Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ User Manual

4.7 (9)

Operation and

Installation Manual

Marine Generator Sets

Models:

3.5CFZ

4CZ

5CFZ

6.5CZ

TP-5695 12/93

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.

Table of Contents

SUBJECT

PAGE

Safety Precautions and Instructions . . . . . . .

i

Reference Material . . . . . . . . . . . . . . . . . . . . . . .

viii

Routine Service Parts . . . . . . . . . . . . . . . . . . . . . .

x

Glossary of Abbreviations . . . . . . . . . . . . . . . .

xi

Section 1. Specifications . . . . . . . . . . . . . . . . . .

1-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

General Specifications . . . . . . . . . . . . . . . . . . .

1-1

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5

Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6

Section 2. Operation . . . . . . . . . . . . . . . . . . . . . .

2-1

Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3

Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3

Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

Engine Safety Shutdown Switches . . . . . . . . . . .

2-4

Remote Panels (Optional) . . . . . . . . . . . . . . . . . .

2-6

Section 3. Scheduled Maintenance . . . . . . . . . 3-1

Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Oil Change/Oil Filter Change . . . . . . . . . . . . . . 3-5

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Fuel Pump Screen . . . . . . . . . . . . . . . . . . . . . . . 3-7

Carburetor/Choke Lubrication . . . . . . . . . . . . . 3-8

Carburetor Adjustments . . . . . . . . . . . . . . . . . . 3-8

Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Ignition System Service . . . . . . . . . . . . . . . . . . 3-9

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Cooling Systems— Closed/Heat Exchanger . . . 3-12

Filling and Checking . . . . . . . . . . . . . . . . . . . . . 3-12

Flushing and Cleaning . . . . . . . . . . . . . . . . . . . 3-14

Anticorrosion Zinc . . . . . . . . . . . . . . . . . . . . . . . 3-16

Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Air Cleaner and Mixing Elbow . . . . . . . . . . . . . . . 3-17

Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . 3-17

Servicing Mixing Elbow . . . . . . . . . . . . . . . . . . . 3-17

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Checking Electrolyte Level . . . . . . . . . . . . . . . . 3-18

Checking Specific Gravity . . . . . . . . . . . . . . . . 3-18

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

SUBJECT

PAGE

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Governor Adjustment . . . . . . . . . . . . . . . . . . . . 3-22

Wattage Requirements . . . . . . . . . . . . . . . . . . . . . 3-23

Generator Service . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Section 4. Troubleshooting . . . . . . . . . . . . . . . . 4-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Section 5. Wiring Diagrams . . . . . . . . . . . . . . . 5-1

Section 6. Installation . . . . . . . . . . . . . . . . . . . . . 6-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Generator Selection and

Wattage Requirements . . . . . . . . . . . . . . . . . . . . . 6-1 Lighting Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Motor Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Appliance Loads . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Kilowatt Derating . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Anti-Siphon Provisions . . . . . . . . . . . . . . . . . . . 6-6 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Fuel Pump Lift Capabilities and

Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . 6-6 Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Closed/Heat Exchanger . . . . . . . . . . . . . . . . . . 6-8 Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Above Waterline . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Mid/Below Waterline . . . . . . . . . . . . . . . . . . . . . 6-11 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 AC Voltage Connections . . . . . . . . . . . . . . . . . . 6-12 Installation in Steel or Aluminum Vessels . . . 6-12 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Remote Start Switch Connection . . . . . . . . . . 6-14

Section 7. Installation Drawings . . . . . . . . . . . 7-1 Section 8. Parts Ordering Instructions . . . . . 8-1 Section 9. Operating Hour Service Log . . . . . 9-1

TP-5695 12/93

Table of Contents

Safety Precautions and Instructions

A generator set, like any other electro-mechanical device, can pose potential dangers to life and limb if improperly maintained or imprudently operated. The best way to prevent accidents is to be aware of the potential dangers and to always use good common sense. In the interest of safety, some general precautions relating to the operation of a generator set follow. Keep these in mind. This manual contains several types of safety precautions which are explained below.

DANGER

Danger is used to indicate the presence of a hazard that will cause severe personal injury, death, or substantial property damage if the warning is ignored.

WARNING

Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.

CAUTION

Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the warning is ignored.

Safety decals are affixed to the generator set in prominent places to advise the operator or service technician of potentially hazardous situations. The decals are reproduced here to improve operator recognition and thereby increase decal effectiveness. For a further explanation of decal information, reference the accompanying safety precautions. Before operating or servicing the generator set, be sure you understand the message of these decals. Replace decals if missing or damaged.

NOTE

Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related.

HAZARDOUS VOLTAGE/

ELECTRICAL SHOCK

WARNING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Moving rotor.

Hazardous voltage.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Can cause severe injury or death.

Do not operate generator set without all guards and electrical enclosures in place.

Hazardous voltage can cause severe injury or death. Wherever electricity is present, there is the hazard of electrocution. Take the same precautions with electrical appliances in your craft that you would observe in your home. Open main circuit breaker on all power sources before servicing equipment. Make sure unqualified persons, especially children, cannot gain access to your set— keep the compartment door locked or securely latched at all times. Be sure that generator is properly grounded. Never touch electrical leads or appliances with wet hands, when standing in water, or on wet ground as the chance of electrocution is especially prevalent under such conditions.

Hazardous voltage can cause severe injury or death. Use caution when handling the capacitor; possible electrical shock can result. Discharge capacitor by shorting terminals together.

Hazardous voltage 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 adjustments are made. Remove wristwatch, rings, and jewelry that can cause short circuits.

Hazardous “backfeed” voltage can cause severe injury or death. Do not connect to any building/marina electrical system without connecting through an approved device and after building main switch is open. Backfeed connections can cause serious injury or death to utility personnel working to repair a power outage and/or personnel in the vicinity. Unauthorized connection may be unlawful in some states and/or localities. A ship-to-shore transfer switch must be installed to prevent interconnection of generator set power and shore power.

TP-5695 12/93

Safety Precautions and Instructions i

EXHAUST SYSTEM

WARNING

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Carbon monoxide can cause severe nausea, fainting, or death. Use the following precautions when installing and operating generator set. Carbon monoxide is particularly threatening in that it is an odorless, colorless, tasteless, nonirritating gas. Be especially careful if operating the generator when moored or anchored under calm conditions as gases may accumulate. If operating the set dockside, moor your craft so that the exhaust discharges on the lee side (the side sheltered from the wind), and always be mindful of others— make sure your exhaust is directed away from other boats and occupied buildings. Do not install exhaust outlet where exhaust can be drawn through portholes, vents, or air conditioners. If generator set’s exhaust discharge hole is near to your craft’s water line, DO NOT OVERLOAD CRAFT so as to close or restrict exhaust discharge hole.

Carbon monoxide can cause severe nausea, fainting, or death. In addition to routine inspection of the exhaust system, a carbon monoxide detector should be considered. Consult your boat builder or marina for installation of approved detectors. It is essential that all detectors be routinely inspected for proper operation.

ii Safety Precautions and Instructions

TP-5695 12/93

BATTERY

WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.

Use protective goggles and clothes. Can cause permanent damage to eyes, burn skin, and eat holes in clothing.

Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can cause permanent damage to eyes, burn skin, and eat holes in clothing. Always wear splash-proof safety goggles when working around the battery. If battery electrolyte is splashed in the eyes or on skin, immediately flush the affected area for 15 minutes with large quantities of clean water. In the case of eye contact, seek immediate medical aid. Never add acid to a battery once the battery has been placed in service. Doing so may result in hazardous spattering of electrolyte.

Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flame or spark to occur near a battery at any time, particularly when it is being charged. Avoid contacting terminals with tools, etc. to prevent burns and to prevent sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling battery. Never connect negative (--) battery cable to positive (+) connection terminal of starter solenoid. Do not test battery condition by shorting terminals together or sparks could ignite battery gases or fuel vapors. Any compartment containing batteries must be well ventilated to prevent accumulation of explosive gases. To avoid sparks, do not disturb battery charger connections while battery is being charged and always turn charger off before disconnecting battery connections. When disconnecting battery, remove negative lead first and reconnect it last.

TP-5695 12/93

Safety Precautions and Instructions iii

FUEL SYSTEM

WARNING

Explosion.

Gasoline vapors can cause explosion and severe injury or death.

Before starting generator set, operate blower 4 minutes and check engine compartment for gasoline vapors.

WARNING

Explosive fuel vapors.

Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

Explosive fuel vapors can cause severe injury or death. All fuels are highly explosive in a vapor state. Use extreme care when handling, storing, and using fuels. Store fuel 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 since spilled fuel may ignite on contact with hot parts or from ignition spark. Do not smoke or permit flame or spark to occur near potential sources of spilled fuel or fuel vapors. Keep fuel lines and connections tight and in good condition— don’t replace flexible fuel lines with rigid lines. Flexible sections are used to avoid breakage due to vibration. Should any fuel leakage, fuel accumulation, or electrical sparks be noted, DO NOT OPERATE GENERATOR SET. Have systems repaired before resuming generator operation.

Explosive fuel vapors can cause severe injury or death. Additional precautions must be taken when using the following fuels:

Gasoline— Store gasoline only in approved red containers clearly marked GASOLINE. Do not store gasoline in any occupied building.

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

Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining fuel system. Wipe up all spilled fuel after draining system.

Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Do not modify the tank or propulsion engine fuel system. Craft must be equipped with a tank allowing one of the two pickup arrangements described. Tank and installation must conform to U.S.C.G. Regulations.

Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. To prevent fuel leakage, use pipe sealant on all threaded fittings. Pipe sealant must be suitable for use in marine applications having oil and gasoline environments.

iv Safety Precautions and Instructions

TP-5695 12/93

ACCIDENTAL STARTING

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect battery cables before working on generator set (negative lead first and reconnect it last).

Accidental starting can cause severe injury or death. Disconnect battery cables (remove negative lead first and reconnect it last) to disable generator set before working on any equipment connected to generator. The generator set can be started by remote start/stop switch unless this precaution is followed.

MOVING PARTS

WARNING

Rotating parts.

Can cause severe injury or death.

Do not operate generator set without all guards, screens, or covers in place.

Flying projectiles can cause severe injury or death.

Retorque all crankshaft and rotor hardware after servicing. When making adjustments or servicing generator set, do not loosen crankshaft hardware or rotor thru-bolt. If rotating crankshaft manually, direction should be clockwise only. Turning crankshaft bolt or rotor thru-bolt counterclockwise can loosen hardware and result in serious personal injury from hardware or pulley flying off engine while unit is running.

Exposed moving parts can cause severe injury or death. Additional Precautions Regarding Sound Shield Equipped Models:

Some scheduled maintenance procedures require the generator set to be running while performing service. If the sound shield has been removed leaving belts and pulleys exposed, be especially careful of this area.

Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from belts and pulleys when unit is running. Replace guards, covers, and screens before operating generator set.

HOT PARTS

WARNING

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on generator set until unit is allowed to cool.

Hot parts can cause severe injury or death. Do not touch hot engine parts. An engine gets hot while running and exhaust system components get extremely hot.

WARNING

Hot coolant and steam.

Can cause severe injury or death.

Before removing pressure cap stop generator, allow to cool and loosen pressure cap to relieve pressure.

Hot coolant can cause severe injury or death. Allow engine to cool and release pressure from cooling system before opening pressure cap. To release pressure, cover the pressure cap with a thick cloth then turn it slowly counterclockwise to the first stop. After pressure has been completely released and the engine has cooled, remove cap. If generator set is equipped with a coolant recovery tank, check coolant level at tank.

TP-5695 12/93

Safety Precautions and Instructions v

ENGINE BACKFIRE/FLASH FIRE

WARNING

Fire.

Can cause severe injury or death.

Do not smoke or permit flame or spark to occur near fuel or fuel system.

A flash fire can cause severe injury or death. Do not smoke or permit flame or spark to occur near carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuel or fuel vapors. When removing fuel line or carburetor, use a proper container to catch all fuel.

A sudden backfire can cause severe injury or death.

Do not operate with backfire flame arrestor removed.

A sudden backfire can cause severe injury or death.

Do not operate with air cleaner/silencer removed.

A sudden flash fire can cause severe injury or death.

Do not smoke or permit flame or spark to occur near fuel system. Keep the compartment and generator set clean and free of debris to minimize chances of fire. Wipe up all spilled fuel and engine oil.

HAZARDOUS NOISE

CAUTION

Hazardous noise.

Can cause loss of hearing.

Never operate generator without a muffler or with faulty exhaust system.

vi Safety Precautions and Instructions

TP-5695 12/93

NOTES

NOTE

HARDWARE DAMAGE! Engine and generator may make use of both American Standard and metric hardware. Be sure to use the correct size tools to prevent rounding of bolt heads and nuts.

NOTE

Special attention should be given when checking for proper coolant level. After the coolant has been drained, it normally requires some time before complete refill of the engine water jacket takes place.

NOTE

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

NOTE

When a fuse replacement is required, be sure fuse has the same ampere rating and is the same type (for example: ABC or 3AB, ceramic). Do not substitute “clear” glass-type fuses for ceramic fuses. If ampere rating is unknown or questionable, see Wiring Diagram.

NOTE

High-mineral content sea water (salt water) can cause rapid destruction of all metals. Wipe up all salt water spillage on and around generator set and keep metal surfaces free from accumulated salt deposits.

NOTICE

This generator set has been rewired from its nameplate voltage to:

246242

NOTICE

This is a positive terminal only.

Do not attach negative lead!

NOTICE

Check zinc anode every 100 hours or 3 months.

NOTICE

Do not use as a step.

Standing on genset could impair operation of unit.

NOTE

Split lock washers may be supplied with some kits. If split lock washers are supplied with kit, their use is optional.

TP-5695 12/93

Safety Precautions and Instructions vii

Reference Material

It is recommended that the following Regulations and

Standards be followed when installing Marine

Generator Sets.

Pleasure Craft

Designed and manufactured to meet U.S. Coast Guard Title 33.

U.S. Coast Guard Code of Federal Regulations

Title 33

Subparts I--Electrical Systems

Subparts J--Fuel Systems

Title 46

Subchapter F--Marine Engineering

Part 58--Main and Auxiliary Machinery and Related

Systems

Order the above publications from: Superintendent of Documents U.S. Government Printing Office Washington, DC 20402 1-202-783-3238

Boating Safety Circular Commandant (G-BC)

Boating Statistics (G-BP-1)

U.S. Coast Guard Headquarters

2100 Second Street, S.W.

Washington, DC 20593-0001

Boating Safety Hotline: 1-800-368-5647

American Bureau of Shipping

“Rules for Building and Classing Steel Vessels” 45 Eisenhower Drive

Paramus, N.J. 07652 201-368-9100

Lloyds Registry of Shipping “Rules for Classification of Ships” 17 Battery Place

New York, N.Y. 10004 212-425-8050

Underwriters Laboratories, Inc. (UL)

Publications Stock

333 Pfingsten Road

Northbrook, IL 60062

Marine Department: 1-919-549-1400

NFPA 302

National Fire Protection Association

60 Batterymarch Park

Quincy, MA 02269

Customer Service

Society of Automotive Engineer’s (SAE) 400 Commonwealth Drive

Warrendale, PA 15096 1-412-776-4970

American Boat and Yacht Council, Inc. (ABYC) 3069 Solomon’s Island Rd.

Edgewater, MD 21037 1-410-956-1050 1-410-974-8112 1-410-956-2737 FAX

IEEE 45

The Institute of Electrical and

Electronics Engineer’s Inc.

345 East 47th Street

New York, NY 10017

viii Reference Material

TP-5695 12/93

Commercial Vessels

In order to use these generator sets for commercial applications where U.S. Coast Guard Title 46 Certificate is required, additional modifications will be necessary.

U.S. Coast Guard Code of Federal Regulations

Title 46

Subchapter F--Marine Engineering

Part 58--Main and Auxiliary Machinery and Related

Systems

Subchapter J--Electrical Engineering

Part 111--Electrical Systems--General Requirements

Part 112--Emergency Lighting and Power Systems

Subchapter T--Small Passenger Vessels

(Under 100 Gross Tons)

Part 182--Machinery Installation

Part 183--Electrical Installation

Order the above publications from: Superintendent of Documents U.S. Government Printing Office Washington, DC 20402 1-202-783-3238

American Bureau of Shipping (ABS)

65 Broadway

New York, NY 10006

Order ABS publications from:

American Bureau of Shipping

Book Order Section

45 Eisenhower Drive

P.O. Box 910

Paramus, NJ 97653-0910

Lloyd’s Register of Shipping

71 Fenchurch Street

London, EC3M 4BS England

Midwest Office:

Lloyd’s Register of Shipping

100 South York Street, Room 226 Elmhurst, IL 60126 1-312-279-5414

Additional References

The following organizations provide a service which

Yacht Corrosion Consultants, Inc.

may be useful to the generator set installer. These

2970 Seaborg Ave.

organizations are not regulatory in nature but rather

Ventura, CA 93003

provide guidelines and assistance. They are listed only

1-805-644-1886

as a source for additional information. No solicitation or

 

representation is hereby given.

Ward’s Marine Electric, Inc.

 

630 S.W. Flagler Ave.

 

Ft. Lauderdale, FL 33301

 

1-305-523-2815

 

1-800-545-9273

 

1-305-523-1967 FAX

TP-5695 12/93

Reference Material ix

Routine Service Parts

Contact your Kohler generator dealer/distributor for a complete listing of service parts for your generator set.

Part Description

Kohler Part No.

Engine:

 

Air Filter

278612

Oil Filter

267714

Belt, Timing

267722

Ignition System:

 

Spark Plug

267713

Sea Water Pump Impeller

229826

Zinc Anode

267928

White Spray Paint

221318

x Routine Service Parts

TP-5695 12/93

Glossary of Abbreviations

Abbreviations are used throughout this manual. Normally in the text they will appear in complete form with the abbreviation following in parenthesis the first time they are used. After that they will appear in the abbreviated form. The commonly used abbreviations are shown below.

Abbreviation

Description

Abbreviation

Description

AC

alternating current

FM

frequency modulation

AHWT

anticipatory high water temp.

fs

full scale

ALOP

anticipatory low oil pressure

ft.

foot, feet

AM

amplitude modulation

ft. lbs.

foot pound, foot pounds

Amp

ampere

ga.

gauge

Amps

amperes

gal., gals.

gallon, gallons

ANSI

American National Standard Institute

gal./hr.

gallons per hour

API

American Petroleum Institute

gph

gallons per hour

approx.

approximate, approximately

gpm

gallons per minute

A/R

as required, as requested

gr.

grade

A/S

as supplied, as stated, as suggested

grd.

ground

ASA

American Standards Association

HCHT

high cylinder head temperature

assy.

assembly

HET

high exhaust temperature

ASTM

American Society for Testing Materials

Hg

mercury (element)

ATDC

after top dead center

H2O

water

ATS

automatic transfer switch

hp

horsepower

aux.

auxiliary

hr, hrs

hour

AWG

American Wire Gauge

HWT

high water temperature

AWM

appliance wiring material

Hz

hertz (cycles per second)

bhp

brake horsepower

ID

inside diameter

bmep

brake mean effective power

in.

inch(es)

Btu

British thermal unit

inc.

incorporated

°C

Celsius degree

in. lbs.

inch pounds

cc

cubic centimeter

int.

internal

CCA

cold cranking Amps.

int.-ext.

internal-external

CEC

Canadian Electrical Code

ISO

International Standards Organization

cfh

cubic feet per hour

J

joule, joules

cfm

cubic feet per minute

JIS

Japanese Industry Standard

CID

cubic inch displacement

kg

kilogram, kilograms

cm

centimeter, centimeters

kg/cm2

kilograms per square centimeter

cmm

cubic meters per minute

kgm

kilogram meter(s)

co.

company

km

kilometer, kilometers

cont’d.

continued

kPa

kiloPascal, kiloPascals

C.S.A.

Canadian Standards Association

kph

kilometers per hour

cu. in.

cubic inch, cubic inches

kV

kilovolt

cyl.

cylinder

kVA

kilovolt amperes

dBA

decibels

kW

kilowatt, kilowatts

DC

direct current

kWH

kilowatt hour

DCR

direct current resistance

L

liter, liters

deg.

degree

LxWxH

length x width x height

dept.

department

LED, LEDs

light emitting diode

dia.

diameter

lb., lbs.

pound, pounds

e.g.

example given

L/hr.

liter per hour, liters per hour

EMI

electromagnetic interference

L/min.

liter(s) per minutes

etc.

etcetera, (and so forth)

LOP

low oil pressure

ext.

external

LP

liquefied petroleum

°F

Fahrenheit degree

LWT

low water temperature

fl. oz.

fluid ounce, fluid ounces

m

meter, meters

TP-5695 12/93

 

 

Glossary of Abbreviations xi

Abbreviation

Description

Abbreviation

Description

m3

cubic meter, cubic meters

PF

power factor

max.

maximum

pot.

potentiometer

MCM

one thousand circular mils.

ppm

parts per million

mi.

mile, miles

psi

pounds per square inch

mil

one one-thousandth of an inch

pt., pts.

pint, pints

min.

minimum

qt., qts.

quart, quarts

mJ

millijoule, millijoules

qty.

quantity

MJ

mega joule, mega joules

ref.

reference

mm

millimeter, millimeters

RFI

radio frequency interference

m3/min

cubic meters per minute

rms

root mean square

MPa

megaPascal

rpm

revolutions per inch

mph

miles per hour

SAE

Society of Automotive Engineers

MS

military standard

sec.

second, seconds

mW

milliwatt, milliwatts

SCR

silicon controlled rectifier

MW

megawatt, megawatts

spec, specs

specification

N/A

not available

sq.

square

NEC

National Electrical Code

sq. cm

square centimeters

NEMA

National Electrical

sq. in.

square inch, square inches

 

Manufacturers Association

tach

tachometer

NFPA

National Fire Protection Association

TDC

top dead center

Nm

Newton meter, Newton meters

temp.

temperature

no., nos.

number, numbers

TIF

telephone influence factor

NPT

National Standard taper pipe

turbo

turbocharger

 

thread per general use

UNC

Unified coarse thread (was NC)

N/R

not required

UNF

Unified fine thread (was NF)

OC

overcrank

UL

Underwriter’s Laboratories, Inc.

OD

outside diameter

US

undersize

OEM

original equipment manufacturer

V

volt, volts

OS

overspeed, oversize

VAC

Volts alternating current

OV

overvoltage

VDC

volts direct current

oz.

ounce, ounces

W

watt, watts

xii Glossary of Abbreviations

TP-5695 12/93

Section 1. Specifications

Introduction

The craft is equipped with a dependable 110 volt (reconnectable to 110/220 volt), 50 Hz; or 120 volt (reconnectable to 120/240 volt), 60 Hz single-phase alternating current marine generator set. Service requirements are minimal but are very important to the safe and efficient operation of the generator set; therefore, inspect associated parts often. It is recommended that an authorized service

dealer/distributor perform required servicing to assure the unit continues to meet U.S.C.G. requirements.

Please take a few moments to read this manual, then carefully follow all service recommendations to keep the set in top condition. Keep this manual aboard the craft for future reference. See Figure 1-1 for identification and location of components.

Specifications

General Specifications

 

3.5CFZ

5CFZ

Dimensions--L x W x H--in. (mm)

27.87 x 17.50 x 16.60

31.07 x 18.10 x 17.50

 

(708 x 445 x 422)

(789 x 460 x 445)

with Sound Shield

31.07 x 18.10 x 17.50

31.07 x 18.10 x 17.50

 

(789 x 460 x 445)

(789 x 460 x 445)

Weight--(wet), lbs. (kg)

208 (94)

231

(104)

with Sound Shield

231 (104)

231

(104)

Air Requirements--cfm (L/min.)

18 (510)

18 (510)

Fuel Consumption U.S. gal./hr. (L/hr.)

 

 

 

 

Load

 

 

 

 

25%

0.42

(1.59)

0.44

(1.67)

50%

0.50

(1.89)

0.54

(2.04)

75%

0.59

(2.23)

0.66

(2.50)

100%

0.68 ( 2.57)

0.80

(3.03)

 

4CZ

6.5CZ

 

 

 

Dimensions--L x W x H --in. (mm)

27.87 x 17.50 x 16.60

31.07 x 18.10 x 17.50

 

(708 x 445 x 422)

(789 x 460 x 445)

with Sound Shield

31.07 x 18.10 x 17.50

31.07 x 18.10 x 17.50

 

(789 x 460 x 445)

(789 x 460 x 445)

Weight--(wet), lbs. (kg)

190 (86)

231

(104)

with Sound Shield

213 (96)

231

(104)

 

 

 

Air Requirements--cfm (L/min.)

18 (510)

18 (510)

Fuel Consumption U.S. gal./hr. (L/hr.)

 

 

 

 

 

 

 

 

 

Load

 

 

 

 

25%

0.48

(1.81)

0.53

(2.00)

 

 

 

 

50%

0.55 (2.08)

0.62

(2.34)

75%

0.62 (2.34)

0.86

(3.25)

 

 

 

 

100%

0.68 (2.57)

1.02

(3.86)

TP-5695 12/93

Specifications 1-1

Generator

 

3.5CFZ

 

5CFZ

Rated kW

3.5

 

5

Frequency--Hz

50

 

50

Rated Voltage

110 Volt, 2&3 Wire, Single Phase or

110/220 Volt, 3 Wire, Single Phase

Rated Amps (110 Volt)

31.8

 

45.5

Rated Amps (220 Volt)

15.9

 

22.7

Rotor Resistance (cold) (ohms)

4--5

 

4--5

Stator Resistance (cold) (ohms)*

 

 

 

Leads:

 

 

 

1--2, 3--4

0.8

 

0.8

55--66

4.2

 

4.2

B1--B2

0.08

 

0.08

 

4CZ

 

6.5CZ

Rated kW

4

 

6.5

Frequency--Hz

60

 

60

Rated Voltage

120 Volt, 2&3 Wire, Single Phase or

120/240 Volt, 3 Wire, Single Phase

Rated Amps (120 Volt)

33.3

 

54.2

Rated Amps (240 Volt)

16.7

 

27.1

Rotor Resistance (cold) (ohms)

3--4

 

4--5

Stator Resistance (cold) (ohms)*

 

 

 

Leads:

 

 

 

1--2, 3--4

0.06

 

0.04

55--66

1.9

 

2.4

B1--B2

0.09

 

0.06

 

3.5CFZ/4CZ

 

5CFZ/6.5CZ

Generator Type

Two-Pole,

Rotating Field

Voltage Regulation

 

±5%

Frequency Regulation

 

±5%

Angular Operation (Max.)

 

20°Continuous

(in all directions)

 

 

 

 

Excitation Method

Brushless, Exciter Winding/Capacitor

Coupling Type

Tapered Shaft--Thru-Bolt

Stator Bolt Torque in. lbs. (Nm)

 

260 (29)

Thru-Bolt Torque ft. lbs. (Nm)

 

37 (50)

Number of Output Leads

 

4, Reconnectable

Insulation (Rotor and Stator)

Class F, Epoxy Varnish, Vacuum Impregnated

Winding Material

 

Copper

Bearing, Number and Type

 

1, Replaceable Ball

Circuit Protection:

 

 

 

Controller

Replaceable 10-Amp Fuse

Battery Charging

Replaceable 10-Amp Fuse

AC Circuit Breakers

 

Optional

* Most ohmmeters will not give accurate readings when measuring less than 1 ohm. The stator can be considered good if a low resistance reading (continuity) is obtained and there is no evidence of shorted windings (discoloration). Do not confuse a low resistance reading with a reading indicating a shorted winding.

1-2 Specifications

TP-5695 12/93

DERATING: All units are rated 1.0 power factor. Derate approximately 3.5% per 1000 ft. (300 m) above 500 ft. (150 m) above sea level.

3.5CFZ, 50 Hz: 3.5 kW at 77°F (25°C) and 3.5 kW at 122°F (50°C). 4CFZ, 60 Hz: 4 kW at 77°F (25°C) and 3.5 kW at 122°F (50°C). 5CFZ, 50 Hz: 5 kW at 77°F (25°C) and 4.85 kW at 122°F (50°C). 6.5CZ, 60 Hz: 6.5 kW at 77°F (25°C) and 6 kW at 122°F (50°C).

Engine

Some general engine specifications are listed below. Refer to the appropriate service section and the engine service manual for specific service details.

 

3.5CFZ/4CZ

 

5CFZ/6.5CZ

Manufacturer

Honda

 

Model

GX360EV

 

Cycle

4

 

Number Cylinders

2

 

Compression Ratio

8:5:1

 

Displacement--cu. in. (L)

21.9 (359)

 

Rated Horsepower--50 Hz

10.7 (3.5CFZ)

 

10.7 (5CFZ)

--60 Hz

12.8 (4CZ)

 

12.8 (6.5CZ)

RPM--50 Hz

3000 (3.5CFZ)

 

3000 (5CFZ)

--60 Hz

3600 (4CZ)

 

3600 (6.5CZ)

Bore x Stroke--in. (mm)

2.28 x 2.68

(58 x 68)

 

Valve Material

Steel Alloy (JIS SUH3)

 

Valve Clearance--in. (mm) (cold)

0.004--0.006 (0.10--0.14)

Cylinder Block Material

Aluminum

 

Cylinder Head Cover Tightening

7(10)

 

Torque--ft. lbs. (Nm)

 

 

 

Cylinder Head Material

Aluminum

 

Connecting Rod Material

Steel

 

Piston Rings

2 Compression/1 Oil Control

Crankshaft Bearings

Replaceable Inserts

 

Governor

Gear-Driven Centrifugal

Lubrication System

Pressure

 

Oil Capacity (with filter)--U.S. qts. (L)

1.48 (1.4)

 

Oil Type (API)

SF, SF/CC, or SF/CD

 

Oil Pressure--psi (kPa)

30--50 (207--345)

 

Fuel Type

Gasoline, 86 or Higher, Octane Unleaded

Fuel System

Single-Barrel, Horizontal Carburetor

Carburetor Choke

Automatic, Electric

 

Fuel Pump

Electric

 

Fuel Pump Lift (max.)

3 ft. (0.9 m)

 

Battery Voltage

12

 

Battery Ground

Negative

 

Battery Recommendation

250 Cold Cranking Amps (Min.)

TP-5695 12/93

Specifications 1-3

Engine (Continued)

 

3.5CFZ/4CZ

 

5CFZ/6.5CZ

Spark Plug Type

Resistor, Radio

Suppression, 14 mm

 

 

BPR4HS (NGK)

 

Kohler Part Number L92YC (Champion)

 

 

R43CFS (AC-Delco)

Spark Plug Gap--in. (mm)

 

0.028--0.031 (0.7--0.8)

Spark Plug Tightening Torque--

 

15--22 (20--30)

ft. lbs. (Nm)

 

 

 

Ignition System

Transistorized, Breakerless

Starter Motor

 

Bendix Automotive Type

Cooling System

Water-Cooled, Closed/Heat Exchanger

Cooling System Capacity--U.S. qts. (L)

 

1.10 (1.00)

Coolant Recovery Tank--U.S. qts. (L)

 

0.38 (0.35)

Thermostat

 

180 °F (82°C)

Pressure Cap Rating

 

15 psi (103 kPa)

Engine Firing Order

 

1--2

Ignition Timing B.T.D.C.

 

24°±2 degrees

Exhaust Manifold to Cylinder

 

16 ft. lbs. (22 Nm)

Head Torque

 

 

 

Water Pump Assembly to

 

7 ft. lbs. (10 Nm)

Cylinder Block Torque

 

 

 

Cooling Fan Torque

 

16 ft. lbs. (22 Nm)

Air Cleaner Elbow to Carburetor

 

6 ft. lbs. (8.5 Nm)

Stud Torque

 

 

 

Timing Belt Cover Torque

 

6 ft. lbs. (8 Nm)

Governor Arm Shaft Nut Torque

 

7 ft. lbs. (10 Nm)

Governor Case to Cylinder Head

 

7 ft. lbs. (10 Nm)

Torque

 

 

 

Fuel Pump Pressure Rating

2.0--3.5 psi (13.8--24.1 kPa)

Battery Charging Winding

 

0.16--0.24 Ohms

Resistance--10 Amp

 

 

 

Ignition Coil Primary Wire

 

0.9--1.1 Ohms

Resistance

 

 

 

Ignition Coil Secondary

 

0.9--1.1 Ohms

(Spark Plug Wire Side) Resistance

(With Spark Plug Boot/Cap Removed)

Transistorized Ignition Air Gap

0.016 ±0.008 in. (0.4 ±0.2 mm)

Timing Belt Deflection

0.16--0.20 in. (4.5 mm) @ 4.4 lbs. (2 kg)

1-4 Specifications

TP-5695 12/93

Accessories

Several accessories are available to finalize the installation or to add convenience to operation and service. All the most current information can be obtained by contacting the local authorized Kohler dealer/distributor. Available accessories at the time of print of this publication are as follows.

Sound Shield (Optional on 3.5CFZ/4CZ; Standard on 5CFZ/6.5CZ)

Provides for highly effective silencing, ease of access for engine/generator servicing, low maintenance, excellent durability, and safety.

Seawater Strainer

The seawater strainer with clear viewing container, allows easy cleaning and maintenance. Threaded for 1/2 NPT fittings.

Ship-to-Shore Transfer Switch

The ship-to-shore transfer switch allows immediate switching to generator set power or shore power protecting the electrical system from the possibility of simultaneous connection of both power sources.

Remote Start Panel

Allows starting/stopping from a location remote of the generator set. Supplied with 15 foot (4.6 m) connection harness. Overall mounting dimensions are 4 1/16 in. (103 mm) by 2 1/8 in. (54 mm) with a minimum mounting depth of 2 1/4 in. (57 mm).

Model

Amps

Poles

4CZ/3.5CFZ

18

2

4CZ/3.5CFZ

35

1

4CZ/3.5CFZ

20

1

6CZ/5CFZ

30

2

6CZ/5CFZ

55

1

6CZ/5CFZ

25

2

6CZ/5CFZ

20

1

Remote Start and

Four-Meter Panel Kit

Allows starting/stopping from a location remote of the generator set. The illuminated meters/gauges include a DC voltmeter, engine oil pressure gauge, water temperature gauge, and an hourmeter which records total generator set operating hours. Overall dimensions are 9 in. (229 mm) by 6 in. (152 mm) with a minimum mounting depth of 4 in. (102 mm). Requires remote connection/extension harness and sender kit.

Remote Start and

Two-Meter Panel Kit

Allows starting/stopping from a location remote of the generator set. The illuminated gauges include engine oil pressure gauge and water temperature gauge. Overall dimensions are 6 in. (152 mm) by 6 in. (152 mm) with a minimum mounting depth of 2 3/4 in. (70 mm). Requires remote connection/extension harness and sender kit.

Remote Connection/

Extension Harness

Provides additional wiring between all remote panels and controller connector. One required for each remote meter panel kit. Available in 15 ft. (46 m) and 25 ft. (76 m) lengths. Extension limited to a total of four kits and 75 ft. (23 m).

Sender Kit

Provides gauge senders for the remote start and two-meter panel kit and the remote start and four-meter panel kit. The gauge sender kit is required to make the oil pressure and water temperature gauges functional.

Circuit Breakers

12-Inch Remote Wiring Harness

This one foot (0.3 m) wiring harness has a 6-pin connector on one end which is keyed to controller box connector. The other end has pigtails for connection to customer-supplied start switch, generator “on” light, hourmeter, etc.

Siphon Break

See price list or dealer/distributor for proper application of circuit breakers.

Prevents the siphoning of water into the engine on generator sets installed below the waterline.

TP-5695 12/93

Specifications 1-5

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ User Manual

Service Views

 

 

 

4

 

 

 

 

5

6

 

 

 

 

 

 

 

 

 

7

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

8

 

 

 

 

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

31

32

10

11

12

 

13

14

15

16

17

 

 

 

INPUT

STOP START

 

 

 

 

 

18

 

 

 

 

 

 

 

 

 

 

 

 

10A

 

 

 

 

 

 

 

19

 

 

 

FUSE

 

 

 

 

 

 

 

 

 

 

 

000 0 0

1/10

 

 

 

 

 

 

 

 

 

TOTAL HOURS

 

 

 

 

 

 

 

30

BATT.

 

 

 

 

 

 

 

 

 

CHRG.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

36

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20

 

 

33

 

 

 

 

 

 

 

 

21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

22

35

34

29

 

28

27

26

 

25

24

23

 

 

 

 

 

 

 

 

 

 

 

 

 

258000-D

 

 

 

 

 

 

 

 

 

 

 

Figure 1-1. Service Views (typical)

1.

Mixer Elbow (Exhaust Water Outlet)

19.

Oil Drain

2.

Belt Guard

20.

Water Temperature Sender (Optional)

3.

Electric Choke Rotary Solenoid

21.

Heat Exchanger

4.

Carburetor

22.

Ignition Coil/Module

5.

Governor Linkage

23.

Low Oil Pressure Shutdown Switch/Sender

6.

Governor Arm

 

(Sender Optional)

7.

Lifting Eye

24.

Oil Dipstick (Oil Check/Oil Fill)

8.

Speed Adjustment (Idle Speed)

25.

Oil Filter

9.

Antidieseling Solenoid

26.

Anticorrosion Zinc

10.

Controller

27.

Electric Fuel Pump

11.

Battery Charger Voltage Regulator

28.

Remote Panel Connector

12.

Coolant Overflow Hose

29.

Positive Battery Lead Connection

13.

Cooling System Pressure Cap

30.

Coolant Recovery Tank

14.

High Water Temperature Safety Shutdown

31.

Air Filter

15.

Switch

Thermostat

32.

Nameplate

16.

High Exhaust Temperature Shutdown

33.

Negative Battery Lead Connection

17.

Switches (2)

34.

Equipment Ground Lug

Spark Plugs

35.

Starter Solenoid

18.

Seawater Pump

36.

Starter Motor

1-6 Specifications

TP-5695 12/93

Section 2. Operation

Prestart Checks

To insure continued satisfactory operation, the following items should be checked before each start-up.

BACKFIRE FLAME ARRESTOR: Air cleaner must be clean and properly installed to prevent unfiltered air from entering engine. See Maintenance--Air Cleaner.

BATTERY: Remove caps and check the electrolyte level of each cell (batteries with filler caps only); add distilled water if necessary. Check to make sure it is connected correctly. Battery installation and connections must meet Coast Guard Standards. Battery should be serviced by authorized personnel only. See Maintenance--Battery.

COMPARTMENT: Keep the engine room or compartment clean and dry. Check for fuel or oil leaks. Check the condition of fuel system, exhaust piping, hoses, and muffler; have any faulty components repaired before getting underway. Open hatch to air out compartment and use “ignition-protected” bilge blowers, if required, to clear fumes from area before each start-up. If fuel leaks, fumes, exhaust gases, or electrical sparks are noted, arrange for qualified personnel to make necessary repairs before operating generator set.

FUEL LEVEL: Make sure the fuel tanks are full and the fuel system primed for operation. See Maintenance--Fuel System.

OIL LEVEL: Should be at or near Max. mark. Add oil as needed to bring level up to this range. See Maintenance Lubrication System.

COOLING: The coolant level on closed-type heat exchanger systems can be checked using the coolant recovery tank, if used. The MIN mark indicates full when cold and the MAX mark indicates full when hot. Maintain the coolant level between these marks. It is recommended that coolant level on closed systems be periodically checked by removing pressure cap. Do not solely rely on level in coolant recovery tank.

Add fresh coolant until level is just below overflow tube opening. See Maintenance--Cooling Systems.

SEAWATER PUMP PRIMING: The seawater pump must be primed before initial start-up. To prime pump, close seacock and remove the hose from water filter outlet. Fill hose and pump with clean water. Replace hose and open seacock. Check for pump operating on start-up by observing water discharge from exhaust outlet.

TP-5695 12/93

Operation 2-1

Controller

For identification and location of controller operating features, refer to the text below and Figure 2-1.

1.Battery Charging Fuse protects battery charging circuitry from short circuits.

2.Input (Controller) Fuse protects controller circuitry from short circuits.

3.Start/Stop Switch is used to stop and start generator set. Rock to start or stop position and hold to start or stop engine. Switch automatically returns to neutral center position when released.

4.Hourmeter records total generator set operating hours. Use as a reference to schedule maintenance.

5.Remote Start Connector provides connection point for optional remote start kits.

6.Optional AC Circuit Breaker(s) protects generator set from short circuits in load. Also used to disconnect generator set from loads during maintenance. To close circuit breaker, place in ON position.

1

2

 

3

6

4

 

 

5

 

A-246486-D

1.

Battery Charging Fuse

4.

Hourmeter

2.

Input (Controller) Fuse

5.

Remote Start Connector

3.

Start/Stop Switch

6.

Optional AC Circuit

 

 

 

Breaker(s)

Figure 2-1. Controller

2-2 Operation

TP-5695 12/93

Starting

WARNING

Explosion.

Gasoline vapors can cause explosion and severe injury or death.

Before starting generator set, operate blower 4 minutes and check engine compartment for gasoline vapors.

NOTE

For reliable starting, allow at least 30 seconds after shutdown before restarting a hot engine.

Ensure that the manual fuel shutoff valve (if equipped) is open. Then rock the master Start/Stop Switch on controller (or use Start/Stop Switch on remote panel) to the Start position for a maximum of 7 seconds or until the engine starts.

NOTE

Do not crank the engine continuously for more than 7 seconds at a time. Allow a 5-second period between starting attempts if the engine does not start. If the engine fails to start after three attempts, contact an authorized Kohler dealer/distributor for repair. Failure to follow these guidelines may result in burn-out of the starter motor from overheating.

If the engine fails to start after the first attempt, close the seacock before a second start-up attempt. This action will help prevent seawater from entering the engine cylinders through the exhaust valve. Once the engine starts, the seacock must be re-opened to allow passage of cooling water.

NOTE

Failure to open the seacock after the generator set is running will result in serious engine damage due to overheating.

NOTE

Ensure that the marine ship-to-shore transfer switch, if used, is in proper position.

Stopping

Disconnect the load from the generator set and allow the generator set to run at no-load for 5 minutes to cool down the engine. Then rock the master Start/Stop switch on the controller (or the Start/Stop Switch on a remote panel) to the Stop position and hold it in the Stop position until the generator set comes to a complete stop.

NOTE

Allow unit to come to a complete stop before attempting to start the generator set again.

TP-5695 12/93

Operation 2-3

Circuit Protection

AC Circuit Breaker (Optional)

The optional AC circuit breaker(s) located on the front panel of the controller protect the generator output windings. If a load circuit loses power, the cause may be a tripped AC circuit breaker. If a tripped circuit breaker is reset and then trips again, find and correct the short in the load circuit that is causing the problem.

Input (Controller) Fuse (10 Amp)

The input fuse protects the controller circuitry. If the generator set engine will not crank and the battery and battery connections appear okay, the input fuse may be blown. If this fuse, located on the front panel of the controller, is replaced and then blows again, find and correct the short that is causing the problem.

Battery-Charging Fuse (10 Amp)

The battery-charging fuse protects the battery-charging circuit. If the battery goes dead and the battery and battery-charging alternator are otherwise normal, the battery-charging fuse may be blown. If this fuse, located on the front panel of the controller, is replaced and blows again, find and correct the short in the charging circuit that is causing the problem.

NOTE

When a fuse replacement is required, be sure fuse has the same ampere rating and is the same type (for example: ABC or 3AB, ceramic). Do not substitute “clear” glass-type fuses for ceramic fuses. If ampere rating is unknown or questionable, see Wiring Diagram.

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect battery cables before working on generator set (negative lead first and reconnect it last).

Accidental starting can cause severe injury or death. Disconnect battery cables (remove negative lead first and reconnect it last) to disable generator set

before working on any equipment connected to generator. The generator set can be started by remote start/stop switch unless this precaution is followed.

Engine Safety

Shutdown Switches

The engine is protected by three engine safety shutdown switches. Activating any of these switches while the generator set is running, results in an immediate, automatic shutdown. During start-up, the engine safety shutdown feature is inhibited until a generator output is sensed in order to allow the oil pump output to reach normal operating pressure.

Low Oil Pressure Shutdown Switch

The low oil pressure shutdown switch protects the engine against internal damage, if the oil pressure drops below 20 psi (138 kPa), due to an engine oil pump failure or other engine malfunction. The location of the low oil pressure shutdown switch is shown in Figure 2-2.

NOTE

The low oil pressure shutdown switch does not act as a low oil level switch. The only way to protect against engine damage due to low oil level is to check the oil level regularly.

1

258000-D

1. Low Oil Pressure Shutdown Switch

Figure 2-2. Low Oil Pressure Shutdown Switch

2-4 Operation

TP-5695 12/93

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