specifications for minimum
members must provide adequate support for recommended clearances for vibration and cooling. If
generator set weight. the unit has a sound shield, maintain clearances per
D Generator set compartment must be sealed to sound shield instructions.
prevent exhaust gases and fuel vapors from These generator sets are not ignition protected.
entering cabins. According to USCG Regulation 183.410,
D Generator sets located above deck must have a gasoline/gaseous-fueled environments require
protective cover to prevent damage from rain and ignition-protected devices.
water splash. This cover must not affect cooling air
flow and serviceability. Mounting
See Section 1— Specifications for dimensions and
Engine stringers generally provide the best support for a
weights. See Figure 6-1 for a typical installation.
generator set. Be sure structural members for mounting
can support generator set weight and withstand engine
vibration. The generator sets include vibration mounts
and mounting tray; install additional vibration isolating
pads between tray and bases.
Mount the generator set as high as possible to avoid
bilge splash and lower lying vapors and to allow for a
downward pitch of the exhaust line.
For angular installation considerations, see Section
1— Specifications.

Ventilation Figure 6-2 lists air requirements for various models.
The air intake silencer/cleaner provides combustion air
to the engine. Do not compromise the recommended
WARNING minimum clearance of 1.5 in. (38mm) between duct
opening and any enclosure wall. Not following these
guidelines will adversely affect engine/generator
performance.
Air Requirements CFM (L/min.)
Combustion Cooling
Explosion. Model
60Hz/50Hz 60Hz/50Hz
Gasoline vapors can cause explosion and
severe injury or death. 13.5/14CCOZ 86.78/72.32 210/175
11/11.5CCFOZ (1422/1185) (5946/4955)
Before starting generator set, operate blower 4 18.5/20/21/24CCOZ 115.91/96.59 210/175
minutes and check engine compartment for 15/17.5/16.5/18/20CCFOZ (1899/1582) (5946/4955
gasoline vapors.
Figure 6-2. Air Requirements
Engine combustion, generator cooling, and expulsion of

flammable and lethal fumes require ventilation.
Ventilation provisions must comply with USCG
Regulations governing sizing of vents and operator
requirements.
As a rule, size each inlet- and outlet-vent area to a
minimum of 2 sq. in. per ft. (13 sq. cm/30.5 cm) of craft’s
beam. Should this rule in any instance conflict with
USCG Regulations, follow Regulations. If using any
screen in inlets, double the size of hull/deck openings.
Extend vent ducts to bilges to expel heavier-than-air
fumes. For generator sets mounted in the engine
compartment, increase air flow to allow for generator
set’s requirements. Install optional sniffer devices to
cause alarm, warning, or engine shutdown should
dangerous fumes accumulate in the compartment.

Fuel Systems 2
Fuel Supply
WARNING
1
1-788
Explosive fuel vapors.
Can cause severe injury or death. 1. Fuel line to propulsion engine
2. Fuel line to generator set
Use extreme care when handling, storing, Figure 6-3. Dual Dip Tubes
and using fuels.
NOTE
Installing fuel system. Explosive fuel vapors can Fuel systems must conform to USCG Regulations and
cause severe injury or death. Fuel leakage can cause tests.
an explosion. Do not modify the tank or propulsion
engine fuel system. Equip craft with a tank allowing one
of the two pickup arrangements described in the 1
installation section. Tank and installation must conform
to U.S.C.G. Regulations.
Generator sets, in most cases, draw fuel from the same

tank as the propulsion engines. If the tank’s fuel pickup
opening allows, use a multiple dip tube arrangement
(Figure 6-3). The alternate tank should have a smaller
separate pickup opening allowing a single dip tube
1-788
(Figure 6-4). Equip the fuel tank with a precipitation tank
and a drain petcock to remove any accumulated dirt and 1. Fuel line to generator set
water. See Figure 6-5. Figure 6-4. Single Dip Tube

Locate the fuel return line as far as practical from the fuel Anti-Siphon Provisions
pickup to allow tank fuel to cool return fuel before
delivery back to the fuel injectors. Incoming fuel cools USCG Regulations do not require anti-siphoning
the injectors and achieves maximum engine efficiency devices with diesel-powered applications. Therefore,
by supplying cool fuel to the engine. Fuel tank capacity Kohler Co. does not recommend using anti-siphoning
and amount of fuel will affect cooling capability. devices.
Fuel Lines And Filters

Use metallic lines from the tank to a flexible hose section
to connect a metallic line to the engine fuel pump inlet
connection point. Use metallic lines from the tank to a
flexible hose section connecting metallic line to the fuel
return line connection point. The flexible hose section
allows vibrational motion of the generator set during
operation. Use 3/8 in. ID size customer-supplied fuel
lines to connect to the fuel pump and fuel return. Fuel
lines and fuel line supports must comply with USCG
Regulations 33CFR183.
1 See Figure 6-6 for fuel feed pump inlet connection and
fuel return line connection.
2 Any in-line fuel filters or strainers must conform to USCG
Regulations.
1-788
1. Precipitation tank Fuel Pump Lift Capabilities And
2. Drain petcock
Fuel Consumption
Figure 6-5. Precipitation Tank (typical)
Locate the fuel pump lift capabilities, fuel line size/type,
Under no circumstances should the propulsion engine
and generator set fuel consumption rates in Section
and generator set share mutual pickup or return lines
1— Specifications.
(tee arrangement) which would allow the larger engine
to starve fuel from the smaller engine. It is also possible
that the operation of either engine could completely
drain the fuel line of the other engine and make starting
difficult.

1
3 2
ADV-5853-A
1. Fuel Return Connection 3. Inlet Connection
2. Fuel Feed Pump
Figure 6-6. Fuel Feed Pump (Inlet Connection) and Fuel Return Connection (Typical)

Cooling Systems
General
The following features are necessary in any marine 2
cooling system.
1
Intake through-hull strainer (seacock cover) Install a
screened strainer to prevent entry of foreign objects.
Accepted types of through-hull strainers are those of the
perforated, slotted-hole, or unrestricted-hole design. 4 3
See Figure 6-8 for examples of typical strainers. The
selected strainer must have oopening(s) that are equal
to or greater than the inside diameter of the waterline NOTE
hose to the seawater pump. Do not align the strainer (in Position intakes in relation to vessel travel so
relation to direction of travel) with the propulsion engine neither is in the wake of the other. 1-789
intake. See Figure 6-7. Flush mount the recommended 1. Generator set intake
through-hull strainer. If the selected strainer is of the 2. Propulsion engine intake
3. Aft
slotted-hole design, install it with the slots parallel to the 4. Fore
direction of vessel movement. Figure 6-7. Intake Strainer
An intake through-hull strainer must not be of the speed
scoop or cup design which can cause a ramming effect
and force water upward, past the seawater pump, and
into engine cylinders when the vessel is moving and the
generator set is shut down. Hull designs incorporating
1
sea chests are also not suitable for intake through-hull
strainers. A sea chest is a concave molded-in-the-hull
chamber that is also aligned to the direction of travel. A
sea chest configuration applies a positive pressure 2
similar to a scoop-type through-hull strainer.
Mount seacock to hull, assemble it to intake, and
ensure it is accessible for operation. Figure 6-8 shows a
typical installation. Install the canvas on the outside of 3
the hull and the canvas or rubber packing on the inside
4
of the hull. Tighten the seacock.
If using caulking to seal seacock, do not apply an
excessive amount. Excess caulk causes incorrect
water flow and, in some cases, develops a barrier which
can force water upward, past the seawater pump, and
into the engine cylinders when the vessel is moving and 5 1-789
the generator set is shut down.
1. Inside packing
2. Outside packing
3. Seacock cover
4. Direction of vessel movement
5. Typical intake through-hull strainers
Figure 6-8. Seacock Installation

Mount seawater strainer of sufficient capacity to Keep pipes as straight and as short as possible. If the
seacock or permanent structure at a point not higher pipe is too long, water draw problems may occur. To
than seawater pump. Ensure that the strainer is remedy some problems with long pipe runs (usually
accessible for servicing. See Figure 6-9 for a typical over 15 ft [4.6 m]), increase the hose size to the next
installation. standard pipe diameter. Example: substitute 3/4 in.
hose for 5/8 in. See Section 1— Specifications for inlet
NOTE
water line hose size. See Figure 6-10 for seawater
Some seawater strainers include seacock and intake connection to seawater pump inlet. The seawater outlet
through-hull strainer. combines with engine exhaust gases.
1-789
1. Seawater pump
2. Seawater strainer
3. Seacock 1
ADV-5853-A
Figure 6-9. Seawater Strainer
1. Seawater pump inlet
Waterlines from seacock to engine-driven seawater
pump are usually flexible hose. Reference ABYC Figure 6-10. Seawater Inlet Connection (Typical)
Standard P-1 for acceptable exhaust hose materials. If
using a non-flexible waterline, a flexible section of hose
is necessary to allow vibrational motion of the generator
set during operation. Support a nonflexible waterline
within 4 in. (102 mm) of its connection to the flexible
section.

Closed/Heat Exchanger
2
Closed heat exchanger cooling is the best alternative for 1
most applications. Kohler Co. recommends using
closed heat exchanger cooling if the craft is operated in
saltwater or water with high silt content.
Provide service accessibility for the water-cooled
exhaust manifold pressure cap. Mount the coolant
recovery tank either to engine or craft stringer. Mount
the coolant recovery tank so that its surface level is the
same height or 2 in. (5 cm) max. below the level of the
pressure cap. See Figure 6-12 for a typical installation.
See Figure 6-11 for coolant recovery tank connections.
Use supplied hose to connect to coolant recovery tank.
NOTE
If not using a coolant recovery tank, be sure that the
DA-250000-H
overflow hose is not immersed in the bilge water to
prevent bilge water from siphoning back into the cooling 1. Overflow tube
2. Cooling system pressure cap
system.
Figure 6-11. Coolant Recovery Tank Connections

1 2
3
4 5
7
6
9
14
13
12
11
10
Seawater
Freshwater (Coolant/Antifreeze)
TP-5592-6
1. Oil cooler 8. Silencer (customer supplied)

2. Engine block 9. Exhaust outlet
3. Thermostat 10. Intake strainer
4. Water-cooled manifold 11. Seacock
5. Heat exchanger 12. Seawater strainer
6. Exhaust mixer elbow 13. Engine-driven seawater pump
7. Water-cooled turbocharger 14. Engine-driven water pump
Figure 6-12. Closed/Heat Exchanger Cooling System

Exhaust Systems
General
WARNING
Use water-cooled exhaust lines in all marine
installations. Keep the lines as short and straight as
possible. ABYC Safety Standards P-1.6.i. recommends
using two corrosion-resistant hose clamps, with a
minimum width of 1/2 in. (13 mm), on each end of flexible
Carbon monoxide. exhaust hose connections A pitch of at least 1/2 in. (13
Can cause severe nausea, fainting, or death. mm) per running foot (30.5 cm) is preferred. Use flexible
The exhaust system must be leakproof and exhaust hose conforming to U.L. Standard 1129 for
routinely inspected. engine wet exhaust components between mixing elbow
and exhaust outlet. Independently mount the silencer to
Inspecting exhaust system. Carbon monoxide can eliminate any stress on exhaust system and exhaust
cause severe nausea, fainting, or death. In addition manifold/mixer elbow. See Section 1— Specifications
to routine exhaust system inspection, install a carbon for mixing elbow water line hose size. See Figure 6-13
monoxide detector. Consult your boat builder or dealer for exhaust connection to mixer elbow.
for approved detector installation. Inspect your detector
before each generator set use.
Operating generator set. Carbon monoxide can 1

cause severe nausea, fainting, or death. Use the
following precautions when installing and operating
generator set. Carbon monoxide is an odorless,
colorless, tasteless, nonirritating gas. Be especially
careful if operating the generator set when moored or
anchored under calm conditions as gases may
accumulate. If operating the generator set dockside,
moor the craft so that the exhaust discharges on the lee
side (the side sheltered from the wind). Always be
aware of others— make sure your exhaust is directed
away from other boats and buildings. Do not install
exhaust outlet where exhaust can be drawn in through
portholes, vents, or air conditioners. If the generator set
exhaust discharge outlet is near the waterline water
DA-250000-H
could enter the exhaust discharge outlet and close or
restrict the flow of exhaust. Avoid overloading the craft. 1. Water/exhaust outlet
Figure 6-13. Mixer Elbow/Exhaust Connection

Locate the exhaust outlet at least 4 in. (10 cm) above the Above Waterline
waterline when craft is loaded to maximum capacity.
Typically, install a flapper at exhaust (transom) outlet to In addition to considerations described earlier, install a
prevent water backup in following seas or when moving customer-supplied silencer with silencer outlet at a
astern (backward). maximum of 10 horizontal ft. (3 m) from center of
engine’s exhaust outlet. See Figure 6-14. Mount a
Exhaust system guidelines for various generator set
typical silencer with inlet and outlet horizontal and with
locations follow. Information and illustrations of stern
drain plug down. A pitch of at least 1/2 in. (13 mm) per
(rear) exhaust installations also apply to side-exhaust
running foot (30.5 cm) is preferred. Some silencers
installations. Where exhaust lines would require
require two supporting brackets or hanger straps for
passage through bulkheads, it may be more practical to
installation to stringers or other suitable structure. Any
use port- (left) or starboard- (right) side exhaust outlets. lift in the exhaust line to improve silencing must be below
This would be especially true where long exhaust lines engine exhaust manifold outlet.
to the transom (rear) could cause excessive back
pressure. Should any information regarding installation
conflict with USCG Regulations, follow regulations.

NOTE
Numbers in Illustrations refer to callouts below
and not to dimensions. 3
4
5
2
1
7
12
14 8
Waterline
15 11
13
10
1. Slight lift improves silencing (keep below level of exhaust 9. Seacock

manifold outlet) 10. Intake strainer
2. Silencer (customer-supplied) 11. Engine-driven seawater pump
3. Exhaust mixer elbow 12. Minimum exhaust hose pitch of 0.5 in. per ft. (1.3 cm per 30.5 cm)
4. Heat exchanger (locations vary by model) 13. Maximum distance between silencer and exhaust mixer elbow of
5. Coolant recovery tank 10 ft. (3 m)
6. Locate coolant recovery tank at same height as heat exchanger 14. Minimum exhaust hose pitch of 0.5 in. per ft. (1.3 cm per 30.5 cm)
7. Maximum seawater pump lift of 3 ft. (1 m) 15. Minimum exhaust outlet distance above waterline of 4 in. (10 cm)
Figure 6-14. Typical Above Water Line Installation
NOTE NOTE
Use two hose clamps on each end of all flexible exhaust Data applies to both rear- and side-exhaust
hose connections. installations.
NOTE
Read text for complete explanation of dimensions and
other installation considerations.

Mid/Below Waterline Locate siphon break above highest point in exhaust line
between the heat exchanger and the exhaust mixer.
Follow ABYC P-1.8.c recommendations for installing an See Figure 6-15 for siphon break connection. Support
anti-siphoning provision to prevent raw water entry into the siphon break and hoses to maintain proper position
the engine. Use the siphon break if exhaust manifold and function. Mount the siphon break directly vertical of
outlet is located less than 9 in. (23 cm) above waterline its connection to generator set where possible.
when craft is loaded to maximum capacity. Install Otherwise, allow a slight offset to clear stringers or other
siphon break, see Figure 6-15, at least 1 ft. (31 cm) permanent structures. Protect the siphon break air inlet
above waterline. from dirt and debris.
NOTE Mount a typical silencer’s base no more than 4 ft. (1.2 m)
Failure to properly install a siphon break will cause below highest point in exhaust line. Attach a separate
engine damage and may void warranty. wood mounting base to hull stringers or other suitable
structure. Secure silencer to hull using silencer
manufacturer’s recommendation. Mount silencer with
outlet not more than 10 horizontal ft. (3 m) from engine
1 exhaust manifold outlet. Use UL-listed marine exhaust
hose.
DA-250000-H
1. Cut hose and connect siphon break and hardware

Figure 6-15. Siphon Break Connection

NOTE
Numbers in Illustrations refer to callouts below
and not to dimensions.
3 7 8
9
10
1
4 11
Waterline 20
21 16
12
19
15
17
13
18
14
1. Mounting base 13. Seacock
2. Retaining cap 14. Intake strainer
3. Reed valve assembly 15. Engine-driven seawater pump
4. Maximum silencer vertical lift of 4 ft. (1.2 m) 16. Minimum exhaust hose pitch of 0.5 in. per ft. (1.3 cm per 30.5 cm)
5. Exhaust mixer elbow distance above waterline. If less than 9 in. 17. Water lock (optional)
(23 cm), siphon break is required. 18. Maximum distance between silencer and exhaust mixer elbow of
6. Minimum siphon break distance above waterline of 1 ft. (30.5 cm) 10 ft. (3 m)
7. Siphon break 19. Silencer (customer supplied)
8. Exhaust mixer elbow 20. Minimum exhaust hose pitch of 0.5 in. per ft. (1.3 cm per 30.5 cm)
9. Heat exchanger (locations vary by model) 21. Minimum exhaust outlet distance above waterline of 4 in. (10 cm)
10. Coolant recovery tank NOTE: Read text for complete explanation of dimensions
11. Indicates coolant recovery tank at same height as heat
exchanger and other installation considerations.
Figure 6-16. Typical Mid- and Below-Waterline Installation
NOTE NOTE
Use two hose clamps on each end of all flexible exhaust Data applies to both rear- and side-exhaust
hose connections. installations.

Electrical Systems
AC Voltage Connections Make AC connections to generator set inside the
controller box. Typically, the generator set is connected
to a ship-to-shore transfer switch which allows the use of
WARNING shore/utility power when docked or generator set power
when docked or at sea. The wiring is then connected to
a main circuit breaker box (panel board) which
distributes branch circuits throughout the craft. See
Figure 6-17 for AC voltage connections to generator
set. See Section 5— Wiring Diagrams for reconnection
Hazardous voltage. Moving rotor.
of generator set.
Operate generator set only with all guards and 1
electrical enclosures in place. 2
Electrical backfeed to utility. Hazardous backfeed

voltage can cause severe injury or death. Connect 3
generator set to building/marina electrical system only
through an approved device and after building/marina
main switch is open. Backfeed connections can cause 4
serious injury or death to utility personnel working on
power lines and/or personnel in the vicinity of the work
area. Unauthorized connection to utility electrical
system may be unlawful in some states and/or localities.
Install a ship-to-shore transfer switch to prevent 5
interconnection of generator set power and shore
power.
6
1. Line side
2. AC circuit breaker
3. Load side
4. L1/L2 phase (black) leads
5. GRD. ground (green) lead
6. L0 neutral (white) lead
Figure 6-17. AC Voltage Connections in
Controller Box

Installation In Steel Or Aluminum Installation Regulations
Vessels Pleasurecraft Generator Installation:
Installation of a generator set in a vessel constructed of The U.S. Coast Guard and the American Boat and Yacht
a material capable of conducting current (e.g.: steel or Council, Inc. govern generator sets installed in
aluminum) is subject to considerations not normally pleasurecrafts.
encountered in fiberglass or wood vessels. These General
differences include equipment grounding, grounding of U.S. Coast Guard Title 33CFR, Part 183
neutral conductors, ground-fault protection, and
Grounded Neutral Systems (required for generator sets
isolation of galvanic currents.
installed in pleasurecrafts)
While the scope of these topics is too extensive to be American Boat and Yacht Council (ABYC) E-8.4.b
fully discussed here, this manual makes references to Wiring Configurations
the appropriate governing bodies for further ABYC E-8.22 through E-8.29
investigation.
Grounding of appliances and equipment
The information provided here is a guideline to boat ABYC E-8.12
manufacturers and generator set installers. This Galvanic corrosion prevention by means of galvanic
information is not intended or implied to be limited to isolator or isolation transformer
these sources and is subject to revision by the ABYC E-8.20 and E-8.11
appropriate governing bodies.
Before installing the generator set, check the available Commercial Craft Generator Installation :
wiring diagrams in Section 5 to become familiar with the The U.S. Coast Guard (Title 46CFR), the American
electrical system. Bureau of Shipping, and Lloyd’s Register of Shipping
govern generator sets installed in commercial vessels.
General
U.S. Coast Guard Title 46CFR
Equipment grounding
American Bureau of Shipping (ABS) 35.9.6
Lloyd’s Register of Shipping, Part 6, Chapter 2-1,
Section 1.3
Types of permissible neutral grounding of generating
equipment
ABS 35.125 and 35.95.1
Section 14.4
Ground-fault protection
Section 14.5
Section 13.6

Battery
Batteries and their installation must conform to USCG
Regulations 183.420 (a) through (g). Provide generator 1
sets with batteries separate from the propulsion engines
whenever possible. The starting/charging systems of
both the generator set and the engine must have a
common negative (--) ground.
USCG Regulation 183.415, Grounding, requires
connection of a common conductor to each grounded
cranking motor circuit. Size this conductor to match the
larger of the engine’s two battery cables. Figure 6-18
lists cable sizes for generator set battery connections at
various ambient temperatures. Connecting a common
conductor to each grounded cranking motor circuit
prevents the starting motor current from using 2
5
alternative electrical paths should the cranking motor 4 3
ground circuit be restricted or open due to oxidation or DA-250000-H
loose hardware. Alternative electrical paths include 1. Starter solenoid
metallic fuel lines which can pose a fire hazard. See 2. Battery positive (+) connection
3. Equipment ground
Figure 6-19 for battery connections to generator set. 4. Engine block mount
5. Battery negative (--) connection
Cable Figure 6-19. Battery Connections
Size
Distance between (AWG) At At
Generator Set At 0°F 32°F 75°F
and Battery ft. (m) (-18°C) (0°C) (24°C)
40 (12.2) 00 0 1
30 (9.1) 0 1 2
25 (7.6) 1 2 4
20 (6.1) 2 2 6
15 (4.6) 2 4 6
10 (3.0) 4 6 8
5 (1.5) 6 6 8
2.5 (0.8) 8 8 8
Figure 6-18. Battery Cable Sizes

Wiring Remote Start Switch Connection
Use only stranded copper wire. Wire gauges and Kohler Co. offers several remote panels for connection
insulation, conductor temperature ratings, sheath to the generator set. See Accessories for further
stripping, conductor support and protection, conductor detailed descriptions. Also available is a wiring harness
terminals and splices, and over-current protection with a connector keyed to the controller box connector.
(circuit breakers, fuses) must conform to USCG The other end of this harness has pigtails which can be
Regulations 183.425 through 183.460. Use rubber used if the installer elects to use a (customer-supplied)
grommets and cable ties as necessary to protect and start/stop switch or separate lights and hourmeter. See
secure wire from sharp objects, exhaust system, and Figure 6-21.
any moving parts. See Figure 6-20 for remote start
NOTE
panel connection to generator set controller.
Senders are available for most generator sets. If using
gauges, be sure they are compatible with generator set
senders. Gauges/senders are available as a service
1 item from authorized Kohler service
distributors/dealers. If gauges are not used, tape
harness leads to insulate.
DA-250000-H
1. Controller remote connector

Figure 6-20. Controller Remote Connector

4
+
1
6
4 5 6 6 5 4
1 2 3 3 2 1
8
10
9
7
1. Use insulink or solder connection (tape to insulate) 6. Start

2. Hourmeter 7. Generator set
3. Stop 8. Senders
4. ON light 9. Controller socket
5. Rocker switch 10. Wiring harness plug
Figure 6-21. Remote Control Panel Wiring
NOTE
All wire is 16 gauge. Tape to insulate all unused lead
ends.
Lead Lead
(older (newer
Pin models) models) Function
1 Black N Ground (--)
2 Tan 5 Water temperature
gauge 3
3 Lt. Blue 7C Oil pressure gauge
4 Violet 70 Generator ON (+)
5 Yellow/Red 47 Start
6 Grey/Black 43 Stop
Figure 6-22. Lead Designations

Section 7. Installation Drawings
ADV-5852-A
Figure 7-1. Dimension Drawing— 13.5/14CCOZ and 11/11.5CCFOZ
TP-5592 7/96 Installation Drawing 7-1

ADV-5853-A
Figure 7-2. Dimension Drawing— 18.5/20/21/24CCOZ and 15/17.5/16.5/18/20CCFOZ
7-2 Installation Drawing TP-5592 7/96

ADV-5841-B
Figure 7-3. Dimension Drawing— All Models
TP-5592 7/96 Installation Drawing 7-3

Appendix A. Generator Selection and
Wattage Requirements
General Lighting Load
The lighting load is usually easiest to calculate. In most
Consider total wattage requirements (lights, motors,
cases, simply add the wattage of each generator
appliances) when selecting a generator set, or when
set-operated lamp. Note that not all of the lights or
sizing wattage usage where available space and
lamps are on the generator set AC circuit— some are DC
construction limit the size of the generator set.
powered by a 12-volt battery. Make sure the calculated
total wattage includes only lights actually on the
Motor Loads generator set AC circuit.
When figuring generator set capacity requirements for
loads that include electric motors, do not overlook the Air Conditioners
high current demanded by the motors during start-up.
The starting characteristics of air conditioners vary
The inrush or starting current is typically 2-3 times
greatly— one 12,000 Btu unit has, for example, lower
higher than that required when the motor reaches
starting requirements than a 10,000 Btu unit of another
normal operating speed. Allow reserve for inrush
variety. When using only one unit, there is usually no
demands plus other loads which could be on the line as
starting problem, provided the lighting and appliance
the electric motor starts. Use Figure 1 as a guide when
load is not too high when starting the unit.
selecting generator set capacity requirements involving
motor loads. Simultaneous starting of two air conditioning units,
however, can present problems if the generator set
Starting
Motor (inrush) Running
capacity is marginal. Because of the variation in starting
HP Watts Watts characteristics among air conditioners, this publication
1/4 750 330 makes no statements regarding multiple-motor starting
capabilities of the generator set covered. Consider
1/3 1000 400
delayed starting or use of easy-starting devices on air
1/2 1500 600
conditioner units whenever simultaneously starting
3/4 2000 750 more than one motor.
1 3300 1100
See Figure 2 for typical air conditioner requirements.
2 4000 2000
Information will vary with manufacturer.
3 5000 3000
Figure 1. Motor Requirements
Air Conditioner Size (Btu/H)

7,000 9,000 12,000 16,000 24,000
Voltage 115 230 115 230 115 230 115 230 230
Full load amps 9.3 4.8 9.9 5.0 11.8 6.3 16.3 8.0 11.6
Rated load amps 7.7 4.0 7.0 3.5 8.9 4.8 13.0 6.2 10.2
Locked rotor amps 34.0 20.0 40.0 20.0 50.0 31.0 75.0 36.0 56.0
Starting (inrush) watts 3910 4600 4600 4600 5750 7130 8630 8280 12,900
Running watts 886 920 805 805 1020 1100 1500 1430 2350
Figure 2. Typical Marine Air Conditioner Requirements (60 Hz)
TP-5592 7/96 Generator Selection and Wattage Requirements A-1

Appliance Loads Motor
Starting Running
Generator sets often furnish AC for appliances such as Electrical Appliance Watts Watts
TV, stereo, electric water heater, etc. With the exception Automatic pilot -- 150-250
of the resistance-type loads such as the water heater, Blanket, electric -- 50-250
requirements for appliances are usually low. Do not
Blender 800 600
overlook such loads, however, when figuring total
Broiler -- 1350
requirements. Allow reserve capacity for anticipated
appliance loads to avoid overloading a generator set. Depthometer -- 25-1000
Figure 3 and Figure 4 list the average power Dryer, hair -- 850-1200
requirements of some common construction tools and Fan, air 50-200 25-100
electrical appliances. circulating
Food, mixer 400 235
Motor
Starting Running Heater, space -- 750-1500
Construction Tools Watts Watts Heater, water -- 1500
Air compressor (small) 1500 725 Iron -- 900-1200
Air compressor, 3/4 hp 4000+ 2000 Light bulbs -- (as indicated)
Drill, 1/4 in. 500 250 Pan, frying -- 1200
Drill, 3/8 in. 600 350 Percolator, -- 650
Drill, 1/2 in. 800 600 coffee
Grinder, 1/2 hp 1500 1200 Radar -- 750-1500
Hammer, demolition 2000 1800 Radio -- 50-100
Hammer, HD rotary 1500 1200 Radiophone -- 100-200
Paint sprayer, airless 400 240 Range, electric -- 1000-1500
(per element)
Polisher, orbit 500 360
Television -- 300-750
Power paint roller 120 90
Toaster -- 750-1200
Power plane 600 450
Water system 500-1500 300-1250
Router 900 700
Saw, circular 6 1/2 in. 2200 1000 Figure 4. Appliance Average Wattage
Requirements (60 Hz)
Saw, circular 7 1/4 in. 2500 1200
Saw, table 10 in. 4000 1500
Saw, sabre (worm drive) 2500 1200
Sander, belt 1500 600
Sander, finishing 900 360
Screwdriver, power 1000 530
Shear, 12 gauge 1800 720
Soldering gun -- 250
Vacuum cleaner, wet/dry 1500 1260
Wrench, impact 1/2 in. 2000 840
Figure 3. Construction Tool Average Wattage

Requirements (60 Hz)
A-2 Generator Selection and Wattage Requirements TP-5592 7/96

Appendix B. Glossary of Abbreviations
Abbreviations are used throughout this manual. Normally they will appear in the text in complete form with the
abbreviation following in parentheses the first time they are used. After that they will appear in the abbreviated form.
The commonly used abbreviations are shown below. Some items may not apply to this application.
Abbreviation Description Abbreviation Description
ABDC after bottom dead center cyl. cylinder
ABS American Bureau of Shipping dB decibels
ABYC American Boat and Yacht Council dBA decibels (A weighted)
AC alternating current DC direct current
AHWT anticipatory high water temp. DCR direct current resistance
ALOP anticipatory low oil pressure deg. degree
AM amplitude modulation dept. department
Amp ampere dia. diameter
Amps amperes e.g. example given
ANSI American National Standard Insti- EMI electromagnetic interference
tute EPA Environmental Protection Agency
API American Petroleum Institute etc. etcetera, (and so forth)
approx. approximate, approximately ext. external
A/R as required, as requested °F Fahrenheit degree
A/S as supplied, as stated, as sug- fl. oz. fluid ounce, fluid ounces
gested
FM frequency modulation
ASA American Standards Association
fs full scale
assy. assembly
ft. foot, feet
ASTM American Society for Testing Mate-
rials ft. lbs. foot pound, foot pounds
ATDC after top dead center ga. gauge
ATS automatic transfer switch gal., gals. gallon, gallons
aux. auxiliary gal./hr. gallons per hour
AWG American Wire Gauge gph gallons per hour
AWM appliance wiring material gpm gallons per minute
bhp brake horsepower gr. grade
bmep brake mean effective power grd. ground
Btu British thermal unit HCHT high cylinder head temperature
°C Celsius degree HET high exhaust temperature
cc cubic centimeter Hg mercury (element)
CCA cold cranking Amps. H2O water
CEC Canadian Electrical Code hp horsepower
cfh cubic feet per hour hr, hrs hour
cfm cubic feet per minute HWT high water temperature
CID cubic inch displacement Hz hertz (cycles per second)
cm centimeter, centimeters ID inside diameter
cmm cubic meters per minute in. inch(es)
co. company inc. incorporated
cont’d. continued in. lbs. inch pounds
C.S.A. Canadian Standards Association int. internal
cu. in. cubic inch, cubic inches int.-ext. internal-external
CW clockwise ISO International Standards Organiza-
tion
TP-5592 7/96 Abbreviations B-1

Abbreviation Description Abbreviation Description
J joule, joules NPT National Standard taper pipe thread
JIS Japanese Industry Standard per general use
kg kilogram, kilograms N/R not required
kg/cm2 kilograms per square centimeter OD outside diameter
kgm kilogram meter(s) OEM original equipment manufacturer
km kilometer, kilometers OS overspeed, oversize
kPa kiloPascal, kiloPascals O/S oversize
kph kilometers per hour OSHA Occupational Safety and Health Act
kV kilovolt OV overvoltage
kVA kilovolt amperes oz. ounce, ounces
kW kilowatt, kilowatts PF power factor
kWH kilowatt hour pot potentiometer
L liter, liters ppm parts per million
LxWxH length x width x height psi pounds per square inch
LED, LEDs light emitting diode pt., pts. pint, pints
lb., lbs. pound, pounds PVC polyvinyl chloride
L/hr. liter per hour, liters per hour qt., qts. quart, quarts
L/min. liter(s) per minutes qty. quantity
LOP low oil pressure ref. reference
LP liquefied petroleum RFI radio frequency interference
LWT low water temperature rms root mean square
m meter, meters RPM revolutions per minute
m3 cubic meter, cubic meters SAE Society of Automotive Engineers
max. maximum sec. second, seconds
MCM one thousand circular mils. SCR silicon controlled rectifier
mi. mile, miles spec, specs specification
mil one one-thousandth of an inch sq. square
min. minimum sq. cm square centimeters
misc. miscellaneous sq. in. square inch, square inches
mJ millijoule, millijoules tach tachometer
MJ mega joule, mega joules TDC top dead center
mm millimeter, millimeters temp. temperature
m3/min cubic meters per minute TIF telephone influence factor
MPa megaPascal turbo turbocharger
mpg miles per gallon UNC Unified coarse thread (was NC)
mph miles per hour UNF Unified fine thread (was NF)
MS military standard UL Underwriter’s Laboratories, Inc.
mW milliwatt, milliwatts U/S undersize
MW megawatt, megawatts U.S.A. United States of America
N/A not available USCG United States Coast Guard
NEC National Electrical Code V volt, volts
NEMA National Electrical vac volts alternating current
Manufacturers Association Vdc volts direct current
NFPA National Fire Protection Association VHF very high frequency
Nm Newton meter, Newton meters W watt, watts
N.O. normally open
no., nos. number, numbers
B-2 Abbreviations TP-5592 7/96

Appendix C. Operating Hour Service Log
The following is provided to help you keep a cumulative dates required services were performed. Enter hours to
record of operating hours on your generator set and the the nearest quarter hour.
OPERATING HOURS SERVICE RECORD
DATE HOURS RUN CUMULATIVE DATE SERVICE
TP-5592 7/96 Operating Hour Service Log C-1

KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Web site www.kohlergenerators.com
TP-5592 7/96a Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International)
For the nearest sales and service outlet in U.S.A. and Canada
E Kohler Co., 1997. All rights reserved. Phone 1-800-544-2444

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Operation and

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Safety Precautions and Instructions . . . . . . I Seawater Pump Belt . . . . . . . . . . . . . . . . . . . . . . 3-17

TP-5592 7/96 Table of Contents

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Danger indicates the presence of a hazard that will

Disabling generator set. Accidental starting can

Caution indicates the presence of a hazard that will or

TP-5592 7/96 Safety Precautions and Instructions I

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II Safety Precautions and Instructions TP-5592 7/96

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Inspecting exhaust system. Carbon monoxide can

TP-5592 7/96 Safety Precautions and Instructions III

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Installing fuel system. Explosive fuel vapors can

IV Safety Precautions and Instructions TP-5592 7/96

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Testing voltage regulator. Hazardous voltage can

Operate generator set only with all guards and

Grounding generator set. Hazardous voltage can

TP-5592 7/96 Safety Precautions and Instructions V

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Hot coolant and steam.

Hot engine and exhaust system.

Checking coolant level. Hot coolant can cause

Servicing exhaust system. Hot parts can cause

VI Safety Precautions and Instructions TP-5592 7/96

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TP-5592 7/96 Safety Precautions and Instructions VII

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VIII Safety Precautions and Instructions TP-5592 7/96

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TP-5592 7/96 Reference Material IX

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X Reference Material TP-5592 7/96

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TP-5592 7/96 Introduction i

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ii Service Assistance TP-5592 7/96

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TP-5592 7/96 Service Assistance iii

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Part Description Kohler Part No.

iv Routine Service Parts TP-5592 7/96

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General Specifications— 1-Phase Models

TP-5592 7/96 Specifications 1-1

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1-2 Specifications TP-5592 7/96

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TP-5592 7/96 Specifications 1-3

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1-4 Specifications TP-5592 7/96

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TP-5592 7/96 Specifications 1-5

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1-6 Specifications TP-5592 7/96

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TP-5592 7/96 Specifications 1-7

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1-8 Specifications TP-5592 7/96

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