Kohler 4EFOZ/5EOZ - Manual

TP-6069 6/03 III Safety Precautions and Instructions Inspecting the exhaust system. Carbon monoxide can cause severenausea, fainting, or death. For the safety of the craft’s occupants, install acarbon monoxide detector. Consult theboat builder or dealer for approveddetector 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 thegenerator set without first disconnecting the battery, controllerwiring harness, and engine electroniccontrol module (ECM). CAUTION Grounding electr...

TP-6069 6/03 V Safety Precautions and Instructions Servicing the exhaust system. Hotparts can cause severe injury ordeath. Do not touch hot engine parts. The engine and exhaust system components become extremely hotduring operation. Moving Parts Hazardous voltage.Can cause severe injury or death. Op...

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 availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever. x:in:001:0...

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 finalplans for locating a generator set, consider thefollowing. Installation Location Considerations 1. Choose a location that allows adequate ...

TP-6069 6/03 5 Section 3 Cooling System Section 3 Cooling System 3.1 Ventilation Engine combustion, generator cooling, and expulsion offlammable and lethal fumes require ventilation. Provideventilation compliant with USCG Regulations governingsizing of vents and other considerations. As a rule, size...

TP-6069 6/03 6 Section 3 Cooling System Do not use a speed scoop or cup design intakethrough-hull strainer because it can cause a rammingeffect and force water upward, past the seawater pump,and into the engine cylinders when the vessel is movingand the generator set is shut down. Do not use hulls i...

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 DescriptionDirection of Flow TP-5586-6 1. Engine block2. Exhaust manifold3. Exhaust mixer elbow4. Outlet flapper (exhaust/water discharge)5. Silencer (customer supplied)6. Thermost...

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 leakproofand routinely inspected. WARNING Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide i...

TP-6069 6/03 12 Section 4 Exhaust System 4.3 Exhaust System Location, Mounting, and Installation Mount the silencer independently to eliminate stress onthe exhaust system and the exhaust manifold/mixerelbow. See Section 7 for the mixer elbow water line hosesize. See Figure 4-1 for the exhaust connec...

TP-6069 6/03 13 Section 4 Exhaust System Waterline 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 exhaustmanifold outlet) 2. Silencer (customer-supplied)3. Exhaust manifold outlet4. Exhaust...

TP-6069 6/03 14 Section 4 Exhaust System 4.3.2 Mid/Below-Waterline Installation Follow USCG Regulations for installing an antisiphonprovision to prevent raw water entry into the engine.Use the siphon break if the exhaust manifold outlet islocated less than 23 cm (9 in.) above the waterline whenthe c...

TP-6069 6/03 15 Section 4 Exhaust System Waterline 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 base2. Retaining cap3. Reed valve assembly4. Maximum silencer vertical lift of 1.2 m (4 ft.)5. Exhaust mixer elbow distance above waterline; if less than 23 cm (9 in.), a si...

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. WARNING Installing the fuel system. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion...

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 whenall guards and electrical enclosuresare in place. Moving rotor. WARNING Electrical backfeed to the utility. Hazardous backfeedvoltage can cau...

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 thegenerator set as follows: (1) Place the generator set start/stopswitch in the STOP position...

TP-6069 6/03 23 Section 6 Electrical System 1 2 3 4 5 6 9 1 5 6 ASSEMBLY VIEW A ASSEMBLY VIEW B DX-250000-B 7 8 ASSEMBLY VIEW C-C 1. Existing mounting hardware2. Load lead access panel3. Screw4. Hang tag5. Circuit breaker 6. Circuit breaker panel7. Extension leads, if equipped8. Rear connection used...

TP-6069 6/03 25 Section 6 Electrical System 6.7 Remote Start Switch Connection Kohler Co. offers several remote panels for connectionto the generator set. Contact your local Kohler r distributor/dealer for detailed descriptions. See Figure 6-8 for remote start panel connection to thegenerator set co...

TP-6069 6/03 29 Section 7 Installation Drawings Section 7 Installation Drawings Use the drawings in this section for installationpurposes. Consult the supplier and verify that the drawings are the most current for your specifications.Installation drawings show exhaust outlet locations, fuelinlet and...

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 39 Section 7 Installation Drawings ADV-6512B-D NOTE: Dimensions in [ ] are inch equivalents. Figure 7-11 Dimension Drawing, 11EFOZ/13EOZ with Sound Shield

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 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 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 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 67 Section 8 Reconnection/Adjustments Section 8 Reconnection/Adjustments 8.1 Four-Lead Reconnection The following information illustrates the reconnection offour-lead generator sets. In all cases, conform to theNational Electrical Code (NEC). NOTICE Voltage reconnection. Affix a notice ...

TP-6069 6/03 68 Section 8 Reconnection/Adjustments 8.1.3 200 -- 240-Volt Configurations The 200--240-volt configuration does not use a jumperlead. If the unit was originally wired for straight 100--120volt, 3-wire, remove the jumper lead (see Figure 8-1 forlocation). 4 3 2 1 Stator Leads L0 GRD. L1 ...

TP-6069 6/03 69 Section 8 Reconnection/Adjustments Note: Position the current transformers with thedot or HI side CT marking toward thegenerator set. Note: Only generator sets equipped with AC metercontrollers and/or safeguard circuit breakers require CTs. 5. If the controller has meters, remove the...

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 orrepairs. Remove all j...

TP-6069 6/03 72 Section 8 Reconnection/Adjustments 7 6 8 5 11 10 12 9 15 14 16 13 L2 L3 To GeneratorSet To ShorePower To Load 4-Wire, 3-Phase Generator Sets L0 3 2 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) TransferSwitch, continued...

TP-6069 6/03 73 Section 8 Reconnection/Adjustments Stabilizer Potentiometer (Pot) fine tunes the regulator circuitry to reduce light flicker. Voltage Adjustment Pot adjusts the generator voltage output within the range of approximately 100 to 130volts. Volts/Hz Pot determines the engine speed (Hz) a...

TP-6069 6/03 A-1 Appendix Appendix A Generator Selection and Wattage Requirements Consider total wattage requirements (lights, motors,appliances) when selecting a generator set or whensizing wattage usage in which available space andconstruction limit the size of the generator set. Motors When figur...

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. adjust, adjustment ADV advertising dimension...

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 calculationsspecified in ISO 3046 and ISO 8528-1. The calculations correct for environmental variables encountered in a generat...