Kohler 9EKOZD Installation Manual
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Kohler 9EKOZD Installation Manual

Kohler 9EKOZD Installation Manual

Marine generator sets
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All manuals and user guides at all-guides.com
Installation
Marine Generator Sets
Models:
6EKOD
9- -11EKOZD
5EFKOD
7- -9EFKOZD
TP-6773 5/12a

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  • Page 1 All manuals and user guides at all-guides.com Installation Marine Generator Sets Models: 6EKOD 9- -11EKOZD 5EFKOD 7- -9EFKOZD TP-6773 5/12a...
  • Page 2 All manuals and user guides at all-guides.com TP-6773 5/12a...

  • Page 3: Table Of Contents

    All manuals and user guides at all-guides.com Table of Contents Safety Precautions and Instructions ............Section 1 Introduction .
  • Page 4 All manuals and user guides at all-guides.com Table of Contents Table of Contents TP-6773 5/12a...

  • Page 5: Safety Precautions And Instructions

    All manuals and user guides at all-guides.com Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Engine Backfire/Flash Electromechanical equipment, Fire including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose WARNING life-threatening danger when improperly installed, operated, or maintained.
  • Page 6 All manuals and user guides at all-guides.com Exhaust System Fuel System Hazardous Noise WARNING CAUTION WARNING Carbon monoxide. Hazardous noise. Explosive fuel vapors. cause severe nausea, Can cause hearing loss. Can cause severe injury or death. fainting, or death. Never operate the generator set Use extreme care when handling, exhaust system...
  • Page 7 All manuals and user guides at all-guides.com Disconnecting the electrical load. Testing live electrical circuits. NOTICE Hazardous voltage cause Hazardous voltage or current can Fuse replacement. Replace fuses severe injury or death. Disconnect cause severe injury or death. Have with fuses of the same ampere rating the generator set from the load by trained and qualified personnel take and type (for example: 3AB or 314,...
  • Page 8 All manuals and user guides at all-guides.com Notes Safety Precautions and Instructions TP-6773 5/12a...

  • Page 9: Section 1 Introduction

    Section 1 Introduction Information in this publication represents data available marine generator set. For operating instructions, refer at the time of print. Kohler Co. reserves the right to to the operation manual. change this publication and the products represented Marine generator set installations must comply with all without notice and without any obligation or liability applicable regulations and standards.
  • Page 10 All manuals and user guides at all-guides.com Notes Section 1 Introduction TP-6773 5/12a...

  • Page 11: Section 2 Location And Mounting

    2. Use craft stringers or other available structural exhaust outlet. members capable of supporting the generator set’s weight. Kohler Co. recommends mounting the generator set on a flat board attached to the craft stringers. Craft 3. Seal the generator set’s engine room from the...
  • Page 12 All manuals and user guides at all-guides.com Notes Section 2 Location and Mounting TP-6773 5/12a...

  • Page 13: Section 3 Cooling System

    All manuals and user guides at all-guides.com Section 3 Cooling System 3.1 Ventilation 3.2.1 Intake Through-Hull Strainer (Seacock Cover) Engine combustion, generator cooling, and expulsion of Install a screened-intake, through-hull strainer to flammable and lethal fumes require ventilation. Provide ventilation compliant with USCG Regulations governing prevent entry of foreign objects.

  • Page 14: Seacock

    All manuals and user guides at all-guides.com 3.2.2 Seacock Mount the seacock to the hull, assemble it to the intake, and ensure that it is accessible for operation. Figure 3-2 shows a typical installation. Avoid overcaulking the seacock. Excess caulk reduces water flow and, in some cases, develops a barrier that can force water upward, past the seawater pump, and into the engine cylinders when the vessel is moving and...

  • Page 15: Water Lines

    All manuals and user guides at all-guides.com 3.2.4 Water Lines Water lines from the seacock to the engine-driven seawater pump are usually constructed of flexible hose. Connect a flexible section of hose to the seawater pump to allow the generator set to vibrate during operation. Support a nonflexible water line within 102 mm (4 in.) of its connection to the flexible section.

  • Page 16: Closed Heat Exchanger

    All manuals and user guides at all-guides.com 3.2.5 Closed Heat Exchanger A closed heat exchanger is the best cooling method for most applications. See Figure 3-6 for a typical installation. Provide space to access the water-cooled exhaust manifold pressure cap. Seawater Freshwater (Coolant/Antifreeze) 1.

  • Page 17: Section 4 Exhaust System

    Kohler Co. requires a downward pitch of at least 13 mm Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of per 30.5 cm (1/2 in.

  • Page 18: Exhaust System Location, Mounting, And Installation

    Allowable Exhaust Back Pressure ≤ (mm H Model 6EKOD/5EFKOD and 14.2 (1444) 9EKOZD/7EFKOZD 11EKOZD/9EFKOZD (1 Phase) and 14.8 (1506) 11EKOZD/9EFKOZD (3 Phase) Figure 4-2 Allowable Exhaust Back Pressures 1. Water/exhaust outlet Figure 4-1 Mixer Elbow/Exhaust Connection, Typical Section 4 Exhaust System...

  • Page 19: Above-Waterline Installation

    17. Maximum silencer vertical lift of 1.2 m (4 ft.) 4. Exhaust mixer elbow 18. If the total exhaust length exceeds 4.6 m (15 ft.), Kohler 5. Heat exchanger (locations vary by model) recommends increasing the exhaust hose to the next 6.

  • Page 20: Mid/Below-Waterline Installation

    Exhaust Hose Diameter Models without Sound Shield Models with Sound Shield mm (in.) 6EKOD/5EFKOD 6EKOD/5EFKOD 9EKOZD/7EFKOZD 9EKOZD/7EFKOZD 51 (2.0) 11EKOZD/9EFKOZD (1 Phase) 11EKOZD/9EFKOZD (1 Phase) 11EKOZD/9EFKOZD (3 Phase) 11EKOZD/9EFKOZD (3 Phase) Figure 4-5 Exhaust Hose Sizes Section 4 Exhaust System...
  • Page 21 All manuals and user guides at all-guides.com Note: Read the text for complete explanation of dimensions and other installation considerations. Note: Use two hose clamps on each end of all flexible exhaust hose connections. Note: Data applies to both rear- and side-exhaust installations.
  • Page 22 21. Exhaust hose (see Figure 4-5 for hose sizes) 6. Minimum siphon break distance above waterline of 30.5 cm 22. If the total exhaust length exceeds 4.6 m (15 ft.), Kohler (1 ft.) recommends increasing the exhaust hose to the next larger 7.
  • Page 23 23. Height of internal lift tube to be below generator exhaust 11. Seawater strainer manifold 12. Seacock 24. Kohler recommends generator be located at elevation that 13. Intake strainer exhaust mixer elbow is above silencer exhaust outlet 14. Engine-driven seawater pump 25.
  • Page 24 All manuals and user guides at all-guides.com Notes Section 4 Exhaust System TP-6773 5/12a...

  • Page 25: Section 5 Fuel System

    All manuals and user guides at all-guides.com Section 5 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. Note: Do not modify the tank or the propulsion engine fuel system.

  • Page 26: Fuel Lines

    9- -11EKOZD/7- -9EFKOZD mm (in.) Note: Fuel Return Dip Tube (6EKOD/5EFKOD and Fuel Inlet 9.7 (3/8) 9- -11EKOZD/7- -9EFKOZD Models). Kohler Co. 6.4 (1/4) recommends utilizing a fuel return dip tube Fuel Return min. located below the fuel supply dip tube. This will...

  • Page 27: Fuel Filters

    (ft.) Model 5.4 Fuel/Water Separator 6EKOD/5EFKOD 0.9 (3) For 6EKOD/5EFKOD and 9--11EKOZD/7--9EFKOZD 9EKOZD/7EFKOZD models, install a fuel/water separator between the fuel tank and the electric fuel pump. The fuel/water 11EKOZD/9EFKOZD (1 ph) 1.2 (4) separator must contain a primary filter of 30--50 micron...
  • Page 28 All manuals and user guides at all-guides.com Notes Section 5 Fuel System TP-6773 5/12a...

  • Page 29: Section 6 Electrical System

    All manuals and user guides at all-guides.com Section 6 Electrical System WARNING Hazardous voltage. Moving parts. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death.

  • Page 30: Circuit Protection

    11EKOZD (3 ph.) subject to change. 9EFKOZD (1 ph.) 11EKOZD (3 ph.) 6.2.1 Circuit Breaker Considerations 9EKOZD & 9EFKOZD (1 ph.) Mounting location. Mount the circuit breakers in the 11EKOZD (1 ph.) generator set’s junction box. See Section 6.2.2. 6EKOD Sizing.

  • Page 31: Circuit Breaker Installation

    All manuals and user guides at all-guides.com 6.2.2 Circuit Breaker Installation WARNING 1. Place the generator set master switch in the OFF position. 2. Disconnect the generator set engine starting battery, negative (--) lead first. Moving parts. Hazardous voltage. Can cause severe injury or death. 3.
  • Page 32 All manuals and user guides at all-guides.com 8. Make the recommended connections for the Note: Wire material. Use stranded copper for all following four reconnection systems using circuit wiring. Use wire gauges and insulation, breakers: conductor temperature ratings, sheath stripping, conductor support and protection, Two-pole circuit breaker with a single-voltage conductor terminals and splices, and system (example: 120-volt, 3-wire).

  • Page 33: Installation In Steel Or Aluminum Vessels

    All manuals and user guides at all-guides.com Junction Box (Inner View) Junction Box GM77889-B (Outer View) 1. Coverplate (qty. 2 for 1-pole kits or qty. 1 for 2-pole kits). 3. Jumper terminal (if supplied in kit) Use existing hardware 4. Use existing hardware 2.

  • Page 34: Battery

    All manuals and user guides at all-guides.com 6.5 Battery Kohler Co. recommends using one 12-volt battery (or two for 24-volt systems, as the spec requires) to start the Batteries and their installation must conform to USCG generator. See Figure 6-6 for minimum cold cranking Regulations 183.420 (a) through (g).

  • Page 35: Remote Connection

    All manuals and user guides at all-guides.com 6.7 Remote Connection Component Amp Part No. Kohler Part No. Plug 350735-1 229998 Kohler Co. offers several remote panels for connection 350218-6 241618 to the generator set. Contact your local Kohlerr Cable Seal 794280-1 GM29252 distributor/dealer for detailed descriptions.
  • Page 36 All manuals and user guides at all-guides.com Notes Section 6 Electrical System TP-6773 5/12a...

  • Page 37: Section 7 Installation Drawings

    Installation drawings show exhaust outlet locations, fuel with sound shield ADV-7943-A inlet and return connections, siphon break locations, with keel cooling ADV-7944-A and battery connections. See Figure 7-1 for installation 9EKOZD and 7EFKOZD ADV-7942A-A drawing identification. (1 phase) ADV-7942B-A with sound shield ADV-7943-A...
  • Page 38 All manuals and user guides at all-guides.com NOTE: Dimensions are shown in mm [in.]. ADV-7941A-A Figure 7-2 Dimension Drawing, 6EKOD and 5EFKOD (Sheet 1 of 2) Section 7 Installation Drawings TP-6773 5/12a...
  • Page 39 All manuals and user guides at all-guides.com NOTE: Dimensions are shown in mm [in.]. ADV-7941B-A Figure 7-3 Dimension Drawing, 6EKOD and 5EFKOD (Sheet 2 of 2) TP-6773 5/12a Section 7 Installation Drawings...
  • Page 40 All manuals and user guides at all-guides.com NOTE: Dimensions are shown in mm [in.]. ADV-7942A-A Figure 7-4 Dimension Drawing, 9--11EKOZD and 7--9EFKOZD (Sheet 1 of 2) Section 7 Installation Drawings TP-6773 5/12a...
  • Page 41 All manuals and user guides at all-guides.com NOTE: Dimensions are shown in mm [in.]. ADV-7942B-A Figure 7-5 Dimension Drawing, 9--11EKOZD and 7--9EFKOZD (Sheet 2 of 2) TP-6773 5/12a Section 7 Installation Drawings...
  • Page 42 All manuals and user guides at all-guides.com NOTE: Dimensions are shown in mm [in.]. ADV-7943-A Figure 7-6 Dimension Drawing, 6EKOD/5EFKOD, 9--11EKOZD, and 7--9EFKOZD with Sound Shield Section 7 Installation Drawings TP-6773 5/12a...
  • Page 43 All manuals and user guides at all-guides.com NOTE: Dimensions are shown in mm [in.]. ADV-7944-A Figure 7-7 Dimension Drawing, 6EKOD/5EFKOD, 9--11EKOZD, and 7--9EFKOZD with Keel Cooling Option with Dry Exhaust TP-6773 5/12a Section 7 Installation Drawings...
  • Page 44 All manuals and user guides at all-guides.com Notes Section 7 Installation Drawings TP-6773 5/12a...

  • Page 45: Section 8 Reconnection

    All manuals and user guides at all-guides.com Section 8 Reconnection 8.1 Voltage Reconnection WARNING Use the following voltage reconnection procedure to change the voltage of 4- and 12-lead generator sets. Frequency changes require voltage regulator and governor adjustments. Hazardous voltage. Moving parts.

  • Page 46: Four-Lead Reconnection

    All manuals and user guides at all-guides.com Voltage Reconnection Procedure 3. Press the selector dial and the voltage selection option (second line on the display) will start to flash. 1. Stop the generator set. 4. Turn selector dial clockwise 2. Turn the controller pushbutton/rotary selector dial counterclockwise until desired...

  • Page 47: 100--120/200--240-Volt Configurations

    All manuals and user guides at all-guides.com L0 (Neutral) L0 (Neutral) GRD. Ground GRD. Ground Load Load Side Side Factory Two-Pole Two-Pole Line Circuit Circuit Line Side Breaker Breaker Side 100- -120/200- -240-Volt, Jumper 3-Wire lead Stator Leads 60 Hz 50 Hz L0--L1 100--120 Volt...
  • Page 48 All manuals and user guides at all-guides.com Electroswitch 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load To Load Kraus Naimler/American Solenoid (Early Rectangular Design) 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power...

  • Page 49: Twelve-Lead Reconnection

    All manuals and user guides at all-guides.com The following information illustrates the reconnection of Kraus Naimler/American Solenoid twelve-lead generator sets. In all cases, conform to the 4-Wire, 3-Phase Generator Sets National Electrical Code (NEC). Reconnect the stator leads of the generator set to change output phase or voltage.
  • Page 50 All manuals and user guides at all-guides.com Notes Section 8 Reconnection TP-6773 5/12a...

  • Page 51: Appendix A Generator Selection And Wattage Requirements

    All manuals and user guides at all-guides.com Appendix A Generator Selection and Wattage Requirements Consider total wattage requirements (lights, motors, are DC powered by a 12-volt battery. Make sure the appliances) when selecting a generator set or when calculated total wattage includes only lights actually on sizing wattage usage in which available space and the generator set AC circuit.

  • Page 52: Appendix B Abbreviations

    All manuals and user guides at all-guides.com Appendix B Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl.
  • Page 53 All manuals and user guides at all-guides.com kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter μF microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat.

  • Page 54: Appendix C Generator Set Output Ratings Procedure

    All manuals and user guides at all-guides.com Appendix C Generator Set Output Ratings Procedure Kohler Co. develops the kilowatt output rating of a Kohlerr generator set installation. Figure 1 outlines the marine generator set based upon the calculations calculations. Figure 2 contains examples of how heat specified in ISO 3046 and ISO 8528-1.
  • Page 55 All manuals and user guides at all-guides.com TP-6773 5/12a...
  • Page 56 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6773 5/12a 7 Jurong Pier Road Singapore 619159 E 2011 and 2012 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...

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