Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ User Manual
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
2
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
3
m
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)
31.07 x 18.10 x 17.50
(789 x 460 x 445)
31.07 x 18.10 x 17.50
(789 x 460 x 445)
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
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
36
32
4
5
6
7
3
8
1
9
2
10
30
INPUT
FUSE
CHRG.
STOP START
10A
1/10
00 0E00
TOTALHOURS
BATT.
17
16131211 143115
18
19
33
35
34
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
29
28
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
20
21
22
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
2
3
6
4
1. Battery Charging Fuse
2. Input (Controller) Fuse
3. Start/Stop Switch
Figure 2-1. Controller
5
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
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.
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
1
258000-D
1. Low Oil Pressure Shutdown Switch
Figure 2-2. Low Oil Pressure Shutdown Switch
TP-5695 12/932-4 Operation
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