Kohler 5E/4EF Installation Manual
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Kohler 5E/4EF Installation Manual

Kohler 5E/4EF Installation Manual

Marine generator sets
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Installation
Marine Generator Sets
5ECD/4EFCD
7.3ECD/6EFCD
13EG/EGZ
15EG/EGZ
15C/12.5CF
20C/17.5CF
Models:
5E/4EF
7.3E/6EF
10EG
TP-5982
4/06f

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  • Page 1 Installation Marine Generator Sets Models: 5E/4EF 7.3E/6EF 5ECD/4EFCD 7.3ECD/6EFCD 10EG 13EG/EGZ 15EG/EGZ 15C/12.5CF 20C/17.5CF TP-5982 4/06f...
  • Page 2 TP-5982 4/06...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Section 1 Introduction .
  • Page 4 TP-5982 4/06...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Battery Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, WARNING 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.
  • Page 6 Battery gases. Explosion can cause Engine Backfire/Flash Engine Fluids and severe injury or death. Battery gases Fire Chemical Products can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when WARNING WARNING it is charging.
  • Page 7 Used engine oil. Contact with used Carbon monoxide symptoms. Operating the generator set. Carbon engine oil may cause severe skin Carbon monoxide can cause severe monoxide can cause severe nausea, irritation. Repeated and prolonged nausea, fainting, or death. Carbon fainting, or death. Carbon monoxide skin exposure may have other monoxide is a poisonous gas present in is an odorless, colorless, tasteless,...
  • Page 8 Installing the fuel system. Explosive Hazardous Voltage/ WARNING fuel vapors can cause severe injury Electrical Shock or death. Fuel leakage can cause an explosion. Do not modify the tank or the propulsion engine fuel system. WARNING Equip the craft with a tank that allows one of the two pickup arrangements Avoid high pressure fluids.
  • Page 9 Short circuits. Hazardous Hot Parts Servicing the exhaust system. Hot voltage/current can cause severe parts can cause severe injury or injury or death. Short circuits can death. Do not touch hot engine parts. WARNING cause bodily injury and/or equipment The engine and exhaust system damage.
  • Page 10 Tightening the hardware. Flying Notice NOTICE projectiles can cause severe injury Electrostatic discharge damage. or death. Loose hardware can cause Electrostatic discharge (ESD) NOTICE the hardware or pulley to release from damages electronic circuit boards. the generator set engine and can cause Prevent electrostatic discharge...

  • Page 11: Section 1 Introduction

    All information in this publication represents data Marine generator set installations must comply with all applicable regulations and standards. available at time of print. Kohler Co. reserves the right to change this literature and the products represented The installer is responsible for improper installations without incurring obligation.
  • Page 12 585711 1. Exhaust mixer elbow (exhaust/water outlet) 10. Fuel supply line * 2. Coolant recovery tank 11. Mounting tray 3. Heat exchanger (not shown) 12. Fuel feed pump (fuel inlet) * 4. Seawater strainer * 13. Battery/battery storage box 5. Seawater pump (seawater inlet) 14.

  • Page 13: Section 2 Location And Mounting

    Section 2 Location and Mounting 2.1 General Considerations Allow clearance for vibration and cooling during operation. Allow a minimum of 38 mm (1.5 in.) The key to installation is location. Before making final clearance on all sides (top, front, rear, and sides) of a plans for locating a generator set, consider the following generator set without an optional sound shield.
  • Page 14 Notes Section 2 Location and Mounting TP-5982 4/06...

  • Page 15: Section 3 Cooling System

    Section 3 Cooling System 3.1 Ventilation Model Normal Intake Restriction* 5/7.3E and 4/6EF Engine combustion, generator cooling, and expulsion of 0 03 psi (0 79 in H 0.03 psi (0.79 in. H flammable and lethal fumes require ventilation. Provide 5/7.3ECD and 4/6EFCD ventilation compliant with USCG regulations governing 10/13/15EG and 13/15EGZ 0.36 psi (10 in.

  • Page 16: Seacock

    Do not align the strainer (in relation to the direction of 3.2.3 Seawater Strainer travel) with any other through-hull intakes. Mount the seawater strainer to the seacock or Figure 3-3. Flush mount recommended permanent structure at a point not higher than the through-hull strainer.

  • Page 17: Waterlines

    3.2.4 Waterlines Waterlines from the seacock to the engine-driven seawater pump are usually constructed of flexible hose or copper tubing. Use a flexible section of hose for connection to the seawater pump to allow for vibrational motion of the generator set during operation. Support a nonflexible waterline within 102 mm (4 in.) of its connection to the flexible section.
  • Page 18 Arrow Description Seawater Freshwater (Coolant/Antifreeze) TP-5586-6 1. Engine block 8. Thermostat closed 2. Exhaust manifold 9. Heat exchanger 3. Exhaust mixer elbow 10. Engine-driven seawater pump 4. Outlet flapper (exhaust/water discharge) 11. Seawater strainer 5. Silencer (customer-supplied) 12. Seacock 6. Thermostat open 13.

  • Page 19: Section 4 Exhaust System

    For the safety of the craft’s occupants, install a carbon monoxide detector. exhaust hose connections. Kohler Co. requires a Consult the boat builder or dealer for approved detector downward pitch of at least 13 mm per 30.5 cm (0.5 in.
  • Page 20 GX-250000- ADV-6395A-K 1. Water/exhaust outlet located on opposite (nonservice) side 1. Water/exhaust outlet Figure 4-1 Mixer Elbow/Exhaust Connection Figure 4-4 Mixer Elbow/Exhaust Connection (5/7.3E) (15/20C) 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 flap at the exhaust (transom) outlet to prevent water backup in following seas or when moving astern (backward).

  • Page 21: Above Waterline Installation

    4.2.1 Above Waterline Installation with drain plug down. Use a pitch of at least 13 mm per 30.5 cm (0.5 in. per running foot). Some silencers In addition to considerations described earlier, install a require two supporting brackets or hanger straps for customer-supplied silencer with the silencer’s outlet at a installation to stringers or other suitable structures.

  • Page 22: Mid/Below Waterline Installation

    4.2.2 Mid/Below Waterline Installation Follow USCG regulations for installing an antisiphon provision to prevent raw water entry into the engine. Use the siphon break if the exhaust manifold outlet is located less than 23 cm (9 in.) above the waterline when the craft is loaded to maximum capacity.
  • Page 23 Waterline 1. Mounting base 13. Seacock 2. Retaining cap 14. Intake strainer 3. Reed valve assembly 15. Engine-driven seawater pump 4. Maximum silencer vertical lift of 1.2 m (4 ft.) 16. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per 5.
  • Page 24 Notes Section 4 Exhaust System TP-5982 4/06...

  • Page 25: Section 5 Fuel System

    Section 5 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, 1-788 1. Fuel line to generator set storing, and using fuels. Figure 5-2 Single Dip-Tube Arrangement Installing the fuel system. Explosive fuel vapors can Installations with the fuel tank located above the cause severe injury or death.

  • Page 26: Fuel Filters Or Strainers

    5.3 Fuel Filters or Strainers 5.3.1 5/7.3E, 4/6EF, 5/7.3ECD, 4/6EFCD, 10/13/15EG, and 13/15EGZ Models These generator sets are shipped with a fuel filter. No additional fuel filter or strainer is required. ADV6817-B 1. Fuel filter Figure 5-6 Fuel Filter Location on 10/13/15EG and 13/15EGZ Models ADV-6395A-K 1.

  • Page 27: 15/20C And 12.5/16Cf Models

    5.3.2 15/20C and 12.5/16CF Models 5.5 Fuel Pump Lift and Fuel Consumption Conform to USCG regulations regarding in-line fuel filters or strainers. Independently mount the in-line fuel See Figure 5-7 for fuel pump lift capabilities. Consult filter or strainer to the craft’s structure. Ensure current generator set specification sheets for generator accessibility for servicing without removing permanent...

  • Page 28: Fuel System Bleed Procedure 5/7.3Ecd And 4/6Efcd Models

    5.6 Fuel System Bleed Procedure 5/7.3ECD and 4/6EFCD Models Before placing the generator set into service for the first time, bleed air from the fuel system in order to reduce rough running or vapor lock. WARNING Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system.

  • Page 29: Section 6 Electrical System

    Section 6 Electrical System 6.1 AC Voltage Connections WARNING Make AC connections to the generator set inside the controller box (5/7.3E, 4/6EF, 15/20C, and 12.5/16CF models) or inside the junction box (5/7.3ECD, 4/6EFCD, 10/13/15EG, and 13/15EGZ models). Typically, the Explosion. generator set connects to a ship-to-shore transfer Gasoline vapors...

  • Page 30: Circuit Breaker Considerations

    Note: Circuit breaker ampere rating and availability are WARNING subject to change. 6.2.1 Circuit Breaker Considerations Mounting location. Mount the circuit breakers in the Moving rotor. Hazardous voltage. generator set controller (5/7.3E, 4/6EF, 15/20C, and Can cause severe injury or death. 12.5/16CF models) or inside the junction box Operate the generator set only when (5/7.3ECD, 4/6EFCD, 10/13/15EG, and 13/15EGZ...

  • Page 31: Circuit Breaker Installation

    6.2.2 Circuit Breaker Installation breaker marked LINE. Do not use a jumper lead (see Section 8). Attach stator leads 2 and 3 to L0. 1. Turn the generator set off and disconnect the generator set engine starting battery, negative (−) Models without ADC 2100: lead first.

  • Page 32: Adc 2100 Continuous Power Mode Jumper (10/13/15Eg Models)

    AUTO position with the jumper connected. If you do not plan to use your generator set for a long period of time, Kohler recommends moving the master switch to the OFF/RESET position (0 mA draw). Remote communications require an active (powered-up) controller.

  • Page 33: Installation In Steel Or Aluminum Vessels

    6.4 Installation in Steel or 6.5 Installation Regulations Aluminum Vessels The U.S. Coast Guard governs generator set installation in U.S. pleasurecraft and commercial Installation of a generator set in a vessel constructed of vessels. Refer to the applicable regulations below: a material capable of conducting current (e.g., steel or aluminum) is subject to considerations not normally encountered in fiberglass or wood vessels.

  • Page 34: Battery

    6.6 Battery Required Battery Cable Batteries and their installation must conform to USCG AWG Gage (Minimum) Regulations 183.420 (a) through (g). Provide generator 2.5 m sets with batteries separate from the propulsion engines Distance (from battery to generator set) (8.3 ft.) (16.4 ft.) whenever possible.

  • Page 35: Wiring

    6.8 Remote Start Switch Connection ADV6843b-a 1. Remote interface connector Kohler Co. offers several remote panels for connection Figure 6-6 Remote Interface Connector, to the generator set. Contact your local Kohlerr 10/13/15EG and 13/15EGZ Model distributor/dealer for further detailed descriptions. See...
  • Page 36 Notes Section 6 Electrical System TP-5982 4/06...

  • Page 37: Section 7 Installation Drawings

    Section 7 Installation Drawings Use the drawings in this section for installation Model No. Drawing Page purposes. Consult the supplier and verify that the 5/7.3ECD and 4/6EFCD ADV-7025A drawings are the most current for your specification. with Sound Shield ADV-7025B Installation drawings show exhaust outlet locations, fuel 5/7.3E and 4/6EF ADV-6395A...
  • Page 38 ADV-7025A-A Note: Dimensions in [ ] are inch equivalents. Figure 7-2 Dimension Drawing—5/7.3ECD and 4/6EFCD Section 7 Installation Drawings TP-5982 4/06...
  • Page 39 ADV-7025B-A Note: Dimensions in [ ] are inch equivalents. Figure 7-3 Dimension Drawing—Sound Shield 5/7.3ECD and 4/6EFCD TP-5982 4/06 Section 7 Installation Drawings...
  • Page 40 ADV-6395A-L Note: Dimensions in [ ] are inch equivalents. Figure 7-4 Dimension Drawing—5/7.3E and 4/6EF Section 7 Installation Drawings TP-5982 4/06...
  • Page 41 ADV-6395B-L Note: Dimensions in [ ] are inch equivalents. Figure 7-5 Dimension Drawing—Sound Shield 5/7.3E and 4/6EF TP-5982 4/06 Section 7 Installation Drawings...
  • Page 42 ADV-6382A-F Note: Dimensions in [ ] are inch equivalents. Figure 7-6 Dimension Drawing—15/20C and 12.5/16CF Section 7 Installation Drawings TP-5982 4/06...
  • Page 43 ADV-6382B-F Note: Dimensions in [ ] are inch equivalents. Figure 7-7 Hydraulic Pump PTO—15/20C and 12.5/16CF (Note: Kohler Co. does not furnish hydraulic pumps.) TP-5982 4/06 Section 7 Installation Drawings...
  • Page 44 ADV-6817A-D Note: Dimensions in [ ] are inch equivalents. Figure 7-8 Dimension Drawing—10/13/15EG Section 7 Installation Drawings TP-5982 4/06...
  • Page 45 ADV-6817B-D Note: Dimensions in [ ] are inch equivalents. Figure 7-9 Dimension Drawing—13/15EGZ with PTO TP-5982 4/06 Section 7 Installation Drawings...
  • Page 46 Notes Section 7 Installation Drawings TP-5982 4/06...

  • Page 47: Section 8 Reconnection/Adjustments

    Section 8 Reconnection/Adjustments WARNING WARNING Hazardous voltage. Moving rotor. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working on the generator set.
  • Page 48 8.1 Four-Lead Reconnection L0 (Neutral) The following information illustrates the reconnection of GRD. four-lead generator sets. In all cases, conform to the Ground National Electrical Code (NEC). Load NOTICE Side Voltage reconnection. Affix a notice to the generator set after Two-Pole reconnecting the set to a voltage different from the voltage on Line...
  • Page 49 100- -120/200- -240-Volt Configurations L0 (Neutral) The 100--120/200--240-volt configuration does not use GRD. Ground a jumper lead. If the unit was originally wired for straight Load 100--120 volt, 3 wire, remove the jumper lead (see Side Figure 8-1 for location). Select a two-pole circuit breaker.

  • Page 50: Voltage Regulator Adjustment (5/7.3E, 4/6Ef, 15/20C, And 12.5/16Cf Models)

    8.2 Voltage Regulator Adjustment (5/7.3E, 4/6EF, 15/20C, and 12.5/16CF Models) WARNING Moving rotor. Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. TT-875-11 1. Voltage adjustment potentiometer Testing the voltage regulator.
  • Page 51 Stabilizer Potentiometer (Pot)—Fine-tunes 6. Rotate the stability pot clockwise to minimize light flicker. regulator circuitry to reduce light flicker. 7. Readjust the voltage adjustment pot, if Voltage Adjustment Potentiometer (Pot)—Adjusts necessary. the generator voltage output within a range of approximately 100--130 volts. 8.

  • Page 52: Adc 2100 Adjustment (5/7.3Ecd, 4/6Efcd, 10/13/15Eg, And 13/15Egz Models)

    1.00. Note: The unit configuration (UC), engine type (EC), and engine data input type (ED) are factory set and should only be changed by an authorized Kohler dealer/distributor. Incorrect settings will make your unit non-functional. 8.3.3 Configuration Mode Figure 8-8 Advanced Digital Control (ADC 2100) Follow the instructions in Figure 8-11 to enter the configuration mode.
  • Page 53 Parameter Setting Definition Connect Unit’s system voltage Single phase, 2W, 60 Hz, 120 VAC 1 Ph, 2W Uu00 Uu00 and frequency * Single phase, 3W, 60 Hz, 120 VAC 1 Ph, 3W Uu01 Single phase, 3W, 60 Hz, 120/240 VAC 1 Ph, 3W Single phase, 3W, 50 Hz, 115/230 VAC 1 Ph, 3W...

  • Page 54: Adjusting The Voltage, Gain, Volts/Hz, And Engine Speed

    8.3.4 Adjusting the Voltage, Gain, Voltage Adjustment Procedure Volts/Hz, and Engine Speed 1. With the generator set off, connect a digital voltmeter to the output leads or an electrical outlet After setting the system voltage, check the output on the load side of the generator set. Set the meter voltage and adjust, if necessary, using the following to measure voltage.
  • Page 55 Controller Configuration Mode (Use with Figure 8-9, Controller Parameters): Hold the Select button: Display: Move the generator set master switch to the RUN position. (The generator set engine will not start.) Wait about 5 seconds until the display shows the 1 0 4 program version number.
  • Page 56 Pressing the up arrow key at the Adnc display (See Figure 8-11) puts you into the Advanced Configuration Mode. Press: E d 0 x To set the engine data input type. To enter battery voltage selection mode. To toggle between 12 and 24 VDC. B t 1 2 12-volt models To enter communications selection mode.
  • Page 57 Output Voltage Adjustment Mode: Display :* x x x x Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours. Hold: Wait about 5 seconds until the display changes from runtime hours to the program version number.
  • Page 58 Notes Section 8 Reconnection/Adjustments TP-5982 4/06...

  • Page 59: Appendix A Generator Selection And Wattage Requirements

    Appendix A Generator Selection and Wattage Requirements General Wattage Requirements Appliance Loads Generator sets often furnish AC for appliances such as Consider total wattage requirements (lights, motors, TVs, stereos, and electric water heaters. Except for appliances) when selecting a generator set, or when resistance-type loads such as the water heater, sizing wattage usage in which available space and requirements for appliances are usually low.

  • Page 60: Appendix B Abbreviations

    Appendix B Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex.
  • Page 61 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter μF microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat.

  • Page 62: Appendix C Generator Set Output Ratings Procedure

    General correct for environmental variables encountered in a genset installation. Figure 3 outlines the calculations. Kohler Co. develops the kilowatt output rating of a Figure 4 contains examples of how heat variables affect Kohler marine genset based upon the calculations genset ratings.
  • Page 63 TP-5982 4/06...
  • Page 64 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-5982 4/06f 7 Jurong Pier Road Singapore 619159 E 1998, 2001, 2002, 2004, 2005, and 2006 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...

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