Abstract: An engine-generator set with a single-cylinder diesel engine and an electrical generator with a rotor secured to the engine crankshaft. The rotor is cantilevered on an end of the crankshaft. The engine has an electrically activatable fuel injector connected to a continuously pressurized fuel supply, such as in a common rail injection system. The engine exhaust passes through a catalyst bed. In a marine version, the catalyst bed is disposed within an injection elbow.

Abstract: An engine-generator set with a single-cylinder diesel engine and an electrical generator with a rotor secured to the engine crankshaft. The rotor is cantilevered on an end of the crankshaft. The engine has an electrically activatable fuel injector connected to a continuously pressurized fuel supply, such as in a common rail injection system. The engine exhaust passes through a catalyst bed. In a marine version, the catalyst bed is disposed within an injection elbow.

Abstract: An exhaust manifold cooling jacket has internal passages for the circulation of liquid coolant and encloses an exhaust manifold such that a gap is created between the exhaust manifold and cooling jacket. Flowing coolant through the jacket regulates outer jacket temperature while enabling high intra-manifold exhaust gas temperatures for thorough intra-manifold combustion and improved emissions. A liquid-cooled exhaust system includes a turbocharger disposed between manifold and elbow, with liquid coolant flowing from manifold to elbow through the turbocharger. Another liquid-cooled exhaust manifold contains an internal exhaust combustion catalyst wrapped in an insulating blanket. In some marine applications, seawater or fresh water coolant is discharged into the exhaust gas stream at an attached exhaust elbow.

Abstract: A method of controlling emissions from a fixed-speed internal combustion engine includes injecting a controlled flow of air into the exhaust between a first catalyst bed adapted to reduce HC and NOx emissions, and a second catalyst bed adapted to reduce CO emissions. The flow of air is controlled to optimize the level of CO emissions, preferably as a function of engine load or temperature. In a marine engine-generator set, the flow of air is controlled as a function of generator load or temperature of the exhaust mixture entering the second catalyst bed, and seawater is injected into the exhaust stream downstream of the catalysts.

Abstract: Engine safety features include an intake silencer defining an internal volume sized to help attenuate air pressure fluctuations generated within the carburetor and engine and transmitted back through the entering combustion air, and also functions as a flame arrester. An internal drip well collects fuel droplets to be siphoned through a hose back to the engine intake system for combustion. The carburetor bowl operates to allow gas and relatively safe vapor out of the carburetor during venting, but disallows liquid fuel from flowing out of the carburetor through the vent. A ball check valve drain disposed in an air intake enables suction of liquid fuel from the silencer into the intake manifold but inhibits suction of air. These features are useful modifications of commercially available engines to improve their suitability for marine applications such as on board electrical power generation, for example.

Abstract: An oil sump for a vertically shafted combustion engine has a housing with an upper face for sealing against a block of the engine. The sump housing defines an internal volume for containing a quantity of oil received from the engine through an oil drain opening in the upper face of the sump, and defines an exhaust inlet for receiving a flow of exhaust from the engine and directing the flow of exhaust toward an exhaust outlet along an exhaust passage defined within the housing. The housing also defines a water inlet for receiving a flow of cooling water into a water passage within the housing about the exhaust passage. The sump also includes means for securely mounting the engine within a boat hull. In some marine applications, seawater or fresh water coolant is discharged into the exhaust gas stream at an attached exhaust elbow.

Abstract: A power controller for controlling an engine-driven generator includes a high voltage DC bus interconnecting various power modules. In electrical communication with the DC bus are: a bi-directional DC-DC converter constructed to transfer electrical power from the DC bus to a battery to charge the battery, and from the battery to the DC bus; a rectifier constructed to rectify electrical power from the generator and to supply the rectified power to the DC bus; an inverter constructed to convert DC bus electrical power to AC electrical power and to supply the AC power to an output connector; and an AC-DC constructed to convert AC electrical power, supplied via an input connector, to DC bus electrical power. The controller may be employed in a power supply on a mobile vehicle or boat, for example. The power modules of the controller cooperate in various combinations to provide a wide variety of power transfer functions.

Abstract: A outboard marine electrical generator unit capable of installation on the transom of a marine vessel which provides an electrical generating unit for small and medium sized marine vessels. The invention thus provides an A/C and D/C electrical power source capable of providing electrical power for appliances, air conditioning units and other electrical loads, even while the primary propulsion system is off and the vessel is docked or at anchor.

Abstract: A outboard marine electrical generator unit capable of installation on the transom of a marine vessel which provides an electrical generating unit for small and medium sized marine vessels. The invention thus provides an A/C and D/C electrical power source capable of providing electrical power for appliances, air conditioning units and other electrical loads, even while the primary propulsion system is off and the vessel is docked or at anchor.

Abstract: A outboard marine electrical generator unit capable of installation on the transom of a marine vessel which provides an electrical generating unit for small and medium sized marine vessels. The invention thus provides an A/C and D/C electrical power source capable of providing electrical power for appliances, air conditioning units and other electrical loads, even while the primary propulsion system is off and the vessel is docked or at anchor.

Abstract: A outboard marine electrical generator unit capable of installation on the transom of a marine vessel which provides an electrical generating unit for small and medium sized marine vessels. The invention thus provides an A/C and D/C electrical power source capable of providing electrical power for appliances, air conditioning units and other electrical loads, even while the primary propulsion system is off and the vessel is docked or at anchor.

Abstract: A outboard marine electrical generator unit capable of installation on the transom of a marine vessel which provides an electrical generating unit for small and medium sized marine vessels. The invention thus provides an A/C and D/C electrical power source capable of providing electrical power for appliances, air conditioning units and other electrical loads, even while the primary propulsion system is off and the vessel is docked or at anchor.

Abstract: An enclosure for enclosing sound-producing equipment (such as a marine propulsion system), the enclosure having first and second opposing end panels, first and second opposing side panels, a base and a top panel, releasably connected to each other at corresponding mitered edge joints. The method of making the enclosure includes molding a single enclosure preform and then severing the preform into side, end and top panels. The enclosure preform may be rotationally molded, for example, and may have a layer of sound absorbing material applied to its inner surface during molding. Other, non-molded sound enclosure embodiments are also disclosed.

Abstract: A method and device for cooling engines and other heat sources having housings with fins protruding from a surface thereof for direct convective heat transfer with a fluid medium, particularly applicable for cooling engines constructed to be air-cooled. The invention features a cooling jacket having recesses defined in a surface thereof for receiving the fins of the housing of the heat source, and a coolant passage defined therein. The cooling jacket is placed in close proximity to the heat source housing, such that the fins of the housing of the heat source protrude into the recesses of the cooling jacket. The small gap between the contoured heat source and jacket surfaces is filled with a thermally conductive material to enhance heat transfer from the heat source to the jacket. The cooling jacket can be readily mounted to an assembled, commercially engine to transform the engine from air-cooling to liquid-cooling.

Abstract: An enclosure for acoustically insulating noise-producing equipment, such as an engine or generator, includes a base, first and second opposing end panels, first and second opposing side panels, and a top panel. The side and end panels rest upon the base and are releasably interconnected at mitered edge joints. The top panel is releasably connected to the end and side panels at similar mitered edge joints. The top, side and end panels are each separately removable from the enclosure without removing any other of the panels, enabling unobstructed access to all sides of the enclosed equipment. Guide pins at the mitered joints align the panels. Methods of use are also disclosed.

Abstract: A cooling system is provided for enclosed first and second heat sources including an enclosure substantially enclosing the heat sources. The first and second heat sources are positioned in the enclosure. A heat exchanger, also positioned within the enclosure, is connected through the enclosure to an external source of cooling fluid and is adapted for cooling air within the enclosure. The heat exchanger has a first surface for receiving the air to be cooled and a second surface for expelling cooled air. First and second air circulation means are provided within the enclosure for circulating air past both the first and second heat sources and the heat exchanger. A first baffle portion separates the first and second heat sources and extends to the first surface of the heat exchanger, and a second baffle portion extends to the second surface of the heat exchanger.

Abstract: A cooling system is provided for an enclosed heat source including an enclosure substantially enclosing the heat source. The heat source is positioned in the enclosure. A heat exchanger, also positioned within the enclosure, is connected through the enclosure to an external source of cooling fluid and is adapted for cooling air within the enclosure. Air circulation means are provided within the enclosure for circulating air past both the heat source and the heat exchanger. A method of cooling an air cooled heat source within an enclosure is also provided.

Abstract: A system for use within an internal combustion engine to facilitate the starting of the engine while cold. The system comprises a reservoir for holding a predetermined volume of lubricant, conduit means extending from the reservoir and having outlets positioned above a valve of each cylinder of the engine, and delivery means responsive to the actuation of the engine's starter for forcing lubricant at a predetermined substantially uniform rate from the reservoir and through the conduit means, whereby lubricant is delivered through the engine valves and cylinders, for the sealing thereof, continuously during the starting of the engine.