Instruction/ maintenance manual of the product 100EFOZ/125EOZ Kohler
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Marine Generator Sets TP-6069 6/03d Installation Models: 3.5EFOZ/4EOZ, 4EFOZ/5EOZ 6.5EFOZ/8EOZ, 8.5EFOZ, 9EFOZ/10EOZ 1 1EFOZ/13EOZ, 1 1.5EFOZ/14EOZ 13EFOZ/15.
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TP-6069 6/03 T able of Contents T able of Contents Safety Precautions and Instructions I ........................................................ Section 1 Introduction 1 ..................................................................... Section 2 Location and Mounting 3 .
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TP-6069 6/03 I Safety Precautions and Instructions Safety Precautions and Instructions IMPORT ANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear , and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained.
TP-6069 6/03 II Safety Precautions and Instructions Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a c o n t a i n e rw i t h4L( 1g a l .
TP-6069 6/03 III Safety Precautions and Instructions Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of the craft’s occupants, install a carbon monoxide detector . Consult the boat builder or dealer for approved detector location and installation.
TP-6069 6/03 IV Safety Precautions and Instructions Welding the generator set. Can cause severe electrical equipment damage. Never weld components of the generator set without first disconnecting the battery , controller wiring harness, and engine electronic control module (ECM).
TP-6069 6/03 V Safety Precautions and Instructions Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Moving Parts Hazardous voltage.
TP-6069 6/03 VI Safety Precautions and Instructions Notes.
TP-6069 6/03 1 Section 1 Introduction Section 1 Introduction Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever .
TP-6069 6/03 2 Section 1 Introduction Notes.
TP-6069 6/03 3 Section 2 Location and Mounting Section 2 Location and Mounting 2.1 General Considerations The key to installation is location. Before making final plans for locating a generator set, consider the following. Installation Location Considerations 1.
TP-6069 6/03 4 Section 2 Location and Mounting Notes.
TP-6069 6/03 5 Section 3 Cooling System Section 3 Cooling System 3.1 V entilation Engine combustion, generator cooling, and expulsion of flammable and lethal fumes require ventilation. Provide ventilation compliant with USCG Regulations governing sizing of vents and other considerations.
TP-6069 6/03 6 Section 3 Cooling System Do not use a speed scoop or cup design intake through-hull strainer because it can cause a ramming effect and force water upward, past the seawater pump, and into the engine cylinders when the vessel is moving and the generator set is shut down.
TP-6069 6/03 7 Section 3 Cooling System Seawater Freshwater (Coolant/Antifreeze) 13 12 11 10 9 7 6 8 3 2 5 4 1 14 Arrow Description Direction of Flow TP-5586-6 1. Engine block 2. Exhaust manifold 3. Exhaust mixer elbow 4. Outlet flapper (exhaust/water discharge) 5.
TP-6069 6/03 8 Section 3 Cooling System Seawater Freshwater (Coolant/Antifreeze) TP-5592-6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1. Oil cooler 2. Engine block 3. Thermostat 4. W ater-cooled manifold 5. Heat exchanger 6. Exhaust mixer elbow 7. W ater-cooled turbocharger 8.
TP-6069 6/03 9 Section 3 Cooling System 1 TP-6134- 1. Intake strainer 2. Seacock 3. Seawater strainer 4. Engine-driven seawater pump 5. Oil exchanger 6.
TP-6069 6/03 10 Section 3 Cooling System Notes.
TP-6069 6/03 11 Section 4 Exhaust System Section 4 Exhaust System Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. W ARNING Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death.
TP-6069 6/03 12 Section 4 Exhaust System 4.3 Exhaust System Location, Mounting, and Installation Mount the silencer independently to eliminate stress on the exhaust system and the exhaust manifold/mixer elbow . See Section 7 for the mixer elbow water line hose size.
TP-6069 6/03 13 Section 4 Exhaust System W aterline 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 3 TP-5856-4 1. Slight lift improves silencing and prevents water backwash into the silencer (keep below the level of the exhaust manifold outlet) 2. Silencer (customer-supplied) 3.
TP-6069 6/03 14 Section 4 Exhaust System 4.3.2 Mid/Below-W aterline Installation Follow USCG Regulations for installing an antisiphon provision to prevent raw water entry into the engine. Use the siphon break if the exhaust manifold outlet is located less than 23 cm (9 in.
TP-6069 6/03 15 Section 4 Exhaust System W aterline 7 14 13 12 15 10 9 8 18 11 19 6 17 4 5 20 16 1 2 3 21 TP-5856-4 1. Mounting base 2. Retaining cap 3. Reed valve assembly 4. Maximum silencer vertical lift of 1.2 m (4 ft.) 5. Exhaust mixer elbow distance above waterline; if less than 23 cm (9 in.
TP-6069 6/03 16 Section 4 Exhaust System Notes.
TP-6069 6/03 17 Section 5 Fuel System Section 5 Fuel System Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. W ARNING Installing the fuel system. Explosive fuel vapors can cause severe injury or death.
TP-6069 6/03 18 Section 5 Fuel System 5.2 Fuel Lines Locate the fuel return line as far as practical from the fuel pickup to allow the tank fuel to cool the return fuel before delivery back to the fuel injectors. Incoming fuel cools the injectors to achieve maximum engine efficiency .
TP-6069 6/03 19 Section 6 Electrical System Section 6 Electrical System Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures a r ei np l a c e . Moving rotor . W ARNING Electrical backfeed to the utility .
TP-6069 6/03 20 Section 6 Electrical System Amps Max. V oltage Number of Poles Model(s) 2 0 250 1 4EFOZ 2 0 600 3 8.5/1 1.5EFOZ, 14EOZ 22 250 2 4EFOZ, 5EOZ 25 250 2 5EOZ 2 5 0 1 6.5EFOZ 3 0 2 5 0 2 6.5EFOZ 3 0 600 3 1 1.5/17.5/20EFOZ, 14/20/24EOZ—3 phase 33 250 2 8EOZ 3 5 2 5 0 1 4EFOZ 3 5 2 5 0 2 8EOZ 250 1 5EOZ 40 600 3 11 .
TP-6069 6/03 21 Section 6 Electrical System Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable t he generator set as follows: (1) Place the generator set start/stop switch in the STOP position.
TP-6069 6/03 22 Section 6 Electrical System 10. Connect the side of the circuit breaker marked LOAD to the ship-to-shore switch or craft wiring. Attach insulation boots to the black leads if the kit includes insulation boots. With a single-pole circuit breaker use one black lead (L1).
TP-6069 6/03 23 Section 6 Electrical System 12 3 4 5 6 9 15 6 ASSEMBL Y VIEW A ASSEMBL Y VIEW B DX-250000-B 7 8 ASSEMBL Y VIEW C-C 1. Existing mounting hardware 2. Load lead access panel 3. Screw 4. Hang tag 5. Circuit breaker 6. Circuit breaker panel 7.
TP-6069 6/03 24 Section 6 Electrical System 6.5 Battery Batteries and their installation must conform to USCG Regulations 183.420 (a) through (g). Provide generator sets with batteries separate from the propulsion engine’s whenever possible.
TP-6069 6/03 25 Section 6 Electrical System 6.7 Remote Start Switch Connection Kohler Co. offers several remote panels for connection to the generator set. Contact your local Kohler r distributor/dealer for detailed descriptions. See Figure 6-8 for remote start panel connection to the generator set controller .
TP-6069 6/03 26 Section 6 Electrical System ADV- -61 15A-A Figure 6-9 Remote Controller and Harness Options (33- - 150 kW Models).
TP-6069 6/03 27 Section 6 Electrical System Figure 6-10 Remote Controller and Harness Options (33 - - 150 kW Models).
TP-6069 6/03 28 Section 6 Electrical System Notes.
TP-6069 6/03 29 Section 7 Installation Drawings Section 7 Installation Drawings Use the drawings in this section for installation purposes. Consult the supplier and verify that the drawings are the most current for your specifications.
TP-6069 6/03 30 Section 7 Installation Drawings ADV- 6652A-B NOTE: Dimensions in [ ] are inch equivalents. Figure 7-2 Dimension Drawing, 3.5EFOZ/4EOZ.
TP-6069 6/03 31 Section 7 Installation Drawings ADV- 6652B-B Figure 7-3 Remote Options, 3.5EFOZ/4EOZ.
TP-6069 6/03 32 Section 7 Installation Drawings ADV- 5850A-H NOTE: Dimensions in [ ] are inch equivalents. Figure 7-4 Dimension Drawing, 4EFOZ/5EOZ.
TP-6069 6/03 33 Section 7 Installation Drawings ADV- 5850B-H NOTE: Dimensions in [ ] are inch equivalents. Figure 7-5 Dimension Drawing, 4EFOZ/5EOZ with Sound Shield.
TP-6069 6/03 34 Section 7 Installation Drawings ADV- 6284A-J NOTE: Dimensions in [ ] are inch equivalents. Figure 7-6 Dimension Drawing, 6.5EFOZ/8EOZ.
TP-6069 6/03 35 Section 7 Installation Drawings ADV- 6284B-J NOTE: Dimensions in [ ] are inch equivalents. Figure 7-7 Dimension Drawing, 6.5EFOZ/8EOZ with Sound Shield.
TP-6069 6/03 36 Section 7 Installation Drawings ADV- 6026A-K NOTE: Dimensions in [ ] are inch equivalents. Figure 7-8 Dimension Drawing, 8.5/9EFOZ and 10EOZ.
TP-6069 6/03 37 Section 7 Installation Drawings ADV- 6026B-K NOTE: Dimensions in [ ] are inch equivalents. Figure 7-9 Dimension Drawing, 8.5/9EFOZ and 10EOZ with Sound Shield.
TP-6069 6/03 38 Section 7 Installation Drawings ADV- 6512A-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-10 Dimension Drawing, 1 1EFOZ/13EOZ.
TP-6069 6/03 39 Section 7 Installation Drawings ADV- 6512B-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-1 1 Dimension Drawing, 1 1EFOZ/13EOZ with Sound Shield.
TP-6069 6/03 40 Section 7 Installation Drawings ADV- 6513A-C NOTE: Dimensions in [ ] are inch equivalents. Figure 7-12 Dimension Drawing, 1 1.5/13EFOZ and 14/15.
TP-6069 6/03 41 Section 7 Installation Drawings ADV- 6513B-C NOTE: Dimensions in [ ] are inch equivalents. Figure 7-13 Dimension Drawing, 1 1.5/13EFOZ and 14/15.
TP-6069 6/03 42 Section 7 Installation Drawings ADV- 6481A-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-14 Dimension Drawing, 16/17.5EFOZ and 20EOZ.
TP-6069 6/03 43 Section 7 Installation Drawings ADV- 6481B-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-15 Dimension Drawing, 16/17.5EFOZ and 20EOZ with Sound Shield.
TP-6069 6/03 44 Section 7 Installation Drawings ADV- 6494A-C NOTE: Dimensions in [ ] are inch equivalents. Figure 7-16 Dimension Drawing, 19/20EFOZ and 23/24EOZ.
TP-6069 6/03 45 Section 7 Installation Drawings ADV- 6494B-C NOTE: Dimensions in [ ] are inch equivalents. Figure 7-17 Dimension Drawing, 19/20EFOZ and 23/24EOZ with Sound Shield.
TP-6069 6/03 46 Section 7 Installation Drawings ADV- 6285A-F NOTE: Dimensions in [ ] are inch equivalents. Figure 7-18 Dimension Drawing, 23/27EFOZ and 28/32EOZ.
TP-6069 6/03 47 Section 7 Installation Drawings ADV- 6285B-F NOTE: Dimensions in [ ] are inch equivalents. Figure 7-19 Dimension Drawing, 23/27EFOZ and 28/32EOZ with Sound Shield.
TP-6069 6/03 48 Section 7 Installation Drawings ADV- 6581A-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-20 Dimension Drawing, 33EFOZ/40EOZ.
TP-6069 6/03 49 Section 7 Installation Drawings ADV- 6581B-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-21 Dimension Drawing, 33EFOZ/40EOZ with Fuel/Water Separator and Dry Exhaust Elbow.
TP-6069 6/03 50 Section 7 Installation Drawings ADV- 6581C-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-22 Dimension Drawing, 33EFOZ/40EOZ with Sound Shield.
TP-6069 6/03 51 Section 7 Installation Drawings ADV- 6581D-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-23 Dimension Drawing, 33EFOZ/40EOZ with Electric Clutch.
TP-6069 6/03 52 Section 7 Installation Drawings ADV- 6582A-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-24 Dimension Drawing, 40EFOZ/50EOZ.
TP-6069 6/03 53 Section 7 Installation Drawings ADV- 6582B-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-25 Dimension Drawing, 40EFOZ/50EOZ with Fuel/Water Separator and Dry Exhaust Elbow.
TP-6069 6/03 54 Section 7 Installation Drawings ADV- 6582C-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-26 Dimension Drawing, 40EFOZ/50EOZ with Sound Shield.
TP-6069 6/03 55 Section 7 Installation Drawings ADV- 6582D-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-27 Dimension Drawing, 40EFOZ/50EOZ with Electric Clutch.
TP-6069 6/03 56 Section 7 Installation Drawings ADV- 6583A-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-28 Dimension Drawing, 55EFOZ/65EOZ.
TP-6069 6/03 57 Section 7 Installation Drawings ADV- 6583B-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-29 Dimension Drawing, 55EFOZ/65EOZ with Fuel/Water Separator and Dry Exhaust Elbow.
TP-6069 6/03 58 Section 7 Installation Drawings ADV- 6583C-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-30 Dimension Drawing, 55EFOZ/65EOZ with Sound Shield.
TP-6069 6/03 59 Section 7 Installation Drawings ADV- 6583D-E NOTE: Dimensions in [ ] are inch equivalents. Figure 7-31 Dimension Drawing, 55EFOZ/65EOZ with Electric Clutch.
TP-6069 6/03 60 Section 7 Installation Drawings ADV- 6603A-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-32 Dimension Drawing, 70/80EFOZ and 80/99EOZ.
TP-6069 6/03 61 Section 7 Installation Drawings ADV- 6603B-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-33 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Fuel/Water Separator and Dry Exhau.
TP-6069 6/03 62 Section 7 Installation Drawings ADV- 6603C-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-34 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Sound Shield.
TP-6069 6/03 63 Section 7 Installation Drawings ADV- 6603D-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-35 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Electric Clutch.
TP-6069 6/03 64 Section 7 Installation Drawings ADV- 6594A-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-36 Dimension Drawing, 100/125EFOZ and 125/150EOZ.
TP-6069 6/03 65 Section 7 Installation Drawings ADV- 6594B-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-37 Dimension Drawing, 100/125EFOZ and 125/150EOZ with Sound Shield.
TP-6069 6/03 66 Section 7 Installation Drawings ADV- 6594C-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-38 Dimension Drawing, 100/125EFOZ and 125/150EOZ with Dry Exhaust Elbow.
TP-6069 6/03 67 Section 8 Reconnection/Adjustments Section 8 Reconnection/Adjustments 8.1 Four -Lead Reconnection The following information illustrates the reconnection of four-lead generator sets. In all cases, conform to the National Electrical Code (NEC).
TP-6069 6/03 68 Section 8 Reconnection/Adjustments 8.1.3 200 - - 240 -V olt Configurations The 200 - - 240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 100 - - 120 volt, 3-wire, remove the jumper lead (see Figure 8-1 for location).
TP-6069 6/03 69 Section 8 Reconnection/Adjustments Note: Position the current transformers with the dot or HI side CT marking toward the generator set. Note: Only generator sets equipped with AC meter controllers and/or safeguard circuit breakers require CT s.
TP-6069 6/03 70 Section 8 Reconnection/Adjustments Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage . Do not contact electrical connections with tools or jewelry while making adjustments or repairs.
TP-6069 6/03 71 Section 8 Reconnection/Adjustments Electroswitch L1 L2 T o Generator Set T o Shore Power T o Load 2-Wire Generator Sets L1 L2 T o Generator Set T o Shore Power T o Load 2-Wire Generato.
TP-6069 6/03 72 Section 8 Reconnection/Adjustments 76 8 5 1 1 10 12 9 15 14 16 13 L2 L3 T o Generator Set T o Shore Power T o Load 4-Wire, 3-Phase Generator Sets L0 32 4 1 L1 L2 L3 L0 L1 L2 L3 L0 L1 Kraus Naimler/American Solenoid I-940 Figure 8-10 Marine Manual (Ship-to-Shore) Transfer Switch, continued 8.
TP-6069 6/03 73 Section 8 Reconnection/Adjustments Stabilizer Potentiometer (Pot) fine tunes the regulator circuitry to reduce light flicker . V oltage Adjustment Pot adjusts the generator v o lt a ge output within the range of approximately 100 to 130 volts.
TP-6069 6/03 74 Section 8 Reconnection/Adjustments Notes.
TP-6069 6/03 A-1 Appendix Appendix A Generator Selection and W attage Requirements Consider total wattage requirements (lights, motors, appliances) when selecting a generator set or when sizing wattage usage in which available space and construction limit the size of the generator set.
TP-6069 6/03 A-2 Appendix Appendix B Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj.
TP-6069 6/03 Appendix A-3 kg kilogram kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k Ω kilo-ohm kPa kilop.
TP-6069 6/03 A-4 Appendix Appendix C Generator Set Output Ratings Procedure Kohler Co. develops the kilowatt output rating of a Kohler r marine generator set based upon the calculations specified in ISO 3046 and ISO 8528-1. The calculations correct for environmental variables encountered in a generator set installation.
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E 2000, 2001, 2002, and 2003 by Kohler Co. All rights reserved. TP-6069 6/03d KOHLER CO. Kohler , Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.
An important point after buying a device Kohler 100EFOZ/125EOZ (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kohler 100EFOZ/125EOZ yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kohler 100EFOZ/125EOZ - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kohler 100EFOZ/125EOZ you will learn all the available features of the product, as well as information on its operation. The information that you get Kohler 100EFOZ/125EOZ will certainly help you make a decision on the purchase.
If you already are a holder of Kohler 100EFOZ/125EOZ, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kohler 100EFOZ/125EOZ.
However, one of the most important roles played by the user manual is to help in solving problems with Kohler 100EFOZ/125EOZ. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kohler 100EFOZ/125EOZ along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
