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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
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TableofContents SafetyPrecautionsandInstructions ........................................................ I Section1 Introduction..................................................................... 1 Section2 LocationandMounting .......................................................... 3 2.1 General Considerations ................................................ 3 2.2 Location ............................................................. 3 2.3 Mounting..........................................
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SafetyPrecautionsandInstructions IMPORTANT SAFETY Disabling the generator set. AccidentalStarting Accidental starting can cause INSTRUCTIONS. Electromechanical severe injury or death. Before equipment, including generator sets, WARNING working on the generator set or transfer switches, switchgear, and equipment connected to the set, accessories, can cause bodily harm disable the generator set as follows: andposelife-threateningdangerwhen (1) Press the generator set on/off improperly installed, o
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Battery acid cleanup. Battery acid EngineBackfire/Flash ExhaustSystem can cause severe injury or death. Fire Battery acid is electrically conductive WARNING and corrosive. Add 500 g (1 lb.) of bicarbonateofsoda(bakingsoda)toa WARNING containerwith4L(1gal.)ofwaterand mixtheneutralizingsolution. Pourthe neutralizing solution on the spilled battery acid and continue to add the Carbonmonoxide. neutralizing solution to the spilled Fire. Can cause severe nausea, battery acid until all evidence of a Ca
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Inspecting the exhaust system. The fuel system. Explosive fuel Ignition-protected equipment. Carbonmonoxidecancausesevere vapors can cause severe injury or Explosive fuel vapors can cause nausea, fainting, or death. For the death. Vaporized fuels are highly severe injury or death. Gasoline safetyofthecraft’soccupants,installa explosive. Use extreme care when vapors can cause an explosion. carbonmonoxidedetector. Consultthe handlingandstoringfuels. Storefuels USCG Regulation33CFR183requires boat
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Welding the generator set. Can Testing live electrical circuits. CAUTION cause severe electrical equipment Hazardous voltage or current can damage. Beforeweldingthegenerator cause severe injury or death. Have set perform the following steps: trained and qualified personnel take (1) Remove the battery cables, diagnostic measurements of live negative (--) lead first. (2) Disconnect circuits. Use adequately rated test all engine electronic control module equipment with electrically insulated (ECM)
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Servicing the exhaust system. Hot Tightening the hardware. Flying NOTICE parts can cause severe injury or projectiles can cause severe injury Hardware damage. The engine and death. Donottouchhotengineparts. ordeath. Loosehardwarecancause generator set may use both American The engine and exhaust system thehardwareor pulleyto releasefrom Standard and metric hardware. Use components become extremely hot thegeneratorsetengineandcancause the correct size tools to prevent during operation. personal i
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Notes VI Safety Precautions and Instructions TP-6069 6/03
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Section1 Introduction Informationinthispublicationrepresentsdataavailable marine generator set. For operating instructions, refer at the time of print. Kohler Co. reserves the right to to the operation manual. change this publication and the products represented Marine generator set installations must comply with all without notice and without any obligation or liability applicable regulations and standards. whatsoever. x:in:001:002:a Usethespecificationsheetsasaguideinplanningyour installation.
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Notes 2 Section 1 Introduction TP-6069 6/03
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Section2 LocationandMounting Allow clearance for vibration and cooling during 2.1 GeneralConsiderations operation. Allow a minimum of 38 mm (1.5 in.) The key to installation is location. Before making final clearance on all sides (top, front, rear, and sides) of a plans for locating a generator set, consider the generatorsetwithoutanoptionalsoundshield. Referto following. the instruction sheet for minimum clearances for sound-shielded units. Also, allow space for the power takeoff (PTO) option,
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Notes 4 Section 2 Location and Mounting TP-6069 6/03
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Section3 CoolingSystem 3.1 Ventilation Enginecombustion,generatorcooling,andexpulsionof flammableandlethalfumesrequireventilation. Provide ventilationcompliantwithUSCGRegulationsgoverning 1 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 2 Regulations,followUSCGRegulations.Forapplications with screened inlets, double the size (4 sq. in. per ft.
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Do not use a speed scoop or cup design intake 3.2.4 WaterLines through-hull strainer because it can cause a ramming Water lines from the seacock to the engine-driven effectandforcewaterupward,pasttheseawaterpump, seawaterpumpareusuallyconstructedofflexiblehose. andintotheenginecylinderswhenthevesselismoving Connectaflexiblesectionofhosetotheseawaterpump and the generator set is shut down. to allow the generator set to vibrate during operation. Do not use hulls incorporating sea chests or other S
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2 1 3 4 6 8 5 7 14 9 ArrowDescription 10 DirectionofFlow Seawater Freshwater (Coolant/Antifreeze) 11 12 13 TP-5586-6 1. Engine block 8. Thermostat closed 2. Exhaust manifold 9. Heat exchanger 3. Exhaust mixer elbow 10. Engine-driven seawater pump 4. Outlet flapper (exhaust/water discharge) 11. Seawater strainer 5. Silencer (customer supplied) 12. Seacock 6. Thermostat open 13. Intake strainer 7. Thermostat 14. Engine-driven water pump Figure3-6 Typical Closed/Heat Exchanger Cooling System (4/6.5
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2 1 3 4 5 7 6 8 9 14 13 12 11 Seawater Freshwater (Coolant/Antifreeze) 10 TP-5592-6 1. Oil cooler 8. Silencer (customer-supplied) 2. Engine block 9. Exhaust outlet 3. Thermostat 10. Intake strainer 4. Water-cooled manifold 11. Seacock 5. Heat exchanger 12. Seawater strainer 6. Exhaust mixer elbow 13. Engine-driven seawater pump 7. Water-cooled turbocharger 14. Engine-driven water pump Figure3-7 Typical Closed/Heat Exchanger Cooling System (11--20EFOZ,13--24EOZ, 33--125EFOZ and 40--150EOZ Models)
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7 6 8 9 10 3 5 4 2 1 TP-6134- 1. Intake strainer 6. Zinc plug 2. Seacock 7. Exhaust manifold elbow 3. Seawater strainer 8. Exhaust hose 4. Engine-driven seawater pump 9. Silencer (customer supplied) 5. Oil exchanger 10. Outlet flapper (exhaust/water discharge) Figure3-8 Direct Water-Cooled Cooling System (3.5EFOZ and 4EOZ Models) TP-6069 6/03 Section 3 Cooling System 9
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Notes 10 Section 3 Cooling System TP-6069 6/03
