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

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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 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

Section 6 Electrical System

WARNING

Hazardous voltage. Can cause severe injury or death.

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

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.

Moving rotor.

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 faultin 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

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 19Section 6 Electrical System

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.

Amps

250

35250

250

240

25600

22 250 2 4EFOZ, 5EOZ

25 250 2 5EOZ

33 250 2 8EOZ

55 250 1 5EOZ

85 250 1 9EFOZ, 10EOZ

100

150 600 2

175 600 2 32EOZ—1 phase

Max.

Voltage

250 1 4EFOZ

600 3 8.5/11.5EFOZ, 14EOZ

600 3

250 1 5EOZ

600 3

250 2 9EFOZ, 10EOZ

480 3

250 1 6.5EFOZ

600 3

250 1 6.5EFOZ, 8EOZ

600 3 20/24EOZ—3 phase

240

250 1 8EOZ

480 3 23EFOZ—3 phase

240

480 3 27EFOZ—3 phase

240 2 23EOZ

480 3

Number of Poles

1 6.5EFOZ

2 6.5EFOZ

1 4EFOZ

2 8EOZ

1 9EFOZ

2 9EFOZ, 8/10EOZ

1 11/13EFOZ

2 11/11.5/17.5EFOZ

1 13EFOZ

2 11/13EFOZ, 13/14EOZ

20/24/28/32EOZ—3 phase

1 16EFOZ

2 13/20EFOZ, 15.5EOZ

1 16/19EFOZ

16EFOZ, 20EOZ—1 phase,

1 19EFOZ

1 phase, 27EFOZ—3 phase

Model(s)

11.5/17.5/20EFOZ,

14/20/24EOZ—3 phase

11. 5 EFOZ,

14/20/24EOZ—3 phase

20/23/27EFOZ,

20/28/32EOZ—3 phase

17.5/20EFOZ,

20/24EOZ—3 phase

19EFOZ—1 phase

20/23EOZ

23/27EFOZ,

28/32EOZ—3 phase

23/27EFOZ, 28EOZ—

23/27EFOZ,

28/32EOZ—3 phase

28/32EOZ—1 phase,

32EOZ— 3 phase

Figure 6-2 AC Circuit Breaker Ratings (4--27EFOZ

and 5--32EOZ Models), Listed By Amps

Amps

100--125 600 3 IEC

100--125 600 3 IEC 70EFOZ, 80EOZ

128--160 600 3 IEC

160--400 600 3 UL

160--400 600 3 IEC

200--250 600 3 IEC

240--600 600 3 UL

250--630 600 3 IEC

Max.

Voltage

60 600 3 UL/IEC 33EFOZ, 40EOZ

70 600 3 UL/IEC 40EFOZ, 40EOZ

80 480 3 UL/IEC 40EFOZ, 50EOZ

100 480 3 UL/IEC 55EFOZ, 50/65EOZ

125 600 3 UL

125 600 3 UL 70EFOZ, 80EOZ

150 600 3 UL

200 600 3 UL

250 600 3 UL 55EFOZ, 65EOZ

250 600 3 UL

Number of Poles

Typ e Model(s)

33/55EFOZ,

40/65EOZ

33/55EFOZ,

40/65EOZ

33/40EFOZ,

40/50EOZ

70/80EFOZ,

80/99EOZ

33/40EFOZ,

40/50EOZ

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

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.

TP-6069 6/0320 Section 6 Electrical System

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

generator set or equipment connected to the set, disable the generator set asfollows: (1) Place thegenerator setstart/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

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.

Hazardous voltage. Can cause severe injury or death.

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

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 tocomply withapplicable codesand 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

Moving rotor.

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.

Note: Kohlerr 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.

TP-6069 6/03 21Section 6 Electrical System

10. Connect the side of the circuit breaker marked LOAD to the ship-to-shore switch or craft wiring. Attach insulation boots to the black leads if the kit includes insulation boots. With a single-pole circuit breaker use one black lead (L1). 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.

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.

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.

9. Check that the generator set master switch is in the OFF position. Reconnect the generator set engine starting battery, negative (--) lead last.

TP-6069 6/0322 Section 6 Electrical System

12 3 4 56

1. Existing mounting hardware

2. Load lead access panel

3. Screw

4. Hang tag

5. Circuit breaker

ASSEMBLY VIEW C-C

ASSEMBLY VIEW A 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

156

DX-250000-B

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.

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

TP-6069 6/03 23Section 6 Electrical System

6.5 Battery

Distancebetween

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 theengine’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.

Cable Size (AWG)

Generator Set

and Battery m (ft.)

12.2 (40) 00 0 1

9.1 (30) 0 1 2

7.6 (25) 1 2 4

6.1 (20) 2 2 6

4.6 (15) 2 4 6

3.0 (10) 4 6 8

1.5 (5) 6 6 8

0.8 (2.5) 8 8 8

At –18°C

(0°F)

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.

At 0°C

(32°F)

At 24°C

(75°F)

1. Starter solenoid

2. Battery positive (+) connection

3. Equipment ground

4. Battery negative (--) connection

5. Engine block mount

TP-5586-6

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.

12-V olt 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

TP-6069 6/0324 Section 6 Electrical System

6.7 Remote Start Switch Connection

Kohler Co. offers several remote panels for connection to the generator set. Contact your local Kohlerr 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 Kohlerr service distributor/dealer. Gauges and senders are available as service items from an authorized Kohlerr service distributor/dealer.

33--150 kW Models: Various wiring harnesses, Y-connectors, pigtail harnesses, remote control panels, and remote annunciator panels (Decision-Makert 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.

DA-250000-H

1. Controller remote connector

Figure 6-8 Controller Remote Connector, Typical

TP-6069 6/03 25Section 6 Electrical System

Figure 6-9 Remote Controller and Harness Options (33--150 kW Models)

ADV--6115A-A

TP-6069 6/0326 Section 6 Electrical System

Figure 6-10 Remote Controller and Harness Options (33--150 kW Models)

TP-6069 6/03 27Section 6 Electrical System

Notes

TP-6069 6/0328 Section 6 Electrical System

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. Drawing Page

3.5EFOZ and 4EOZ ADV-6652A-B 30

with remote options ADV-6652B-B 31

4EFOZ and 5EOZ ADV-5850A-H 32

with sound shield ADV-5850B-H 33

6.5EFOZ and 8EOZ ADV-6284A-J 34

with sound shield ADV-6284B-J 35

8.5/9EFOZ and 10EOZ ADV-6026A-K 36

with sound shield ADV-6026B-K 37

11EFOZ and 13EOZ ADV-6512A-D 38

with sound shield ADV-6512B-D 39

11.5/13EFOZ and 14/15.5EOZ ADV-6513A-C 40

with sound shield ADV-6513B-C 41

16/17.5EFOZ and 20EOZ ADV-6481A-D 42

with sound shield ADV-6481B-D 43

19/20EFOZ and 23/24EOZ ADV-6494A-C 44

with sound shield ADV-6494B-C 45

23/27EFOZ and 28/32EOZ ADV-6285A-F 46

with sound shield ADV-6285B-F 47

33EFOZ and 40EOZ ADV-6581A-E 48

with fuel/water separator and dry exhaust elbow

with sound shield ADV-6581C-E 50

with electric clutch ADV-6581D-E 51

40EFOZ and 50EOZ ADV-6582A-E 52

with fuel/water separator and dry exhaust elbow

with sound shield ADV-6582C-E 54

with electric clutch ADV-6582D-E 55

55EFOZ and 65EOZ ADV-6583A-E 56

with fuel/water separator and dry exhaust elbow

with sound shield ADV-6583C-E 58

with electric clutch ADV-6583D-E 59

70/80EFOZ and 80/99EOZ ADV-6603A-D 60

with fuel/water separator and dry exhaust elbow

with sound shield ADV-6603C-D 62

with electric clutch ADV-6603D-D 63

100/125EFOZ and 125/150EOZ ADV-6594A-D 64

with sound shield ADV-6594B-D 65

with dry exhaust elbow ADV-6594C-D 66

ADV-6581B-E 49

ADV-6582B-E 53

ADV-6583B-E 57

ADV-6603B-D 61

Figure 7-1 Installation Drawings

TP-6069 6/03 29Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-2 Dimension Drawing, 3.5EFOZ/4EOZ

ADV-6652A-B

TP-6069 6/0330 Section 7 Installation Drawings

ADV-6652B-B

Figure 7-3 Remote Options, 3.5EFOZ/4EOZ

TP-6069 6/03 31Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-4 Dimension Drawing, 4EFOZ/5EOZ

ADV-5850A-H

TP-6069 6/0332 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-5850B-H

Figure 7-5 Dimension Drawing, 4EFOZ/5EOZ with Sound Shield

TP-6069 6/03 33Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-6 Dimension Drawing, 6.5EFOZ/8EOZ

ADV-6284A-J

TP-6069 6/0334 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6284B-J

Figure 7-7 Dimension Drawing, 6.5EFOZ/8EOZ with Sound Shield

TP-6069 6/03 35Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-8 Dimension Drawing, 8.5/9EFOZ and 10EOZ

ADV-6026A-K

TP-6069 6/0336 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6026B-K

Figure 7-9 Dimension Drawing, 8.5/9EFOZ and 10EOZ with Sound Shield

TP-6069 6/03 37Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-10 Dimension Drawing, 11EFOZ/13EOZ

ADV-6512A-D

TP-6069 6/0338 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6512B-D

Figure 7-11 Dimension Drawing, 11EFOZ/13EOZ with Sound Shield

TP-6069 6/03 39Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-12 Dimension Drawing, 11.5/13EFOZ and 14/15.5EOZ

ADV-6513A-C

TP-6069 6/0340 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6513B-C

Figure 7-13 Dimension Drawing, 11.5/13EFOZ and 14/15.5EOZ with Sound Shield

TP-6069 6/03 41Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-14 Dimension Drawing, 16/17.5EFOZ and 20EOZ

ADV-6481A-D

TP-6069 6/0342 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6481B-D

Figure 7-15 Dimension Drawing, 16/17.5EFOZ and 20EOZ with Sound Shield

TP-6069 6/03 43Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-16 Dimension Drawing, 19/20EFOZ and 23/24EOZ

ADV-6494A-C

TP-6069 6/0344 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6494B-C

Figure 7-17 Dimension Drawing, 19/20EFOZ and 23/24EOZ with Sound Shield

TP-6069 6/03 45Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-18 Dimension Drawing, 23/27EFOZ and 28/32EOZ

ADV-6285A-F

TP-6069 6/0346 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6285B-F

Figure 7-19 Dimension Drawing, 23/27EFOZ and 28/32EOZ with Sound Shield

TP-6069 6/03 47Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-20 Dimension Drawing, 33EFOZ/40EOZ

ADV-6581A-E

TP-6069 6/0348 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6581B-E

Figure 7-21 Dimension Drawing, 33EFOZ/40EOZ with Fuel/Water Separator and Dry Exhaust Elbow

TP-6069 6/03 49Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-22 Dimension Drawing, 33EFOZ/40EOZ with Sound Shield

ADV-6581C-E

TP-6069 6/0350 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6581D-E

Figure 7-23 Dimension Drawing, 33EFOZ/40EOZ with Electric Clutch

TP-6069 6/03 51Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-24 Dimension Drawing, 40EFOZ/50EOZ

ADV-6582A-E

TP-6069 6/0352 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6582B-E

Figure 7-25 Dimension Drawing, 40EFOZ/50EOZ with Fuel/Water Separator and Dry Exhaust Elbow

TP-6069 6/03 53Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-26 Dimension Drawing, 40EFOZ/50EOZ with Sound Shield

ADV-6582C-E

TP-6069 6/0354 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6582D-E

Figure 7-27 Dimension Drawing, 40EFOZ/50EOZ with Electric Clutch

TP-6069 6/03 55Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-28 Dimension Drawing, 55EFOZ/65EOZ

ADV-6583A-E

TP-6069 6/0356 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6583B-E

Figure 7-29 Dimension Drawing, 55EFOZ/65EOZ with Fuel/Water Separator and Dry Exhaust Elbow

TP-6069 6/03 57Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-30 Dimension Drawing, 55EFOZ/65EOZ with Sound Shield

ADV-6583C-E

TP-6069 6/0358 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6583D-E

Figure 7-31 Dimension Drawing, 55EFOZ/65EOZ with Electric Clutch

TP-6069 6/03 59Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-32 Dimension Drawing, 70/80EFOZ and 80/99EOZ

ADV-6603A-D

TP-6069 6/0360 Section 7 Installation Drawings

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 61Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-34 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Sound Shield

ADV-6603C-D

TP-6069 6/0362 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6603D-D

Figure 7-35 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Electric Clutch

TP-6069 6/03 63Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-36 Dimension Drawing, 100/125EFOZ and 125/150EOZ

ADV-6594A-D

TP-6069 6/0364 Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6594B-D

Figure 7-37 Dimension Drawing, 100/125EFOZ and 125/150EOZ with Sound Shield

TP-6069 6/03 65Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-38 Dimension Drawing, 100/125EFOZ and 125/150EOZ with Dry Exhaust Elbow

ADV-6594C-D

TP-6069 6/0366 Section 7 Installation Drawings

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 anotice tothe generator setafter 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.

L0 (Neutral)

Ground

Load Side

Line Side

GRD.

L1 L2

Two-Pole Circuit Breaker

Jumper lead

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

Line Side

4321

Stator Leads

60 Hz 50 Hz

L0--L1 100--120 Volt 100--120 Volt L0--L2 100--120 Volt 100--120 Volt

GRD.

Single-Pole Circuit Breaker

Figure 8-2 100--120-Volt, 2-Wire Configuration

L0 (Neutral)

Ground

Load Side

Line Side

GRD.

Factory Two-Pole Circuit Breaker

4321

100--120/200 --240-Volt,

Figure 8-1 100--120-Volt, 3-Wire Configuration

8.1.2 100--120/200--240-Volt

Configurations

4321

Stator Leads

L0--L1 100--120 Volt 100--120 Volt L0--L2 100--120 Volt 100--120 Volt L1--L2 200--240 Volt 200--240 Volt

3-Wire

60 Hz 50 Hz

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

TP-6069 6/03 67Section 8 Reconnection/Adjustments

Figure 8-3 100--120/200--240-Volt, 3-Wire

Configuration

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).

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).

L0 (Neutral)

Ground

Load Side

Line Side

4321

Stator Leads

60 Hz

L0--L1 200-240 Volt 200--220--240 Volt

Single-Pole Circuit Breaker

Tape to insulate from ground

200--220 --240 Volt 2 Wire

GRD.

50 Hz

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

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 anotice tothe generator setafter 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

EM-250000-E

TP-6069 6/0368 Section 8 Reconnection/Adjustments

Note: Position the current transformers with the

dot or HI side CT marking toward the generator set.

Note: Only generator sets equipped with AC meter

controllers and/or safeguard circuit breakers require 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).

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.

UPPER METER SCALES

OFF

L3--L1

L0--L1

HERTZ A--CVOLTS A --CAMPERES

00000

TOTALHOURS

PRESS

VOLTAGE

EMERGENCY

ADJUST

OIL

WATER TEMP

STOP ONLY

BATTERY

PREALARM HIGHENGINE TEMPERATURE

PREALARM LOWOIL PRESSURE

LOWWATER TEMPERATURE

LOWFUEL

HIGHENGINE TEMPERATURE

LOWOIL PRESSURE

EMERGENCY STOP

OVERSPEED

OFF/RESET

L1--L2

LOWER METER SCALES

AUXILIARY FAULT

BATTERY CHARGERFAULT

LOWBATTERY VOLTAGE

OVERCRANK

AMPS

L1--L2L2L2--L3

VOLTS

AUXILIARY PREALARM

AIR DAMPER

SYSTEM READY

GENERATOR SWITCH NOTIN AUTO

AUTORUN

ALARM

LAMP TEST

L1--L2

NORMALSILENCE

1. Lamp Jumper

TP-5353-6

Figure 8-6 Meter Scale Lamp Jumper

6. The overvoltage shutdown is standard on Decision-Makert 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. Output voltage adjustment potentiometer

Figure 8-7 Voltage Adjustment

This is bpid

8.3 Decision-Maker 3+ Controller, Overvoltage Shutdown Adjustment

Disconnecting theelectrical 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 69Section 8 Reconnection/Adjustments

Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury

and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. 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).

Figure 8-8. The generator set should shut down on an overvoltage fault in approximately 2 seconds.

R41

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

LED4

1. Overvoltage adjustment potentiometer (R41)

2. LED4 (red)

A-336415-A

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.

TP-6069 6/0370 Section 8 Reconnection/Adjustments

Electroswitch

To Generator Set

2-Wire Generator Sets

2134

6578

To Load

To Shore Power

Kraus Naimler/American Solenoid

(Early Rectangular Design)

2-Wire Generator Sets

1265

348 7

To Shore Power

To Generator Set

3-Wire Generator Sets

2134

657 8

10 9 11 12

To Load

3-Wire Generator Sets

1265

348 7

91014 13

To Shore Power

To Load

Kraus Naimler/American Solenoid

(Newer Round Design)

2-Wire Generator Sets

To Generator Set

3241

768 5

To Load

To Shore Power

To Generator Set

Figure 8-9 Marine Manual (Ship-to-Shore) Transfer Switch

To Load

3-Wire Generator Sets

3241

768 5

11 10 12 9

To Load

To Shore Power

TP-5399-5

TP-6069 6/03 71Section 8 Reconnection/Adjustments

Kraus Naimler/American Solenoid

4-Wire, 3-Phase Generator Sets

3241

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.

To Generator Set

7685

11 10 12 9

15 14 16 13

L2 L3 L0L1

To Load

To Shore Power

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

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.

1. Voltage adjustment potentiometer

2. Stability adjustment potentiometer

3. Volts/Hz adjustment potentiometer

TT-875-11

Hazardous voltage.

Moving rotor.

Can cause severe injury or death.

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

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

voltage regulator heat sink. To prevent electricalshock do not touch the voltage regulator heat sink when testing the voltage regulator.

(PowerBoostt, 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.

Figure 8-11 PowerBoost IIIE Voltage Regulator

STAB

VOLTSV/HZ

1. Voltage adjustment potentiometer

2. Stability adjustment potentiometer

3. Volts/Hz adjustment potentiometer

TT-875-11

Figure 8-12 PowerBoost V Voltage Regulator

TP-6069 6/0372 Section 8 Reconnection/Adjustments

Stabilizer Potentiometer (Pot) fine tunes the regulator circuitry to reduce light flicker.

V oltage 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.

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.

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

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 73Section 8 Reconnection/Adjustments

Notes

TP-6069 6/0374 Section 8 Reconnection/Adjustments

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

1/4 750 330

1/3 1000 400

1/2 1500 600

3/4 2000 750

1 3300 1100

2 4000 2000

3 5000 3000

Starting (Inrush)

Watts

Running

Watts

Figure 1 Motor Requirements

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.

Air Conditioner Size (Btu/Hr.)

7,000 9,000 12,000 16,000 24,000

Voltage 115 230 115 230 115 230 115 230 230

Full load amps 9.3 4.8 9.9 5.0 11.8 6.3 16.3 8.0 11.6

Rated load amps 7.7 4.0 7.0 3.5 8.9 4.8 13.0 6.2 10.2

Locked rotor amps 34.0 20.0 40.0 20.0 50.0 31.0 75.0 36.0 56.0

Starting (inrush) watts 3910 4600 4600 4600 5750 7130 8630 8280 12,900

Running watts 886 920 805 805 1020 1100 1500 1430 2350

Figure 2 Typical Marine Air Conditioner Requirements, 60 Hz

TP-6069 6/03 A-1Appendix

Appendix B Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimensional

AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards

AO anticipatory only API American Petroleum Institute approx. approximate, approximately AR as required, as requested AS as supplied, as stated, as

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary A/V audiovisual avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery

BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block

blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CARB California Air Resources Board CB circuit breaker cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide

cogen. cogeneration Com communications (port) conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards

CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., ° degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung

DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection

EPS emergency power system ER emergency relay ES engineering special,

ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust ext. external F Fahrenheit, female

substrate (semiconductor)

Association

e. V. (also Deutsche Industrie Normenausschuss)

Association

Agency

engineered special

fglass. fiberglass FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lbs. foot pounds (torque) ft./min. feet per minute ggram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter

GND, gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temperature hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air

HWT high water temperature Hz hertz (cycles per second) IC integrated circuit ID inside diameter, identification IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting in. inch in. H in. Hg inches of mercury in. lbs. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe ISO International Organization for

J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (2

ground

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

bytes)

TP-6069 6/03A-2 Appendix

kg kilogram

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound, pounds

lbm/ft

pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side L

sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (10

units), male

cubic meter

/min. cubic meters per minute

when used with SI

mA milliampere man. manual max. maximum MB megabyte (2

bytes) MCM one thousand circular mils MCCB molded-case circuit breaker meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, m Ω

milliohm

MOhm, MΩ

megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second MTBF mean time between failure MTBO mean time between overhauls mtg. mounting

MW megawatt mW milliwatt µF microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical

Manufacturers Association

NFPA National Fire Protection

Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe

thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment

manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health

Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor

ph.,

∅ phase

PHC Phillips head crimptite (screw) PHH Phillips hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent-magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only

memory psi pounds per square inch pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart qty. quantity R replacement (emergency)

power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote RFI radio frequency interference RH round head RHM round head machine (screw) rly. relay

rms root mean square rnd. round ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive

Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites,

International System of Units SI/EO side in/end out sil. silencer SN serial number SPDT single--pole, double--throw SPST single--pole, single--throw spec, specs

specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to

normal TDES time delay engine start TDNE time delay normal to

emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple

locations) UF underfrequency UHF ultrahigh frequency UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer

TP-6069 6/03 Appendix A-3

Appendix C Generator Set Output Ratings Procedure

Kohler Co. develops the kilowatt output rating of a Kohlerr marine generator set based upon the calculations specified in ISO 3046 and ISO 8528-1. The calculations

generator set installation. Figure 1 outlines the calculations. Figure 2 contains examples of how heat variables affect generator set ratings.

correct for environmental variables encountered in a

Generator Output

corrected

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) x Alternator Efficiency

Reference

2. For turbocharged compression ignition engines: C.F. = [1.175 (29.2 / Barometer x Alternator Efficiency

Reference

3. For turbocharged and intercooled compression ignition engines: C.F. = [1.175 (29.2 / Barometer x Alternator Efficiency

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)

Reference

= Generator Output

/ Alternator Efficiency

Observed

/ Alternator Efficiency

Observed

/ Alternator Efficiency

in. Hg).7(Temperature _F + 460/537)2-- .175]

in. Hg).7(Temperature _F + 460/537)

observed

Observed

x Correction Factor

.75

-- .175]

1.2

-- .175]

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 80 85 90 95 100 105 110 115 120

Temperature (_F)

Figure 2 Example: 6.5EFOZ/8EOZ kW Derates (ISO 3046/ISO 8258-1)

TP-6069 6/03A-4 Appendix

TP-6069 6/03d

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455

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

Specifications and Main Features

Frequently Asked Questions

User Manual