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Kohler 13.5CCOZ Operation And Installation Manual

Marine generator sets
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Operation and
Installation Manual
Marine Generator Sets
13.5CCOZ/11CCFOZ
18.5 CCOZ/15CCFOZ
21CCOZ/16.5CCFOZ
14CCOZ/11.5CCFOZ
20CCOZ/17.5CCFOZ
24CCOZ/20CCFOZ
Models:
18CCFOZ
1 Phase
and 3 Phase
TP-5592 7/96a

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Summary of Contents for Kohler 13.5CCOZ

  • Page 1 Operation and Installation Manual Marine Generator Sets Models: 13.5CCOZ/11CCFOZ 18.5 CCOZ/15CCFOZ 21CCOZ/16.5CCFOZ 18CCFOZ 14CCOZ/11.5CCFOZ 20CCOZ/17.5CCFOZ 24CCOZ/20CCFOZ 1 Phase and 3 Phase TP-5592 7/96a...
  • Page 2 California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

  • Page 3: Table Of Contents

    Table of Contents SUBJECT PAGE SUBJECT PAGE Safety Precautions and Instructions ..Seawater Pump Belt ..... . 3-17 Reference Material .

  • Page 4: Safety Precautions And Instructions

    Safety Precautions and Instructions A generator set, like any other electromechanical Safety decals affixed to the generator set in prominent device, can pose potential dangers to life and limb if places advise the operator or service technician of improperly maintained or operated. The best way to potential hazards and how to act safely.
  • Page 5 Battery Engine Backfire/Flash Fire WARNING WARNING Fire. Sulfuric acid in batteries. Can cause severe injury or death. Can cause severe injury or death. Do not smoke or permit flame or spark to occur Use protective goggles and clothes. Battery acid can near fuel or fuel system.
  • Page 6 Exhaust System Copper tubing exhaust systems. Carbon monoxide can cause severe nausea, fainting, or death. Do not WARNING use copper tubing in diesel exhaust systems. Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems resulting in exhaust/water leakage.
  • Page 7 Fuel System Draining fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause WARNING an explosion. Use a container to catch fuel when draining fuel system. Wipe up all spilled fuel after draining system. Installing fuel system. Explosive fuel vapors can cause severe injury or death.
  • Page 8 Hazardous Noise Short circuits. Hazardous voltage can cause severe injury or death. Short circuits can cause bodily injury CAUTION and/or equipment damage. Do not contact electrical connections with tools or jewelry while adjustments are made. Remove wristwatch, rings, and jewelry before servicing equipment.
  • Page 9 Heavy Equipment Hot Parts WARNING WARNING Hot coolant and steam. Can cause severe injury or death. Unbalanced weight. Before removing pressure cap, stop generator set Improper lift can cause severe injury or death and allow it to cool. Then loosen pressure cap to and/or equipment damage.
  • Page 10 Moving Parts Tightening hardware. Flying projectiles can cause severe injury or death. Retorque all crankshaft and WARNING rotor hardware after servicing. Do not loosen crankshaft hardware or rotor thrubolt when making adjustments or servicing generator set. Rotate crankshaft manually in a clockwise direction only.
  • Page 11 Notice NOTICE When replacing hardware, do not substitute with NOTICE inferior grade hardware. Screws and nuts are available in different hardness ratings. American Standard hardware uses a series of markings and This generator set has been rewired from its metric hardware uses a numeric system to indicate nameplate voltage to: hardness.

  • Page 12: Reference Material

    Reference Material Observe the regulations and standards below when installing marine generator sets. Pleasurecraft U.S. Coast Guard Code of Federal Regulations Underwriters Laboratories, Inc. (UL) Title 33, Part 183 Publications Stock Subpart I— Electrical Systems 333 Pfingsten Road Subpart J— Fuel Systems Northbrook, IL 60062 Marine Department Phone: 1-919-549-1400 Order the above publication from:...
  • Page 13 Ft. Lauderdale, FL 33301 guidelines and assistance. They are listed only as a Phone: 1-305-523-2815 source for additional information. Kohler Co. hereby Phone: 1-800-545-9273 gives no solicitation or representation. Fax: 1-305-523-1967 Yacht Corrosion Consultants, Inc.

  • Page 14: Introduction

    All information in this publication represents data See Figure 1-1 and Figure 1-2 to identify and locate available at time of printing. Kohler Co. reserves the major components. right to change this literature and the products represented without incurring obligation.

  • Page 15: Service Assistance

    Accessory Nos. For sales and service outside the U.S.A. and Canada, contact your local distributor. For further information or questions, contact the company directly at: KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone: 414-565-3381 Fax: 414-459-1646 (U.S.A. Sales) 414-459-1614 (International) To ensure supply of correct parts or information, make...
  • Page 16 At the time of print, this manual applied to the model Model No. Spec. No. Wiring Diagram numbers and specification (spec.) numbers listed on 13.5CCOZ/ 126147 229937 this page. On occasion this manual may be used for 11CCFOZ 126148 229991 specifications not listed such as when similar new 18.5CCOZ/...

  • Page 17: Routine Service Parts

    Routine Service Parts Contact your Kohler generator distributor/dealer for a complete list of service parts for your generator set. Part Description Kohler Part No. Air Filter Element 250902 Oil Filter 252834 Fuel Filter Element 225021 Seawater Pump Impeller 229955 V-Belt (Seawater Pump)

  • Page 18: Section 1. Specifications

    Section 1. Specifications General Specifications— 1-Phase Models 21CCOZ 16.5CCFOZ 13.5CCOZ 18.5CCOZ 18CCFOZ * 11CCFOZ 15CCFOZ Dimensions— in. (mm) Length 36.62 (930) 41.35 (1050) Width 22.31 (567) 22.31 (567) Height 26.01 (661) 26.42 (671) Length w/sound shield 41.24 (1047) 44.75 (1137) Wisth w/sound shield 25.75 (654)

  • Page 19: General Specifications- 3-Phase Models

    General Specifications— 3-Phase Models 14CCOZ 20CCOZ 24CCOZ 11.5CCFOZ 17.5CCFOZ 20CCFOZ Dimensions— in. (mm) Length 36.62 (930) 41.35 (1050) Width 22.31 (567) 22.31 (567) Height 26.01 (661) 26.42 (671) Length w/sound shield 41.24 (1047) 44.75 (1137) Width w/sound shield 25.75 (654) 25.75 (654) Height w/sound shield 28.25 (718)

  • Page 20: Generator

    Generator Alternator Features The generator is direct mounted to the engine for permanent alignment. The unit uses a static excited, rotating-field construction with a four-pole rotor. Generator Type four pole, rotating field Coupling Type flexible disc Generator Features Excitation Type brushless exciter D Brushless, rotating field design permits power to Shaft RPM (50/60 Hz)

  • Page 21: Generator Ratings- 1-Phase Models

    Generator Ratings— 1-Phase Models 77_ F (25_ C) 77_ F (25_ C) Amps kW/kVA Model Series Voltage Phase 13.5CCOZ 13.5CCOZ 100/200 125/62.5 12.5/12.5 120/240 112.5/56.3 13.5/13.5 11CCFOZ 11CCFOZ 100/200 110/55 11/11 110/220 100/50 11/11 11/11 45.8 11/11 18.5CCOZ 18.5CCOZ 100/200 165/82.5...

  • Page 22: Generator Ratings- 3-Phase Models

    Generator Ratings— 3-Phase Models 77_ F (25_ C) 77_ F (25_ C) Amps kW/kVA Model Series Voltage Phase 14CCOZ 14CCOZ 120/208 38.9 14/14 120/240 33.7 14/14 120/240 58.3 14/14 127/220 36.8 14/14 139/240 33.7 14/14 220/380 21.3 14/14 227/480 16.9 14/14 11.5CCFOZ 11.5CCFOZ...

  • Page 23: Engine

    14CCOZ Heat D Water-cooled turbocharger 3JH2LT-K 11.5CFOZ Exchanger D Air intake heater circuit for cold starting (optional 20CCOZ Heat 4JH2LT-K on models 13.5CCOZ/11CCFOZ, 18.5CCOZ/ 17.5CCFOZ Exchanger 15CCOZ, 14CCOZ/11.5CCFOZ, and 20CCOZ/ 24CCOZ Heat 4JH2LHT-K 17.5CCFOZ) 20CCFOZ Exchanger D Electric rotary vane fuel pump with 1/4 NPT fuel...

  • Page 24: Engine Specifications- 1-Phase Models

    Engine Specifications— 1-Phase Models 13.5CCOZ/ 18.5CCOZ/ 21CCOZ/ 11CCFOZ 15CCFOZ 18CCFOZ 16.5CCFOZ Engine Manufacturer Yanmar Engine Model 3JH2LT-K 4JH2LT-K 4JH2LHT-K Number of cylinders Cylinder Block Material cast iron Cylinder Head Material cast iron Piston Rings 2 compression/1 oil Crankshaft stamped forging...
  • Page 25 Engine Specifications— 1-Phase Models (Continued) 13.5CCOZ/ 18.5CCOZ/ 21CCOZ/ 11CCFOZ 15CCFOZ 18CCFOZ 16.5CCFOZ Flex Plate to Rotor Bolt Torque 30 (41) — ft. lbs. (Nm) Cylinder Head Torque— ft. lbs. (Nm) Initial ft. lbs (Nm) 29 (39) Final ft. lbs (Nm) (2-step intervals)

  • Page 26: Engine Specifications- 3-Phase Models

    Engine Specifications— 3-Phase Models 14CCOZ/ 20CCOZ/ 24CCOZ 11.5CCFOZ 17.5CCFOZ 20CCFOZ Engine Manufacturer Yanmar Engine Model 3JH2LT-K 4JH2LT-K 4JH2LHT-K Number of cylinders Cylinder Block Material cast iron Cylinder Head Material cast iron Piston Rings 2 compression/1 oil Crankshaft stamped forging Connecting Rod Material forged carbon steel Governor centrifugal, mechanical...

  • Page 27: Controller

    Engine Specifications— 3-Phase Models (Continued) 14CCOZ/ 20CCOZ/ 24CCOZ 11.5CCFOZ 17.5CCFOZ 20CCFOZ Flex Plate to Rotor Bolt Torque 30 (41) — ft. lbs. (Nm) Cylinder Head Torque— ft. lbs. (Nm) Initial ft. lbs (Nm) 29 (39) Final ft. lbs (Nm) (2-step 58 (79) intervals) Flex Plate to Flywheel Bolt Torque...

  • Page 28: Accessories

    Accessories Kohler Co. offers several accessories to finalize the Remote start and four-meter panel kit allows installation or to add convenience to operation and starting/stopping from a location remote of the service. Contact a local Kohler distributor/dealer to generator set. The illuminated meters/gauges include a obtain the most current information.
  • Page 29 ADV-5852-A DA-250000-H Figure 1-1. Service Views— 13.5CCOZ/11CCFOZ and 14CCOZ/11.5CCFOZ 1-12 Specifications TP-5592 7/96...

  • Page 30: Service Views

    Service Views 1. Controller 25. Heat exchanger 2. Air intake silencer 26. Coolant (freshwater) drain 3. Fuel solenoid 27. Seawater drain 4. Lifting eye 28. High exhaust temperature safety shutdown switch 5. Lifting eye 29. AC load lead connector 6. Fuel injectors 30.
  • Page 31 ADV-5853-A DA-250000-H Figure 1-2. Service Views— 18CCFOZ, 18.5CCOZ/15CCFOZ, 20CCOZ/17.5CCFOZ, 21CCOZ/16.5CCFOZ, and 24CCOZ/20CCFOZ 1-14 Specifications TP-5592 7/96...
  • Page 32 Service Views 1. Controller 25. Heat exchanger 2. Air intake silencer 26. Coolant (freshwater) drain 3. Fuel solenoid 27. Seawater drain 4. Lifting eye 28. High exhaust temperature safety shutdown switch 5. Lifting eye 29. AC load lead connector 6. Fuel injectors 30.

  • Page 33: Section 2. Operation

    50% ethylene glycol can cause engine or component damage. Do not use alcohol or methanol Kohler Co. recommends that all boat owners have their antifreeze or mix them with the specified coolant. vessels— especially the exhaust system attached to the Consult the engine manufacturer’...

  • Page 34: Exercising The Generator Set

    Exercising the Generator Set Run the generator set under load once each week for generator set to ensure there are no fluid or exhaust one hour with an operator present. leaks. Perform all prestart checks before starting the exercise Start the generator set according to the starting procedure.

  • Page 35: Starting Procedure

    If the unit fails to start after three attempts, contact an The start/stop switches of all controllers indicate authorized Kohler distributor/dealer for repair. Failure to preheat. However, an optional preheat kit is required to follow these guidelines may result in starter motor make the air intake coil (preheat) functional.

  • Page 36: Circuit Protection

    Circuit Protection AC circuit breakers (optional) trip when a fault is DC Circuit Breaker (10 amp) will trip when a fault detected in the output circuit. Correct the fault and then occurs in the controller circuit. See Section place the AC circuit breaker(s) in the ON position to 4—...

  • Page 37: Remote Panels (Optional)

    Remote Panels (Optional) Remote Start Panel Engine Oil Pressure Gauge. Measures engine oil pressure. Normal engine operating range is 40-60 psi Remote start panel allows starting/stopping from a (276-414 kPa) for 60 Hz models. 50 Hz models may location remote of the generator set. Standard show a slightly lower pressure range.
  • Page 38 Remote Start and Water Temperature Gauge. Measures engine coolant temperature. Normal engine operating range is Four-Meter Panel Kit 170-195°F (77-91°C). Allows starting/stopping from a location remote of the Hourmeter. Records total generator set operating generator set. The illuminated gauges include a DC hours for reference in maintenance scheduling.

  • Page 39: Section 3. Scheduled Maintenance

    Section 3. Scheduled Maintenance General Servicing generator set when operating. Exposed WARNING moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from belts and pulleys when generator set is running. Replace guards, screens, and covers before operating generator set.
  • Page 40 Blow dust out with the generator set owner. running. Direct the stream of air through openings in the Kohler Co. recommends that all boat owners have their generator end bracket. vessels— especially the exhaust system attached to the See Safety Precautions and Instructions at the generator set—...

  • Page 41: Service Schedule

    Service Schedule After Every Every Every Before 50 Hrs./ 100 Hrs./ 300 Hrs./ 500 Hrs./ Perform Service at Intervals Indicated (X) Starting 1 Month 3 Months 6 Months Yearly FUEL SYSTEM Check the fuel oil level Fill the fuel tank Remove sediment from fuel tank (During Check for any abnormal fuel injection sound...
  • Page 42 Service Schedule (Continued) After Every Every Every Before 50 Hrs./ 100 Hrs./ 300 Hrs./ 500 Hrs./ Perform Service at Intervals Indicated (X) Starting 1 Month 3 Months 6 Months Yearly AIR CLEANER, etc. (During Check the exhaust gas condition * operation) Inspect turbocharger compressor * # Check for abnormal turbocharger...
  • Page 43 Service Schedule (Continued) After Every Every Every Before 50 Hrs./ 100 Hrs./ 300 Hrs./ 500 Hrs./ Perform Service at Intervals Indicated (X) Starting 1 Month 3 Months 6 Months Yearly REMOTE CONTROL SYSTEM, etc. Check compartment condition (fuel, oil, or water leaks) Test run generator set (Monthly) Check remote control operation...

  • Page 44: Lubrication System

    Lubrication System Specifications Oil Check Engine oil selection is very important to a diesel engine. Check the oil level in the crankcase daily or before each Use of an unsuitable oil or neglecting an oil change may start-up to ensure that the level is in the safe range. To result in damage and a shorter engine life.

  • Page 45: Oil Change

    Oil Change 7. Disconnect pump and replace the oil drain hose end cap and turn the valve at the base of the oil Change oil according to the service schedule. Change drain hose. oil more frequently under dirty, dusty conditions. 8.

  • Page 46: Oil Filter Change

    Oil Filter Change If not using an automatic oil drain/oil fill pump: 1. To drain oil, turn valve (if equipped) at the base of Replace the oil filter as listed in the service schedule. the oil drain hose. See Figure 3-3 for location. Change more frequently if operating in dirty, dusty Remove oil drain hose end cap and place oil drain conditions.

  • Page 47: Fuel System

    Fuel System Specifications Fuel Filter Use a clean, good quality No. 1-D or No. 2-D diesel fuel Clean the fuel filter with fresh fuel oil and compressed oil with a cetane number of 45 or greater. The fuel must air. The quality and condition of the fuel largely meet the requirements of the American Society of determine the filter’...

  • Page 48: Bleeding Fuel System

    Bleeding Fuel System If the generator set engine runs out of fuel, if air leaks develop in the suction side of the fuel system, or when replacing the fuel filter, bleed the entire system to prevent starting failures and/or erratic operation. NOTE Connect the battery during the priming procedure to allow engine cranking.

  • Page 49: Air Intake Silencer/Cleaner

    Air Intake Silencer/Cleaner A round polyurethane sound-absorbing type intake silencer silences the intake air drawn into the cylinder head from the intake port. Besides providing a silencing effect, the silencer also acts as an air cleaner. Clean the air silencer as listed in the service schedule. Clean more frequently if operating in dirty, dusty conditions.

  • Page 50: Turbocharger

    (blower wheel) for buildup of carbon residue. If the compressor requires cleaning, contact authorized Kohler service distributor/dealer, who should use a Yanmar approved turbocharger cleaner. 4. Place air intake silencer over turbocharger compressor housing inlet and tighten clamp. Direct the air intake silencer duct down and away from the engine.

  • Page 51: Governor

    Governor The centrifugal, mechanical governor keeps engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. The governor requires no regular service. The governor is adjusted during run-in at the factory. Further adjustments are unnecessary except under greatly varying load conditions or if poor governor control develops after extended usage.

  • Page 52: Cooling Systems

    Cooling Systems Closed/Heat Exchanger WARNING In a closed cooling system, the seawater does not circulate through the engine. Rather, the seawater circulates through the separate chambers within the manifold to cool the engine water. The seawater then mixes with engine exhaust and ejects out the exhaust Hot coolant and steam.

  • Page 53: Siphon Break

    Seawater Pump NOTICE Seawater damage! High-mineral content seawater These models use a belt-driven seawater pump located (saltwater) causes rapid deterioration of all metals. on the service side. Check and change the seawater Wipe up all saltwater spillage on and around generator pump as listed in the service schedule.
  • Page 54 NOTE Numbers in illustration refer to callouts be- low and not to dimensions. Waterline 1. Mounting base 12. Seawater strainer 2. Retaining cap 13. Seacock 3. Reed valve assembly 14. Intake strainer 4. Maximum silencer vertical lift of 4 ft. (1.2 m) 15.

  • Page 55: Belt Tension

    Belt Tension Seawater Pump Belt WARNING 1. Remove the belt guard. 2. Check belt tension at the midpoint of the longest span of the belt. At midpoint, the belt should deflect about 0.4-0.6 in. (10-15 mm) with about 22 lbs. (10 kg) of force.

  • Page 56: Battery Charging Alternator/Engine-Driven Water Pump Belt

    Battery Charging Alternator/ 3. Loosen adjusting arm pivot screw, alternator pivot screw, and alternator adjusting screw. Engine-Driven Water Pump Belt 4. While prying alternator outward, tighten alternator 1. Remove belt guard. adjusting screw. 2. Check belt tension at the midpoint of the longest 5.

  • Page 57: Battery

    Battery Kohler Co. recommends using one 12-volt battery as Battery gases. Explosion can cause severe injury the starting battery. It must have a minimum of 500 cold or death. Battery gases can cause an explosion. Do cranking amps (CCA) at 0° F (--18° C) or 100 amp. hr. A not smoke or permit flame or spark to occur near a battery at any time, particularly when it is charging.

  • Page 58: Charging

    Charging The engine alternator will provide a charge of 12 volts at up to 50 amps. To adjust belt tension, see Belt Tension. NOTE Operation of on-board electrical equipment, such as auxiliary lights and radios, off of battery power drains the batteries.

  • Page 59: Checking Specific Gravity

    Checking Specific Gravity Correction ° ° 71.1 + .032 Use a battery hydrometer to check the specific gravity of + .030 the electrolyte in each battery cell. While holding the 65.6 + .028 EXAMPLE NO. 1— hydrometer vertically, read the number on the glass bulb + .026 at the top of the electrolyte level (or the number adjacent °...

  • Page 60: Generator Service

    The sealed end bracket bearing requires no out of the generator while the generator set is running. additional lubrication. Have an authorized Kohler Direct the stream of air in through the cooling slots at the service distributor/dealer perform all generator service.

  • Page 61: Storage Procedure

    Storage Procedure -- Or -- Keep the craft afloat until completing generator set storage since the unit must be started during the storage procedure. f. Close seacock and drain all seawater out of 1. Start and run generator set until it reaches cooling system.

  • Page 62: Section 4. Troubleshooting

    Section 4. Troubleshooting When troubles occur, do not overlook simple causes. A the generator set to an authorized Kohler service starting problem, for example, could be caused by distributor/dealer. Tell the dealer exactly what happened incorrect fuel or an empty fuel tank. The following charts when the problem occurred and of any adjustments list some common problems.

  • Page 63: Corrective Action

    Fuel line restriction Check fuel lines and tank Dirty fuel filter Service fuel filter No/low oil pressure See authorized Kohler service distributor/dealer Defective low oil pressure (LOP) safety Replace LOP shutdown switch shutdown switch High temperature shutdown Check engine coolant system for coolant level Defective high exhaust temp.
  • Page 64 Air intake clogged Service air intake silencer Bad or stale fuel Replace fuel Engine not operating at rated RPM See authorized Kohler service distributor/dealer Governor adjustments incorrect See authorized Kohler service distributor/dealer Carbon build-up Clean carbon from cylinder heads Inadequate cooling...
  • Page 65 Check and increase clearances structure or compartment) No compartment sound insulation Install approved insulation Excessive vibration engine/ generator (internal See authorized Kohler service distributor/dealer imbalance) Worn or defective bearing or gear See authorized Kohler service distributor/dealer Abnormal noise Abnormal noise...
  • Page 66 Turn switch to generator power position Controller circuit breaker tripped Reset circuit breaker Generator malfunction such as defective rotor, See authorized Kohler service distributor/dealer faulty voltage regulator, or other internal fault Low output or Low output or Engine speed too low...

  • Page 67: Section 5. Wiring Diagrams

    Load from nameplate voltage, place a notice on the unit Side indicating the voltage change. A decal (part no. 246242) is Single-Pole available for this purpose from authorized Kohler Circuit distributors/dealers. Breaker Line Jumper lead not used. Circuit breaker MUST be a circuit Side breaker manufacturer two-pole circuit breaker.
  • Page 68 L0 (Neutral) L0 (Neutral) GRD. GRD. Ground Ground Load Load Side Side Single-Pole Circuit Factory Breaker Line Two-Pole Side Circuit Breaker Line Side Tape to insulate from ground 100-120/200-240 Volt, Stator Leads 200-220-240 Volt 3 Wire Stator Leads 2 Wire 60 Hz 50 Hz 60 Hz...
  • Page 69 NOTES TP-5592 7/96 Wiring Diagrams 5-3...
  • Page 70 Voltage Reconnection (12-lead) This reconnection procedure details voltage NOTE reconnections only. If the generator set requires Voltage reconnection! Affix notice to generator set after frequency changes, the governor and voltage regulator reconnecting to a voltage different than the nameplate. will need adjustment. See the generator service manual Order voltage reconnection decal 246242 from authorized service distributors/dealers.
  • Page 71 EM-250000- Figure 5-4. Generator Reconnection TP-5592 7/96 Wiring Diagrams 5-5...
  • Page 72 Electro Switch 2-Wire Generator Sets 3-Wire Generator Sets To Shore To Generator Power To Shore To Generator Power To Load To Load Kraus Naimler/American Solenoid (Early Rectangular Design) 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load...
  • Page 73 Kraus Naimer/American Solenoid 4-Wire, three phase Generator Sets To Generator To Shore Power L3 L0 To Load I-940 Figure 5-6. Marine Manual (Ship-to-Shore) Transfer Switch TP-5592 7/96 Wiring Diagrams 5-7...
  • Page 74 229937-A Figure 5-7. Schematic Wiring Diagram— 13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ (1-Phase Models) 5-8 Wiring Diagrams TP-5592 7/96...
  • Page 75 229937-A Figure 5-8. Point-to-Point Wiring Diagram— 13.5/18.5/21CCOZ and 11/15/16.5/18CCFOZ (1-Phase Models) TP-5592 7/96 Wiring Diagrams 5-9...
  • Page 76 229938- Figure 5-9. Schematic Wiring Diagram— 14/20/24CCOZ and 11.5/17.5/20CCFOZ (3-Phase Models) 5-10 Wiring Diagrams TP-5592 7/96...
  • Page 77 229938- Figure 5-10. Point-to-Point Wiring Diagram— 14/20/24CCOZ and 11.5/17.5/20CCFOZ (3-Phase Models) TP-5592 7/96 Wiring Diagrams 5-11...
  • Page 78 229991-B Figure 5-11. Schematic Wiring Diagram— 13.5/18.5/21CCOZ (Specs: PA-126148, PA-126152, and PA-126155 1-Phase Models) 5-12 Wiring Diagrams TP-5592 7/96...
  • Page 79 229991-B Figure 5-12. Point-to-Point Wiring Diagram— 13.5/18.5/21CCOZ (Specs: PA-126148, PA-126152, and PA-126155 1-Phase Models) TP-5592 7/96 Wiring Diagrams 5-13...

  • Page 80: Section 6. Installation

    Section 6. Installation Introduction Use this section as a guide when installing the marine NOTE generator set, then refer to the operation section for There is a wood block located under some generator set specific service instructions. Reliable and safe end brackets to prevent damage during shipment.
  • Page 81 KOHLER 1. Exhaust mixer elbow (exhaust/water outlet) (not shown) 11. Hose clamps 2. Heat exchanger (not shown) 12. Fuel supply line * 3. Coolant recovery tank 13. Mounting tray 4. Seawater strainer * 14. Battery/battery storage box 5. Seawater pump (seawater inlet) 15.

  • Page 82: Location

    Location General Space Consider the following when selecting or constructing a Location should allow easy access to the generator set’ s generator set location. engine, controller, cooling, and fuel system components for routine service. The engine compartment is often the D Allow adequate space for ventilation, cooling and ideal generator set location if propulsion engine(s) do exhaust system installation, service access to set...

  • Page 83: Ventilation

    Ventilation Figure 6-2 lists air requirements for various models. The air intake silencer/cleaner provides combustion air to the engine. Do not compromise the recommended WARNING minimum clearance of 1.5 in. (38mm) between duct opening and any enclosure wall. Not following these guidelines will adversely affect engine/generator performance.

  • Page 84: Fuel Systems

    Fuel Systems Fuel Supply WARNING 1-788 Explosive fuel vapors. Can cause severe injury or death. 1. Fuel line to propulsion engine 2. Fuel line to generator set Use extreme care when handling, storing, Figure 6-3. Dual Dip Tubes and using fuels. NOTE Installing fuel system.

  • Page 85: Anti-Siphon Provisions

    Incoming fuel cools devices with diesel-powered applications. Therefore, the injectors and achieves maximum engine efficiency Kohler Co. does not recommend using anti-siphoning by supplying cool fuel to the engine. Fuel tank capacity devices. and amount of fuel will affect cooling capability.
  • Page 86 ADV-5853-A 1. Fuel Return Connection 3. Inlet Connection 2. Fuel Feed Pump Figure 6-6. Fuel Feed Pump (Inlet Connection) and Fuel Return Connection (Typical) TP-5592 7/96 Installation 6-7...

  • Page 87: Cooling Systems

    Cooling Systems General The following features are necessary in any marine cooling system. Intake through-hull strainer (seacock cover) Install a screened strainer to prevent entry of foreign objects. Accepted types of through-hull strainers are those of the perforated, slotted-hole, or unrestricted-hole design. See Figure 6-8 for examples of typical strainers.
  • Page 88 Mount seawater strainer of sufficient capacity to Keep pipes as straight and as short as possible. If the seacock or permanent structure at a point not higher pipe is too long, water draw problems may occur. To than seawater pump. Ensure that the strainer is remedy some problems with long pipe runs (usually accessible for servicing.

  • Page 89: Closed/Heat Exchanger

    Closed/Heat Exchanger Closed heat exchanger cooling is the best alternative for most applications. Kohler Co. recommends using closed heat exchanger cooling if the craft is operated in saltwater or water with high silt content. Provide service accessibility for the water-cooled exhaust manifold pressure cap.
  • Page 90 Seawater Freshwater (Coolant/Antifreeze) TP-5592-6 1. Oil cooler 8. Silencer (customer supplied) 2. Engine block 9. Exhaust outlet 3. Thermostat 10. Intake strainer 4. Water-cooled manifold 11. Seacock 5. Heat exchanger 12. Seawater strainer 6. Exhaust mixer elbow 13. Engine-driven seawater pump 7.

  • Page 91: Exhaust Systems

    Exhaust Systems General WARNING Use water-cooled exhaust lines in all marine installations. Keep the lines as short and straight as possible. ABYC Safety Standards P-1.6.i. recommends using two corrosion-resistant hose clamps, with a minimum width of 1/2 in. (13 mm), on each end of flexible Carbon monoxide.

  • Page 92: Above Waterline

    Above Waterline Locate the exhaust outlet at least 4 in. (10 cm) above the waterline when craft is loaded to maximum capacity. In addition to considerations described earlier, install a Typically, install a flapper at exhaust (transom) outlet to customer-supplied silencer with silencer outlet at a prevent water backup in following seas or when moving maximum of 10 horizontal ft.
  • Page 93 NOTE Numbers in Illustrations refer to callouts below and not to dimensions. Waterline 1. Slight lift improves silencing (keep below level of exhaust 9. Seacock manifold outlet) 10. Intake strainer 2. Silencer (customer-supplied) 11. Engine-driven seawater pump 3. Exhaust mixer elbow 12.

  • Page 94: Mid/Below Waterline

    Mid/Below Waterline Locate siphon break above highest point in exhaust line between the heat exchanger and the exhaust mixer. Follow ABYC P-1.8.c recommendations for installing an See Figure 6-15 for siphon break connection. Support anti-siphoning provision to prevent raw water entry into the siphon break and hoses to maintain proper position the engine.
  • Page 95 NOTE Numbers in Illustrations refer to callouts below and not to dimensions. 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 4 ft. (1.2 m) 16.

  • Page 96: Electrical Systems

    Electrical Systems AC Voltage Connections Make AC connections to generator set inside the controller box. Typically, the generator set is connected to a ship-to-shore transfer switch which allows the use of WARNING shore/utility power when docked or generator set power when docked or at sea.

  • Page 97: Installation In Steel Or Aluminum Vessels

    Installation In Steel Or Aluminum Installation Regulations Vessels Pleasurecraft Generator Installation: The U.S. Coast Guard and the American Boat and Yacht Installation of a generator set in a vessel constructed of Council, Inc. govern generator sets installed in a material capable of conducting current (e.g.: steel or pleasurecrafts.

  • Page 98: Battery

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

  • Page 99: Wiring

    Wiring Remote Start Switch Connection Use only stranded copper wire. Wire gauges and Kohler Co. offers several remote panels for connection insulation, conductor temperature ratings, sheath to the generator set. See Accessories for further stripping, conductor support and protection, conductor detailed descriptions.
  • Page 100 1. Use insulink or solder connection (tape to insulate) 6. Start 2. Hourmeter 7. Generator set 3. Stop 8. Senders 4. ON light 9. Controller socket 5. Rocker switch 10. Wiring harness plug Figure 6-21. Remote Control Panel Wiring NOTE All wire is 16 gauge.

  • Page 101: Section 7. Installation Drawings

    Section 7. Installation Drawings ADV-5852-A Figure 7-1. Dimension Drawing— 13.5/14CCOZ and 11/11.5CCFOZ TP-5592 7/96 Installation Drawing 7-1...
  • Page 102 ADV-5853-A Figure 7-2. Dimension Drawing— 18.5/20/21/24CCOZ and 15/17.5/16.5/18/20CCFOZ 7-2 Installation Drawing TP-5592 7/96...
  • Page 103 ADV-5841-B Figure 7-3. Dimension Drawing— All Models TP-5592 7/96 Installation Drawing 7-3...

  • Page 104: Appendix A. Generator Selection And Wattage Requirements

    Appendix A. Generator Selection and Wattage Requirements General Lighting Load The lighting load is usually easiest to calculate. In most Consider total wattage requirements (lights, motors, cases, simply add the wattage of each generator appliances) when selecting a generator set, or when set-operated lamp.
  • Page 105 Appliance Loads Motor Starting Running Generator sets often furnish AC for appliances such as Watts Electrical Appliance Watts TV, stereo, electric water heater, etc. With the exception Automatic pilot 150-250 of the resistance-type loads such as the water heater, Blanket, electric 50-250 requirements for appliances are usually low.

  • Page 106: Appendix B. Glossary Of Abbreviations

    Appendix B. Glossary of Abbreviations Abbreviations are used throughout this manual. Normally they will appear in the text in complete form with the abbreviation following in parentheses the first time they are used. After that they will appear in the abbreviated form. The commonly used abbreviations are shown below.
  • Page 107 Abbreviation Description Abbreviation Description joule, joules National Standard taper pipe thread per general use Japanese Industry Standard not required kilogram, kilograms outside diameter kg/cm kilograms per square centimeter original equipment manufacturer kilogram meter(s) overspeed, oversize kilometer, kilometers oversize kiloPascal, kiloPascals OSHA Occupational Safety and Health Act kilometers per hour...

  • Page 108: Appendix C. Operating Hour Service Log

    Appendix C. Operating Hour Service Log The following is provided to help you keep a cumulative dates required services were performed. Enter hours to record of operating hours on your generator set and the the nearest quarter hour. OPERATING HOURS SERVICE RECORD HOURS RUN CUMULATIVE...
  • Page 109 KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Web site www.kohlergenerators.com TP-5592 7/96a Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada E Kohler Co., 1997. All rights reserved. Phone 1-800-544-2444...

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