Kohler 9EKOZD Generator Set

⚠ Hazardous voltage. Moving parts. Operate the generator set only when all guards and electrical enclosures are in place.

1. Remove the belt guard.
2. Check the belt tension at the midpoint of the longest span by pressing with approx. 10 kg (22 lbs.) of force.
3. Recheck a new belt tension after 10 minutes of operation.
4. Loosen the pivot and adjusting screws.
5. While prying the seawater pump outward, tighten the adjusting screw.
6. Tighten the pivot screw.
7. Recheck and adjust as necessary.
8. Replace the belt guard.

⚠ Do not substitute inferior grade hardware; replacement grade should be equal to or better than the original.

1. Determine entry hole type: round or slotted.
2. Determine exit hole type: fixed female thread (weld nut), round, or slotted.
3. For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter, or 1/2 inch or less.
4. Hardware greater than 1/2 inch in diameter takes a standard nut and SAE washer.
5. Hardware 1/2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut.
6. Always use a washer between hardware and a slot.
7. Always use a washer under a nut.
8. Use a washer under a bolt when the female thread is fixed (weld nut).

Tools: Wire brush

1. With the generator set cooled, close the seacock, open the petcock on the engine, and drain the coolant.
2. Remove the anticorrosion zinc anode (plug) from the heat exchanger.
3. Use a wire brush to remove loose corrosion; replace the anode when <50% of length/diameter remains.
4. Clean the threaded hole and coat the anode threads with pipe sealant suitable for marine applications.
5. Cut the anticorrosion zinc to the correct length and install it into the heat exchanger.
6. Close the petcock, open the seacock, and refill the cooling system.
7. Start the generator set and check for leaks at the anticorrosion zinc anode location.

⚠ Hot coolant and steam. Before removing the pressure cap, stop the generator set and allow it to cool.

1. Open the pressure cap and open petcocks at the heat exchanger, engine block, and cooling system; let the system drain completely.
2. Drain, clean, and flush the coolant recovery tank.
3. Flush the system with clean water.
4. Fill the system with recommended coolant.

⚠ Wash hands after any contact with fuel oil. Dispose of the fuel filter in an approved manner.

Tools: Rags

1. Close the fuel supply valve.
2. Loosen the fuel filter by turning it counterclockwise; remove and clean up spilled fuel oil.
3. Clean the contact surface of the fuel oil filter adapter.
4. Lightly lubricate the gasket surface of the new fuel filter with fresh fuel oil; thread on until gasket contacts, hand-tighten one-half turn.
5. Open the fuel supply valve.
6. Bleed the system.

⚠ Wipe up any spilled diesel fuel. Wash hands after any contact with fuel.

Tools: Rag

1. Loosen the fuel filter's air vent screw.
2. Initiate the auto/start sequence until fuel, free of air bubbles, flows from the vent screw.
3. Tighten the fuel filter's air vent screw.

⚠ To prevent damage to the starter motor, do not crank the engine to prime the fuel system.

1. Push the Power button on the Advanced Digital Control IId to the ON position.
2. When run time hours appear, rotate the pushbutton/rotary selector dial until PUSH TO PRIME appears.
3. Push the pushbutton/rotary selector dial.
4. Rotate the pushbutton/rotary selector dial to CONFIRM PRIME: Yes.
5. Push the pushbutton/rotary selector dial to begin the 30-second fuel priming sequence.
6. Push the control knob to stop the priming procedure before 30 seconds if necessary.

⚠ Do not allow coolant mixture to flow into waterways. Use antifreeze capable of withstanding the lowest possible temperatures.

1. Start and run the generator set until it reaches operating temperature or about 15 minutes.
2. Stop the generator set.
3. Change the oil and oil filter.
4. Close the seacock and remove the hose at the seacock; place the hose in a container of about 3.7-7.5 L (1-2 U.S. gallons) of coolant/antifreeze.
5. Disconnect the lead (#87) to the low seawater pressure (LWP) switch.
6. With a container at the exhaust outlet, run the generator set until coolant discharges or the mixture is depleted.
7. Reconnect the lead (#87) to the low seawater pressure (LWP) switch.
8. Stop the generator set.
9. Connect a hose to the seacock; leave the seacock closed.
10. Check the heat exchanger coolant level and add coolant if necessary.
11. Clean the exterior and spread a light film of oil or silicon spray over exposed surfaces.
12. Disconnect and remove the battery; store in a warm, dry location and recharge monthly.
13. Select a well-ventilated (not humid or dusty) location to store the generator.
14. Cover the entire unit with a dust cover.
15. Run the generator set once a month whenever possible.

1. Close the seacock.
2. Remove the seawater pump coverplate.
3. Remove the impeller.
4. Inspect the impeller for damaged, cracked, broken, missing or flattened vanes; vanes should be straight and flexible.
5. Lubricate the impeller with soapy water before installation.
6. Install the impeller, pushing and rotating in the same direction as engine rotation until seated.
7. Inspect the coverplate and gasket for corrosion and/or damage; replace as necessary.
8. Lubricate the gasket with silicon grease and attach the gasket and coverplate.
9. Open the seacock.
10. Start the generator set and check for leaks.
11. Stop the generator set and repair leaks or replace damaged or worn components.

⚠ Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner.

Tools: Oil filter wrench, Oil collection container

1. Whenever possible, drain the oil while it is still warm.
2. Place master switch OFF; disconnect power to battery charger; disconnect battery negative (-) lead first.
3. Remove oil drain hose from retaining clip, remove cap, lower into oil collection container.
4. Open the oil drain valve on the engine and allow the engine oil to drain completely; close the valve.
5. Remove the oil filter by rotating it counterclockwise with an oil filter wrench.
6. Apply a light coat of clean oil to the rubber seal of the new oil filter.
7. Install the new oil filter following the instructions provided with the filter.
8. Fill with new oil of the weight, grade, and quantity specified in Section 3.3.
9. Reconnect the battery, negative (-) lead last; reconnect power to the battery charger.
10. Start the generator set and check for leaks around the oil filter.
11. Stop the generator set and tighten the oil filter to stop any leaks.

1. Close the seacock.
2. Remove the hose from the seawater-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 pump operation on startup as indicated by water discharge from the exhaust outlet.

⚠ Ensure that the siphon break's cap is tight before operating the generator set.

Tools: Mild detergent

1. Stop the generator set.
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 the material has hardened or deteriorated.
6. Install the reed valve into the mounting base with the valve downward.
7. Install and only finger tighten the retaining cap.