Kohler 100Efoz 125Eoz Users Manual Kfc

23EFOZ28EOZ to the manual 5c7f0fd8-af57-4032-ab34-3aaba29f438e

2015-01-21

: Kohler Kohler-100Efoz-125Eoz-Users-Manual-220075 kohler-100efoz-125eoz-users-manual-220075 kohler pdf

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Installation
Marine Generator Sets

Models:

3.5EFOZ/4EOZ, 4EFOZ/5EOZ
6.5EFOZ/8EOZ, 8.5EFOZ, 9EFOZ/10EOZ
11EFOZ/13EOZ, 11.5EFOZ/14EOZ
13EFOZ/15.5EOZ, 16EFOZ/20EOZ
17.5EFOZ/20EOZ, 19EFOZ/23EOZ
20EFOZ/24EOZ, 23EFOZ/28EOZ
27EFOZ/32EOZ, 33EFOZ/40EOZ
40EFOZ/50EOZ, 55EFOZ/65EOZ
70EFOZ/80EOZ, 80EFOZ/99EOZ
100EFOZ/125EOZ, 125EFOZ/150EOZ

TP-6069 6/03d

Table of Contents
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Section 2 Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
3
3
3

Section 3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1
Intake Through-Hull Strainer (Seacock Cover) . . . . . . . . . . . . . . . . . . . . .
3.2.2
Seacock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3
Seawater Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4
Water Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.5
Closed Heat Exchanger (4--125EFOZ/5--150EOZ Models) . . . . . . . . . .
3.2.6
Direct Water Cooled (3.5EFOZ/4EOZ Models) . . . . . . . . . . . . . . . . . . . . .

5
5
5
5
6
6
6
6
6

Section 4 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Exhaust Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Exhaust System Location, Mounting, and Installation . . . . . . . . . . . . . . . . . . . . . . .
4.3.1
Above-Waterline Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2
Mid/Below-Waterline Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11
11
11
12
12
14

Section 5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Fuel Pump Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17
17
18
18
18
18

Section 6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 AC Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1
Circuit Breaker Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2
Circuit Breaker Installation (4--27EFOZ and 5--32EOZ Models) . . . . . .
6.2.3
Circuit Breaker Installation (33--125EFOZ and 40--150EOZ Models) . .
6.3 Installation In Steel or Aluminum Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Remote Start Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19
19
19
19
21
22
23
23
24
24
25

Section 7 Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Section 8 Reconnection/Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Four-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1
100--120-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2
100--120/200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.3
200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Twelve-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Decision-Maker 3+ Controller Overvoltage Shutdown Adjustment . . . . . . . . . . . .
8.4 Voltage Regulator Adjustment (4--27EFOZ and 5--32EOZ Models) . . . . . . . . . . .

67
67
67
67
68
68
69
72

Appendix A Generator Selection and Wattage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix C Generator Set Output Ratings Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
TP-6069 6/03

Table of Contents

Safety Precautions and Instructions
IMPORTANT
SAFETY
INSTRUCTIONS. Electromechanical
equipment, including generator sets,
transfer switches, switchgear, and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.

DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death, or substantial
property damage.

WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or substantial
property damage.

CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.

NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition.
Replace missing or
damaged decals.

TP-6069 6/03

Accidental Starting
WARNING

Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling
the
generator set.
Accidental starting can cause
severe injury or death.
Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Disabling
the
generator set.
Accidental starting can cause
severe injury or death.
Before
working on the generator set or
equipment connected to the set,
disable the generator set as follows:
(1) Place the generator set start/stop
switch in the STOP position.
(2) Disconnect the power to the battery
charger, if equipped. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.

Disabling
the
generator set.
Accidental starting can cause
severe injury or death.
Before
working on the generator set or
equipment connected to the set,
disable the generator set as follows:
(1) Press the generator set on/off
button to shut down the generator set.
All indicator lamps dim. (2) Disconnect
the power to the battery charger, if
equipped. (3) Remove the battery
cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.

Battery
WARNING

Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and
burn skin.

Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.

Safety Precautions and Instructions

Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
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
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.

Engine Backfire/Flash
Fire

Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or
equipment
damage.
Disconnect
the
battery
before
generator
set
installation
or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery.
Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.

Safety Precautions and Instructions

Exhaust System
WARNING

WARNING

Fire.
Can cause severe injury or death.

Carbon monoxide.
Can cause severe
fainting, or death.

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

The exhaust system must be leakproof
and routinely inspected.

Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.

Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner/silencer
removed.
Combustible materials. A sudden
flash fire can cause severe injury or
death. Do not smoke or permit flames
or sparks near the fuel system. Keep
the compartment and the generator set
clean and free of debris to minimize the
risk of fire. Wipe up spilled fuels and
engine oil.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency.
Train all
personnel
on
fire extinguisher
operation
and
fire
prevention
procedures.

nausea,

Copper tubing exhaust systems.
Carbon monoxide can cause severe
nausea, fainting, or death. Do not
use copper tubing in diesel exhaust
systems. Sulfur in diesel exhaust
causes rapid deterioration of copper
tubing exhaust systems, resulting in
exhaust/water leakage.

TP-6069 6/03

Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the
safety of the craft’s occupants, install a
carbon monoxide detector. Consult the
boat builder or dealer for approved
detector location and installation.
Inspect the detector before each
generator set use. In addition to routine
exhaust system inspection, test the
carbon monoxide detector per the
manufacturer’s instructions and keep
the detector operational at all times.
Operating the generator set. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Use the
following precautions when installing
and operating the generator set. Do not
install the exhaust outlet where exhaust
can be drawn in through portholes,
vents, or air conditioners.
If the
generator set exhaust discharge outlet
is near the waterline, water could enter
the exhaust discharge outlet and close
or restrict the flow of exhaust. Never
operate the generator set without a
functioning carbon monoxide detector.
Be especially careful if operating the
generator set when moored or
anchored under calm conditions
because gases may accumulate. If
operating the generator set dockside,
moor the craft so that the exhaust
discharges on the lee side (the side
sheltered from the wind). Always be
aware of others, making sure your
exhaust is directed away from other
boats and buildings. Avoid overloading
the craft.

Fuel System
WARNING

The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
in a well-ventilated area away from
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an
explosion. Use a container to catch fuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.
Installing the fuel system. Explosive
fuel vapors can cause severe injury
or death. Fuel leakage can cause an
explosion. Do not modify the tank or
the propulsion engine fuel system.
Equip the craft with a tank that allows
one of the two pickup arrangements
described in the installation section.
The tank and installation must conform
to USCG Regulations.
Pipe sealant. Explosive fuel vapors
can cause severe injury or death.
Fuel leakage can cause an explosion.
Use pipe sealant on all threaded fittings
to prevent fuel leakage. Use pipe
sealant that resists gasoline, grease,
lubrication oil, common bilge solvents,
salt deposits, and water.

Ignition-protected
equipment.
Explosive fuel vapors can cause
severe injury or death. Gasoline
vapors can cause an explosion.
USCG Regulation 33CFR183 requires
that all electrical devices (ship-to-shore
transfer switch, remote start panel,
etc.) must be ignition protected when
used in a gasoline and gaseous-fueled
environment. The electrical devices
listed above are not ignition protected
and are not certified to operate in a
gasoline
and
gaseous-fueled
environment such as an engine room or
near fuel tanks. Acceptable locations
are the wheelhouse and other living
areas sheltered from rain and water
splash.

Hazardous Noise
CAUTION

Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.

Hazardous Voltage/
Electrical Shock
WARNING

Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing,
and using fuels.

Hazardous voltage. Moving rotor.
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

CAUTION

Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator
set
without
first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present.
Open the main circuit
breakers of all power sources before
servicing the equipment. Configure the
installation to electrically ground the
generator set, transfer switch, and
related equipment and electrical
circuits to comply with applicable codes
and standards.
Never contact
electrical leads or appliances when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.
Disconnecting the electrical load.
Hazardous voltage can cause
severe injury or death. Disconnect
the generator set from the load by
opening the line circuit breaker or by
disconnecting the generator set output
leads from the transfer switch and
heavily taping the ends of the leads.
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.

Safety Precautions and Instructions

Welding the generator set. Can
cause severe electrical equipment
damage. Before welding the generator
set perform the following steps:
(1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine batterycharging
alternator
connections.
(5) Attach the weld ground connection
close to the weld location.
Short
circuits.
Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.
Testing the voltage regulator.
Hazardous voltage can cause
severe injury or death. High voltage
is present at the voltage regulator heat
sink. To prevent electrical shock do not
touch the voltage regulator heat sink
when testing the voltage regulator.
(PowerBoostt, PowerBoostt III, and
PowerBoostt V voltage regulator
models only)
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death.
Connect the generator set to the
building/marina electrical system only
through an approved device and after
the building/marina main switch is
opened. Backfeed connections can
cause severe injury or death to utility
personnel working on power lines
and/or personnel near the work area.
Some states and localities prohibit
unauthorized connection to the utility
electrical
system.
Install
a
ship-to-shore transfer switch to prevent
interconnection of the generator set
power and shore power.

Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and follow the instructions of the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)

Hot Parts
WARNING

Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap, stop
the generator set and allow it to cool. Then
loosen the pressure cap to relieve
pressure.

WARNING

Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it
cools.

Checking the coolant level. Hot
coolant can cause severe injury or
death. Allow the engine to cool.
Release pressure from the cooling
system before removing the pressure
cap. To release pressure, cover the
pressure 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.
TP-6069 6/03

Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.

Moving Parts
WARNING

Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.

WARNING

Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.

Tightening the hardware. Flying
projectiles can cause severe injury
or death. Loose hardware can cause
the hardware or pulley to release from
the generator set engine and can cause
personal injury.
Retorque all
crankshaft and rotor hardware after
servicing. Do not loosen the crankshaft
hardware or rotor thrubolt when making
adjustments or servicing the generator
set. Rotate the crankshaft manually in
a clockwise direction only. Turning the
crankshaft bolt or rotor thrubolt
counterclockwise can loosen the
hardware.
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.
Sound shield removal. Exposed
moving parts can cause severe
injury or death. The generator set
must be operating in order to perform
some
scheduled
maintenance
procedures. Be especially careful if the
sound shield has been removed,
leaving the belts and pulleys exposed.
(Sound-shield-equipped models only)

Notice

WARNING

NOTICE
This generator set has been
rewired from its nameplate voltage
to
Airborne particles.
Can cause severe
blindness.

injury

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

246242

NOTICE
Hardware damage. The engine and
generator set may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads and nuts.

NOTICE
When replacing hardware, do not
substitute with inferior grade
hardware.
Screws and nuts are
available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of
markings, and metric hardware uses a
numeric system. Check the markings
on the bolt heads and nuts for
identification.

NOTICE
Electrostatic discharge damage.
Electrostatic
discharge
(ESD)
damages electronic circuit boards.
Prevent
electrostatic
discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short, to
ground.

NOTICE
Fuse replacement. Replace fuses
with fuses of the same ampere rating
and type (for example: 3AB or 314,
ceramic). Do not substitute clear
glass-type fuses for ceramic fuses.
Refer to the wiring diagram when the
ampere rating is unknown or
questionable.

NOTICE
Saltwater damage. Saltwater quickly
deteriorates metals. Wipe up saltwater
on and around the generator set and
remove salt deposits from metal
surfaces.

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

Notes

Safety Precautions and Instructions

TP-6069 6/03

Section 1 Introduction
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.

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

x:in:001:002:a

Use the specification sheets as a guide in planning your
installation. Use current dimension drawings and wiring
diagrams.

Marine generator set installations must comply with all
applicable regulations and standards.

The safe and successful operation of a marine power
system depends primarily on the installation. See
Figure 1-1. Use this manual as a guide to install the
2

1
17

3
16
KOHLER

4
14

5
13
9
8
6

7
10

585711

1.
2.
3.
4.
5.
6.
7.
8.
9.

Exhaust mixer elbow (exhaust/water outlet) (not shown)
Heat exchanger (not shown)
Coolant recovery tank (located on the unit on some models)
Seawater strainer *
Seawater pump (seawater inlet)
Seawater line *
Seacock *
Craft stringers
Fuel feed pump (fuel inlet) *

Figure 1-1

Fuel return line *
Hose clamps
Fuel supply line *
Mounting tray (mounting skid on 33--150 kW models)
Battery/battery storage box
Battery cables
Exhaust hose or exhaust line *
Electrical leads (AC output leads/remote start panel leads)

* Indicated components must conform to USCG regulations.

Typical Generator Set Location and Mounting

Note: See text for complete explanation of installation
requirements.

TP-6069 6/03

10.
11.
12.
13.
14.
15.
16.
17.

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

Section 1 Introduction

Notes

Section 1 Introduction

TP-6069 6/03

Section 2 Location and Mounting
2.1 General Considerations
The key to installation is location. Before making final
plans for locating a generator set, consider the
following.

Installation Location Considerations

Allow clearance for vibration and cooling during
operation. Allow a minimum of 38 mm (1.5 in.)
clearance on all sides (top, front, rear, and sides) of a
generator set without an optional sound shield. Refer to
the instruction sheet for minimum clearances for
sound-shielded units. Also, allow space for the power
takeoff (PTO) option, if equipped.

1. Choose a location that allows adequate space for
cooling and exhaust system installation, fuel
system installation, ventilation, and service access
to the generator set (engine and generator).

Diesel generator sets are not ignition-protected. USCG
Regulation 183.410 requires ignition-protected devices
only in gasoline/gaseous-fueled environments.

2. Use craft stringers or other available structural
members capable of supporting the generator set’s
weight.

2.3 Mounting

3. Seal the generator set compartment from the cabin
to prevent exhaust gases and fuel vapors from
entering the cabin.
See the current generator set specification sheet or
Section 7 of this manual for generator set dimensions
and weights. See Figure 1-1 for a typical installation.
m:is:101:001

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

Mount the generator set as high as possible to avoid
contact with bilge splash and lower-lying vapors and to
allow for downward pitch of the exhaust line toward the
exhaust outlet.
Craft stringers generally provide the best generator set
support. Ensure that the structural members can
support the generator set’s weight and withstand its
vibration.
The generator set includes vibration mounts and a
mounting tray or skid. If desired, install additional
vibration isolating pads underneath the generator set’s
base.
Use the four mounting holes in the mounting tray to
mount the generator set securely to the craft.
For angular operating limits, consult the operation
manual.

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

TP-6069 6/03

Section 2 Location and Mounting

Notes

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.

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

3
4

For generator sets mounted in the engine compartment,
increase the air flow to allow for the generator set’s
requirements. Install optional detection devices to
cause alarm, warning, or engine shutdown should
dangerous fumes accumulate in the compartment.
See the generator set specification sheet that shipped
with the generator set for air requirements. The air intake
silencer/cleaner provides combustion air to the engine.
Do not compromise the recommended minimum
clearance of 38 mm (1.5 in.) between a duct opening and
enclosure wall. The engine/generator performance will
decline if you compromise these guidelines. See
Figure 3-1 for allowable intake restriction.
Note: ISO 3046 derates apply. See Appendix C.
Model

Allowable Intake Restriction

3.5EFOZ/4EOZ

200 mm H2O (1.96 kPa or less)

5
1.
2.
3.
4.
5.

1-789

Inside packing
Outside packing
Seacock cover
Direction of vessel movement
Typical intake through-hull strainers

Figure 3-2

Seacock Installation

Do not align the strainer (in relation to the craft’s direction
of travel) with any other through-hull intakes. See
Figure 3-3. Flush mount the recommended through-hull
strainer. Install slotted-hole-design strainers with the
slots parallel to the direction of the vessel’s movement.

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

The marine generator set’s cooling system requires the
following components.
4

3.2.1

Intake Through-Hull Strainer
(Seacock Cover)

Install a screened-intake, through-hull strainer to
prevent entry of foreign objects. Use perforated,
slotted-hole, or unrestricted-hole design strainers. See
Figure 3-2 for examples of typical strainers. The inner
diameter of the strainer opening must be equal to or
greater than the inner diameter of the water-line hose to
the seawater pump.
TP-6069 6/03

Note: Position the intakes in relation to the vessel’s
1-789
travel so neither is in the wake of the other.
1.
2.
3.
4.

Generator set intake
Main engine intake
Aft (rearward)
Fore (forward)

Figure 3-3

Intake Strainer

Section 3 Cooling System

Do not use a speed scoop or cup design intake
through-hull strainer because it can cause a ramming
effect and force water upward, past the seawater pump,
and into the engine cylinders when the vessel is moving
and the generator set is shut down.
Do not use hulls incorporating sea chests or other
designs that provide a positive pressure to the raw water
pump for the intake through-hull strainers. Positive
pressure forces water past the raw water pump and into
the engine. A sea chest is a concave molded-in-the-hull
chamber that aligns to the vessel’s direction of travel. A
sea chest configuration applies positive pressure similar
to a scoop-type through-hull strainer.

3.2.2

Seacock

3.2.4

Water Lines

Water lines from the seacock to the engine-driven
seawater pump are usually constructed of flexible hose.
Connect a flexible section of hose to the seawater pump
to allow the generator set to vibrate during operation.
Support a nonflexible water line within 102 mm (4 in.) of
its connection to the flexible section.
Keep the seawater hose as straight and short as
possible. If the hose is too long, usually over 4.6 m
(15 ft.), water draw problems may occur. See Section 7
for the inlet water line hose size and the seawater
connection to the seawater pump inlet. Avoid running
the inlet pipe above the generator. See Figure 3-5 for
the seawater hose connection to the seawater pump
inlet.

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
intake through-hull strainer.

1
1. Seawater pump inlet

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

Figure 3-5

3.2.5

TP-5586-6

Seawater Inlet Connection, Typical

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

A closed heat exchanger is the best cooling method for
most applications. See Figure 3-6 or Figure 3-7 for a
typical installation. Provide space to access the
water-cooled exhaust manifold pressure cap.

3.2.6

1. Seawater pump
2. Seawater strainer
3. Seacock

Figure 3-4
6

Seawater Strainer

Section 3 Cooling System

1-789

Direct Water Cooled
(3.5EFOZ/4EOZ Models)

In a direct seawater cooling system, the impeller pump
circulates the seawater around the cylinder and through
the cylinder head. A thermostat controls the cooling water
circuit temperature. Consult Figure 3-8 and the engine
operation manual for the cooling water circuit diagrams.
TP-6069 6/03

4
6
8

5
7

Arrow Description
Direction of Flow

Seawater
Freshwater (Coolant/Antifreeze)

13
TP-5586-6

1.
2.
3.
4.
5.
6.
7.

Engine block
Exhaust manifold
Exhaust mixer elbow
Outlet flapper (exhaust/water discharge)
Silencer (customer supplied)
Thermostat open
Thermostat

Figure 3-6

TP-6069 6/03

8.
9.
10.
11.
12.
13.
14.

Thermostat closed
Heat exchanger
Engine-driven seawater pump
Seawater strainer
Seacock
Intake strainer
Engine-driven water pump

Typical Closed/Heat Exchanger Cooling System (4/6.5/8.5/9/23/27EFOZ and 5/8/10/28/32EOZ
Models)

Section 3 Cooling System

2
3
4

7
6

8
9
14

Seawater
Freshwater (Coolant/Antifreeze)

10
TP-5592-6

1.
2.
3.
4.
5.
6.
7.

Oil cooler
Engine block
Thermostat
Water-cooled manifold
Heat exchanger
Exhaust mixer elbow
Water-cooled turbocharger

Figure 3-7

8.
9.
10.
11.
12.
13.
14.

Silencer (customer-supplied)
Exhaust outlet
Intake strainer
Seacock
Seawater strainer
Engine-driven seawater pump
Engine-driven water pump

Typical Closed/Heat Exchanger Cooling System (11--20EFOZ,13--24EOZ, 33--125EFOZ and
40--150EOZ Models)

Section 3 Cooling System

TP-6069 6/03

7
6
8

5
4
2
1

TP-6134-

1.
2.
3.
4.
5.

Intake strainer
Seacock
Seawater strainer
Engine-driven seawater pump
Oil exchanger

Figure 3-8

TP-6069 6/03

6.
7.
8.
9.
10.

Zinc plug
Exhaust manifold elbow
Exhaust hose
Silencer (customer supplied)
Outlet flapper (exhaust/water discharge)

Direct Water-Cooled Cooling System (3.5EFOZ and 4EOZ Models)

Section 3 Cooling System

Notes

Section 3 Cooling System

TP-6069 6/03

Section 4 Exhaust System
WARNING

Carbon monoxide.
Can cause severe
fainting, or death.

nausea,

The exhaust system must be leakproof
and routinely inspected.

Carbon monoxide symptoms. Carbon monoxide can
cause severe nausea, fainting, or death. Carbon monoxide
is a poisonous gas present in exhaust gases. Carbon
monoxide poisoning symptoms include but are not limited to
the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide
poisoning is possible, seek fresh air immediately and remain
active. Do not sit, lie down, or fall asleep. Alert others to the
possibility of carbon monoxide poisoning. Seek medical
attention if the condition of affected persons does not improve
within minutes of breathing fresh air.
Inspecting the exhaust system. Carbon monoxide can
cause severe nausea, fainting, or death. For the safety of
the craft’s occupants, install a carbon monoxide detector.
Consult the boat builder or dealer for approved detector
location and installation. Inspect the detector before each
generator set use. In addition to routine exhaust system
inspection, test the carbon monoxide detector per the
manufacturer’s instructions and keep the detector operational
at all times.

TP-6069 6/03

Operating the generator set. Carbon monoxide can cause
severe nausea, fainting, or death. Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can cause
death if inhaled for even a short time. Use the following
precautions when installing and operating the generator set.
Do not install the exhaust outlet where exhaust can be drawn
in through portholes, vents, or air conditioners. If the generator
set exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the flow
of exhaust. Never operate the generator set without a
functioning carbon monoxide detector. Be especially careful if
operating the generator set when moored or anchored under
calm conditions because gases may accumulate. If operating
the generator set dockside, moor the craft so that the exhaust
discharges on the lee side (the side sheltered from the wind).
Always be aware of others, making sure your exhaust is
directed away from other boats and buildings. Avoid
overloading the craft.

4.1 Types
Kohlerr generator sets covered in this manual use
either wet or dry exhaust systems. Dry exhaust systems
are common in commercial applications. See the
engine manual for specifications.

4.2 Exhaust Lines
Use water-cooled exhaust lines in all marine
installations. Keep the lines as short and straight as
possible. NFPA 302 Fire Protection Standard for
Pleasure and Commercial Motor Craft, Clause 4-3,
recommends using two corrosion-resistant hose
clamps with a minimum width of 13 mm (1/2 in.) on each
end of the flexible exhaust hose connections.
Kohler Co. requires a downward pitch of at least 13 mm
per 30.5 cm (1/2 in. per running foot). Use a flexible
exhaust hose that conforms to UL Standard 1129 for the
engine’s wet exhaust components between the mixer
elbow and the exhaust outlet.

Section 4 Exhaust System

4.3 Exhaust System Location,
Mounting, and Installation
Mount the silencer independently to eliminate stress on
the exhaust system and the exhaust manifold/mixer
elbow. See Section 7 for the mixer elbow water line hose
size. See Figure 4-1 for the exhaust connection to the
mixer elbow. Provide an adequate hose length from the
exhaust mixer to the silencer to allow for generator set
movement.

Locate the exhaust outlet at least 10 cm (4 in.) above the
waterline when the craft is loaded to maximum capacity.
Install an exhaust port with the flap at the exhaust
(transom) outlet to prevent water backup in following
seas or when moving astern (backward). A lift in the
exhaust piping before the piping exits the craft prevents
backwash. See Figure 4-4, item 1. Support the exhaust
lines to prevent the formation of water pockets.
Exhaust system installation guidelines for various
generator set locations follow.
Information and
illustrations of stern- (rear) exhaust installations also
apply to side-exhaust installations. Where exhaust lines
require passage through bulkheads, use port (left)- or
starboard (right)- side exhaust outlets, also in
applications in which long exhaust lines to the transom
(rear) could cause excessive back pressure. See
Figure 4-3 for allowable back pressures. Should any
information regarding installation conflict with USCG
Regulations, follow USCG Regulations.

Model
4/8.5/9/23/27EFOZ and
5/10/28/32EOZ
6.5EFOZ and 8EOZ
1
1. Water/exhaust outlet

Figure 4-1

TP-5586-6

Mixer Elbow/Exhaust Connection,
Typical

1. Water/exhaust outlet

Figure 4-2

Mixer Elbow/Exhaust Connection,
3.5EFOZ/4EOZ Model Only

Section 4 Exhaust System

11.77 (1200)
6.37 (650)

3.5/11.5/13/19/20EFOZ and
4/14/15.5/23/24EOZ

4.90 (500)

33/40/55/70/80/100/125EFOZ
and 40/50/65/80/99/125/150EOZ

7.47 (762)

4.3.1

TP-6134-

9.81 (1000)

11/16/17.5EFOZ and 13/20EOZ

Figure 4-3

Allowable Exhaust
Back Pressure,
≤ kPa (mm H2O)

Allowable Exhaust Back Pressures

Above-Waterline Installation

Install a customer-supplied silencer with the silencer’s
outlet at a maximum of 3 m (10 horizontal ft.) from the
center of the engine’s exhaust outlet. See Figure 4-4.
Mount a typical silencer with the inlet and outlet
horizontal and with the drain plug down. Use an exhaust
hose pitch of at least 13 mm per 30.5 cm (0.5 in. per
running foot). Some silencers require two support
brackets or hanger straps for installation to stringers or
other suitable structure.
Follow the instructions
provided with the silencer.
Install any lift (see
Figure 4-4, item 1) in the exhaust line below the engine
exhaust manifold outlet.

TP-6069 6/03

4
5
6

2
1
7
8
13

15
Waterline
12

14
11

1. Slight lift improves silencing and prevents water backwash
into the silencer (keep below the level of the exhaust
manifold outlet)
2. Silencer (customer-supplied)
3. Exhaust manifold outlet
4. Exhaust mixer elbow
5. Heat exchanger (locations vary by model)
6. Coolant recovery tank (located on the unit on some models)
7. Locate the coolant recovery tank at the same height as the
heat exchanger
8. Maximum seawater pump lift of 1 m (3 ft.)
9. Seawater strainer
10. Seacock
11. Intake strainer
12. Engine-driven seawater pump

Figure 4-4

TP-6069 6/03

TP-5856-4

13. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.
per ft.)
14. Maximum distance between silencer and exhaust mixer
elbow of 3 m (10 ft.)
15. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.
per ft.)
16. Minimum exhaust outlet distance above waterline of 10 cm
(4 in.). Note: Vessel fully loaded.
Note:

Data applies to both rear- and side-exhaust installations.

Note:

Use two hose clamps on each end of all flexible exhaust
hose connections.

Note:

Read the text for complete explanation of dimensions
and other installation considerations.

Typical Above-Waterline Installation

Section 4 Exhaust System

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
maintain their position and function. Allow a slight offset
to clear the stringers or other permanent structures.
Protect the siphon break air inlet from dirt and debris.
Note: To prevent water leakage on the generator set, do
not mount the siphon break directly over the
generator set.

Section 4 Exhaust System

TP-5586-6

1. Cut hose and connect siphon break and hardware

Figure 4-5

Siphon Break Connection (4EFOZ/5EOZ
model shown)

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

TP-6069 6/03

2
7

8
9
10

1
6

Waterline

15
13

17
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Mounting base
Retaining cap
Reed valve assembly
Maximum silencer vertical lift of 1.2 m (4 ft.)
Exhaust mixer elbow distance above waterline; if less than
23 cm (9 in.), a siphon break is required
Minimum siphon break distance above waterline of 30.5 cm
(1 ft.)
Siphon break
Exhaust mixer elbow
Heat exchanger (locations vary by model)
Coolant recovery tank (located on the unit on some models)
Indicates the coolant recovery tank is at the same height as the
heat exchanger
Seawater strainer
Seacock
Intake strainer

Figure 4-6

15. Engine-driven seawater pump
16. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)
17. Maximum distance between silencer and exhaust mixer elbow
of 3 m (10 ft.)
18. Silencer (customer-supplied)
19. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm
(0.5 in. per ft.)
20. Minimum exhaust outlet distance above waterline of 10 cm
(4 in.)
21. Exhaust hose (see Figure 4-7 for hose sizes)
Note:

Read the text for complete explanation of dimensions and
other installation considerations.

Note:

Use two hose clamps on each end of all flexible exhaust
hose connections.

Note:

Data applies to both rear- and side-exhaust installations.

Typical Mid and Below Waterline Installation

Models with Sound Shield

Exhaust Hose
Diameter
mm (in.)

3.5/4/6.5/8.5/9EFOZ
4/5/8/10EOZ

4/6.5/8.5/9/11/11.5/13/16/17.5/19/20EFOZ
5/8/10/13/14/15.5/20/23/24EOZ

51 (2.0)

11/11.5/13/16/17.5/19/20/23/27EFOZ
13/14/15.5/20/23/24/28/32EOZ

27EFOZ
32EOZ

76 (3.0)

33EFOZ
40EOZ

89 (3.5)

40/55/70/80/100/125EFOZ
50/65/80/99/125/150EOZ

Models without Sound Shield

Figure 4-7

TP-6069 6/03

TP-5856-4

102 (4.0)

Exhaust Hose Sizes

Section 4 Exhaust System

Notes

Section 4 Exhaust System

TP-6069 6/03

Section 5 Fuel System
2

WARNING
1

Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing,
and using fuels.

Installing the fuel system. Explosive fuel vapors can
cause severe injury or death. Fuel leakage can cause an
explosion. Do not modify the tank or the propulsion engine fuel
system. Equip the craft with a tank that allows one of the two
pickup arrangements described in the installation section. The
tank and installation must conform to USCG Regulations.

Note: Fuel system installations must conform to USCG
Regulations.

1-788

1. Fuel line to propulsion engine
2. Fuel line to generator set

Figure 5-1

Multiple Dip Tube Arrangement
m:is:102:001

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

5.2 Fuel Lines

5.3 Fuel Filters

Locate the fuel return line as far as practical from the fuel
pickup to allow the tank fuel to cool the return fuel before
delivery back to the fuel injectors. Incoming fuel cools
the injectors to achieve maximum engine efficiency.

Conform to USCG Regulations regarding inline fuel
filters or strainers.

Note: Do not tee into the main propulsion engine’s fuel
line.
Under no circumstances should the propulsion engine
and generator set share pickup or return lines (through a
tee arrangement) that would allow the larger engine to
starve fuel from the smaller engine. It is possible that the
operation of either engine could completely drain the
fuel line of the other engine and make starting difficult.
Use a flexible hose section to connect the metallic line
from the fuel tank to the engine’s fuel pump inlet
connection point. Also, use a flexible hose section to
connect the metallic line from the fuel tank to the fuel
return connection point. The flexible section allows the
generator set to vibrate during operation.

Model

Fuel Line
ID Size
mm (in.)

3.5EFOZ and 4EOZ

6.4 (1/4)

4--125EFOZ and 5--150EOZ

9.7 (3/8)

Figure 5-2

5.4 Fuel Pump Lift
See Figure 5-3 for fuel pump lift capabilities.

Model

Fuel
Pump
Lift
m (ft.)

3.5/4/6.5/8.5/9/11/11.5/13/16/17.5/19/20/23/
27EFOZ and
4/5/8/10/13/14/15.5/20/23/24/28/32EOZ

1.2 (4)

33/40/55/70/80/100/125EFOZ
and 40/50/65/80/99/125/150EOZ

0.9 (3)

Figure 5-3

Fuel Pump Lift

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

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.

Section 5 Fuel System

TP-6069 6/03

Section 6 Electrical System
6.1 AC Voltage Connections

WARNING

Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Electrical backfeed to the utility. Hazardous backfeed
voltage can cause severe injury or death. Connect the
generator set to the building/marina electrical system only
through an approved device and after the building/marina
main switch is opened. Backfeed connections can cause
severe injury or death to utility personnel working on power
lines and/or personnel near the work area. Some states and
localities prohibit unauthorized connection to the utility
electrical system. Install a ship-to-shore transfer switch to
prevent interconnection of the generator set power and shore
power.
1
2

Make AC connections to the generator set inside the
controller box (4--27EFOZ and 5--32EOZ models) or
inside the junction box (33--125EFOZ and 40--150EOZ
models). Typically, the generator set connects to a
ship-to-shore transfer switch that allows the use of
shore/utility power when docked or generator set power
when docked or at sea. The wiring then connects to a
main circuit breaker box (panel board) that distributes
branch circuits throughout the craft. See Figure 6-1 for
AC voltage connections to the generator set. See
Section 8 for reconnection of the generator set.

6.2 Circuit Protection
The AC circuit breakers (optional) protect the wiring
from the AC circuit breakers to the vessel’s distribution
panel. AC circuit breakers trip when they detect a fault in
the output circuit.
After correcting the fault, reset the AC circuit breaker(s)
by placing them in the ON position. Restart the unit. Do
not start the unit under load. See Figure 6-2 or
Figure 6-3 for AC circuit breaker ratings. The unit’s
voltage configuration determines the circuit breaker
selection.
Note: Circuit breaker ampere rating and availability are
subject to change.

6.2.1
5
6
1.
2.
3.
4.
5.
6.

Line side
AC circuit breaker
Load side
L1/L2 phase (black) leads
GRD ground (green) lead
L0 neutral (white) lead

Figure 6-1

585771

AC Voltage Connections in Controller
Box (5--32EOZ Models, Typical)

Circuit Breaker Considerations

Mounting location. Mount the circuit breakers in the
generator set’s controller (4--27EFOZ and 5--32EOZ
models) or the generator set’s junction box
(33--125EFOZ and 40--150EOZ models).
See
Section 6.2.2 or Section 6.2.3.
Note: 3.5EFOZ and 4EOZ models already have circuit
breakers installed.
Sizing. Use the generator set voltage/frequency
configuration to determine the circuit breaker
amperage. If the generator set voltage configuration
changes, change the circuit breaker to provide optimum
protection.
For circuit breaker application and selection
information, contact an authorized distributor/dealer.
Have a qualified electrician or technician install circuit
breakers and reconnect the generator set. Comply with
all governing standards and codes.

TP-6069 6/03

Section 6 Electrical System

Amps
20

Max.
Voltage
250

Number
of Poles
1

Model(s)
4EFOZ

Number
of Poles

Type

Model(s)

600

UL/IEC

33EFOZ, 40EOZ

600

UL/IEC

40EFOZ, 40EOZ

480

UL/IEC

40EFOZ, 50EOZ

100

480

UL/IEC

55EFOZ, 50/65EOZ

600

8.5/11.5EFOZ, 14EOZ

250

4EFOZ, 5EOZ

250

5EOZ

6.5EFOZ

100--125

600

IEC

33/55EFOZ,
40/65EOZ

600

11.5/17.5/20EFOZ,
14/20/24EOZ—3 phase

100--125

600

IEC

70EFOZ, 80EOZ

250

8EOZ

125

600

4EFOZ

33/55EFOZ,
40/65EOZ

8EOZ

125

600

70EFOZ, 80EOZ

250

5EOZ

128--160

600

IEC

600

11.5EFOZ,
14/20/24EOZ—3 phase

33/40EFOZ,
40/50EOZ

9EFOZ

128--160

600

IEC

70/80EFOZ,
80/99EOZ

9EFOZ, 8/10EOZ

150

600

11/13EFOZ

33/40EFOZ,
40/50EOZ

11/11.5/17.5EFOZ

150

600

250

9EFOZ, 10EOZ

70/80EFOZ,
80/99EOZ

480

20/23/27EFOZ,
20/28/32EOZ—3 phase

160--400

600

70/80/100EFOZ,
80/99/125/150EOZ

250

5EOZ

160--400

600

IEC

70/80/100/125EFOZ,
80/99/125/150EOZ

200

600

40/55EFOZ,
50/65EOZ

200

600

100EFOZ,
99/125EOZ

200--250

600

IEC

40/55EFOZ,
50/65EOZ

200--250

600

IEC

70/100/125EFOZ,
80/125/150EOZ

240--600

600

125EFOZ,
125/150EOZ

250
30

33
35

250

250
240

240
60

250
600
240

100

125

13EFOZ

11/13EFOZ, 13/14EOZ

6.5EFOZ

17.5/20EFOZ,
20/24/28/32EOZ—3 phase

16EFOZ

13/20EFOZ, 15.5EOZ

6.5EFOZ, 8EOZ

600

20/24EOZ—3 phase

16/19EFOZ

16EFOZ, 20EOZ—1 phase,
20/24EOZ—3 phase

250

600

55EFOZ, 65EOZ

250

8EOZ

250

600

70/125EFOZ,
80/125/150EOZ

480

23EFOZ—3 phase

250

9EFOZ, 10EOZ

250--630

600

IEC

125EFOZ,
125/150EOZ

240

250

19EFOZ

19EFOZ—1 phase
20/23EOZ

480

27EFOZ—3 phase

240

23EOZ

23/27EFOZ,
28/32EOZ—3 phase

23/27EFOZ, 28EOZ—
1 phase, 27EFOZ—3 phase

23/27EFOZ,
28/32EOZ—3 phase

240

480

600

150

600

28/32EOZ—1 phase,
32EOZ— 3 phase

175

600

32EOZ—1 phase

Figure 6-2

Max.
Voltage

Amps

AC Circuit Breaker Ratings (4--27EFOZ
and 5--32EOZ Models), Listed By Amps

Section 6 Electrical System

Figure 6-3

AC Circuit Breaker Ratings (33--150 kW
Models), Listed By Amps

WARNING

TP-6069 6/03

Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the
generator set as follows: (1) Place the generator set start/stop
switch in the STOP position. (2) Disconnect the power to the
battery charger, if equipped. (3) Remove the battery cables,
negative (--) lead first. Reconnect the negative (--) lead last
when reconnecting the battery. Follow these precautions to
prevent the starting of the generator set by the remote
start/stop switch.

WARNING

3. Remove the controller cover screws and remove
the access cover.
4. Remove the screws and nuts to remove the circuit
breaker cover plate. Save the mounting hardware.
5. Install the circuit breaker from the inside of the
cutout panel and mount it using existing screws
removed in step 4. Position the circuit breaker with
the ON in the normal upright position or to the left
side. Cover the cutout opening, if applicable, with
the circuit breaker cover plate. Use existing screws
to mount the cover plate.
6. See Section 8 for voltage reconnection.

Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator
set, transfer switch, and related equipment and electrical
circuits to comply with applicable codes and standards. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk of
electrocution.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
Electrical backfeed to the utility. Hazardous backfeed
voltage can cause severe injury or death. Connect the
generator set to the building/marina electrical system only
through an approved device and after the building/marina
main switch is opened. Backfeed connections can cause
severe injury or death to utility personnel working on power
lines and/or personnel near the work area. Some states and
localities prohibit unauthorized connection to the utility
electrical system. Install a ship-to-shore transfer switch to
prevent interconnection of the generator set power and shore
power.

6.2.2

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

1. Place the generator set start/stop switch in the
STOP position.
2. Disconnect the generator set engine starting
battery, negative (--) lead first.
TP-6069 6/03

Note: Kohlerr marine diesel generator sets are
fully frequency adjustable and voltage
reconnectable. To determine reconnection
options, check the model’s specification
sheet.
7. Install insulation boots over stator lead terminals if
the kit includes insulation boots.
Note: See Section 8 for wiring instructions.
8. Make the recommended connections for the
following four reconnection systems using circuit
breakers:
Two-pole circuit breaker with a single-voltage
system (example: 120-volt, 3-wire). Attach
stator leads marked 2 and 4 to the side of the circuit
breaker marked LINE. Install the jumper lead
across the LINE side of circuit breaker terminals
(see Section 8). Attach stator leads 1 and 3 to L0.
Single-pole circuit breaker with a 120-volt,
2-wire, single-voltage system. Attach stator
leads marked 2 and 4 to the side of the circuit
breaker marked LINE (see Section 8). Attach stator
leads 1 and 3 to L0.
Two-pole circuit breaker with a dual-voltage
system (example: 120/240-volt, 3-wire). Attach
stator leads marked 1 and 4 to the side of the circuit
breaker marked LINE. Do not use a jumper lead
(see Section 8). Attach stator leads 2 and 3 to L0.
Single-pole circuit breaker with a 240-volt,
2-wire, single-voltage system. Attach the stator
lead marked 2 to the side of the circuit breaker
marked LINE (see Section 8). Bolt together leads 1
and 4 and tape to insulate from ground. Attach the
stator lead marked 3 to L0.
9. Connect the stator lead(s) used for neutral
connection to the L0 stud. See the illustrations in
Section 8.
Section 6 Electrical System

10. Connect the side of the circuit breaker marked
LOAD to the ship-to-shore switch or craft wiring.
Attach insulation boots to the black leads if the kit
includes insulation boots. With a single-pole circuit
breaker use one black lead (L1). With a two-pole
circuit breaker use two black leads, L1 and L2.
Connect the neutral (white) lead to the L0 stud.
Connect the equipment ground (green) lead to
GRD stud.
Note: Wire material. Use stranded copper for all
wiring. Use wire gauges and insulation,
conductor temperature ratings, sheath
stripping, conductor support and protection,
conductor terminals and splices, and
overcurrent protection (circuit breakers,
fuses) that conform to standards and codes.
Note: Follow USCG Regulations CFR33, Part 183
(Pleasurecraft) and CFR46 (Commercial
Craft) for marine applications.
Note: Wire protection. Use rubber grommets
and cable ties as necessary to protect and
secure wiring from sharp objects, the
exhaust system, and any moving parts.
11. Replace the controller cover or circuit breaker box
access panel.

6.2.3

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

1. Place the generator set master switch in the OFF
position.
2. Disconnect the generator set engine starting
battery, negative (--) lead first.
3. Remove the six screws from the right side junction
box panel and remove the panel.
4. Install the circuit breaker on the new panel with the
screws and washers. Position the ON side of the
circuit breaker toward the rear of the junction box.
See Figure 6-4.
5. Attach stator leads L1, L2, and L3 to the extension
leads (if supplied) or to the line side of the circuit
breaker. See Figure 8-5.
Note: Insulate leads with electrical tape after
connecting extension leads to stator leads.
6. Connect the neutral connection stator leads to the
L0 stud.
Note: Verify that terminal positions and previously
made line lead connections allow room for
load connections to load studs.

12. Reconnect the generator set engine starting
battery, negative (--) lead last.

7. Connect the load side of the circuit breaker to
customer-supplied craft wiring.
Connect the
neutral lead to the L0 stud. See Figure 8-5.

13. Make voltage or frequency adjustments according
to Section 8.

8. Attach the new panel to the junction box using the
original six screws. See Figure 6-4.

Note: Voltage/frequency adjustable.
Some
four-lead
generator
sets
are
not
voltage/frequency adjustable. To determine
adjustment possibilities, check the model’s
specification sheet or service manual. If you
are reconnecting the generator set from a
single-voltage
to
a
dual-voltage
configuration (example: from 120-volt to
120/240-volt) or a dual voltage to a single
voltage (example: from 120/240-volt to
120-volt) with the same primary voltage, do
not
adjust
the
voltage/frequency
adjustment. Adjust the voltage/frequency
for frequency changes or setting changes of
the primary voltage (example: from 120-volt
to 100-volt).
Refer to the model’s
specification sheet for reconnection
capability.

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

Section 6 Electrical System

TP-6069 6/03

ASSEMBLY VIEW C-C

ASSEMBLY VIEW A

ASSEMBLY VIEW B

DX-250000-B

1.
2.
3.
4.
5.

Existing mounting hardware
Load lead access panel
Screw
Hang tag
Circuit breaker

Figure 6-4

6.
7.
8.
9.

Circuit breaker panel
Extension leads, if equipped
Rear connection used on 125-250 amp circuit breaker
Spacer used on 125-250 amp circuit breaker

Circuit Breaker Mounting

6.3 Installation In Steel or
Aluminum Vessels
Installation of a generator set in a vessel constructed of
a material capable of conducting current (e.g., steel or
aluminum) is subject to considerations not normally
encountered in fiberglass or wood vessels. These
differences include equipment grounding, grounding of
neutral conductors, ground-fault protection, and
isolation of galvanic currents.
The scope of these topics is too extensive to be fully
discussed here. Consult your local marine authority for
more information.
Before installing the generator set, check the available
wiring diagrams in the operation manual to become
familiar with the electrical system.

6.4 Installation Regulations
The U.S. Coast Guard governs generator set
installation in U.S. pleasurecraft and commercial
vessels. Refer to the applicable regulations below:

U.S. Pleasurecraft Installation
Regulations
Title 33CFR, Chapter I, U.S. Coast Guard, Part 183
1. Subpart I—Electrical Equipment
2. Subpart J—Fuel Systems

U.S. Commercial Vessel Installation
Regulations
Title 46CFR, Chapter I, U.S. Coast Guard
1. Part 111—Electrical Systems
2. Part 182—Machinery Installation
m:sc:001:001

TP-6069 6/03

Section 6 Electrical System

6.5 Battery
Batteries and their installation must conform to USCG
Regulations 183.420 (a) through (g). Provide generator
sets with batteries separate from the propulsion
engine’s whenever possible. The starting/charging
systems of both the generator set and the engine must
have a common negative (--) ground.
USCG Regulation 183.415, Grounding, requires
connection of a common conductor to each grounded
cranking-motor circuit. Size the conductor to match the
larger of the engine’s two battery cables. Figure 6-5 lists
cable sizes for generator set battery connections at
various ambient temperatures. Connecting a common
conductor to each grounded cranking motor circuit
prevents the starting motor current from using
alternative electrical paths should the cranking motor
ground circuit be restricted or open because of oxidation
or loose hardware. Alternative electrical paths include
metallic fuel lines that can pose a fire hazard. See
Figure 6-7 and Section 7 for battery connections to the
generator set.
Distance between
Generator Set
and Battery m (ft.)
12.2
(40)

Cable Size (AWG)
At –18°C
(0°F)
00

At 0°C
(32°F)
0

At 24°C
(75°F)
1

9.1

(30)

7.6

(25)

6.1

(20)

4.6

(15)

3.0

(10)

1.5

(5)

0.8

(2.5)

Figure 6-5

Battery Cable Sizes

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

1.
2.
3.
4.
5.

2
TP-5586-6

Starter solenoid
Battery positive (+) connection
Equipment ground
Battery negative (--) connection
Engine block mount

Figure 6-7

Battery Connections (5EOZ/4EFOZ
model shown)

6.6 Wiring
Use only stranded copper wire. Conform to USCG
Regulations 183.425 through 183.460 for wire gauges
and insulation, conductor temperature ratings, sheath
stripping, conductor support and protection, conductor
terminals and splices, and over-current protection
(circuit breakers, fuses). Use rubber grommets and
cable ties as necessary to protect and secure the wire
from sharp objects, the exhaust system, and moving
parts.

12-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

Section 6 Electrical System

TP-6069 6/03

6.7 Remote Start Switch
Connection
Kohler Co. offers several remote panels for connection
to the generator set. Contact your local Kohlerr
distributor/dealer for detailed descriptions.
See
Figure 6-8 for remote start panel connection to the
generator set controller. Kohler Co. also offers a wiring
harness with a connector keyed to the controller box
connector. The other end of this harness has pigtails
that the installer can use to connect to a
customer-supplied start/stop switch or separate lights
and hourmeter. Consult wiring diagrams and instruction
sheets for connection information/details.

Note: Gauge senders. Gauge senders are available
for most generator sets. If using customersupplied gauges, be sure they are compatible
with generator set senders.
Contact an
authorized Kohlerr service distributor/dealer.
Gauges and senders are available as service
items from an authorized Kohlerr service
distributor/dealer.
33--150 kW Models:
Various wiring harnesses,
Y-connectors, pigtail harnesses, remote control panels,
and remote annunciator panels (Decision-Makert 3+
only) are available. See Figure 6-9 and Figure 6-10 for
wiring options.
3.5EFOZ/4EOZ Models: See Figure 7-3 for the
optional remote panel wiring.

DA-250000-H

1. Controller remote connector

Figure 6-8

TP-6069 6/03

Controller Remote Connector, Typical

Section 6 Electrical System

ADV--6115A-A

Figure 6-9
26

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

Section 6 Electrical System

TP-6069 6/03

Figure 6-10 Remote Controller and Harness Options (33--150 kW Models)
TP-6069 6/03

Section 6 Electrical System

Notes

Section 6 Electrical System

TP-6069 6/03

Section 7 Installation Drawings
Use the drawings in this section for installation
purposes. Consult the supplier and verify that the
drawings are the most current for your specifications.
Installation drawings show exhaust outlet locations, fuel
inlet and return connections, siphon break locations,
and battery connections. See Figure 7-1 for installation
drawing identification.

Model No.
3.5EFOZ and 4EOZ
with remote options

Drawing
ADV-6652A-B
ADV-6652B-B

Page
30
31

4EFOZ and 5EOZ
with sound shield
6.5EFOZ and 8EOZ
with sound shield
8.5/9EFOZ and 10EOZ

ADV-5850A-H
ADV-5850B-H
ADV-6284A-J
ADV-6284B-J
ADV-6026A-K

32
33
34
35
36

with sound shield
11EFOZ and 13EOZ
with sound shield
11.5/13EFOZ and 14/15.5EOZ
with sound shield

ADV-6026B-K
ADV-6512A-D
ADV-6512B-D
ADV-6513A-C
ADV-6513B-C

37
38
39
40
41

16/17.5EFOZ and 20EOZ
with sound shield
19/20EFOZ and 23/24EOZ
with sound shield
23/27EFOZ and 28/32EOZ

ADV-6481A-D
ADV-6481B-D
ADV-6494A-C
ADV-6494B-C
ADV-6285A-F

42
43
44
45
46

with sound shield
33EFOZ and 40EOZ
with fuel/water separator
and dry exhaust elbow
with sound shield
with electric clutch

ADV-6285B-F
ADV-6581A-E

47
48

ADV-6581B-E
ADV-6581C-E
ADV-6581D-E

49
50
51

40EFOZ and 50EOZ
with fuel/water separator
and dry exhaust elbow
with sound shield
with electric clutch
55EFOZ and 65EOZ

ADV-6582A-E

ADV-6582B-E
ADV-6582C-E
ADV-6582D-E
ADV-6583A-E

53
54
55
56

ADV-6583B-E
ADV-6583C-E
ADV-6583D-E
ADV-6603A-D

57
58
59
60

ADV-6603B-D

ADV-6603C-D
ADV-6603D-D
ADV-6594A-D
ADV-6594B-D
ADV-6594C-D

62
63
64
65
66

with fuel/water separator
and dry exhaust elbow
with sound shield
with electric clutch
70/80EFOZ and 80/99EOZ
with fuel/water separator
and dry exhaust elbow
with sound shield
with electric clutch
100/125EFOZ and 125/150EOZ
with sound shield
with dry exhaust elbow

Figure 7-1

TP-6069 6/03

Installation Drawings

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-2
30

ADV-6652A-B

Dimension Drawing, 3.5EFOZ/4EOZ

Section 7 Installation Drawings

TP-6069 6/03

ADV-6652B-B

Figure 7-3
TP-6069 6/03

Remote Options, 3.5EFOZ/4EOZ
Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-4
32

ADV-5850A-H

Dimension Drawing, 4EFOZ/5EOZ

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-5
TP-6069 6/03

ADV-5850B-H

Dimension Drawing, 4EFOZ/5EOZ with Sound Shield
Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-6
34

ADV-6284A-J

Dimension Drawing, 6.5EFOZ/8EOZ

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-7
TP-6069 6/03

ADV-6284B-J

Dimension Drawing, 6.5EFOZ/8EOZ with Sound Shield
Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-8
36

ADV-6026A-K

Dimension Drawing, 8.5/9EFOZ and 10EOZ

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-9
TP-6069 6/03

ADV-6026B-K

Dimension Drawing, 8.5/9EFOZ and 10EOZ with Sound Shield
Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6512A-D

Figure 7-10 Dimension Drawing, 11EFOZ/13EOZ
38

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6512B-D

Figure 7-11 Dimension Drawing, 11EFOZ/13EOZ with Sound Shield
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6513A-C

Figure 7-12 Dimension Drawing, 11.5/13EFOZ and 14/15.5EOZ
40

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6513B-C

Figure 7-13 Dimension Drawing, 11.5/13EFOZ and 14/15.5EOZ with Sound Shield
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6481A-D

Figure 7-14 Dimension Drawing, 16/17.5EFOZ and 20EOZ
42

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6481B-D

Figure 7-15 Dimension Drawing, 16/17.5EFOZ and 20EOZ with Sound Shield
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6494A-C

Figure 7-16 Dimension Drawing, 19/20EFOZ and 23/24EOZ
44

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6494B-C

Figure 7-17 Dimension Drawing, 19/20EFOZ and 23/24EOZ with Sound Shield
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6285A-F

Figure 7-18 Dimension Drawing, 23/27EFOZ and 28/32EOZ
46

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6285B-F

Figure 7-19 Dimension Drawing, 23/27EFOZ and 28/32EOZ with Sound Shield
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6581A-E

Figure 7-20 Dimension Drawing, 33EFOZ/40EOZ
48

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6581B-E

Figure 7-21 Dimension Drawing, 33EFOZ/40EOZ with Fuel/Water Separator and Dry Exhaust Elbow
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6581C-E

Figure 7-22 Dimension Drawing, 33EFOZ/40EOZ with Sound Shield
50

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6581D-E

Figure 7-23 Dimension Drawing, 33EFOZ/40EOZ with Electric Clutch
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6582A-E

Figure 7-24 Dimension Drawing, 40EFOZ/50EOZ
52

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6582B-E

Figure 7-25 Dimension Drawing, 40EFOZ/50EOZ with Fuel/Water Separator and Dry Exhaust Elbow
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6582C-E

Figure 7-26 Dimension Drawing, 40EFOZ/50EOZ with Sound Shield
54

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6582D-E

Figure 7-27 Dimension Drawing, 40EFOZ/50EOZ with Electric Clutch
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6583A-E

Figure 7-28 Dimension Drawing, 55EFOZ/65EOZ
56

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6583B-E

Figure 7-29 Dimension Drawing, 55EFOZ/65EOZ with Fuel/Water Separator and Dry Exhaust Elbow
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6583C-E

Figure 7-30 Dimension Drawing, 55EFOZ/65EOZ with Sound Shield
58

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6583D-E

Figure 7-31 Dimension Drawing, 55EFOZ/65EOZ with Electric Clutch
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6603A-D

Figure 7-32 Dimension Drawing, 70/80EFOZ and 80/99EOZ
60

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6603B-D

Figure 7-33 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Fuel/Water Separator and Dry Exhaust Elbow
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6603C-D

Figure 7-34 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Sound Shield
62

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6603D-D

Figure 7-35 Dimension Drawing, 70/80EFOZ and 80/99EOZ with Electric Clutch
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6594A-D

Figure 7-36 Dimension Drawing, 100/125EFOZ and 125/150EOZ
64

Section 7 Installation Drawings

TP-6069 6/03

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6594B-D

Figure 7-37 Dimension Drawing, 100/125EFOZ and 125/150EOZ with Sound Shield
TP-6069 6/03

Section 7 Installation Drawings

NOTE: Dimensions in [ ] are inch equivalents.

ADV-6594C-D

Figure 7-38 Dimension Drawing, 100/125EFOZ and 125/150EOZ with Dry Exhaust Elbow
66

Section 7 Installation Drawings

TP-6069 6/03

Section 8 Reconnection/Adjustments
8.1 Four-Lead Reconnection
The following information illustrates the reconnection of
four-lead generator sets. In all cases, conform to the
National Electrical Code (NEC).

breaker. Application of two single-pole circuit breakers
does not conform to NEC requirements for supplying a
200--240-volt load, even if the breakers are
mechanically attached together. Leads L1 and L2 are
for different phases; never connect them together.

NOTICE
L0 (Neutral)

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.

8.1.1

Ground
Load
Side

100--120-Volt Configurations

If the installation requires a factory two-pole circuit
breaker, do not connect the load-side terminals of the
circuit breaker together; see Figure 8-1.
If the
installation requires a 100--120-volt, 2-wire system, use
a single-pole circuit breaker. See Figure 8-2. When
connecting stator phase leads together, size the output
lead (L1) to handle the amperage. Use a jumper lead on
the line side of the circuit breaker to balance the load of
the generator set.

Line
Side

100--120 Volt
100--120 Volt

Figure 8-2

Figure 8-1

100--120 Volt
100--120 Volt

100--120-Volt, 2-Wire Configuration

L1
L2

L0 (Neutral)

L0
GRD.

Ground

Two-Pole
Circuit
Breaker

L2
L1

Load
Side

Jumper
lead
3

50 Hz

L0
GRD.

Load
Side

Single-Pole
Circuit
Breaker

Stator Leads

L0--L1
L0--L2

Ground

Line
Side

60 Hz
L0 (Neutral)

L0
GRD.

Factory
Two-Pole
Circuit
Breaker

Line
Side

100--120-Volt, 3-Wire Configuration

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

Stator Leads

8.1.2

100--120/200--240-Volt
Configurations

The 100--120/200--240-volt configuration does not use
a jumper lead. If the unit was originally wired for straight
100--120 volt, 3-wire, remove the jumper lead (see
Figure 8-1 for location). Select a two-pole circuit

TP-6069 6/03

60 Hz
L0--L1
L0--L2
L1--L2

Figure 8-3

100--120 Volt
100--120 Volt
200--240 Volt

50 Hz
100--120 Volt
100--120 Volt
200--240 Volt

100--120/200--240-Volt, 3-Wire
Configuration

Section 8 Reconnection/Adjustments

8.1.3

200--240-Volt Configurations

The 200--240-volt configuration does not use a jumper
lead. If the unit was originally wired for straight 100--120
volt, 3-wire, remove the jumper lead (see Figure 8-1 for
location).
L0 (Neutral)

L0
GRD.

Ground

Load
Side
Line
Side

Single-Pole
Circuit
Breaker
Tape to insulate
from ground

regulator. See the generator set service manual for
information regarding frequency adjustment.
The following information illustrates the reconnection of
twelve-lead generator sets. In all cases, conform to the
National Electrical Code (NEC).
Reconnect the stator leads of the generator set to
change output phase or voltage. Refer to the following
procedure and connection schematics. Follow all safety
precautions at the front of this manual and in the text
during the reconnection procedure.
NOTICE
Voltage reconnection. Affix 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.

Twelve-Lead Reconnection Procedure
4

Stator Leads
60 Hz
L0--L1

Figure 8-4

200--220--240 Volt
2 Wire
50 Hz

200-240 Volt 200--220--240 Volt

200--220--240-Volt, 2-Wire Configuration

8.2 Twelve-Lead Reconnection
The
reconnection
procedure
details
voltage
reconnections only. If the generator set requires
frequency changes, adjust the governor and voltage

1. Place the generator start/stop switch in the STOP
position.
2. Disconnect generator set engine starting battery,
negative (--) lead first.
3. Disconnect power to battery charger, if equipped.
4. Use Figure 8-5 to determine the generator set
voltage configuration. Note the original voltage
and reconnect the generator set as needed. Route
leads through current transformers (CTs) and
connect the leads according to the diagram for the
desired phase and voltage.

EM-250000-E

Note:

Current Transformers (CTs) are not used on all sets. CT dot or “HI” toward generator.

Figure 8-5
68

Generator Reconnection

Section 8 Reconnection/Adjustments

TP-6069 6/03

Note: Position the current transformers with the
dot or HI side CT marking toward the
generator set.
Note: Only generator sets equipped with AC meter
controllers
and/or
safeguard
circuit
breakers require CTs.
5. If the controller has meters, remove the controller
cover and reposition the meter scale lamp jumper
(see Figure 8-6) matching the position of the
desired voltage (shown in Figure 8-5).
1

Note: Equipment damage. Verify that the voltage
ratings of the transfer switch, line circuit
breakers, and other accessories match the
desired line voltage.
8. Reconnect the starting battery, negative (--) lead
last. Place the generator set master switch in the
RUN position to start the generator set. Observe
the voltmeter and verify that the unit has the
desired line voltage connection.
Adjust the voltage using the voltage adjustment
potentiometer on the generator controller front
panel. See Figure 8-7.
9. Stop the generator set after completing the voltage
adjustment.
10. Disconnect the external voltmeter if used. Replace
the controller cover.

UPPER METER SCALES
1

OFF

L0--L1

HERTZ

A--C VOLTS

L2
L1--L2

A--C AMPERES

L3
L3--L1
L1
L1--L2

L1
L1--L2

AMPS
L2--L3
VOLTS
LOWER METER SCALES

OIL
PRESS

ADJUST

EMERGENCY
STOP
ONLY

WATER
TEMP

S
O

VOLTAGE

00000

TOTAL HOURS

PREALARM
HIGH ENGINE
TEMPERATURE

HIGH ENGINE
TEMPERATURE

AUXILIARY
FAULT

AUXILIARY
PREALARM

PREALARM
LOW OIL
PRESSURE

LOW OIL
PRESSURE

BATTERY
CHARGER FAULT

AIR
DAMPER

LOW WATER
TEMPERATURE

EMERGENCY
STOP

LOW BATTERY
VOLTAGE

SYSTEM
READY

LOW FUEL

OVERSPEED

OVERCRANK

RUN

BATTERY

OFF/RESET

AUTO

GENERATOR
SWITCH
NOT IN AUTO
SILENCE NORMAL
ALARM
LAMP

TEST

ADV-5849A-

1. Output voltage adjustment potentiometer
TP-5353-6

1. Lamp Jumper

Figure 8-6

Meter Scale Lamp Jumper

6. The overvoltage shutdown is standard on
Decision-Makert 3+
controllers.
The
139/240-volt (low wye) and 277/480-volt (high
wye), 3-phase, 4-wire, 60 Hz configurations use
different overvoltage shutdown settings than all
other configurations. Recalibrate the overvoltage
shutdown if the reconnection changes the voltage
to or from one of these configurations. See
Section 8.3, Decision-Maker 3+ Controller,
Overvoltage Shutdown Adjustment.
Do not
recalibrate the overvoltage adjustment for other
voltage changes.
7. If the controller has meters, set the phase selector
switch to the L1-L2 position (1-phase or 3-phase
configuration depending on generator set
connection). Connect a voltmeter across leads L1
and L2 if the controller has no meters.

TP-6069 6/03

Figure 8-7

Voltage Adjustment
This is bpid

8.3 Decision-Maker 3+ Controller,
Overvoltage Shutdown
Adjustment
Disconnecting the electrical load. Hazardous voltage can
cause severe injury or death. Disconnect the generator set
from the load by opening the line circuit breaker or by
disconnecting the generator set output leads from the transfer
switch and heavily taping the ends of the leads. High voltage
transferred to the load during testing may cause personal
injury and equipment damage. Do not use the safeguard
circuit breaker in place of the line circuit breaker. The
safeguard circuit breaker does not disconnect the generator
set from the load.

Section 8 Reconnection/Adjustments

Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.

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

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
line circuit breaker to disconnect the load from the
generator set.

LED4

3. Remove the controller cover.

P1
A-336415-A

4. Wrap the shaft of an insulated-handle screwdriver
with electrical tape to insulate the metal shaft. Turn
the overvoltage potentiometer (R41) on the main
circuit board fully clockwise. See Figure 8-8.

1. Overvoltage adjustment potentiometer (R41)
2. LED4 (red)

Figure 8-8
5. Connect a digital AC voltmeter (or other 1%
minimum accuracy voltmeter) to terminals V0 and
V7 on the controller terminal block.
See
Figure 8-6.
6. Reconnect the battery, negative (--) lead last.
7. Start the generator set by placing the generator set
master switch in the RUN position.
8. Adjust the output voltage to 115% of the nominal
output voltage using the voltage adjustment
potentiometer. If the voltage configuration is
139/240 volts (low wye) or 277/480 volts (high
wye), 3-phase, 4-wire, 60 Hz, adjust output voltage
to 160 volts across terminals V0 and V7. For all
other voltages, adjust the output to 140 volts
across terminals V0 and V7.
Adjust the voltage using the voltage adjustment
potentiometer on the generator controller front
panel. See Figure 8-7.
9. Use the insulated screwdriver to slowly rotate the
overvoltage adjustment potentiometer (R41)
counterclockwise until red LED4 lights. See

Section 8 Reconnection/Adjustments

Overvoltage Shutdown Adjustment on
Main Circuit Board

10. Turn the voltage adjustment potentiometer
counterclockwise to prevent overvoltage shutdown
upon restart. Restart the generator set. Slowly
increase the voltage by turning the voltage
adjustment potentiometer clockwise. Verify the
shutdown voltage point (115% of the nominal
output voltage) by observing the voltmeter and
noting when LED4 lights. The generator set should
shut down on overvoltage fault in approximately
2 seconds. If the shutdown voltage point is not
115% of nominal voltage, repeat the calibration
output procedure; otherwise, continue to step 11.
11. Turn the voltage adjustment potentiometer
counterclockwise to prevent overvoltage shutdown
upon restart. Restart the generator set. Readjust
the generator set output to the nominal voltage
using the voltage adjustment potentiometer.
12. Stop the generator set by placing the generator set
master switch in the OFF/RESET position. Seal
the overvoltage adjustment potentiometer (R41)
with RTV sealant or equivalent. Replace the
controller cover.

TP-6069 6/03

Electroswitch
2-Wire Generator Sets

3-Wire Generator Sets

L1
To Generator
Set

L1
2

To Shore
Power

L2
6

To Generator
Set

To Shore
Power

L0
10

To Load
To Load

Kraus Naimler/American Solenoid
(Early Rectangular Design)

2-Wire Generator Sets

3-Wire Generator Sets
L1

L1
To Generator
Set

5 To Shore
Power

L2
8

To Generator
Set

To Shore
Power

L0
13

To Load
To Load

Kraus Naimler/American Solenoid
(Newer Round Design)

2-Wire Generator Sets

3-Wire Generator Sets
L1

L1
To Generator
Set
L2

To Shore
Power

L2
8

To Generator
Set

To Shore
Power

L0
12

To Load
To Load
TP-5399-5

Figure 8-9

TP-6069 6/03

Marine Manual (Ship-to-Shore) Transfer Switch

Section 8 Reconnection/Adjustments

Note: Broadrange generator sets. The following
adjustment procedure is for readjustment of the
voltage regulator and governor for broadrange
generator sets with mechanical governors.

Kraus Naimler/American Solenoid
4-Wire, 3-Phase Generator Sets

L1
3

L2
To Generator 7
Set

Note: Special tool. Frequency meter 50/60 Hz.
L2
To Shore
Power
L3

Note: Rheostat
connection.
Connect
a
customer-provided rheostat across regulator
leads/terminals 33 and 66 to adjust the generator
output voltage from a location remote from the
generator set. The rheostat (10 kOhms, 1/2 watt
minimum) provides a 5-volt adjustment range.

L0
15

L1 L2

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)
WARNING

1. Voltage adjustment potentiometer
2. Stability adjustment potentiometer
3. Volts/Hz adjustment potentiometer

TT-875-11

Figure 8-11 PowerBoost IIIE Voltage Regulator
Hazardous voltage. Moving rotor.
Can cause severe injury or death.
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
voltage regulator heat sink. To prevent electrical shock do not
touch the voltage regulator heat sink when testing the voltage
regulator.
(PowerBoostt, PowerBoostt III, and PowerBoostt V
voltage regulator models only)

The voltage regulator is typically located in the
controller. Adjustments are possible without removing
the voltage regulator. The voltage regulator adjustment
procedure applies to both the PowerBoost IIIE
(Figure 8-11) and PowerBoost V (Figure 8-12) voltage
regulators.

8
7
STAB

6
5
V/HZ VOLTS

4
3

2
1

1. Voltage adjustment potentiometer
2. Stability adjustment potentiometer
3. Volts/Hz adjustment potentiometer

TT-875-11

Figure 8-12 PowerBoost V Voltage Regulator

Section 8 Reconnection/Adjustments

TP-6069 6/03

Stabilizer Potentiometer (Pot) fine tunes the regulator
circuitry to reduce light flicker.
Voltage Adjustment Pot adjusts the generator voltage
output within the range of approximately 100 to 130
volts.
Volts/Hz Pot determines the engine speed (Hz) at
which the generator output voltage begins to drop.
Note: The volts/Hz adjustment does not apply to the
following models:
Model
4/6.5/8/8.5/9EFOZ
5/8/9/10EOZ

Note: On these models, turn the volts/Hz adjustment
pot full counterclockwise to stop and seal. No
further volts/Hz adjustments are required.

locknut and turn it clockwise or counterclockwise
to achieve the desired frequency.
See
Figure 8-13. If a second screw holds the governor
arm, loosen the locknut and back out the screw.
9. If applicable, rotate the volts/Hz adjustment pot
clockwise until the voltage level begins to drop (as
measured on the voltmeter). When set to these
specifications, the generator attempts to maintain
normal output until the engine speed drops below
the frequency set in step 8 as load is applied.
10. Readjust the engine speed to normal (63 Hz/
1890 rpm for 60 Hz or 52.5 Hz/1575 rpm for
50 Hz). Tighten the locknut when the adjustments
are complete. Turn the second screw, if used, to
lock the governor arm in place and tighten the
locknut.
11. Readjust the voltage adjustment pot if necessary.
12. Readjust the stability pot if necessary.

Note: For optimum results, apply full load for voltage
regulator adjustment.
Voltage Regulator Adjustment Procedure

13. Use the remote rheostat, if equipped, to make final
voltage adjustments.
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
frequency (factory setting 57.5–58 Hz for 60 Hz
models or 47.5–48 Hz for 50 Hz models) as
measured on frequency meter. To change engine
speed adjust the governor arm. Loosen the

TP-6069 6/03

1. Locknut
2. Speed adjusting screw

1-929

Figure 8-13 Governor Adjustment (4EFOZ/5EOZ
shown)

Section 8 Reconnection/Adjustments

Notes

Section 8 Reconnection/Adjustments

TP-6069 6/03

Appendix A Generator Selection and Wattage Requirements
are DC powered by a 12-volt battery. Make sure the
calculated total wattage includes only lights actually on
the generator set AC circuit.

Consider total wattage requirements (lights, motors,
appliances) when selecting a generator set or when
sizing wattage usage in which available space and
construction limit the size of the generator set.

Air Conditioners
Motors

The starting characteristics of air conditioners vary
greatly; one 12,000 Btu unit has, for example, lower
starting requirements than a 10,000 Btu unit of another
variety. When using only one unit, there is usually no
starting problem, provided the lighting and appliance
load is not too high when starting the unit.

When figuring generator set capacity requirements for
loads that include electric motors, consider the high
current demanded by the motors during startup. The
inrush or starting current is typically 2--3 times higher
than that required when the motor reaches normal
operating speed. Allow reserve for inrush demands plus
other loads which could be on the line as the electric
motor starts. Use Figure 1 as a guide when selecting
generator set capacity requirements involving motor
loads.
Motor
HP

Starting (Inrush)
Watts

Running
Watts

1/4

750

330

1/3

1000

400

1/2

1500

600

3/4

2000

750

3300

1100

4000

2000

5000

3000

Figure 1

Simultaneous starting of two air conditioning units,
however, can present problems if the generator set
capacity is marginal. Because of the variation in starting
characteristics among air conditioners, this publication
makes no statements regarding multiple-motor starting
capabilities of the generator set covered. Consider
delayed starting or use of easy-starting devices on air
conditioner units whenever simultaneously starting
more than one motor.
See Figure 2 for typical air conditioner requirements.
Information will vary with manufacturer.

Appliances
Generator sets often furnish AC for appliances such as
TV, stereo, electric water heater, etc. With the exception
of the resistance-type loads such as the water heater,
requirements for appliances are usually low. Do not
overlook such loads when figuring total requirements.
Allow reserve capacity for anticipated appliance loads to
avoid overloading a generator set.

Motor Requirements

Lighting
To calculate lighting load, add the wattage of each
generator set-operated lamp. Note that not all of the
lights or lamps are on the generator set AC circuit; some

Air Conditioner Size (Btu/Hr.)
7,000

9,000

12,000

16,000

24,000

Voltage

115

230

115

230

115

230

115

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

5750

7130

8630

8280

12,900

886

920

805

1020

1100

1500

1430

2350

Running watts

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
ABDC
AC
A/D
ADC
adj.
ADV
AHWT
AISI
ALOP
alt.
Al
ANSI

AO
API
approx.
AR
AS
ASE
ASME
assy.
ASTM
ATDC
ATS
auto.
aux.
A/V
avg.
AVR
AWG
AWM
bat.
BBDC
BC
BCA
BCI
BDC
BHP
blk.
blk. htr.
BMEP
bps
br.
BTDC
Btu
Btu/min.
C
cal.
CARB
CB
cc
CCA
ccw.
CEC
cfh
cfm

ampere
after bottom dead center
alternating current
analog to digital
analog to digital converter
adjust, adjustment
advertising dimensional
drawing
anticipatory high water
temperature
American Iron and Steel
Institute
anticipatory low oil pressure
alternator
aluminum
American National Standards
Institute
(formerly American Standards
Association, ASA)
anticipatory only
American Petroleum Institute
approximate, approximately
as required, as requested
as supplied, as stated, as
suggested
American Society of Engineers
American Society of
Mechanical Engineers
assembly
American Society for Testing
Materials
after top dead center
automatic transfer switch
automatic
auxiliary
audiovisual
average
automatic voltage regulator
American Wire Gauge
appliance wiring material
battery
before bottom dead center
battery charger, battery
charging
battery charging alternator
Battery Council International
before dead center
brake horsepower
black (paint color), block
(engine)
block heater
brake mean effective pressure
bits per second
brass
before top dead center
British thermal unit
British thermal units per minute
Celsius, centigrade
calorie
California Air Resources Board
circuit breaker
cubic centimeter
cold cranking amps
counterclockwise
Canadian Electrical Code
cubic feet per hour
cubic feet per minute

A-2 Appendix

CG
CID
CL
cm
CMOS
cogen.
Com
conn.
cont.
CPVC
crit.
CRT
CSA
CT
Cu
cu. in.
cw.
CWC
cyl.
D/A
DAC
dB
dBA
DC
DCR
deg., °
dept.
dia.
DI/EO
DIN

DIP
DPDT
DPST
DS
DVR
E, emer.
EDI
EFR
e.g.
EG
EGSA
EIA
EI/EO
EMI
emiss.
eng.
EPA
EPS
ER
ES
ESD
est.
E-Stop
etc.
exh.
ext.
F

center of gravity
cubic inch displacement
centerline
centimeter
complementary metal oxide
substrate (semiconductor)
cogeneration
communications (port)
connection
continued
chlorinated polyvinyl chloride
critical
cathode ray tube
Canadian Standards
Association
current transformer
copper
cubic inch
clockwise
city water-cooled
cylinder
digital to analog
digital to analog converter
decibel
decibel (A weighted)
direct current
direct current resistance
degree
department
diameter
dual inlet/end outlet
Deutsches Institut fur Normung
e. V.
(also Deutsche Industrie
Normenausschuss)
dual inline package
double-pole, double-throw
double-pole, single-throw
disconnect switch
digital voltage regulator
emergency (power source)
electronic data interchange
emergency frequency relay
for example (exempli gratia)
electronic governor
Electrical Generating Systems
Association
Electronic Industries
Association
end inlet/end outlet
electromagnetic interference
emission
engine
Environmental Protection
Agency
emergency power system
emergency relay
engineering special,
engineered special
electrostatic discharge
estimated
emergency stop
et cetera (and so forth)
exhaust
external
Fahrenheit, female

fglass.
FHM
fl. oz.
flex.
freq.
FS
ft.
ft. lbs.
ft./min.
g
ga.
gal.
gen.
genset
GFI

fiberglass
flat head machine (screw)
fluid ounce
flexible
frequency
full scale
foot, feet
foot pounds (torque)
feet per minute
gram
gauge (meters, wire size)
gallon
generator
generator set
ground fault interrupter

GND,
gov.
gph
gpm
gr.
GRD
gr. wt.
HxWxD
HC
HCHT
HD
HET
hex
Hg
HH
HHC
HP
hr.
HS
hsg.
HVAC

ground
governor
gallons per hour
gallons per minute
grade, gross
equipment ground
gross weight
height by width by depth
hex cap
high cylinder head temperature
heavy duty
high exhaust temperature
hexagon
mercury (element)
hex head
hex head cap
horsepower
hour
heat shrink
housing
heating, ventilation, and air
conditioning
high water temperature
hertz (cycles per second)
integrated circuit
inside diameter, identification
International Electrotechnical
Commission
Institute of Electrical and
Electronics Engineers
improved motor starting
inch
inches of water
inches of mercury
inch pounds
incorporated
industrial
internal
internal/external
input/output
iron pipe
International Organization for
Standardization
joule
Japanese Industry Standard
kilo (1000)
kelvin
kiloampere
kilobyte (210 bytes)

HWT
Hz
IC
ID
IEC
IEEE
IMS
in.
in. H2O
in. Hg
in. lbs.
Inc.
ind.
int.
int./ext.
I/O
IP
ISO
J
JIS
k
K
kA
KB

TP-6069 6/03

kg
kg/cm2

kilogram
kilograms per square
centimeter
kgm
kilogram-meter
kilograms per cubic meter
kg/m3
kHz
kilohertz
kJ
kilojoule
km
kilometer
kOhm, kΩ kilo-ohm
kPa
kilopascal
kph
kilometers per hour
kV
kilovolt
kVA
kilovolt ampere
kVAR
kilovolt ampere reactive
kW
kilowatt
kWh
kilowatt-hour
kWm
kilowatt mechanical
L
liter
LAN
local area network
L x W x H length by width by height
lb.
pound, pounds
lbm/ft3
pounds mass per cubic feet
LCB
line circuit breaker
LCD
liquid crystal display
ld. shd.
load shed
LED
light emitting diode
Lph
liters per hour
Lpm
liters per minute
LOP
low oil pressure
LP
liquefied petroleum
LPG
liquefied petroleum gas
LS
left side
Lwa
sound power level, A weighted
LWL
low water level
LWT
low water temperature
m
meter, milli (1/1000)
M
mega (106 when used with SI
units), male
m3
cubic meter
m3/min. cubic meters per minute
mA
milliampere
man.
manual
max.
maximum
MB
megabyte (220 bytes)
MCM
one thousand circular mils
MCCB
molded-case circuit breaker
meggar
megohmmeter
MHz
megahertz
mi.
mile
mil
one one-thousandth of an inch
min.
minimum, minute
misc.
miscellaneous
MJ
megajoule
mJ
millijoule
mm
millimeter
mOhm, mΩ
milliohm
MOhm, MΩ
megohm
MOV
metal oxide varistor
MPa
megapascal
mpg
miles per gallon
mph
miles per hour
MS
military standard
m/sec.
meters per second
MTBF
mean time between failure
MTBO
mean time between overhauls
mtg.
mounting

TP-6069 6/03

MW
mW
µF
N, norm.
NA
nat. gas
NBS
NC
NEC
NEMA
NFPA
Nm
NO
no., nos.
NPS
NPSC
NPT
NPTF
NR
ns
OC
OD
OEM
OF
opt.
OS
OSHA
OV
oz.
p., pp.
PC
PCB
pF
PF
ph., ∅
PHC
PHH
PHM
PLC
PMG
pot
ppm
PROM
psi
pt.
PTC
PTO
PVC
qt.
qty.
R
rad.
RAM
RDO
ref.
rem.
RFI
RH
RHM
rly.

megawatt
milliwatt
microfarad
normal (power source)
not available, not applicable
natural gas
National Bureau of Standards
normally closed
National Electrical Code
National Electrical
Manufacturers Association
National Fire Protection
Association
newton meter
normally open
number, numbers
National Pipe, Straight
National Pipe, Straight-coupling
National Standard taper pipe
thread per general use
National Pipe, Taper-Fine
not required, normal relay
nanosecond
overcrank
outside diameter
original equipment
manufacturer
overfrequency
option, optional
oversize, overspeed
Occupational Safety and Health
Administration
overvoltage
ounce
page, pages
personal computer
printed circuit board
picofarad
power factor
phase
Phillips head crimptite (screw)
Phillips hex head (screw)
pan head machine (screw)
programmable logic control
permanent-magnet generator
potentiometer, potential
parts per million
programmable read-only
memory
pounds per square inch
pint
positive temperature coefficient
power takeoff
polyvinyl chloride
quart
quantity
replacement (emergency)
power source
radiator, radius
random access memory
relay driver output
reference
remote
radio frequency interference
round head
round head machine (screw)
relay

rms
rnd.
ROM
rot.
rpm
RS
RTV
SAE

root mean square
round
read only memory
rotate, rotating
revolutions per minute
right side
room temperature vulcanization
Society of Automotive
Engineers
scfm
standard cubic feet per minute
SCR
silicon controlled rectifier
s, sec.
second
SI
Systeme international d’unites,
International System of Units
SI/EO
side in/end out
sil.
silencer
SN
serial number
SPDT
single--pole, double--throw
SPST
single--pole, single--throw
spec, specs
specification(s)
sq.
square
sq. cm
square centimeter
sq. in.
square inch
SS
stainless steel
std.
standard
stl.
steel
tach.
tachometer
TD
time delay
TDC
top dead center
TDEC
time delay engine cooldown
TDEN
time delay emergency to
normal
TDES
time delay engine start
TDNE
time delay normal to
emergency
TDOE
time delay off to emergency
TDON
time delay off to normal
temp.
temperature
term.
terminal
TIF
telephone influence factor
TIR
total indicator reading
tol.
tolerance
turbo.
turbocharger
typ.
typical (same in multiple
locations)
UF
underfrequency
UHF
ultrahigh frequency
UL
Underwriter’s Laboratories, Inc.
UNC
unified coarse thread (was NC)
UNF
unified fine thread (was NF)
univ.
universal
US
undersize, underspeed
UV
ultraviolet, undervoltage
V
volt
VAC
volts alternating current
VAR
voltampere reactive
VDC
volts direct current
VFD
vacuum fluorescent display
VGA
video graphics adapter
VHF
very high frequency
W
watt
WCR
withstand and closing rating
w/
with
w/o
without
wt.
weight
xfmr
transformer

Appendix A-3

Appendix C Generator Set Output Ratings Procedure
Kohler Co. develops the kilowatt output rating of a Kohlerr
marine generator set based upon the calculations
specified in ISO 3046 and ISO 8528-1. The calculations
correct for environmental variables encountered in a

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

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

For turbocharged compression ignition engines:
C.F. = [1.175 (29.2 / Barometer Observed in. Hg).7 (Temperature _F + 460/537)2 -- .175]
x Alternator Efficiency Reference / Alternator Efficiency Observed

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]
x Alternator Efficiency Reference / Alternator Efficiency Observed

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
50 Hz

8.0
7.9
7.8
7.7
7.6
7.5
7.4
7.3
7.2
7.1
7.0
6.9
6.8
6.7
6.6
6.5
6.4
6.3
6.2
6.1
6.0
5.9
5.8
5.7
5.6
5.5
75 77

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
7 Jurong Pier Road
Singapore 619159
Phone (65)264-6422, Fax (65)264-6455

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