Kohler 3.5EFOZ-4EOZ, 6.5EFOZ-8EOZ, 125EFOZ-150EOZ, 19EFOZ-23EOZ, 20EFOZ-24EOZ User Manual

...

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 I........................................................

Section 1 Introduction 1.....................................................................

Section 2 Location and Mounting 3..........................................................

2.1 General Considerations 3................................................

2.2 Location 3.............................................................

2.3 Mounting 3.............................................................

Section 3 Cooling System 5.................................................................

3.1 Ventilation 5............................................................

3.2 Cooling System Components 5...........................................

3.2.1 Intake Through-Hull Strainer (Seacock Cover) 5.....................

3.2.2 Seacock 6.....................................................

3.2.3 Seawater Strainer 6.............................................

3.2.4 Water Lines 6..................................................

3.2.5 Closed Heat Exchanger (4--125EFOZ/5--150EOZ Models) 6..........

3.2.6 Direct Water Cooled (3.5EFOZ/4EOZ Models) 6.....................

Section 4 Exhaust System 11.................................................................

4.1 Types 11...............................................................

4.2 Exhaust Lines 11........................................................

4.3 Exhaust System Location, Mounting, and Installation 12.......................

4.3.1 Above-Waterline Installation 12....................................

4.3.2 Mid/Below-Waterline Installation 14.................................

Section 5 Fuel System 17.....................................................................

5.1 Fuel Tank 17............................................................

5.2 Fuel Lines 18............................................................

5.3 Fuel Filters 18...........................................................

5.4 Fuel Pump Lift 18........................................................

5.5 Fuel Consumption 18.....................................................

Section 6 Electrical System 19................................................................

6.1 AC Voltage Connections 19...............................................

6.2 Circuit Protection 19......................................................

6.2.1 Circuit Breaker Considerations 19..................................

6.2.2 Circuit Breaker Installation (4--27EFOZ and 5--32EOZ Models) 21......

6.2.3 Circuit Breaker Installation (33--125EFOZ and 40--150EOZ Models) 22..

6.3 Installation In Steel or Aluminum Vessels 23.................................

6.4 Installation Recommendations 23..........................................

6.5 Battery 24...............................................................

6.6 Wiring 24...............................................................

6.7 Remote Start Switch Connection 25........................................

Section 7 Installation Drawings 29............................................................

Section 8 Reconnection/Adjustments 67.......................................................

8.1 Four-Lead Reconnection 67...............................................

8.1.1 100--120-Volt Configurations 67....................................

8.1.2 100--120/200--240-Volt Configurations 67............................

8.1.3 200--240-Volt Configurations 68....................................

8.2 Twelve-Lead Reconnection 68.............................................

8.3 Decision-Maker 3+ Controller Overvoltage Shutdown Adjustment 69............

8.4 Voltage Regulator Adjustment (4--27EFOZ and 5--32EOZ Models) 72...........

Appendix A Generator Selection and Wattage Requirements A-1................................

Appendix B Abbreviations 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,orsubstantial 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 startingof the generator set by an automatic transfer switch, remote start/stop switch, orengine startcommand 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 acidcan 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 inthe case of eye contact. Never add acid to a battery after placing the battery in service, asthis mayresult inhazardous spattering of battery acid.

TP-6069 6/03 ISafety Precautions and Instructions

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a containerwith4L(1gal.)ofwaterand 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.

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.

Exhaust System

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

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 alljewelry beforeservicing 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.

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.

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 improvewithin minutesof 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.

TP-6069 6/03II Safety Precautions and Instructions

Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the

safety of the craft’s occupants, install a carbon monoxidedetector. 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 thegenerator set. Carbon monoxide cancause severenausea, fainting, or death. Carbon monoxide

is an odorless, colorless, tasteless, nonirritating gasthat cancause death if inhaled for even a short time. Use the following precautions when installing and operating the generator set. Do not install the exhaustoutlet 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 inawell-ventilatedareaawayfrom 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 notoperate 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 acontainer tocatch 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 pipesealant onall threadedfittings 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 engineroom 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 IIISafety Precautions and Instructions

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

Moving rotor.

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 theequipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to complywith applicablecodes 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 alljewelry beforeservicing the equipment.

Testing the voltage regulator. Hazardous voltage can cause severe injury or death. High voltage

is present at the voltage regulator heat sink. Toprevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator.

(PowerBoostt, PowerBoostt III, and PowerBoostt 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.

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 followthe 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, approvedelectrically 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 setand allowit 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 capwith a thick cloth and then slowly turn the cap counterclockwiseto the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check thecoolant levelat thetank ifthe generator set has a coolant recovery tank.

TP-6069 6/03IV Safety Precautions and Instructions

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.

The engine and exhaust system components become extremely hot during operation.

Moving Parts

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

WARNING

Rotating parts. Can cause severe injury or death.

Operate the generator set only when all guards, screens, and coversare in place.

WARNING

Airborne particles. Can cause severe injury or blindness.

Wear protective goggles andclothing when using power tools, hand tools, or compressed air.

Moving rotor.

Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause

the hardware or pulley to release from the generator setengine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do notloosen thecrankshaft 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 especiallycareful 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 fromits 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 VSafety Precautions and Instructions

Notes

TP-6069 6/03VI Safety Precautions and Instructions

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

KOHLER

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.

1. Exhaust mixer elbow (exhaust/water outlet) (not shown)

2. Heat exchanger (not shown)

3. Coolant recovery tank (locatedon 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

585711

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.

TP-6069 6/03 1Section 1 Introduction

Note: Use two hose clamps on each end of all flexible

exhaust hose connections.

Notes

TP-6069 6/032 Section 1 Introduction

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.

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.

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.

TP-6069 6/03 3Section 2 Location and Mounting

Notes

TP-6069 6/034 Section 2 Location and Mounting

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.

Section 3 Cooling System

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 H2O (1.96 kPa or less)

4--125EFOZ/5--150EOZ 635 mm H2O (6.23 kPa or less)

Figure 3-1 Combustion Air Intake Restriction

1. Inside packing

2. Outside packing

3. Seacock cover

4. Direction of vessel movement

5. Typical intake through-hull strainers

1-789

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.

3.2 Cooling System Components

The marine generator set’s cooling system requires the following components.

4 3

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 5Section 3 Cooling System

Note: Position the intakes in relation to the vessel’s

travel so neither is in the wake of the other.

1. Generator set intake

2. Main engine intake

3. Aft (rearward)

4. Fore (forward)

Figure 3-3 Intake Strainer

1-789

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.

3.2.4 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.

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 inletpressure at the seawater pump is 34.5 kPa (5 psi). Excessive pressure will cause water ingestion.

1. Seawater pump inlet

TP-5586-6

Figure 3-5 Seawater Inlet Connection, Typical

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)

1. Seawater pump

2. Seawater strainer

3. Seacock

Figure 3-4 Seawater Strainer

1-789

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 6/036 Section 3 Cooling System

Arrow Description Direction of Flow

Seawater

Freshwater (Coolant/Antifreeze)

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 7Section 3 Cooling System

TP-5586-6

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

Seawater

Freshwater (Coolant/Antifreeze)

TP-5592-6

Figure 3-7 Typical Closed/Heat Exchanger Cooling System (11--20EFOZ,13--24EOZ, 33--125EFOZ and

40--150EOZ Models)

TP-6069 6/038 Section 3 Cooling System

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-6069 6/03 9Section 3 Cooling System

TP-6134-

Notes

TP-6069 6/0310 Section 3 Cooling System

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, ordeath. 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

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 thegenerator set. Carbon monoxidecan 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 airconditioners. If the generator set exhaust discharge outlet is near the waterline, watercould enter the exhaust discharge outlet and closeor restrictthe flow of exhaust. Never operate the generator set without a functioning carbonmonoxide 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

Kohlerr 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 11Section 4 Exhaust System

4.3 Exhaust System Location,

Mounting, and Installation

Mount the silencer independently to eliminate stress on the exhaust system and the exhaust manifold/mixer elbow. See Section 7 for the mixer elbow water line hose size. 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.

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.

Allowable Exhaust

Back Pressure,

kPa (mm H2O)

Model

≤

1. Water/exhaust outlet

Figure 4-1 Mixer Elbow/Exhaust Connection,

Typical

1. Water/exhaust outlet

Figure 4-2 Mixer Elbow/Exhaust Connection,

3.5EFOZ/4EOZ Model Only

TP-5586-6

TP-6134-

4/8.5/9/23/27EFOZ and 5/10/28/32EOZ

6.5EFOZ and 8EOZ 11.77 (1200)

11/16/17.5EFOZ and 13/20EOZ 6.37 (650)

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

9.81 (1000)

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.

TP-6069 6/0312 Section 4 Exhaust System

Waterline

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

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-5856-4

Figure 4-4 Typical Above-Waterline Installation

TP-6069 6/03 13Section 4 Exhaust System

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: Toprevent water leakage on the generator set, do

not mount the siphon break directly over the generator set.

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 morethan 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.

TP-6069 6/0314 Section 4 Exhaust System

Waterline

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 thecoolant recovery tank isat the same heightas the heat exchanger

12. Seawater strainer

13. Seacock

14. Intake strainer

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 betweensilencer andexhaust 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.

TP-5856-4

Figure 4-6 Typical Mid and Below Waterline Installation

Exhaust Hose

Diameter

Models without Sound Shield Models with 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

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

mm (in.)

51 (2.0)

76 (3.0)

89 (3.5)

102 (4.0)

Figure 4-7 Exhaust Hose Sizes

TP-6069 6/03 15Section 4 Exhaust System

Notes

TP-6069 6/0316 Section 4 Exhaust System

Section 5 Fuel System

WARNING

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 orthe propulsion engine fuel system. Equip the craft with a tank that allows one of the two pickup arrangements describedin theinstallation 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 fromthe 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 17Section 5 Fuel System

5.2 Fuel Lines

5.3 Fuel Filters

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.

Fuel Line

ID Size

Model

mm (in.)

Conform to USCG Regulations regarding inline fuel filters or strainers.

5.4 Fuel Pump Lift

See Figure 5-3 for fuel pump lift capabilities.

Fuel

Pump

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

Lift

m (ft.)

1.2 (4)

0.9 (3)

Figure 5-3 Fuel Pump Lift

5.5 Fuel Consumption

Consult the current generator set specification sheets for generator set fuel consumption rates.

3.5EFOZ and 4EOZ 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.

TP-6069 6/0318 Section 5 Fuel System

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