Kohler 5E/4EF User manual

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
Installation

TP-5982 4/062

TP-5982 4/06 Table of Contents 3
Table of Contents
Safety Precautions and Instructions 5........................................................
Section 1 Introduction 11.....................................................................
Section 2 Location and Mounting 13..........................................................
2.1 General Considerations 13................................................
2.2 Location 13.............................................................
2.3 Mounting 13.............................................................
Section 3 Cooling System 15.................................................................
3.1 Ventilation 15............................................................
3.2 Cooling System Components 15...........................................
3.2.1 Intake Through-Hull Strainer (Seacock Cover) 15.....................
3.2.2 Seacock 16.....................................................
3.2.3 Seawater Strainer 16.............................................
3.2.4 Waterlines 17....................................................
3.2.5 Closed Heat Exchanger 17........................................
Section 4 Exhaust System 19.................................................................
4.1 Exhaust Lines 19........................................................
4.2 Exhaust Systems 19.....................................................
4.2.1 Above Waterline Installation 21....................................
4.2.2 Mid/Below Waterline Installation 22.................................
Section 5 Fuel System 25.....................................................................
5.1 Fuel Tank 25............................................................
5.2 Fuel Inlet Line 25........................................................
5.3 Fuel Filters or Strainers 26................................................
5.3.1 5/7.3E, 4/6EF, 5/7.3ECD, 4/6EFCD, 10/13/15EG, and
13/15EGZ Models 26.............................................
5.3.2 15/20C and 12.5/16CF Models 27..................................
5.4 Antisiphon Device Installation 27...........................................
5.5 Fuel Pump Lift and Fuel Consumption 27...................................
5.6 Fuel System Bleed Procedure 5/7.3ECD and 4/6EFCD Models 28..............
Section 6 Electrical System 29................................................................
6.1 AC Voltage Connections 29...............................................
6.2 Circuit Protection 29......................................................
6.2.1 Circuit Breaker Considerations 30..................................
6.2.2 Circuit Breaker Installation 31......................................
6.3 ADC 2100 Continuous Power Mode Jumper (10/13/15EG Models) 32...........
6.4 Installation in Steel or Aluminum Vessels 33.................................
6.5 Installation Regulations 33................................................
6.6 Battery 34...............................................................
6.7 Wiring 35...............................................................
6.8 Remote Start Switch Connection 35........................................
Section 7 Installation Drawings 37............................................................
Section 8 Reconnection/Adjustments 47.......................................................
8.1 Four-Lead Reconnection 47...............................................
8.2 Voltage Regulator Adjustment (5/7.3E, 4/6EF, 15/20C, and 12.5/16CF Models) 50
8.3 ADC 2100 Adjustment (5/7.3ECD, 4/6EFCD, 10/13/15EG, and
13/15EGZ Models) 52....................................................
8.3.1 Configuration Mode Time Out 52...................................
8.3.2 Controller Software Version Number 52.............................
8.3.3 Configuration Mode 52
............................................
8.3.4 Adjusting the Voltage, Gain, Volts/Hz, and Engine Speed 54...........
8.3.5 Voltage Adjustment 54............................................
Appendix A Generator Selection and Wattage Requirements 59....................................
Appendix B Abbreviations 60..................................................................
Appendix C Generator Set Output Ratings Procedure 62..........................................

TP-5982 4/064

TP-5982 4/06 5Safety Precautions and Instructions
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,orsubstantial
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.
Accidental Starting
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.
WARNING
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
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.
Battery
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
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.
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
containerwith4L(1gal.)ofwaterand
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.