16efoz 20eoz

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
TP-6069 6/03d
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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 Accidental Starting Disabling the generator set.

INSTRUCTIONS. Electromechanical Accidental starting can cause
equipment, including generator sets, severe injury or death. Before
transfer switches, switchgear, and WARNING working on the generator set or
accessories, can cause bodily harm equipment connected to the set,
and pose life-threatening danger when disable the generator set as follows:
improperly installed, operated, or (1) Press the generator set on/off
maintained. To prevent accidents be button to shut down the generator set.
aware of potential dangers and act All indicator lamps dim. (2) Disconnect
Accidental starting. the power to the battery charger, if
safely. Read and follow all safety
Can cause severe injury or death. equipped. (3) Remove the battery
precautions and instructions. SAVE
cables, negative (--) lead first.
THESE INSTRUCTIONS. Disconnect the battery cables before Reconnect the negative (--) lead last
working on the generator set.
when reconnecting the battery. Follow
This manual has several types of safety Remove the negative (--) lead first
these precautions to prevent the
precautions and instructions: Danger, when disconnecting the battery.
starting of the generator set by the
Warning, Caution, and Notice. Reconnect the negative (--) lead last
remote start/stop switch.
when reconnecting the battery.
DANGER Disabling the generator set. Battery

Accidental starting can cause
Danger indicates the presence of a severe injury or death. Before
hazard that will cause severe working on the generator set or WARNING
personal injury, death, or substantial connected equipment, disable the
property damage. generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
WARNING the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last Sulfuric acid in batteries.
Warning indicates the presence of a
when reconnecting the battery. Follow Can cause severe injury or death.
hazard that can cause severe
personal injury, death, or substantial these precautions to prevent starting of Wear protective goggles and clothing.
property damage. the generator set by an automatic Battery acid may cause blindness and
transfer switch, remote start/stop burn skin.
switch, or engine start command from a
CAUTION remote computer.
Battery electrolyte is a diluted
Disabling the generator set. sulfuric acid. Battery acid can cause
Caution indicates the presence of a Accidental starting can cause severe injury or death. Battery acid
hazard that will or can cause minor severe injury or death. Before can cause blindness and burn skin.
personal injury or property damage. working on the generator set or Always wear splashproof safety
equipment connected to the set, goggles, rubber gloves, and boots
NOTICE disable the generator set as follows: when servicing the battery. Do not
Notice communicates installation, (1) Place the generator set start/stop open a sealed battery or mutilate the
operation, or maintenance information switch in the STOP position. battery case. If battery acid splashes in
that is safety related but not hazard (2) Disconnect the power to the battery the eyes or on the skin, immediately
related. charger, if equipped. (3) Remove the flush the affected area for 15 minutes
battery cables, negative (--) lead first. with large quantities of clean water.
Safety decals affixed to the equipment Reconnect the negative (--) lead last
in prominent places alert the operator Seek immediate medical aid in the case
when reconnecting the battery. Follow
or service technician to potential of eye contact. Never add acid to a
these precautions to prevent the
hazards and explain how to act safely. battery after placing the battery in
starting of the generator set by the
The decals are shown throughout this service, as this may result in hazardous
remote start/stop switch.
publication to improve operator spattering of battery acid.
recognition. Replace missing or
damaged decals.
TP-6069 6/03 Safety Precautions and Instructions I

Battery acid cleanup. Battery acid Engine Backfire/Flash Exhaust System
can cause severe injury or death.
Battery acid is electrically conductive Fire
and corrosive. Add 500 g (1 lb.) of
WARNING
bicarbonate of soda (baking soda) to a WARNING
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the Carbon monoxide.
neutralizing solution to the spilled Fire. Can cause severe nausea,
battery acid until all evidence of a Can cause severe injury or death. fainting, or death.
chemical reaction (foaming) has
Do not smoke or permit flames or sparks The exhaust system must be leakproof
ceased. Flush the resulting liquid with near fuels or the fuel system. and routinely inspected.
water and dry the area.
Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms.
severe injury or death. Battery gases fire can cause severe injury or death. Carbon monoxide can cause severe
can cause an explosion. Do not smoke Do not smoke or permit flames or nausea, fainting, or death. Carbon
or permit flames or sparks to occur near sparks near the carburetor, fuel line, monoxide is a poisonous gas present in
a battery at any time, particularly when fuel filter, fuel pump, or other potential exhaust gases. Carbon monoxide
it is charging. Do not dispose of a sources of spilled fuels or fuel vapors. poisoning symptoms include but are
battery in a fire. To prevent burns and Catch fuels in an approved container not limited to the following:
sparks that could cause an explosion, when removing the fuel line or D Light-headedness, dizziness
avoid touching the battery terminals carburetor. D Physical fatigue, weakness in
with tools or other metal objects. joints and muscles
Servicing the air cleaner. A sudden
Remove all jewelry before servicing the D Sleepiness, mental fatigue,
backfire can cause severe injury or
equipment. Discharge static electricity inability to concentrate
death. Do not operate the generator
or speak clearly, blurred vision
from your body before touching set with the air cleaner/silencer
D Stomachache, vomiting, nausea
batteries by first touching a grounded removed.
If experiencing any of these symptoms
metal surface away from the battery. To
Combustible materials. A sudden and carbon monoxide poisoning is
avoid sparks, do not disturb the battery
flash fire can cause severe injury or possible, seek fresh air immediately
charger connections while the battery and remain active. Do not sit, lie down,
death. Do not smoke or permit flames
is charging. Always turn the battery or fall asleep. Alert others to the
or sparks near the fuel system. Keep
charger off before disconnecting the the compartment and the generator set possibility of carbon monoxide
battery connections. Ventilate the clean and free of debris to minimize the poisoning. Seek medical attention if
compartments containing batteries to risk of fire. Wipe up spilled fuels and the condition of affected persons does
prevent accumulation of explosive engine oil. not improve within minutes of breathing
gases. fresh air.
Combustible materials. A fire can
Battery short circuits. Explosion cause severe injury or death. Copper tubing exhaust systems.
can cause severe injury or death. Generator set engine fuels and fuel Carbon monoxide can cause severe
Short circuits can cause bodily injury vapors are flammable and explosive. nausea, fainting, or death. Do not
and/or equipment damage. Handle these materials carefully to use copper tubing in diesel exhaust
Disconnect the battery before minimize the risk of fire or explosion. systems. Sulfur in diesel exhaust
generator set installation or Equip the compartment or nearby area causes rapid deterioration of copper
maintenance. Remove all jewelry with a fully charged fire extinguisher. tubing exhaust systems, resulting in
before servicing the equipment. Use Select a fire extinguisher rated ABC or exhaust/water leakage.
tools with insulated handles. Remove BC for electrical fires or as
the negative (--) lead first when recommended by the local fire code or
disconnecting the battery. Reconnect an authorized agency. Train all
personnel on fire extinguisher
the negative (--) lead last when
operation and fire prevention
reconnecting the battery. Never
procedures.
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.
II Safety Precautions and Instructions TP-6069 6/03

Inspecting the exhaust system. The fuel system. Explosive fuel Ignition-protected equipment.
Carbon monoxide can cause severe 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
safety of the craft’s occupants, install a explosive. Use extreme care when vapors can cause an explosion.
carbon monoxide detector. Consult the handling and storing fuels. Store fuels USCG Regulation 33CFR183 requires
boat builder or dealer for approved in a well-ventilated area away from that all electrical devices (ship-to-shore
detector location and installation. spark-producing equipment and out of transfer switch, remote start panel,
Inspect the detector before each the reach of children. Never add fuel to etc.) must be ignition protected when
generator set use. In addition to routine the tank while the engine is running used in a gasoline and gaseous-fueled
exhaust system inspection, test the because spilled fuel may ignite on environment. The electrical devices
carbon monoxide detector per the contact with hot parts or from sparks. listed above are not ignition protected
manufacturer’s instructions and keep Do not smoke or permit flames or and are not certified to operate in a
the detector operational at all times. sparks to occur near sources of spilled gasoline and gaseous-fueled
fuel or fuel vapors. Keep the fuel lines environment such as an engine room or
Operating the generator set. Carbon
and connections tight and in good near fuel tanks. Acceptable locations
monoxide can cause severe nausea, condition. Do not replace flexible fuel are the wheelhouse and other living
fainting, or death. Carbon monoxide lines with rigid lines. Use flexible areas sheltered from rain and water
is an odorless, colorless, tasteless,
sections to avoid fuel line breakage splash.
nonirritating gas that can cause death if caused by vibration. Do not operate the
inhaled for even a short time. Use the
generator set in the presence of fuel
following precautions when installing leaks, fuel accumulation, or sparks. Hazardous Noise
and operating the generator set. Do not Repair fuel systems before resuming
install the exhaust outlet where exhaust
generator set operation.
can be drawn in through portholes, CAUTION
vents, or air conditioners. If the Draining the fuel system. Explosive
generator set exhaust discharge outlet fuel vapors can cause severe injury
is near the waterline, water could enter or death. Spilled fuel can cause an
the exhaust discharge outlet and close explosion. Use a container to catch fuel
or restrict the flow of exhaust. Never when draining the fuel system. Wipe up
operate the generator set without a spilled fuel after draining the system. Hazardous noise.
functioning carbon monoxide detector. Can cause hearing loss.
Be especially careful if operating the Installing the fuel system. Explosive
generator set when moored or fuel vapors can cause severe injury Never operate the generator set
or death. Fuel leakage can cause an without a muffler or with a faulty
anchored under calm conditions
because gases may accumulate. If explosion. Do not modify the tank or exhaust system.
the propulsion engine fuel system.
operating the generator set dockside,
moor the craft so that the exhaust Equip the craft with a tank that allows Engine noise. Hazardous noise can
discharges on the lee side (the side one of the two pickup arrangements cause hearing loss. Generator sets
described in the installation section. not equipped with sound enclosures
sheltered from the wind). Always be
aware of others, making sure your The tank and installation must conform can produce noise levels greater than
to USCG Regulations. 105 dBA. Prolonged exposure to noise
exhaust is directed away from other
boats and buildings. Avoid overloading Pipe sealant. Explosive fuel vapors levels greater than 85 dBA can cause
the craft. can cause severe injury or death. permanent hearing loss. Wear hearing
Fuel leakage can cause an explosion. protection when near an operating
Use pipe sealant on all threaded fittings generator set.
Fuel System to prevent fuel leakage. Use pipe
sealant that resists gasoline, grease,
lubrication oil, common bilge solvents, Hazardous Voltage/
WARNING salt deposits, and water. Electrical Shock
WARNING
Explosive fuel vapors.

Can cause severe injury or death.
Use extreme care when handling, storing, Hazardous voltage. Moving rotor.
and using fuels. Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
TP-6069 6/03 Safety Precautions and Instructions III

Welding the generator set. Can Testing live electrical circuits.
CAUTION cause severe electrical equipment Hazardous voltage or current can
damage. Before welding the generator 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
Welding the generator set. (ECM) connectors. (3) Disconnect all probes and follow the instructions of the
Can cause severe electrical generator set controller and voltage test equipment manufacturer when
equipment damage. regulator circuit board connectors. performing voltage tests. Observe the
(4) Disconnect the engine battery- following precautions when performing
Never weld components of the charging alternator connections. voltage tests: (1) Remove all jewelry.
generator set without first
(5) Attach the weld ground connection (2) Stand on a dry, approved electrically
disconnecting the battery, controller
close to the weld location. insulated mat. (3) Do not touch the
wiring harness, and engine electronic
enclosure or components inside the
control module (ECM). Short circuits. Hazardous enclosure. (4) Be prepared for the
voltage/current can cause severe system to operate automatically.
Grounding electrical equipment. injury or death. Short circuits can
(600 volts and under)
Hazardous voltage can cause cause bodily injury and/or equipment
severe injury or death. Electrocution damage. Do not contact electrical
is possible whenever electricity is connections with tools or jewelry while Hot Parts
present. Open the main circuit making adjustments or repairs.
breakers of all power sources before Remove all jewelry before servicing the
servicing the equipment. Configure the equipment. WARNING
installation to electrically ground the
Testing the voltage regulator.
generator set, transfer switch, and
Hazardous voltage can cause
related equipment and electrical
severe injury or death. High voltage
circuits to comply with applicable codes
is present at the voltage regulator heat
and standards. Never contact Hot coolant and steam.
sink. To prevent electrical shock do not
electrical leads or appliances when Can cause severe injury or death.
touch the voltage regulator heat sink
standing in water or on wet ground
when testing the voltage regulator. Before removing the pressure cap, stop
because these conditions increase the
(PowerBoostt, PowerBoostt III, and the generator set and allow it to cool. Then
risk of electrocution.
PowerBoostt V voltage regulator loosen the pressure cap to relieve
Disconnecting the electrical load. models only) pressure.
Hazardous voltage can cause
Electrical backfeed to the utility.
severe injury or death. Disconnect
Hazardous backfeed voltage can
the generator set from the load by WARNING
cause severe injury or death.
opening the line circuit breaker or by
Connect the generator set to the
disconnecting the generator set output
building/marina electrical system only
leads from the transfer switch and
through an approved device and after
heavily taping the ends of the leads.
the building/marina main switch is
High voltage transferred to the load
opened. Backfeed connections can Hot engine and exhaust system.
during testing may cause personal
cause severe injury or death to utility Can cause severe injury or death.
injury and equipment damage. Do not
personnel working on power lines
use the safeguard circuit breaker in Do not work on the generator set until it
and/or personnel near the work area.
place of the line circuit breaker. The cools.
Some states and localities prohibit
safeguard circuit breaker does not
unauthorized connection to the utility
disconnect the generator set from the
electrical system. Install a Checking the coolant level. Hot
load.
ship-to-shore transfer switch to prevent coolant can cause severe injury or
interconnection of the generator set death. Allow the engine to cool.
power and shore power. Release pressure from the cooling
system before removing the pressure
cap. To release pressure, cover the
pressure cap with a thick cloth and then
slowly turn the cap counterclockwise to
the first stop. Remove the cap after
pressure has been completely
released and the engine has cooled.
Check the coolant level at the tank if the
generator set has a coolant recovery
tank.
IV Safety Precautions and Instructions TP-6069 6/03

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. Do not touch hot engine parts. or death. Loose hardware can cause generator set may use both American
The engine and exhaust system the hardware or pulley to release from Standard and metric hardware. Use
components become extremely hot the generator set engine and can cause the correct size tools to prevent
during operation. personal injury. Retorque all rounding of the bolt heads and nuts.
crankshaft and rotor hardware after
servicing. Do not loosen the crankshaft NOTICE
Moving Parts hardware or rotor thrubolt when making When replacing hardware, do not
adjustments or servicing the generator substitute with inferior grade
WARNING set. Rotate the crankshaft manually in hardware. Screws and nuts are
a clockwise direction only. Turning the available in different hardness ratings.
crankshaft bolt or rotor thrubolt To indicate hardness, American
counterclockwise can loosen the Standard hardware uses a series of
hardware. markings, and metric hardware uses a
Servicing the generator set when it numeric system. Check the markings
Hazardous voltage. Moving rotor. on the bolt heads and nuts for
Can cause severe injury or death. is operating. Exposed moving parts
can cause severe injury or death. identification.
Operate the generator set only when Keep hands, feet, hair, clothing, and
all guards and electrical enclosures test leads away from the belts and NOTICE
are in place. pulleys when the generator set is Electrostatic discharge damage.
running. Replace guards, screens, and Electrostatic discharge (ESD)
covers before operating the generator damages electronic circuit boards.
WARNING set. Prevent electrostatic discharge
damage by wearing an approved
Sound shield removal. Exposed grounding wrist strap when handling
moving parts can cause severe electronic circuit boards or integrated
injury or death. The generator set circuits. An approved grounding wrist
must be operating in order to perform strap provides a high resistance (about
some scheduled maintenance 1 megohm), not a direct short, to
Rotating parts.
procedures. Be especially careful if the ground.
sound shield has been removed,
Operate the generator set only when leaving the belts and pulleys exposed. NOTICE
all guards, screens, and covers are in (Sound-shield-equipped models only) Fuse replacement. Replace fuses
place. with fuses of the same ampere rating
and type (for example: 3AB or 314,
Notice ceramic). Do not substitute clear
WARNING
glass-type fuses for ceramic fuses.
NOTICE Refer to the wiring diagram when the
ampere rating is unknown or
This generator set has been questionable.
rewired from its nameplate voltage
to NOTICE
Airborne particles. Saltwater damage. Saltwater quickly
Can cause severe injury or deteriorates metals. Wipe up saltwater
blindness. on and around the generator set and
Wear protective goggles and clothing 246242
remove salt deposits from metal
when using power tools, hand tools, surfaces.
or compressed air.
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.
TP-6069 6/03 Safety Precautions and Instructions V

Notes
VI Safety Precautions and Instructions TP-6069 6/03

Section 1 Introduction
Information in this publication represents data available 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
without notice and without any obligation or liability Marine generator set installations must comply with all
whatsoever. applicable regulations and standards.
x:in:001:002:a
Use the specification sheets as a guide in planning your
The safe and successful operation of a marine power installation. Use current dimension drawings and wiring
system depends primarily on the installation. See diagrams.
Figure 1-1. Use this manual as a guide to install the
1 2
17
3
16
KOHLER
15
4
14
5
13
9
8
12 6
11 7
10
585711
1. Exhaust mixer elbow (exhaust/water outlet) (not shown) 10. Fuel return line *
2. Heat exchanger (not shown) 11. Hose clamps
3. Coolant recovery tank (located on the unit on some models) 12. Fuel supply line *
4. Seawater strainer * 13. Mounting tray (mounting skid on 33--150 kW models)
5. Seawater pump (seawater inlet) 14. Battery/battery storage box
6. Seawater line * 15. Battery cables
7. Seacock * 16. Exhaust hose or exhaust line *
8. Craft stringers 17. Electrical leads (AC output leads/remote start panel leads)
9. Fuel feed pump (fuel inlet) * * Indicated components must conform to USCG regulations.
Figure 1-1 Typical Generator Set Location and Mounting
Note: See text for complete explanation of installation Note: Use two hose clamps on each end of all flexible
requirements. exhaust hose connections.
TP-6069 6/03 Section 1 Introduction 1

Notes
2 Section 1 Introduction TP-6069 6/03

Section 2 Location and Mounting
2.1 General Considerations Allow clearance for vibration and cooling during
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 generator set without an optional sound shield. Refer to
following. the instruction sheet for minimum clearances for
sound-shielded units. Also, allow space for the power
Installation Location Considerations takeoff (PTO) option, if equipped.
1. Choose a location that allows adequate space for Diesel generator sets are not ignition-protected. USCG
cooling and exhaust system installation, fuel Regulation 183.410 requires ignition-protected devices
system installation, ventilation, and service access only in gasoline/gaseous-fueled environments.
to the generator set (engine and generator).
2. Use craft stringers or other available structural 2.3 Mounting

members capable of supporting the generator set’s
weight. Mount the generator set as high as possible to avoid
contact with bilge splash and lower-lying vapors and to
3. Seal the generator set compartment from the cabin allow for downward pitch of the exhaust line toward the
to prevent exhaust gases and fuel vapors from exhaust outlet.
entering the cabin.
Craft stringers generally provide the best generator set
See the current generator set specification sheet or support. Ensure that the structural members can
Section 7 of this manual for generator set dimensions support the generator set’s weight and withstand its
and weights. See Figure 1-1 for a typical installation. vibration.
m:is:101:001
The generator set includes vibration mounts and a
mounting tray or skid. If desired, install additional
2.2 Location vibration isolating pads underneath the generator set’s
Locate the generator set to allow easy service access to base.
the generator set’s engine, controller, cooling, and fuel
Use the four mounting holes in the mounting tray to
system components. The engine compartment is often
mount the generator set securely to the craft.
the ideal location for the generator set if the propulsion
engine(s) does not obstruct access to the generator set For angular operating limits, consult the operation
and controller. 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 Section 2 Location and Mounting 3

Notes
4 Section 2 Location and Mounting TP-6069 6/03

Section 3 Cooling System
3.1 Ventilation
Engine combustion, generator cooling, and expulsion of
flammable and lethal fumes require ventilation. Provide
ventilation compliant with USCG Regulations governing
sizing of vents and other considerations. 1
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, 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. 3
For generator sets mounted in the engine compartment, 4

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

5
with the generator set for air requirements. The air intake 1-789
silencer/cleaner provides combustion air to the engine. 1. Inside packing

Do not compromise the recommended minimum 2. Outside packing
clearance of 38 mm (1.5 in.) between a duct opening and 3. Seacock cover
4. Direction of vessel movement
enclosure wall. The engine/generator performance will 5. Typical intake through-hull strainers
decline if you compromise these guidelines. See
Figure 3-1 for allowable intake restriction. Figure 3-2 Seacock Installation
Note: ISO 3046 derates apply. See Appendix C. 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
Model Allowable Intake Restriction
strainer. Install slotted-hole-design strainers with the
3.5EFOZ/4EOZ 200 mm H2O (1.96 kPa or less) slots parallel to the direction of the vessel’s movement.
4--125EFOZ/5--150EOZ 635 mm H2O (6.23 kPa or less)
Figure 3-1 Combustion Air Intake Restriction

2
3.2 Cooling System Components 1
The marine generator set’s cooling system requires the

following components.
4 3
3.2.1 Intake Through-Hull Strainer
(Seacock Cover) Note: Position the intakes in relation to the vessel’s
1-789
travel so neither is in the wake of the other.
Install a screened-intake, through-hull strainer to
1. Generator set intake
prevent entry of foreign objects. Use perforated,
2. Main engine intake
slotted-hole, or unrestricted-hole design strainers. See 3. Aft (rearward)
Figure 3-2 for examples of typical strainers. The inner 4. Fore (forward)
diameter of the strainer opening must be equal to or
Figure 3-3 Intake Strainer
greater than the inner diameter of the water-line hose to
the seawater pump.
TP-6069 6/03 Section 3 Cooling System 5

Do not use a speed scoop or cup design intake 3.2.4 Water Lines
through-hull strainer because it can cause a ramming
effect and force water upward, past the seawater pump, Water lines from the seacock to the engine-driven
and into the engine cylinders when the vessel is moving seawater pump are usually constructed of flexible hose.
and the generator set is shut down. Connect a flexible section of hose to the seawater pump
to allow the generator set to vibrate during operation.
Do not use hulls incorporating sea chests or other Support a nonflexible water line within 102 mm (4 in.) of
designs that provide a positive pressure to the raw water its connection to the flexible section.
pump for the intake through-hull strainers. Positive
pressure forces water past the raw water pump and into Keep the seawater hose as straight and short as
the engine. A sea chest is a concave molded-in-the-hull possible. If the hose is too long, usually over 4.6 m
chamber that aligns to the vessel’s direction of travel. A (15 ft.), water draw problems may occur. See Section 7
sea chest configuration applies positive pressure similar for the inlet water line hose size and the seawater
to a scoop-type through-hull strainer. 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
3.2.2 Seacock inlet.
Mount the seacock to the hull, assemble it to the intake,
and ensure that it is accessible for operation. Figure 3-2
shows a typical installation.
Avoid overcaulking the seacock. Excess caulk reduces

water flow and, in some cases, develops a barrier that
can force water upward, past the seawater pump, and
into the engine cylinders when the vessel is moving and
the generator set is shut down.
3.2.3 Seawater Strainer

Mount the seawater strainer to the seacock or
permanent structure at a point not higher than the
seawater pump. Ensure that the strainer is accessible
for service. See Figure 3-4 for a typical installation.
Some seawater strainers include a seacock and an 1

intake through-hull strainer. TP-5586-6
1. Seawater pump inlet
Maximum seawater inlet pressure at the seawater pump
is 34.5 kPa (5 psi). Excessive pressure will cause water Figure 3-5 Seawater Inlet Connection, Typical
ingestion.
3.2.5 Closed Heat Exchanger
(4--125EFOZ/5--150EOZ Models)
A closed heat exchanger is the best cooling method for
1 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.
2
3 3.2.6 Direct Water Cooled

(3.5EFOZ/4EOZ Models)
In a direct seawater cooling system, the impeller pump
1-789
1. Seawater pump circulates the seawater around the cylinder and through
2. Seawater strainer the cylinder head. A thermostat controls the cooling water
3. Seacock circuit temperature. Consult Figure 3-8 and the engine
Figure 3-4 Seawater Strainer operation manual for the cooling water circuit diagrams.
6 Section 3 Cooling System TP-6069 6/03

2
1
3
8 5
14
Arrow Description
10 Direction of Flow
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
Figure 3-6 Typical Closed/Heat Exchanger Cooling System (4/6.5/8.5/9/23/27EFOZ and 5/8/10/28/32EOZ
Models)

1 2
3
4 5
7
6
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
Figure 3-7 Typical Closed/Heat Exchanger Cooling System (11--20EFOZ,13--24EOZ, 33--125EFOZ and
40--150EOZ Models)

7
6
8
10
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)
Figure 3-8 Direct Water-Cooled Cooling System (3.5EFOZ and 4EOZ Models)

Notes

Section 4 Exhaust System
Operating the generator set. Carbon monoxide can cause

WARNING severe nausea, fainting, or death. Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can cause
death if inhaled for even a short time. Use the following
precautions when installing and operating the generator set.
Do not install the exhaust outlet where exhaust can be drawn
in through portholes, vents, or air conditioners. If the generator
Carbon monoxide.
set exhaust discharge outlet is near the waterline, water could
Can cause severe nausea,
enter the exhaust discharge outlet and close or restrict the flow
fainting, or death.
of exhaust. Never operate the generator set without a
The exhaust system must be leakproof functioning carbon monoxide detector. Be especially careful if
and routinely inspected. operating the generator set when moored or anchored under
calm conditions because gases may accumulate. If operating
Carbon monoxide symptoms. Carbon monoxide can the generator set dockside, moor the craft so that the exhaust
cause severe nausea, fainting, or death. Carbon monoxide discharges on the lee side (the side sheltered from the wind).
is a poisonous gas present in exhaust gases. Carbon Always be aware of others, making sure your exhaust is
monoxide poisoning symptoms include but are not limited to directed away from other boats and buildings. Avoid
the following: overloading the craft.
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles 4.1 Types
D Sleepiness, mental fatigue,
inability to concentrate
Kohlerr generator sets covered in this manual use
or speak clearly, blurred vision either wet or dry exhaust systems. Dry exhaust systems
D Stomachache, vomiting, nausea are common in commercial applications. See the
If experiencing any of these symptoms and carbon monoxide engine manual for specifications.
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 4.2 Exhaust Lines
attention if the condition of affected persons does not improve
within minutes of breathing fresh air. Use water-cooled exhaust lines in all marine
installations. Keep the lines as short and straight as
Inspecting the exhaust system. Carbon monoxide can
possible. NFPA 302 Fire Protection Standard for
cause severe nausea, fainting, or death. For the safety of
the craft’s occupants, install a carbon monoxide detector.
Pleasure and Commercial Motor Craft, Clause 4-3,
Consult the boat builder or dealer for approved detector recommends using two corrosion-resistant hose
location and installation. Inspect the detector before each clamps with a minimum width of 13 mm (1/2 in.) on each
generator set use. In addition to routine exhaust system end of the flexible exhaust hose connections.
inspection, test the carbon monoxide detector per the Kohler Co. requires a downward pitch of at least 13 mm
manufacturer’s instructions and keep the detector operational per 30.5 cm (1/2 in. per running foot). Use a flexible
at all times. exhaust hose that conforms to UL Standard 1129 for the
engine’s wet exhaust components between the mixer
elbow and the exhaust outlet.
TP-6069 6/03 Section 4 Exhaust System 11

4.3 Exhaust System Location, Locate the exhaust outlet at least 10 cm (4 in.) above the
waterline when the craft is loaded to maximum capacity.
Mounting, and Installation Install an exhaust port with the flap at the exhaust
Mount the silencer independently to eliminate stress on (transom) outlet to prevent water backup in following
the exhaust system and the exhaust manifold/mixer seas or when moving astern (backward). A lift in the
elbow. See Section 7 for the mixer elbow water line hose exhaust piping before the piping exits the craft prevents
size. See Figure 4-1 for the exhaust connection to the backwash. See Figure 4-4, item 1. Support the exhaust
mixer elbow. Provide an adequate hose length from the lines to prevent the formation of water pockets.
exhaust mixer to the silencer to allow for generator set
Exhaust system installation guidelines for various
movement.
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,
Model ≤ kPa (mm H2O)
4/8.5/9/23/27EFOZ and
9.81 (1000)
5/10/28/32EOZ
6.5EFOZ and 8EOZ 11.77 (1200)
1 11/16/17.5EFOZ and 13/20EOZ 6.37 (650)

TP-5586-6
1. Water/exhaust outlet
3.5/11.5/13/19/20EFOZ and
4.90 (500)
Figure 4-1 Mixer Elbow/Exhaust Connection, 4/14/15.5/23/24EOZ
Typical
33/40/55/70/80/100/125EFOZ
7.47 (762)
and 40/50/65/80/99/125/150EOZ
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
1 brackets or hanger straps for installation to stringers or
TP-6134- other suitable structure. Follow the instructions
1. Water/exhaust outlet provided with the silencer. Install any lift (see
Figure 4-4, item 1) in the exhaust line below the engine
Figure 4-2 Mixer Elbow/Exhaust Connection, exhaust manifold outlet.
3.5EFOZ/4EOZ Model Only
12 Section 4 Exhaust System TP-6069 6/03

4
5
6
3
2
1
7
13
9
15
Waterline
16 12
10
14
11
TP-5856-4
1. Slight lift improves silencing and prevents water backwash 13. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.
into the silencer (keep below the level of the exhaust per ft.)
manifold outlet) 14. Maximum distance between silencer and exhaust mixer
2. Silencer (customer-supplied) elbow of 3 m (10 ft.)
3. Exhaust manifold outlet 15. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.
4. Exhaust mixer elbow per ft.)
5. Heat exchanger (locations vary by model) 16. Minimum exhaust outlet distance above waterline of 10 cm
6. Coolant recovery tank (located on the unit on some models) (4 in.). Note: Vessel fully loaded.
7. Locate the coolant recovery tank at the same height as the Note: Data applies to both rear- and side-exhaust installations.
heat exchanger
8. Maximum seawater pump lift of 1 m (3 ft.) Note: Use two hose clamps on each end of all flexible exhaust
9. Seawater strainer hose connections.
10. Seacock
11. Intake strainer Note: Read the text for complete explanation of dimensions
12. Engine-driven seawater pump and other installation considerations.
Figure 4-4 Typical Above-Waterline Installation

4.3.2 Mid/Below-Waterline Installation
1
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 TP-5586-6
maintain their position and function. Allow a slight offset

1. Cut hose and connect siphon break and hardware
to clear the stringers or other permanent structures.
Protect the siphon break air inlet from dirt and debris. Figure 4-5 Siphon Break Connection (4EFOZ/5EOZ
model shown)
Note: To prevent water leakage on the generator set, do
not mount the siphon break directly over the Mount a typical silencer’s base no more than 1.2 m (4 ft.)
generator set. 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.

2
3 7 8
9
10
1
6
21
5
4 11
Waterline 19
20 16
12
18
15
13
17 14 TP-5856-4
1. Mounting base 15. Engine-driven seawater pump

2. Retaining cap 16. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)
3. Reed valve assembly 17. Maximum distance between silencer and exhaust mixer elbow
4. Maximum silencer vertical lift of 1.2 m (4 ft.) of 3 m (10 ft.)
5. Exhaust mixer elbow distance above waterline; if less than 18. Silencer (customer-supplied)
23 cm (9 in.), a siphon break is required 19. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm
6. Minimum siphon break distance above waterline of 30.5 cm (0.5 in. per ft.)
(1 ft.) 20. Minimum exhaust outlet distance above waterline of 10 cm
7. Siphon break (4 in.)
8. Exhaust mixer elbow 21. Exhaust hose (see Figure 4-7 for hose sizes)
9. Heat exchanger (locations vary by model) Note: Read the text for complete explanation of dimensions and
10. Coolant recovery tank (located on the unit on some models) other installation considerations.
11. Indicates the coolant recovery tank is at the same height as the
heat exchanger Note: Use two hose clamps on each end of all flexible exhaust
12. Seawater strainer hose connections.
13. Seacock
14. Intake strainer Note: Data applies to both rear- and side-exhaust installations.
Figure 4-6 Typical Mid and Below Waterline Installation
Exhaust Hose
Diameter
Models without Sound Shield Models with Sound Shield mm (in.)
3.5/4/6.5/8.5/9EFOZ 4/6.5/8.5/9/11/11.5/13/16/17.5/19/20EFOZ
4/5/8/10EOZ 5/8/10/13/14/15.5/20/23/24EOZ 51 (2.0)
11/11.5/13/16/17.5/19/20/23/27EFOZ 27EFOZ
13/14/15.5/20/23/24/28/32EOZ 32EOZ 76 (3.0)
33EFOZ 33EFOZ
40EOZ 40EOZ 89 (3.5)
40/55/70/80/100/125EFOZ 40/55/70/80/100/125EFOZ
50/65/80/99/125/150EOZ 50/65/80/99/125/150EOZ 102 (4.0)
Figure 4-7 Exhaust Hose Sizes

Notes

Section 5 Fuel System
2
WARNING
Explosive fuel vapors.

Use extreme care when handling, storing,
and using fuels.
Installing the fuel system. Explosive fuel vapors can

cause severe injury or death. Fuel leakage can cause an
explosion. Do not modify the tank or the propulsion engine fuel
system. Equip the craft with a tank that allows one of the two
pickup arrangements described in the installation section. The 1-788
tank and installation must conform to USCG Regulations. 1. Fuel line to propulsion engine
2. Fuel line to generator set
Note: Fuel system installations must conform to USCG
Regulations. Figure 5-1 Multiple Dip Tube Arrangement
m:is:102:001
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.
TP-6069 6/03 Section 5 Fuel System 17

5.2 Fuel Lines 5.3 Fuel Filters
Locate the fuel return line as far as practical from the fuel Conform to USCG Regulations regarding inline fuel
pickup to allow the tank fuel to cool the return fuel before filters or strainers.
delivery back to the fuel injectors. Incoming fuel cools
the injectors to achieve maximum engine efficiency.
5.4 Fuel Pump Lift
Note: Do not tee into the main propulsion engine’s fuel
line. See Figure 5-3 for fuel pump lift capabilities.
Under no circumstances should the propulsion engine Fuel

and generator set share pickup or return lines (through a Pump
Lift
tee arrangement) that would allow the larger engine to Model m (ft.)
starve fuel from the smaller engine. It is possible that the
operation of either engine could completely drain the 3.5/4/6.5/8.5/9/11/11.5/13/16/17.5/19/20/23/
fuel line of the other engine and make starting difficult. 27EFOZ and 1.2 (4)
4/5/8/10/13/14/15.5/20/23/24/28/32EOZ
Use a flexible hose section to connect the metallic line 33/40/55/70/80/100/125EFOZ
0.9 (3)
from the fuel tank to the engine’s fuel pump inlet and 40/50/65/80/99/125/150EOZ
connection point. Also, use a flexible hose section to
Figure 5-3 Fuel Pump Lift
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. 5.5 Fuel Consumption
Fuel Line Consult the current generator set specification sheets
ID Size for generator set fuel consumption rates.
Model mm (in.)
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.
18 Section 5 Fuel System TP-6069 6/03

Section 6 Electrical System
WARNING 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
Hazardous voltage. Moving rotor.
ship-to-shore transfer switch that allows the use of
shore/utility power when docked or generator set power
Operate the generator set only when when docked or at sea. The wiring then connects to a
all guards and electrical enclosures main circuit breaker box (panel board) that distributes
are in place. branch circuits throughout the craft. See Figure 6-1 for
AC voltage connections to the generator set. See
Electrical backfeed to the utility. Hazardous backfeed Section 8 for reconnection of the generator set.
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 6.2 Circuit Protection
main switch is opened. Backfeed connections can cause
severe injury or death to utility personnel working on power The AC circuit breakers (optional) protect the wiring
lines and/or personnel near the work area. Some states and from the AC circuit breakers to the vessel’s distribution
localities prohibit unauthorized connection to the utility
panel. AC circuit breakers trip when they detect a fault in
electrical system. Install a ship-to-shore transfer switch to
the output circuit.
prevent interconnection of the generator set power and shore
power.
After correcting the fault, reset the AC circuit breaker(s)
by placing them in the ON position. Restart the unit. Do
1 not start the unit under load. See Figure 6-2 or
2 Figure 6-3 for AC circuit breaker ratings. The unit’s
voltage configuration determines the circuit breaker
selection.
3
Note: Circuit breaker ampere rating and availability are
4 subject to change.
6.2.1 Circuit Breaker Considerations

Mounting location. Mount the circuit breakers in the
5 generator set’s controller (4--27EFOZ and 5--32EOZ
models) or the generator set’s junction box
(33--125EFOZ and 40--150EOZ models). See
6
Section 6.2.2 or Section 6.2.3.
1. Line side 585771
2. AC circuit breaker
3. Load side
Note: 3.5EFOZ and 4EOZ models already have circuit
4. L1/L2 phase (black) leads breakers installed.
5. GRD ground (green) lead
6. L0 neutral (white) lead Sizing. Use the generator set voltage/frequency
configuration to determine the circuit breaker
Figure 6-1 AC Voltage Connections in Controller
amperage. If the generator set voltage configuration
Box (5--32EOZ Models, Typical)
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.
TP-6069 6/03 Section 6 Electrical System 19

Max. Number Max. Number
Amps Voltage of Poles Model(s) Amps Voltage of Poles Type Model(s)
250 1 4EFOZ 60 600 3 UL/IEC 33EFOZ, 40EOZ
20
600 3 8.5/11.5EFOZ, 14EOZ 70 600 3 UL/IEC 40EFOZ, 40EOZ
22 250 2 4EFOZ, 5EOZ
80 480 3 UL/IEC 40EFOZ, 50EOZ
25 250 2 5EOZ
100 480 3 UL/IEC 55EFOZ, 50/65EOZ
1 6.5EFOZ
250 33/55EFOZ,
2 6.5EFOZ 100--125 600 3 IEC
30 40/65EOZ
11.5/17.5/20EFOZ,
600 3 100--125 600 3 IEC 70EFOZ, 80EOZ
14/20/24EOZ—3 phase
33 250 2 8EOZ 33/55EFOZ,
125 600 3 UL
40/65EOZ
1 4EFOZ
35 250 125 600 3 UL 70EFOZ, 80EOZ
2 8EOZ
250 1 5EOZ 33/40EFOZ,
128--160 600 3 IEC
40 40/50EOZ
11.5EFOZ,
600 3
14/20/24EOZ—3 phase 70/80EFOZ,
128--160 600 3 IEC
1 9EFOZ 80/99EOZ
42 250
2 9EFOZ, 8/10EOZ 33/40EFOZ,
150 600 3 UL
40/50EOZ
1 11/13EFOZ
240 70/80EFOZ,
2 11/11.5/17.5EFOZ 150 600 3 UL
80/99EOZ
50 250 2 9EFOZ, 10EOZ
70/80/100EFOZ,
20/23/27EFOZ, 160--400 600 3 UL
480 3 80/99/125/150EOZ
20/28/32EOZ—3 phase
55 250 1 5EOZ 70/80/100/125EFOZ,
160--400 600 3 IEC
80/99/125/150EOZ
1 13EFOZ
240 40/55EFOZ,
2 11/13EFOZ, 13/14EOZ 200 600 3 UL
50/65EOZ
60 250 1 6.5EFOZ
100EFOZ,
17.5/20EFOZ, 200 600 3 UL
600 3 99/125EOZ
20/24/28/32EOZ—3 phase
40/55EFOZ,
1 16EFOZ 200--250 600 3 IEC
240 50/65EOZ
2 13/20EFOZ, 15.5EOZ
70 70/100/125EFOZ,
250 1 6.5EFOZ, 8EOZ 200--250 600 3 IEC
80/125/150EOZ
600 3 20/24EOZ—3 phase 125EFOZ,
240--600 600 3 UL
1 16/19EFOZ 125/150EOZ
240 16EFOZ, 20EOZ—1 phase, 250 600 3 UL 55EFOZ, 65EOZ
2
80 20/24EOZ—3 phase
70/125EFOZ,
250 1 8EOZ 250 600 3 UL
80/125/150EOZ
480 3 23EFOZ—3 phase
125EFOZ,
85 250 1 9EFOZ, 10EOZ 250--630 600 3 IEC
125/150EOZ
1 19EFOZ
240 19EFOZ—1 phase Figure 6-3 AC Circuit Breaker Ratings (33--150 kW
90 2
20/23EOZ Models), Listed By Amps
480 3 27EFOZ—3 phase
240 2 23EOZ
WARNING
100 23/27EFOZ,
480 3
28/32EOZ—3 phase
23/27EFOZ, 28EOZ—
2
1 phase, 27EFOZ—3 phase
125 600
23/27EFOZ,
3
28/32EOZ—3 phase
28/32EOZ—1 phase, Accidental starting.
150 600 2
32EOZ— 3 phase Can cause severe injury or death.
175 600 2 32EOZ—1 phase
Disconnect the battery cables before
Figure 6-2 AC Circuit Breaker Ratings (4--27EFOZ working on the generator set.
and 5--32EOZ Models), Listed By Amps Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
20 Section 6 Electrical System TP-6069 6/03

Disabling the generator set. Accidental starting can 3. Remove the controller cover screws and remove
cause severe injury or death. Before working on the the access cover.
generator set or equipment connected to the set, disable the
generator set as follows: (1) Place the generator set start/stop 4. Remove the screws and nuts to remove the circuit
switch in the STOP position. (2) Disconnect the power to the breaker cover plate. Save the mounting hardware.
battery charger, if equipped. (3) Remove the battery cables,
negative (--) lead first. Reconnect the negative (--) lead last 5. Install the circuit breaker from the inside of the
when reconnecting the battery. Follow these precautions to cutout panel and mount it using existing screws
prevent the starting of the generator set by the remote removed in step 4. Position the circuit breaker with
start/stop switch. the ON in the normal upright position or to the left
side. Cover the cutout opening, if applicable, with
WARNING the circuit breaker cover plate. Use existing screws
to mount the cover plate.
6. See Section 8 for voltage reconnection.
Note: Kohlerr marine diesel generator sets are

fully frequency adjustable and voltage
reconnectable. To determine reconnection
Operate the generator set only when options, check the model’s specification
all guards and electrical enclosures sheet.
are in place.
7. Install insulation boots over stator lead terminals if
Grounding electrical equipment. Hazardous voltage can the kit includes insulation boots.
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit Note: See Section 8 for wiring instructions.
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator 8. Make the recommended connections for the
set, transfer switch, and related equipment and electrical following four reconnection systems using circuit
circuits to comply with applicable codes and standards. Never breakers:
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk of Two-pole circuit breaker with a single-voltage
electrocution. system (example: 120-volt, 3-wire). Attach
stator leads marked 2 and 4 to the side of the circuit
Short circuits. Hazardous voltage/current can cause
breaker marked LINE. Install the jumper lead
severe injury or death. Short circuits can cause bodily injury
across the LINE side of circuit breaker terminals
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
(see Section 8). Attach stator leads 1 and 3 to L0.
repairs. Remove all jewelry before servicing the equipment.
Single-pole circuit breaker with a 120-volt,
Electrical backfeed to the utility. Hazardous backfeed 2-wire, single-voltage system. Attach stator
voltage can cause severe injury or death. Connect the leads marked 2 and 4 to the side of the circuit
generator set to the building/marina electrical system only breaker marked LINE (see Section 8). Attach stator
through an approved device and after the building/marina leads 1 and 3 to L0.
main switch is opened. Backfeed connections can cause
severe injury or death to utility personnel working on power Two-pole circuit breaker with a dual-voltage
lines and/or personnel near the work area. Some states and system (example: 120/240-volt, 3-wire). Attach
localities prohibit unauthorized connection to the utility stator leads marked 1 and 4 to the side of the circuit
electrical system. Install a ship-to-shore transfer switch to
breaker marked LINE. Do not use a jumper lead
(see Section 8). Attach stator leads 2 and 3 to L0.
prevent interconnection of the generator set power and shore
power.
Single-pole circuit breaker with a 240-volt,
2-wire, single-voltage system. Attach the stator
6.2.2 Circuit Breaker Installation lead marked 2 to the side of the circuit breaker
(4--27EFOZ and 5--32EOZ Models) marked LINE (see Section 8). Bolt together leads 1
and 4 and tape to insulate from ground. Attach the
1. Place the generator set start/stop switch in the stator lead marked 3 to L0.
STOP position.
9. Connect the stator lead(s) used for neutral
2. Disconnect the generator set engine starting connection to the L0 stud. See the illustrations in
battery, negative (--) lead first. Section 8.

10. Connect the side of the circuit breaker marked 6.2.3 Circuit Breaker Installation
LOAD to the ship-to-shore switch or craft wiring. (33--125EFOZ and 40--150EOZ
Attach insulation boots to the black leads if the kit
includes insulation boots. With a single-pole circuit
Models)
breaker use one black lead (L1). With a two-pole 1. Place the generator set master switch in the OFF
circuit breaker use two black leads, L1 and L2. position.
Connect the neutral (white) lead to the L0 stud.
2. Disconnect the generator set engine starting
Connect the equipment ground (green) lead to
battery, negative (--) lead first.
GRD stud.
3. Remove the six screws from the right side junction
Note: Wire material. Use stranded copper for all box panel and remove the panel.
wiring. Use wire gauges and insulation,
conductor temperature ratings, sheath 4. Install the circuit breaker on the new panel with the
stripping, conductor support and protection, screws and washers. Position the ON side of the
conductor terminals and splices, and circuit breaker toward the rear of the junction box.
overcurrent protection (circuit breakers, See Figure 6-4.
fuses) that conform to standards and codes. 5. Attach stator leads L1, L2, and L3 to the extension
leads (if supplied) or to the line side of the circuit
Note: Follow USCG Regulations CFR33, Part 183 breaker. See Figure 8-5.
(Pleasurecraft) and CFR46 (Commercial
Craft) for marine applications. Note: Insulate leads with electrical tape after
connecting extension leads to stator leads.
Note: Wire protection. Use rubber grommets
and cable ties as necessary to protect and 6. Connect the neutral connection stator leads to the
secure wiring from sharp objects, the L0 stud.
exhaust system, and any moving parts.
Note: Verify that terminal positions and previously
11. Replace the controller cover or circuit breaker box made line lead connections allow room for
access panel. load connections to load studs.
7. Connect the load side of the circuit breaker to
12. Reconnect the generator set engine starting
customer-supplied craft wiring. Connect the
battery, negative (--) lead last.
neutral lead to the L0 stud. See Figure 8-5.
13. Make voltage or frequency adjustments according 8. Attach the new panel to the junction box using the
to Section 8. original six screws. See Figure 6-4.
Note: Voltage/frequency adjustable. Some 9. Check that the generator set master switch is in the
four-lead generator sets are not OFF position. Reconnect the generator set engine
voltage/frequency adjustable. To determine starting battery, negative (--) lead last.
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.

8
1 2 3 4 5 6 ASSEMBLY VIEW C-C

6 1 5
7
ASSEMBLY VIEW A ASSEMBLY VIEW B
DX-250000-B
1. Existing mounting hardware 6. Circuit breaker panel

2. Load lead access panel 7. Extension leads, if equipped
3. Screw 8. Rear connection used on 125-250 amp circuit breaker
4. Hang tag 9. Spacer used on 125-250 amp circuit breaker
5. Circuit breaker
Figure 6-4 Circuit Breaker Mounting
6.3 Installation In Steel or 6.4 Installation Regulations

Aluminum Vessels The U.S. Coast Guard governs generator set
Installation of a generator set in a vessel constructed of installation in U.S. pleasurecraft and commercial
a material capable of conducting current (e.g., steel or vessels. Refer to the applicable regulations below:
aluminum) is subject to considerations not normally
encountered in fiberglass or wood vessels. These U.S. Pleasurecraft Installation
differences include equipment grounding, grounding of Regulations
neutral conductors, ground-fault protection, and
isolation of galvanic currents. Title 33CFR, Chapter I, U.S. Coast Guard, Part 183
The scope of these topics is too extensive to be fully 1. Subpart I—Electrical Equipment
discussed here. Consult your local marine authority for
more information. 2. Subpart J—Fuel Systems
Before installing the generator set, check the available U.S. Commercial Vessel Installation
wiring diagrams in the operation manual to become
Regulations
familiar with the electrical system.
Title 46CFR, Chapter I, U.S. Coast Guard
1. Part 111—Electrical Systems
2. Part 182—Machinery Installation

m:sc:001:001

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 1
cranking-motor circuit. Size the conductor to match the
larger of the engine’s two battery cables. Figure 6-5 lists
cable sizes for generator set battery connections at 5
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
3 2
ground circuit be restricted or open because of oxidation 4 TP-5586-6
or loose hardware. Alternative electrical paths include
metallic fuel lines that can pose a fire hazard. See
1. Starter solenoid
Figure 6-7 and Section 7 for battery connections to the
2. Battery positive (+) connection
generator set. 3. Equipment ground
4. Battery negative (--) connection
5. Engine block mount
Cable Size (AWG)
Distance between
Generator Set At –18°C At 0°C At 24°C Figure 6-7 Battery Connections (5EOZ/4EFOZ
and Battery m (ft.) (0°F) (32°F) (75°F)
model shown)
12.2 (40) 00 0 1
9.1 (30) 0 1 2
7.6 (25) 1 2 4
6.6 Wiring
6.1 (20) 2 2 6 Use only stranded copper wire. Conform to USCG
4.6 (15) 2 4 6 Regulations 183.425 through 183.460 for wire gauges
and insulation, conductor temperature ratings, sheath
3.0 (10) 4 6 8
stripping, conductor support and protection, conductor
1.5 (5) 6 6 8 terminals and splices, and over-current protection
0.8 (2.5) 8 8 8 (circuit breakers, fuses). Use rubber grommets and
cable ties as necessary to protect and secure the wire
Figure 6-5 Battery Cable Sizes
from sharp objects, the exhaust system, and moving
Kohler Co. recommends using one 12-volt or 24-volt parts.
battery (as the spec requires) to start the generator. See
Figure 6-6 for minimum cold cranking amps (CCA)
recommendations.
12-Volt Starting Battery Size CCA

at --18°C (0°F) or 100 Amp. Hr.
Models CCA
3.5–20EFOZ and
4--24EOZ 500
23/27/100/125EFOZ and
28/32/125/150EOZ 800
33--80EFOZ and
40--99EOZ 640
Figure 6-6 Battery Recommendations

6.7 Remote Start Switch Note: Gauge senders. Gauge senders are available
for most generator sets. If using customer-
Connection supplied gauges, be sure they are compatible
Kohler Co. offers several remote panels for connection with generator set senders. Contact an
authorized Kohlerr service distributor/dealer.
to the generator set. Contact your local Kohlerr
Gauges and senders are available as service
distributor/dealer for detailed descriptions. See
items from an authorized Kohlerr service
Figure 6-8 for remote start panel connection to the
distributor/dealer.
generator set controller. Kohler Co. also offers a wiring
harness with a connector keyed to the controller box 33--150 kW Models: Various wiring harnesses,
connector. The other end of this harness has pigtails Y-connectors, pigtail harnesses, remote control panels,
that the installer can use to connect to a and remote annunciator panels (Decision-Makert 3+
customer-supplied start/stop switch or separate lights only) are available. See Figure 6-9 and Figure 6-10 for
and hourmeter. Consult wiring diagrams and instruction wiring options.
sheets for connection information/details.
3.5EFOZ/4EOZ Models: See Figure 7-3 for the
optional remote panel wiring.
1
DA-250000-H
1. Controller remote connector
Figure 6-8 Controller Remote Connector, Typical

ADV--6115A-A
Figure 6-9 Remote Controller and Harness Options (33--150 kW Models)

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

Notes

Section 7 Installation Drawings
Use the drawings in this section for installation Model No. Drawing Page
purposes. Consult the supplier and verify that the 3.5EFOZ and 4EOZ ADV-6652A-B 30
drawings are the most current for your specifications.
with remote options ADV-6652B-B 31
Installation drawings show exhaust outlet locations, fuel
4EFOZ and 5EOZ ADV-5850A-H 32
inlet and return connections, siphon break locations,
with sound shield ADV-5850B-H 33
and battery connections. See Figure 7-1 for installation
drawing identification. 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
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 ADV-6581B-E 49
with sound shield ADV-6581C-E 50
with electric clutch ADV-6581D-E 51
70/80EFOZ and 80/99EOZ ADV-6603A-D 60
and dry exhaust elbow ADV-6603B-D 61
with sound shield ADV-6603C-D 62
with electric clutch ADV-6603D-D 63
100/125EFOZ and 125/150EOZ ADV-6594A-D 64
with dry exhaust elbow ADV-6594C-D 66
Figure 7-1 Installation Drawings
TP-6069 6/03 Section 7 Installation Drawings 29

NOTE: Dimensions in [ ] are inch equivalents.
ADV-6652A-B
Figure 7-2 Dimension Drawing, 3.5EFOZ/4EOZ
30 Section 7 Installation Drawings TP-6069 6/03

ADV-6652B-B
Figure 7-3 Remote Options, 3.5EFOZ/4EOZ

NOTE: Dimensions in [ ] are inch equivalents.
ADV-5850A-H
Figure 7-4 Dimension Drawing, 4EFOZ/5EOZ

NOTE: Dimensions in [ ] are inch equivalents. ADV-5850B-H
Figure 7-5 Dimension Drawing, 4EFOZ/5EOZ with Sound Shield

NOTE: Dimensions in [ ] are inch equivalents. ADV-6284A-J
Figure 7-6 Dimension Drawing, 6.5EFOZ/8EOZ

NOTE: Dimensions in [ ] are inch equivalents. ADV-6284B-J
Figure 7-7 Dimension Drawing, 6.5EFOZ/8EOZ with Sound Shield

NOTE: Dimensions in [ ] are inch equivalents. ADV-6026A-K
Figure 7-8 Dimension Drawing, 8.5/9EFOZ and 10EOZ

NOTE: Dimensions in [ ] are inch equivalents. ADV-6026B-K
Figure 7-9 Dimension Drawing, 8.5/9EFOZ and 10EOZ with Sound Shield

NOTE: Dimensions in [ ] are inch equivalents. ADV-6512A-D

NOTE: Dimensions in [ ] are inch equivalents. ADV-6512B-D

NOTE: Dimensions in [ ] are inch equivalents. ADV-6513A-C
Figure 7-12 Dimension Drawing, 11.5/13EFOZ and 14/15.5EOZ

NOTE: Dimensions in [ ] are inch equivalents. ADV-6513B-C
Figure 7-13 Dimension Drawing, 11.5/13EFOZ and 14/15.5EOZ with Sound Shield

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

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

NOTE: Dimensions in [ ] are inch equivalents. ADV-6494A-C
Figure 7-16 Dimension Drawing, 19/20EFOZ and 23/24EOZ

NOTE: Dimensions in [ ] are inch equivalents. ADV-6494B-C
Figure 7-17 Dimension Drawing, 19/20EFOZ and 23/24EOZ with Sound Shield

NOTE: Dimensions in [ ] are inch equivalents. ADV-6285A-F

NOTE: Dimensions in [ ] are inch equivalents. ADV-6285B-F

NOTE: Dimensions in [ ] are inch equivalents. ADV-6581A-E

NOTE: Dimensions in [ ] are inch equivalents. ADV-6581B-E
Figure 7-21 Dimension Drawing, 33EFOZ/40EOZ with Fuel/Water Separator and Dry Exhaust Elbow

NOTE: Dimensions in [ ] are inch equivalents. ADV-6581C-E

NOTE: Dimensions in [ ] are inch equivalents. ADV-6581D-E
Figure 7-23 Dimension Drawing, 33EFOZ/40EOZ with Electric Clutch










Figure 7-33 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Fuel/Water Separator and Dry Exhaust Elbow

NOTE: Dimensions in [ ] are inch equivalents. ADV-6603C-D

NOTE: Dimensions in [ ] are inch equivalents. ADV-6603D-D
Figure 7-35 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Electric Clutch



NOTE: Dimensions in [ ] are inch equivalents. ADV-6594C-D
Figure 7-38 Dimension Drawing, 100/125EFOZ and 125/150EOZ with Dry Exhaust Elbow

Section 8 Reconnection/Adjustments
8.1 Four-Lead Reconnection breaker. Application of two single-pole circuit breakers

does not conform to NEC requirements for supplying a
The following information illustrates the reconnection of 200--240-volt load, even if the breakers are
four-lead generator sets. In all cases, conform to the mechanically attached together. Leads L1 and L2 are
National Electrical Code (NEC). for different phases; never connect them together.
NOTICE
Voltage reconnection. Affix a notice to the generator set after L0 (Neutral)
L0
reconnecting the set to a voltage different from the voltage on GRD.
the nameplate. Order voltage reconnection decal 246242 Ground
from an authorized service distributor/dealer.
L1
Load
Side
8.1.1 100--120-Volt Configurations Single-Pole
Circuit
If the installation requires a factory two-pole circuit Breaker
Line
breaker, do not connect the load-side terminals of the Side
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 4 3 2 1
the line side of the circuit breaker to balance the load of Stator Leads
the generator set.
60 Hz 50 Hz
L0--L1 100--120 Volt 100--120 Volt
L0 (Neutral) L0--L2 100--120 Volt 100--120 Volt
L0
GRD. Figure 8-2 100--120-Volt, 2-Wire Configuration
Ground
L1
L2 L0 (Neutral)
Load L0
Side GRD.
Ground
Two-Pole
Line L2
Circuit
Side Breaker L1
Load
Side
Factory
Two-Pole
Jumper Line Circuit
lead Side Breaker
4 3 2 1
100--120/200--240-Volt,
4 3 2 1 3-Wire
Figure 8-1 100--120-Volt, 3-Wire Configuration
Stator Leads
60 Hz 50 Hz
8.1.2 100--120/200--240-Volt
L0--L1 100--120 Volt 100--120 Volt
Configurations L0--L2 100--120 Volt 100--120 Volt
L1--L2 200--240 Volt 200--240 Volt
The 100--120/200--240-volt configuration does not use
a jumper lead. If the unit was originally wired for straight
Figure 8-3 100--120/200--240-Volt, 3-Wire
100--120 volt, 3-wire, remove the jumper lead (see
Configuration
Figure 8-1 for location). Select a two-pole circuit
TP-6069 6/03 Section 8 Reconnection/Adjustments 67

8.1.3 200--240-Volt Configurations regulator. See the generator set service manual for
information regarding frequency adjustment.
The 200--240-volt configuration does not use a jumper
lead. If the unit was originally wired for straight 100--120 The following information illustrates the reconnection of
volt, 3-wire, remove the jumper lead (see Figure 8-1 for twelve-lead generator sets. In all cases, conform to the
location). National Electrical Code (NEC).
L0 (Neutral) Reconnect the stator leads of the generator set to

L0 change output phase or voltage. Refer to the following
Ground GRD. procedure and connection schematics. Follow all safety
L1 precautions at the front of this manual and in the text
Load
Side during the reconnection procedure.
Line Single-Pole NOTICE

Side Circuit Voltage reconnection. Affix a notice to the generator set after
Breaker
reconnecting the set to a voltage different from the voltage on
the nameplate. Order voltage reconnection decal 246242
Tape to insulate
from an authorized service distributor/dealer.
from ground
Twelve-Lead Reconnection Procedure

4 3 2 1
200--220--240 Volt
Stator Leads 1. Place the generator start/stop switch in the STOP
2 Wire
position.
60 Hz 50 Hz
2. Disconnect generator set engine starting battery,
L0--L1 200-240 Volt 200--220--240 Volt
negative (--) lead first.
Figure 8-4 200--220--240-Volt, 2-Wire Configuration 3. Disconnect power to battery charger, if equipped.
4. Use Figure 8-5 to determine the generator set

8.2 Twelve-Lead Reconnection voltage configuration. Note the original voltage
The reconnection procedure details voltage and reconnect the generator set as needed. Route
reconnections only. If the generator set requires leads through current transformers (CTs) and
connect the leads according to the diagram for the
frequency changes, adjust the governor and voltage
desired phase and voltage.
EM-250000-E
Note: Current Transformers (CTs) are not used on all sets. CT dot or “HI” toward generator.
Figure 8-5 Generator Reconnection
68 Section 8 Reconnection/Adjustments TP-6069 6/03

Note: Position the current transformers with the Note: Equipment damage. Verify that the voltage
dot or HI side CT marking toward the ratings of the transfer switch, line circuit
generator set. breakers, and other accessories match the
desired line voltage.
Note: Only generator sets equipped with AC meter
controllers and/or safeguard circuit 8. Reconnect the starting battery, negative (--) lead
breakers require CTs. last. Place the generator set master switch in the
RUN position to start the generator set. Observe
5. If the controller has meters, remove the controller the voltmeter and verify that the unit has the
cover and reposition the meter scale lamp jumper desired line voltage connection.
(see Figure 8-6) matching the position of the
desired voltage (shown in Figure 8-5). Adjust the voltage using the voltage adjustment
potentiometer on the generator controller front
1 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

1 OFF 3
L3
L0--L1 L3--L1
L2 L1
HERTZ A--C VOLTS A--C AMPERES L1--L2 L1--L2
L1 L2
L1--L2AMPS L2--L3
VOLTS
LOWER METER SCALES
VOLTAGE S
EMERGENCY PREALARM
HIGH ENGINE HIGH ENGINE
TEMPERATURE
AUXILIARY
FAULT
AUXILIARY
PREALARM
TEMPERATURE
O
00000 STOP
TOTAL HOURS
ADJUST ONLY PREALARM
LOW OIL LOW OIL
PRESSURE
BATTERY
CHARGER FAULT
AIR
DAMPER
PRESSURE
LOW WATER EMERGENCY LOW BATTERY SYSTEM

TEMPERATURE STOP VOLTAGE READY
GENERATOR
LOW FUEL OVERSPEED OVERCRANK SWITCH
NOT IN AUTO
RUN OFF/RESET AUTO SILENCE NORMAL

OIL WATER BATTERY ALARM
PRESS TEMP
LAMP TEST
ADV-5849A-
1
1. Output voltage adjustment potentiometer
TP-5353-6
1. Lamp Jumper Figure 8-7 Voltage Adjustment
This is bpid
Figure 8-6 Meter Scale Lamp Jumper
6. The overvoltage shutdown is standard on 8.3 Decision-Maker 3+ Controller,

Decision-Makert 3+ controllers. The Overvoltage Shutdown
139/240-volt (low wye) and 277/480-volt (high
wye), 3-phase, 4-wire, 60 Hz configurations use Adjustment
different overvoltage shutdown settings than all Disconnecting the electrical load. Hazardous voltage can
other configurations. Recalibrate the overvoltage cause severe injury or death. Disconnect the generator set
shutdown if the reconnection changes the voltage from the load by opening the line circuit breaker or by
to or from one of these configurations. See disconnecting the generator set output leads from the transfer
Section 8.3, Decision-Maker 3+ Controller, switch and heavily taping the ends of the leads. High voltage
Overvoltage Shutdown Adjustment. Do not transferred to the load during testing may cause personal
recalibrate the overvoltage adjustment for other injury and equipment damage. Do not use the safeguard
voltage changes. circuit breaker in place of the line circuit breaker. The
safeguard circuit breaker does not disconnect the generator
7. If the controller has meters, set the phase selector set from the load.
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.

Short circuits. Hazardous voltage/current can cause Figure 8-8. The generator set should shut down on
severe injury or death. Short circuits can cause bodily injury an overvoltage fault in approximately 2 seconds.
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. 1 2
Overvoltage Shutdown Adjustment Procedure

1. Disconnect the generator set engine starting
battery, negative (--) lead first. Disconnect power to
the battery charger (if equipped). R41
2. With the generator set shut down, open the output LED4
line circuit breaker to disconnect the load from the

generator set.
P2 P1
3. Remove the controller cover.
A-336415-A
4. Wrap the shaft of an insulated-handle screwdriver

with electrical tape to insulate the metal shaft. Turn
1. Overvoltage adjustment potentiometer (R41)
the overvoltage potentiometer (R41) on the main 2. LED4 (red)
circuit board fully clockwise. See Figure 8-8.
Figure 8-8 Overvoltage Shutdown Adjustment on
5. Connect a digital AC voltmeter (or other 1% Main Circuit Board
minimum accuracy voltmeter) to terminals V0 and
V7 on the controller terminal block. See 10. Turn the voltage adjustment potentiometer
Figure 8-6. counterclockwise to prevent overvoltage shutdown
upon restart. Restart the generator set. Slowly
6. Reconnect the battery, negative (--) lead last. increase the voltage by turning the voltage
adjustment potentiometer clockwise. Verify the
7. Start the generator set by placing the generator set shutdown voltage point (115% of the nominal
master switch in the RUN position. output voltage) by observing the voltmeter and
noting when LED4 lights. The generator set should
8. Adjust the output voltage to 115% of the nominal
shut down on overvoltage fault in approximately
output voltage using the voltage adjustment
2 seconds. If the shutdown voltage point is not
potentiometer. If the voltage configuration is
115% of nominal voltage, repeat the calibration
139/240 volts (low wye) or 277/480 volts (high
output procedure; otherwise, continue to step 11.
wye), 3-phase, 4-wire, 60 Hz, adjust output voltage
to 160 volts across terminals V0 and V7. For all 11. Turn the voltage adjustment potentiometer
other voltages, adjust the output to 140 volts counterclockwise to prevent overvoltage shutdown
across terminals V0 and V7. upon restart. Restart the generator set. Readjust
Adjust the voltage using the voltage adjustment the generator set output to the nominal voltage
potentiometer on the generator controller front using the voltage adjustment potentiometer.
panel. See Figure 8-7. 12. Stop the generator set by placing the generator set
master switch in the OFF/RESET position. Seal
9. Use the insulated screwdriver to slowly rotate the the overvoltage adjustment potentiometer (R41)
overvoltage adjustment potentiometer (R41) with RTV sealant or equivalent. Replace the
counterclockwise until red LED4 lights. See controller cover.

Electroswitch
2-Wire Generator Sets 3-Wire Generator Sets
L1 L1
2 1 3 4 2 1 3 4
To Generator To Shore
Set Power
L2 L2
6 5 7 8 To Generator 6 5 7 8 To Shore
Set Power
L0
10 9 11 12
To Load
To Load
Kraus Naimler/American Solenoid

(Early Rectangular Design)
L1 L1
To Generator 1 2 6 5 To Shore 1 2 6 5
Set Power
L2 L2
Set Power
L0
9 10 14 13
To Load
To Load

(Newer Round Design)
L1 L1
3 2 4 1 To Shore 3 2 4 1
To Generator
Set Power
L2 L2
Set Power
L0
11 10 12 9
To Load
To Load
TP-5399-5
Figure 8-9 Marine Manual (Ship-to-Shore) Transfer Switch

Note: Broadrange generator sets. The following
adjustment procedure is for readjustment of the
4-Wire, 3-Phase Generator Sets
voltage regulator and governor for broadrange
generator sets with mechanical governors.
L1 L1
3 2 4 1 Note: Special tool. Frequency meter 50/60 Hz.
L2 L2
Note: Rheostat connection. Connect a
customer-provided rheostat across regulator
To Generator 7 6 8 5 To Shore
Set Power leads/terminals 33 and 66 to adjust the generator
output voltage from a location remote from the
L3 L3
generator set. The rheostat (10 kOhms, 1/2 watt
11 10 12 9
minimum) provides a 5-volt adjustment range.
L0 L0
15 14 16 13
L1 L2 L3 L0
To Load
I-940
Figure 8-10 Marine Manual (Ship-to-Shore) Transfer

Switch, continued
8.4 Voltage Regulator Adjustment

(4--27EFOZ and 5--32EOZ
Models) 1
2
3
WARNING 1. Voltage adjustment potentiometer TT-875-11
2. Stability adjustment potentiometer
3. Volts/Hz adjustment potentiometer
Figure 8-11 PowerBoost IIIE Voltage Regulator

Operate the generator set only when
all guards and electrical enclosures
are in place.
Testing the voltage regulator. Hazardous voltage can

cause severe injury or death. High voltage is present at the 8
voltage regulator heat sink. To prevent electrical shock do not 7
touch the voltage regulator heat sink when testing the voltage
STAB 6
regulator.
(PowerBoostt, PowerBoostt III, and PowerBoostt V 5
voltage regulator models only) V/HZ VOLTS
4
The voltage regulator is typically located in the 3

controller. Adjustments are possible without removing 2 3 1 2
the voltage regulator. The voltage regulator adjustment 1
procedure applies to both the PowerBoost IIIE
(Figure 8-11) and PowerBoost V (Figure 8-12) voltage 1. Voltage adjustment potentiometer
TT-875-11
regulators. 2. Stability adjustment potentiometer
3. Volts/Hz adjustment potentiometer
Figure 8-12 PowerBoost V Voltage Regulator

Stabilizer Potentiometer (Pot) fine tunes the regulator locknut and turn it clockwise or counterclockwise
circuitry to reduce light flicker. to achieve the desired frequency. See
Figure 8-13. If a second screw holds the governor
Voltage Adjustment Pot adjusts the generator voltage arm, loosen the locknut and back out the screw.
output within the range of approximately 100 to 130
volts. 9. If applicable, rotate the volts/Hz adjustment pot
clockwise until the voltage level begins to drop (as
Volts/Hz Pot determines the engine speed (Hz) at measured on the voltmeter). When set to these
which the generator output voltage begins to drop. specifications, the generator attempts to maintain
normal output until the engine speed drops below
Note: The volts/Hz adjustment does not apply to the the frequency set in step 8 as load is applied.
following models:
10. Readjust the engine speed to normal (63 Hz/
Model 1890 rpm for 60 Hz or 52.5 Hz/1575 rpm for
50 Hz). Tighten the locknut when the adjustments
4/6.5/8/8.5/9EFOZ
are complete. Turn the second screw, if used, to
5/8/9/10EOZ lock the governor arm in place and tighten the
locknut.
Note: On these models, turn the volts/Hz adjustment
pot full counterclockwise to stop and seal. No 11. Readjust the voltage adjustment pot if necessary.
further volts/Hz adjustments are required.
12. Readjust the stability pot if necessary.
Note: For optimum results, apply full load for voltage
regulator adjustment. 13. Use the remote rheostat, if equipped, to make final
voltage adjustments.
Voltage Regulator Adjustment Procedure 14. Stop the generator set.
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 1 2 1-929

frequency (factory setting 57.5–58 Hz for 60 Hz 1. Locknut
2. Speed adjusting screw
models or 47.5–48 Hz for 50 Hz models) as
measured on frequency meter. To change engine Figure 8-13 Governor Adjustment (4EFOZ/5EOZ
speed adjust the governor arm. Loosen the shown)

Notes

Appendix A Generator Selection and Wattage Requirements
Consider total wattage requirements (lights, motors, are DC powered by a 12-volt battery. Make sure the
appliances) when selecting a generator set or when calculated total wattage includes only lights actually on
sizing wattage usage in which available space and the generator set AC circuit.
construction limit the size of the generator set.
Air Conditioners
Motors
The starting characteristics of air conditioners vary
When figuring generator set capacity requirements for greatly; one 12,000 Btu unit has, for example, lower
loads that include electric motors, consider the high starting requirements than a 10,000 Btu unit of another
current demanded by the motors during startup. The variety. When using only one unit, there is usually no
inrush or starting current is typically 2--3 times higher starting problem, provided the lighting and appliance
than that required when the motor reaches normal load is not too high when starting the unit.
operating speed. Allow reserve for inrush demands plus
other loads which could be on the line as the electric Simultaneous starting of two air conditioning units,
motor starts. Use Figure 1 as a guide when selecting however, can present problems if the generator set
generator set capacity requirements involving motor capacity is marginal. Because of the variation in starting
loads. characteristics among air conditioners, this publication
makes no statements regarding multiple-motor starting
Motor Starting (Inrush) Running capabilities of the generator set covered. Consider
HP Watts Watts delayed starting or use of easy-starting devices on air
1/4 750 330 conditioner units whenever simultaneously starting
1/3 1000 400 more than one motor.
1/2 1500 600 See Figure 2 for typical air conditioner requirements.
3/4 2000 750 Information will vary with manufacturer.
1 3300 1100
2 4000 2000 Appliances
3 5000 3000
Generator sets often furnish AC for appliances such as
Figure 1 Motor Requirements TV, stereo, electric water heater, etc. With the exception
of the resistance-type loads such as the water heater,
Lighting requirements for appliances are usually low. Do not
overlook such loads when figuring total requirements.
To calculate lighting load, add the wattage of each Allow reserve capacity for anticipated appliance loads to
generator set-operated lamp. Note that not all of the avoid overloading a generator set.
lights or lamps are on the generator set AC circuit; some
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 Appendix A-1

Appendix B Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere CG center of gravity fglass. fiberglass
ABDC after bottom dead center CID cubic inch displacement FHM flat head machine (screw)
AC alternating current CL centerline fl. oz. fluid ounce
A/D analog to digital cm centimeter flex. flexible
ADC analog to digital converter CMOS complementary metal oxide freq. frequency
adj. adjust, adjustment substrate (semiconductor) FS full scale
ADV advertising dimensional cogen. cogeneration ft. foot, feet
drawing Com communications (port) ft. lbs. foot pounds (torque)
AHWT anticipatory high water conn. connection ft./min. feet per minute
temperature cont. continued g gram
AISI American Iron and Steel CPVC chlorinated polyvinyl chloride ga. gauge (meters, wire size)
Institute crit. critical
ALOP anticipatory low oil pressure gal. gallon
CRT cathode ray tube gen. generator
alt. alternator CSA Canadian Standards
Al aluminum genset generator set
Association GFI ground fault interrupter
ANSI American National Standards CT current transformer
Institute Cu copper GND, ground
(formerly American Standards gov. governor
Association, ASA) cu. in. cubic inch
cw. clockwise gph gallons per hour
AO anticipatory only
CWC city water-cooled gpm gallons per minute
API American Petroleum Institute
cyl. cylinder gr. grade, gross
approx. approximate, approximately
D/A digital to analog GRD equipment ground
AR as required, as requested
DAC digital to analog converter gr. wt. gross weight
AS as supplied, as stated, as
suggested dB decibel HxWxD height by width by depth
ASE American Society of Engineers dBA decibel (A weighted) HC hex cap
ASME American Society of DC direct current HCHT high cylinder head temperature
Mechanical Engineers DCR direct current resistance HD heavy duty
assy. assembly deg., ° degree HET high exhaust temperature
ASTM American Society for Testing dept. department hex hexagon
Materials dia. diameter Hg mercury (element)
ATDC after top dead center DI/EO dual inlet/end outlet HH hex head
ATS automatic transfer switch DIN Deutsches Institut fur Normung HHC hex head cap
auto. automatic e. V. HP horsepower
aux. auxiliary (also Deutsche Industrie hr. hour
A/V audiovisual Normenausschuss) HS heat shrink
avg. average DIP dual inline package hsg. housing
AVR automatic voltage regulator DPDT double-pole, double-throw HVAC heating, ventilation, and air
AWG American Wire Gauge DPST double-pole, single-throw conditioning
AWM appliance wiring material DS disconnect switch HWT high water temperature
bat. battery DVR digital voltage regulator Hz hertz (cycles per second)
BBDC before bottom dead center E, emer. emergency (power source) IC integrated circuit
BC battery charger, battery EDI electronic data interchange ID inside diameter, identification
charging EFR emergency frequency relay IEC International Electrotechnical
BCA battery charging alternator e.g. for example (exempli gratia) Commission
BCI Battery Council International EG electronic governor IEEE Institute of Electrical and
BDC before dead center EGSA Electrical Generating Systems Electronics Engineers
BHP brake horsepower Association IMS improved motor starting
blk. black (paint color), block EIA Electronic Industries in. inch
(engine) Association in. H2O inches of water
blk. htr. block heater EI/EO end inlet/end outlet in. Hg inches of mercury
BMEP brake mean effective pressure EMI electromagnetic interference in. lbs. inch pounds
bps bits per second emiss. emission Inc. incorporated
br. brass eng. engine ind. industrial
BTDC before top dead center EPA Environmental Protection int. internal
Agency int./ext. internal/external
Btu British thermal unit
EPS emergency power system I/O input/output
Btu/min. British thermal units per minute
ER emergency relay IP iron pipe
C Celsius, centigrade
ES engineering special, ISO International Organization for
cal. calorie engineered special
CARB California Air Resources Board Standardization
ESD electrostatic discharge J joule
CB circuit breaker est. estimated
cc cubic centimeter JIS Japanese Industry Standard
E-Stop emergency stop k kilo (1000)
CCA cold cranking amps etc. et cetera (and so forth)
ccw. counterclockwise K kelvin
exh. exhaust kA kiloampere
CEC Canadian Electrical Code
cfh cubic feet per hour
ext. external KB kilobyte (210 bytes)
F Fahrenheit, female
cfm cubic feet per minute
A-2 Appendix TP-6069 6/03

kg kilogram MW megawatt rms root mean square
kg/cm2 kilograms per square mW milliwatt rnd. round
centimeter µF microfarad ROM read only memory
kgm kilogram-meter N, norm. normal (power source) rot. rotate, rotating
kg/m3 kilograms per cubic meter NA not available, not applicable rpm revolutions per minute
kHz kilohertz nat. gas natural gas RS right side
kJ kilojoule NBS National Bureau of Standards RTV room temperature vulcanization
km kilometer NC normally closed SAE Society of Automotive
kOhm, kΩ kilo-ohm NEC National Electrical Code Engineers
kPa kilopascal NEMA National Electrical scfm standard cubic feet per minute
kph kilometers per hour Manufacturers Association SCR silicon controlled rectifier
kV kilovolt NFPA National Fire Protection s, sec. second
kVA kilovolt ampere Association SI Systeme international d’unites,
kVAR kilovolt ampere reactive Nm newton meter International System of Units
kW kilowatt NO normally open SI/EO side in/end out
kWh kilowatt-hour no., nos. number, numbers sil. silencer
kWm kilowatt mechanical NPS National Pipe, Straight SN serial number
L liter NPSC National Pipe, Straight-coupling SPDT single--pole, double--throw
LAN local area network NPT National Standard taper pipe SPST single--pole, single--throw
L x W x H length by width by height thread per general use spec, specs
lb. pound, pounds NPTF National Pipe, Taper-Fine specification(s)
lbm/ft3 pounds mass per cubic feet NR not required, normal relay sq. square
LCB line circuit breaker ns nanosecond sq. cm square centimeter
LCD liquid crystal display OC overcrank sq. in. square inch
ld. shd. load shed OD outside diameter SS stainless steel
LED light emitting diode OEM original equipment std. standard
manufacturer stl. steel
Lph liters per hour
OF overfrequency tach. tachometer
Lpm liters per minute
opt. option, optional TD time delay
LOP low oil pressure
OS oversize, overspeed TDC top dead center
LP liquefied petroleum OSHA Occupational Safety and Health
LPG liquefied petroleum gas TDEC time delay engine cooldown
Administration TDEN time delay emergency to
LS left side OV overvoltage normal
Lwa sound power level, A weighted oz. ounce TDES time delay engine start
LWL low water level p., pp. page, pages TDNE time delay normal to
LWT low water temperature PC personal computer emergency
m meter, milli (1/1000) PCB printed circuit board TDOE time delay off to emergency
M mega (106 when used with SI pF picofarad TDON time delay off to normal
units), male PF power factor temp. temperature
m3 cubic meter
ph., ∅ phase term. terminal
m3/min. cubic meters per minute TIF telephone influence factor
mA milliampere PHC Phillips head crimptite (screw)
PHH Phillips hex head (screw) TIR total indicator reading
man. manual tol. tolerance
max. maximum PHM pan head machine (screw)
PLC programmable logic control turbo. turbocharger
MB megabyte (220 bytes)
PMG permanent-magnet generator typ. typical (same in multiple
MCM one thousand circular mils locations)
MCCB molded-case circuit breaker pot potentiometer, potential
ppm parts per million UF underfrequency
meggar megohmmeter UHF ultrahigh frequency
MHz megahertz PROM programmable read-only
memory UL Underwriter’s Laboratories, Inc.
mi. mile psi pounds per square inch UNC unified coarse thread (was NC)
mil one one-thousandth of an inch pt. pint UNF unified fine thread (was NF)
min. minimum, minute PTC positive temperature coefficient univ. universal
misc. miscellaneous PTO power takeoff US undersize, underspeed
MJ megajoule PVC polyvinyl chloride UV ultraviolet, undervoltage
mJ millijoule qt. quart V volt
mm millimeter VAC volts alternating current
qty. quantity
mOhm, mΩ VAR voltampere reactive
milliohm R replacement (emergency)
power source VDC volts direct current
MOhm, MΩ rad. radiator, radius VFD vacuum fluorescent display
megohm
MOV metal oxide varistor RAM random access memory VGA video graphics adapter
MPa megapascal RDO relay driver output VHF very high frequency
mpg miles per gallon ref. reference W watt
mph miles per hour rem. remote WCR withstand and closing rating
MS military standard RFI radio frequency interference w/ with
m/sec. meters per second RH round head w/o without
MTBF mean time between failure RHM round head machine (screw) wt. weight
MTBO mean time between overhauls rly. relay xfmr transformer
mtg. mounting
TP-6069 6/03 Appendix A-3

Appendix C Generator Set Output Ratings Procedure
Kohler Co. develops the kilowatt output rating of a Kohlerr generator set installation. Figure 1 outlines the
marine generator set based upon the calculations calculations. Figure 2 contains examples of how heat
specified in ISO 3046 and ISO 8528-1. The calculations variables affect generator set ratings.
correct for environmental variables encountered in a
Generator Output corrected = Generator Output observed x Correction Factor

Output power is expected to be within ±5% of the specified rating when corrected to reference conditions.
Correction factors are determined using the following formulas:
1. For naturally aspirated compression-ignition engines (power limited by excess air):
C.F. = [1.175 (29.2 / Dry Barometer in. Hg)1 (Temperature _F + 460/537).75 -- .175]
x Alternator Efficiency Reference / Alternator Efficiency Observed
2. For turbocharged compression ignition engines:
C.F. = [1.175 (29.2 / Barometer Observed in. Hg).7 (Temperature _F + 460/537)2 -- .175]
3. For turbocharged and intercooled compression ignition engines:
C.F. = [1.175 (29.2 / Barometer Observed in. Hg).7 (Temperature _F + 460/537)1.2 -- .175]
Reference conditions:
Temperature: 77_F; Pressure: 29.2 in. Hg dry barometer.
Kohler sound shield increases ambient intake air approx. 12_F
Approximate derates:
Temperature: approximately 1% per 10_F (turbocharged engines have a greater derate);
Pressure (altitude): approximately 4% per 1000 ft. (1 in. Hg)
Figure 1 Generator Output
KEY
60 Hz 8.0
50 Hz 7.9
7.8
7.7
7.6
7.5
7.4
7.3
7.2
7.1
7.0
6.9
6.8
6.7
6.6
6.5
6.4
6.3
6.2
6.1
6.0
5.9
5.8
5.7
5.6
5.5
75 77 80 85 90 95 100 105 110 115 120
Temperature (_F)
Figure 2 Example: 6.5EFOZ/8EOZ kW Derates (ISO 3046/ISO 8258-1)
A-4 Appendix TP-6069 6/03

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
TP-6069 6/03d 7 Jurong Pier Road
Singapore 619159
E 2000, 2001, 2002, and 2003 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455

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Installation

Marine Generator Sets

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Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

TP-6069 6/03 Table of Contents

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IMPORTANT SAFETY Accidental Starting Disabling the generator set.

DANGER Disabling the generator set. Battery

TP-6069 6/03 Safety Precautions and Instructions I

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II Safety Precautions and Instructions TP-6069 6/03

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Explosive fuel vapors.

TP-6069 6/03 Safety Precautions and Instructions III

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IV Safety Precautions and Instructions TP-6069 6/03

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TP-6069 6/03 Safety Precautions and Instructions V

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VI Safety Precautions and Instructions TP-6069 6/03

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Figure 1-1 Typical Generator Set Location and Mounting

TP-6069 6/03 Section 1 Introduction 1

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2 Section 1 Introduction TP-6069 6/03

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2. Use craft stringers or other available structural 2.3 Mounting

Marine Generator Set Installations in

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

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

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As a rule, size each inlet- and outlet-vent area to a

For generator sets mounted in the engine compartment, 4

See the generator set specification sheet that shipped

silencer/cleaner provides combustion air to the engine. 1. Inside packing

Figure 3-1 Combustion Air Intake Restriction

3.2 Cooling System Components 1

The marine generator set’s cooling system requires the

TP-6069 6/03 Section 3 Cooling System 5

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Avoid overcaulking the seacock. Excess caulk reduces

3.2.3 Seawater Strainer

Some seawater strainers include a seacock and an 1

3 3.2.6 Direct Water Cooled

6 Section 3 Cooling System TP-6069 6/03

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1. Engine block 8. Thermostat closed

TP-6069 6/03 Section 3 Cooling System 7

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1. Oil cooler 8. Silencer (customer-supplied)

8 Section 3 Cooling System TP-6069 6/03

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1. Intake strainer 6. Zinc plug

TP-6069 6/03 Section 3 Cooling System 9

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10 Section 3 Cooling System TP-6069 6/03

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Operating the generator set. Carbon monoxide can cause

TP-6069 6/03 Section 4 Exhaust System 11

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6.5EFOZ and 8EOZ 11.77 (1200)