KOHLER 3.5EFOZ/4EOZ, 4EFOZ/5EOZ, 6.5EFOZ/8EOZ, 8.5EFOZ, 9EFOZ/10EOZ, 11EFOZ/13EOZ, 11.5EFOZ/14EOZ, 13EFOZ/15.5EOZ, 16EFOZ/20EOZ, 17.5EFOZ/20EOZ, 19EFOZ/23EOZ, 20EFOZ/24EOZ, 23EFOZ/28EOZ, 27EFOZ/32EOZ, 33EFOZ/40EOZ Installation instructions
Below you will find brief information for Marine Generator Sets 3.5EFOZ/4EOZ, Marine Generator Sets 4EFOZ/5EOZ, Marine Generator Sets 6.5EFOZ/8EOZ, Marine Generator Sets 8.5EFOZ, Marine Generator Sets 9EFOZ/10EOZ, Marine Generator Sets 11EFOZ/13EOZ, Marine Generator Sets 11.5EFOZ/14EOZ, Marine Generator Sets 13EFOZ/15.5EOZ, Marine Generator Sets 16EFOZ/20EOZ, Marine Generator Sets 17.5EFOZ/20EOZ. This instruction manual will walk you through the process of installing your new Kohler marine generator set. It provides step-by-step instructions on how to locate and mount the generator, connect the cooling and exhaust systems, and wire the electrical system.
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Installation
Marine Generator Sets
Models:
3.5EFOZ/4EOZ, 4EFOZ/5EOZ
6.5EFOZ/8EOZ, 8.5EFOZ, 9EFOZ/10EOZ
11EFOZ/13EOZ, 11.5EFOZ/14EOZ
13EFOZ/15.5EOZ, 16EFOZ/20EOZ
17.5EFOZ/20EOZ, 19EFOZ/23EOZ
20EFOZ/24EOZ, 23EFOZ/28EOZ
27EFOZ/32EOZ, 33EFOZ/40EOZ
40EFOZ/50EOZ, 55EFOZ/65EOZ
70EFOZ/80EOZ, 80EFOZ/99EOZ
100EFOZ/125EOZ, 125EFOZ/150EOZ
TP-6069 6/03d
Table of Contents
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2 Location and Mounting
2.1
General Considerations
2.2
Location
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1
Intake Through-Hull Strainer (Seacock Cover) . . . . . . . . . . . . . . . . . . . . .
3.2.2
Seacock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3
Seawater Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4
Water Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.5
Closed Heat Exchanger (4--125EFOZ/5--150EOZ Models) . . . . . . . . . .
3.2.6
Direct Water Cooled (3.5EFOZ/4EOZ Models) . . . . . . . . . . . . . . . . . . . . .
Section 4 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
Exhaust Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
Exhaust System Location, Mounting, and Installation . . . . . . . . . . . . . . . . . . . . . . .
4.3.1
Above-Waterline Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2
Mid/Below-Waterline Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4
Fuel Pump Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
AC Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1
Circuit Breaker Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2
Circuit Breaker Installation (4--27EFOZ and 5--32EOZ Models) . . . . . .
6.2.3
Circuit Breaker Installation (33--125EFOZ and 40--150EOZ Models) . .
6.3
Installation In Steel or Aluminum Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7
Remote Start Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 7 Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
24
24
25
19
19
19
21
22
23
23
17
17
18
18
18
18
29
5
6
6
6
5
6
6
5
5
3
3
3
3
11
11
11
12
12
14
1
I
Section 8 Reconnection/Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
Four-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1
100--120-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2
100--120/200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.3
200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2
Twelve-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3
Decision-Maker 3+ Controller Overvoltage Shutdown Adjustment
8.4
Voltage Regulator Adjustment (4--27EFOZ and 5--32EOZ Models)
. . . . . . . . . . . .
. . . . . . . . . . .
67
67
67
67
68
68
69
72
Appendix A Generator Selection and Wattage Requirements
Appendix B Abbreviations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
A-2
Appendix C Generator Set Output Ratings Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4
TP-6069 6/03 Table of Contents
Safety Precautions and Instructions
IMPORTANT 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. To prevent accidents be aware of potential dangers and act safely.
Read and follow all safety precautions and instructions.
SAVE
THESE INSTRUCTIONS.
This manual has several types of safety precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.
WARNING
Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.
CAUTION
Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.
NOTICE
Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.
Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.
The decals are shown throughout this publication to improve operator recognition.
Replace missing or damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
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 the generator set as follows:
(1) Place the generator set start/stop switch in the STOP position.
(2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.
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 the generator set as follows:
(1) Press the generator set on/off button to shut down the generator set.
All indicator lamps dim. (2) Disconnect the power to the battery charger, if equipped.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and burn skin.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.
Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.
Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
TP-6069 6/03 Safety Precautions and Instructions I
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 container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.
Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.
Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.
Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits.
Explosion can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage.
Disconnect the battery before generator set installation or maintenance.
Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.
Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
Engine Backfire/Flash
Fire
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or sparks near fuels or the fuel system.
Servicing the fuel system. A flash fire can cause severe injury or death.
Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.
Catch fuels in an approved container when removing the fuel line or carburetor.
Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner/silencer removed.
Combustible materials. A sudden flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the fuel system. Keep the compartment and the generator set clean and free of debris to minimize the risk of fire. Wipe up spilled fuels and engine oil.
Combustible materials. A fire can cause severe injury or death.
Generator set engine fuels and fuel vapors are flammable and explosive.
Handle these materials carefully to minimize the risk of fire or explosion.
Equip the compartment or nearby area with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as recommended by the local fire code or an authorized agency.
Train all personnel on fire extinguisher operation and fire prevention procedures.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Carbon monoxide symptoms.
Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases.
Carbon monoxide poisoning symptoms include but are not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in joints and muscles
D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.
Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.
Copper tubing exhaust systems.
Carbon monoxide can cause severe nausea, fainting, or death. Do not use copper tubing in diesel exhaust systems.
Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in exhaust/water leakage.
II Safety Precautions and Instructions TP-6069 6/03
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.
Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.
Operating the generator set. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Use the following precautions when installing and operating the generator set. Do not install the exhaust outlet where exhaust can be drawn in through portholes, vents, or air conditioners.
If the generator set exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow of exhaust. Never operate the generator set without a functioning carbon monoxide detector.
Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate.
If operating the generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always be aware of others, making sure your exhaust is directed away from other boats and buildings. Avoid overloading the craft.
Fuel System
WARNING
The fuel system.
Explosive fuel vapors can cause severe injury or death.
Vaporized fuels are highly explosive.
Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.
Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines.
Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming generator set operation.
Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.
Installing the fuel system. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Do not modify the tank or the propulsion engine fuel system.
Equip the craft with a tank that allows one of the two pickup arrangements described in the installation section.
The tank and installation must conform to USCG Regulations.
Pipe sealant. Explosive fuel vapors can cause severe injury or death.
Fuel leakage can cause an explosion.
Use pipe sealant on all threaded fittings to prevent fuel leakage.
Use pipe sealant that resists gasoline, grease, lubrication oil, common bilge solvents, salt deposits, and water.
Ignition-protected equipment.
Explosive fuel vapors can cause severe injury or death.
Gasoline vapors can cause an explosion.
USCG Regulation 33CFR183 requires that all electrical devices (ship-to-shore transfer switch, remote start panel, etc.) must be ignition protected when used in a gasoline and gaseous-fueled environment.
The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous-fueled environment such as an engine room or near fuel tanks. Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash.
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.
Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than
105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.
Hazardous Voltage/
Electrical Shock
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
TP-6069 6/03
Hazardous voltage.
Moving rotor.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Safety Precautions and Instructions III
CAUTION
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).
Grounding electrical equipment.
Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.
Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards.
Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
Disconnecting the electrical load.
Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads.
High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load.
Welding the generator set.
Can cause severe electrical equipment damage. Before welding the generator set perform the following steps:
(1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module
(ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors.
(4) Disconnect the engine batterycharging alternator connections.
(5) Attach the weld ground connection close to the weld location.
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.
Remove all jewelry before servicing the equipment.
Testing the voltage regulator.
Hazardous voltage can cause severe injury or death. High voltage is present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator.
(PowerBoost t, PowerBoostt III, and
PowerBoost t V voltage regulator models only)
Electrical backfeed to the utility.
Hazardous backfeed voltage can cause severe injury or death.
Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is opened.
Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near the work area.
Some states and localities prohibit unauthorized connection to the utility electrical system.
Install a ship-to-shore transfer switch to prevent interconnection of the generator set power and shore power.
IV Safety Precautions and Instructions
Testing live electrical circuits.
Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits.
Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure.
(4) Be prepared for the system to operate automatically.
(600 volts and under)
Hot Parts
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Checking the coolant level.
Hot coolant can cause severe injury or death.
Allow the engine to cool.
Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled.
Check the coolant level at the tank if the generator set has a coolant recovery tank.
TP-6069 6/03
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
WARNING
Hazardous voltage.
Moving rotor.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when all guards, screens, and covers are in place.
WARNING
Airborne particles.
Can cause severe injury or blindness.
Wear protective goggles and clothing when using power tools, hand tools, or compressed air.
Tightening the hardware.
Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury.
Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.
Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death.
Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.
Sound shield removal.
Exposed moving parts can cause severe injury or death.
The generator set must be operating in order to perform some scheduled maintenance procedures. Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.
(Sound-shield-equipped models only)
Notice
NOTICE
This generator set has been rewired from its nameplate voltage to
246242
NOTICE
Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate.
Order voltage reconnection decal 246242 from an authorized service distributor/dealer.
NOTICE
Hardware damage. The engine and generator set may use both American
Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.
NOTICE
When replacing hardware, do not substitute with inferior grade hardware.
Screws and nuts are available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.
NOTICE
Electrostatic discharge damage.
Electrostatic discharge (ESD) damages electronic circuit boards.
Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about
1 megohm), not a direct short, to ground.
NOTICE
Fuse replacement.
Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic).
Do not substitute clear glass-type fuses for ceramic fuses.
Refer to the wiring diagram when the ampere rating is unknown or questionable.
NOTICE
Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.
TP-6069 6/03 Safety Precautions and Instructions V
Notes
VI Safety Precautions and Instructions TP-6069 6/03
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.
x:in:001:002:a
The safe and successful operation of a marine power system depends primarily on the installation.
See
Figure 1-1. Use this manual as a guide to install the
1
2
17 marine generator set. For operating instructions, refer to the operation manual.
Marine generator set installations must comply with all applicable regulations and standards.
Use the specification sheets as a guide in planning your installation. Use current dimension drawings and wiring diagrams.
3
15
16
KOHLER
4
14
5
13
9
8
11
12
7
6
10
585711
1. Exhaust mixer elbow (exhaust/water outlet) (not shown)
2. Heat exchanger (not shown)
3. Coolant recovery tank (located on the unit on some models)
4. Seawater strainer *
5. Seawater pump (seawater inlet)
6. Seawater line *
7. Seacock *
8. Craft stringers
9. Fuel feed pump (fuel inlet) *
Figure 1-1 Typical Generator Set Location and Mounting
10. Fuel return line *
11. Hose clamps
12. Fuel supply line *
13. Mounting tray (mounting skid on 33--150 kW models)
14. Battery/battery storage box
15. Battery cables
16. Exhaust hose or exhaust line *
17. Electrical leads (AC output leads/remote start panel leads)
* Indicated components must conform to USCG regulations.
Note: See text for complete explanation of installation requirements.
Note: Use two hose clamps on each end of all flexible exhaust hose connections.
TP-6069 6/03 Section 1 Introduction 1
Notes
2 Section 1 Introduction TP-6069 6/03
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. Choose a location that allows adequate space for cooling and exhaust system installation, fuel system installation, ventilation, and service access to the generator set (engine and generator).
2. Use craft stringers or other available structural members capable of supporting the generator set’s weight.
3. Seal the generator set compartment from the cabin to prevent exhaust gases and fuel vapors from entering the cabin.
See the current generator set specification sheet or
Section 7 of this manual for generator set dimensions and weights. See Figure 1-1 for a typical installation.
m:is:101:001
2.2 Location
Locate the generator set to allow easy service access to the generator set’s engine, controller, cooling, and fuel system components. The engine compartment is often the ideal location for the generator set if the propulsion engine(s) does not obstruct access to the generator set and controller.
Marine Generator Set Installations in
European Union Member Countries
This generator set is specifically intended and approved for installation below the deck in the engine compartment.
Installation above the deck and/or outdoors would constitute a violation of European Union
Directive 2000/14/EC noise emission standard.
Allow clearance for vibration and cooling during operation.
Allow a minimum of 38 mm (1.5 in.) clearance on all sides (top, front, rear, and sides) of a generator set without an optional sound shield. Refer to the instruction sheet for minimum clearances for sound-shielded units. Also, allow space for the power takeoff (PTO) option, if equipped.
Diesel generator sets are not ignition-protected. USCG
Regulation 183.410 requires ignition-protected devices only in gasoline/gaseous-fueled environments.
2.3 Mounting
Mount the generator set as high as possible to avoid contact with bilge splash and lower-lying vapors and to allow for downward pitch of the exhaust line toward the exhaust outlet.
Craft stringers generally provide the best generator set support.
Ensure that the structural members can support the generator set’s weight and withstand its vibration.
The generator set includes vibration mounts and a mounting tray or skid.
If desired, install additional vibration isolating pads underneath the generator set’s base.
Use the four mounting holes in the mounting tray to mount the generator set securely to the craft.
For angular operating limits, consult the operation manual.
TP-6069 6/03 Section 2 Location and Mounting 3
Notes
4 Section 2 Location and Mounting TP-6069 6/03
Section 3 Cooling System
3.1 Ventilation
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.
As a rule, size each inlet- and outlet-vent area to a minimum of 13 sq. cm/30.5 cm (2 sq. in. per ft.) of the craft’s beam.
Should this rule conflict with USCG
Regulations, follow USCG Regulations. For applications with screened inlets, double the size (4 sq. in. per ft.) of the hull/deck openings. Extend the vent ducts to bilges to expel heavier-than-air fumes.
For generator sets mounted in the engine compartment, increase the air flow to allow for the generator set’s requirements.
Install optional detection devices to cause alarm, warning, or engine shutdown should dangerous fumes accumulate in the compartment.
See the generator set specification sheet that shipped with the generator set for air requirements. The air intake silencer/cleaner provides combustion air to the engine.
Do not compromise the recommended minimum clearance of 38 mm (1.5 in.) between a duct opening and enclosure wall. The engine/generator performance will decline if you compromise these guidelines.
See
Figure 3-1 for allowable intake restriction.
Note: ISO 3046 derates apply. See Appendix C.
Model Allowable Intake Restriction
3.5EFOZ/4EOZ 200 mm H
2
O (1.96 kPa or less)
4--125EFOZ/5--150EOZ 635 mm H
2
O (6.23 kPa or less)
Figure 3-1 Combustion Air Intake Restriction
3.2 Cooling System Components
The marine generator set’s cooling system requires the following components.
3.2.1
Intake Through-Hull Strainer
(Seacock Cover)
Install a screened-intake, through-hull strainer to prevent entry of foreign objects.
Use perforated, slotted-hole, or unrestricted-hole design strainers. See
Figure 3-2 for examples of typical strainers. The inner diameter of the strainer opening must be equal to or greater than the inner diameter of the water-line hose to the seawater pump.
TP-6069 6/03
1
5
1-789
1. Inside packing
2. Outside packing
3. Seacock cover
4. Direction of vessel movement
5. Typical intake through-hull strainers
Figure 3-2 Seacock Installation
Do not align the strainer (in relation to the craft’s direction of travel) with any other through-hull intakes.
See
Figure 3-3. Flush mount the recommended through-hull strainer.
Install slotted-hole-design strainers with the slots parallel to the direction of the vessel’s movement.
1
4
2
3
2
4 3
Note: Position the intakes in relation to the vessel’s travel so neither is in the wake of the other.
1-789
1. Generator set intake
2. Main engine intake
3. Aft (rearward)
4. Fore (forward)
Figure 3-3 Intake Strainer
Section 3 Cooling System 5
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.
Do not use hulls incorporating sea chests or other designs that provide a positive pressure to the raw water pump for the intake through-hull strainers.
Positive pressure forces water past the raw water pump and into the engine. A sea chest is a concave molded-in-the-hull chamber that aligns to the vessel’s direction of travel. A sea chest configuration applies positive pressure similar to a scoop-type through-hull strainer.
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 the generator set is shut down.
3.2.3
Seawater Strainer
Mount the seawater strainer to the seacock or permanent structure at a point not higher than the seawater pump. Ensure that the strainer is accessible for service. See Figure 3-4 for a typical installation.
Some seawater strainers include a seacock and an intake through-hull strainer.
Maximum seawater inlet pressure at the seawater pump is 34.5 kPa (5 psi). Excessive pressure will cause water ingestion.
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.
Keep the seawater hose as straight and short as possible. If the hose is too long, usually over 4.6 m
(15 ft.), water draw problems may occur. See Section 7 for the inlet water line hose size and the seawater connection to the seawater pump inlet. Avoid running the inlet pipe above the generator. See Figure 3-5 for the seawater hose connection to the seawater pump inlet.
1. Seawater pump
2. Seawater strainer
3. Seacock
Figure 3-4 Seawater Strainer
6 Section 3 Cooling System
3
1
2
1-789
1
1. Seawater pump inlet
Figure 3-5 Seawater Inlet Connection, Typical
TP-5586-6
3.2.5
Closed Heat Exchanger
(4--125EFOZ/5--150EOZ Models)
A closed heat exchanger is the best cooling method for most applications. See Figure 3-6 or Figure 3-7 for a typical installation.
Provide space to access the water-cooled exhaust manifold pressure cap.
3.2.6
Direct Water Cooled
(3.5EFOZ/4EOZ Models)
In a direct seawater cooling system, the impeller pump circulates the seawater around the cylinder and through the cylinder head. A thermostat controls the cooling water circuit temperature. Consult Figure 3-8 and the engine operation manual for the cooling water circuit diagrams.
TP-6069 6/03
1
2
3
4
6
8
5
7
14
9
10
Arrow Description
Direction of Flow
Seawater
Freshwater (Coolant/Antifreeze)
11
12
13
TP-5586-6
1. Engine block
2. Exhaust manifold
3. Exhaust mixer elbow
4. Outlet flapper (exhaust/water discharge)
5. Silencer (customer supplied)
6. Thermostat open
7. Thermostat
8. Thermostat closed
9. Heat exchanger
10. Engine-driven seawater pump
11. Seawater strainer
12. Seacock
13. Intake strainer
14. Engine-driven water pump
Figure 3-6 Typical Closed/Heat Exchanger Cooling System (4/6.5/8.5/9/23/27EFOZ and 5/8/10/28/32EOZ
Models)
TP-6069 6/03 Section 3 Cooling System 7
1
2
3
4
5
6
7
8
9
14
13
12
11
Seawater
Freshwater (Coolant/Antifreeze)
10
1. Oil cooler
2. Engine block
3. Thermostat
4. Water-cooled manifold
5. Heat exchanger
6. Exhaust mixer elbow
7. Water-cooled turbocharger
8. Silencer (customer-supplied)
9. Exhaust outlet
10. Intake strainer
11. Seacock
12. Seawater strainer
13. Engine-driven seawater pump
14. Engine-driven water pump
Figure 3-7 Typical Closed/Heat Exchanger Cooling System (11--20EFOZ,13--24EOZ, 33--125EFOZ and
40--150EOZ Models)
TP-5592-6
8 Section 3 Cooling System TP-6069 6/03
6
8
7
9
10
3
5
2
1
4
1. Intake strainer
2. Seacock
3. Seawater strainer
4. Engine-driven seawater pump
5. Oil exchanger
6. Zinc plug
7. Exhaust manifold elbow
8. Exhaust hose
9. Silencer (customer supplied)
10. Outlet flapper (exhaust/water discharge)
Figure 3-8 Direct Water-Cooled Cooling System (3.5EFOZ and 4EOZ Models)
TP-6134-
TP-6069 6/03 Section 3 Cooling System 9
Notes
10 Section 3 Cooling System TP-6069 6/03
Section 4 Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Carbon monoxide symptoms.
Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases.
Carbon monoxide poisoning symptoms include but are not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in joints and muscles
D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning.
Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.
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. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times.
Operating the generator set. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Use the following precautions when installing and operating the generator set.
Do not install the exhaust outlet where exhaust can be drawn in through portholes, vents, or air conditioners. If the generator set exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow of exhaust.
Never operate the generator set without a functioning carbon monoxide detector. Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate. If operating the generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind).
Always be aware of others, making sure your exhaust is directed away from other boats and buildings.
Avoid overloading the craft.
4.1 Types
Kohler r generator sets covered in this manual use either wet or dry exhaust systems. Dry exhaust systems are common in commercial applications.
See the engine manual for specifications.
4.2 Exhaust Lines
Use water-cooled exhaust lines in all marine installations. Keep the lines as short and straight as possible.
NFPA 302 Fire Protection Standard for
Pleasure and Commercial Motor Craft, Clause 4-3, recommends using two corrosion-resistant hose clamps with a minimum width of 13 mm (1/2 in.) on each end of the flexible exhaust hose connections.
Kohler Co. requires a downward pitch of at least 13 mm per 30.5 cm (1/2 in. per running foot). Use a flexible exhaust hose that conforms to UL Standard 1129 for the engine’s wet exhaust components between the mixer elbow and the exhaust outlet.
TP-6069 6/03 Section 4 Exhaust System 11
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. See Figure 4-1 for the exhaust connection to the mixer elbow. Provide an adequate hose length from the exhaust mixer to the silencer to allow for generator set movement.
1
1. Water/exhaust outlet
Figure 4-1 Mixer Elbow/Exhaust Connection,
Typical
TP-5586-6
1. Water/exhaust outlet
Figure 4-2 Mixer Elbow/Exhaust Connection,
3.5EFOZ/4EOZ Model Only
1
TP-6134-
Locate the exhaust outlet at least 10 cm (4 in.) above the waterline when the craft is loaded to maximum capacity.
Install an exhaust port with the flap at the exhaust
(transom) outlet to prevent water backup in following seas or when moving astern (backward). A lift in the exhaust piping before the piping exits the craft prevents backwash. See Figure 4-4, item 1. Support the exhaust lines to prevent the formation of water pockets.
Exhaust system installation guidelines for various generator set locations follow.
Information and illustrations of stern- (rear) exhaust installations also apply to side-exhaust installations. Where exhaust lines require passage through bulkheads, use port (left)- or starboard (right)side exhaust outlets, also in applications in which long exhaust lines to the transom
(rear) could cause excessive back pressure.
See
Figure 4-3 for allowable back pressures. Should any information regarding installation conflict with USCG
Regulations, follow USCG Regulations.
Model
4/8.5/9/23/27EFOZ and
5/10/28/32EOZ
6.5EFOZ and 8EOZ
11/16/17.5EFOZ and 13/20EOZ
3.5/11.5/13/19/20EFOZ and
4/14/15.5/23/24EOZ
33/40/55/70/80/100/125EFOZ and 40/50/65/80/99/125/150EOZ
Allowable Exhaust
≤
Back Pressure
, kPa (mm H
2
O)
9.81 (1000)
11.77 (1200)
6.37
(650)
4.90
(500)
7.47
(762)
Figure 4-3 Allowable Exhaust Back Pressures
4.3.1
Above-Waterline Installation
Install a customer-supplied silencer with the silencer’s outlet at a maximum of 3 m (10 horizontal ft.) from the center of the engine’s exhaust outlet. See Figure 4-4.
Mount a typical silencer with the inlet and outlet horizontal and with the drain plug down. Use an exhaust hose pitch of at least 13 mm per 30.5 cm (0.5 in. per running foot).
Some silencers require two support brackets or hanger straps for installation to stringers or other suitable structure.
Follow the instructions provided with the silencer.
Install any lift (see
Figure 4-4, item 1) in the exhaust line below the engine exhaust manifold outlet.
12 Section 4 Exhaust System TP-6069 6/03
4
5
6
3
2
1
13
7
8
9
Waterline
15
16
12
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. Exhaust manifold outlet
4. Exhaust mixer elbow
5. Heat exchanger (locations vary by model)
6. Coolant recovery tank (located on the unit on some models)
7. Locate the coolant recovery tank at the same height as the heat exchanger
8. Maximum seawater pump lift of 1 m (3 ft.)
9. Seawater strainer
10. Seacock
11. Intake strainer
12. Engine-driven seawater pump
Figure 4-4 Typical Above-Waterline Installation
10
14
11
TP-5856-4
13. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.
per ft.)
14. Maximum distance between silencer and exhaust mixer elbow of 3 m (10 ft.)
15. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.
per ft.)
16. Minimum exhaust outlet distance above waterline of 10 cm
(4 in.). Note: Vessel fully loaded.
Note: Data applies to both rear- and side-exhaust installations.
Note: Use two hose clamps on each end of all flexible exhaust hose connections.
Note: Read the text for complete explanation of dimensions and other installation considerations.
TP-6069 6/03 Section 4 Exhaust System 13
4.3.2
Mid/Below-Waterline 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.) above the waterline when the craft is loaded to maximum capacity. Install the siphon break at least 31 cm (1 ft.) above the waterline using the instructions provided with the siphon break kit.
Note: An improperly installed siphon break will cause engine damage and may void the warranty.
Install the siphon break above the highest point in the exhaust line between the heat exchanger and the exhaust mixer. See Figure 4-5 for the siphon break connection. Support the siphon break and hoses to maintain their position and function. Allow a slight offset to clear the stringers or other permanent structures.
Protect the siphon break air inlet from dirt and debris.
Note: To prevent water leakage on the generator set, do not mount the siphon break directly over the generator set.
1
TP-5586-6
1. Cut hose and connect siphon break and hardware
Figure 4-5 Siphon Break Connection (4EFOZ/5EOZ model shown)
Mount a typical silencer’s base no more than 1.2 m (4 ft.) below the highest point in the exhaust line. Attach a separate wood mounting base to the hull stringers or other suitable structures.
Use the silencer manufacturer’s recommendation for securing the silencer to the hull. Mount the silencer with the outlet not more than 3 m (10 horizontal ft.) from the engine’s exhaust manifold outlet. Use a USCG-type certified marine exhaust hose.
14 Section 4 Exhaust System TP-6069 6/03
2
3
7
8
9
10
1
21
6
5
Waterline
19
4
11
20
16
12
18
15
13
17
14
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.), a siphon break is required
6. Minimum siphon break distance above waterline of 30.5 cm
(1 ft.)
7. Siphon break
8. Exhaust mixer elbow
9. Heat exchanger (locations vary by model)
10. Coolant recovery tank (located on the unit on some models)
11. Indicates the coolant recovery tank is at the same height as the heat exchanger
12. Seawater strainer
13. Seacock
14. Intake strainer
Figure 4-6 Typical Mid and Below Waterline Installation
15. Engine-driven seawater pump
16. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)
17. Maximum distance between silencer and exhaust mixer elbow of 3 m (10 ft.)
18. Silencer (customer-supplied)
19. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm
(0.5 in. per ft.)
20. Minimum exhaust outlet distance above waterline of 10 cm
(4 in.)
21. Exhaust hose (see Figure 4-7 for hose sizes)
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.
Models without Sound Shield
3.5/4/6.5/8.5/9EFOZ
4/5/8/10EOZ
11/11.5/13/16/17.5/19/20/23/27EFOZ
13/14/15.5/20/23/24/28/32EOZ
33EFOZ
40EOZ
40/55/70/80/100/125EFOZ
50/65/80/99/125/150EOZ
Figure 4-7 Exhaust Hose Sizes
Models with Sound Shield
4/6.5/8.5/9/11/11.5/13/16/17.5/19/20EFOZ
5/8/10/13/14/15.5/20/23/24EOZ
27EFOZ
32EOZ
33EFOZ
40EOZ
40/55/70/80/100/125EFOZ
50/65/80/99/125/150EOZ
Exhaust Hose
Diameter mm (in.)
51 (2.0)
76 (3.0)
89 (3.5)
102 (4.0)
TP-6069 6/03 Section 4 Exhaust System 15
Notes
16 Section 4 Exhaust System TP-6069 6/03
Section 5 Fuel System
WARNING
2
1
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
Installing the fuel system.
Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Do not modify the tank or the propulsion engine fuel system. Equip the craft with a tank that allows one of the two pickup arrangements described in the installation section. The tank and installation must conform to USCG Regulations.
Note: Fuel system installations must conform to USCG
Regulations.
5.1 Fuel Tank
Most marine generator sets draw fuel from the same fuel tank as the craft’s propulsion engine(s). If the tank’s fuel pickup opening allows a multiple dip tube, use a multiple dip tube arrangement. See Figure 5-1. The multiple dip tube arrangement incorporates a shorter dip tube for the generator set and a longer dip tube for the propulsion engine. With this arrangement, the generator set runs out of fuel before the propulsion engine during a low fuel supply situation. Equip the fuel system with a fuel/water separator to remove any accumulated dirt and water.
1-788
1. Fuel line to propulsion engine
2. Fuel line to generator set
Figure 5-1 Multiple Dip Tube Arrangement m:is:102:001
TP-6069 6/03 Section 5 Fuel System 17
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.
Note: Do not tee into the main propulsion engine’s fuel line.
Under no circumstances should the propulsion engine and generator set share pickup or return lines (through a tee arrangement) that would allow the larger engine to starve fuel from the smaller engine. It is possible that the operation of either engine could completely drain the fuel line of the other engine and make starting difficult.
Use a flexible hose section to connect the metallic line from the fuel tank to the engine’s fuel pump inlet connection point. Also, use a flexible hose section to connect the metallic line from the fuel tank to the fuel return connection point. The flexible section allows the generator set to vibrate during operation.
Model
3.5EFOZ and 4EOZ
Fuel Line
ID Size mm (in.)
6.4 (1/4)
4--125EFOZ and 5--150EOZ 9.7 (3/8)
Figure 5-2 Fuel Line ID Size
See Figure 5-2 for the ID size of the customer-supplied fuel line that connects to the fuel pump and fuel return.
Route the fuel lines from the fuel tank in a gradual incline to the engine—do not exceed the height of the generator set and do not route fuel lines above the generator set.
Comply with USCG Regulation 46CFR182.20
regarding fuel lines and supports.
See Section 7 for fuel feed pump inlet connection and fuel return line connection.
5.3 Fuel Filters
Conform to USCG Regulations regarding inline fuel filters or strainers.
5.4 Fuel Pump Lift
See Figure 5-3 for fuel pump lift capabilities.
Model
3.5/4/6.5/8.5/9/11/11.5/13/16/17.5/19/20/23/
27EFOZ and
4/5/8/10/13/14/15.5/20/23/24/28/32EOZ
33/40/55/70/80/100/125EFOZ and 40/50/65/80/99/125/150EOZ
Figure 5-3 Fuel Pump Lift
Fuel
Pump
Lift m (ft.)
1.2 (4)
0.9 (3)
5.5 Fuel Consumption
Consult the current generator set specification sheets for generator set fuel consumption rates.
18 Section 5 Fuel System TP-6069 6/03
Section 6 Electrical System
Hazardous voltage.
Moving rotor.
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. Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is opened. Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near the work area. Some states and localities prohibit unauthorized connection to the utility electrical system. Install a ship-to-shore transfer switch to prevent interconnection of the generator set power and shore power.
1
2
5
6
1. Line side
2. AC circuit breaker
3. Load side
4. L1/L2 phase (black) leads
5. GRD ground (green) lead
6. L0 neutral (white) lead
585771
Figure 6-1 AC Voltage Connections in Controller
Box (5--32EOZ Models, Typical)
TP-6069 6/03
WARNING
3
4
6.1 AC Voltage Connections
Make AC connections to the generator set inside the controller box (4--27EFOZ and 5--32EOZ models) or inside the junction box (33--125EFOZ and 40--150EOZ models).
Typically, the generator set connects to a ship-to-shore transfer switch that allows the use of shore/utility power when docked or generator set power when docked or at sea. The wiring then connects to a main circuit breaker box (panel board) that distributes branch circuits throughout the craft. See Figure 6-1 for
AC voltage connections to the generator set.
See
Section 8 for reconnection of the generator set.
6.2 Circuit Protection
The AC circuit breakers (optional) protect the wiring from the AC circuit breakers to the vessel’s distribution panel. AC circuit breakers trip when they detect a fault in the output circuit.
After correcting the fault, reset the AC circuit breaker(s) by placing them in the ON position. Restart the unit. Do not start the unit under load.
See Figure 6-2 or
Figure 6-3 for AC circuit breaker ratings. The unit’s voltage configuration determines the circuit breaker selection.
Note: Circuit breaker ampere rating and availability are subject to change.
6.2.1
Circuit Breaker Considerations
Mounting location. Mount the circuit breakers in the generator set’s controller (4--27EFOZ and 5--32EOZ models) or the generator set’s junction box
(33--125EFOZ and 40--150EOZ models).
See
Section 6.2.2 or Section 6.2.3.
Note: 3.5EFOZ and 4EOZ models already have circuit breakers installed.
Sizing.
Use the generator set voltage/frequency configuration to determine the circuit breaker amperage. If the generator set voltage configuration changes, change the circuit breaker to provide optimum protection.
For circuit breaker application and selection information, contact an authorized distributor/dealer.
Have a qualified electrician or technician install circuit breakers and reconnect the generator set. Comply with all governing standards and codes.
Section 6 Electrical System 19
Amps
22
25
33
40
50
55
60
85
90
100
150
Max.
Voltage
250
600
250
250
600
250
250
600
250
480
250
250
600
250
600
240
250
480
250
240
480
240
480
600
2
3
2
3
1
1
1
3
3
1
3
1
2
1
2
Number of Poles
1
3
2
2
1
2
3
3
1
1
2
1
2
1
2
1
3
1
2
1
2
2
2
3
2
Model(s)
4EFOZ
8.5/11.5EFOZ, 14EOZ
4EFOZ, 5EOZ
5EOZ
6.5EFOZ
6.5EFOZ
11.5/17.5/20EFOZ,
14/20/24EOZ—3 phase
8EOZ
4EFOZ
8EOZ
5EOZ
11.5EFOZ,
14/20/24EOZ—3 phase
9EFOZ
9EFOZ, 8/10EOZ
11/13EFOZ
11/11.5/17.5EFOZ
9EFOZ, 10EOZ
20/23/27EFOZ,
20/28/32EOZ—3 phase
5EOZ
13EFOZ
11/13EFOZ, 13/14EOZ
6.5EFOZ
17.5/20EFOZ,
20/24/28/32EOZ—3 phase
16EFOZ
13/20EFOZ, 15.5EOZ
6.5EFOZ, 8EOZ
20/24EOZ—3 phase
16/19EFOZ
16EFOZ, 20EOZ—1 phase,
20/24EOZ—3 phase
8EOZ
23EFOZ—3 phase
9EFOZ, 10EOZ
19EFOZ
19EFOZ—1 phase
20/23EOZ
27EFOZ—3 phase
23EOZ
23/27EFOZ,
28/32EOZ—3 phase
23/27EFOZ, 28EOZ—
1 phase, 27EFOZ—3 phase
23/27EFOZ,
28/32EOZ—3 phase
28/32EOZ—1 phase,
32EOZ— 3 phase
32EOZ—1 phase 175 600 2
Figure 6-2 AC Circuit Breaker Ratings (4--27EFOZ and 5--32EOZ Models), Listed By Amps
Amps
60
70
80
100
Max.
Voltage
600
600
480
480
100--125
100--125
125
125
128--160
128--160
150
150
160--400
160--400
200
200
200--250
200--250
240--600
250
250
250--630
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
Number of Poles Type
3 UL/IEC
3 UL/IEC
3
3
3
3
3
UL/IEC
Model(s)
33EFOZ, 40EOZ
40EFOZ, 40EOZ
UL/IEC 55EFOZ, 50/65EOZ
IEC
33/55EFOZ,
40/65EOZ
IEC
UL
40EFOZ, 50EOZ
70EFOZ, 80EOZ
33/55EFOZ,
40/65EOZ
3 UL
3
3
3
IEC
IEC
UL
70EFOZ, 80EOZ
33/40EFOZ,
40/50EOZ
70/80EFOZ,
80/99EOZ
33/40EFOZ,
40/50EOZ
3
3
3
3
3
3
3
3
3
3
3
UL
UL
IEC
UL
UL
IEC
IEC
UL
UL
UL
IEC
70/80EFOZ,
80/99EOZ
70/80/100EFOZ,
80/99/125/150EOZ
70/80/100/125EFOZ,
80/99/125/150EOZ
40/55EFOZ,
50/65EOZ
100EFOZ,
99/125EOZ
40/55EFOZ,
50/65EOZ
70/100/125EFOZ,
80/125/150EOZ
125EFOZ,
125/150EOZ
55EFOZ, 65EOZ
70/125EFOZ,
80/125/150EOZ
125EFOZ,
125/150EOZ
Figure 6-3 AC Circuit Breaker Ratings (33--150 kW
Models), Listed By Amps
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
20 Section 6 Electrical System TP-6069 6/03
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 the generator set as follows: (1) Place the generator set start/stop switch in the STOP position. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.
WARNING
Hazardous voltage.
Moving rotor.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.
Open the main circuit breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
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. Remove all jewelry before servicing the equipment.
Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is opened. Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near the work area. Some states and localities prohibit unauthorized connection to the utility electrical system. Install a ship-to-shore transfer switch to prevent interconnection of the generator set power and shore power.
6.2.2
Circuit Breaker Installation
(4--27EFOZ and 5--32EOZ Models)
1. Place the generator set start/stop switch in the
STOP position.
2. Disconnect the generator set engine starting battery, negative (--) lead first.
TP-6069 6/03
3. Remove the controller cover screws and remove the access cover.
4. Remove the screws and nuts to remove the circuit breaker cover plate. Save the mounting hardware.
5. Install the circuit breaker from the inside of the cutout panel and mount it using existing screws removed in step 4. Position the circuit breaker with the ON in the normal upright position or to the left side. Cover the cutout opening, if applicable, with the circuit breaker cover plate. Use existing screws to mount the cover plate.
6. See Section 8 for voltage reconnection.
Note: Kohler r marine diesel generator sets are fully frequency adjustable and voltage reconnectable. To determine reconnection options, check the model’s specification sheet.
7. Install insulation boots over stator lead terminals if the kit includes insulation boots.
Note: See Section 8 for wiring instructions.
8. Make the recommended connections for the following four reconnection systems using circuit breakers:
Two-pole circuit breaker with a single-voltage system (example: 120-volt, 3-wire).
Attach stator leads marked 2 and 4 to the side of the circuit breaker marked LINE.
Install the jumper lead across the LINE side of circuit breaker terminals
(see Section 8). Attach stator leads 1 and 3 to L0.
Single-pole circuit breaker with a 120-volt,
2-wire, single-voltage system.
Attach stator leads marked 2 and 4 to the side of the circuit breaker marked LINE (see Section 8). Attach stator leads 1 and 3 to L0.
Two-pole circuit breaker with a dual-voltage system (example: 120/240-volt, 3-wire). Attach stator leads marked 1 and 4 to the side of the circuit breaker marked LINE. Do not use a jumper lead
(see Section 8). Attach stator leads 2 and 3 to L0.
Single-pole circuit breaker with a 240-volt,
2-wire, single-voltage system. Attach the stator lead marked 2 to the side of the circuit breaker marked LINE (see Section 8). Bolt together leads 1 and 4 and tape to insulate from ground. Attach the stator lead marked 3 to L0.
9. Connect the stator lead(s) used for neutral connection to the L0 stud. See the illustrations in
Section 8.
Section 6 Electrical System 21
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). With a two-pole circuit breaker use two black leads, L1 and L2.
Connect the neutral (white) lead to the L0 stud.
Connect the equipment ground (green) lead to
GRD stud.
Note: Wire material. Use stranded copper for all wiring.
Use wire gauges and insulation, conductor temperature ratings, sheath stripping, conductor support and protection, conductor terminals and splices, and overcurrent protection (circuit breakers, fuses) that conform to standards and codes.
Note: Follow USCG Regulations CFR33, Part 183
(Pleasurecraft) and CFR46 (Commercial
Craft) for marine applications.
Note: Wire protection.
Use rubber grommets and cable ties as necessary to protect and secure wiring from sharp objects, the exhaust system, and any moving parts.
11. Replace the controller cover or circuit breaker box access panel.
12. Reconnect the generator set engine starting battery, negative (--) lead last.
13. Make voltage or frequency adjustments according to Section 8.
Note: Voltage/frequency adjustable.
Some four-lead generator sets are not voltage/frequency adjustable. To determine adjustment possibilities, check the model’s specification sheet or service manual. If you are reconnecting the generator set from a single-voltage to a dual-voltage configuration (example: from 120-volt to
120/240-volt) or a dual voltage to a single voltage (example: from 120/240-volt to
120-volt) with the same primary voltage, do not adjust the voltage/frequency adjustment. Adjust the voltage/frequency for frequency changes or setting changes of the primary voltage (example: from 120-volt to 100-volt).
Refer to the model’s specification sheet for reconnection capability.
6.2.3
Circuit Breaker Installation
(33--125EFOZ and 40--150EOZ
Models)
1. Place the generator set master switch in the OFF position.
2. Disconnect the generator set engine starting battery, negative (--) lead first.
3. Remove the six screws from the right side junction box panel and remove the panel.
4. Install the circuit breaker on the new panel with the screws and washers. Position the ON side of the circuit breaker toward the rear of the junction box.
See Figure 6-4.
5. Attach stator leads L1, L2, and L3 to the extension leads (if supplied) or to the line side of the circuit breaker. See Figure 8-5.
Note: Insulate leads with electrical tape after connecting extension leads to stator leads.
6. Connect the neutral connection stator leads to the
L0 stud.
Note: Verify that terminal positions and previously made line lead connections allow room for load connections to load studs.
7. Connect the load side of the circuit breaker to customer-supplied craft wiring.
Connect the neutral lead to the L0 stud. See Figure 8-5.
8. Attach the new panel to the junction box using the original six screws. See Figure 6-4.
9. Check that the generator set master switch is in the
OFF position. Reconnect the generator set engine starting battery, negative (--) lead last.
22 Section 6 Electrical System TP-6069 6/03
1 2 3 4 5 6
ASSEMBLY VIEW C-C
7
8
9
6 1 5
TP-6069 6/03
ASSEMBLY VIEW A
1. Existing mounting hardware
2. Load lead access panel
3. Screw
4. Hang tag
5. Circuit breaker
Figure 6-4 Circuit Breaker Mounting
6.3 Installation In Steel or
Aluminum Vessels
Installation of a generator set in a vessel constructed of a material capable of conducting current (e.g., steel or aluminum) is subject to considerations not normally encountered in fiberglass or wood vessels.
These differences include equipment grounding, grounding of neutral conductors, ground-fault protection, and isolation of galvanic currents.
The scope of these topics is too extensive to be fully discussed here. Consult your local marine authority for more information.
Before installing the generator set, check the available wiring diagrams in the operation manual to become familiar with the electrical system.
ASSEMBLY VIEW B
6. Circuit breaker panel
7. Extension leads, if equipped
8. Rear connection used on 125-250 amp circuit breaker
9. Spacer used on 125-250 amp circuit breaker
DX-250000-B
6.4 Installation Regulations
The U.S.
Coast Guard governs generator set installation in U.S. pleasurecraft and commercial vessels. Refer to the applicable regulations below:
U.S. Pleasurecraft Installation
Regulations
Title 33CFR, Chapter I, U.S. Coast Guard, Part 183
1. Subpart I—Electrical Equipment
2. Subpart J—Fuel Systems
U.S. Commercial Vessel Installation
Regulations
Title 46CFR, Chapter I, U.S. Coast Guard
1. Part 111—Electrical Systems
2. Part 182—Machinery Installation m:sc:001:001
Section 6 Electrical System 23
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.
The starting/charging systems of both the generator set and the engine must have a common negative (--) ground.
USCG Regulation 183.415, Grounding, requires connection of a common conductor to each grounded cranking-motor circuit. Size the conductor to match the larger of the engine’s two battery cables. Figure 6-5 lists cable sizes for generator set battery connections at various ambient temperatures. Connecting a common conductor to each grounded cranking motor circuit prevents the starting motor current from using alternative electrical paths should the cranking motor ground circuit be restricted or open because of oxidation or loose hardware. Alternative electrical paths include metallic fuel lines that can pose a fire hazard. See
Figure 6-7 and Section 7 for battery connections to the generator set.
Generator Set and Battery m (ft.)
12.2
(40)
9.1
7.6
(30)
(25)
6.1
4.6
3.0
(20)
(15)
(10)
1.5
0.8
(5)
(2.5)
At –18
°C
(0
°F)
00
Cable Size (AWG)
At 0
(32
0
°C
°F)
At 24
°C
(75
°F)
1
0
1
1
2
2
4
2
2
4
2
4
6
6
6
8
6
8
6
8
8
8
Figure 6-5 Battery Cable Sizes
Kohler Co. recommends using one 12-volt or 24-volt battery (as the spec requires) to start the generator. See
Figure 6-6 for minimum cold cranking amps (CCA) recommendations.
12-Volt Starting Battery Size CCA at --18
°C (0°F) or 100 Amp. Hr.
Models CCA
3.5–20EFOZ and
4--24EOZ
23/27/100/125EFOZ and
28/32/125/150EOZ
33--80EFOZ and
40--99EOZ
500
800
640
Figure 6-6 Battery Recommendations
5
1
4
3
2
TP-5586-6
1. Starter solenoid
2. Battery positive (+) connection
3. Equipment ground
4. Battery negative (--) connection
5. Engine block mount
Figure 6-7 Battery Connections (5EOZ/4EFOZ model shown)
6.6 Wiring
Use only stranded copper wire.
Conform to USCG
Regulations 183.425 through 183.460 for wire gauges and insulation, conductor temperature ratings, sheath stripping, conductor support and protection, conductor terminals and splices, and over-current protection
(circuit breakers, fuses). Use rubber grommets and cable ties as necessary to protect and secure the wire from sharp objects, the exhaust system, and moving parts.
24 Section 6 Electrical System TP-6069 6/03
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. Kohler Co. also offers a wiring harness with a connector keyed to the controller box connector. The other end of this harness has pigtails that the installer can use to connect to a customer-supplied start/stop switch or separate lights and hourmeter. Consult wiring diagrams and instruction sheets for connection information/details.
Note: Gauge senders. Gauge senders are available for most generator sets.
If using customersupplied gauges, be sure they are compatible with generator set senders.
Contact an authorized Kohler r service distributor/dealer.
Gauges and senders are available as service items from an authorized Kohler r service distributor/dealer.
33--150 kW Models: Various wiring harnesses,
Y-connectors, pigtail harnesses, remote control panels, and remote annunciator panels (Decision-Maker t 3+ only) are available. See Figure 6-9 and Figure 6-10 for wiring options.
3.5EFOZ/4EOZ Models: See Figure 7-3 for the optional remote panel wiring.
1
DA-250000-H
1. Controller remote connector
Figure 6-8 Controller Remote Connector, Typical
TP-6069 6/03 Section 6 Electrical System 25
Figure 6-9 Remote Controller and Harness Options (33--150 kW Models)
26 Section 6 Electrical System
ADV--6115A-A
TP-6069 6/03
Figure 6-10 Remote Controller and Harness Options (33--150 kW Models)
TP-6069 6/03 Section 6 Electrical System 27
Notes
28 Section 6 Electrical System TP-6069 6/03
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.
Installation drawings show exhaust outlet locations, fuel inlet and return connections, siphon break locations, and battery connections. See Figure 7-1 for installation drawing identification.
Model No.
3.5EFOZ and 4EOZ with remote options
4EFOZ and 5EOZ with sound shield
6.5EFOZ and 8EOZ with sound shield
8.5/9EFOZ and 10EOZ with sound shield
11EFOZ and 13EOZ with sound shield
11.5/13EFOZ and 14/15.5EOZ
with sound shield
16/17.5EFOZ and 20EOZ with sound shield
19/20EFOZ and 23/24EOZ with sound shield
23/27EFOZ and 28/32EOZ with sound shield
33EFOZ and 40EOZ with fuel/water separator and dry exhaust elbow with sound shield with electric clutch
40EFOZ and 50EOZ with fuel/water separator and dry exhaust elbow with sound shield
ADV-6581B-E
ADV-6581C-E
ADV-6581D-E
ADV-6582A-E
ADV-6582B-E
ADV-6582C-E with electric clutch
55EFOZ and 65EOZ with fuel/water separator and dry exhaust elbow with sound shield with electric clutch
70/80EFOZ and 80/99EOZ
ADV-6582D-E
ADV-6583A-E
ADV-6583B-E
ADV-6583C-E
ADV-6583D-E
ADV-6603A-D with fuel/water separator and dry exhaust elbow with sound shield with electric clutch
ADV-6603B-D
ADV-6603C-D
ADV-6603D-D
100/125EFOZ and 125/150EOZ ADV-6594A-D with sound shield with dry exhaust elbow
ADV-6594B-D
ADV-6594C-D
Drawing
ADV-6652A-B
ADV-6652B-B
ADV-5850A-H
ADV-5850B-H
ADV-6284A-J
ADV-6284B-J
ADV-6026A-K
ADV-6026B-K
ADV-6512A-D
ADV-6512B-D
ADV-6513A-C
ADV-6513B-C
ADV-6481A-D
ADV-6481B-D
ADV-6494A-C
ADV-6494B-C
ADV-6285A-F
ADV-6285B-F
ADV-6581A-E
Figure 7-1 Installation Drawings
38
39
40
41
42
43
44
45
46
47
48
Page
30
31
32
33
34
35
36
37
61
62
63
64
65
66
53
54
55
56
49
50
51
52
57
58
59
60
TP-6069 6/03 Section 7 Installation Drawings 29
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-2 Dimension Drawing, 3.5EFOZ/4EOZ
30 Section 7 Installation Drawings
ADV-6652A-B
TP-6069 6/03
Figure 7-3 Remote Options, 3.5EFOZ/4EOZ
TP-6069 6/03
ADV-6652B-B
Section 7 Installation Drawings 31
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-4 Dimension Drawing, 4EFOZ/5EOZ
32 Section 7 Installation Drawings
ADV-5850A-H
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-5 Dimension Drawing, 4EFOZ/5EOZ with Sound Shield
TP-6069 6/03
ADV-5850B-H
Section 7 Installation Drawings 33
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-6 Dimension Drawing, 6.5EFOZ/8EOZ
34 Section 7 Installation Drawings
ADV-6284A-J
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-7 Dimension Drawing, 6.5EFOZ/8EOZ with Sound Shield
TP-6069 6/03
ADV-6284B-J
Section 7 Installation Drawings 35
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-8 Dimension Drawing, 8.5/9EFOZ and 10EOZ
36 Section 7 Installation Drawings
ADV-6026A-K
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-9 Dimension Drawing, 8.5/9EFOZ and 10EOZ with Sound Shield
TP-6069 6/03
ADV-6026B-K
Section 7 Installation Drawings 37
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-10 Dimension Drawing, 11EFOZ/13EOZ
38 Section 7 Installation Drawings
ADV-6512A-D
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-11 Dimension Drawing, 11EFOZ/13EOZ with Sound Shield
TP-6069 6/03
ADV-6512B-D
Section 7 Installation Drawings 39
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-12 Dimension Drawing, 11.5/13EFOZ and 14/15.5EOZ
40 Section 7 Installation Drawings
ADV-6513A-C
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-13 Dimension Drawing, 11.5/13EFOZ and 14/15.5EOZ with Sound Shield
TP-6069 6/03
ADV-6513B-C
Section 7 Installation Drawings 41
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-14 Dimension Drawing, 16/17.5EFOZ and 20EOZ
42 Section 7 Installation Drawings
ADV-6481A-D
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-15 Dimension Drawing, 16/17.5EFOZ and 20EOZ with Sound Shield
TP-6069 6/03
ADV-6481B-D
Section 7 Installation Drawings 43
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-16 Dimension Drawing, 19/20EFOZ and 23/24EOZ
44 Section 7 Installation Drawings
ADV-6494A-C
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-17 Dimension Drawing, 19/20EFOZ and 23/24EOZ with Sound Shield
TP-6069 6/03
ADV-6494B-C
Section 7 Installation Drawings 45
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-18 Dimension Drawing, 23/27EFOZ and 28/32EOZ
46 Section 7 Installation Drawings
ADV-6285A-F
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-19 Dimension Drawing, 23/27EFOZ and 28/32EOZ with Sound Shield
TP-6069 6/03
ADV-6285B-F
Section 7 Installation Drawings 47
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-20 Dimension Drawing, 33EFOZ/40EOZ
48 Section 7 Installation Drawings
ADV-6581A-E
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-21 Dimension Drawing, 33EFOZ/40EOZ with Fuel/Water Separator and Dry Exhaust Elbow
ADV-6581B-E
TP-6069 6/03 Section 7 Installation Drawings 49
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-22 Dimension Drawing, 33EFOZ/40EOZ with Sound Shield
50 Section 7 Installation Drawings
ADV-6581C-E
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-23 Dimension Drawing, 33EFOZ/40EOZ with Electric Clutch
TP-6069 6/03
ADV-6581D-E
Section 7 Installation Drawings 51
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-24 Dimension Drawing, 40EFOZ/50EOZ
52 Section 7 Installation Drawings
ADV-6582A-E
TP-6069 6/03
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
ADV-6582B-E
Section 7 Installation Drawings 53
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-26 Dimension Drawing, 40EFOZ/50EOZ with Sound Shield
54 Section 7 Installation Drawings
ADV-6582C-E
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-27 Dimension Drawing, 40EFOZ/50EOZ with Electric Clutch
TP-6069 6/03
ADV-6582D-E
Section 7 Installation Drawings 55
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-28 Dimension Drawing, 55EFOZ/65EOZ
56 Section 7 Installation Drawings
ADV-6583A-E
TP-6069 6/03
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
ADV-6583B-E
Section 7 Installation Drawings 57
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-30 Dimension Drawing, 55EFOZ/65EOZ with Sound Shield
58 Section 7 Installation Drawings
ADV-6583C-E
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-31 Dimension Drawing, 55EFOZ/65EOZ with Electric Clutch
TP-6069 6/03
ADV-6583D-E
Section 7 Installation Drawings 59
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-32 Dimension Drawing, 70/80EFOZ and 80/99EOZ
60 Section 7 Installation Drawings
ADV-6603A-D
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
ADV-6603B-D
Figure 7-33 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Fuel/Water Separator and Dry Exhaust Elbow
TP-6069 6/03 Section 7 Installation Drawings 61
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-34 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Sound Shield
62 Section 7 Installation Drawings
ADV-6603C-D
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-35 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Electric Clutch
TP-6069 6/03
ADV-6603D-D
Section 7 Installation Drawings 63
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-36 Dimension Drawing, 100/125EFOZ and 125/150EOZ
64 Section 7 Installation Drawings
ADV-6594A-D
TP-6069 6/03
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-37 Dimension Drawing, 100/125EFOZ and 125/150EOZ with Sound Shield
TP-6069 6/03
ADV-6594B-D
Section 7 Installation Drawings 65
NOTE: Dimensions in [ ] are inch equivalents.
Figure 7-38 Dimension Drawing, 100/125EFOZ and 125/150EOZ with Dry Exhaust Elbow
66 Section 7 Installation Drawings
ADV-6594C-D
TP-6069 6/03
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).
NOTICE
Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.
8.1.1
100--120-Volt Configurations
If the installation requires a factory two-pole circuit breaker, do not connect the load-side terminals of the circuit breaker together; see Figure 8-1.
If the installation requires a 100--120-volt, 2-wire system, use a single-pole circuit breaker. See Figure 8-2. When connecting stator phase leads together, size the output lead (L1) to handle the amperage. Use a jumper lead on the line side of the circuit breaker to balance the load of the generator set.
breaker. Application of two single-pole circuit breakers does not conform to NEC requirements for supplying a
200--240-volt load, even if the breakers are mechanically attached together. Leads L1 and L2 are for different phases; never connect them together.
L0 (Neutral)
Ground
Load
Side
Single-Pole
Circuit
Breaker
Line
Side
L0
GRD.
L1
Load
Side
Line
Side
L0 (Neutral)
Ground
L0
GRD.
L1
L2
Two-Pole
Circuit
Breaker
Jumper lead
4 3 2 1
Figure 8-1 100--120-Volt, 3-Wire Configuration
8.1.2
100--120/200--240-Volt
Configurations
The 100--120/200--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).
Select a two-pole circuit
4 3 2 1
Stator Leads
60 Hz
L0--L1 100--120 Volt
L0--L2 100--120 Volt
50 Hz
100--120 Volt
100--120 Volt
Figure 8-2 100--120-Volt, 2-Wire Configuration
L0 (Neutral)
Ground
L0
GRD.
L2
L1
Load
Side
Line
Side
Factory
Two-Pole
Circuit
Breaker
4 3 2 1
Stator Leads
100--120/200--240-Volt,
3-Wire
60 Hz
L0--L1 100--120 Volt
L0--L2 100--120 Volt
L1--L2 200--240 Volt
50 Hz
100--120 Volt
100--120 Volt
200--240 Volt
Figure 8-3 100--120/200--240-Volt, 3-Wire
Configuration
TP-6069 6/03 Section 8 Reconnection/Adjustments 67
8.1.3
200--240-Volt 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).
L0 (Neutral)
Load
Side
Ground
Line
Side
L0
GRD.
L1
Single-Pole
Circuit
Breaker
Tape to insulate from ground
4 3 2 1
Stator Leads
200--220--240 Volt
2 Wire
L0--L1
60 Hz 50 Hz
200-240 Volt 200--220--240 Volt
Figure 8-4 200--220--240-Volt, 2-Wire Configuration
8.2 Twelve-Lead Reconnection
The reconnection procedure details voltage reconnections only.
If the generator set requires frequency changes, adjust the governor and voltage regulator. See the generator set service manual for information regarding frequency adjustment.
The following information illustrates the reconnection of twelve-lead generator sets. In all cases, conform to the
National Electrical Code (NEC).
Reconnect the stator leads of the generator set to change output phase or voltage. Refer to the following procedure and connection schematics. Follow all safety precautions at the front of this manual and in the text during the reconnection procedure.
NOTICE
Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.
Twelve-Lead Reconnection Procedure
1. Place the generator start/stop switch in the STOP position.
2. Disconnect generator set engine starting battery, negative (--) lead first.
3. Disconnect power to battery charger, if equipped.
4. Use Figure 8-5 to determine the generator set voltage configuration.
Note the original voltage and reconnect the generator set as needed. Route leads through current transformers (CTs) and connect the leads according to the diagram for the desired phase and voltage.
Note: Current Transformers (CTs) are not used on all sets. CT dot or “HI” toward generator.
Figure 8-5 Generator Reconnection
68 Section 8 Reconnection/Adjustments
EM-250000-E
TP-6069 6/03
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 CTs.
5. If the controller has meters, remove the controller cover and reposition the meter scale lamp jumper
(see Figure 8-6) matching the position of the desired voltage (shown in Figure 8-5).
1
Note: Equipment damage. Verify that the voltage ratings of the transfer switch, line circuit breakers, and other accessories match the desired line voltage.
8. Reconnect the starting battery, negative (--) lead last. Place the generator set master switch in the
RUN position to start the generator set. Observe the voltmeter and verify that the unit has the desired line voltage connection.
Adjust the voltage using the voltage adjustment potentiometer on the generator controller front panel. See Figure 8-7.
9. Stop the generator set after completing the voltage adjustment.
10. Disconnect the external voltmeter if used. Replace the controller cover.
HERTZ
0 0 0 0 0
TOTAL HOURS
OIL
PRESS
VOLTAGE
ADJUST
WATER
TEMP
A--C VOLTS
EMERGENCY
STOP
ONLY
S
BATTERY
A--C AMPERES
UPPER METER SCALES
1
OFF
3
L0--L1
L2
L1--L2
L1
L1--L2
L1
L1--L2
AMPS
VOLTS
L2
L2--L3
LOWER METER SCALES
PREALARM
TEMPERATURE
PREALARM
LOW OIL
PRESSURE
LOW WATER
TEMPERATURE
LOW FUEL
HIGH ENGINE
TEMPERATURE
AUXILIARY
FAULT
AUXILIARY
PREALARM
EMERGENCY
STOP
OVERSPEED
RUN OFF/RESET
LOW BATTERY
VOLTAGE
OVERCRANK
AUTO
SYSTEM
READY
SWITCH
NOT IN AUTO
SILENCE NORMAL
ALARM
LAMP TEST
TP-5353-6
1. Lamp Jumper
Figure 8-6 Meter Scale Lamp Jumper
6. The overvoltage shutdown is standard on
Decision-Maker t 3+ controllers.
The
139/240-volt (low wye) and 277/480-volt (high wye), 3-phase, 4-wire, 60 Hz configurations use different overvoltage shutdown settings than all other configurations. Recalibrate the overvoltage shutdown if the reconnection changes the voltage to or from one of these configurations.
See
Section 8.3, Decision-Maker 3+ Controller,
Overvoltage Shutdown Adjustment.
Do not recalibrate the overvoltage adjustment for other voltage changes.
7. If the controller has meters, set the phase selector switch to the L1-L2 position (1-phase or 3-phase configuration depending on generator set connection). Connect a voltmeter across leads L1 and L2 if the controller has no meters.
ADV-5849A-
1
1. Output voltage adjustment potentiometer
Figure 8-7 Voltage Adjustment
This is bpid
8.3 Decision-Maker 3+ Controller,
Overvoltage Shutdown
Adjustment
Disconnecting the electrical load. Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads. High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker.
The safeguard circuit breaker does not disconnect the generator set from the load.
TP-6069 6/03 Section 8 Reconnection/Adjustments 69
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. Remove all jewelry before servicing the equipment.
Overvoltage Shutdown Adjustment Procedure
1. Disconnect the generator set engine starting battery, negative (--) lead first. Disconnect power to the battery charger (if equipped).
2. With the generator set shut down, open the output line circuit breaker to disconnect the load from the generator set.
3. Remove the controller cover.
4. Wrap the shaft of an insulated-handle screwdriver with electrical tape to insulate the metal shaft. Turn the overvoltage potentiometer (R41) on the main circuit board fully clockwise. See Figure 8-8.
5. Connect a digital AC voltmeter (or other 1% minimum accuracy voltmeter) to terminals V0 and
V7 on the controller terminal block.
See
Figure 8-6.
6. Reconnect the battery, negative (--) lead last.
7. Start the generator set by placing the generator set master switch in the RUN position.
8. Adjust the output voltage to 115% of the nominal output voltage using the voltage adjustment potentiometer.
If the voltage configuration is
139/240 volts (low wye) or 277/480 volts (high wye), 3-phase, 4-wire, 60 Hz, adjust output voltage to 160 volts across terminals V0 and V7. For all other voltages, adjust the output to 140 volts across terminals V0 and V7.
Adjust the voltage using the voltage adjustment potentiometer on the generator controller front panel. See Figure 8-7.
9. Use the insulated screwdriver to slowly rotate the overvoltage adjustment potentiometer (R41) counterclockwise until red LED4 lights.
See
Figure 8-8. The generator set should shut down on an overvoltage fault in approximately 2 seconds.
R41
LED4
1
2
P2
P1
A-336415-A
1. Overvoltage adjustment potentiometer (R41)
2. LED4 (red)
Figure 8-8 Overvoltage Shutdown Adjustment on
Main Circuit Board
10. Turn the voltage adjustment potentiometer counterclockwise to prevent overvoltage shutdown upon restart. Restart the generator set. Slowly increase the voltage by turning the voltage adjustment potentiometer clockwise.
Verify the shutdown voltage point (115% of the nominal output voltage) by observing the voltmeter and noting when LED4 lights. The generator set should shut down on overvoltage fault in approximately
2 seconds. If the shutdown voltage point is not
115% of nominal voltage, repeat the calibration output procedure; otherwise, continue to step 11.
11. Turn the voltage adjustment potentiometer counterclockwise to prevent overvoltage shutdown upon restart. Restart the generator set. Readjust the generator set output to the nominal voltage using the voltage adjustment potentiometer.
12. Stop the generator set by placing the generator set master switch in the OFF/RESET position. Seal the overvoltage adjustment potentiometer (R41) with RTV sealant or equivalent.
Replace the controller cover.
70 Section 8 Reconnection/Adjustments TP-6069 6/03
Electroswitch
L1
To Generator
Set
L2
2
6
2-Wire Generator Sets
1 3
5 7
L1
4
To Shore
Power
8
L2
To Generator
Set
L0
To Load
6
10
2
3-Wire Generator Sets
1 3 4
5 7
9 11
8
To Shore
Power
12
To Load
Kraus Naimler/American Solenoid
(Early Rectangular Design)
L1
To Generator
Set
L2
1
3
2-Wire Generator Sets
2 6
4 8
L1
5
To Shore
Power
7
L2
To Generator
Set
L0
To Load
1
3-Wire Generator Sets
2 6 5
3
9
4
10
8
14
7
To Shore
Power
13
To Load
Kraus Naimler/American Solenoid
(Newer Round Design)
L1
To Generator
Set
L2
3
7
2-Wire Generator Sets
2 4
6 8
L1
1
To Shore
Power
5
L2
To Generator
Set
L0
To Load
7
11
3
3-Wire Generator Sets
2 4 1
6 8
10 12
To Load
5
To Shore
Power
9
TP-5399-5
Figure 8-9 Marine Manual (Ship-to-Shore) Transfer Switch
TP-6069 6/03 Section 8 Reconnection/Adjustments 71
Kraus Naimler/American Solenoid
4-Wire, 3-Phase Generator Sets
L1
L2
To Generator
Set
7
L3
11
L0
3
15
2
6
10
14
4
8
12
16
1
5
9
13
L1
L2
To Shore
Power
L3
L0
Note: Broadrange generator sets.
The following adjustment procedure is for readjustment of the voltage regulator and governor for broadrange generator sets with mechanical governors.
Note: Special tool. Frequency meter 50/60 Hz.
Note: Rheostat connection.
Connect a customer-provided rheostat across regulator leads/terminals 33 and 66 to adjust the generator output voltage from a location remote from the generator set. The rheostat (10 kOhms, 1/2 watt minimum) provides a 5-volt adjustment range.
L1 L2 L3 L0
To Load
I-940
Figure 8-10 Marine Manual (Ship-to-Shore) Transfer
Switch, continued
8.4 Voltage Regulator Adjustment
(4--27EFOZ and 5--32EOZ
Models)
WARNING
1
2
3
1. Voltage adjustment potentiometer
2. Stability adjustment potentiometer
3. Volts/Hz adjustment potentiometer
TT-875-11
Figure 8-11 PowerBoost
IIIE Voltage Regulator
Hazardous voltage.
Moving rotor.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Testing the voltage regulator. Hazardous voltage can cause severe injury or death. High voltage is present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator.
(PowerBoost t, PowerBoostt III, and PowerBoostt V voltage regulator models only)
The voltage regulator is typically located in the controller. Adjustments are possible without removing the voltage regulator. The voltage regulator adjustment procedure applies to both the PowerBoost
IIIE
(Figure 8-11) and PowerBoost
V (Figure 8-12) voltage regulators.
2
STAB
V/HZ VOLTS
3
1
6
5
4
3
2
1
8
7
1. Voltage adjustment potentiometer
2. Stability adjustment potentiometer
3. Volts/Hz adjustment potentiometer
Figure 8-12 PowerBoost
V Voltage Regulator
TT-875-11
72 Section 8 Reconnection/Adjustments TP-6069 6/03
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 130 volts.
Volts/Hz Pot determines the engine speed (Hz) at which the generator output voltage begins to drop.
Note: The volts/Hz adjustment does not apply to the following models:
Model
4/6.5/8/8.5/9EFOZ
5/8/9/10EOZ
Note: On these models, turn the volts/Hz adjustment pot full counterclockwise to stop and seal. No further volts/Hz adjustments are required.
Note: For optimum results, apply full load for voltage regulator adjustment.
Voltage Regulator Adjustment Procedure
1. With the generator set off, turn the remote rheostat, if equipped, to the midpoint.
2. Turn the voltage, volts/Hz, and stability pots fully counterclockwise.
3. Connect the voltmeter and frequency meter to the
AC circuit or an electrical outlet.
4. Start the generator set.
5. Rotate the voltage adjustment pot clockwise to increase the voltage (counterclockwise to decrease voltage) to achieve the desired output voltage.
6. Rotate the stability pot clockwise to minimize light flicker.
7. Readjust the voltage adjustment pot if necessary.
8. Adjust the engine speed to the desired cut-in frequency (factory setting 57.5–58 Hz for 60 Hz models or 47.5–48 Hz for 50 Hz models) as measured on frequency meter. To change engine speed adjust the governor arm.
Loosen the locknut and turn it clockwise or counterclockwise to achieve the desired frequency.
See
Figure 8-13. If a second screw holds the governor arm, loosen the locknut and back out the screw.
9. If applicable, rotate the volts/Hz adjustment pot clockwise until the voltage level begins to drop (as measured on the voltmeter). When set to these specifications, the generator attempts to maintain normal output until the engine speed drops below the frequency set in step 8 as load is applied.
10. Readjust the engine speed to normal (63 Hz/
1890 rpm for 60 Hz or 52.5 Hz/1575 rpm for
50 Hz). Tighten the locknut when the adjustments are complete. Turn the second screw, if used, to lock the governor arm in place and tighten the locknut.
11. Readjust the voltage adjustment pot if necessary.
12. Readjust the stability pot if necessary.
13. Use the remote rheostat, if equipped, to make final voltage adjustments.
14. Stop the generator set.
1. Locknut
2. Speed adjusting screw
1 2
Figure 8-13 Governor Adjustment (4EFOZ/5EOZ shown)
1-929
TP-6069 6/03 Section 8 Reconnection/Adjustments 73
Notes
74 Section 8 Reconnection/Adjustments TP-6069 6/03
Appendix A Generator Selection and Wattage 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.
Motors
When figuring generator set capacity requirements for loads that include electric motors, consider the high current demanded by the motors during startup. The inrush or starting current is typically 2--3 times higher than that required when the motor reaches normal operating speed. Allow reserve for inrush demands plus other loads which could be on the line as the electric motor starts. Use Figure 1 as a guide when selecting generator set capacity requirements involving motor loads.
Motor
HP
1/4
1/3
1/2
3/4
1
2
3
Starting (Inrush)
Watts
750
1000
1500
2000
3300
4000
5000
Figure 1 Motor Requirements
Running
Watts
330
400
600
750
1100
2000
3000
Lighting
To calculate lighting load, add the wattage of each generator set-operated lamp. Note that not all of the lights or lamps are on the generator set AC circuit; some are DC powered by a 12-volt battery. Make sure the calculated total wattage includes only lights actually on the generator set AC circuit.
Air Conditioners
The starting characteristics of air conditioners vary greatly; one 12,000 Btu unit has, for example, lower starting requirements than a 10,000 Btu unit of another variety. When using only one unit, there is usually no starting problem, provided the lighting and appliance load is not too high when starting the unit.
Simultaneous starting of two air conditioning units, however, can present problems if the generator set capacity is marginal. Because of the variation in starting characteristics among air conditioners, this publication makes no statements regarding multiple-motor starting capabilities of the generator set covered. Consider delayed starting or use of easy-starting devices on air conditioner units whenever simultaneously starting more than one motor.
See Figure 2 for typical air conditioner requirements.
Information will vary with manufacturer.
Appliances
Generator sets often furnish AC for appliances such as
TV, stereo, electric water heater, etc. With the exception of the resistance-type loads such as the water heater, requirements for appliances are usually low. Do not overlook such loads when figuring total requirements.
Allow reserve capacity for anticipated appliance loads to avoid overloading a generator set.
Voltage
Full load amps
Rated load amps
Locked rotor amps
Starting (inrush) watts
Running watts
Air Conditioner Size (Btu/Hr.)
7,000
115 230
9.3
7.7
34.0
3910
886
4.8
4.0
20.0
4600
920
9,000
115
9.9
7.0
40.0
4600
805
230
5.0
3.5
20.0
4600
805
12,000
115 230
11.8
8.9
50.0
5750
1020
6.3
4.8
31.0
7130
1100
Figure 2 Typical Marine Air Conditioner Requirements, 60 Hz
16,000
115 230
16.3
13.0
75.0
8630
1500
8.0
6.2
36.0
8280
1430
24,000
230
11.6
10.2
56.0
12,900
2350
TP-6069 6/03 Appendix A-1
Appendix B Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere
ABDC after bottom dead center
AC
A/D alternating current analog to digital
ADC adj.
ADV
AHWT analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature
AISI
ALOP alt.
Al
ANSI
AO
API approx.
approximate, approximately
AR
AS as required, as requested as supplied, as stated, as suggested
ASE
ASME assy.
ASTM
American Society of Engineers
American Society of
Mechanical Engineers assembly
ATDC
ATS auto.
aux.
American Iron and Steel
Institute anticipatory low oil pressure alternator aluminum
American National Standards
Institute
(formerly American Standards
Association, ASA) anticipatory only
American Petroleum Institute
American Society for Testing
Materials after top dead center automatic transfer switch automatic auxiliary
A/V avg.
AVR
AWG
AWM bat.
BBDC
BC audiovisual average automatic voltage regulator
American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging
BCA
BCI
BDC
BHP battery charging alternator
Battery Council International before dead center brake horsepower blk.
black (paint color), block
(engine) blk. htr.
block heater
CARB
CB cc
CCA ccw.
CEC cfh cfm
BMEP bps br.
BTDC brake mean effective pressure bits per second brass before top dead center
Btu British thermal unit
Btu/min.
British thermal units per minute
C cal.
Celsius, centigrade calorie
California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise
Canadian Electrical Code cubic feet per hour cubic feet per minute
CT
Cu cu. in.
cw.
CWC cyl.
D/A
DAC dB dBA
DC
DCR deg.,
° dept.
dia.
DI/EO
DIN
CG
CID
CL cm
CMOS cogen.
Com conn.
cont.
CPVC crit.
CRT
CSA center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogeneration communications (port) connection continued chlorinated polyvinyl chloride critical cathode ray tube
Canadian Standards
Association current transformer copper cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter decibel decibel (A weighted) direct current direct current resistance degree department diameter dual inlet/end outlet
Deutsches Institut fur Normung e. V.
(also Deutsche Industrie
Normenausschuss)
DIP
DPDT
DPST
DS dual inline package double-pole, double-throw double-pole, single-throw disconnect switch
DVR digital voltage regulator
E, emer.
emergency (power source)
EDI
EFR electronic data interchange emergency frequency relay e.g.
EG
EGSA
EIA for example (exempli gratia) electronic governor
Electrical Generating Systems
Association
Electronic Industries
Association
EI/EO
EMI emiss.
eng.
EPA
EPS
ER
ES end inlet/end outlet electromagnetic interference emission engine
Environmental Protection
Agency emergency power system emergency relay engineering special, engineered special
ESD est.
electrostatic discharge estimated
E-Stop emergency stop etc.
et cetera (and so forth) exh.
ext.
F exhaust external
Fahrenheit, female
A-2 Appendix fglass.
FHM fl. oz.
flex.
freq.
FS ft.
ft. lbs.
fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) ft./min.
feet per minute g gram ga.
gal.
gauge (meters, wire size) gallon gen.
genset
GFI generator generator set ground fault interrupter
HD
HET hex
Hg
HH
HHC
HP hr.
HS hsg.
HVAC
GND, gov.
gph gpm gr.
GRD ground governor gallons per hour gallons per minute grade, gross equipment ground gr. wt.
gross weight
H x W x D height by width by depth
HC
HCHT hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning
J
JIS k
K kA
KB
HWT
Hz
IC
ID
IEC
IEEE
IMS in.
improved motor starting inch in. H
2 in. Hg
O inches of water inches of mercury in. lbs.
inch pounds
Inc.
ind.
incorporated industrial int.
internal int./ext.
internal/external
I/O
IP
ISO high water temperature hertz (cycles per second) integrated circuit inside diameter, identification
International Electrotechnical
Commission
Institute of Electrical and
Electronics Engineers input/output iron pipe
International Organization for
Standardization joule
Japanese Industry Standard kilo (1000) kelvin kiloampere kilobyte (2
10 bytes)
TP-6069 6/03
kg kg/cm
2 kilogram kilograms per square centimeter kgm kg/m
3 kHz kJ kilogram-meter kilograms per cubic meter kilohertz kilojoule km kilometer kOhm, k
Ω kilo-ohm kPa kilopascal kph kilometers per hour kV kVA kVAR kW kWh kWm
L
LAN kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical liter local area network
L x W x H length by width by height lb.
lbm/ft
3 pound, pounds pounds mass per cubic feet
LCB
LCD line circuit breaker liquid crystal display ld. shd.
load shed
LED light emitting diode
Lph
Lpm
LOP
LP liters per hour liters per minute low oil pressure liquefied petroleum
LPG
LS liquefied petroleum gas left side
L wa
LWL
LWT
MB
MCM sound power level, A weighted low water level man.
max.
low water temperature m
M meter, milli (1/1000) mega (10
6 when used with SI m
3 m
3 units), male cubic meter
/min.
cubic meters per minute mA milliampere manual maximum megabyte (2
20 bytes) one thousand circular mils
MOV
MPa mpg mph
MS m/sec.
MTBF
MTBO mtg.
MCCB molded-case circuit breaker meggar megohmmeter
MHz mi.
megahertz mile mil min.
misc.
MJ one one-thousandth of an inch minimum, minute miscellaneous megajoule mJ millijoule mm millimeter mOhm, m
Ω milliohm
MOhm, M
Ω megohm metal oxide varistor megapascal miles per gallon miles per hour military standard meters per second mean time between failure mean time between overhauls mounting
MW megawatt mW
µF milliwatt microfarad
N, norm.
normal (power source)
NA not available, not applicable nat. gas natural gas
NBS
NC
National Bureau of Standards normally closed
NEC
NEMA
National Electrical Code
National Electrical
Manufacturers Association
NFPA National Fire Protection
Association newton meter Nm
NO normally open no., nos.
number, numbers
NPS
NPSC
NPT
National Pipe, Straight
National Pipe, Straight-coupling
National Standard taper pipe thread per general use
NPTF
NR ns
OC
OD
OEM
OF opt.
OS
OSHA
National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option, optional oversize, overspeed
Occupational Safety and Health
Administration
OV oz.
p., pp.
PC
PCB pF overvoltage ounce page, pages personal computer printed circuit board picofarad psi pt.
PTC
PTO
PVC qt.
qty.
R rad.
RAM
RDO ref.
rem.
RFI
RH
RHM rly.
PF ph., power factor
∅ phase
PHC
PHH
Phillips head crimptite (screw)
Phillips hex head (screw)
PHM
PLC
PMG pot ppm
PROM pan head machine (screw) programmable logic control permanent-magnet generator potentiometer, potential parts per million programmable read-only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement (emergency) power source radiator, radius random access memory relay driver output reference remote radio frequency interference round head round head machine (screw) relay
VAC
VAR
VDC
VFD
VGA
VHF
W
WCR w/ w/o wt.
xfmr rms rnd.
ROM rot.
rpm
RS
RTV
SAE scfm
SCR s, sec.
SI root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization
Society of Automotive
Engineers standard cubic feet per minute silicon controlled rectifier second
Systeme international d’unites,
International System of Units
UF
UHF
UL
UNC
UNF univ.
US
UV
V
TDOE
TDON temp.
term.
TIF
TIR tol.
turbo.
typ.
SI/EO sil.
SN
SPDT side in/end out silencer serial number single--pole, double--throw
SPST single--pole, single--throw spec, specs specification(s) sq.
sq. cm sq. in.
SS std.
stl.
tach.
TD
TDC
TDEC
TDEN
TDES
TDNE square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency
Underwriter’s Laboratories, Inc.
unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer
TP-6069 6/03 Appendix A-3
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 calculations.
set installation.
Figure 1 outlines the
Figure 2 contains examples of how heat variables affect generator set ratings.
Generator Output corrected
= Generator Output observed x Correction Factor
Output power is expected to be within
±5% of the specified rating when corrected to reference conditions.
Correction factors are determined using the following formulas:
1.
For naturally aspirated compression-ignition engines (power limited by excess air):
C.F. = [1.175 (29.2 / Dry Barometer in. Hg)
1
(Temperature
_F + 460/537)
.75
-- .175] x Alternator Efficiency
Reference
/ Alternator Efficiency
Observed
2.
For turbocharged compression ignition engines:
C.F. = [1.175 (29.2 / Barometer x Alternator Efficiency
Reference
Observed in. Hg)
.7
(Temperature
_F + 460/537)
2
-- .175]
/ Alternator Efficiency
Observed
3.
For turbocharged and intercooled compression ignition engines:
C.F. = [1.175 (29.2 / Barometer x Alternator Efficiency
Reference
Observed in. Hg)
.7
(Temperature
_F + 460/537)
1.2
-- .175]
/ Alternator Efficiency
Observed
Reference conditions:
Temperature: 77
_F; Pressure: 29.2 in. Hg dry barometer.
Kohler sound shield increases ambient intake air approx. 12
_F
Approximate derates:
Temperature: approximately 1% per 10
_F (turbocharged engines have a greater derate);
Pressure (altitude): approximately 4% per 1000 ft. (1 in. Hg)
Figure 1 Generator Output
KEY
60 Hz
50 Hz
8.0
7.9
7.8
7.7
7.6
7.5
7.4
7.3
7.2
7.1
7.0
6.9
6.8
6.7
6.6
6.5
6.4
6.3
6.2
6.1
6.0
5.9
5.8
5.7
5.6
5.5
75
77
80 85 90 95 100
Temperature (
_F)
105
Figure 2 Example: 6.5EFOZ/8EOZ kW Derates (ISO 3046/ISO 8258-1)
110 115 120
A-4 Appendix TP-6069 6/03
TP-6069 6/03d
E 2000, 2001, 2002, and 2003 by Kohler Co. All rights reserved.
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.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65)264-6422, Fax (65)264-6455

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Key features
- Location and mounting
- Cooling system
- Exhaust system
- Fuel system
- Electrical system
- Installation drawings
- Reconnection
- Adjustments
- Generator selection
- Wattage requirements