Kohler 55EOZC Generator Set

⚠ Never operate without a functioning carbon monoxide detector.

1. Shut down; disconnect battery charger and battery, negative lead first.
2. Inspect manifold, mixing elbow, hoses, clamps, silencer and outlet flapper for cracks, leaks, corrosion.
3. Check hoses for softness, cracks, leaks or dents; replace as needed.
4. Check for corroded or broken metal parts and replace them.
5. Check for loose, corroded, or missing clamps; tighten or replace.
6. Confirm the exhaust outlet is unobstructed.
7. Look for carbon or soot residue indicating exhaust leaks; seal leaks.
8. Reconnect battery (negative lead last) and battery charger power, if equipped.

⚠ Follow the instructions included with the impeller kit.

Tools: Impeller kit, Silicon grease

1. Shut down the generator set; disconnect battery charger and battery, negative lead first.
2. Close the seacock.
3. Remove the seawater pump cover plate and remove the impeller.
4. Inspect impeller for damaged, cracked, broken, missing or flattened vanes.
5. Lubricate the impeller with soapy water before installation.
6. Install the impeller, pushing and rotating it in the engine rotation direction.
7. Inspect cover plate and gasket; lubricate gasket with silicon grease and attach.
8. Open the seacock, reconnect battery, start and check for leaks.

⚠ Hot coolant and steam can cause severe injury or death; allow the engine to cool.

1. Press the generator set OFF/RESET button to shut down the generator set.
2. Disconnect the power to the battery charger, if equipped.
3. Disconnect the engine starting battery, negative (-) lead first.
4. Deenergize the block heater, if equipped.
5. Remove the pressure cap to allow the entire system to drain.
6. Open the radiator and/or engine block coolant drain valve(s).
7. Allow the system to drain.
8. If deposits are present, refer to the flush and clean procedure.

Tools: Radiator cleaner

1. Flush the cooling system with clean water.
2. Use a radiator cleaner if the radiator still has mineral deposits.
3. Follow the radiator cleaner manufacturer's instructions.
4. Drain, clean, and flush the coolant recovery tank.

⚠ Do not add coolant to a hot engine; it can crack the cylinder block or head.

1. Remove the pressure cap.
2. Close the coolant drain valve(s) and tighten cooling system hose clamps.
3. Open the air-bleed petcocks; close them when coolant begins to flow.
4. Add coolant additives or water pump lubricants per the engine manufacturer.
5. Fill with 50% ethylene glycol and 50% clean, softened water.
6. Replace the pressure cap and fill the coolant recovery tank to the low mark.
7. Reconnect battery (negative lead last) and battery charger power, if equipped.
8. Run until the thermostat opens, stop, cool, and top up coolant.

⚠ Do not overtighten the retaining cap.

Tools: Mild detergent

1. Press OFF/RESET; disconnect battery charger and battery, negative lead first.
2. Remove the retaining cap and remove the reed valve for inspection.
3. Use a mild detergent to remove residue and oxidation from the reed valve.
4. Clear blockage from the reed valve opening.
5. Replace the siphon break if the reed valve is cracked or deteriorated.
6. Install the reed valve into the mounting base with the valve downward.
7. Install and only finger tighten the retaining cap.
8. Reconnect battery (negative lead last) and battery charger power, if equipped.

Tools: Float/equalize battery charger or trickle charger

1. Place the generator set master switch in the OFF/RESET position.
2. Disconnect the battery(ies), negative (-) lead first.
3. Clean the battery per the battery manufacturer's instructions.
4. Place the battery in a cool, dry location.
5. Connect to a float/equalize charger or charge monthly with a trickle charger.
6. Maintain a full charge to extend battery life.

1. Fill the fuel tank with #2 diesel fuel.
2. Condition the fuel system with compatible additives to control microbial growth.
3. Change the fuel filter/separator and bleed the fuel system.

1. Run the generator set a minimum of 30 minutes to reach normal temperature.
2. Stop the generator set.
3. With the engine still warm, drain the oil from the crankcase.
4. Remove and replace the oil filter.
5. Refill the crankcase with oil suited to the climate.
6. Run the generator set two minutes to distribute the clean oil.
7. Stop the generator set, check the oil level, and adjust if needed.

⚠ Read the Safety Precautions section before proceeding.

1. Disconnect the generator set load using the line circuit breaker or transfer switch.
2. Correct the cause of the fault shutdown or warning.
3. Reset the fault by pressing the OFF/RESET button.
4. Press OFF/RESET, then RUN; silence remote annunciator alarm horn if equipped.
5. Test operate the generator set by pressing the RUN button.
6. Press OFF/RESET to stop the generator set.
7. Press the AUTO button, then ALARM SILENCE to silence the alarm horn.
8. Reconnect the generator set load via the line circuit breaker or transfer switch.

⚠ Use the emergency stop switch for emergency shutdowns only.

1. Investigate and correct the cause of the emergency stop.
2. Reset the controller emergency stop switch by pulling the switch dial outward.
3. Press the generator set OFF/RESET button.
4. After resetting all faults, press the RUN and/or AUTO button to restart.

⚠ Prime the seawater pump before initial startup.

1. Close the seacock.
2. Remove the hose from the water-filter outlet.
3. Fill the hose and seawater pump with clean water.
4. Reconnect the hose to the water filter outlet.
5. Open the seacock.
6. Confirm seawater flow by water discharge from the exhaust outlet on startup.