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

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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 chemicalsknowntotheState of Californiato cause cancer, birth defects, or other reproductive harm.

Table of Contents

SUBJECT PAGE 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. . . .. . . .. . . .. . . .. . . .. . . .. .

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 areexplained below.

DANGER

Dangerisusedtoindicatethepresenceofahazardthat 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

Cautionis used to indicate thepresence of a hazardthat 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. Forafurtherexplanation of decal information, reference theaccompanying safety precautions. Before operating or servicing the generator set, be sure you understand the message of these decals. Replacedecals if missing or damaged.

NOTE

Noteis used to notify people ofinstallation,operation,or maintenance information that is important but not hazard-related.

HAZARDOUS VOLTAGE/ ELECTRICAL SHOCK

WARNING

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

hazardof electrocution. Take thesameprecautionswith 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 thecompartment door locked orsecurely latched at all times.Besure 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. Donot connect to anybuilding/marina

electrical system without connecting through an approved device and afterbuilding mainswitch is open. Backfeedconnections can causeseriousinjury 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.

Moving rotor.

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 yourcraftsothatthe 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’swater line, DO NOTOVERLOAD CRAFT so asto close or restrict exhaust discharge hole.

Carbon monoxide can cause severe nausea, fainting, or death. In addition to routine inspection of

theexhaust system,acarbon monoxidedetectorshould 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.

TP-5695 12/93ii Safety Precautions and Instructions

BATTER Y

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. Alwayswearsplash-proof safety goggles when working around the battery. If battery electrolyte is splashed in the eyes or on skin, immediately flush the affected area for15 minutes with large quantities of clean water.In the caseofeyecontact,seek immediate medical aid. Never addacid toabattery oncethebattery hasbeenplaced in service. Doing so may result in hazardous spattering of electrolyte.

Explosion can cause severe injury ordeath. 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 terminalswith tools, etc. to prevent burns and toprevent sparks that could cause an explosion. Remove wristwatch,rings,andanyotherjewelry 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

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.

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.

Useextreme care when handling, storing, and using fuels.

Explosive fuel vapors can cause severe injury or death.Allfuelsarehighlyexplosiveinavapor 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 potentialsources of spilled fuelorfuelvapors.Keepfuellinesand 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. Gasoline vapors can explode and can cause

death or severe injury. USCG Regulation 33CFR183 requires all electrical devices (ship-to-shore transfer switch,remotestartpanel, etc.)to be“ignitionprotected” whenusedinagasoline(gaseous)-fueledenvironment. 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 wheelhouseor otherliving areasshelteredfrom rainand 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.

TP-5695 12/93iv Safety Precautions and Instructions

ACCIDENTAL STARTING

WARNING

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.

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.

HOT PARTS

WARNING

Hot engine and exhaust system. Can cause severe injury or death.

Donotworkongeneratorsetuntilunitis allowed to cool.

Hot parts can cause severe injury or death. Do not touchhot engine parts. Anenginegets hot whilerunning and exhaust system components get extremely hot.

WARNING

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.

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 thepressure 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 witha coolantrecoverytank, checkcoolantlevel at tank.

TP-5695 12/93 Safety Precautions and Instructions v

ENGINE BACKFIRE/FLASH FIRE

Asudden backfire cancause severeinjury or death.

Do not operate with air cleaner/silencer removed.

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. Donot smokeor permitflameor sparktooccur nearcarburetor, fuel line, fuel filter,fuel pump, or other potential sources of spilled fuel orfuel vapors. When removing fuel line or carburetor, use a proper container to catch all fuel.

A suddenbackfire can cause severe injury or death.

Do not operate with backfire flame arrestor removed.

Asudden flashfire cancause severeinjury ordeath.

Donot smokeorpermit flameorspark tooccur nearfuel system.Keepthecompartmentandgeneratorsetclean 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.

TP-5695 12/93vi Safety Precautions and Instructions

NOTES

NOTE

NOTICE

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 propercoolant level. After the coolanthas 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.

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

Checkzinc anode every100 hours or 3months.

NOTICE

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 orquestionable, 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.

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

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

American Bureau of Shipping “Rules for Building and Classing Steel Vessels” 45 Eisenhower Drive Paramus, N.J. 07652 201-368-9100

IEEE 45 The Institute of Electrical and Electronics Engineer’s Inc. 345 East 47th Street New York, NY 10017

TP-5695 12/93viii Reference Material

Commercial Vessels

In order to use these generator sets for commercial applicationswhere U.S. Coast GuardTitle46Certificate 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

Part111--ElectricalSystems--GeneralRequirements 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 may be useful to the generator set installer. These organizations are not regulatory in nature but rather provide guidelines and assistance. They are listed only as a source for additional information. No solicitation or representation is hereby given.

Yacht Corrosion Consultants, Inc. 2970 Seaborg Ave. Ventura, CA 93003 1-805-644-1886

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

AC alternating current AHWT anticipatory high water temp. ALOP anticipatory low oil pressure AM amplitude modulation Amp ampere Amps amperes ANSI American National Standard Institute API American Petroleum Institute approx. approximate, approximately A/R as required, as requested A/S as supplied, as stated, as suggested ASA American Standards Association assy. assembly ASTM American Society for Testing Materials ATDC after top dead center ATS automatic transfer switch aux. auxiliary AWG American Wire Gauge AWM appliance wiring material bhp brake horsepower bmep brake mean effective power Btu British thermal unit °C Celsius degree cc cubic centimeter CCA cold cranking Amps. CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute CID cubic inch displacement cm centimeter, centimeters cmm cubic meters per minute co. company cont’d. continued C.S.A. Canadian Standards Association cu. in. cubic inch, cubic inches cyl. cylinder dBA decibels DC direct current DCR direct current resistance deg. degree dept. department dia. diameter e.g. example given EMI electromagnetic interference etc. etcetera, (and so forth) ext. external °F Fahrenheit degree fl. oz. fluid ounce, fluid ounces

Abbreviation Description

FM frequency modulation fs full scale ft. foot, feet ft. lbs. foot pound, foot pounds ga. gauge gal., gals. gallon, gallons gal./hr. gallons per hour gph gallons per hour gpm gallons per minute gr. grade grd. ground HCHT high cylinder head temperature HET high exhaust temperature Hg mercury (element) H2O water hp horsepower hr, hrs hour HWT high water temperature Hz hertz (cycles per second) ID inside diameter in. inch(es) inc. incorporated in. lbs. inch pounds int. internal int.-ext. internal-external ISO International Standards Organization J joule, joules JIS Japanese Industry Standard kg kilogram, kilograms

kg/cm kgm kilogram meter(s) km kilometer, kilometers kPa kiloPascal, kiloPascals kph kilometers per hour kV kilovolt kVA kilovolt amperes kW kilowatt, kilowatts kWH kilowatt hour L liter, liters LxWxH length x width x height LED, LEDs light emitting diode lb., lbs. pound, pounds L/hr. liter per hour, liters per hour L/min. liter(s) per minutes LOP low oil pressure LP liquefied petroleum LWT low water temperature m meter, meters

kilograms per square centimeter

TP-5695 12/93 Glossary of Abbreviations xi

Abbreviation Description

cubic meter, cubic meters max. maximum MCM one thousand circular mils. mi. mile, miles mil one one-thousandth of an inch min. minimum mJ millijoule, millijoules MJ mega joule, mega joules mm millimeter, millimeters m3/min cubic meters per minute MPa megaPascal mph miles per hour MS military standard mW milliwatt, milliwatts MW megawatt, megawatts N/A not available NEC National Electrical Code NEMA National Electrical

Manufacturers Association NFPA National Fire Protection Association Nm Newton meter, Newton meters no., nos. number, numbers NPT National Standard taper pipe

thread per general use N/R not required OC overcrank OD outside diameter OEM original equipment manufacturer OS overspeed, oversize OV overvoltage oz. ounce, ounces

Abbreviation Description

PF power factor pot. potentiometer ppm parts per million psi pounds per square inch pt., pts. pint, pints qt., qts. quart, quarts qty. quantity ref. reference RFI radio frequency interference rms root mean square rpm revolutions per inch SAE Society of Automotive Engineers sec. second, seconds SCR silicon controlled rectifier spec, specs specification sq. square sq. cm square centimeters sq. in. square inch, square inches tach tachometer TDC top dead center temp. temperature TIF telephone influence factor turbo turbocharger UNC Unified coarse thread (was NC) UNF Unified fine thread (was NF) UL Underwriter’s Laboratories, Inc. US undersize V volt, volts VAC Volts alternating current VDC volts direct current 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 carefullyfollow all service recommendations tokeepthe 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

(708 x 445 x 422)

with Sound Shield 31.07 x 18.10 x 17.50

(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

(708 x 445 x 422) with Sound Shield 31.07 x 18.10 x 17.50

(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)

31.07 x 18.10 x 17.50 (789 x 460 x 445)

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.)

(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.

20° Continuous

TP-5695 12/931-2 Specifications

DERATING: Allunits are rated 1.0 powerfactor.Derateapproximately 3.5% per 1000 ft.(300 m) above 500ft. (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 engineservice 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

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.)

7(10)

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--

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

Head Torque Water Pump Assembly to

Cylinder Block Torque Cooling Fan Torque 16 ft. lbs. (22 Nm) Air Cleaner Elbow to Carburetor

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

Torque Fuel Pump Pressure Rating 2.0--3.5 psi (13.8--24.1 kPa) Battery Charging Winding

Resistance--10 Amp Ignition Coil Primary Wire

Resistance Ignition Coil Secondary

(Spark Plug Wire Side) Resistance 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)

(With Spark Plug Boot/Cap Removed)

15--22 (20--30)

16 ft. lbs. (22 Nm)

7 ft. lbs. (10 Nm)

6 ft. lbs. (8.5 Nm)

7 ft. lbs. (10 Nm)

0.16--0.24 Ohms

0.9--1.1 Ohms

TP-5695 12/931-4 Specifications

Accessories

Several accessories are available to finalize the installation or to add convenience to operation and service.All themost currentinformationcan beobtained by contacting the local authorized Kohler dealer/distributor. Available accessories at the time of print of this publication are as follows.

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

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 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 generatorset. The illuminated gaugesincludeengine 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/

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. (103mm) by 2 1/8 in.(54mm) with a minimum mounting depth of 2 1/4 in. (57 mm).

Sender Kit

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

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).

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.

Circuit Breakers

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

TP-5695 12/93 Specifications 1-5

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

Extension Harness

Siphon Break

Service Views

INPUT

FUSE

CHRG.

STOP START

10A

1/10

00 0E00

TOTALHOURS

BATT.

16131211 143115

Figure 1-1. Service Views (typical)

1. Mixer Elbow (Exhaust Water Outlet)

2. Belt Guard

3. Electric Choke Rotary Solenoid

4. Carburetor

5. Governor Linkage

6. Governor Arm

7. Lifting Eye

8. Speed Adjustment (Idle Speed)

9. Antidieseling Solenoid

10. Controller

11. Battery Charger Voltage Regulator

12. Coolant Overflow Hose

13. Cooling System Pressure Cap

14. High Water Temperature Safety Shutdown Switch

15. Thermostat

16. High Exhaust Temperature Shutdown Switches (2)

17. Spark Plugs

18. Seawater Pump

27 26 25 24 23

258000-D

19. Oil Drain

20. Water Temperature Sender (Optional)

21. Heat Exchanger

22. Ignition Coil/Module

23. Low Oil Pressure Shutdown Switch/Sender (Sender Optional)

24. Oil Dipstick (Oil Check/Oil Fill)

25. Oil Filter

26. Anticorrosion Zinc

27. Electric Fuel Pump

28. Remote Panel Connector

29. Positive Battery Lead Connection

30. Coolant Recovery Tank

31. Air Filter

32. Nameplate

33. Negative Battery Lead Connection

34. Equipment Ground Lug

35. Starter Solenoid

36. Starter Motor

TP-5695 12/931-6 Specifications

Section 2. Operation

Prestart Checks

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

BACKFIRE FLAME ARRESTOR: Air cleaner must be cleanand properlyinstalledto preventunfiltered airfrom 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 ator nearMax. mark. Add oil as neededtobringlevelupto this range. See Maintenance Lubrication System.

COOLING: The coolant level on closed-type heat exchanger systems can be checked using the coolant recoverytank, if used. The MIN markindicatesfullwhen coldandtheMAXmarkindicatesfullwhen 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. Battery Charging Fuse

2. Input (Controller) Fuse

3. Start/Stop Switch

Figure 2-1. Controller

A-246486-D

4. Hourmeter

5. Remote Start Connector

6. Optional AC Circuit Breaker(s)

TP-5695 12/932-2 Operation

Starting

WARNING

Explosion. Gasoline vapors can cause explosion and severe injury or death.

Iftheenginefailstostart 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.

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.

Ensurethat the manual fuelshutoffvalve (if equipped)is open. Then rock the master Start/Stop Switch on controller (or use Start/Stop Switch on remote panel) to theStartpositionfor amaximum of7 secondsoruntil 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.

NOTE

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

Stopping

Disconnectthe loadfrom thegenerator setandallow 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 remotepanel)totheStoppositionandhold it in the Stop position until the generator set comes to a complete stop.

NOTE

Allow unit to cometo a complete stop beforeattempting to start the generator set again.

TP-5695 12/93 Operation 2-3

Circuit Protection

AC Circuit Breaker (Optional)

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

The optional AC circuit breaker(s) located on the front panel of the controller protect the generator output windings.Ifaloadcircuit loses power,the cause may be atrippedAC 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-chargingfusemaybeblown. If this fuse, located onthe front panelof the controller,isreplacedand blows again, find and correct the short in the charging circuit that is causing the problem.

NOTE

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 generatoroutputissensedinordertoallowthe oil pump output to reach normal operating pressure.

Low Oil Pressure Shutdown Switch

The low oil pressure shutdown switch protects the engineagainst internaldamage,if the oilpressuredrops below20 psi(138kPa), duetoan engineoilpump 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.

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

258000-D

1. Low Oil Pressure Shutdown Switch

Figure 2-2. Low Oil Pressure Shutdown Switch

TP-5695 12/932-4 Operation

High Water Temperature

High Exhaust Temperature

Shutdown Switch

The high water temperature shutdown switch protects the engine against internal damage if the cooling water temperature in the engine block is too high due to cooling water or coolant circulation problems. The switch is set to trip at 248--266° F (120--130° C). The location of the high water temperature shutdown switch is shown in Figure 2-3.

1 (hidden)

STARTSTOP

INPUT

10A FUSE

1/10

00 000

TOTALHOURS

BATT.

CHRG.

258000-D

1. High Water TemperatureShutdown Switch

Figure 2-3. High Water Temperature

Shutdown Switch

Shutdown Switches

The two high exhaust temperature shutdown switches protect the engine against internal damage due to excessive exhaust temperatures. The switches are set at 210--220° F (99--105° C). The locations of the high exhaust temperature shutdown switches are shown in Figure 2-4.

STARTSTOP

INPUT

10A

FUSE

1/10

00 000

TOTALHOURS

BATT. CHRG.

258000-D

1. High Exhaust Temperature Shutdown Switches (one located on each manifold)

Figure 2-4. High Exhaust Temperature

Shutdown Switches

TP-5695 12/93 Operation 2-5

Remote Panels (Optional)

Remote Start Panel

Remote start panel allows starting-stopping from a locationremoteofthegeneratorset.Generator sets are equippedwitha6-pinconnectoroncontrollerbottomfor connection of the kit. See Figure 2-5.

KOHLER

GENERATOR

START

STOP

1. “ON” Light 2. Start/Stop Switch

Figure 2-5. Remote Panel Features

1-656

Remote Start and

Two-Meter Panel Kit

Allows starting-stopping from a location remote of the generator set. The illuminated gauges include an engine oil pressure gauge and a water temperature gauge. Generator sets come equipped with a 6-pin connector on controller bottom for connection of the kit. See Figure 2-6 for remote start and meter panel kit.

4 3

1-762

1. Engine Oil Pressure

2. Water Temperature

Figure 2-6. Remote Start and Two-Meter

Panel Features

Start/Stop Switch is a rocker-type switch with “ON”

light used to start and stop generator set. Engine Oil Pressure Gauge measures engine oil

pressure. Normal engine operating range is 30--50 psi (207--345 kPa).

NOTE

During the engine break-in period, it is normal for the engine to produce higher oil pressure readings.

Water Temperature Gauge measures engine coolant temperature. Normal engine operating range is 170--195_ F (77--91_ C).

3. Start/Stop Switch

4. “On” Light

TP-5695 12/932-6 Operation

Remote Start and Four-Meter

Panel Kit

Allows starting-stopping from a location remote of the generator set. The illuminated gauges include a DC voltmeter, engine oil pressure gauge, water temperature gauge, and generator running time hourmeter.Generator sets come equipped with a 6-pin connector on controller bottom for connection of the kit. See Figure 2-7 for remote start and four-meter panel features.

DC Voltmeter measuresvoltage of starting battery(ies). Normalbattery operating range is 12--14 volts.

Engine Oil Pressure Gauge measures engine oil pressure. Normal engine operating range is 30--50 psi (207--345 kPa).

NOTE

During the engine break-in period, it is normal for the engine to produce higher oil pressure readings.

Water Temperature Gauge measures engine coolant temperature. Normal engine operating range is 170--195_ F (77--91_ C).

Start/Stop Switch is a rocker-type switch with “ON” light used to start and stop the generator set.

Hourmeter records total generator set operating hours for reference in maintenance scheduling.

1-830

1. Engine Oil Pressure

2. Hourmeter

3. Voltmeter

4. Water Temperature

5. Start/Stop Switch

6. “ON” Light

Figure 2-7. Remote Start and Four-Meter Features

TP-5695 12/93 Operation 2-7

Section 3. Scheduled Maintenance

Use the following service schedule and the hourmeter on the controller to schedule routine maintenance. In addition to the routine services listed in this manual, there are other important steps that should be taken to keep a generator set in top condition. Usually tools and instruments required for these additional steps are not availableto thegeneratorset owner.Forthis reason,the set should be returned periodically to an authorized service dealer/distributor for complete servicing and tune-up. The benefits of such service will be improved performance and continuous satisfactory operation duringa long trouble-free servicelife.Use the Operating HourService Loginthe backofthis manualto document services performed.

Service intervals are located on the top rows of the Service Schedule chart. It indicates how often maintenance tasks need to be done. Each service item is to be repeated at the specified interval. For example, an item required at 50 hours will again need to be performed at 100 hours, 150 hours, etc.

Forcontinued satisfactoryoperation andlongevity ofthe engine and generator set, proper maintenance and eventual overhaul by a competent mechanic/technician are essential. While it is not possible to anticipate component failure, rough operation, metallic noises, and excessive oil loss are among the indicators of potential problems. Do not ignore these conditions!

NOTE

Operate the generator set with load applied at least oncea month. Allow generator settorun about onehour to reach operating temperature. This prevents the formation of corrosion on internal engine components when exposed to the breakdown of exhaust gases and seawaterfor long periods ofgenerator inactivity.If unitis to be out of service for several months, see Storage Procedure.

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

NOTE

HARDWARE DAMAGE! Engine and generator make

useof bothAmerican Standardandmetric hardware.Be sure to use the correct size tools to prevent rounding of bolt heads and nuts.

NOTE

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

TP-5695 12/93 Scheduled Maintenance 3-1

Service Schedule

After 20

Hrs. or

Before

Starting

LUBRICATION SYSTEM

Check oil level X Change oil Change oil filter X

FUEL SYSTEM

Check the fuel level X Fill fuel tank X Lubricate carburetor and choke

linkage Clean fuel screen X Service fuel lines X

IGNITION SYSTEM

Replace spark plugs X

COOLING SYSTEM

Check coolant level X Check seawater outlet Inspect exhaust system

components for cracks and corrosion (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and outlet flapper)

Check function of siphon break (if equipped)

Check condition of heat exchanger anticorrosion zinc

Replace heat exchanger anticorrosion zinc

Replace the impeller of seawater pump

Check thermostat function X

INTAKE/EXHAUST SYSTEM

Check exhaust gas condition Clean the exhaust/water mixing

elbow Clean air filter element X

X (During

Operation)

X X

X (During

Operation)

One

Month

X (Break-in

Period)

X (Break-in

Period)

Every 50 Hrs. or 3

Months

Every

100 Hrs.

or 6

Months

X (100 Hrs.

or 3

Months)

Every

200 Hrs.

or Yearly

Every

300 Hrs.

or 2 Years

TP-5695 12/933-2 Scheduled Maintenance

Service Schedule (Continued)

After 20

Hrs. or

Before

Starting

ELECTRICAL SYSTEM

Check electrolyte level (Batteries with filler caps only)

Check and tighten electrical connections

Check specific gravity (Batteries with filler caps only)

Clean battery cables X

ENGINE AND MOUNTING

Check for leakage of water, fuel, or oil

Lubricate governor linkage Retighten all major nuts and

bolts Check and tighten mounting

bolts and vibromounts Check intake/exhaust

valve clearance

REMOTE CONTROL SYSTEM, ETC.

Check compartment condition (fuel, oil, or water leaks)

Check the remote control operation

Test run generator set

GENERATOR

Blow dust out of generator X

X X

One

Month

X (Break-in

Period)

X (Break-in

Period)

X (Break-in

Period)

(Monthly)

Every 50 Hrs. or 3

Months

Every

100 Hrs.

or 6

Months

Every

200 Hrs.

or Yearly

Every

300 Hrs.

or 2 Years

TP-5695 12/93 Scheduled Maintenance 3-3

Lubrication System

Specifications

Use high quality detergent oil of API (American PetroleumInstitute) service class SF,SF/CC, or SF/CD. This information can be found on most oil containers, see Figure 3-1. The symbol illustratedidentifies theAPI service class in the upper portion. The center indicates the SAE (Society of Automotive Engineers) viscosity grade. The bottom portion (when used) signifies the oil is intended to improve fuel economy and displays the phrase “Energy Conserving.” Select viscosity based on the air temperature at the time of operation. (See Figure 3-2.)

SAE 10W40 is the preferred oil for general use where temperatures permit.

Oil Check

Checkoillevelincrankcasedaily or before each startup to insure that the level is in the safe range.

NOTE

Do not check oil level when unit is running. Generator set must be stopped and level to get an accurate reading.

If generator set has just been run, allow a few minutes for the oil to return to the oil pan before checking level.

To check oil level, remove dipstick and wipe the end clean, place bottom thread of dipstickagainst oil fill hole and remove. Do not screw in dipstickwhen checking oil level. Level should bebetween MIN and MAX marks on dipstick. See Figure 3-3.

NOTE

Do not operate the set if thelevel isbelow the MIN mark or above the MAX mark. Oil above the MAX mark is wasted due to increased oil consumption.

1--792

Figure 3-1. Oil Service Class and

SAE Viscosity Grade Symbol

When Outside Temperature is Consistently:

Below 5_ F (--15_ C)

--5_ F (--21_ C) to 90_ F (32_ C)

Above 15_ F (--10_ C) Above --5_ F (--21_ C)

Figure 3-2. Recommended SAE

Viscosity Grades

Using other than the appropriate service class oil or extended oil change intervals could cause engine damage which is not covered by the engine warranty.

Do not mix oils of different viscosities. It is also best not to mix different brands of oils. Possible incompatibility could cause a breakdown of lubricating ingredients and reduce engine protection.

Use SAE

Viscosity Grade:

5W30

10W30

20W40 or 20W50

10W40 (Preferred)

1. MAX Limit

2. MIN Limit

Figure 3-3. Checking Oil Level

3. Safe Range

1-826

TP-5695 12/933-4 Scheduled Maintenance

Adding Oil

It is normal to add some oil between oil changes. The amountwill vary with the usage.Openfill cap and pour a small amount of oil using a funnel or other suitable pouring device. See Figure 3-4. Wait a few minutesand check level. If necessary, add more oil and then check again. Each time be sure to add small quantities and check to prevent overfilling.

1. Place oil drain hose in a proper container. Remove oil drain cap. If a drain pump is used, remove oil draincap and connect oil drainhoseto drain pump.

2. Allow ample time for all oil to drain into container. If drain pump is used, activate pump until oil is removed.

3. Loosen oil filter by turning in a counterclockwise direction. Oil filter is 2 1/2 in. (64 mm) dia. with 14 flutes. Use oil filter wrench, if necessary. See Figure 3-6. Use rags to handle hot oil filter and clean up spilled oil. Remove filter from oil filter adapter on engine and discard oil filter in a proper container.

4. Clean contact surface of oil filter adapter.

5. Lightly lubricate the gasket surface of new oil filter with fresh engine oil. Thread oil filter onto oil filter adapter until gasket makes contact; then hand-tighten oil filter an additional 3/4 turn.

1-826

Figure 3-4. Adding Oil

Oil Change/Oil Filter Change

Change oil and oil filter every 200 hours or yearly. Change oil more frequently under dirty, dusty conditions.Changeoilwhile theengine isstill warm.See Figure 3-5 and use the following procedure.

STARTSTOP

INPUT

10A FUSE

1/10

00 000

TOTALHOURS

BATT.

CHRG.

258000-D

1. Oil Drain Cap

Figure 3-5. Oil Drain Cap

NOTE

If an automatic oil drain/oil fill pump is used, omit Step 6. Fill with proper amount and type of oil, see Step 6. When complete, replace cap and disconnect pump.

6. Replace oil drain cap. Remove oil fill cap. Add oil usinga funnelorother suitablepouring device.See Specifications—Engine for oil capacity and Lubrication System—Specifications for proper service class and SAE viscosity of oil. Replace oil fill cap.

7. Start generator set and check for leaks at oil drain cap and oil filter.

8. Stop generator set. Wait a few minutes for oil to return to oil pan. Remove dipstick and wipe clean, reinsert as far as possible and remove to check oil level. Add oil, as necessary, to bring level up to MAX mark.

TP-5695 12/93 Scheduled Maintenance 3-5

1. Oil Filter Wrench 2 1/2 in. (64 mm) Dia.

Figure 3-6. Removing Oil Filter

1-826

Fuel System

Specifications

For best results, use only clean fresh, regular grade unleaded gasoline. Use fuel with a minimum octane rating as designated by the following:

Antiknock Index (Average of Research 86 Octane Number and Motor Octane Number)

Unleaded fuel is recommended since it leaves less combustion chamber deposits. Oil must not be mixed with fuel.

If using a gasoline containing alcohol (gasohol), be sure the octane rating is at least 86(Antiknock Index). There are two types of gasohol: one containing ethanol, and another containing methanol.

Do not use gasohol that contains more than 10% ethanol. Do not use gasohol containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitorsfor methanol. Never usegasoline containing more than 5%methanol,even if it has cosolvents and corrosion inhibitors.

NOTE

Fuel system damage and engine performance problems resulting from the use of such fuels are not coveredunderWarranty.Hondacannot endorsethe use offuels containingmethanolsince evidenceofsuitability is as yet incomplete. Before purchasing fuel from an unfamiliar station, try to confirm whether the fuel contains alcohol, and to what percentage. If any undesirableoperating symptoms are noticed after using a gasoline that contains alcohol, or one that contains alcohol, switch to a gasoline that does not contain alcohol.

NOTE

Discontinue use of any gasohol or alcohol/gasoline blend if engine performance or fuel system problems occur. Do not use such fuel unless it is UNLEADED.

Usefresh gasoline to ensure itisblended for the season and to prevent the formation of gum deposits which could clog the fuel system. Do notuse gasolineleft over from the previous season.

TP-5695 12/933-6 Scheduled Maintenance

Fuel Pump Screen

3. Remove the three nuts that secure the electric fuel pump to the mounting bracket.

4. Remove the three mountingstuds from theelectric fuel pump.

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Useextreme care when handling, storing, and using fuels.

Explosive fuel vapors can cause severe injury or death.Allfuelsarehighlyexplosiveinavapor state.Use

5. Remove the cover plate and inspect the screen. Remove any debris orresidue. Be sure the screen is intact. If the screen is damaged, replace the fuel pump.

6. Check the O-ring seal. Replace the O-ring if it is nicked or eroded.

7. Reinstall the cover plate and secure it to the fuel pump by reinstalling the three mounting studs.

8. Insert the three mounting studs on the fuel pump through the mating holes in the mounting bracket. Reinstall the three nuts to secure the fuel pump in place.

9. Reconnect the fuel lines to the fuel pump.

10. Open fuel line at tank or in-line shutoff valve and check for leaks from the fuel pump at fuel line connections and cover plate.

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

The electric fuel pump includes a screen. (See Figure 3-7.) At the recommended interval or when clogging is suspected, inspect and clean the screen as follows:

1. Shut off fuel flow to electric fuel pump at tank or at in-line shutoff valve. Disconnect harness plug(see Figure 3-7 for location).

2. Disconnect fuel lines from electric fuel pump, drainingfuel fromthelines andpumpinto asuitable container to prevent spillage into the bilge.

2 (enclosed)

258000-D

1. Harness Plug 2. Fuel Pump Screen

Figure 3-7. Fuel Pump Screen

TP-5695 12/93 Scheduled Maintenance 3-7

Carburetor/Choke Lubrication

Theonly maintenancerequiredis to lubricatecarburetor and choke linkage at the specified interval using white lithium grease or lubriplate.

WARNING

Carburetor Adjustments

The carburetor is a single-barrel, horizontal design and uses an electric choke.

Lack of power usually indicates that the fuel mixture is too rich. An overrich mixture may also be caused by a clogged air intake (backfire flame arrestor)—check this before readjusting carburetor. Fuel mixture may be too lean if engine skips or backfires. Minor carburetor adjustment may be necessary to compensate for differences in altitude, fuel, and temperature.

1. With ENGINE STOPPED, turn fuel mixture screw in (clockwise) until it seats lightly. DO NOT FORCE! Turn fuel mixture screw out 2 to 2 1/2 turns. See Figure 3-8.

2. Start engine and let it run at no load for about 5 minutes. Before making adjustments engine should be thoroughly warmed up running at governed speed, and connected to full load.

Fire. Can cause severe injury or death.

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

Asudden flashfire cancause severeinjury ordeath.

Donot smokeorpermit flameorspark tooccur nearfuel system.Keepthecompartmentandgeneratorsetclean and free of debris to minimize chances of fire. Wipe up all spilled fuel and engine oil.

3. Turn low speed mixture screw in until engine instability (hunting) develops and then screw out until engine instability is again apparent. Turn screwbackin until it is positioned halfway between the points of increasing stability. When properly adjusted, engine will operate with steady governor action.

4. Toadjustthe idle speed, runthegenerator set atno load. Push the throttle lever counterclockwise until it hits the idle speed screw. Holding the throttle leveragainstthescrew,adjustthe idlespeedscrew untilunit runs at55Hz (3300 rpm)for60 Hz models or 45 Hz (2700 rpm) for 50 Hz models.

NOTE

If engine runs poorly after adjusting carburetor and doing scheduled maintenance, return generator set to an authorized service dealer/distributor to have problem corrected.

1. Governor Arm

2. Low Speed Mixture Screw

Figure 3-8. Fuel Mixture Adjustment

3. Idle Speed Screw

1-829

TP-5695 12/933-8 Scheduled Maintenance

Ignition System

Ignition System Service

The ignition system is transistorized and breakerless. Under normal conditions, only the spark plugs need service on a regular basis. The electronic ignition module requires no maintenance and should giveyears of trouble-free service. If a module problem is suspected, have service performed by an authorized service dealer/distributor.

Spark Plugs

At the recommended interval (shown in the service schedule) service spark plugs.

1. Remove spark plug wires by grasping boot and turning slightly while pulling. Do not pull wire. See Figure 3-9.

NOTE

Pullingwireratherthanbootmaycausedamageto wire or terminal.

NOTE

Do not sandblast, wire brush, scrape, or otherwise service spark plug in poor condition. Best results are obtained with a new plug.

1-827

Figure 3-9. Removing Spark Plug Wires

2. Where possible, usecompressed air to removedirt from around each spark plug before removal. This procedurewillpreventdirtparticlesfrom falling into combustion chamber. Loosen spark plug with a ratchetandsparkplugsocket witharubberinsertto prevent damage to spark plug. See Figure 3-10. Remove spark plugs one at a time and examine. See Figure 3-11 to evaluate engine conditions by color/condition of spark plugs.

3. Clean spark plugsbywiping with a rag and then file the center electrode so that it is parallel to the side electrode. Should replacement be necessary, see “Specifications” for spark plug type.

1-827

1. 13/16 in. Spark Plug Socket

Figure 3-10. Removing Spark Plug

TP-5695 12/93 Scheduled Maintenance 3-9

Problem Means of Identification Possible Cause

Normal Light tan or gray deposit on the

firing tip.

Gap bridged Deposits built-up and closing gap

between electrodes.

Oil fouled Wet black deposits on the insulator

shell bore electrode.

Carbon fouled Black, dry fluffy carbon deposits

on insulator tips, exposed shell surfaces, and electrodes.

Lead fouled Dark gray, black, yellow, or tan

deposits; or a glazed coating on the insulator tip.

Pre-ignition Melted electrodes and possibly

blistered insulator. Metallic deposits on insulator suggests internal engine damage.

Overheating White or light gray insulator with

small black or gray/brown spots with bluish (burnt) appearance on electrodes.

Worn Severely eroded or worn

electrodes.

Good operating conditions and maintenance.

Oil or carbon fouling. Clean and regap.

Excessive oil entering combustion chamber through worn rings and pistons, excessive clearance between valve guides and stems, or worn or loose bearings. Replace plug.

Using too cold range plug, weak ignition, clogged air intake or improper carburetor adjustments, defective fuel pump, overrich fuel mixture, or excessive no load operation. Clean and regap.

Caused by highly leaded fuel. Replace plug.

Wrong type of fuel, incorrect timing or advance, too hot of a plug, burnt valves, or engine overheating. Replace and plug.

Engine overheating, wrong type of fuel, loose spark plugs, too hot a plug, low fuel pump pressure or incorrect ignition timing. Replace plug.

Caused by normal wear and failure to replace at proper interval. Replace plug.

Figure 3-11. Spark Plug Condition

4. Before installing any spark plug, check the gap. See Figure 3-12. The proper gap is attained when the feeler (or wire) gauge just passes between the spark plug electrodes. It should pass easily, but with some resistance or drag. The correct gap is

0.028--0.031 in. (0.7--0.8 mm).

5. To readjust the spark plug gap, use gapping tool to gently bend the side electrode closer to or further from the center electrode. See Figure 3-13. The side electrode must be centered over the center electrode.

6. Being careful not to bump the electrode, hand threadspark plug clockwise into cylinder head until resistance is felt.

7. Using atorque wrench, tighteneach sparkplugto a torque of 18--22 ft. lbs. (20--30 Nm). If a torque wrench is not available, hand-tighten spark plug until resistance is felt and then use a ratchet wrench to tighten the plug an additional 1/2 turn (if installing a new plug) or 1/8--1/4 turn (if reinstalling a used plug). Do NOT overtighten asthis may strip threads or alter electrode gap setting.

8. Check spark plug wire connector in boot for accumulated dirt, grease, etc., and clean as necessary. Firmly push spark plug connector and boot onto spark plug.

TP-5695 12/933-10 Scheduled Maintenance

1. 0.028--0.031 in. (0.7--0.8 mm) Gap

2. Spark Plug Electrodes

Figure 3-12. Checking Spark Plug Gap

1-514

1-511

Figure 3-13. Adjusting Spark Plug Gap

TP-5695 12/93 Scheduled Maintenance 3-11

Cooling Systems—

Closed/Heat Exchanger

In a closed cooling system, the seawater does not circulate through the engine but circulates through separate chambers within the heat exchanger to cool the engine coolant. The seawater is then mixed with engine exhaust and ejected out the exhaust outlet. The coolant is circulated through cooling passages to cool theengine. All models make useofa coolant thermostat andacoolantrecoverytank.The coolant capacity of the engine with heat exchanger is 0.72 U.S.qts. (0.68L) for all models. A solution of 50% ethylene glycol and 50% clean, softened water is recommended to inhibit rust/corrosion.A coolantsolutionof 50% ethyleneglycol will provide freezing protection to --34°F (--37°C) and overheating protection to 265°F (129°C). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can cause damage to engine and components. Do not use alcohol or methanol antifreeze or mix them withthe coolant.

Filling and Checking

WARNING

Hot coolant and steam. Can cause severe injury or death.

NOTE

ENGINE DAMAGE! Failure to bleed air from cooling

system may cause overheating and subsequent damage to engine.

NOTE

Before filling the cooling system, verify that all hose clamps are tight. Loosenair-bleed screw located ontop of the engine to allow trapped air to escape. See Figure 3-14. Place a rag around the screw to prevent coolant spillage onto the block. Remove pressure cap locatedon thetopof theengine(see Figure 3-15)and fill with the recommended coolant until level is just below overflow tube opening. Tighten air-bleed screw when coolant, free of air bubbles, starts to flow. Replace pressure cap. Start generator set and allow to run for about20--30seconds.STOP generatorsetand recheck coolant level by removing pressure cap. Repeat procedure, as necessary,until coolant can nolonger be added.

A coolant overflow bottle is provided. Fill bottle to just below the MAX mark. See Figure 3-16. Maintain proper coolant level in coolant overflow bottle. The MIN mark indicates full when coldand the MAX mark indicatesfull when hot. Coolant level should always be between these marks. The coolant level can be checked using the overflow bottle markings, but it is recommended to periodicallyremove the coolant pressure cap andcheck coolant level.

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

TP-5695 12/933-12 Scheduled Maintenance

STARTSTOP

INPUT

10A FUSE

1/10

00 000

TOTALHOURS

BATT. CHRG.

1. Air-Bleed Screw; Use 12 mm Wrench

Figure 3-14. Air-Bleed Screw

STARTSTOP

INPUT

10A

FUSE

1/10

00 000

TOTALHOURS

BATT. CHRG.

1. Coolant Recovery Tank

2. Overflow Hose

3. Coolant Pressure Cap

Figure 3-15. Coolant Pressure Cap

1-828

258000-D

1. MAX. Mark 2. MIN. Mark

Figure 3-16. Checking Coolant Level

TP-5695 12/93 ScheduledMaintenance 3-13

Flushing and Cleaning

If required, flush coolant from generator set. To properly flush coolant, obtain Kit #267999 and use the following procedure:

WARNING

Accidental starting. Can cause severe injury or death.

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

4. Connect a garden hose to the female connector of large kit hose. Place the free end of the small kit hose in a 1--2 gal. (min.) bucket.

NOTE

Heat exchanger pressure cap MUST be installed.

5. Turn on water supply to flush coolant from engine block. Turn off water supply when clean water is observed coming from hose in bucket.

6. Disconnect gardenhose.Place free endoflarge kit hoseintobucketandconnectanairhose tothe free end of the smaller kit hose. Apply air pressure (40 psi[276 kPa] min.) until waterstopsflowing from kit hose in bucket. This will remove about 16 fl. oz. (0.47 L) of water from engine block.

Accidental starting can cause severe injury or death. Disconnect battery cables (remove negative

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.

NOTE

Engine coolant capacity is 23 fl. oz. (0.68 L).

NOTE

Some small air compressors may not maintain pressure under the required flow conditions. In these cases, it isrecommended that the endof the kit hose in the bucket be closed off momentarily until pressure is allowed tobuild up. After pressure has accumulated, open end to allow water to flow into bucket. Repeat closing and opening end of kit hose, as required.

7. Remove kit hoses with hose fittings from engine.

8. Apply pipe sealant to threads of high water temperature safety shutdown switch and install switch in thermostat housing. Reconnect wiring harness lead to switch.

9. Apply pipesealant totheair-bleed screwand install screw into engine. Do not final tighten!

10. Remove cap of coolant overflow bottle and pour contents into a suitable container. Reinstall bottle on unit.

11. Add fresh coolant to coolant overflow bottle. A solution of 50% ethylene glycol and 50% clean, softened water is recommended to inhibit rust/ corrosion and provide freezing protection. Fill to MIN mark. Install coolant overflow bottle cap.

1. Disconnect the battery, negative lead first.

2. With engine cooled, remove the air-bleed screw and the high water temperature safety shutdown switch from the thermostat housing.

3. Connect kit hose fittings to the engine. Install kit hoses to fittings (if not already done).

12. Remove heat exchanger pressure cap and add about 5 fl. oz. (0.15 L) of clean, softened water. Then fill remainder of engine with straight coolant (100%) until level is just below the overflow tube opening. Final tighten the air-bleed screw when coolant,free of air bubbles, startstoflow.Install the heat exchanger pressure cap.

TP-5695 12/933-14 Scheduled Maintenance

13. Reconnect battery, negative lead last.

14. Start generator set and allow the set to run for about 20--30 seconds. Stop generator set and recheck coolant level byremoving heat exchanger pressure cap. Add straight coolant, if necessary, until level is just below the overflow tube opening, then reinstall pressure cap. Repeat this step until coolant can no longer be added. This procedure should give an approximate mixture of 50% ethylene glycol and 50% water.

15. Wipe up spilled coolant and water with rags. Dispose of rags in a proper container.

16. Test run generator set for about five minutes and check for coolant leaks. This will allow the coolant mixture to mix completely. Stop generator set.

17. Rinse coolant flush kit hoses and fittings withclean water. Store kit for future use.

18. Dispose of used coolant in a proper manner. Do NOT pollute waterways!

TP-5695 12/93 ScheduledMaintenance 3-15

Anticorrosion Zinc

An anticorrosion zinc anode is installed in the heat exchangerto preventelectrolyticcorrosion byseawater. When different metals, such as iron and copper, are placed in a highly conductive liquid (seawater), the iron gradually rusts. The zinc has chemical propertieswhich cause the seawater to react to it rather than the engine components.

The anticorrosion zinc anode should be checked every 100 hours or three months and replaced every 200 hours or yearly. Depending upon operating conditions and seawater properties, the anticorrosion zinc anode may have to be replaced more frequently. See Figure 3-17 and use the following procedure.

STARTSTOP

INPUT

10A

FUSE

1/10

00 000

TOTALHOURS

BATT. CHRG.

1. With generator set cooled, drain the cooling seawater system. Close seacock, remove anticorrosion zinc anode from heat exchanger.

2. Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode. Replace the anode when less than 50% of the 11/32 in. (9 mm) dia. by 9/16 in. (14 mm) long portion of zinc remains.

3. Clean threaded hole of heat exchanger and coat threads of anticorrosion zinc anode with pipe sealant (suitable for marine applications). Install anticorrosion zinc anode into heat exchanger.

4. Open seacock. Start generator set and check for leaks at the anticorrosion zinc anode location. Check for seawater flow by observing water discharge from exhaust outlet.

258000-D

1. Heat Exchanger 2. Anticorrosion Zinc

Figure 3-17. Removing Anticorrosion Zinc

TP-5695 12/933-16 Scheduled Maintenance

Pressure Cap

Closed-loop cooling systems incorporate a pressurized capto raisethe boilingpoint ofthecoolant andmake use of higher operating temperatures. If leakage or malfunction occurs, replace the pressurized cap with one supplied by Kohler Co. part number 229958.

valvedownward intothemounting base.Installretaining cap and tighten finger-tight only. Do NOT overtighten.

Air Cleaner and

Mixing Elbow

Servicing Air Cleaner

The engine is equipped with a dry-type air cleaner. Every 50 hours (more often if operating under dusty or dirtyconditions) remove element andserviceby tapping element lightly against flat surface to dislodge loose surface dirt. Do not clean in any liquid or blow out with compressedairasthiswillruin filter material in element. Service air cleaner after each 50 hours of operation. If dirty, bent, or damaged replace element with genuine Kohler replacement. See Figure 3-19.

1-779

1. Mounting Base

2. Retaining Cap

Figure 3-18. Siphon Break

3. Reed Valve Assembly

Siphon Break

An optional siphon break is used to prevent seawater entry into the engine when the generator set is shut down.Corrosion buildup may not allowthe siphon break tofunction properly.Therefore, if used, the siphonbreak must be inspected and cleaned periodically.

NOTE

To prevent siphoning of seawater, run the generator while performing this inspection.

Removethe retaining cap to inspect the reed valve. See Figure 3-18. Clean the reed valve to remove residue and oxidation. Check that the reed valve (opening) is clear. Replace the siphon break if the material has hardened or deteriorated. Install the reed valve with the

1-905

Figure 3-19. Air Cleaner Service

Servicing Mixing Elbow

The mixing elbow combines high temperature exhaust and cooling seawater. These conditions are conducive to rapid deterioration and, combined with engine vibrations,premature failures if notproperlymaintained. Check the mixing elbow for carbon buildup and corrosion inside the pipe. Clean or replace the mixing elbow as necessary. Inspect the exhaust manifold mounting threads for cracking and corrosion.

TP-5695 12/93 ScheduledMaintenance 3-17

Battery

The starting battery should be a 12-volt unit with a minimum 250 CCA (cold cranking Amps) at 0_ F (--18_ C). When using a maintenance-free battery it is not necessary to check the specific gravity or electrolyte level. Otherwise, these procedures should be done at the intervals specified in the Service Schedule.

Cleaning

Keep battery clean by wiping it with a damp cloth. Keep all electrical connections dry and tight. If corrosion is present, disconnect cables from battery and remove corrosion with a wire brush. Clean battery and cables with a solution of baking soda andwater.Be careful that cleaning solution does not enter battery cells. When cleaningis complete,flushbattery andcableswith clean water and wipe with a dry cloth. After the battery cables are reconnected, coat terminals with petroleum jelly, silicon grease, or other nonconductive grease.

Checking Electrolyte Level

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

Check the level of electrolyte before each startup. Remove filler caps and check to see that electrolyte level is up to bottoms of filler holes, see Figure 3-20. Refill as necessary with distilled water or clean tap water.DO NOT add fresh electrolyte!Then reinstall and tighten filler caps. If water is added during freezing temperatures, run generator set 20--30 minutes to allow mixing of added water and electrolyte. This will prevent damage to battery due to freezing.

1-046

1. Filter Caps 2. Electrolyte Level

Figure 3-20. Checking Electrolyte Level

Checking Specific Gravity

Usea battery hydrometertocheck the specificgravityof the electrolyte in each battery cell. Correct actual hydrometer readings for temperature.If the hydrometer used does not have a correction table, use the one in Figure 3-21. The battery is fully charged if the specific gravity is 1.260 at an electrolyte temperature of 80_ F (26.7_ C). The difference between specific gravities of

TP-5695 12/933-18 Scheduled Maintenance

each cell should not exceed ±0.01. The battery should be charged if the specific gravity is below 1.215 at an electrolyte temperature of 80_ F (26.7_ C).

°C °F

71.1

65.6

60.0

54.4

48.9

43.3

37.8

32.2

26.7

21.1

15.6

4.4

-- 1.1

-- 6.7

-- 12.2

160

150

140

130

120

110

100

Correction + .032 + .030 + .028

EXAMPLE NO. 1—

+ .026

Temperature below 80°F (26.7°C)

+ .024 + .022

Hydrometer Reading 1.250

+ .020

Acid Temperature 20°F (--6.7°C)

+ .018 + .016

Subtract .024 Specific Gravity Corrected SpecificGravity is 1.226

+ .014 + .012 + .010 + .008 + .006

EXAMPLE NO. 2—

+ .004

Temperature above 80°F (26.7°C)

+ .002

Hydrometer Reading 1.235

-- .002

Acid Temperature 100°F (37.8°C)

-- .004

Add .008 Specific Gravity

--. 006

Corrected Specific Gravity is

-- .008

1.243

-- .010

-- .012

-- .014

-- .016

-- .018

-- .020

-- .022

-- .024

-- .026

-- .028

NOTE

Some battery testers simply have fouror fivebeads in a tube. Draw electrolyte into the tube. Use instructions with tester; otherwise see the following chart.

Five Beads Floating—Overcharged

Four Beads Floating—Fully Charged

Three Beads Floating—A Good Charge

One or Two Beads Floating—A Low Charge

No Beads Floating—A Dead Battery

Charging

Theenginebatterychargingcircuitwillprovide a charge of 12 volts at up to 10 amps.

NOTE

If the battery is used while the craft is docked and the generatorset is not runningi.e.,auxiliary lights, two-way radio, etc., the battery will be drained and may not have enoughpower to startthegenerator set later.Therefore, it may be necessary to connect a battery charger while the craft is docked and running on shore power.

1-787

The temperature correction amountsto about .004 (4 “points”) ofspecificgravityforeach10°F(5.5°C)changeintemperature.

Figure 3-21. Specific Gravity

Temperature Correction

TP-5695 12/93 ScheduledMaintenance 3-19

Valve Adjustment

b. Remove two screws to release seawater pump

bracket.

With overhead cam engines, each valve is spring-held in the closed position until forced open by the action of the rocker arm in contact with the camshaft. Rocker arms have adjusting screws and locknuts for adjusting valve stem-to-rocker arm clearance. Check clearance with the engine cold. See Specifications—Engine for intake and exhaust valve clearances.

WARNING

Rotating parts. Can cause severe injury or death.

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

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.

Flying projectiles can cause severe injury or death.

c. Remove housing enclosing ignition coil. d. Remove seawater pump from camshaft pulley. e. Remove timing belt cover (belt guard).

NOTE

To reduce force needed to rotate crankshaft, remove the spark plugs.

3. Using a ratchet wrench on the crankshaft nut, rotate the crankshaft clockwise (as viewed from engine end) until No. 1 cylinder is at the top of its compression stroke and the ‘T’ markon flywheelis aligned with the triangle symbol on the engine block. See Figure 3-22. The compression stroke is the period between the closing of the intake valve and the opening of the exhaust valve. The marks define the TDC (top dead center)point where both intake and exhaust valves will be closed.

4. Insert feeler gauge between rocker arm and exhaust valve for No. 1 cylinder. If necessary, adjust screw so that very slight drag is felt on the feeler gauge as it is withdrawn. Loosen the adjusting screw locknut and turn the adjusting screw to obtain the specified clearance. Retighten the locknut while holding the adjusting screw. See Figure 3-23. Recheck the valve clearance after tightening the locknut. Repeat step for intakevalve of No. 1 cylinder.

5. Rotate crankshaft 360 degrees clockwise and set valve clearances on No. 2 cylinder.

6. Reassembly of timing belt components:

a. Install timing belt cover (belt guard). b. Install seawater pump to camshaft pulley.

1. Remove rocker arm cover screws using a 10 mm wrench. Carefully pry rocker armcover off cylinder cover. Wipe excess oil from components using a clean rag.

2. Expose timing belt:

a. Close seacock and drain seawater from hoses.

Remove seawater pump hoses at seawater pump.

c. Install housing for ignition coil. d. Mount seawater pump bracket using two

screws.

e. Install seawaterpump hosestoseawater pump.

Open seacock.

7. With mating surfaces clean and gasket properly aligned, install rocker arm cover and screws. Remove ratchet wrench from crankshaft nut.

TP-5695 12/933-20 Scheduled Maintenance

1-831

1. “Y” Mark

2. “T” Mark

Figure 3-22. Determining Top Dead Center

1-827

1. Feeler Gauge

2. Adjusting Screw 3 mm Square Head

Figure 3-23. Valve Adjustment

3. Locknut; Use 9 mm Wrench

TP-5695 12/93 ScheduledMaintenance 3-21

Governor

The gear-driven centrifugal type governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in load.

Lubrication

2. Move the governor arm end fully in the direction shown (toward the electric choke solenoid) and readjust governor screw. Tighten locking nut.

3. Start engine and run to reach operating temperature.

4. Apply full load and turn engine speed adjustment screw to 3600 rpm for 60 Hz generator set, 3000 rpm for 50 Hz set.

Lubricate governor linkage at the specified interval using white lithium grease or lubriplate.

Governor Adjustment

The gear-driven centrifugal type governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in load. No regular service is required on the unit. The governor is adjusted during run-in at the factory and further adjustment should not be needed unless greatly varying load conditions are encountered or if poor governor control develops after extended usage. See Figure 3-25 for correct placement of governor linkage (models may vary).

60 Hz generator sets are designed to operate at 60-63 Hz, 3600 rpm under full load and 3780 rpm under no load. 50 Hz generator sets are designed to operate at 50--52.5 Hz, 3000 rpm under full load and 3150 rpm underno load. Tocheck speed,usehand tachometer or frequency meter. Use the following procedure toadjust governor.

1. Loosen governor arm locking nut. See Figure 3-24.

5. Check regulation by applying and removing full load.

6. STOP generator set.

1-829

1. Mixture Screw

2. Idle Speed Screw

Figure 3-24. Governor Adjustment

3. Governor Adjustment

Locknut

Governor Adjustment Screw

Pivot Point

Governor Rod

Carburetor

Hole Nearest to Pivot Point

Figure 3-25. Governor Linkage

Throttle Rod/Spring

Governor Cross Shaft

Governor Spring

Outer Hole

TP-5695 12/933-22 Scheduled Maintenance

Wattage Requirements

Generator Service

Iftheratedcapacityofthegenerator setis exceeded,the circuitbreaker locatedonthe controllerwilltrip toprotect the generator against damage. Tripping could be caused by a short in the AC circuit in the craft or simply by having too many appliances on at the same time resulting in an overload condition. If the circuit breaker trips, the set may continue running but there will be no AC output to the protected circuit. Before resetting the circuitbreaker,turn offsome oftheappliances andlights inside the craft to bring the load down within the rated limitsoftheset.Ifthisisdoneandthecircuit breakertrips again after being reset, see a qualified electrician.

For more information regarding generator set capacity, see Installation—Generator Selection and Wattage Requirements.

General

Under normal conditions generator service will not be requiredon a regular basis. Ifoperatingunder dusty and dirty conditions, use DRY compressed air to blow dust outofthegenerator atfrequent intervals.Dothis withthe generator set operating and direct the stream of air in through the cooling slots at the end of the generator.

The end bracket bearing should be replaced every 10,000 hours of operation. Have bearing replaced sooner if bearing inspection indicates excessive rotor end play or bearing damage from corrosion or heat buildup.Theend bracket bearing is sealed and requires no additional lubrication. All generator service must be performed by an authorized service dealer/distributor.

TP-5695 12/93 ScheduledMaintenance 3-23

Storage Procedure

4. Closeseacockand drainall seawaterout ofcooling system.

It is recommended that the craft be afloat when the generator set is prepared for storage since the engine must be started.

1. Add fuel stabilizer to fuel tank. Use recommendations of fuel stabilizer manufacturer.

2. Start generator set and run until operating temperature is reached or about 15 minutes. Stop generator set. Drain oil from crankcase while engine is still warm. Replace oil filter. Refill crankcase with specified weight oil.

NOTE

For storage, seawater must be replaced with antifreezeas described in steps 3a--cor drainedas described in steps 4a--c.

3. Close seacockand removehoseat seacock.Place hose in a container of coolant/antifreeze. Container should have approximately 1--2 U.S. gallons (3.7--7.5 L) of antifreeze. A mixture of 50% ethylene glycol and 50% clean, softened water is sufficient.

a. With a suitable container at exhaust outlet, run

generator set until coolant discharge is observed at exhaust outlet or until coolant mixtureis used up. Do not allow coolant mixture to flow into waterways. Stop generator set.

b. Connect hose to seacock. Leave seacock

closed.

c. Check coolant level of heat exchanger and add

if necessary.

NOTE

If steps 3a--c were performed to replace seawater with antifreeze, omit steps 4a--c.

a. Drain seawater from strainer and seawater

pump.

b. Remove zinc anode or end cap on heat

exchanger, whichever is more convenient, to drainonlyseawater.Useanair hose to blow out any remaining seawater, if necessary. Check coolant level of heat exchanger and add if necessary.

c. Drain seawater from exhaust waterline.

NOTE

Iffreezing temperatures willbeencountered during storage, be sure engine coolant is capable of withstanding the lowest possible temperatures. Generally, a mixture of 50% ethylene glycol and 50% clean, softened water is sufficient.

5. Remove spark plugs and pour one teaspoon of engine oil into each cylinder. Crank the engine several times to coat the cylinder walls with oil. Reinstall the spark plugs.

6. If fuel stabilizer was not added to fuel tank, drain fuel completely from fuel tank. Gum deposits will develop if gasoline is stored for the season.

7. Clean exterior of generator set and spread a light film of oil or silicon spray over any exposed surfaceswhichmaybesubjecttorust or corrosion.

8. Using tape, seal air inlet, exhaust pipe, and fuel tank cap.

9. Disconnect and remove battery. Battery should be placedin a warm, dry locationforperiod of storage. Recharge battery once a month to maintain full charge.

10. Cover entire unit with a dust cover.

TP-5695 12/933-24 Scheduled Maintenance

Section 4. Troubleshooting

Unitwillnotcran

Unitcranksbutwill

notstar

Enginestarts,bu

doesnotcontinueto

Hardstartin

When troubles occur,do not overlook simple causes. A starting problem, for example, could be caused by improperfuel or an empty fueltank.The following charts list some common problems. If procedures in this manual do not explain how to correct the problem, take

Engine

Problem Possible Cause Corrective Action

Unit will not crank

Unit cranks but will not start

Engine starts, but does not continue to run after start switch is released

Hard starting

Weak or dead battery Recharge or replace battery Reversed or poor battery connections.

Poor ground. Fuse blown in controller Replace fuse Defective start/stop switch Check function, replace as necessary. Defective starter solenoid Check starter solenoid and wiring. Replace

Defective starter Attempt starting by direct connection to

Out of fuel Replenish Clogged fuel screen Clean fuel screen Faulty antidieseling solenoid Replace solenoid Air intake clogged Clean or replace Faulty spark plug(s) Replace (and regap) spark plug(s) Loose spark plug connection Reconnect wires Faulty ground (--) connection Clean and retighten Carburetor adjustment wrong Adjust carburetor Defective electric fuel pump Check pressure. Replace as necessary. Shorted or open ignition coil Replace coil Weak or dead battery Recharge or replace Bad fuel mixture Replace fuel; clean carburetor Flooded carburetor Wait a few minutes and attempt restart Engine malfunction See authorized Kohler service

No generator output voltage Check AC voltage No/low oil pressure Check oil pressure and pump Defective low oil pressure (LOP) safety

shutdown switch High temperature shutdown Check cooling system Defective high exhaust temp. (HET) and/or high water temp. (HWT) safety shutdown switch(es) Stale or bad fuel Replace fuel Fuel vapor lock Check fuel line routing Faulty spark plug(s) Replace (and regap) plug(s) Weak ignition coil Replace Carburetor adjustment wrong Adjust carburetor Air intake clogged Clean

the generator set to an authorized service dealer/distributor.Tellthe dealerexactlywhat happened when the problem occurred and of any adjustments made to the set.

Check connections

as necessary.

battery. Replace/repair as necessary.

dealer/distributor

Check LOP shutdown switch

Check HET and/or HWT shutdown switch(es)

TP-5695 12/93 Troubleshooting 4-1

Engine (Continued)

Stopssuddenly

Lackspowe

Operateserratically

Problem Possible Cause Corrective Action

Stops suddenly

Lacks power

Operates erratically

Out of fuel Replenish Air intake clogged Clean Fuse blown in controller Replace fuse Defective seawater pump impeller Replace Clogged seawater strainer Clean strainer Ignition coil failure Check for spark Fuel line restriction Check fuel lines and tank Fuel vapor lock Check fuel line routing Defective electric fuel pump Check pump Dirty fuel screen Clean fuel screen Faulty spark plug(s) Replace spark plug(s) No/low oil pressure Check oil pressure and pump Defective low oil pressure (LOP) safety

shutdown switch High temperature shutdown Check engine coolant system Defective high exhaust temp. (HET) and/or high water temp. (HWT) safety shutdown switch(es) Loss of AC output See authorized Kohler service

Faulty antidieseling solenoid Replace solenoid Air intake clogged Clean Bad or stale fuel Replace fuel Faulty spark plug(s) Replace (and regap) plug(s) Improper timing Check timing Choke solenoid defective Check and/or change Engine not operating at rated RPM Check governor Governor adjustments incorrect Adjust governor Carbon build-up Clean carbon from cylinder heads Improper cooling Inspect cooling system Dirty fuel screen Clean screen Defective ignition coil Replace coil Fuel line restricted Check fuel lines Engine overloaded Reduce load Carburetor adjustment wrong Adjust carburetor Air intake clogged Clean Stale or bad fuel Replace fuel Fuel pump vapor lock Allow unit to cool and attempt restart Clogged fuel screen Clean screen Faulty spark plug(s) Replace spark plug(s) Carburetor adjustment incorrect Adjust carburetor

Check LOP shutdown switch

Check HET and HWT shutdown switch(es)

dealer/distributor

TP-5695 12/934-2 Troubleshooting

Engine (Continued)

Unitisnoisy

Batterywillno

Starterdoesno

slowl

Problem Possible Cause Corrective Action

Overheats

Unit is noisy

Improper cooling Check intake and outlet openings. Check

coolant level and pressure cap. Check raw

water strainer. Thermostat defective Replace Sea strainer clogged Clean sea strainer Carburetor adjustment too lean Adjust carburetor mixture Engine ignition timing incorrect Adjust timing Exhaust system leak Check exhaust system Exhaust system not securely installed Check for loose parts Broken or damaged vibromounts Check vibromounts No installation clearance (unit hits craft structure or compartment) No compartment sound insulation Install approved insulation Excessive vibration engine/ generator (internal imbalance) Loose or vibrating sheet metal Check shrouds

Check clearances

See authorized Kohler service

dealer/distributor

Electrical System

Problem Possible Cause Corrective Action

Battery will not charge

Starter does not work properly

Starter cranks slowly

Loose or corroded connections Clean and tighten connections Sulfated or worn-out battery Check electrolyte level and specific gravity

(batteries with filler caps only) Defective battery charging system Check charging system Battery charging fuse blown Replace fuse. If fuse blows again see

authorized Kohler service dealer/distributor Loose or corroded connections Clean and tighten loose connections Low battery output Check electrolyte level and specific gravity

(batteries with filler caps only). Check

battery voltage. Defective starter solenoid Replace starter solenoid Defective start/stop switch Replace switch Defective wiring Check wiring Low battery output Check electrolyte level and specific gravity

(batteries with filler caps only) Too heavy viscosity lube oil Use proper viscosity oil Loose or corroded wiring Clean and tighten loose connections High starter current draw Rebuild or replace starter Battery cable undersize See Installation Section--Electrical

Systems

TP-5695 12/93 Troubleshooting 4-3

Generator

NoACoutpu

Lowoutputor

voltage

outputvoltage

Willnotcran

Problem Possible Cause Corrective Action

No AC output

Circuit breaker in OFF position Reset breaker to ON position Circuit breaker tripped due to overload on

generator set Ship-to-shore transfer switch in “OFF” or

“SHORE” position No DC power to controller Check battery connections Controller fuse blown Replace fuse

Reduce load. See Wattage Requirements.

Reset breaker to ON position.

Turn switch to generator power

Low output or excessive drop in

High generator output voltage

Will not crank

Generator malfunction such as capacitor or other internal fault

Engine speed too low Adjust governor Generator overloaded Reduce load. See Wattage Requirements. Engine in poor condition If routine services are performed and

Defective capacitor See authorized Kohler service

Defective capacitor and/or poor wiring connections

Excessive speed or frequency Adjust governor. Check governor linkage

No DC power to controller Check battery connections Controller circuit fuse blown Replace fuse and attempt start-up. If fuse

See authorized Kohler service

dealer/distributor

condition persists, see authorized Kohler

dealer/distributor

See authorized Kohler service

dealer/distributor

and spring for damage or binding.

blows again, contact authorized Kohler

service dealer/distributor.

TP-5695 12/934-4 Troubleshooting

Section 5. Wiring Diagrams

P4--1

P4--16

P4--22

SCHEMATIC

12 VOLT

P4--11

10A

P1--14

P1--1

IGNITION SYSTEM

P4--8

P4--14

P5--2

LED2

K2 C2

LED3R3

P4--15

P4--9

AD 4573

P5--3

HOT

CHOKE

P5--1

BOARD

P5--4

P1--4

P1--5

P1--8

P2--3

D9 1A

LED4R4

1A D3

P1--10

P1--7

P4--19

P2--1

P3--4

P4--3

P4--4

P8--1

P1--12

VIOLET

P8--2

N70

P2--2 13

P1--13 30

BLUE

P1--9

P4--18

P1--15

K4 K2

P2--5

STOP

START

P3--3

P2--4

P2--6

P4--13

ENGINE

P4--20

HIGH ENGINE TEMP.

HIGH EXHAUST TEMP.

LOW OIL PRESSURE

P2--8

P2--9

P2--7

OPS

P4--21

CONTROLLER

P3--6

STOP

P3--1

REMOTE

START

P3--5

BLACK

GEN

P3--2

TAN

WTS

P4--2

LED1R1

FOR AMPERAGE RATINGSEE OWNERS MANUAL

L2 LO

HAZARD GROUND

P1--2

LEGEND

AC CRANK DISCONNECTRELAY

ENGINE RUN RELAY

ENGINE CRANK RELAY

FAULTSHUTDOWN RELAY

K4 K5

FAULTSHUTDOWN TIME DELAYRELAY STARTERMOTOR

FUEL PUMP

CHOKE

ANTI--DIESELSOLENOID

HOURMETER

OIL PRESSURE GAUGE

WATERTEMPERATURE GAUGE

BATTERYVOLTMETER

THERMAL SWITCH

OPS

OIL PRESSURE SENDER WATERTEMP. SENDER

WTS

246482-D

P6--1

P1--3

P1--6

P6--2

EXCITATION

CAPACITOR

BR1

PTC1

ALTERNATOR

+--

VR1

+12V

4 3 2

BC N

VOLTAGE

REGULATOR

BATTERY CHARGING

ALTERNATOR

AUXILIARY

WINDING

BATTERYCHARGING

AUXILIARY WINDING

120/240 V.CONNECTION

Figure 5-1. Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ

TP-5695 12/93 Wiring Diagrams 5-1

GRD

RATINGSEE

FORA MPERAGE

CIRCUIT BREAKERS

GRD

120 V. CONNECTION

10A

INPUT

7070

FUEL PUMP

SWITCH

THERMAL

CHOKE

ENGINE CONTROLLER

GREEN

SOLENOID

ANTI--DIESEL

GREEN/WHITE

STOPSTART

HOUR METER

72378N

P7C

8N3772

P 7C

BC BC

BATTERY

OWNERS MANUAL

GRD

120/240 V.CONNECTION

1234

10A

CHRG.

BATT.

HIGH ENGINE

TEMPERATURE

NUT

GROUND

MOTOR

SOLENOID

STARTER

OWNERS MANUAL

RATINGSEE

FORA MPERAGE

CIRCUIT BREAKERS

YELLOW

SWITCH

GREEN

BATTERY

CHARGING

ALTERNATOR

N73

2 1

FORA MPERAGE

RATINGSEE

OWNERS MANUAL

CIRCUIT BREAKERS

220 V. CONNECTION

LO (NEUTRAL)

GRD

1234

4 3 2 1

LUG

GROUND

9 8 7

3 2 1

6 5 4

12 1110 B2

NBC

VOLTAGE

REGULATOR

EXHAUST

SWITCHES

TEMPERATURE

B2 B1

3 654 9

RELAY BOARD

SYSTEM

IGNITION

WATER

(OPTIONAL)

OIL

15 1413

N 43

HOT CHOKE

CIRCUIT BOARD

GENERATOR

3B12

SENDING UNIT

TEMPERATURE

SWITCH

PRESSURE

WK G

CAPACITOR

EXCITATION

PIN INSERTIONEND.

CONNECTOR SHOWNFROM

NOTE :

REMOTE PANEL

WHEN NOTUSED.

TAPE LEADS”5”OR”7C”

SWITCH

(OPTIONAL)

OIL PRESSURE

SENDING UNIT/

LOW OILPRESSURE

123

45566

B2 B1

VIOLET

YEL/RED

LTBLUE

VIOLET

OIL

BLK

VIOLET

HOUR

BLK

ALTERNATOR

BLACK

START

TEMP

BLK

VOLT

BLK

GREY/BLK

TAN

STOP

VIOLET

VIOLET VIOLET

BLK

VIOLET VIOLET

BLK

BACK VIEWOF PANEL

(2 AND4 GAUGEREMOTE PANEL)

246482-D

Figure 5-2. Point-to-Point Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ

5-2 Wiring Diagrams TP-5695 12/93

Electro Switch

To Generator

Set

To Generator

Set

2-Wire Generator Sets

2 1 3 4

6 5 7 8

To Load

Kraus Naimler/American Solenoid

(Early Rectangular Design)

2-Wire Generator Sets

1 2 6 5

3 4 8 7

To Shore

Power

To Shore

Power

To Generator

Set

To Generator

Set

3-Wire Generator Sets

2 1 3 4

6 5 7 8

10 9 11 12

To Load

3-Wire Generator Sets

1 2 6 5

3 4 8 7

9 10 14 13

To Shore

Power

To Shore

Power

To Generator

Set

To Load

Kraus Naimler/American Solenoid

2-Wire Generator Sets

3 2 4 1

7 6 8 5

To Load

(Newer Round Design)

To Shore

Power

To Generator

Set

To Load

3-Wire Generator Sets

3 2 4 1

7 6 8 5

11 10 12 9

To Load

To Shore

Power

Figure 5-3. Marine Manual (Ship-to-Shore) Transfer Switch

TP-5695 12/93 Wiring Diagrams 5-3

Four-Lead Reconnectable (Single-Phase) Generator Sets Where Generator

Output Can Be Reconnected For 120 volt or 120/240 volt, 60 Hz,

110 volt or 110/220 volt, 50 Hz

NOTE

When a generator set is reconnected to a voltage different than nameplate voltage, notice should be placed on the unit indicating this change.Decals forthis purpose are available from authorized Kohler dealers/distributors.

120- or 110-Volt 3-Wire 2-Pole

Configuration--Figure 5-4

Jumper lead to be placed on line side of circuit breaker. Leads L1 and L2 can either be left as separate leads or can be connected together depending upon which is practical for the given application. Regardless of the number of phase (black) leads used in the application, both circuit breakers must have leads attached to the load side. It is recommended that jumper lead be maintainedfor allstraight 120-or110-voltsystemssince it helps balance the load of the generator set.

LO (Neutral)

Ground

Load Side

LO GRD.

L2 L1

120- or 110- Volt 2-Wire Configuration

Figure 5-5 (Single Pole)

If the installation requires a 120 or 110 volt, 2-wire system, a single-pole circuit breaker mustbe used.See Figure 5-5. When connecting stator phase leads together,theoutput lead (L1) mustbesized accordingly.

Stator Leads

4 3 2 1

Line Side

1-Pole Circuit Breaker

Load Side

Ground

LO (Neutral)

GRD. LO

Circuit

Breaker

Line Side

Jumper

Lead

4 3 2 1

Stator Leads

60 Hz 50 Hz

L0--L1 120 volt 110 volt L0--L2 120 volt 110 volt

Figure 5-4. With Jumper Lead

60 Hz 50 Hz

L0--L1 100-120 volt 100-120 volt

Figure 5-5. 120 Volt, 2-Wire

5-4 Wiring Diagrams TP-5695 12/93

120/240- or 110/220-Volt

Configuration--Figure 5-6

Jumper lead not used. If unit was originally wired for straight 120 or 110volt, be sure jumper leadis removed (see Figure 5-6 for location). Leads L1 and L2 are differentphases and must neverbeconnected together.

LO (Neutral)

Ground

Load Side

Line Side

4 3 2 1

Stator Leads

60 Hz 50 Hz

L0--L1 120 volt 110 volt L0--L2 120 volt 110 volt L1--L3 240 volt 220 volt

LO GRD.

L2 L1

Circuit Breaker

Figure 5-6. Without Jumper Lead

TP-5695 12/93 Wiring Diagrams 5-5

Section 6. Installation

Introduction

Use this section as a guide when installing the Marine generator set, then refer to Section 2. Operation for specific service instructions. Reliable and safe generator set operation depends largely upon proper installation. Remember that the generator set will probably be the craft’s sole source of electrical power.

When installing a marine generator set, it is recommended that the installation comply with all applicable Regulations and Standards. See Reference Material for documents issued by governing agencies. Information presented here should be followed in planning and making installations. Specifications given should be used only in initial planning. Use current dimension drawings and wiring diagrams.

NOTE

A wood block is located under some generator set end brackets to prevent damage during shipment. For the same reason, metal brackets are used to attach some generator sets to their wood shipping bases. These items MUST be removed prior to installation in order to provide adequate vibration clearance during generator setoperation.Checkthatallpacking material, literature, and loose accessories are removed from generator set prior to operation.

Generator Selection and

Wattage Requirements

Total wattage requirements (lights, motors, appliances) must be considered when selecting a generator set, or when sizing wattage usage where available space and construction limit the size of the generator set. The 4-lead reconnectable generator set can be connected for 120 volt or 120/240 volt 60 Hz (110 volt or 110/220 volt 50 Hz), see Section 5. Wiring Diagrams.

Lighting Load

The lighting load is usually easiest to calculate. In most cases, simply add the wattage of each lamp to be operated off the generator set. Note that in many applications, not all of the lights or lamps are in the generator set AC circuit—some are DC powered by the 12-volt battery in the craft. Make sure the total includes only lights actually on the generator set AC circuit.

Motor Loads

When figuring generator set capacity requirements that include electric motors, do not overlookthe high current demanded by the motors during start-up.The in-rushor starting current is typically 2--3 times higher than that required when the motor reaches normal operating speed. Reserve capacity must be allowed for in-rush demands plus other loads which could be on the line as the electric motor starts.

Air conditioning units are perhaps the most common type of motor load for generator sets in marine applications. The starting characteristics ofthe different varieties of air conditionersvary greatly—one particular 12,000 Btu unit has, for example, lower starting requirements than a 10,000 Btu unit of another make. When only one unit is involved, there is usually no starting problem, provided the lighting and appliance load is not too high when the unit is started.

Simultaneous starting of two air conditioning units, however, can present problems if the capacity is marginal. Because of the variation in starting characteristics of the various makes of air conditioners, no definite statements are made in this publication regarding multiple-motor starting capabilities of the marine generator set covered. Delayed starting or use of easy-starting devices on air conditioner units should be considered whenever simultaneous starting of more than one motor is involved.

NOTE

When a generator set is reconnected to produce a voltage different than nameplate voltage, notice should beplacedontheunitindicatingthischange.Decals(part number 246242) for this purpose are available from authorized Kohler dealers/distributors.

TP-5695 12/93 Installation 6-1

The starting and running requirements of some motor loads common to marine applications are listed in Figure 6-1;usethisas aguidewhen selectinggenerator set capacity requirements involving motor loads. See Figure 6-2 for generator set capabilities regarding air conditioners.

Capabilities will vary according to Kilowatt Derating following.

3.5CFZ, 50 Hz: 3.5 kW at 77_F (25_C) and 3.5 kW at 122_F (50_C).

Motor Requirements (HP)

1/4 750 330 1/3 1000 400 1/2 1500 600 3/4 2000 750

1 3300 1100 2 4000 2000 3 5000 3000

Figure 6-1. Motor Requirements

Model Wattage

4CZ 4000 One 13,500 Btu 2100

6.5 CZ 6500 One 13,500 Btu 4600

Figure 6-2. Air Conditioner Requirements

(50 Hz units will have slightly lower “power

to spare” figures than those indicated)

Starting

(In-Rush)

Watts

Will Operate Air

Conditioner of Size Indicated

Two 13,500 Btu 2700

Running

Watts

“Power to

Spare” for

Lighting

Appliances,

Tools

Appliance Loads

Marine generator sets are often used to furnish AC for appliances such as TV, stereo, electric water heaters, etc. With the exception of the resistance-type loads such as the water heater, requirements for appliances are usually low. Such loads must not, however, be overlooked when figuring total requirements. Reserve capacity should be available for anticipated appliance loads to avoid overloading of a set. The average power requirements of some common electrical appliances are given in Figure 6-3.

Kilowatt Derating

Units are rated as listed below at 1.0 power factor. Deratethelisted rating by approximately 3.5% per 1000 ft.(300 m)whenthe unitisoperated at altitudesof 500 ft. (150 m) or more above sea level.

4CZ, 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: 6.5kW at77_F(25_C) and 6kWat 122_F (50_C).

Motor Electrical Appliance

Automatic Pilot -- 150--250 Blanket, Electric -- 50--250 Blender 800 600 Broiler -- 1350 Depthometer -- 25--1000 Drill, 3/8” 600 350 Dryer, Hair -- 850--1200 Fan, Air

Circulating Food, Mixer 400 235 Heater, Space -- 750--1500 Heater, Water -- 1500 Iron -- 900--1200 Light Bulbs -- (as indicated) Pan, Frying -- 1200 Percolator,

Coffee Radar -- 750--1500 Radio -- 50--100 Radiophone -- 100--200 Range, Electric

(per element) Soldering Gun -- 250 Television -- 300--750 Toaster -- 750--1200 Water System 500--1500 300--1250

Figure 6-3. Appliance Average Wattage Ratings

Starting

Watts

50--200 25--100

-- 650

-- 1000--1500

(60 Hz)

Running

Watts

TP-5695 12/936-2 Installation

INPUT

FUSE

CHRG.

STOP/START

10A

1/10

00 000

TOTALHOURS

BATT.

*14 12

NOTE

Use two hose clamps on each end of all flexible exhaust hose connections.

*Indicated components must conform to U.S.C.G. Regulations.

1. Heat Exchanger

2. Siphon Break (See Instruction Sheet TT-927 for Proper Installation.)

3. Exhaust Mixer

4. Engine-Driven Seawater Pump

5. Exhaust Hose

6. Seawater Strainer

7. Raw Waterline

8. Intake Through-Hull Strainer

9. Seacock

10. Mounting Base

11. Mounting Tray

12. Coolant Recovery Tank

13. Hose Clamp

14. Fuel Line

Figure 6-4. Typical Location and Mounting

258000-D

TP-5695 12/93 Installation 6-3

Location

General

Consider the following in selecting or constructing a generator set location.

Compartment/location must allow adequate space for ventilation, cooling and exhaust system installation, service access to the engine and generator, and proper fuel system installation.

Engine stringers or other available structural members must provide adequate support for the generator set weight.

Ageneratorsetcompartmentmust be sealed to prevent exhaust gases and fuel vapors from entering cabins.

Generator sets located above deck must have a protective cover to prevent damage fromrain andwater splash. This cover must not affect cooling air flow and serviceability.

Ventilation

Ventilation is required to support engine combustion, generator cooling, and expulsion of flammable and lethal fumes. Ventilation provisions must comply with U.S.C.G. Regulations governing sizing of vents and operator requirements.

As a rule, inlet and outlet vent areas should each be sizedto aminimum of2sq. in.per ft.(13sq. cm/30.5cm) of craft’s beam. Should this rule in any instance conflict with U.S.C.G. Regulations, appropriate Regulations should be followed. If any screening is used in inlets, size of hull/deck openings should be doubled. Vent ducts should extend to bilges to expel heavier-than-air fumes.Ifthegeneratorsetistobemountedintheengine compartment, air flow must be increased to allow for generator set’s requirements. UL-listed ignitionprotected blowers should be installed in outlet vents, and wired to operate before engine(s) are started. Snifferdevices may also be optionally installed to cause alarm, warning, or engine shutdown should dangerous fumes accumulate in the compartment.

SeeFigure 6-4for atypical installationand Section1. for dimensions and weights.

Space

Locationshouldalloweasyaccesstothe generatorset’s engine,controller,cooling, and fuel system components forroutine service.Engine compartmentsareoften ideal generator set locations, but access should not be obstructed by propulsion engines or generator and controller. Also allow clearance for vibration during operation. Minimum recommended clearance for vibration and cooling of top, front, rear, and sides of generator set is 1 1/2 in. (38 mm).

Mounting

Enginestringers generally providethebest support fora generator set. Any structural members considered for mounting must support the generator set weight and withstand engine vibration. The generator set includes vibration mounts and mounting trays; additional vibration isolating pads may be installed between trays and bases.

A generator set should be mounted as high as possible to avoid bilgesplash and lower-lying vapors and also to allow downward pitch of the exhaust line. For angular installation, the maximum operation angle of the engine/generator set is 20_ (in all directions).

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.

Air requirements for various models are given in Figure 6-5. The air intake silencer provides combustion air to the engine. It is imperative that the recommended minimum clearance of 1 1/2 in. (38 mm) between duct opening and any enclosure wall not be compromised. Engine/generator performance will be affected adversely if these guidelines are not followed.

Air Requirements

CFM (L/min.)

Model Combustion Cooling

3.5CFZ 18 (510) 323 (9145) 4CZ 18 (510) 323 (9145) 5CFZ 18 (510) 600 (16988)

6.5CZ 18 (510) 600 (16988)

Figure 6-5. Air Requirements

TP-5695 12/936-4 Installation

Fuel Systems

Fuel Supply

Generator sets, in most cases, must draw fuel from the same tank as the propulsion engines. If the tank’s fuel pickup opening allows, a multiple dip tube arrangement (Figure 6-6) may be used. An alternate tank, if used, shouldhave a smallerseparatepickup opening allowing a single dip tube (Figure 6-7).

NOTE

Fuelsystemsmustconform toU.S.C.G Regulationsand tests.

WARNING

Explosive fuel vapors. Can cause severe injury or death.

1-788

1. Fuel Line to Propulsion

Engine

Figure 6-6. Dual Dip Tubes

For installations where the highest point of the gasoline source (fuel tank) is above the generator set carburetor, an auxiliary fuel shutoff valve is required. This fuel shutoffvalve shouldbeclosed when thegeneratoris not in use to prevent fuel leakage resulting from fuel flow throughthe fuel pump andinto the carburetor shouldthe float valve not seat properly.

2. Fuel Line to Generator Set

Useextreme care when handling, storing, and using fuels.

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.

1-788

1. Fuel Line to Generator Set

Figure 6-7. Single Dip Tube

TP-5695 12/93 Installation 6-5

Anti-Siphon Provisions

Anti-siphon devices must be installed if any section of fuel line lies below the highest pointof thefuel tank.The anti-siphon device should be either a spring-loaded check valve (tested to function with the particular installation’s siphon head), or an electrically operated shutoff valve (UL ignition-protected, tested to U.S.C.G. Regulations) which may be operated manually.A check valve should be installed at a point above fuel tank’s highest point, secured to craft’s structure, and be accessible without removing any permanent structure. The fuel line section between the tank and check valve must be located above the tank’s highest point. An electric shutoff valve should be installed at the tank’s fuel withdrawal fitting, and be wired to open when the generator set engine is cranking or running.

Anti-siphon holes drilled in fuel dip tubes within the tank are not reliable anti-siphon devices as they become ineffective when restricted by dirt or gum.

Any in-line fuel filters or strainers must conform to U.S.C.G. Regulations, must be independently mounted to the craft’s structure, and must be accessible for servicing without removing any permanent structures.

NOTE

If a fuel strainer is installed, each fuel filter and strainer must be supported on the engine or boat structure independent from its fuel line connections, unless the fuel filter or strainer is inside a fuel tank.

Fuel Pump Lift Capabilities and

Fuel Consumption

Fuel Lines

Metallic lines should be used from the tank to a flexible hose section connecting metallic line to the engine fuel pump. Metallic lines must have wall thickness of at least

0.029 in. (0.74 mm). Seamless annealed nickel copper, copper-nickel, or copper tubing must be used. The flexiblesection(necessaryto allow vibrational motion of the generator set during operation) must be U.S.C.G. TYPE A HOSE, marked and tagged according to Regulations. Metallic line must be supportedwithin 4 in. (102 mm) of its connection to the flexible section. See Figure 6-8 for fuel pump inlet connection.

Figure 6-9 lists electric fuel pump lift capabilities and fuel line sizes. Figure 6-10 shows generator set fuel consumption rates.

Fuel Pump

Model

3.5CFZ 3 (0.9) 3/8 (9.5) 4CZ 3 (0.9) 3/8 (9.5) 5CFZ 3 (0.9) 3/8 (9.5)

6.5CZ 3 (0.9) 3/8 (9.5)

Figure 6-9. Fuel Pump Lift and Fuel Line Size

Model 1/4 1/2 3/4 Full

3.5 CFZ 0.42

4CZ 0.48

Max. Lift ft. (m)

Load and GPH (L/hr.)

0.50

(1.59)

(1.81)

(1.89)

0.55

(2.08)

Fuel Inlet Size

I.D. in. (mm)

0.59

(2.23)

0.62

(2.34)

0.68

(2.57)

0.68

(2.57)

1. 1/4 in. NPT Female Pipe Thread

Figure 6-8. Fuel Pump Inlet Connection

2. Electric Fuel Pump

258000-D

5CFZ 0.44

(1.67)

6.5CZ 0.53 (2.00)

Figure 6-10. Fuel Consumption

0.54

(2.04)

0.62

(2.34)

0.66

(2.50)

0.86

(3.25)

0.80

(3.03)

1.02

(3.86)

TP-5695 12/936-6 Installation

Cooling Systems

General

The following features are necessary in the cooling system.

An intake thru-hull strainer (seacock cover) must be screened to prevent entry of foreign objects and must not be aligned (in relation to direction of travel) with the propulsion engine intake. See Figure 6-11. The recommended thru-hull strainer should be flush mounted. Strainers with slotted holes must be installed with their slots parallel to the direction of vessel movement. The area of the strainer opening(s) must be equal to or greater than the inside diameter of the waterline hose to the seawater pump.

An intake thru-hull strainer must not be of the scoop or cup design. This style can cause a ramming effect and force water upward, past the seawater pump, and into the engine cylinders when the vessel is moving and the generator set is shut down. Hull designs incorporating sea chests are also not suitable for intake thru-hull strainers. A sea chest is a concave molded-in-the-hull chamber that is also aligned to the direction of travel. A sea chest configuration applies a positive pressure similar to a scoop-type thru-hull strainer.

4 3

NOTE

Intakes are positioned in relation to vessel travel so neither will be in the wake of the other.

1. Generator Set Intake

2. Propulsion Engine Intake

3. Aft

4. Fore

1-789

Figure 6-11. Intake Strainer

A seacock istobe mounted to hull, assembled onto the intake and accessible for operation. Figure 6-12 shows a typical installation. Installthe canvas on the outsideof the hull, and the canvas or rubber packing on theinside of the hull.

If caulking is used to seal the seacock, be sure not to apply an excessive amount. Excess caulk can cause improper water flow and in some cases develop a barrierwhich canforcewater upward, pasttheseawater pump, and into the engine cylinders when the vessel is moving and generator set is shut down.

1. Inside Packing

2. Outside Packing

3. Seacock Cover

Figure 6-12. Seacock Installation

4. Direction of Vessel Movement

5. Typical Intake Thru-Hull Strainers

1-789

TP-5695 12/93 Installation 6-7

A seawater strainer of sufficient capacity should be mounted to the seacock or permanent structure at a point not higher than the seawater pump. The strainer shouldbeaccessibleforservicing.See Figure 6-13fora typical installation. The optional Kohler seawater strainer is threaded for 1/2 NPT fittings.

1-789

1. Seawater Pump

2. Seawater Strainer

3. Seacock

NOTE

A 5/8 in. (16 mm) waterline hose can be substituted for the recommended 3/4 in. waterline hose.

Piping should be kept straight and as short as possible. See Figure 6-14 for the seawater connection to the seawater pump inlet. The seawater outlet is combined with engine exhaust gases.(On sound shielded units,a small section of molded hose is required for the seawater inlet connection.)

Figure 6-13. Seawater Strainer

NOTE

Some seawater strainers include seacock and intake thru-hull strainer.

Waterlines from the seacock to the engine-driven seawater pump can be copper tubing orflexible hose.A flexiblesection of hose is used for the actual connection to the seawater pump to allow vibrational motion of the generator set during operation. The hose should have aninside diameterof3/4 in.(19 mm).Copper lineshould be supported within 4 in. (102 mm) of its connection to the flexible section.

ADV-5792-D

1. 3/4 in. Seawater Pump Inlet

Figure 6-14. Seawater Inlet Connection

Closed/Heat Exchanger

A closed, heat exchanger cooling system, the best alternative for most applications especially if craft is to be operated in salt waters or waters with high silt content, is provided as part of the generator set.

Service accessibility must be provided for the heat exchanger pressure cap. See Figure 6-15.

TP-5695 12/936-8 Installation

STOP/START

INPUT

10A FUSE

1/10

00 000

TOTALHOURS

BATT. CHRG.

NOTE

Usetwo hoseclamps oneach end of all flexible exhaust hose connections.

1. Exhaust Manifold

2. 3 ft. (1 m) Max.

3. Engine-Driven Seawater Pump

4. Heat Exchanger

5. Waterline

Figure 6-15. Closed/Heat Exchanger Cooling System

Exhaust Systems

General

Water-cooledexhaust lines should be used in all marine installations. The hose used for the lines should have a 2 in. (51 mm) inside diameter. Keep the lines as short andstraightas possible. The use of two hose clamps on each end of flexible exhaust hose connections is highly recommended. ABYC Safety Standards P-1.6.c recommend a pitch of at least 1/2 in. (12.8 mm) per running foot (30.5 cm). Use flexible steam hose conforming to UL Standard 1129 for “Engine wet exhaust components” between the mixing elbow and the exhaust outlet. A silencer should be independently mounted to eliminate any stress on the exhaust system and exhaust manifold/mixer elbow. See Figure 6-16 for the exhaust connection to the mixer elbow.

8 9

258000-D

6. Seawater Strainer

7. Intake Strainer

8. Engine Coolant

9. Seawater

10. Seacock

11. Coolant Recovery Tank

1. Seawater/Exhaust Outlet

Figure 6-16. Mixer Elbow/Exhaust Connection

1-894

TP-5695 12/93 Installation 6-9

Locatethe exhaustoutletat least4in. (10cm)above the waterlinewhenthecraftisloadedtomaximumcapacity. Usually a flapper is installedat exhaust (transom) outlet toprevent water backup in following seas or when going astern (backward).

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

NOTE

Data given is applicable to side-exhaust installations.

INPUT

FUSE

BATT. CHRG.

STOP/START

10A

1/10

00 000

TOTALHOURS

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 yourcraftsothatthe 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’swaterline, DO NOT OVERLOAD CRAFT so as to close or restrict exhaust discharge hole.

NOTE

Use two hose clamps on each end of all flexible exhaust hose connections.

1. Heat Exchanger

2. Exhaust Manifold

3. Engine-Driven Seawater Pump

4. 3 ft. (1 m) Max. Lift of Seawater Pump

5. Silencer (Customer Supplied)

6. Exhaust Hose Slope 0.5 in. (1.3 cm) per ft. (30.5 cm)

7. Slight Lift Improves Silencing (Keep Below Level of Exhaust Manifold Outlet)

Figure 6-17. Typical Above Waterline Installation

Exhaust system guidelines for various generator set locations follow. Where exhaust lines would require passage through bulkheads, it may bemore practical to use port (left) or starboard (right) side exhaust outlets. This would be especially true where long exhaust lines to the transom (rear) could cause excessive back

258000-D

8. 4 in. (10 cm) Min. of Exhaust Line Above Waterline

9. Waterline

10. Seawater Strainer

11. Intake Strainer

12. 10 ft. (3 m) Max. Between Exhaust Outlet and Silencer

13. Seacock

14. Coolant Recovery Tank

pressure. Information and illustrations of stern (rear) exhaust installations also apply to side exhaust installations. Should any information regarding installation conflict with U.S.C.G. Regulations, appropriate Regulations should be followed.

TP-5695 12/936-10 Installation

Above Waterline

In addition to considerations described earlier, a customer-supplied silencer should be installed with its outlet at a maximum of 10 horizontal ft. (3 m) from the center of the engine’s exhaust outlet (see Figure 6-17). A typical silencer should be mounted with the inlet and outlet level and with the drain plug down. The silencer may require two supporting brackets or hanger straps for installation to stringers or other suitable structure. Any“lift” in the exhaust line to improvesilencingmustbe below the engine exhaust manifold outlet.

Mid/Below Waterline

U.S.C.G. Regulations require that an anti-siphoning provision be used to prevent raw water entry into the engineiftheexhaustmanifoldoutlet is located less than 9in.(23cm)abovethewaterlinewhenthecraftisloaded to maximum capacity. Install a siphon break, see Figure 6-18, at least 1 ft. (31 cm) above waterline as shown in Figure 6-19.

STOP/START

INPUT

10A FUSE

1/10

00 000

TOTALHOURS

BATT. CHRG.

1-779

1. Mounting Base

2. Retaining Cap

3. Reed Valve Assembly

Figure 6-18. Siphon Break Components

The siphon break must be located at least 1 foot above the waterline at maximum vessel capacity between the heat exchanger and water elbow (three-way fittings). The siphon break and fitting must be supported to maintainproperpositionandfunction.The siphon break should be mounted directly vertical of its connection to generator set where possible. Otherwise, a slight offset is allowable to clear stringers or other permanent structures.

NOTE

Use two hose clamps on each end of all flexible exhaust hose connections.

1. Siphon Break

2. Exhaust Manifold

3. Heat Exchanger

4. 4 ft. (1.2 m) Max.

5. Exhaust Hose Slope 0.5 in. (1.3 cm) per ft. (30.5 cm)

6. 4 in. (10 cm) Min.

Data given is alsoapplicable to side-exhaust installations.

NOTE

7. Waterline

8. Silencer (Customer Supplied)

9. 10 ft. (3 m) Max.

10. Install Optional Water Lock Here

11. Coolant Recovery Tank

12. 1 ft. (30.5 cm) Min.

258000-D

Figure 6-19. Typical Mid and Below Waterline Installation

TP-5695 12/93 Installation 6-11

A typical silencer should be mounted no more than 4 ft. (1.2 m) below the highest point in the exhaust line. Attach a separate wood mounting base to hull stringers or other suitable structure. Then secure the silencer to hull using silencer manufacturer’s recommendation. Be sure the silencer outletis not more than10 horizontal ft. (3 m) from the engine exhaust manifold outlet. UL marine exhaust hose should be used.

Electrical Systems

AC Voltage Connections

WARNING

Hazardous “backfeed” voltage can cause severe injury or death. Donot connect to anybuilding/marina

AC connections to generator set are made inside the controllerbox. The generatorset is usually connectedto a ship-to-shore transfer switch which allows the use of shore/utility power when docked or generator set power whendockedoratsea.Thewiringis thenconnected toa main circuit breaker box (panelboard) which distributes branch circuits throughout the craft. See Section 5. Wiring Diagrams for reconnectability of generator set.

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.

Explosive fuel vapors can cause severe injury or death. Gasoline vapors can explode and can cause

WARNING

Hazardous voltage. Can cause severe injury or death.

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

Moving rotor.

Installation in Steel or

Aluminum Vessels

Installation of a generator set in a vessel constructed of a material capable of conducting current (e.g.: steel or aluminum) is subject to considerations not normally encountered in fiberglass or wood vessels. These differences include equipment grounding, grounding of neutral conductors, ground fault protection, and isolation of galvanic currents.

While the scope of these topics is too extensive to be fully discussed here, references to the appropriate governing bodies will be identified for further investigation.

The information provided here is intended to serve as a guideline to boat manufacturers and generator set installers. This information is not intended or implied to be limited to these sources and is subject to revision by the appropriate governing bodies.

Prior to installing the generator set, check the wiring diagrams to become familiar with the electrical system.

Generator sets installed in pleasure craft are governed by the U.S. Coast Guard and the American Boat and Yacht Council, Inc. Compliance with U.S. Coast Guard Regulationsgiven in Title33, Part 183 must be followed. Generator sets installed in pleasure craft require a grounded neutral system as specified in ABYC E-8.4.b. Various wiring configurations are illustrated in ABYC Standards E-8.22 through E-8.29. Grounding of appliances and equipment is covered in ABYC E-8.12. Galvanic corrosion prevention by means of galvanic

TP-5695 12/936-12 Installation

isolator or isolation transformer is referenced in ABYC E-8.20 and ABYC E-8.11.

Generator sets installed in commercial vessels are governedbyU.S.CoastGuardRegulations, Title46,the American Bureau of Shipping, and Lloyd’s Register of Shipping. Grounding of equipment is covered in ABS

35.9.6 and Lloyd’s Part 6, Chapter 2-1, Section 1.3. The types of permissible neutral grounding of generating equipment are referenced in ABS 35.125 and 35.95.1 andin Lloyd’s Part 6,Chapter2-1, Section 14.4. Ground fault protection information can be found in Lloyd’s Part 6, Chapter 2-1, Section 14.5 and Part 6, Chapter 2-2, Section 13.6.

Battery

Batteriesand theirinstallationmust conformto U.S.C.G. Regulations 183.420 (a) through (g). Generator sets should use batteries separate from the propulsion engines whenever possible. Boththe generator set and the propulsion engines’ starting/charging systems must have a common negative (--) ground.

Cable

Size Distance Between Generator Set and Battery

At 0° F

(--18° C)

(AWG)

At 32° F

(0° C)

At 75° F

(24° C)

40 ft. (12.2 m) 00 0 1 30 ft. (9.1 m) 0 1 2 25 ft. (7.6 m) 1 2 4 20 ft. (6.1 m) 2 2 6 15 ft. (4.6 m) 2 4 6 10 ft. (3.0 m) 4 6 8 5 ft. (1.5 m) 6 6 8

2.5 ft. (0.8 m) 8 8 8

Figure 6-20. Battery Cable Sizes

U.S.C.G Regulation 183.415, Grounding, requires a common conductor to be connected to each grounded crankingmotorcircuit.Thisconductorshouldbesized to match the larger of the engines’ two battery cables. (Cable sizes for generator set battery connections are given in Figure 6-20.) This requirement prevents the starting motor current from using alternative electrical paths should the cranking motor ground circuit be restricted or open due to oxidation or loose hardware. These alternative electrical paths include metallic fuel lines which can pose a fire hazard. See Figure 6-21 for battery connections to generator set.

ADV-5792-D

1. Battery Positive (+) Connection

2. Battery Negative (--) Connection

Figure 6-21. Battery Connection Bracket

Wiring

All wiring must be stranded copper. Wire gauges and insulation, conductor temperature ratings, sheath stripping, conductor support and protection, conductor terminals and splices, and overcurrent protection (circuit breakers, fuses) must conform to U.S.C.G. Regulations 183.425 through 183.460. Use rubber grommets and cable ties, as necessary, to protect and secure wiring from sharp objects, exhaust system, and any moving parts.

TP-5695 12/93 Installation 6-13

Remote Start Switch Connection

elects to use just a start-stop switch or separate lights and hourmeter. See Figure 6-22.

Kohler offers several remote panels for connection to the generator set. See Accessories for further detailed description. A wiring harness with a connector keyed to the controller box connector is available to connect these panels to the generator set. The other end of this harness has pigtails which can be used if the installer

Lead Designations

Pin Lead Function

J3-1 Black Ground (--) J3-2 Tan Water Temp. Ga. J3-3 Lt. Blue Oil Pressure Ga. J3-4 Violet Gen. “ON” (+) J3-5 Yellow/Red Start J3-6 Grey/Black Stop

NOTE

If gauges are to be used, there must also be generator set senders. Senders are optional on these generator sets. Gauges and senders are available as service items from an authorized Kohler service dealer/distributor.

1 2 3

4 5 6

1. Use Insulink or Solder Connection (Tapeto Insulate)

2. Hourmeter

3. “ON” Light

4. Stop

Figure 6-22. Remote Control Panel Wiring

NOTE

All wire is 16 gauge. Tape to insulate all unused lead ends.

5. Start

6. Rocker Switch

7. Gauges Senders

TP-5695 12/936-14 Installation

Section 7. Installation Drawings

WATERCOOLED EXHAUST

OUTLET FOR 2.0 (51) I.D.

RUBBER HOSE

SEA WATER INLET

.75 (.19) I.D. HOSE

(223)

8.77

17.50

(445)

15.43

(392)

6.34

(161)

(360)

14.19

ADV-5792-D

Sheet 1

WITH HUSH COVER.

5/6.5 SUPPLIED STANDARD

WITH HEATEXCHANGER

WATER--COOLED

IGNITION PROTECTED

4/6.5KW 60HZ. GASOLINE MARINE

3.5/5KW 50HZ. GASOLINE

.406 DIA. (4) HOLES

(10)

21.20

(538)

.62

(16)

ENGINE

(25)

1.0

(394)

15.50

24.44

(621)

MOUNTING PATTERN

1.0

(25)

OIL DRAIN

ENGINE COOLANT

CHECKANDFILL

START/STOP SWITCH

CIRCUIT BREAKERS(OPTIONAL)

ENGINE OIL

CHECKANDFILL

OIL FILTER

EQUIVALENT.

DIMENSIONS IN ( )

ARE MILLIMETER

NOTE:

27.87

(708)

26.44

(672)

9.13

(232)

.44

(11)

(422)

16.60

(68)

2.69

(150)

5.89

REMOTE

CONNECTION

FUEL INLET

1/4 N.P.T.

1.65

5/16 STUD FOR

BATTERY CONNECTION

(NEGATIVE).

1/4 STUD FOR

BATTERY CONNECTION

(POSITIVE)

VIEW A--A

(42)

GROUND LUG

Figure 7-1. Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ

TP-5695 12/93 Installation Drawings 7-1

3.12 DIA. (79)

EXHAUST

OUTLET

OPENING

.625 R. (16)

SEA WATER INLET

(445)

17.50 (326)

12.82

(220)

8.67

.50 R.

(13)

3.07

(78)

1.92

(49)

(44)

1.75

17.86

(454)

MILLIMETER EQUIV.

DIMENSIONS IN ( ) ARE

NOTE:

ADV-5792-D

Sheet 2

KIT # 267994 (4 PIECECOVER).

SOUND SHIELD SERVICE

WITH SOUND SHIELD.

5/6.5KW SUPPLIED STANDARD

15.62

(397)

(138)

5.45

267957

CAUTION

Donot useas astep.

Standingon genset could

impairoperation ofunit.

(102)

4.00

USING INDENTATIONS FOR

SIPHON BREAKASSEMBLY.

MOUNTING LOCATION FOR

DRILL (2) 1.00”DIA. HOLES

VIEW A--A

31.07

(789)

A A

LATCHOPENING

CLEARANCEREQ’D FOR

TYP.

1.57

(40)

.51

LOCATION. (OPTIONAL)

(13)

(44)

1.75

.50 R. (13)

30.06

(764)

26.76

(680)

1.65

(42)

2 PLACES

OPENING FOR FUEL

INLET HOSEAND

2.75

(70)

2.12

(54)

18.10

BATTERY CONNECTIONS

(460)

OPENING FOR

A.C. LOAD LEADS

Figure 7-2. Sound Shield--Optional on 3.5CFZ and 4CZ; Standard on 5CFZ and 6.5CZ

TP-5695 12/937-2 Installation Drawings

Section 8. Parts Ordering Instructions

Forservice orinformation,check theyellow pagesofthe telephone directory under the heading GENERATORS--ELECTRIC orcontact thelocal marina forthe authorizedKohler servicedealer/distributorin the area.

KOHLER CO. KOHLER, WISCONSIN 53044 PHONE 414-565-3381 FAX 414-459-1646 (North American Sales), 414-459-1614 (International) FORSALES & SERVICEIN U.S.A. & CANADAPHONE 1-800-544-2444

A major service manual and parts catalog may be ordered through an authorized Kohler service dealer/distributor. When ordering, state MODEL and

SPEC. numbers from the Generator Nameplate. (See NO TAG.)

In any communications regarding this generator set, pleasereport theMODEL,SPEC. andSERIAL numbers as found on the nameplate attached to the generator and engine. Enter numbers in spaces provided below. This information will enable the authorized Kohler service dealer/distributor to supply the correct part or data for this particular model.

Model No. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specification No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-5695 12/93 Parts Ordering Instructions 8-1

Section 9. Operating Hour Service Log

The following is provided to help you keep acumulative record of operating hourson your generator set andthe

OPERATING HOURS SERVICE RECORD

DATE

HOURS RUN CUMULATIVE DATE SERVICE

datesrequired services were performed. Enter hours to the nearest quarter hour.

TP-5695 12/93 Operating Hour Service Log 9-1

TP-5695 12/93 PRINTED IN U.S.A.

KOHLER CO. KOHLER, WISCONSIN 53044 PHONE 414-565-3381 FAX 414-459-1646 (North AmericanSales), 414-459-1614 (International) FOR SALES & SERVICE IN U.S.A.& CANADA PHONE 1-800-544-2444

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

Specifications and Main Features

Frequently Asked Questions

User Manual