Kohler 40-150EOZDJ, 40-150EOZCJ, 33-125EFOZDJ, 33-125EFOZCJ Installation Manual

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Installation

Marine Generator Sets

Pleasure Craft Models:

40--150EOZDJ

33--125EFOZDJ

Commercial Models:

40--150EOZCJ

33--125EFOZCJ

Controller:

Decision-Makerr 3500

TP-6862 6/14a

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TP-6862 6/142

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Table of Contents

Safety Precautions and Instructions 5.........................................................

Section 1 Introduction 9.....................................................................

Section 2 Location and Mounting 11...........................................................

2.1 General Considerations 1 1................................................

2.2 Location 11..............................................................

2.3 Mounting 11.............................................................

Section 3 Cooling System 13..................................................................

3.1 Ventilation 13............................................................

3.2 Cooling System Components 13............................................

3.2.1 Intake Through-Hull Strainer (Seacock Cover) 13.....................

3.2.2 Seacock 14......................................................

3.2.3 Seawater Strainer 14.............................................

3.2.4 Water Lines 14...................................................

3.2.5 Closed Heat Exchanger 14........................................

Section 4 Exhaust System 17..................................................................

4.1 Types 17................................................................

4.2 Exhaust Lines 17.........................................................

4.3 Sound Shielded Units with Dry Exhaust 18...................................

4.4 Exhaust System Location, Mounting, and Installation 18.......................

4.4.1 Above-Waterline Installation 19.....................................

4.4.2 Mid/Below-Waterline Installation 20.................................

Section 5 Fuel System 25.....................................................................

5.1 Fuel Tank 25.............................................................

5.2 Fuel Lines 26............................................................

5.3 Fuel Filters 26............................................................

5.4 Fuel/Water Separator 26..................................................

5.5 Fuel Pump Lift 26.........................................................

5.6 Fuel Consumption 26.....................................................

Section 6 Electrical System 29................................................................

6.1 AC Voltage Connections 29................................................

6.2 Circuit Protection 29......................................................

6.2.1 Circuit Breaker Considerations 29..................................

6.2.2 Circuit Breaker Installation 30......................................

6.3 Installation In Steel or Aluminum Vessels 32.................................

6.4 Installation Regulations 32.................................................

6.5 Battery 32...............................................................

6.6 Wiring 33................................................................

6.7 Remote Connection 33....................................................

6.8 Paralleling Generator Sets 33..............................................

Section 7 Installation Drawings 35.............................................................

Section 8 Reconnection/Adjustments 53.......................................................

8.1 Twelve-Lead Reconnection 55.............................................

Section 9 Paralleling Generator Sets 57........................................................

Introduction 57.................................................................

9.1 Paralleling Basics 58

9.1.1 Why Parallel Generator Sets 58....................................

9.1.2 Paralleling Functions 58...........................................

9.2 Paralleling Considerations 61..............................................

9.2.1 Generator Requirements 61.......................................

9.2.2 Paralleling Controller—PGEN 61...................................

TP-6862 6/14 Table of Contents 3

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9.3 Paralleling Set Up 62.....................................................

9.3.1 PGEN Communication Wiring 62...................................

9.3.2 Decision-Makerr 3500 Paralleling Sequence of Operation 63...........

9.4 Troubleshooting When Breaker Does Not Close to Bus 64.....................

9.4.1 Faults Not Shown 64..............................................

9.4.2 Faults Shown 65.................................................

9.5 Troubleshooting When Breaker Does Close to Bus 67.........................

9.5.1 Faults Shown 67.................................................

9.6 Troubleshooting When Running in AUTO 71.................................

9.6.1 Faults Shown 71.................................................

9.7 Generator Management Setup 75..........................................

9.7.1 Manual Order Selection Setup: 75..................................

9.7.2 Run Time Order Selection Setup 75.................................

9.7.3 Fuel Level Selection Setup 75......................................

9.7.4 Paralleling Parameters 76.........................................

9.8 Load Add/Shed Configuration 77...........................................

9.8.1 Load Add/Shed Setup 77..........................................

Appendix A Generator Selection and Wattage Requirements 79.................................

Appendix B Abbreviations 80................................................................

TP-6862 6/14Table of Contents4

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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.

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 equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (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.

Engine Backfire/Flash Fire

WARNING

Fire. Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the fuel system. A flash fire can cause severeinjury or death.

Do not smoke or permit flames or sparks near the fuel injection system, 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 fuel system.

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 generator set. Keep the compartment and the generator set clean and free of debris to minimize the risk of fire. Catch fuels in an approved container. Wipe up spilled fuels and engine oil.

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.

TP-6862 6/14 5Safety Precautions and Instructions

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.

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Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon

monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

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

safety of the craft’s occupants, install a carbon monoxide detector. Never operate the generator set without a functioning carbon monoxide detector. Inspect the detector before each generator set use.

Operating the generatorset. Carbon monoxide can cause severe nausea, fainting, or death. 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.

Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly

explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Donot operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation.

Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an

explosion. Use a container to catch fuel when drainingthe fuel system. Wipe up spilled fuel after draining the system.

Hazardous Noise

CAUTION

Hazardous noise. Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

Hazardous Voltage/ Moving Parts

WARNING

Hazardous voltage. Can cause severe injury or death.

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

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.

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution

is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. 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 turning off 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.

Moving parts.

TP-6862 6/146 Safety Precautions and Instructions

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

cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death.

Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is turned off. 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 follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry,approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically.

(600 volts and under)

Notice

NOTICE

This generator set has been rewired from its nameplate voltage to

246242

NOTICE

Voltage reconnection. Affix a notice

to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.

NOTICE

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.

Hot Parts

WARNING

Hot coolant and steam. Can cause severe injury or death.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

TP-6862 6/14 7Safety Precautions and Instructions

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Notes

TP-6862 6/148 Safety Precautions and Instructions

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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.

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 marine generator set. For operating instructions, refer to the operation manual.

Note: Only qualified persons should install the

generator set.

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)

2. Fuel return connection

3. Heat exchanger (not shown)

4. Fuel feed pump *

5. Fuel inlet connection

6. Seawater pump (seawater inlet)

7. Coolant recovery tank (located on the unit on some models)

8. Seawater strainer *

9. Seawater inlet c onnection

10. Seawater line *

11. Seacock *

12. Craft stringers

13. Fuel/water separator (see Section 5 for more information)

14. Fuel supply line *

15. Hose clamps

16. Fuel return line *

17. Mounting skid

18. Battery/battery storage box

19. Battery cables

20. Exhaust hose or exhaust line *

21. Electrical leads (AC output leads/remote start panel leads)

* Indicated components must conform to USCG regulations.

Figure 1-1 Typical Generator Set Location and Mounting (40EOZDJ Model Shown Without Sound Shield)

Note: See text for complete explanation of installation

requirements.

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

exhaust hose connections.

ADV8500-

TP-6862 6/14 9Section 1 Introduction

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Notes

TP-6862 6/1410 Section 1 Introduction

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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 Co n sid erations

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’s engine room 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.

2.2 Location

Locate the generator set to allow easy service access to the generator set’s engine, controller, cooling, and fuel system components. The engine compartment is often the ideal location for the generator set if the propulsion engine(s) does not obstruct access to the generator set and controller.

Marine Generator Set Installations in European Union Member Countries

This generator set is specifically intended and approved for installation below the deck in the engine compartment. Installation above the deck and/or outdoors would constitute a violation of European Union Directive 2000/14/EC noise emission standard.

Allow clearance for vibration and cooling during operation. Allow a minimum of 38 mm (1.5 in.) clearance on all sides (top, front, rear, and sides) o f a generator set without an optional sound shield. For sound-shielded units, allow 305 mm (12 inches) minimum clearance for the left-rear door and front door (intake and discharge openings). Also, allow space for the power takeoff (PTO) option, if equipped.

Kohler ignition -protected generator sets carry a UL1500 marine mark (decal). Check for this mark to ensure that your specific model is 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.

Kohler Co. recommends mounting the generator set on a flat board attached to the craft stringers. Craft stringers generally provide the best generator set support. Ensure that the structural members can support the generator set’s weight and withstand its vibration.

The generator set includes vibration mounts and a mounting tray or skid. If desired, install additional vibration isolating pads underneath the generator set’s base. Use the four mounting holes in the mounting tray to mount the generator set securely to the craft.

For angular operating limits, consult the operation manual.

TP-6862 6/14 11Section 2 Location and Mounting

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Notes

TP-6862 6/1412 Section 2 Location and Mounting

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3.1 Ventilation

Section 3 Cooling System

Engine combustion, generator cooling, and expulsion of flammable and lethal fumes require ventilation. Provide ventilation compliant with USCG regulations governing the sizing of vents and other considerations.

As a rule, size each inlet- and outlet-vent area to a minimum of 13 sq. cm/30.5 cm (2 sq. in. per ft.) of the craft’s beam. Should this rule conflict with USCG regulations, follow USCG regulations. For applications with screened inlets, double the size (4 sq. in. per ft.) of the hull/deck openings. Extend the vent ducts to bilges to expel heavier-than-air fumes.

For generator sets mounted in the engine compartment, increase the air flow to allow for the generator set’s requirements. Install optional detection devices to cause alarm, warning, or engine shutdown should dangerous fumes accumulate in the compartment.

See the generator set specification sheet that shipped with the generator set for air requirements. The air intake silencer/cleaner provides combustion air to the engine. Do not compromise the recommended minimum clearance (shown in Section 2) 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.

1. Inside packing

2. Outside packing

3. Seacock c over

4. Direction of v essel movement

5. Typical intake through-hull strainers

5982--3.1

Figure 3-2 Seacock Installation

Do not align the strainer (in relation to the 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.

Model

40--150EOZDJ/EOZCJ 33--125EFOZDJ/EFOZCJ

Allowable

Intake Restriction

25 in. H2O

(6.25kPa)orless

or or

Figure 3-1 Combustion Air Intake Restriction

3 2

3.2 Cooling System Components

Design the marine generator set’s cooling system to include the following features.

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

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-6862 6/14 13Section 3 Cooling System

Figure 3-3 Intake Strainer

travel so neither is in the wake of the other.

1. Generator set intake

2. Aft (rearward)

3. Fore (forward)

5982--3.2

Page 14

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 hull designs 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 direction of travel. A sea chest configuration applies a 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.

Mount the seawater strainer to the seacock or permanent structure at a point not higher than the seawater pump. Ensure that the strainer is accessible for service. See Figure 3-4 for a typical installation.

Some seawater strainers include a seacock and an intake through-hull strainer.

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

3.2.4 Water Lines

Water lines from the seacock to the engine-driven seawater pump are usually constructed of flexible hose. Connect a flexible section of hose to the seawater pump to allow for vibrational motion of the generator set during operation. Support a nonflexible water line within 102 mm (4 in.) of its connection to the flexible section.

Avoid overcaulking the seacock. Excess caulk reduces water flow and, in some cases, develops a barrier that can force water upward, past the seawater pump, and into the engine cylinders when the vessel is moving and the generator set is shut down.

3.2.3 Seawater Strainer

123

Keep the seawater hose as straight and short as possible. If the hose is too long, usually over 4.6 m (15 ft.), water suction 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 inlet connection.

1. Seawater pump

2. Seawater inlet (opposite side)

ADV8500A-

Figure 3-5 Seawater Inlet Connection (Located on

non-service side), Typical

1. Seawater pump

2. Seawater strainer

3. Seacock

Figure 3-4 Seawater Strainer

3.2.5 Closed Heat Exchanger

5982--3.3

A closed heat exchanger is the best cooling method for most applications. See Figure 3-6 for a typical installation. Provide space to access the water-cooled exhaust manifold pressure cap.

TP-6862 6/1414 Section 3 Cooling System

Page 15

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 s eawater pump

14. Engine-driven water pump

Seawater

Freshwater (Coolant/Antifreeze)

TP-5592-6

Figure 3-6 Typical Closed/Heat Exchanger Cooling System (40--99EOZD(C)J/33--80EFOZD(C)J Models)

TP-6862 6/14 15Section 3 Cooling System

Page 16

Overflow bottle or tank with cap

1 1/4 in. (31.75 mm) ID fill/vent line with a slope not less than 30 degrees *

Bypass

Inlet Line

Engine Block & Exhaust Manifold

Return LineOutlet Line

Water pump

Hull

* If a single fill/vent line between the expansion tank and the engine cannot be used, separate lines must be used for filling and venting the

tank. A 1/4 in. (6 mm) vent line is routed from the engine top tank to the expansion tank. The expansion tank fill line goes from the bottom of the expansion tank to the top of the keel cooler return line. A separate line, dedicated to filling the system, must be sized to meet the fill rate requirements published by the engine manufacturer.

Keel Cooler

Figure 3-7 Keel Cooling System Installation (Single Fill/Vent Line)

Figure 3-8 Keel Cooling System Installation (Multiple Vent Lines)

1/4” max. vent lines from high points in system to top of tank.

3/4” min. fill line to water pump inlet. (Tee in as close to the engine pump inlet as practical in customer-supplied piping).

TP-6862 6/1416 Section 3 Cooling System

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Section 4 Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide

is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. 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

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.

Note: Silencer selection is the responsibility of the

installer but must meet the parameters outlined in this manual.

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.

See Figure 4-1 for minimum recommended exhaust line hose selection. See Section 7 for exhaust outlet size and location.

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. Never operate the generator set without a functioning carbon monoxide detector. Inspect the detector before each generator set use.

Operating the generator set. Carbon monoxide can cause severe nausea, fainting, or death. 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.

Min.

Wet Exhaust

Hose

Diameter

Models

40EOZD(C)J 33EFOZD(C)J

40/50EFOZD(C)J 102 (4.0) 102 (4.0)

55/65EOZD(C)J 45/55EFOZD(C)J

80/99EOZD(C)J 70/80EFOZD(C)J

125/150EOZD(C)J 100/125EFOZD(C)J

mm (in.)

89 (3.5) 89 (3.5)

102 (4.0) 102 (4.0)

127 (5.0) 102 (4.0)

Min.

Dry Exhaust

Hose

Diameter

mm (in.)

Figure 4-1 Exhaust Hose Sizes (Minimum)

TP-6862 6/14 17Section 4 Exhaust System

Page 18

4.3 Sound Shielded Units with Dry

Exhaust

For units equipped with a dry exhaust and sound shield, insulate the exhaust system inside of the sound shield to the turbocharger/manifold. Use fiberglass exhaust tape/wrap (or equivalent) and secure with stainless wire (or material suitable for use in a marine environment). The exhaust system around the elbow inside of the sound shield must be insulated so that temperatures do not exceed 88_C (190_F). See Figure 4-2.

Alternator-End View

1. Dry exhaust elbow

2. Turbocharger

Figure 4-2 Dry Exhaust/Turbocharger Location

(Shown with Sound Shield removed)

4.4 Exhaust System Location,

Mounting, and Installation

Note: Should any information regarding installation

conflict with USCG regulations, follow USCG regulations.

Mount the silencer independently to eliminate stress on the exhaust system and the exhaust manifold/mixer elbow. See Section 7 for the mixer elbowwater line hose size. See Figure 4-3 for the exhaust connection to the mixer elbow. Provide an adequate hose length from the exhaust mixer to the silencer to allow for generator set movement.

1. Exhaust outlet

ADV8501B-

Figure 4-3 Mixer Elbow/Exhaust Connection,

Typical

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 4-5, item 2. 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 exhaustlines 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 4-4 for allowable back pressures.

Maximum Allowable

Exhaust Back

Model

40--150EOZDJ/EOZCJ 33--125EFOZDJ/EFOZCJ

* Under ALL engine loading conditions.

Pressure

≤

(in. H

7.5 (30) *

kPa

Figure 4-4 Allowable Exhaust Back Pressures

TP-6862 6/1418 Section 4 Exhaust System

Page 19

4.4.1 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 4-5. Mount a typical silencer with the inlet and outlet horizontal and with the drain plug down. Use an exhaust

Note: Data applies to both rear- and side-exhaust installations. Note: Numbers in illustration refer to callouts below and not to

dimensions.

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: Damage caused by water ingestion will not be covered by the

generator warranty.

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 4-5, item 2) in the exhaust line below the engine exhaust manifold outlet.

1. Minimum exhaust outlet distance above waterline of 10 cm (4 in.). Note: Vessel fully loaded

2. Slight lift improves silencing and prevents water backwash into the silencer (keep below the level of the exhaust manifold outlet)

3. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)

4. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)

5. Exhaust m anifold outlet

6. Exhaust mixer elbow

7. Heat exchanger (locations vary by model)

8. Coolant recovery tank (located on the unit on some models)

9. Locate the coolant recovery tank at the same height as the heat exchanger

10. Maximum seawater pump lift of 3 m (10 ft.)

11. Seawater strainer

12. Intake strainer

13. Seacock

14. Engine-driven s eawater pump

15. Maximum distance between silencer and exhaust mixer elbow of 3 m (10 ft.)

16. Maximum distance between silencer and exhaust outlet of

1.5 m (5 ft.)

17. Silencer (customer -supplied)

18. Waterline

19. Maximum silencer vertical lift of 1.2 m (4 ft.)

20. Kohler recommends locating the generator set at elevation that exhaust mixer is above the highest point of the exhaust outlet hose.

Figure 4-5 Typical Above-Waterline Installation

TP-6862 6/14 19Section 4 Exhaust System

Page 20

4.4.2 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 4-6 for the siphon break connection. Support the siphon break and hoses to maintain their position and function. Allow a slight offset to clear the stringers or other permanent structures. Protect the siphon break air inlet from dirt and debris.

Note: To prevent water leakage on the generator set, do

not mount the siphon break directly over the generator set.

Note: Ensure that the siphon break’s cap is tight before

operating the generator set.

Non-Service Side View

ADV8501B-

1. Cut hose and connect siphon break and hardware

Figure 4-6 Siphon Break Connection (Typical for

Non-Sound Shielded Units)

Mount a typical silencer’s base no more than 1.2 m (4 ft.) below the highest point in the exhaust line. Attach a separate wood mounting base to the hull stringers or other suitable structures. Use the silencer manufacturer’s recommendation for securing the silencer to the hull. Mount the silencer with the outlet not more than 3 m (10 horizontal ft.) from the engine’s exhaust manifold outlet. Use a USCG-type certified marine exhaust hose.

TP-6862 6/1420 Section 4 Exhaust System

Page 21

1. Cap

2. Reed valve

3. Mounting base

4. Maximum silencer vertical lift of 1.2 m (4 ft.)

5. Exhaust mixer elbow distance above waterline; if less than 23 cm (9 in.), a siphon break is required

6. Minimum siphon break distance above waterline of 30.5 cm (1 ft.)

7. Siphon break

8. Exhaust mixer elbow

9. Heat exchanger (locations vary by model)

10. Coolant recovery tank (located on the unit on some models)

11. Indicates the coolant recovery tank is at the same height as the heat exchanger

12. Seawater strainer

13. Seacock

14. Intake strainer

15. Engine-driven s eawater pump

16. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)

17. Maximum distance between silencer and exhaust mixer elbow of 3 m (10 ft.)

18. Maximum distance between silencer and exhaust outlet of

1.5 m (5 ft.)

19. Silencer (customer -supplied)

20. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)

Waterline

21. Maximum distance between exhaust outlet and generator of

4.6 m (15 ft.)

22. Minimum exhaust outlet distance above waterline of 10 cm (4 in.)

23. Exhaust hose, exhaust gas outlet hose after separator. See Figure 4-1 for hose sizes.

24. Gas/water separator (optional). Install directly above the canister muffler.

25. Distance above waterline for drain outlet from silencer must be equal to or greater than water drain (item 26) to be greater than 30.5 cm (1 ft.)

26. Water drain distance below waterline

27. Water drain (separated water from item 24)

28. System installer is responsible for designing enough capacity into the lift muffler and plumbing to prevent engine water ingestion upon shutdown. Otherwise, water will drain back into item 19 on generator set shutdown.

Note: Read the text for complete explanation of dimensions and

other installation considerations.

Note: Numbers in illustration refer to callouts below and not to

dimensions.

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

hose connections.

Note: Data applies to both rear- and side-exhaust installations. Note: Damage caused by water ingestion will not be covered by

the generator warranty.

Figure 4-7 Typical Mid- and Below-Waterline Installation with Optional Gas/Water Separator

TP-6862 6/14 21Section 4 Exhaust System

Page 22

Note: Data applies to both rear- and side-exhaust installations. Note: Numbers in illustration refer to callouts below and not to

dimensions.

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: Damage caused by water ingestion will not be covered by the

generator warranty.

1. Minimum exhaust outlet distance above waterline of 10 cm (4 in.)

2. Exhaust hose (see Figure 4-1 for hose sizes)

3. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)

4. Maximum silencer vertical lift of 1.2 m (4 ft.)

5. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)

6. Exhaust mixer elbow distance above waterline; if less than 23 cm (9 in.), a siphon break is required

7. Minimum siphon break distance above waterline of 30.5 cm (1 ft.)

8. Exhaust mixer elbow

9. Siphon break

10. Cap

11. Reed valve

12. Mounting base

13. Heat exchanger (locations vary by model)

14. Coolant recovery tank (located on the unit on some models)

15. Indicates the coolant recovery tank is at the same height as the heat exchanger

16. Seawater strainer

17. Seacock

18. Intake strainer

19. Engine-driven s eawater pump

20. Install optional water lock here

21. Maximum distance between silencer and exhaust mixer elbow of 3 m (10 ft.)

22. Maximum distance between silencer and exhaust outlet of

1.5 m (5 ft.)

23. Silencer (customer -supplied)

24. Waterline

25. Kohler recommends locating the generator set at elevation that exhaust mixer is above the highest point of the exhaust outlet hose.

Figure 4-8 Typical Mid- and Below-Waterline Installation

TP-6862 6/1422 Section 4 Exhaust System

Page 23

Note: Data applies to both rear- and side-exhaust installations. Note: Numbers in illustration refer to callouts below and not to

dimensions.

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: Damage caused by water ingestion will not be covered by the

generator warranty.

1. Cap

2. Reed valve

3. Mounting base

4. Maximum silencer internal 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

9. Heat exchanger

10. Coolant recovery bottle

11. Indicates the coolant recovery tank is at the same height as the heat exchanger

12. Seawater strainer

13. Seacock

14. Intake strainer

15. Engine-driven s eawater pump

16. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)

17. Maximum distance between silencer and exhaust mixer elbow of 3 m (10 ft.)

18. Water drain distance below waterline

19. Combination silencer that contains lift muffler and gas water separating sections in single component (customer-supplied)

20. Distance above waterline for drain outlet from silencer must be equal to or greater than water drain (item 18) to be greater than 30.5 cm (1 ft.)

21. Exhaust outlet to be diameter appropriate so exhaust back pressure does not exceed limit at engine exhaust manifold

22. Minimum exhaust outlet distance above waterline of 10 cm (4 in.)

23. Exhaust hose

24. Height of internal lift tube to be below generator exhaust manifold

25. Kohler recommends generator be located at elevation that exhaust mixer elbow is above silencer exhaust outlet

26. Seawater pump lift

27. Waterline

Figure 4-9 Exhaust System

TP-6862 6/14 23Section 4 Exhaust System

Page 24

Satisfactory generator set performance requires proper exhaust system installation. Figure 4-10 and Figure 4-11 show typical arrangements for commercial marine exhaust systems.

Ensure that there is a means to periodically drain condensation in exhaust, such as a silencer equipped with a drain plug (see Figure 4-12), or a wye- or tee-type condensation trap with a drain plug, or petcock installed between the engine and silencer (see Figure 4-13).

1. Supports

2. Pitch line downward

3. Silencer

4. Water trap

5. Drain petcock

6. Flexible section

7. Solid section 152 --203 mm (6--8 in.)

8. Manifold

NOTE: Horizontal silencer shown.

Figure 4-10 Exhaust System, End Inlet Silencer

1. Silencer

2. 45 Y fitting

3. Water trap

4. Drain petcock

NOTE: Horizontal silencer shown.

5. Outer diameter adapter and clamp

6. Flexible section

7. Manifold

8. 45 elbow

TP-5700-5

NOTE: Horizontal silencer shown.

1. Pipe Plug

Figure 4-12 Silencer Condensation Drain Plug

NOTE: Horizontal silencer shown.

1. Condensation trap

Figure 4-13 Condensation Trap

TP-5700-5

Figure 4-11 Exhaust System, Side Inlet Silencer

TP-6862 6/1424 Section 4 Exhaust System

Page 25

Section 5 Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

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.

Note: Fuel system installations must conform to USCG

regulations.

5.1 Fuel Tank

Most marine generator sets draw fuel from the same fuel tank as the craft’s propulsion engine(s). If the tank’s fuel pickup opening allows a multiple dip tube, use a multiple dip tube arrangement. See Figure 5-1. The multiple dip tube arrangement incorporates a shorter dip tube for the generator set and a longer dip tube for the propulsion engine. With this arrangement, the generator set runs out of fuel before the propulsion engine during a low fuel supply situation. Equip the fuel system with a fuel/water separator to remove any accumulated dirt and water.

1-788

1. Fuel line to propulsion engine

2. Fuel line to generator set

Figure 5-1 Multiple Dip Tube Arrangement

m:is:102:001

TP-6862 6/14 25Section 5 Fuel System

Page 26

5.2 Fuel Lines

5.3 Fuel Filters

Return the generator set fuel return line to the fuel tank. 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 vibrational motion of the generator set during operation.

Fuel Line

ID Size

Model

40--150EOZDJ/EOZCJ 40--125EFOZDJ/EFOCJ

mm (in.)

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.

Conform to USCG regulations regarding inline fuel filters or strainers.

5.4 Fuel/Water Separator

A fuel/water separator is standard on 33--150 kW models. Consult the engine operation manual for service procedure.

5.5 Fuel Pump Lift

See Figure 5-3 for fuel pump lift capabilities.

Fuel Pump Lift

Model

Pleasure Craft: 40EOZDJ/33EFOZDJ 40EFOZDJ 50EFOZDJ Commercial Craft: 40EOZCJ/33EFOZCJ 40EFOZCJ 50EFOZCJ

Pleasure Craft: 55EOZDJ/45EFOZDJ 65EOZDJ/55EFOZDJ 80EOZDJ/70EFOZDJ 99EOZDJ/80EFOZDJ 125EOZDJ/100EFOZDJ 150EOZDJ/125EFOZDJ Commercial Craft: 55EOZCJ/45EFOZCJ 65EOZCJ/55EFOZCJ 80EOZCJ/70EFOZCJ 99EOZCJ/80EFOZCJ 125EOZCJ/100EFOZCJ 150EOZCJ/125EFOZCJ

Figure 5-3 Fuel Pump Lift

m (ft.)

3 (10)

2.4 (7.9)

See Section 7 for fuel feed pump inlet connection and fuel return line connection.

5.6 Fuel Consumption

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

TP-6862 6/1426 Section 5 Fuel System

Page 27

1. Electric fuel or mechanical check valve

2. Permanent supports for fuel system components

3. Fuel lift pump

4. Flexible line

Figure 5-4 Fuel System, Typical

5. Fuel return line (diesels only)

6. Carburetor or injection pump

7. Secondary filter

8. Primary filter

9. Flexible fuel line

Fuel Return (Diesel Only) (Below Fluid Level)

Fuel Supply

10. Clamp

11. Support clamp

12. Metallic line

13. Dip tube

14. Fuel tank

Check Valve (Optional) *

Baffles

* Anti-siphon protection is required for gasoline-powered units if diptube opening is below the waterline.

12 in. min.

Main Fuel Tank

Figure 5-5 Fuel System, Typical

Fuel Lift

Drain Valve

TP-6862 6/14 27Section 5 Fuel System

Page 28

Notes

TP-6862 6/1428 Section 5 Fuel System

Page 29

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 turned off. 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 parts.

6.1 AC Voltage Connections

Make AC connections to the generator set inside the junction box. 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 Section 8 for reconnection of the generator set.

6.2 Circuit Protection

The AC circuit breakers (optional) protect the wiring from the AC circuit breakers to the vessel’s distribution panel. AC circuit breakers trip when they detect a fault in the output circuit.

After correcting the fault, reset the AC circuit breaker(s) by placing them in the ON position. Restart the unit. Do not start the unit under load. See Figure 6-1 and Figure 6-2 for AC circuit breaker ratings. The unit’s voltage configuration determines the circuit breaker selection.

6.2.1 Circuit Breaker Consideratio ns

Mounting location. Mount the circuit breakers in the

generator set’s junction box. See Section 6.2.2.

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.

Max.

Amps

Figure 6-1 3-Pole AC Circuit Breaker Ratings

Vol ta ge

70 600 40EOZD(C)DJ, 33EFOZD(C)J

80 600 40EFOZD(C)J, 45EFOZD(C)J

90 480 40EFOZD(C)J, 45EFOZD(C)J

100 480 55EOZD(C)J, 45EFOZD(C)J, 50EFOZD(C)J

125 480 50EFOZD(C)J, 65EOZD(C)J, 55EFOZD(C)J

125 600 33EFOZD(C)J

150 480 80EOZD(C)J, 70EFOZD(C)J

150 600 40EOZD(C)J, 33EFOZD(C)J, 40EFOZD(C)J

175 480 99EOZD(C)J, 70EFOZD(C)J 80EFOZD(C)J

175 600

200 600 40EFOZD(C)J, 50EFOZD(C)J, 55EOZD(C)J

250 600

400 600

600 600

40EOZD(C)J, 33EFOZD(C)J, 40EFOZD(C)J,

50EFOZD(C)J, 55EOZD(C)J, 45EFOZD(C)J, 65EOZD(C)J, 55EFOZD(C)J, 125EOZD(C)J,

80EOZD(C)J, 70EFOZD(C)J, 99EOZD(C)J,

80EFOZD(C)J, 150EOZD(C)J,

100EFOZD(C)J, 125EFOZD(C)J

125EOZD(C)J 150EOZD(C)J,

100EFOZD(C)J, 125EFOZD(C)J

Model(s)

45EFOZD(C)J

100EFOZDJ(C)J

(33--150 kW Models), Listed By Amps

Note: Circuit breaker ampere rating and availability are

subject to change.

TP-6862 6/14 29Section 6 Electrical System

Page 30

Amps

63 33EFOZD(C)J

100

125

160

200

250

400

630

40EOZD(C)J, 33EFOZD(C)J, 40EFOZD(C)J,

40EFOZD(C)J, 50EFOZD(C)J, 55EOZD(C)J,

33EFOZD(C)J, 50EFOZD(C)J, 65EOZD(C)J,

40EOZD(C)J, 33EFOZD(C)J, 40EFOZD(C)J,

80EOZD(C)J, 70EFOZD(C)J

40EOZD(C)J. 40EFOZD(C)J, 50EFOZD(C)J,

55EOZD(C)J, 45EFOZD(C)J

50EFOZD(C)J, 55EOZD(C)J, 45EFOZD(C)J, 65EOZD(C)J, 55EFOZD(C)J, 125EOZD(C)J,

80EOZD(C)J, 70EFOZD(C)J, 100EFOZD(C)J,

150EOZD(C)J, 125EFOZD(C)J

125EOZD(C)J, 100EFOZD(C)J, 150EOZD(C)J,

Model(s)

45EFOZD(C)J

55EFOZD(C)J

100EFOZD(C)J

125EFOZD(C)J

Figure 6-2 4-Pole AC Circuit Breaker Ratings

(33--150 kW Models), Listed By Amps

WARNING

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible

whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. 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

Accidental starting. Can cause severe injury or death.

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 off/reset button to shut down the generator set. (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

6.2.2 Circuit Breaker Installation

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. SeeFigure6-3.

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 8-3.

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.

Hazardous voltage. Can cause severe injury or death.

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

Moving parts.

7. Connect the load side of the circuit breaker to customer-supplied craft wiring. Connect the neutral lead to the L0 stud. See Figure 8-3.

8. Attach the new panel to the junction box using the original six screws. See Figure 6-3.

TP-6862 6/1430 Section 6 Electrical System

Page 31

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

1. Circuit breaker

2. Circuit breaker mounting panel

3. Load lead access panel

Figure 6-3 Circuit Breaker Mounting, Typical

TP-6862 6/14 31Section 6 Electrical System

JW250000

4. Bus

5. Hardware

6. Bus line

Page 32

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.

Note: Isolated ground kits are available as options for

steel- or aluminum-hulled vessels. Consult your local dealer/distributor for more information.

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.

6.5 Battery

Batteries and their installation must conform to USCG Regulations 183.420 (a) through (g). Provide generator sets with batteries separate from the propulsion engine’s whenever possible. The starting/charging systems of both the generator set and the engine must have a common negative (--) ground.

USCG Regulation 183.415, Grounding, requires connection of a common conductor to each grounded cranking-motor circuit. Size the conductor to match the larger of the engine’s two battery cables. Figure 6-4 lists recommended minimum cable sizes for generator set battery connections at various generator set-to-battery distances. 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 restrictedor open because of oxidation or loose hardware. Alternative electrical paths include metallic fuel lines that can pose a hazard. See Section 7 for locations of the battery connections to the generator set.

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

Required Battery Cable

(Minimum)

Distance (from battery to generator set)

Battery Voltage 12V 24V 12V 24V

40--65EOZDJ/EOZCJ 33--50EFOZDJ/EFOZCJ

80--99EOZDJ/EOZCJ 70--80EFOZDJ/EFOZCJ

125--150EOZDJ/EOZCJ 100--125EFOZDJ/EFOZCJ

Figure 6-4 Battery Cable Sizing Recommendations

2.5 m (8.3 ft.) 5 m (16.4 ft.)

#0 #4 #3/0 #2

#2/0 #2 #4/0 #1/0

TP-6862 6/1432 Section 6 Electrical System

Page 33

Kohler Co. recommends using one 12-volt battery (or two for 24-volt systems, as the spec requires) to start the generator. See Figure 6-5 for minimum cold cranking amps (CCA) recommendations.

12-V olt Starting Battery Size CCA

at --18C(0F) or 100 Amp. Hr.

Models CCA

40EOZDJ and 33EFOZDJ 40EOZCJ and 33EFOZCJ

40EFOZDJ 40EFOZCJ 50EFOZDJ 50EFOZCJ 55EOZDJ and 45EFOZDJ 55EOZCJ and 45EFOZCJ 65EOZDJ and 55EFOZDJ 65EOZCJ and 55EFOZCJ

80EOZDJ and 70EFOZDJ 80EOZCJ and 70EFOZCJ 99EOZDJ and 80EFOZDJ 99EOZCJ and 80EFOZCJ 125EOZDJ and 100EFOZDJ 125EOZCJ and 100EFOZCJ 150EOZDJ and 125EFOZDJ 150EOZCJ and 125EFOZCJ

640

625

925

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.

Various wiring harnesses, Y-connectors, pigtail harnesses, remote control panels, and remote annunciator panels are available.

6.8 Paralleling Generator Sets

See Section 9 for information on paralleling generator sets.

Figure 6-5 Battery Recommendations

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.

6.7 Remote Connection

Kohler Co. offers several remote panels for connection to the generator set. Contact your local Kohlerr distributor/dealer for detailed descriptions. Kohler Co. also offers wiring harnesses in various lengths with a connector keyed to the controller box connector. A “pigtail” harness is also offered which includes the appropriate connector on one end and has pigtails that the installer can use to connect to a customer-supplied start/stop switch or separate lights and hourmeter. Consult wiring diagrams, ADVs, and instruction sheets for connection information/details.

TP-6862 6/14 33Section 6 Electrical System

Page 34

Notes

TP-6862 6/1434 Section 6 Electrical System

Page 35

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

40EOZD(C)J and 33EFOZD(C)J

open unit (sheet 1 of 2) ADV-8500A-A 36

open unit (sheet 2 of 2) ADV-8500B-A 37

with sound shield (not available on EOZCJ/ EFOZCJ models)

with radiator ADV-8505A-A 48

with electric clutch ADV-8505B-A 49

with keel cooling & dry exhaust ADV-8505C-A 50

40EFOZD(C)J 50EFOZD(C)J 55EOZD(C)J and 45EFOZD(C)J 65EOZD(C)J and 55EFOZD(C)J

open unit (sheet 1 of 2) ADV-8501A-A 39

open unit (sheet 2 of 2) ADV-8501B-A 40

with sound shield (not available on EOZCJ/ EFOZCJ models)

with radiator ADV-8505A-A 48

with electric clutch ADV-8505B-A 49

with keel cooling & dry exhaust ADV-8505C-A 50

80EOZD(C)J and 70EFOZD(C)J 99EOZD(C)J and 80EFOZD(C)J

open unit (sheet 1 of 2) ADV-8506A-B 42

open unit (sheet 2 of 2) ADV-8506B-B 43

with sound shield (not available on EOZCJ/ EFOZCJ models)

with radiator ADV-8505A-A 48

with electric clutch ADV-8505B-A 49

with keel cooling & dry exhaust ADV-8505C-A 50

125EOZD(C)J and 150EFOZD(C)J 100EOZD(C)J and 125EFOZD(C)J

open unit (sheet 1 of 2) ADV-8508A- 45

open unit (sheet 2 of 2) ADV-8508B- 46

with sound shield (not available on EOZCJ/ EFOZCJ models)

with radiator ADV-8505A-A 48

with electric clutch ADV-8505B-A 49

with keel cooling & dry exhaust ADV-8505D-A 51

ADV-8503- 38

ADV-8504- 41

ADV-8507-A 44

ADV-8509- 47

TP-6862 6/14 35Section 7 Installation Drawings

Figure 7-1 Installation Drawings

(33--150 kW Models)

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