Operation and Installation Manual - 30plus · PDF fileOperation and Installation Manual Marine Generator Sets Models: ... install exhaust outlet where exhaust can be drawn ... KOHLER

Operation andInstallation Manual

Marine Generator Sets

Models:3.5CFZ

4CZ5CFZ6.5CZ

TP-5695 12/93

Engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

WARNINGCalifornia Proposition 65

TP-5695 12/93 Table of Contents

Table of ContentsSUBJECT 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 andWattage 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 andFuel 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 Safety Precautions and Instructions i

Safety Precautions and InstructionsA generator set, like any other electro-mechanicaldevice, can pose potential dangers to life and limb ifimproperly maintained or imprudently operated. Thebest way to prevent accidents is to be aware of thepotential dangers and to always use good commonsense. In the interest of safety, some generalprecautions relating to the operation of a generator setfollow. Keep these in mind. This manual containsseveral types of safety precautions which are explainedbelow.

DANGER

Danger is used to indicate the presence of a hazard thatwill cause severe personal injury, death, or substantialproperty damage if the warning is ignored.

WARNING

Warning is used to indicate the presence of a hazardthat can cause severe personal injury, death, orsubstantial property damage if the warning is ignored.

CAUTION

Caution is used to indicate the presence of a hazard thatwill or can cause minor personal injury or propertydamage if the warning is ignored.

Safety decals are affixed to the generator set inprominent places to advise the operator or servicetechnician of potentially hazardous situations. Thedecals are reproduced here to improve operatorrecognition and thereby increase decal effectiveness.For a further explanation of decal information, referencethe accompanying safety precautions. Before operatingor servicing the generator set, be sure you understandthe message of these decals. Replace decals if missingor damaged.

NOTENote is used to notify people of installation, operation, ormaintenance information that is important but nothazard-related.

HAZARDOUS VOLTAGE/ELECTRICAL SHOCK

WARNING

Hazardous voltage.

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

Moving rotor.

Can cause severe injury or death.

Hazardous voltage can cause severe injury ordeath. Wherever electricity is present, there is thehazard of electrocution. Take the same precautions withelectrical appliances in your craft that you wouldobserve in your home. Open main circuit breaker on allpower sources before servicing equipment. Make sureunqualified persons, especially children, cannot gainaccess to your set— keep the compartment door lockedor securely latched at all times. Be sure that generator isproperly grounded. Never touch electrical leads orappliances with wet hands, when standing in water, oron wet ground as the chance of electrocution isespecially prevalent under such conditions.

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

Hazardous voltage can cause severe injury ordeath. Short circuits can cause bodily injury and/orequipment damage. Do not contact electricalconnections with tools or jewelry while adjustments aremade. Remove wristwatch, rings, and jewelry that cancause short circuits.

Hazardous “backfeed” voltage can cause severeinjury or death. Do not connect to any building/marinaelectrical system without connecting through anapproved device and after building main switch is open.Backfeed connections can cause serious injury or deathto utility personnel working to repair a power outageand/or personnel in the vicinity. Unauthorizedconnection may be unlawful in some states and/orlocalities. A ship-to-shore transfer switch must beinstalled to prevent interconnection of generator setpower and shore power.

TP-5695 12/93ii Safety Precautions and Instructions

EXHAUST SYSTEM

WARNING

Carbon monoxide.Can cause severe nausea, fainting, or death.The exhaust system must be leakproof androutinely inspected.

Carbon monoxide can cause severe nausea,fainting, or death. Use the following precautions wheninstalling and operating generator set. Carbonmonoxide is particularly threatening in that it is anodorless, colorless, tasteless, nonirritating gas. Beespecially careful if operating the generator whenmoored or anchored under calm conditions as gasesmay accumulate. If operating the set dockside, mooryour craft so that the exhaust discharges on the lee side(the side sheltered from the wind), and always bemindful of others— make sure your exhaust is directedaway from other boats and occupied buildings. Do notinstall exhaust outlet where exhaust can be drawnthrough portholes, vents, or air conditioners. Ifgenerator set’s exhaust discharge hole is near to yourcraft’s water line, DO NOT OVERLOAD CRAFT so as toclose or restrict exhaust discharge hole.

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

TP-5695 12/93 Safety Precautions and Instructions iii

BATTERY

WARNING

Sulfuric acid in batteries.Can cause severe injury or death.

Use protective goggles and clothes. Can causepermanent damage to eyes, burn skin, and eat holesin clothing.Sulfuric acid in batteries can cause severe injury ordeath. Sulfuric acid in battery can cause permanentdamage to eyes, burn skin, and eat holes in clothing.Always wear splash-proof safety goggles when workingaround the battery. If battery electrolyte is splashed inthe eyes or on skin, immediately flush the affected areafor 15 minutes with large quantities of clean water. In thecase of eye contact, seek immediate medical aid. Neveradd acid to a battery once the battery has been placed inservice. Doing so may result in hazardous spattering ofelectrolyte.

Explosion can cause severe injury or death. Batterygases can cause an explosion. Do not smoke or permitflame or spark to occur near a battery at any time,particularly when it is being charged. Avoid contactingterminals with tools, etc. to prevent burns and to preventsparks that could cause an explosion. Removewristwatch, rings, and any other jewelry before handlingbattery. Never connect negative (--) battery cable topositive (+) connection terminal of starter solenoid. Donot test battery condition by shorting terminals togetheror sparks could ignite battery gases or fuel vapors. Anycompartment containing batteries must be wellventilated to prevent accumulation of explosive gases.To avoid sparks, do not disturb battery chargerconnections while battery is being charged and alwaysturn charger off before disconnecting batteryconnections. When disconnecting battery, removenegative lead first and reconnect it last.

TP-5695 12/93iv Safety Precautions and Instructions

FUEL SYSTEM

WARNING

Explosion.Gasoline vapors can cause explosion andsevere injury or death.Before starting generator set, operate blower 4minutes and check engine compartment forgasoline vapors.

WARNING

Explosive fuel vapors.Can cause severe injury or death.

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

Explosive fuel vapors can cause severe injury ordeath. All fuels are highly explosive in a vapor state. Useextreme care when handling, storing, and using fuels.Store fuel in a well-ventilated area away fromspark-producing equipment and out of the reach ofchildren. Never add fuel to the tank while the engine isrunning since spilled fuel may ignite on contact with hotparts or from ignition spark. Do not smoke or permitflame or spark to occur near potential sources of spilledfuel or fuel vapors. Keep fuel lines and connections tightand in good condition— don’t replace flexible fuel lineswith rigid lines. Flexible sections are used to avoidbreakage due to vibration. Should any fuel leakage, fuelaccumulation, or electrical sparks be noted, DO NOTOPERATE GENERATOR SET. Have systems repairedbefore resuming generator operation.

Explosive fuel vapors can cause severe injury ordeath. Additional precautions must be taken whenusing the following fuels:

Gasoline— Store gasoline only in approved redcontainers clearly marked GASOLINE. Do not storegasoline in any occupied building.

Explosive fuel vapors can cause severe injury ordeath. Gasoline vapors can explode and can causedeath or severe injury. USCG Regulation 33CFR183requires all electrical devices (ship-to-shore transferswitch, remote start panel, etc.) to be “ignition protected”when used in a gasoline (gaseous)-fueled environment.These electrical devices are not “ignition protected”andare not certified to operate in a gasoline(gaseous)-fueled environment such as engine room ornear fuel tanks. Acceptable locations would bewheelhouse or other living areas sheltered from rain andwater splash.

Explosive fuel vapors can cause severe injury ordeath. Spilled fuel can cause an explosion. Use acontainer to catch fuel when draining fuel system. Wipeup all spilled fuel after draining system.

Explosive fuel vapors can cause severe injury ordeath. Fuel leakage can cause an explosion. Do notmodify the tank or propulsion engine fuel system. Craftmust be equipped with a tank allowing one of the twopickup arrangements described. Tank and installationmust conform to U.S.C.G. Regulations.

Explosive fuel vapors can cause severe injury ordeath. Fuel leakage can cause an explosion. Toprevent fuel leakage, use pipe sealant on all threadedfittings. Pipe sealant must be suitable for use in marineapplications having oil and gasoline environments.

TP-5695 12/93 Safety Precautions and Instructions v

ACCIDENTAL STARTING

WARNING

Accidental starting.Can cause severe injury or death.Disconnect battery cables before working ongenerator set (negative lead first and reconnect itlast).

Accidental starting can cause severe injury ordeath. Disconnect battery cables (remove negativelead first and reconnect it last) to disable generator setbefore working on any equipment connected togenerator. The generator set can be started by remotestart/stop switch unless this precaution is followed.

MOVING PARTS

WARNING

Rotating parts.Can cause severe injury or death.

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

Flying projectiles can cause severe injury or death.Retorque all crankshaft and rotor hardware afterservicing. When making adjustments or servicinggenerator set, do not loosen crankshaft hardware orrotor thru-bolt. If rotating crankshaft manually, directionshould be clockwise only. Turning crankshaft bolt orrotor thru-bolt counterclockwise can loosen hardwareand result in serious personal injury from hardware orpulley flying off engine while unit is running.

Exposed moving parts can cause severe injury ordeath. Additional Precautions Regarding Sound ShieldEquipped Models:Some scheduled maintenance procedures require thegenerator set to be running while performing service. Ifthe sound shield has been removed leaving belts andpulleys exposed, be especially careful of this area.

Exposed moving parts can cause severe injury ordeath. Keep hands, feet, hair, clothing, and test leadsaway from belts and pulleys when unit is running.Replace guards, covers, and screens before operatinggenerator set.

HOT PARTS

WARNING

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

Do not work on generator set until unit is allowed tocool.

Hot parts can cause severe injury or death. Do nottouch hot engine parts. An engine gets hot while runningand exhaust system components get extremely hot.

WARNING

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

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

Hot coolant can cause severe injury or death. Allowengine to cool and release pressure from coolingsystem before opening pressure cap. To releasepressure, cover the pressure cap with a thick cloth thenturn it slowly counterclockwise to the first stop. Afterpressure has been completely released and the enginehas cooled, remove cap. If generator set is equippedwith a coolant recovery tank, check coolant level at tank.

TP-5695 12/93vi Safety Precautions and Instructions

ENGINE BACKFIRE/FLASH FIRE

WARNING

Fire.Can cause severe injury or death.

Do not smoke or permit flame or spark to occurnear fuel or fuel system.

A flash fire can cause severe injury or death. Do notsmoke or permit flame or spark to occur near carburetor,fuel line, fuel filter, fuel pump, or other potential sourcesof spilled fuel or fuel vapors. When removing fuel line orcarburetor, use a proper container to catch all fuel.

A sudden backfire can cause severe injury or death.Do not operate with backfire flame arrestor removed.

A sudden backfire can cause severe injury or death.Do not operate with air cleaner/silencer removed.

A sudden flash fire can cause severe injury or death.Do not smoke or permit flame or spark to occur near fuelsystem. Keep the compartment and generator set cleanand free of debris to minimize chances of fire. Wipe upall spilled fuel and engine oil.

HAZARDOUS NOISE

CAUTION

Hazardous noise.Can cause loss of hearing.Never operate generator without a muffler or withfaulty exhaust system.

TP-5695 12/93 Safety Precautions and Instructions vii

NOTESNOTE

HARDWARE DAMAGE! Engine and generator maymake use of both American Standard and metrichardware. Be sure to use the correct size tools toprevent rounding of bolt heads and nuts.

NOTE

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

NOTE

When replacing hardware, do not substitute withinferior grade hardware. Screws and nuts areavailable in different hardness ratings. AmericanStandard hardware uses a series of markings andmetric hardware uses a numeric system to indicatehardness. Check markings on bolt head and nuts forproper identification.

NOTE

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

NOTE

High-mineral content sea water (salt water) can causerapid destruction of all metals. Wipe up all salt waterspillage on and around generator set and keep metalsurfaces free from accumulated salt deposits.

NOTICEThis generator set has been rewired from itsnameplate voltage to:

246242

NOTICEThis is a positive terminal only.Do not attach negative lead!

NOTICECheck zinc anode every 100 hours or 3 months.

NOTICE

Do not use as a step.

Standing on genset could impair operation of unit.

NOTE

Split lock washers may be supplied with some kits. Ifsplit lock washers are supplied with kit, their use isoptional.

TP-5695 12/93viii Reference Material

Reference MaterialIt is recommended that the following Regulations andStandards be followed when installing MarineGenerator Sets.

Pleasure CraftDesigned and manufactured to meet U.S. Coast GuardTitle 33.

U.S. Coast Guard Code of Federal RegulationsTitle 33Subparts I--Electrical SystemsSubparts J--Fuel Systems

Title 46Subchapter F--Marine Engineering

Part 58--Main and Auxiliary Machinery and RelatedSystems

Order the above publications from:Superintendent of DocumentsU.S. Government Printing OfficeWashington, DC 204021-202-783-3238

Boating Safety Circular Commandant (G-BC)Boating Statistics (G-BP-1)

U.S. Coast Guard Headquarters2100 Second Street, S.W.Washington, DC 20593-0001Boating Safety Hotline: 1-800-368-5647

American Bureau of Shipping“Rules for Building and Classing Steel Vessels”45 Eisenhower DriveParamus, N.J. 07652201-368-9100

Lloyds Registry of Shipping“Rules for Classification of Ships”17 Battery PlaceNew York, N.Y. 10004212-425-8050

Underwriters Laboratories, Inc. (UL)Publications Stock333 Pfingsten RoadNorthbrook, IL 60062Marine Department: 1-919-549-1400

NFPA 302National Fire Protection Association60 Batterymarch ParkQuincy, MA 02269

Customer ServiceSociety of Automotive Engineer’s (SAE)400 Commonwealth DriveWarrendale, PA 150961-412-776-4970

American Boat and Yacht Council, Inc. (ABYC)3069 Solomon’s Island Rd.Edgewater, MD 210371-410-956-10501-410-974-81121-410-956-2737 FAX

IEEE 45The Institute of Electrical andElectronics Engineer’s Inc.345 East 47th StreetNew York, NY 10017

TP-5695 12/93 Reference Material ix

Commercial VesselsIn order to use these generator sets for commercialapplications where U.S. Coast Guard Title 46 Certificateis required, additional modifications will be necessary.

U.S. Coast Guard Code of Federal RegulationsTitle 46Subchapter F--Marine Engineering

Part 58--Main and Auxiliary Machinery and RelatedSystems

Subchapter J--Electrical EngineeringPart 111--Electrical Systems--General RequirementsPart 112--Emergency Lighting and Power Systems

Subchapter T--Small Passenger Vessels(Under 100 Gross Tons)Part 182--Machinery InstallationPart 183--Electrical Installation

Order the above publications from:Superintendent of DocumentsU.S. Government Printing OfficeWashington, DC 204021-202-783-3238

American Bureau of Shipping (ABS)65 BroadwayNew York, NY 10006

Order ABS publications from:

American Bureau of ShippingBook Order Section45 Eisenhower DriveP.O. Box 910Paramus, NJ 97653-0910

Lloyd’s Register of Shipping71 Fenchurch StreetLondon, EC3M 4BS England

Midwest Office:Lloyd’s Register of Shipping100 South York Street, Room 226Elmhurst, IL 601261-312-279-5414

Additional ReferencesThe following organizations provide a service whichmay be useful to the generator set installer. Theseorganizations are not regulatory in nature but ratherprovide guidelines and assistance. They are listed onlyas a source for additional information. No solicitation orrepresentation is hereby given.

Yacht Corrosion Consultants, Inc.2970 Seaborg Ave.Ventura, CA 930031-805-644-1886

Ward’s Marine Electric, Inc.630 S.W. Flagler Ave.Ft. Lauderdale, FL 333011-305-523-28151-800-545-92731-305-523-1967 FAX

x Routine Service Parts TP-5695 12/93

Routine Service PartsContact your Kohler generator dealer/distributor for acomplete listing of service parts for your generator set.

Part Description Kohler Part No.Engine:

Air Filter 278612Oil Filter 267714Belt, Timing 267722

Ignition System:Spark Plug 267713

Sea Water Pump Impeller 229826Zinc Anode 267928White Spray Paint 221318

TP-5695 12/93 Glossary of Abbreviations xi

Glossary of AbbreviationsAbbreviations are used throughout this manual. Normally in the text they will appear in complete form with theabbreviation 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 DescriptionAC alternating currentAHWT anticipatory high water temp.ALOP anticipatory low oil pressureAM amplitude modulationAmp ampereAmps amperesANSI American National Standard InstituteAPI American Petroleum Instituteapprox. approximate, approximatelyA/R as required, as requestedA/S as supplied, as stated, as suggestedASA American Standards Associationassy. assemblyASTM American Society for Testing MaterialsATDC after top dead centerATS automatic transfer switchaux. auxiliaryAWG American Wire GaugeAWM appliance wiring materialbhp brake horsepowerbmep brake mean effective powerBtu British thermal unit°C Celsius degreecc cubic centimeterCCA cold cranking Amps.CEC Canadian Electrical Codecfh cubic feet per hourcfm cubic feet per minuteCID cubic inch displacementcm centimeter, centimeterscmm cubic meters per minuteco. companycont’d. continuedC.S.A. Canadian Standards Associationcu. in. cubic inch, cubic inchescyl. cylinderdBA decibelsDC direct currentDCR direct current resistancedeg. degreedept. departmentdia. diametere.g. example givenEMI electromagnetic interferenceetc. etcetera, (and so forth)ext. external°F Fahrenheit degreefl. oz. fluid ounce, fluid ounces

Abbreviation DescriptionFM frequency modulationfs full scaleft. foot, feetft. lbs. foot pound, foot poundsga. gaugegal., gals. gallon, gallonsgal./hr. gallons per hourgph gallons per hourgpm gallons per minutegr. gradegrd. groundHCHT high cylinder head temperatureHET high exhaust temperatureHg mercury (element)H2O waterhp horsepowerhr, hrs hourHWT high water temperatureHz hertz (cycles per second)ID inside diameterin. inch(es)inc. incorporatedin. lbs. inch poundsint. internalint.-ext. internal-externalISO International Standards OrganizationJ joule, joulesJIS Japanese Industry Standardkg kilogram, kilogramskg/cm2 kilograms per square centimeterkgm kilogram meter(s)km kilometer, kilometerskPa kiloPascal, kiloPascalskph kilometers per hourkV kilovoltkVA kilovolt ampereskW kilowatt, kilowattskWH kilowatt hourL liter, litersLxWxH length x width x heightLED, LEDs light emitting diodelb., lbs. pound, poundsL/hr. liter per hour, liters per hourL/min. liter(s) per minutesLOP low oil pressureLP liquefied petroleumLWT low water temperaturem meter, meters

xii Glossary of Abbreviations TP-5695 12/93

Abbreviation Descriptionm3 cubic meter, cubic metersmax. maximumMCM one thousand circular mils.mi. mile, milesmil one one-thousandth of an inchmin. minimummJ millijoule, millijoulesMJ mega joule, mega joulesmm millimeter, millimetersm3/min cubic meters per minuteMPa megaPascalmph miles per hourMS military standardmW milliwatt, milliwattsMW megawatt, megawattsN/A not availableNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection AssociationNm Newton meter, Newton metersno., nos. number, numbersNPT National Standard taper pipe

thread per general useN/R not requiredOC overcrankOD outside diameterOEM original equipment manufacturerOS overspeed, oversizeOV overvoltageoz. ounce, ounces

Abbreviation DescriptionPF power factorpot. potentiometerppm parts per millionpsi pounds per square inchpt., pts. pint, pintsqt., qts. quart, quartsqty. quantityref. referenceRFI radio frequency interferencerms root mean squarerpm revolutions per inchSAE Society of Automotive Engineerssec. second, secondsSCR silicon controlled rectifierspec, specs specificationsq. squaresq. cm square centimeterssq. in. square inch, square inchestach tachometerTDC top dead centertemp. temperatureTIF telephone influence factorturbo turbochargerUNC Unified coarse thread (was NC)UNF Unified fine thread (was NF)UL Underwriter’s Laboratories, Inc.US undersizeV volt, voltsVAC Volts alternating currentVDC volts direct currentW watt, watts

TP-5695 12/93 Specifications 1-1

Section 1. Specifications

IntroductionThe 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-phasealternating current marine generator set. Servicerequirements are minimal but are very important to thesafe and efficient operation of the generator set;therefore, inspect associated parts often. It isrecommended that an authorized service

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

Please take a few moments to read this manual, thencarefully follow all service recommendations to keep theset in top condition. Keep this manual aboard the craftfor future reference. See Figure 1-1 for identificationand location of components.

Specifications

General Specifications3.5CFZ 5CFZ

Dimensions--L x W x H--in. (mm) 27.87 x 17.50 x 16.60(708 x 445 x 422)

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

with Sound Shield 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)

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.)Load25% 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 6.5CZDimensions--L x W x H --in. (mm) 27.87 x 17.50 x 16.60

(708 x 445 x 422)31.07 x 18.10 x 17.50

(789 x 460 x 445)with Sound Shield 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)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.)Load25% 0.48 (1.81) 0.53 (2.00)50% 0.55 (2.08) 0.62 (2.34)75% 0.62 (2.34) 0.86 (3.25)100% 0.68 (2.57) 1.02 (3.86)

TP-5695 12/931-2 Specifications

Generator3.5CFZ 5CFZ

Rated kW 3.5 5Frequency--Hz 50 50Rated Voltage 110 Volt, 2&3 Wire, Single Phase or 110/220 Volt, 3 Wire, Single PhaseRated Amps (110 Volt) 31.8 45.5Rated Amps (220 Volt) 15.9 22.7Rotor Resistance (cold) (ohms) 4--5 4--5Stator Resistance (cold) (ohms)*Leads:1--2, 3--4 0.8 0.855--66 4.2 4.2B1--B2 0.08 0.08

4CZ 6.5CZRated kW 4 6.5Frequency--Hz 60 60Rated Voltage 120 Volt, 2&3 Wire, Single Phase or 120/240 Volt, 3 Wire, Single PhaseRated Amps (120 Volt) 33.3 54.2Rated Amps (240 Volt) 16.7 27.1Rotor Resistance (cold) (ohms) 3--4 4--5Stator Resistance (cold) (ohms)*Leads:1--2, 3--4 0.06 0.0455--66 1.9 2.4B1--B2 0.09 0.06

3.5CFZ/4CZ 5CFZ/6.5CZGenerator Type Two-Pole, Rotating FieldVoltage Regulation ±5%Frequency Regulation ±5%Angular Operation (Max.)(in all directions) 20°Continuous

Excitation Method Brushless, Exciter Winding/CapacitorCoupling Type Tapered Shaft--Thru-BoltStator Bolt Torque in. lbs. (Nm) 260 (29)Thru-Bolt Torque ft. lbs. (Nm) 37 (50)Number of Output Leads 4, ReconnectableInsulation (Rotor and Stator) Class F, Epoxy Varnish, Vacuum ImpregnatedWinding Material CopperBearing, Number and Type 1, Replaceable BallCircuit Protection:Controller Replaceable 10-Amp FuseBattery Charging Replaceable 10-Amp FuseAC Circuit Breakers Optional* Most ohmmeters will not give accurate readings when measuring less than 1 ohm. The stator can beconsidered good if a low resistance reading (continuity) is obtained and there is no evidence of shortedwindings (discoloration). Do not confuse a low resistance reading with a reading indicating a shorted winding.


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

3.5CFZ, 50 Hz: 3.5 kW at 77°F (25°C) and 3.5 kW at 122°F (50°C).

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

5CFZ, 50 Hz: 5 kW at 77°F (25°C) and 4.85 kW at 122°F (50°C).

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

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

3.5CFZ/4CZ 5CFZ/6.5CZManufacturer HondaModel GX360EVCycle 4Number Cylinders 2Compression Ratio 8:5:1Displacement--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 AluminumCylinder Head Cover TighteningTorque--ft. lbs. (Nm)

7(10)

Cylinder Head Material AluminumConnecting Rod Material SteelPiston Rings 2 Compression/1 Oil ControlCrankshaft Bearings Replaceable InsertsGovernor Gear-Driven CentrifugalLubrication System PressureOil Capacity (with filter)--U.S. qts. (L) 1.48 (1.4)Oil Type (API) SF, SF/CC, or SF/CDOil Pressure--psi (kPa) 30--50 (207--345)Fuel Type Gasoline, 86 or Higher, Octane UnleadedFuel System Single-Barrel, Horizontal CarburetorCarburetor Choke Automatic, ElectricFuel Pump ElectricFuel Pump Lift (max.) 3 ft. (0.9 m)Battery Voltage 12Battery Ground NegativeBattery Recommendation 250 Cold Cranking Amps (Min.)


Engine (Continued)3.5CFZ/4CZ 5CFZ/6.5CZ

Spark Plug Type Resistor, Radio Suppression, 14 mmBPR4HS (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)

15--22 (20--30)

Ignition System Transistorized, BreakerlessStarter Motor Bendix Automotive TypeCooling System Water-Cooled, Closed/Heat ExchangerCooling 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--2Ignition Timing B.T.D.C. 24°±2 degreesExhaust Manifold to CylinderHead Torque

16 ft. lbs. (22 Nm)

Water Pump Assembly toCylinder Block Torque

7 ft. lbs. (10 Nm)

Cooling Fan Torque 16 ft. lbs. (22 Nm)Air Cleaner Elbow to CarburetorStud Torque

6 ft. lbs. (8.5 Nm)

Timing Belt Cover Torque 6 ft. lbs. (8 Nm)Governor Arm Shaft Nut Torque 7 ft. lbs. (10 Nm)Governor Case to Cylinder HeadTorque

7 ft. lbs. (10 Nm)

Fuel Pump Pressure Rating 2.0--3.5 psi (13.8--24.1 kPa)Battery Charging WindingResistance--10 Amp

0.16--0.24 Ohms

Ignition Coil Primary WireResistance

0.9--1.1 Ohms

Ignition Coil Secondary(Spark Plug Wire Side) Resistance

0.9--1.1 Ohms(With Spark Plug Boot/Cap Removed)

Transistorized Ignition Air Gap 0.016 ±0.008 in. (0.4 ±0.2 mm)Timing Belt Deflection 0.16--0.20 in. (4.5 mm) @ 4.4 lbs. (2 kg)


Accessories

Several accessories are available to finalize theinstallation or to add convenience to operation andservice. All the most current information can be obtainedby contacting the local authorized Kohlerdealer/distributor. Available accessories at the time ofprint of this publication are as follows.

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

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

Seawater Strainer

The seawater strainer with clear viewing container,allows easy cleaning and maintenance. Threaded for1/2 NPT fittings.

Ship-to-Shore Transfer Switch

The ship-to-shore transfer switch allows immediateswitching to generator set power or shore powerprotecting the electrical system from the possibility ofsimultaneous connection of both power sources.

Remote Start Panel

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

Sender Kit

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

Circuit Breakers

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

Model Amps Poles4CZ/3.5CFZ 18 24CZ/3.5CFZ 35 14CZ/3.5CFZ 20 16CZ/5CFZ 30 26CZ/5CFZ 55 16CZ/5CFZ 25 26CZ/5CFZ 20 1

Remote Start andFour-Meter Panel Kit

Allows starting/stopping from a location remote of thegenerator set. The illuminated meters/gauges include aDC voltmeter, engine oil pressure gauge, watertemperature gauge, and an hourmeter which recordstotal generator set operating hours. Overall dimensionsare 9 in. (229 mm) by 6 in. (152 mm) with a minimummounting depth of 4 in. (102 mm). Requires remoteconnection/extension harness and sender kit.

Remote Start andTwo-Meter Panel Kit

Allows starting/stopping from a location remote of thegenerator set. The illuminated gauges include engine oilpressure gauge and water temperature gauge. Overalldimensions are 6 in. (152 mm) by 6 in. (152 mm) with aminimum mounting depth of 2 3/4 in. (70 mm). Requiresremote connection/extension harness and sender kit.

Remote Connection/Extension Harness

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

12-Inch Remote Wiring HarnessThis one foot (0.3 m) wiring harness has a 6-pinconnector on one end which is keyed to controller boxconnector. The other end has pigtails for connection tocustomer-supplied start switch, generator “on” light,hourmeter, etc.

Siphon BreakPrevents the siphoning of water into the engine ongenerator sets installed below the waterline.


Service Views

TOTAL HOURS00 0

E

00 1/10

10AFUSE

BATT.CHRG.

INPUT

2

9

45

36

35

30

29 28 27 26 25 24 23

21

19

33

258000-D

1

34

STOP START

10 1716131211 1431 15

18

20

67

8

32

3

22

Figure 1-1. Service Views (typical)1. Mixer Elbow (Exhaust Water Outlet)2. Belt Guard3. Electric Choke Rotary Solenoid4. Carburetor5. Governor Linkage6. Governor Arm7. Lifting Eye8. Speed Adjustment (Idle Speed)9. Antidieseling Solenoid

10. Controller11. Battery Charger Voltage Regulator12. Coolant Overflow Hose13. Cooling System Pressure Cap14. High Water Temperature Safety Shutdown

Switch15. Thermostat16. High Exhaust Temperature Shutdown

Switches (2)17. Spark Plugs18. Seawater Pump

19. Oil Drain20. Water Temperature Sender (Optional)21. Heat Exchanger22. Ignition Coil/Module23. Low Oil Pressure Shutdown Switch/Sender

(Sender Optional)24. Oil Dipstick (Oil Check/Oil Fill)25. Oil Filter26. Anticorrosion Zinc27. Electric Fuel Pump28. Remote Panel Connector29. Positive Battery Lead Connection30. Coolant Recovery Tank31. Air Filter32. Nameplate33. Negative Battery Lead Connection34. Equipment Ground Lug35. Starter Solenoid36. Starter Motor

TP-5695 12/93 Operation 2-1

Section 2. OperationPrestart Checks

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

BACKFIRE FLAME ARRESTOR: Air cleaner must beclean and properly installed to prevent unfiltered air fromentering engine. See Maintenance--Air Cleaner.

BATTERY: Remove caps and check the electrolytelevel of each cell (batteries with filler caps only); adddistilled water if necessary. Check to make sure it isconnected correctly. Battery installation andconnections must meet Coast Guard Standards.Battery should be serviced by authorized personnelonly. See Maintenance--Battery.

COMPARTMENT: Keep the engine room orcompartment clean and dry. Check for fuel or oil leaks.Check the condition of fuel system, exhaust piping,hoses, and muffler; have any faulty componentsrepaired before getting underway. Open hatch to air outcompartment and use “ignition-protected” bilgeblowers, if required, to clear fumes from area beforeeach start-up. If fuel leaks, fumes, exhaust gases, orelectrical sparks are noted, arrange for qualifiedpersonnel to make necessary repairs before operatinggenerator set.

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

OIL LEVEL: Should be at or near Max. mark. Add oil asneeded to bring level up to this range. See MaintenanceLubrication System.

COOLING: The coolant level on closed-type heatexchanger systems can be checked using the coolantrecovery tank, if used. The MIN mark indicates full whencold and the MAX mark indicates full when hot. Maintainthe coolant level between these marks. It isrecommended that coolant level on closed systems beperiodically checked by removing pressure cap. Do notsolely rely on level in coolant recovery tank.

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

SEAWATER PUMP PRIMING: The seawater pumpmust be primed before initial start-up. To prime pump,close seacock and remove the hose from water filteroutlet. Fill hose and pump with clean water. Replacehose and open seacock. Check for pump operating onstart-up by observing water discharge from exhaustoutlet.

TP-5695 12/932-2 Operation

ControllerFor identification and location of controller operatingfeatures, refer to the text below and Figure 2-1.

1. Battery Charging Fuse protects battery chargingcircuitry from short circuits.

2. Input (Controller) Fuse protects controllercircuitry from short circuits.

3. Start/Stop Switch is used to stop and startgenerator set. Rock to start or stop position andhold to start or stop engine. Switch automaticallyreturns to neutral center position when released.

4. Hourmeter records total generator set operatinghours. Use as a reference to schedulemaintenance.

5. Remote Start Connector provides connectionpoint for optional remote start kits.

6. Optional AC Circuit Breaker(s) protectsgenerator set from short circuits in load. Also usedto disconnect generator set from loads duringmaintenance. To close circuit breaker, place in ONposition.

1

3

5

2

46

1. Battery Charging Fuse2. Input (Controller) Fuse3. Start/Stop Switch

4. Hourmeter5. Remote Start Connector6. Optional AC Circuit

Breaker(s)

A-246486-D

Figure 2-1. Controller


Starting

WARNING


NOTEFor reliable starting, allow at least 30 seconds aftershutdown before restarting a hot engine.

Ensure that the manual fuel shutoff valve (if equipped) isopen. Then rock the master Start/Stop Switch oncontroller (or use Start/Stop Switch on remote panel) tothe Start position for a maximum of 7 seconds or until theengine starts.

NOTEDo not crank the engine continuously for more than 7seconds at a time. Allow a 5-second period betweenstarting attempts if the engine does not start. If theengine fails to start after three attempts, contact anauthorized Kohler dealer/distributor for repair. Failure tofollow these guidelines may result in burn-out of thestarter motor from overheating.

If the engine fails to start after the first attempt, close theseacock before a second start-up attempt. This actionwill help prevent seawater from entering the enginecylinders through the exhaust valve. Once the enginestarts, the seacock must be re-opened to allow passageof cooling water.

NOTE

Failure to open the seacock after the generator set isrunning will result in serious engine damage due tooverheating.

NOTE

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

Stopping

Disconnect the load from the generator set and allow thegenerator set to run at no-load for 5 minutes to cooldown the engine. Then rock the master Start/Stopswitch on the controller (or the Start/Stop Switch on aremote panel) to the Stop position and hold it in the Stopposition until the generator set comes to a completestop.

NOTE

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


Circuit Protection

AC Circuit Breaker (Optional)The optional AC circuit breaker(s) located on the frontpanel of the controller protect the generator outputwindings. If a load circuit loses power, the cause may bea tripped AC circuit breaker. If a tripped circuit breaker isreset and then trips again, find and correct the short inthe load circuit that is causing the problem.

Input (Controller) Fuse (10 Amp)The input fuse protects the controller circuitry. If thegenerator set engine will not crank and the battery andbattery connections appear okay, the input fuse may beblown. If this fuse, located on the front panel of thecontroller, is replaced and then blows again, find andcorrect the short that is causing the problem.

Battery-Charging Fuse (10 Amp)The battery-charging fuse protects the battery-chargingcircuit. If the battery goes dead and the battery andbattery-charging alternator are otherwise normal, thebattery-charging fuse may be blown. If this fuse, locatedon the front panel of the controller, is replaced and blowsagain, find and correct the short in the charging circuitthat is causing the problem.

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

WARNING


Accidental starting can cause severe injury ordeath. Disconnect battery cables (remove negativelead first and reconnect it last) to disable generator set

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

Engine SafetyShutdown Switches

The engine is protected by three engine safetyshutdown switches. Activating any of these switcheswhile the generator set is running, results in animmediate, automatic shutdown. During start-up, theengine safety shutdown feature is inhibited until agenerator output is sensed in order to allow the oil pumpoutput to reach normal operating pressure.

Low Oil Pressure Shutdown SwitchThe low oil pressure shutdown switch protects theengine against internal damage, if the oil pressure dropsbelow 20 psi (138 kPa), due to an engine oil pump failureor other engine malfunction. The location of the low oilpressure shutdown switch is shown in Figure 2-2.

NOTEThe low oil pressure shutdown switch does not act as alow oil level switch. The only way to protect againstengine damage due to low oil level is to check the oillevel regularly.

1

258000-D

1. Low Oil Pressure Shutdown Switch

Figure 2-2. Low Oil Pressure Shutdown Switch


High Water TemperatureShutdown Switch

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

TOTAL HOURS00 000 1/10

10AFUSE

STARTSTOP

BATT.CHRG.

INPUT

258000-D

1 (hidden)

1. High Water Temperature Shutdown Switch

Figure 2-3. High Water TemperatureShutdown Switch

High Exhaust TemperatureShutdown Switches

The two high exhaust temperature shutdown switchesprotect the engine against internal damage due toexcessive exhaust temperatures. The switches are setat 210--220°F (99--105°C). The locations of the highexhaust temperature shutdown switches are shown inFigure 2-4.


10AFUSE

STARTSTOP

BATT.CHRG.

INPUT

258000-D

1

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

Figure 2-4. High Exhaust TemperatureShutdown Switches


Remote Panels (Optional)

Remote Start PanelRemote start panel allows starting-stopping from alocation remote of the generator set. Generator sets areequipped with a 6-pin connector on controller bottom forconnection of the kit. See Figure 2-5.

2

1

1. “ON”Light 2. Start/Stop Switch1-656

KOHLERGENERATOR

START

STOP

Figure 2-5. Remote Panel Features

Remote Start andTwo-Meter Panel Kit

Allows starting-stopping from a location remote of thegenerator set. The illuminated gauges include anengine oil pressure gauge and a water temperaturegauge. Generator sets come equipped with a 6-pinconnector on controller bottom for connection of the kit.See Figure 2-6 for remote start and meter panel kit.

1

2

4 3

1. Engine Oil Pressure2. Water Temperature

3. Start/Stop Switch4. “On”Light

1-762

Figure 2-6. Remote Start and Two-MeterPanel 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 oilpressure. Normal engine operating range is 30--50 psi(207--345 kPa).

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

Water Temperature Gauge measures engine coolanttemperature. Normal engine operating range is170--195_F (77--91_C).


Remote Start and Four-MeterPanel Kit

Allows starting-stopping from a location remote of thegenerator set. The illuminated gauges include a DCvoltmeter, engine oil pressure gauge, watertemperature gauge, and generator running timehourmeter. Generator sets come equipped with a 6-pinconnector on controller bottom for connection of the kit.See Figure 2-7 for remote start and four-meter panelfeatures.

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

DC Voltmeter measures voltage of starting battery(ies).Normal battery operating range is 12--14 volts.

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

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

Water Temperature Gauge measures engine coolanttemperature. Normal engine operating range is170--195_F (77--91_C).

Hourmeter records total generator set operating hoursfor reference in maintenance scheduling.

1 2

6

53

4

1. Engine Oil Pressure2. Hourmeter3. Voltmeter

4. Water Temperature5. Start/Stop Switch6. “ON”Light

1-830

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

TP-5695 12/93 Scheduled Maintenance 3-1

Section 3. Scheduled MaintenanceUse the following service schedule and the hourmeteron the controller to schedule routine maintenance. Inaddition to the routine services listed in this manual,there are other important steps that should be taken tokeep a generator set in top condition. Usually tools andinstruments required for these additional steps are notavailable to the generator set owner. For this reason, theset should be returned periodically to an authorizedservice dealer/distributor for complete servicing andtune-up. The benefits of such service will be improvedperformance and continuous satisfactory operationduring a long trouble-free service life. Use the OperatingHour Service Log in the back of this manual to documentservices performed.

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

For continued satisfactory operation and longevity of theengine and generator set, proper maintenance andeventual overhaul by a competent mechanic/technicianare essential. While it is not possible to anticipatecomponent failure, rough operation, metallic noises,and excessive oil loss are among the indicators ofpotential problems. Do not ignore these conditions!

NOTEOperate the generator set with load applied at leastonce a month. Allow generator set to run about one hourto reach operating temperature. This prevents theformation of corrosion on internal engine componentswhen exposed to the breakdown of exhaust gases andseawater for long periods of generator inactivity. If unit isto be out of service for several months, see StorageProcedure.

WARNING



NOTEHARDWARE DAMAGE! Engine and generator makeuse of both American Standard and metric hardware. Besure to use the correct size tools to prevent rounding ofbolt heads and nuts.

NOTEHigh-mineral content seawater (salt water) can causerapid destruction of metals. Wipe up all salt waterspillage on and around generator set and keep metalsurfaces free from accumulated salt deposits.

TP-5695 12/933-2 Scheduled Maintenance

Service Schedule

BeforeStarting

After 20Hrs. or

OneMonth

Every 50Hrs. or 3Months

Every100 Hrs.

or 6Months

Every200 Hrs.or Yearly

Every300 Hrs.

or 2 YearsLUBRICATION SYSTEMCheck oil level X

Change oil X (Break-inPeriod) X

Change oil filter XFUEL SYSTEMCheck the fuel level XFill fuel tank XLubricate carburetor and chokelinkage

X (Break-inPeriod) X

Clean fuel screen XService fuel lines XIGNITION SYSTEMReplace spark plugs XCOOLING SYSTEMCheck coolant level X

Check seawater outlet X (DuringOperation)

Inspect exhaust systemcomponents for cracks andcorrosion (exhaust manifold,mixing elbow, exhaust line,hose clamps, silencer, andoutlet flapper)

X X

Check function of siphon break(if equipped) X

Check condition of heatexchanger anticorrosion zinc

X (100 Hrs.or 3

Months)Replace heat exchangeranticorrosion zinc X

Replace the impeller ofseawater pump X

Check thermostat function XINTAKE/EXHAUST SYSTEM

Check exhaust gas condition X (DuringOperation)

Clean the exhaust/water mixingelbow X

Clean air filter element X


Service Schedule (Continued)

BeforeStarting

After 20Hrs. or

OneMonth

Every 50Hrs. or 3Months

Every100 Hrs.

or 6Months

Every200 Hrs.or Yearly

Every300 Hrs.

or 2 YearsELECTRICAL SYSTEMCheck electrolyte level(Batteries with filler caps only) X X

Check and tighten electricalconnections X

Check specific gravity(Batteries with filler caps only) X

Clean battery cables XENGINE AND MOUNTINGCheck for leakage of water, fuel,or oil X X

Lubricate governor linkage X (Break-inPeriod) X

Retighten all major nuts andbolts

X (Break-inPeriod) X

Check and tighten mountingbolts and vibromounts X

Check intake/exhaustvalve clearance X

REMOTE CONTROL SYSTEM,ETC.Check compartment condition(fuel, oil, or water leaks) X

Check the remote controloperation

X (Break-inPeriod)

Test run generator set X(Monthly)

GENERATORBlow dust out of generator X


Lubrication SystemSpecifications

Use high quality detergent oil of API (AmericanPetroleum Institute) service class SF, SF/CC, or SF/CD.This information can be found on most oil containers,see Figure 3-1. The symbol illustrated identifies the APIservice class in the upper portion. The center indicatesthe SAE (Society of Automotive Engineers) viscositygrade. The bottom portion (when used) signifies the oilis intended to improve fuel economy and displays thephrase “Energy Conserving.”Select viscosity based onthe air temperature at the time of operation. (SeeFigure 3-2.)

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

1--792

Figure 3-1. Oil Service Class andSAE Viscosity Grade Symbol

When Outside Temperatureis Consistently:

Use SAEViscosity Grade:

Below 5_F (--15_C) 5W30--5_F (--21_C) to90_F (32_C) 10W30

Above 15_F (--10_C) 20W40 or 20W50Above --5_F (--21_C) 10W40 (Preferred)

Figure 3-2. Recommended SAEViscosity Grades

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

Do not mix oils of different viscosities. It is also best notto mix different brands of oils. Possible incompatibilitycould cause a breakdown of lubricating ingredients andreduce engine protection.

Oil Check

Check oil level in crankcase daily or before each startupto insure that the level is in the safe range.

NOTEDo not check oil level when unit is running. Generatorset must be stopped and level to get an accuratereading.

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

To check oil level, remove dipstick and wipe the endclean, place bottom thread of dipstick against oil fill holeand remove. Do not screw in dipstick when checking oillevel. Level should be between MIN and MAX marks ondipstick. See Figure 3-3.

NOTEDo not operate the set if the level is below the MIN markor above the MAX mark. Oil above the MAX mark iswasted due to increased oil consumption.

1 2

3

1. MAX Limit2. MIN Limit

3. Safe Range

1-826

Figure 3-3. Checking Oil Level


Adding OilIt is normal to add some oil between oil changes. Theamount will vary with the usage. Open fill cap and pour asmall amount of oil using a funnel or other suitablepouring device. See Figure 3-4. Wait a few minutes andcheck level. If necessary, add more oil and then checkagain. Each time be sure to add small quantities andcheck to prevent overfilling.

1-826

Figure 3-4. Adding Oil

Oil Change/Oil Filter ChangeChange oil and oil filter every 200 hours or yearly.Change oil more frequently under dirty, dustyconditions. Change oil while the engine is still warm. SeeFigure 3-5 and use the following procedure.


10AFUSE

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BATT.CHRG.

INPUT

1

258000-D1. Oil Drain Cap

Figure 3-5. Oil Drain Cap

1. Place oil drain hose in a proper container. Removeoil drain cap. If a drain pump is used, remove oildrain cap and connect oil drain hose to drain pump.

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

3. Loosen oil filter by turning in a counterclockwisedirection. Oil filter is 2 1/2 in. (64 mm) dia. with 14flutes. Use oil filter wrench, if necessary. SeeFigure 3-6. Use rags to handle hot oil filter andclean up spilled oil. Remove filter from oil filteradapter on engine and discard oil filter in a propercontainer.

4. Clean contact surface of oil filter adapter.

5. Lightly lubricate the gasket surface of new oil filterwith fresh engine oil. Thread oil filter onto oil filteradapter until gasket makes contact; thenhand-tighten oil filter an additional 3/4 turn.

NOTE

If an automatic oil drain/oil fill pump is used, omitStep 6. Fill with proper amount and type of oil, seeStep 6. When complete, replace cap anddisconnect pump.

6. Replace oil drain cap. Remove oil fill cap. Add oilusing a funnel or other suitable pouring device. SeeSpecifications— Engine for oil capacity andLubrication System— Specifications for properservice class and SAE viscosity of oil. Replace oilfill cap.

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

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


11-826

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

Figure 3-6. Removing Oil Filter

Fuel SystemSpecifications

For best results, use only clean fresh, regular gradeunleaded gasoline. Use fuel with a minimum octanerating as designated by the following:Antiknock Index (Average of Research 86Octane Number and Motor Octane Number)Unleaded fuel is recommended since it leaves lesscombustion chamber deposits. Oil must not be mixedwith fuel.If using a gasoline containing alcohol (gasohol), be surethe octane rating is at least 86 (Antiknock Index). Thereare two types of gasohol: one containing ethanol, andanother 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 containcosolvents and corrosion inhibitors for methanol. Neveruse gasoline containing more than 5% methanol, even ifit has cosolvents and corrosion inhibitors.

NOTEFuel system damage and engine performanceproblems resulting from the use of such fuels are notcovered under Warranty. Honda cannot endorse the useof fuels containing methanol since evidence of suitabilityis as yet incomplete. Before purchasing fuel from anunfamiliar station, try to confirm whether the fuelcontains alcohol, and to what percentage. If anyundesirable operating symptoms are noticed after usinga gasoline that contains alcohol, or one that containsalcohol, switch to a gasoline that does not containalcohol.

NOTEDiscontinue use of any gasohol or alcohol/gasolineblend if engine performance or fuel system problemsoccur. Do not use such fuel unless it is UNLEADED.

Use fresh gasoline to ensure it is blended for the seasonand to prevent the formation of gum deposits whichcould clog the fuel system. Do not use gasoline left overfrom the previous season.


Fuel Pump Screen

WARNING



Explosive fuel vapors can cause severe injury ordeath. All fuels are highly explosive in a vapor state. Useextreme care when handling, storing, and using fuels.Store fuel in a well-ventilated area away fromspark-producing equipment and out of the reach ofchildren. Never add fuel to the tank while the engine isrunning since spilled fuel may ignite on contact with hotparts or from ignition spark. Do not smoke or permitflame or spark to occur near potential sources of spilledfuel or fuel vapors. Keep fuel lines and connections tightand in good condition— don’t replace flexible fuel lineswith rigid lines. Flexible sections are used to avoidbreakage due to vibration. Should any fuel leakage, fuelaccumulation, or electrical sparks be noted, DO NOTOPERATE GENERATOR SET. Have systems repairedbefore resuming generator operation.

Gasoline— Store gasoline only in approved redcontainers clearly marked GASOLINE. Do not storegasoline in any occupied building.

The electric fuel pump includes a screen. (SeeFigure 3-7.) At the recommended interval or whenclogging is suspected, inspect and clean the screen asfollows:

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

2. Disconnect fuel lines from electric fuel pump,draining fuel from the lines and pump into a suitablecontainer to prevent spillage into the bilge.

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

4. Remove the three mounting studs from the electricfuel pump.

5. Remove the cover plate and inspect the screen.Remove any debris or residue. Be sure the screenis intact. If the screen is damaged, replace the fuelpump.

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

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

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

9. Reconnect the fuel lines to the fuel pump.

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

258000-D

2 (enclosed)

1. Harness Plug 2. Fuel Pump Screen

1

Figure 3-7. Fuel Pump Screen


Carburetor/Choke Lubrication

The only maintenance required is to lubricate carburetorand choke linkage at the specified interval using whitelithium grease or lubriplate.

Carburetor Adjustments

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

Lack of power usually indicates that the fuel mixture istoo rich. An overrich mixture may also be caused by aclogged air intake (backfire flame arrestor)— check thisbefore readjusting carburetor. Fuel mixture may be toolean if engine skips or backfires. Minor carburetoradjustment may be necessary to compensate fordifferences in altitude, fuel, and temperature.

1. With ENGINE STOPPED, turn fuel mixture screwin (clockwise) until it seats lightly. DO NOTFORCE! Turn fuel mixture screw out 2 to2 1/2 turns. See Figure 3-8.

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

3. Turn low speed mixture screw in until engineinstability (hunting) develops and then screw outuntil engine instability is again apparent. Turnscrew back in until it is positioned halfway betweenthe points of increasing stability. When properlyadjusted, engine will operate with steady governoraction.

4. To adjust the idle speed, run the generator set at noload. Push the throttle lever counterclockwise untilit hits the idle speed screw. Holding the throttlelever against the screw, adjust the idle speed screwuntil unit runs at 55 Hz (3300 rpm) for 60 Hz modelsor 45 Hz (2700 rpm) for 50 Hz models.

NOTE

If engine runs poorly after adjusting carburetor anddoing scheduled maintenance, return generatorset to an authorized service dealer/distributor tohave problem corrected.

WARNING

Fire.Can cause severe injury or death.

Do not smoke or permit flame or spark to occurnear fuel or fuel system.

A sudden flash fire can cause severe injury or death.Do not smoke or permit flame or spark to occur near fuelsystem. Keep the compartment and generator set cleanand free of debris to minimize chances of fire. Wipe upall spilled fuel and engine oil.

2

1

3

1. Governor Arm2. Low Speed

Mixture Screw

3. Idle Speed Screw

1-829

1-829

Figure 3-8. Fuel Mixture Adjustment


Ignition System

Ignition System ServiceThe ignition system is transistorized and breakerless.Under normal conditions, only the spark plugs needservice on a regular basis. The electronic ignitionmodule requires no maintenance and should give yearsof trouble-free service. If a module problem issuspected, have service performed by an authorizedservice dealer/distributor.

Spark PlugsAt the recommended interval (shown in the serviceschedule) service spark plugs.

1. Remove spark plug wires by grasping boot andturning slightly while pulling. Do not pull wire. SeeFigure 3-9.

NOTEPulling wire rather than boot may cause damage towire or terminal.

2. Where possible, use compressed air to remove dirtfrom around each spark plug before removal. Thisprocedure will prevent dirt particles from falling intocombustion chamber. Loosen spark plug with aratchet and spark plug socket with a rubber insert toprevent 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 bycolor/condition of spark plugs.

3. Clean spark plugs by wiping with a rag and then filethe center electrode so that it is parallel to the sideelectrode. Should replacement be necessary, see“Specifications”for spark plug type.

NOTEDo not sandblast, wire brush, scrape, or otherwiseservice spark plug in poor condition. Best resultsare obtained with a new plug.

1-827

Figure 3-9. Removing Spark Plug Wires

11-827

1. 13/16 in. Spark Plug Socket

Figure 3-10. Removing Spark Plug


Problem Means of Identification Possible CauseNormal Light tan or gray deposit on the

firing tip.Good operating conditions andmaintenance.

Gap bridged Deposits built-up and closing gapbetween electrodes.

Oil or carbon fouling. Clean andregap.

Oil fouled Wet black deposits on the insulatorshell bore electrode.

Excessive oil entering combustionchamber through worn rings andpistons, excessive clearancebetween valve guides and stems,or worn or loose bearings.Replace plug.

Carbon fouled Black, dry fluffy carbon depositson insulator tips, exposed shellsurfaces, and electrodes.

Using too cold range plug, weakignition, clogged air intake orimproper carburetor adjustments,defective fuel pump, overrich fuelmixture, or excessive no loadoperation. Clean and regap.

Lead fouled Dark gray, black, yellow, or tandeposits; or a glazed coating onthe insulator tip.

Caused by highly leaded fuel.Replace plug.

Pre-ignition Melted electrodes and possiblyblistered insulator. Metallic depositson insulator suggests internalengine damage.

Wrong type of fuel, incorrect timingor advance, too hot of a plug, burntvalves, or engine overheating.Replace and plug.

Overheating White or light gray insulator withsmall black or gray/brown spotswith bluish (burnt) appearance onelectrodes.

Engine overheating, wrong type offuel, loose spark plugs, too hot aplug, low fuel pump pressure orincorrect ignition timing. Replaceplug.

Worn Severely eroded or wornelectrodes.

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

Figure 3-11. Spark Plug Condition4. Before installing any spark plug, check the gap.

See Figure 3-12. The proper gap is attained whenthe feeler (or wire) gauge just passes between thespark plug electrodes. It should pass easily, butwith some resistance or drag. The correct gap is0.028--0.031 in. (0.7--0.8 mm).

5. To readjust the spark plug gap, use gapping tool togently bend the side electrode closer to or furtherfrom the center electrode. See Figure 3-13. Theside electrode must be centered over the centerelectrode.

6. Being careful not to bump the electrode, handthread spark plug clockwise into cylinder head untilresistance is felt.

7. Using a torque wrench, tighten each spark plug to atorque of 18--22 ft. lbs. (20--30 Nm). If a torquewrench is not available, hand-tighten spark pluguntil resistance is felt and then use a ratchetwrench to tighten the plug an additional 1/2 turn (ifinstalling a new plug) or 1/8--1/4 turn (if reinstallinga used plug). Do NOT overtighten as this may stripthreads or alter electrode gap setting.

8. Check spark plug wire connector in boot foraccumulated dirt, grease, etc., and clean asnecessary. Firmly push spark plug connector andboot onto spark plug.


1

2

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

2. Spark Plug Electrodes

1-514

Figure 3-12. Checking Spark Plug Gap

1-511

Figure 3-13. Adjusting Spark Plug Gap


Cooling Systems—Closed/Heat Exchanger

In a closed cooling system, the seawater does notcirculate through the engine but circulates throughseparate chambers within the heat exchanger to coolthe engine coolant. The seawater is then mixed withengine exhaust and ejected out the exhaust outlet. Thecoolant is circulated through cooling passages to coolthe engine. All models make use of a coolant thermostatand a coolant recovery tank. The coolant capacity of theengine with heat exchanger is 0.72 U.S. qts. (0.68 L) forall models. A solution of 50% ethylene glycol and 50%clean, softened water is recommended to inhibitrust/corrosion. A coolant solution of 50% ethylene glycolwill provide freezing protection to --34°F (--37°C) andoverheating protection to 265°F (129°C). A coolantsolution with less than 50% ethylene glycol may notprovide adequate freezing and overheating protection.A coolant solution with more than 50% ethylene glycolcan cause damage to engine and components. Do notuse alcohol or methanol antifreeze or mix them with thecoolant.

Filling and Checking

WARNING




NOTEENGINE DAMAGE! Failure to bleed air from coolingsystem may cause overheating and subsequentdamage to engine.

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

Before filling the cooling system, verify that all hoseclamps are tight. Loosen air-bleed screw located on topof the engine to allow trapped air to escape. SeeFigure 3-14. Place a rag around the screw to preventcoolant spillage onto the block. Remove pressure caplocated on the top of the engine (see Figure 3-15) and fillwith the recommended coolant until level is just belowoverflow tube opening. Tighten air-bleed screw whencoolant, free of air bubbles, starts to flow. Replacepressure cap. Start generator set and allow to run forabout 20--30 seconds. STOP generator set and recheckcoolant level by removing pressure cap. Repeatprocedure, as necessary, until coolant can no longer beadded.

A coolant overflow bottle is provided. Fill bottle to justbelow the MAX mark. See Figure 3-16. Maintain propercoolant level in coolant overflow bottle. The MIN markindicates full when cold and the MAX mark indicates fullwhen hot. Coolant level should always be betweenthese marks. The coolant level can be checked usingthe overflow bottle markings, but it is recommended toperiodically remove the coolant pressure cap and checkcoolant level.


1

1-8281. Air-Bleed Screw; Use 12 mm Wrench

Figure 3-14. Air-Bleed Screw


10AFUSE

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BATT.CHRG.

INPUT

321

1. Coolant Recovery Tank2. Overflow Hose

3. Coolant Pressure Cap

258000-D

Figure 3-15. Coolant Pressure Cap


10AFUSE

STARTSTOP

BATT.CHRG.

INPUT

1

2

1. MAX. Mark 2. MIN. Mark

258000-D

Figure 3-16. Checking Coolant Level


Flushing and Cleaning

If required, flush coolant from generator set. To properlyflush coolant, obtain Kit #267999 and use the followingprocedure:

WARNING



WARNING




1. Disconnect the battery, negative lead first.

2. With engine cooled, remove the air-bleed screwand the high water temperature safety shutdownswitch from the thermostat housing.

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

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

NOTEHeat exchanger pressure cap MUST be installed.

5. Turn on water supply to flush coolant from engineblock. Turn off water supply when clean water isobserved coming from hose in bucket.

6. Disconnect garden hose. Place free end of large kithose into bucket and connect an air hose to the freeend of the smaller kit hose. Apply air pressure (40psi [276 kPa] min.) until water stops flowing from kithose in bucket. This will remove about 16 fl. oz.(0.47 L) of water from engine block.

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

NOTESome small air compressors may not maintainpressure under the required flow conditions. Inthese cases, it is recommended that the end of thekit hose in the bucket be closed off momentarilyuntil pressure is allowed to build up. After pressurehas accumulated, open end to allow water to flowinto bucket. Repeat closing and opening end of kithose, as required.

7. Remove kit hoses with hose fittings from engine.

8. Apply pipe sealant to threads of high watertemperature safety shutdown switch and installswitch in thermostat housing. Reconnect wiringharness lead to switch.

9. Apply pipe sealant to the air-bleed screw and installscrew into engine. Do not final tighten!

10. Remove cap of coolant overflow bottle and pourcontents into a suitable container. Reinstall bottleon unit.

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

12. Remove heat exchanger pressure cap and addabout 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 tubeopening. Final tighten the air-bleed screw whencoolant, free of air bubbles, starts to flow. Install theheat exchanger pressure cap.


13. Reconnect battery, negative lead last.

14. Start generator set and allow the set to run forabout 20--30 seconds. Stop generator set andrecheck coolant level by removing heat exchangerpressure cap. Add straight coolant, if necessary,until level is just below the overflow tube opening,then reinstall pressure cap. Repeat this step untilcoolant can no longer be added. This procedureshould 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 andcheck for coolant leaks. This will allow the coolantmixture to mix completely. Stop generator set.

17. Rinse coolant flush kit hoses and fittings with cleanwater. Store kit for future use.

18. Dispose of used coolant in a proper manner. DoNOT pollute waterways!


Anticorrosion ZincAn anticorrosion zinc anode is installed in the heatexchanger to prevent electrolytic corrosion by seawater.When different metals, such as iron and copper, areplaced in a highly conductive liquid (seawater), the irongradually rusts. The zinc has chemical properties whichcause the seawater to react to it rather than the enginecomponents.The anticorrosion zinc anode should be checked every100 hours or three months and replaced every 200hours or yearly. Depending upon operating conditionsand seawater properties, the anticorrosion zinc anodemay have to be replaced more frequently. SeeFigure 3-17 and use the following procedure.


10AFUSE

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BATT.CHRG.

INPUT

1. Heat Exchanger 2. Anticorrosion Zinc

2 1258000-D

Figure 3-17. Removing Anticorrosion Zinc

1. With generator set cooled, drain the coolingseawater system. Close seacock, removeanticorrosion zinc anode from heat exchanger.

2. Use a wire brush to remove the loose corrosion onthe anticorrosion zinc anode. Replace the anodewhen less than 50% of the 11/32 in. (9 mm) dia. by9/16 in. (14 mm) long portion of zinc remains.

3. Clean threaded hole of heat exchanger and coatthreads of anticorrosion zinc anode with pipesealant (suitable for marine applications). Installanticorrosion zinc anode into heat exchanger.

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


Pressure Cap

Closed-loop cooling systems incorporate a pressurizedcap to raise the boiling point of the coolant and make useof higher operating temperatures. If leakage ormalfunction occurs, replace the pressurized cap withone supplied by Kohler Co. part number 229958.

1

2

3

1. Mounting Base2. Retaining Cap

3. Reed Valve Assembly

1-779

Figure 3-18. Siphon Break

Siphon Break

An optional siphon break is used to prevent seawaterentry into the engine when the generator set is shutdown. Corrosion buildup may not allow the siphon breakto function properly. Therefore, if used, the siphon breakmust be inspected and cleaned periodically.

NOTETo prevent siphoning of seawater, run the generatorwhile performing this inspection.

Remove the retaining cap to inspect the reed valve. SeeFigure 3-18. Clean the reed valve to remove residueand oxidation. Check that the reed valve (opening) isclear. Replace the siphon break if the material hashardened or deteriorated. Install the reed valve with the

valve downward into the mounting base. Install retainingcap and tighten finger-tight only. Do NOT overtighten.

Air Cleaner andMixing Elbow

Servicing Air CleanerThe engine is equipped with a dry-type air cleaner.Every 50 hours (more often if operating under dusty ordirty conditions) remove element and service by tappingelement lightly against flat surface to dislodge loosesurface dirt. Do not clean in any liquid or blow out withcompressed air as this will ruin filter material in element.Service air cleaner after each 50 hours of operation. Ifdirty, bent, or damaged replace element with genuineKohler replacement. See Figure 3-19.

1-905

Figure 3-19. Air Cleaner Service

Servicing Mixing ElbowThe mixing elbow combines high temperature exhaustand cooling seawater. These conditions are conduciveto rapid deterioration and, combined with enginevibrations, premature failures if not properly maintained.Check the mixing elbow for carbon buildup andcorrosion inside the pipe. Clean or replace the mixingelbow as necessary. Inspect the exhaust manifoldmounting threads for cracking and corrosion.


Battery

The starting battery should be a 12-volt unit with aminimum 250 CCA (cold cranking Amps) at 0_F (--18_C). When using a maintenance-free battery it is notnecessary to check the specific gravity or electrolytelevel. Otherwise, these procedures should be done atthe intervals specified in the Service Schedule.

WARNING

Sulfuric acid in batteries.Can cause severe injury or death.

Use protective goggles and clothes. Can causepermanent damage to eyes, burn skin, and eat holesin clothing.

Sulfuric acid in batteries can cause severe injury ordeath. Sulfuric acid in battery can cause permanentdamage to eyes, burn skin, and eat holes in clothing.Always wear splash-proof safety goggles when workingaround the battery. If battery electrolyte is splashed inthe eyes or on skin, immediately flush the affected areafor 15 minutes with large quantities of clean water. In thecase of eye contact, seek immediate medical aid. Neveradd acid to a battery once the battery has been placed inservice. Doing so may result in hazardous spattering ofelectrolyte.

Explosion can cause severe injury or death. Batterygases can cause an explosion. Do not smoke or permitflame or spark to occur near a battery at any time,particularly when it is being charged. Avoid contactingterminals with tools, etc. to prevent burns and to preventsparks that could cause an explosion. Removewristwatch, rings, and any other jewelry before handlingbattery. Never connect negative (--) battery cable topositive (+) connection terminal of starter solenoid. Donot test battery condition by shorting terminals togetheror sparks could ignite battery gases or fuel vapors. Anycompartment containing batteries must be wellventilated to prevent accumulation of explosive gases.To avoid sparks, do not disturb battery chargerconnections while battery is being charged and alwaysturn charger off before disconnecting batteryconnections. When disconnecting battery, removenegative lead first and reconnect it last.

CleaningKeep battery clean by wiping it with a damp cloth. Keepall electrical connections dry and tight. If corrosion ispresent, disconnect cables from battery and removecorrosion with a wire brush. Clean battery and cableswith a solution of baking soda and water. Be careful thatcleaning solution does not enter battery cells. Whencleaning is complete, flush battery and cables with cleanwater and wipe with a dry cloth. After the battery cablesare reconnected, coat terminals with petroleum jelly,silicon grease, or other nonconductive grease.

Checking Electrolyte LevelCheck the level of electrolyte before each startup.Remove filler caps and check to see that electrolytelevel is up to bottoms of filler holes, see Figure 3-20.Refill as necessary with distilled water or clean tapwater. DO NOT add fresh electrolyte! Then reinstall andtighten filler caps. If water is added during freezingtemperatures, run generator set 20--30 minutes to allowmixing of added water and electrolyte. This will preventdamage to battery due to freezing.

1

2

1. Filter Caps 2. Electrolyte Level

1-046

Figure 3-20. Checking Electrolyte Level

Checking Specific GravityUse a battery hydrometer to check the specific gravity ofthe electrolyte in each battery cell. Correct actualhydrometer readings for temperature. If the hydrometerused does not have a correction table, use the one inFigure 3-21. The battery is fully charged if the specificgravity is 1.260 at an electrolyte temperature of 80_F(26.7_C). The difference between specific gravities of


each cell should not exceed ±0.01. The battery shouldbe charged if the specific gravity is below 1.215 at anelectrolyte temperature of 80_F (26.7_C).

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

-- 12.2

-- 6.7

-- 1.1

4.4

10

21.1

26.7

32.2

37.8

43.3

48.9

54.4

60.0

65.6

71.1

15.6

+ .032

+ .030

+ .028

+ .026

+ .024

+ .022

+ .020

+ .018

+ .016

+ .014

+ .012

+ .010

+ .008

+ .006

+ .004

+ .002

0

-- .002

-- .004

--. 006

-- .008

-- .010

-- .012

-- .014

-- .016

-- .018

-- .020

-- .022

-- .024

-- .026

-- .028

°C °F

EXAMPLE NO. 1—

Temperature below 80°F (26.7°C)

Hydrometer Reading 1.250

Acid Temperature 20°F (--6.7°C)

Subtract .024 Specific GravityCorrected Specific Gravity is 1.226

EXAMPLE NO. 2—

Temperature above 80°F (26.7°C)

Hydrometer Reading 1.235

Acid Temperature 100°F (37.8°C)

Add .008 Specific GravityCorrected Specific Gravity is1.243

The temperature correction amounts to about .004 (4 “points”)of specific gravity for each 10°F (5.5°C) change in temperature.

Correction

1-787

Figure 3-21. Specific GravityTemperature Correction

NOTESome battery testers simply have four or five beads in atube. Draw electrolyte into the tube. Use instructionswith tester; otherwise see the following chart.

Five Beads Floating— OverchargedFour Beads Floating— Fully Charged

Three Beads Floating— A Good ChargeOne or Two Beads Floating— A Low Charge

No Beads Floating— A Dead Battery

ChargingThe engine battery charging circuit will provide a chargeof 12 volts at up to 10 amps.

NOTEIf the battery is used while the craft is docked and thegenerator set is not running i.e., auxiliary lights, two-wayradio, etc., the battery will be drained and may not haveenough power to start the generator set later. Therefore,it may be necessary to connect a battery charger whilethe craft is docked and running on shore power.


Valve AdjustmentWith overhead cam engines, each valve is spring-heldin the closed position until forced open by the action ofthe rocker arm in contact with the camshaft. Rockerarms have adjusting screws and locknuts for adjustingvalve stem-to-rocker arm clearance. Check clearancewith the engine cold. See Specifications— Engine forintake 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 ordeath. Keep hands, feet, hair, clothing, and test leadsaway from belts and pulleys when unit is running.Replace guards, covers, and screens before operatinggenerator set.

Flying projectiles can cause severe injury or death.Retorque all crankshaft and rotor hardware afterservicing. When making adjustments or servicinggenerator set, do not loosen crankshaft hardware orrotor thru-bolt. If rotating crankshaft manually, directionshould be clockwise only. Turning crankshaft bolt orrotor thru-bolt counterclockwise can loosen hardwareand result in serious personal injury from hardware orpulley flying off engine while unit is running.

1. Remove rocker arm cover screws using a 10 mmwrench. Carefully pry rocker arm cover off cylindercover. Wipe excess oil from components using aclean rag.

2. Expose timing belt:

a. Close seacock and drain seawater from hoses.Remove seawater pump hoses at seawaterpump.

b. Remove two screws to release seawater pumpbracket.

c. Remove housing enclosing ignition coil.

d. Remove seawater pump from camshaft pulley.

e. Remove timing belt cover (belt guard).

NOTETo 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 fromengine end) until No. 1 cylinder is at the top of itscompression stroke and the ‘T’mark on flywheel isaligned with the triangle symbol on the engineblock. See Figure 3-22. The compression stroke isthe period between the closing of the intake valveand the opening of the exhaust valve. The marksdefine the TDC (top dead center) point where bothintake and exhaust valves will be closed.

4. Insert feeler gauge between rocker arm andexhaust valve for No. 1 cylinder. If necessary,adjust screw so that very slight drag is felt on thefeeler gauge as it is withdrawn. Loosen theadjusting screw locknut and turn the adjustingscrew to obtain the specified clearance. Retightenthe locknut while holding the adjusting screw. SeeFigure 3-23. Recheck the valve clearance aftertightening the locknut. Repeat step for intake valveof No. 1 cylinder.

5. Rotate crankshaft 360 degrees clockwise and setvalve 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.

c. Install housing for ignition coil.

d. Mount seawater pump bracket using twoscrews.

e. Install seawater pump hoses to seawater pump.Open seacock.

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


1. “Y ”Mark 2. “T”Mark

2

1

1-827

Figure 3-22. Determining Top Dead Center

12

3

1. Feeler Gauge2. Adjusting Screw 3 mm

Square Head

3. Locknut; Use 9 mmWrench

1-831

Figure 3-23. Valve Adjustment


GovernorThe gear-driven centrifugal type governor serves tokeep engine speed constant by automatically adjustingthe amount of fuel supplied to the engine according tochanges in load.

LubricationLubricate governor linkage at the specified intervalusing white lithium grease or lubriplate.

Governor AdjustmentThe gear-driven centrifugal type governor serves tokeep engine speed constant by automatically adjustingthe amount of fuel supplied to the engine according tochanges in load. No regular service is required on theunit. The governor is adjusted during run-in at thefactory and further adjustment should not be neededunless greatly varying load conditions are encounteredor if poor governor control develops after extendedusage. See Figure 3-25 for correct placement ofgovernor linkage (models may vary).

60 Hz generator sets are designed to operate at 60-63Hz, 3600 rpm under full load and 3780 rpm under noload. 50 Hz generator sets are designed to operate at50--52.5 Hz, 3000 rpm under full load and 3150 rpmunder no load. To check speed, use hand tachometer orfrequency meter. Use the following procedure to adjustgovernor.

1. Loosen governor arm locking nut. SeeFigure 3-24.

2. Move the governor arm end fully in the directionshown (toward the electric choke solenoid) andreadjust governor screw. Tighten locking nut.

3. Start engine and run to reach operatingtemperature.

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

5. Check regulation by applying and removing fullload.

6. STOP generator set.

1

2

1. Mixture Screw2. Idle Speed Screw

3. Governor Adjustment

1-829

3

Figure 3-24. Governor Adjustment

Carburetor

GovernorAdjustmentScrew

Throttle Rod/Spring

Governor Spring

Governor Cross Shaft

Governor RodOuter Hole

Hole Nearestto Pivot Point

Pivot Point

Locknut

Figure 3-25. Governor Linkage


Wattage RequirementsIf the rated capacity of the generator set is exceeded, thecircuit breaker located on the controller will trip to protectthe generator against damage. Tripping could becaused by a short in the AC circuit in the craft or simplyby having too many appliances on at the same timeresulting in an overload condition. If the circuit breakertrips, the set may continue running but there will be noAC output to the protected circuit. Before resetting thecircuit breaker, turn off some of the appliances and lightsinside the craft to bring the load down within the ratedlimits of the set. If this is done and the circuit breaker tripsagain after being reset, see a qualified electrician.

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

Generator Service

GeneralUnder normal conditions generator service will not berequired on a regular basis. If operating under dusty anddirty conditions, use DRY compressed air to blow dustout of the generator at frequent intervals. Do this with thegenerator set operating and direct the stream of air inthrough the cooling slots at the end of the generator.

The end bracket bearing should be replaced every10,000 hours of operation. Have bearing replacedsooner if bearing inspection indicates excessive rotorend play or bearing damage from corrosion or heatbuildup. The end bracket bearing is sealed and requiresno additional lubrication. All generator service must beperformed by an authorized service dealer/distributor.


Storage ProcedureIt is recommended that the craft be afloat when thegenerator set is prepared for storage since the enginemust be started.

1. Add fuel stabilizer to fuel tank. Userecommendations of fuel stabilizer manufacturer.

2. Start generator set and run until operatingtemperature is reached or about 15 minutes. Stopgenerator set. Drain oil from crankcase whileengine is still warm. Replace oil filter. Refillcrankcase with specified weight oil.

NOTEFor storage, seawater must be replaced withantifreeze as described in steps 3a--c or drained asdescribed in steps 4a--c.

3. Close seacock and remove hose at seacock. Placehose 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 issufficient.

a. With a suitable container at exhaust outlet, rungenerator set until coolant discharge isobserved at exhaust outlet or until coolantmixture is used up. Do not allow coolant mixtureto flow into waterways. Stop generator set.

b. Connect hose to seacock. Leave seacockclosed.

c. Check coolant level of heat exchanger and addif necessary.

NOTEIf steps 3a--c were performed to replaceseawater with antifreeze, omit steps 4a--c.

4. Close seacock and drain all seawater out of coolingsystem.

a. Drain seawater from strainer and seawaterpump.

b. Remove zinc anode or end cap on heatexchanger, whichever is more convenient, todrain only seawater. Use an air hose to blow outany remaining seawater, if necessary. Checkcoolant level of heat exchanger and add ifnecessary.

c. Drain seawater from exhaust waterline.

NOTEIf freezing temperatures will be encountered duringstorage, be sure engine coolant is capable ofwithstanding the lowest possible temperatures.Generally, a mixture of 50% ethylene glycol and50% clean, softened water is sufficient.

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

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

7. Clean exterior of generator set and spread a lightfilm of oil or silicon spray over any exposedsurfaces which may be subject to rust or corrosion.

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

9. Disconnect and remove battery. Battery should beplaced in a warm, dry location for period of storage.Recharge battery once a month to maintain fullcharge.

10. Cover entire unit with a dust cover.

TP-5695 12/93 Troubleshooting 4-1

Section 4. TroubleshootingWhen troubles occur, do not overlook simple causes. Astarting problem, for example, could be caused byimproper fuel or an empty fuel tank. The following chartslist some common problems. If procedures in thismanual do not explain how to correct the problem, take

the generator set to an authorized servicedealer/distributor. Tell the dealer exactly what happenedwhen the problem occurred and of any adjustmentsmade to the set.

EngineProblem Possible Cause Corrective Action

Unit will not crank Weak or dead battery Recharge or replace batteryUnit will not crankReversed or poor battery connections.Poor ground.

Check connections

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

as necessary.Defective starter Attempt starting by direct connection to

battery. Replace/repair as necessary.Unit cranks but willnot start

Out of fuel ReplenishUnit cranks but willnot start Clogged fuel screen Clean fuel screennot start

Faulty antidieseling solenoid Replace solenoidAir intake clogged Clean or replaceFaulty spark plug(s) Replace (and regap) spark plug(s)Loose spark plug connection Reconnect wiresFaulty ground (--) connection Clean and retightenCarburetor adjustment wrong Adjust carburetorDefective electric fuel pump Check pressure. Replace as necessary.Shorted or open ignition coil Replace coilWeak or dead battery Recharge or replaceBad fuel mixture Replace fuel; clean carburetorFlooded carburetor Wait a few minutes and attempt restartEngine malfunction See authorized Kohler service

dealer/distributorEngine starts, butdoes not continue to

No generator output voltage Check AC voltageEngine starts, butdoes not continue torun after start switch

No/low oil pressure Check oil pressure and pumpdoes not continue torun after start switchis released

Defective low oil pressure (LOP) safetyshutdown switch

Check LOP shutdown switch

High temperature shutdown Check cooling systemDefective high exhaust temp. (HET) and/orhigh water temp. (HWT) safety shutdownswitch(es)

Check HET and/or HWT shutdownswitch(es)

Hard starting Stale or bad fuel Replace fuelHard startingFuel vapor lock Check fuel line routingFaulty spark plug(s) Replace (and regap) plug(s)Weak ignition coil ReplaceCarburetor adjustment wrong Adjust carburetorAir intake clogged Clean

TP-5695 12/934-2 Troubleshooting

Engine (Continued)Problem Possible Cause Corrective Action

Stops suddenly Out of fuel ReplenishStops suddenlyAir intake clogged CleanFuse blown in controller Replace fuseDefective seawater pump impeller ReplaceClogged seawater strainer Clean strainerIgnition coil failure Check for sparkFuel line restriction Check fuel lines and tankFuel vapor lock Check fuel line routingDefective electric fuel pump Check pumpDirty fuel screen Clean fuel screenFaulty spark plug(s) Replace spark plug(s)No/low oil pressure Check oil pressure and pumpDefective low oil pressure (LOP) safetyshutdown switch

Check LOP shutdown switch

High temperature shutdown Check engine coolant systemDefective high exhaust temp. (HET) and/orhigh water temp. (HWT) safety shutdownswitch(es)

Check HET and HWT shutdown switch(es)

Loss of AC output See authorized Kohler servicedealer/distributor

Faulty antidieseling solenoid Replace solenoidLacks power Air intake clogged CleanLacks power

Bad or stale fuel Replace fuelFaulty spark plug(s) Replace (and regap) plug(s)Improper timing Check timingChoke solenoid defective Check and/or changeEngine not operating at rated RPM Check governorGovernor adjustments incorrect Adjust governorCarbon build-up Clean carbon from cylinder headsImproper cooling Inspect cooling systemDirty fuel screen Clean screenDefective ignition coil Replace coilFuel line restricted Check fuel linesEngine overloaded Reduce loadCarburetor adjustment wrong Adjust carburetor

Operates erratically Air intake clogged CleanOperates erraticallyStale or bad fuel Replace fuelFuel pump vapor lock Allow unit to cool and attempt restartClogged fuel screen Clean screenFaulty spark plug(s) Replace spark plug(s)Carburetor adjustment incorrect Adjust carburetor

TP-5695 12/93 Troubleshooting 4-3

Engine (Continued)Problem Possible Cause Corrective Action

Overheats Improper cooling Check intake and outlet openings. Checkcoolant level and pressure cap. Check rawwater strainer.

Thermostat defective ReplaceSea strainer clogged Clean sea strainerCarburetor adjustment too lean Adjust carburetor mixtureEngine ignition timing incorrect Adjust timing

Unit is noisy Exhaust system leak Check exhaust systemUnit is noisyExhaust system not securely installed Check for loose partsBroken or damaged vibromounts Check vibromountsNo installation clearance (unit hits craftstructure or compartment)

Check clearances

No compartment sound insulation Install approved insulationExcessive vibration engine/ generator(internal imbalance)

See authorized Kohler servicedealer/distributor

Loose or vibrating sheet metal Check shrouds

Electrical SystemProblem Possible Cause Corrective Action

Battery will notcharge

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

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

authorized Kohler service dealer/distributorStarter does notwork properly

Loose or corroded connections Clean and tighten loose connectionsStarter does notwork properly Low battery output Check electrolyte level and specific gravity

(batteries with filler caps only). Checkbattery voltage.

Defective starter solenoid Replace starter solenoidDefective start/stop switch Replace switchDefective wiring Check wiring

Starter cranksslowly

Low battery output Check electrolyte level and specific gravity(batteries with filler caps only)slowly

Too heavy viscosity lube oil Use proper viscosity oilLoose or corroded wiring Clean and tighten loose connectionsHigh starter current draw Rebuild or replace starterBattery cable undersize See Installation Section--Electrical

Systems

TP-5695 12/934-4 Troubleshooting

GeneratorProblem Possible Cause Corrective Action

No AC output Circuit breaker in OFF position Reset breaker to ON positionNo AC outputCircuit breaker tripped due to overload ongenerator set

Reduce load. See Wattage Requirements.Reset breaker to ON position.

Ship-to-shore transfer switch in “OFF”or“SHORE”position

Turn switch to generator power

No DC power to controller Check battery connectionsController fuse blown Replace fuseGenerator malfunction such as capacitoror other internal fault

See authorized Kohler servicedealer/distributor

Low output orexcessive drop in

Engine speed too low Adjust governorLow output orexcessive drop involtage

Generator overloaded Reduce load. See Wattage Requirements.voltage

Engine in poor condition If routine services are performed andcondition persists, see authorized Kohlerdealer/distributor

Defective capacitor See authorized Kohler servicedealer/distributor

High generatoroutput voltage

Defective capacitor and/or poor wiringconnections

See authorized Kohler servicedealer/distributoroutput voltage

Excessive speed or frequency Adjust governor. Check governor linkageand spring for damage or binding.

Will not crank No DC power to controller Check battery connectionsWill not crankController circuit fuse blown Replace fuse and attempt start-up. If fuse

blows again, contact authorized Kohlerservice dealer/distributor.

TP-5695 12/93 Wiring Diagrams 5-1

Section 5. Wiring Diagrams

THERMAL SWITCHBATTERY VOLTMETERWATER TEMPERATURE GAUGEOIL PRESSURE GAUGE

WATER TEMP. SENDER

HOURMETERANTI--DIESEL SOLENOIDCHOKEFUEL PUMPSTARTER MOTOR

FAULT SHUTDOWN RELAYENGINE CRANK RELAYENGINE RUN RELAYAC CRANK DISCONNECT RELAY

L1

LO

120/240 V. CONNECTION

L2

GROUNDHAZARD

1

2

3

4

WTSOIL PRESSURE SENDER

TSBVWTOP

OPS

HRADCHFPS

K4K3K2K1

BOARDCHOKE

HOT

P5--2

P5--4P4--3

8N

N

P1--8

5

7C

BV

BC N

N

BC

K2

HR

7N

VIOLET

P

N

SCHEMATIC

BLACK

12

345566

B1

B2

OWNERS MANUALRATING SEEFOR AMPERAGE

LEGEND

AUXILIARY WINDINGBATTERY CHARGING

WINDINGAUXILIARY

CAPACITOREXCITATION

ALTERNATOR

FAULT SHUTDOWN TIME DELAY RELAY

C12

1

B1P1--3

P1--6B2

+12VVR1

K5

K1

LED1R1

BR13

+--

54

1A

REGULATORVOLTAGE

ALTERNATORCHARGINGBATTERY

ONGEN

WTSP3--2TAN

OPSP3--3BLUELT

WT

OPP3--4

76P2--3K1

D4

73P2--1

HR

5A

D8FN

P1--125A

D5

75

K1START

REMOTESTOP

P3--643

P3--547

43

P2--8

P2--7

START

P1--1537

37

37

37

LOW OIL PRESSURE

HIGH EXHAUST TEMP.

HIGH ENGINE TEMP.

STOP

P2--4

P2--5

P1--9

47

N

N

K1

70

P3--1

K4

P1--471

P2--9K3S

FP

CHTS

K4

1A

D7P1--1072SYSTEMIGNITION

P1--7AD 4573

P2--6N

5A

1AD3

D6

30P1--131A

D1

13P2--2

K1K4

LED4R4

K1D9

K2

K3

LED3R3

M

12 VOLT

+ C2

LED2R2

K21A

D2

S

P1--14

P1--1

1A

K1

PTC1N

P1--2

P4--16

BC

37HIGH EXHAUST TEMP.

10A10A

CONTROLLER

P

ENGINE

N

NN

P4--20

P4--21

P4--18

45

72

P4--8

P4--15

P4--1 P4--11

P4--22

P4--9

7N

P4--1473

P5--3

P5--1

73

73

71P4--4

N70

P4--13

P4--2

P1--5

P8--1 P8--2

P4--19

P6--1P6--2

246482-D

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

5-2 Wiring Diagrams TP-5695 12/93

FOR

AMPE

RAG

ER

ATIN

GSE

EO

WN

ERS

MAN

UAL

CIR

CU

ITBR

EAKE

RS

220

V.C

ON

NEC

TIO

N

L0 GR

D

43

21

LO(N

EUTR

AL)

GR

DL1

BC

7237

8N

4573

71

52

4

9

15

2022

21

19

BC

14

8

31

L1

GR

DLO

12

34

L2GR

DL0

120/

240

V.C

ON

NEC

TIO

N

GR

DLO

12

34

L2GR

D

CIR

CU

ITBR

EAKE

RS

75 8N

P6

N73

342

1

CIR

CU

ITBO

ARD

HO

TC

HO

KE

75

8N

N

J3

HO

UR

BLK

VIOLET

VIO

LET

BLK

TEM

P

OIL

LTBL

UE

VIO

LET

VIOLET

BLK

BLK

BLK

BLK

PIN

INSE

RTI

ON

END

.C

ON

NEC

TOR

SHO

WN

FRO

MN

OTE

:

VOLT

TAN

BLAC

K

VIO

LET

GR

EY/B

LK

65

32

41

YEL/

RED

(2AN

D4

GAU

GE

REM

OTE

PAN

EL)

BAC

KVI

EWO

FPA

NEL

STO

P

STAR

T

REG

ULA

TOR

VOLT

AGE

12

ALTE

RN

ATO

RC

HAR

GIN

GBA

TTER

Y

NBC

3 125

4

BC

N

N

7N

76

BC

7C

SS

+ +

+

+

VIOLETVIOLET

VIOLETVIOLET

BLK

BLK

SWIT

CH

TEM

PER

ATU

RE

HIG

HEN

GIN

E

N

N

SOLE

NO

IDAN

TI--D

IESE

L

SWIT

CH

THER

MAL

CH

OKE

70

73

72SY

STEM

IGN

ITIO

N

7345

37

SWIT

CH

ESTE

MPE

RAT

UR

EEX

HAU

ST

N

NU

TG

RO

UN

D

SEN

DIN

GU

NIT

TEM

PER

ATU

RE

WAT

ER(O

PTIO

NAL

)

SWIT

CH

LOW

OIL

PRES

SUR

ESE

ND

ING

UN

IT/

OIL

PRES

SUR

E(O

PTIO

NAL

)

FUEL

PUM

P

5

L0

5

120

V.C

ON

NEC

TIO

N

12

3

L1

B2B1

7C

455

66

55 66

B2

N 37P1 N

P2

4347

73

47R

ELAY

BOAR

D

43

12

34

55

66

B1 B2

N

SOLE

NO

IDST

ARTE

R

7673

43N

47

P

P

P

N

10A

INPU

TST

OP

STAR

T HO

UR

MET

ER

N

BC

LUG

GR

OU

ND

J4

CAP

ACIT

OR

EXC

ITAT

ION

ALTE

RN

ATO

R

1514

1312

1110

98

76

54

32

1

9

10A

CH

RG

.BA

TT.

8 7

6 5 4

3 2 1

3

B1

26

47

51

4

N

43

37

P 71

N

ENG

INE

CO

NTR

OLL

ER

REM

OTE

PAN

ELG

ENER

ATO

R

CIR

CU

ITBR

EAKE

RS

GR

EEN

GR

EEN

/WH

ITE

OW

NER

SM

ANU

ALR

ATIN

GSE

EFO

RAM

PER

AGE

OW

NER

SM

ANU

ALR

ATIN

GSE

EFO

RAM

PER

AGE

4571

70

BCBCBC

BC

WH

ENN

OT

USE

D.

TAPE

LEAD

S”5

”OR

”7C

”

7C

3737

3737

37

37

37 37

SWIT

CH

PRES

SUR

EO

IL

G

GR

EEN

YELL

OW

B2B1

N

NN

7070

P4

P8

P3

73

P5

72

WK

N

BC

8N37

72

7345

73

53

8

14 19

2122

20

15

BC

9

4

21

NN

P7C

71

MO

TOR

STAR

TER

BATT

ERY

NN

P7C

73

246482-D

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


Electro Switch

L1

L2

To GeneratorSet

To ShorePower

To Load

2-Wire Generator Sets

L1

L2

To GeneratorSet

To ShorePower

To Load



Kraus Naimler/American Solenoid(Early Rectangular Design)

Kraus Naimler/American Solenoid(Newer Round Design)

2 1 3 4

6 5 7 8

1 2 6 5

3 4 8 7

L1

L2

To GeneratorSet

To ShorePower

To Load

3 2 4 1

7 6 8 5

L1

L2To Generator

Set To ShorePower

To Load


2 1 3 4

6 5 7 8

L010 9 11 12

1 2 6 5

3 4 8 7

9 10 14 13

L1

L2To Generator

SetTo Shore

Power

To Load


L0

3 2 4 1

7 6 8 5

11 10 12 9

L1

L2To Generator

Set To ShorePower

To Load


L0

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

5-4 Wiring Diagrams TP-5695 12/93

Four-Lead Reconnectable (Single-Phase) Generator Sets Where GeneratorOutput Can Be Reconnected For 120 volt or 120/240 volt, 60 Hz,

110 volt or 110/220 volt, 50 HzNOTE

When a generator set is reconnected to a voltagedifferent than nameplate voltage, notice should beplaced on the unit indicating this change. Decals for thispurpose are available from authorized Kohlerdealers/distributors.

120- or 110-Volt 3-Wire 2-PoleConfiguration--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 orcan be connected together depending upon which ispractical for the given application. Regardless of thenumber of phase (black) leads used in the application,both circuit breakers must have leads attached to theload side. It is recommended that jumper lead bemaintained for all straight 120- or 110-volt systems sinceit helps balance the load of the generator set.

4 3 2 1

Stator Leads

LOGRD.

L2L1

LO (Neutral)

Ground

Load Side

Line Side

CircuitBreaker

JumperLead

60 Hz 50 HzL0--L1 120 volt 110 voltL0--L2 120 volt 110 volt

Figure 5-4. With Jumper Lead

120- or 110- Volt 2-Wire ConfigurationFigure 5-5 (Single Pole)

If the installation requires a 120 or 110 volt, 2-wiresystem, a single-pole circuit breaker must be used. SeeFigure 5-5. When connecting stator phase leadstogether, the output lead (L1) must be sized accordingly.

4 3 2 1Stator Leads

LOGRD.

LO (Neutral)

Ground

LoadSide

LineSide

1-PoleCircuitBreaker

L1

60 Hz 50 HzL0--L1 100-120 volt 100-120 volt

Figure 5-5. 120 Volt, 2-Wire


120/240- or 110/220-VoltConfiguration--Figure 5-6

Jumper lead not used. If unit was originally wired forstraight 120 or 110 volt, be sure jumper lead is removed(see Figure 5-6 for location). Leads L1 and L2 aredifferent phases and must never be connected together.

4 3 2 1

Stator Leads

LOGRD.

L2L1

LO (Neutral)

Load Side

Line Side

CircuitBreaker

Ground

60 Hz 50 HzL0--L1 120 volt 110 voltL0--L2 120 volt 110 voltL1--L3 240 volt 220 volt

Figure 5-6. Without Jumper Lead

6

TP-5695 12/93 Installation 6-1

Section 6. InstallationIntroduction

Use this section as a guide when installing the Marinegenerator set, then refer to Section 2. Operation forspecific service instructions. Reliable and safegenerator set operation depends largely upon properinstallation. Remember that the generator set willprobably be the craft’s sole source of electrical power.

When installing a marine generator set, it isrecommended that the installation comply with allapplicable Regulations and Standards. See ReferenceMaterial for documents issued by governing agencies.Information presented here should be followed inplanning and making installations. Specifications givenshould be used only in initial planning. Use currentdimension drawings and wiring diagrams.

NOTEA wood block is located under some generator set endbrackets to prevent damage during shipment. For thesame reason, metal brackets are used to attach somegenerator sets to their wood shipping bases. Theseitems MUST be removed prior to installation in order toprovide adequate vibration clearance during generatorset operation. Check that all packing material, literature,and loose accessories are removed from generator setprior to operation.

Generator Selection andWattage Requirements

Total wattage requirements (lights, motors, appliances)must be considered when selecting a generator set, orwhen sizing wattage usage where available space andconstruction limit the size of the generator set. The4-lead reconnectable generator set can be connectedfor 120 volt or 120/240 volt 60 Hz (110 volt or 110/220volt 50 Hz), see Section 5. Wiring Diagrams.

NOTEWhen a generator set is reconnected to produce avoltage different than nameplate voltage, notice shouldbe placed on the unit indicating this change. Decals (partnumber 246242) for this purpose are available fromauthorized Kohler dealers/distributors.

Lighting Load

The lighting load is usually easiest to calculate. In mostcases, simply add the wattage of each lamp to beoperated off the generator set. Note that in manyapplications, not all of the lights or lamps are in thegenerator set AC circuit— some are DC powered by the12-volt battery in the craft. Make sure the total includesonly lights actually on the generator set AC circuit.

Motor Loads

When figuring generator set capacity requirements thatinclude electric motors, do not overlook the high currentdemanded by the motors during start-up. The in-rush orstarting current is typically 2--3 times higher than thatrequired when the motor reaches normal operatingspeed. Reserve capacity must be allowed for in-rushdemands plus other loads which could be on the line asthe electric motor starts.

Air conditioning units are perhaps the most commontype of motor load for generator sets in marineapplications. The starting characteristics of the differentvarieties of air conditioners vary greatly— one particular12,000 Btu unit has, for example, lower startingrequirements than a 10,000 Btu unit of another make.When only one unit is involved, there is usually nostarting problem, provided the lighting and applianceload is not too high when the unit is started.

Simultaneous starting of two air conditioning units,however, can present problems if the capacity ismarginal. Because of the variation in startingcharacteristics of the various makes of air conditioners,no definite statements are made in this publicationregarding multiple-motor starting capabilities of themarine generator set covered. Delayed starting or useof easy-starting devices on air conditioner units shouldbe considered whenever simultaneous starting of morethan one motor is involved.

The starting and running requirements of some motorloads common to marine applications are listed inFigure 6-1; use this as a guide when selecting generatorset capacity requirements involving motor loads. SeeFigure 6-2 for generator set capabilities regarding airconditioners.

TP-5695 12/936-2 Installation

Capabilities will vary according to Kilowatt Deratingfollowing.

MotorRequirements(HP)

Starting(In-Rush)

WattsRunning

Watts1/4 750 3301/3 1000 4001/2 1500 6003/4 2000 750

1 3300 11002 4000 20003 5000 3000

Figure 6-1. Motor Requirements

Model Wattage

Will Operate AirConditioner ofSize Indicated

“Power toSpare” for

LightingAppliances,

Tools4CZ 4000 One 13,500 Btu 21006.5 CZ 6500 One 13,500 Btu 4600

Two 13,500 Btu 2700

Figure 6-2. Air Conditioner Requirements(50 Hz units will have slightly lower “power

to spare” figures than those indicated)

Appliance LoadsMarine generator sets are often used to furnish AC forappliances such as TV, stereo, electric water heaters,etc. With the exception of the resistance-type loadssuch as the water heater, requirements for appliancesare usually low. Such loads must not, however, beoverlooked when figuring total requirements. Reservecapacity should be available for anticipated applianceloads to avoid overloading of a set. The average powerrequirements of some common electrical appliancesare given in Figure 6-3.

Kilowatt DeratingUnits are rated as listed below at 1.0 power factor.Derate the listed rating by approximately 3.5% per 1000ft. (300 m) when the unit is operated at altitudes of 500 ft.(150 m) or more above sea level.

3.5CFZ, 50 Hz: 3.5 kW at 77_F (25_C) and 3.5 kW at122_F (50_C).

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 at122_F (50_C).

6.5CZ, 60 Hz: 6.5 kW at 77_F (25_C) and 6 kW at 122_F(50_C).

ElectricalAppliance

MotorStarting

WattsRunning

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

50--200 25--100

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

-- 650

Radar -- 750--1500Radio -- 50--100Radiophone -- 100--200Range, Electric(per element)

-- 1000--1500

Soldering Gun -- 250Television -- 300--750Toaster -- 750--1200Water System 500--1500 300--1250

Figure 6-3. Appliance Average Wattage Ratings(60 Hz)



10AFUSE

BATT.CHRG.

INPUT

NOTEUse two hose clamps on each end ofall flexible exhaust hose connections.

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

4

*5

6

7

8

*9

10

11

STOP/START

258000-D

21

13

*14 12

3

1. Heat Exchanger2. Siphon Break (See Instruction Sheet TT-927 for

Proper Installation.)3. Exhaust Mixer4. Engine-Driven Seawater Pump5. Exhaust Hose6. Seawater Strainer7. Raw Waterline

8. Intake Through-Hull Strainer9. Seacock

10. Mounting Base11. Mounting Tray12. Coolant Recovery Tank13. Hose Clamp14. Fuel Line

Figure 6-4. Typical Location and Mounting


Location

General

Consider the following in selecting or constructing agenerator set location.

Compartment/location must allow adequate space forventilation, cooling and exhaust system installation,service access to the engine and generator, and properfuel system installation.

Engine stringers or other available structural membersmust provide adequate support for the generator setweight.

A generator set compartment must be sealed to preventexhaust gases and fuel vapors from entering cabins.

Generator sets located above deck must have aprotective cover to prevent damage from rain and watersplash. This cover must not affect cooling air flow andserviceability.

See Figure 6-4 for a typical installation and Section 1. fordimensions and weights.

Space

Location should allow easy access to the generator set’sengine, controller, cooling, and fuel system componentsfor routine service. Engine compartments are often idealgenerator set locations, but access should not beobstructed by propulsion engines or generator andcontroller. Also allow clearance for vibration duringoperation. Minimum recommended clearance forvibration and cooling of top, front, rear, and sides ofgenerator set is 1 1/2 in. (38 mm).

Mounting

Engine stringers generally provide the best support for agenerator set. Any structural members considered formounting must support the generator set weight andwithstand engine vibration. The generator set includesvibration mounts and mounting trays; additionalvibration isolating pads may be installed between traysand bases.

A generator set should be mounted as high as possibleto avoid bilge splash and lower-lying vapors and also toallow downward pitch of the exhaust line. For angularinstallation, the maximum operation angle of theengine/generator set is 20_(in all directions).

VentilationVentilation is required to support engine combustion,generator cooling, and expulsion of flammable andlethal fumes. Ventilation provisions must comply withU.S.C.G. Regulations governing sizing of vents andoperator requirements.As a rule, inlet and outlet vent areas should each besized to a minimum of 2 sq. in. per ft. (13 sq. cm/30.5 cm)of craft’s beam. Should this rule in any instance conflictwith U.S.C.G. Regulations, appropriate Regulationsshould be followed. If any screening is used in inlets,size of hull/deck openings should be doubled. Ventducts should extend to bilges to expel heavier-than-airfumes. If the generator set is to be mounted in the enginecompartment, air flow must be increased to allow forgenerator set’s requirements. UL-listed ignition-protected blowers should be installed in outlet vents,and wired to operate before engine(s) are started.Sniffer devices may also be optionally installed to causealarm, warning, or engine shutdown should dangerousfumes accumulate in the compartment.

WARNING


Air requirements for various models are given inFigure 6-5. The air intake silencer provides combustionair to the engine. It is imperative that the recommendedminimum clearance of 1 1/2 in. (38 mm) between ductopening and any enclosure wall not be compromised.Engine/generator performance will be affectedadversely if these guidelines are not followed.

Air RequirementsCFM (L/min.)

Model Combustion Cooling3.5CFZ 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


Fuel Systems

Fuel SupplyGenerator sets, in most cases, must draw fuel from thesame tank as the propulsion engines. If the tank’s fuelpickup opening allows, a multiple dip tube arrangement(Figure 6-6) may be used. An alternate tank, if used,should have a smaller separate pickup opening allowinga single dip tube (Figure 6-7).

1

2

1-7881. Fuel Line to Propulsion

Engine2. Fuel Line to Generator

Set

Figure 6-6. Dual Dip Tubes

For installations where the highest point of the gasolinesource (fuel tank) is above the generator set carburetor,an auxiliary fuel shutoff valve is required. This fuelshutoff valve should be closed when the generator is notin use to prevent fuel leakage resulting from fuel flowthrough the fuel pump and into the carburetor should thefloat valve not seat properly.

NOTEFuel systems must conform to U.S.C.G Regulations andtests.

WARNING



Explosive fuel vapors can cause severe injury ordeath. Fuel leakage can cause an explosion. Do notmodify the tank or propulsion engine fuel system. Craftmust be equipped with a tank allowing one of the twopickup arrangements described. Tank and installationmust conform to U.S.C.G. Regulations.

1

1-788

1. Fuel Line to Generator Set

Figure 6-7. Single Dip Tube


Anti-Siphon ProvisionsAnti-siphon devices must be installed if any section offuel line lies below the highest point of the fuel tank. Theanti-siphon device should be either a spring-loadedcheck valve (tested to function with the particularinstallation’s siphon head), or an electrically operatedshutoff valve (UL ignition-protected, tested to U.S.C.G.Regulations) which may be operated manually. A checkvalve should be installed at a point above fuel tank’shighest point, secured to craft’s structure, and beaccessible without removing any permanent structure.The fuel line section between the tank and check valvemust be located above the tank’s highest point. Anelectric shutoff valve should be installed at the tank’sfuel withdrawal fitting, and be wired to open when thegenerator set engine is cranking or running.Anti-siphon holes drilled in fuel dip tubes within the tankare not reliable anti-siphon devices as they becomeineffective when restricted by dirt or gum.

Fuel LinesMetallic lines should be used from the tank to a flexiblehose section connecting metallic line to the engine fuelpump. Metallic lines must have wall thickness of at least0.029 in. (0.74 mm). Seamless annealed nickel copper,copper-nickel, or copper tubing must be used. Theflexible section (necessary to allow vibrational motion ofthe generator set during operation) must be U.S.C.G.TYPE A HOSE, marked and tagged according toRegulations. Metallic line must be supported within 4 in.(102 mm) of its connection to the flexible section. SeeFigure 6-8 for fuel pump inlet connection.

1. 1/4 in. NPT FemalePipe Thread

2. Electric Fuel Pump

1

2258000-D

Figure 6-8. Fuel Pump Inlet Connection

Any in-line fuel filters or strainers must conform toU.S.C.G. Regulations, must be independently mountedto the craft’s structure, and must be accessible forservicing without removing any permanent structures.

NOTE

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

Fuel Pump Lift Capabilities andFuel Consumption

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

ModelFuel Pump

Max. Lift ft. (m)Fuel Inlet Size

I.D. in. (mm)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

Load and GPH (L/hr.)

Model 1/4 1/2 3/4 Full

3.5 CFZ 0.42(1.59)

0.50(1.89)

0.59(2.23)

0.68(2.57)

4CZ 0.48(1.81)

0.55(2.08)

0.62(2.34)

0.68(2.57)

5CFZ 0.44(1.67)

0.54(2.04)

0.66(2.50)

0.80(3.03)

6.5CZ 0.53(2.00)

0.62(2.34)

0.86(3.25)

1.02(3.86)

Figure 6-10. Fuel Consumption


Cooling Systems

General

The following features are necessary in the coolingsystem.

An intake thru-hull strainer (seacock cover) must bescreened to prevent entry of foreign objects and mustnot be aligned (in relation to direction of travel) with thepropulsion engine intake. See Figure 6-11. Therecommended thru-hull strainer should be flushmounted. Strainers with slotted holes must be installedwith their slots parallel to the direction of vesselmovement. The area of the strainer opening(s) must beequal to or greater than the inside diameter of thewaterline hose to the seawater pump.

An intake thru-hull strainer must not be of the scoop orcup design. This style can cause a ramming effect andforce water upward, past the seawater pump, and intothe engine cylinders when the vessel is moving and thegenerator set is shut down. Hull designs incorporatingsea chests are also not suitable for intake thru-hullstrainers. A sea chest is a concave molded-in-the-hullchamber that is also aligned to the direction of travel. Asea chest configuration applies a positive pressuresimilar to a scoop-type thru-hull strainer.

A seacock is to be mounted to hull, assembled onto theintake and accessible for operation. Figure 6-12 showsa typical installation. Install the canvas on the outside ofthe hull, and the canvas or rubber packing on the insideof the hull.

If caulking is used to seal the seacock, be sure not toapply an excessive amount. Excess caulk can causeimproper water flow and in some cases develop abarrier which can force water upward, past the seawaterpump, and into the engine cylinders when the vessel ismoving and generator set is shut down.

NOTEIntakes are positioned in relation to vessel travelso neither will be in the wake of the other.

12

4 3

1-7891. Generator Set Intake2. Propulsion Engine

Intake

3. Aft4. Fore

Figure 6-11. Intake Strainer

1

2

3

4

1. Inside Packing2. Outside Packing3. Seacock Cover

4. Direction of VesselMovement

5. Typical Intake Thru-HullStrainers

5 1-789

Figure 6-12. Seacock Installation


A seawater strainer of sufficient capacity should bemounted to the seacock or permanent structure at apoint not higher than the seawater pump. The strainershould be accessible for servicing. See Figure 6-13 for atypical installation. The optional Kohler seawaterstrainer is threaded for 1/2 NPT fittings.

1

2

3

1-7891. Seawater Pump2. Seawater Strainer

3. Seacock

Figure 6-13. Seawater Strainer

NOTESome seawater strainers include seacock and intakethru-hull strainer.

Waterlines from the seacock to the engine-drivenseawater pump can be copper tubing or flexible hose. Aflexible section of hose is used for the actual connectionto the seawater pump to allow vibrational motion of thegenerator set during operation. The hose should havean inside diameter of 3/4 in. (19 mm). Copper line shouldbe supported within 4 in. (102 mm) of its connection tothe flexible section.

NOTEA 5/8 in. (16 mm) waterline hose can be substituted forthe 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 theseawater pump inlet. The seawater outlet is combinedwith engine exhaust gases. (On sound shielded units, asmall section of molded hose is required for theseawater inlet connection.)

1

ADV-5792-D1. 3/4 in. Seawater Pump Inlet

Figure 6-14. Seawater Inlet Connection

Closed/Heat ExchangerA closed, heat exchanger cooling system, the bestalternative for most applications especially if craft is tobe operated in salt waters or waters with high siltcontent, is provided as part of the generator set.

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



10AFUSE

BATT.CHRG.

INPUT

NOTEUse two hose clamps on eachend of all flexible exhausthose connections.

1. Exhaust Manifold2. 3 ft. (1 m) Max.3. Engine-Driven Seawater Pump4. Heat Exchanger5. Waterline

6. Seawater Strainer7. Intake Strainer8. Engine Coolant9. Seawater

10. Seacock11. Coolant Recovery Tank

12

3

4

56

7 89

1011

STOP/START

258000-D

Figure 6-15. Closed/Heat Exchanger Cooling System

Exhaust Systems

GeneralWater-cooled exhaust lines should be used in all marineinstallations. The hose used for the lines should have a2 in. (51 mm) inside diameter. Keep the lines as shortand straight as possible. The use of two hose clamps oneach end of flexible exhaust hose connections is highlyrecommended. ABYC Safety Standards P-1.6.crecommend a pitch of at least 1/2 in. (12.8 mm) perrunning foot (30.5 cm). Use flexible steam hoseconforming to UL Standard 1129 for “Engine wetexhaust components” between the mixing elbow andthe exhaust outlet. A silencer should be independentlymounted to eliminate any stress on the exhaust systemand exhaust manifold/mixer elbow. See Figure 6-16 forthe exhaust connection to the mixer elbow.

1 1-894

1. Seawater/Exhaust Outlet

Figure 6-16. Mixer Elbow/Exhaust Connection


Locate the exhaust outlet at least 4 in. (10 cm) above thewaterline when the craft is loaded to maximum capacity.Usually a flapper is installed at exhaust (transom) outletto prevent water backup in following seas or when goingastern (backward).

WARNING

Carbon monoxide.Can cause severe nausea, fainting, or death.The exhaust system must be leakproof androutinely inspected.

Carbon monoxide can cause severe nausea,fainting, or death. Use the following precautions wheninstalling and operating generator set. Carbonmonoxide is particularly threatening in that it is anodorless, colorless, tasteless, nonirritating gas. Beespecially careful if operating the generator whenmoored or anchored under calm conditions as gasesmay accumulate. If operating the set dockside, mooryour craft so that the exhaust discharges on the lee side(the side sheltered from the wind), and always bemindful of others— make sure your exhaust is directedaway from other boats and occupied buildings. Do notinstall exhaust outlet where exhaust can be drawnthrough portholes, vents, or air conditioners. Ifgenerator set’s exhaust discharge hole is near to yourcraft’s waterline, DO NOT OVERLOAD CRAFT so as toclose or restrict exhaust discharge hole.


10AFUSE

BATT.CHRG.

INPUT

NOTEUse two hose clamps on each end ofall flexible exhaust hose connections.

1. Heat Exchanger2. Exhaust Manifold3. Engine-Driven Seawater Pump4. 3 ft. (1 m) Max. Lift of Seawater Pump5. 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)

8. 4 in. (10 cm) Min. of Exhaust Line Above Waterline9. Waterline

10. Seawater Strainer11. Intake Strainer12. 10 ft. (3 m) Max. Between Exhaust Outlet and Silencer13. Seacock14. Coolant Recovery Tank

11

NOTEData given is applicable toside-exhaust installations.

1 2

5

6

7

8

9

10

4

12

STOP/START

14 13

3

258000-D

Figure 6-17. Typical Above Waterline InstallationExhaust system guidelines for various generator setlocations follow. Where exhaust lines would requirepassage through bulkheads, it may be more practical touse port (left) or starboard (right) side exhaust outlets.This would be especially true where long exhaust linesto the transom (rear) could cause excessive back

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


Above WaterlineIn addition to considerations described earlier, acustomer-supplied silencer should be installed with itsoutlet at a maximum of 10 horizontal ft. (3 m) from thecenter of the engine’s exhaust outlet (see Figure 6-17).A typical silencer should be mounted with the inlet andoutlet level and with the drain plug down. The silencermay require two supporting brackets or hanger strapsfor installation to stringers or other suitable structure.Any “lift”in the exhaust line to improve silencing must bebelow the engine exhaust manifold outlet.

Mid/Below WaterlineU.S.C.G. Regulations require that an anti-siphoningprovision be used to prevent raw water entry into theengine if the exhaust manifold outlet is located less than9 in. (23 cm) above the waterline when the craft is loadedto maximum capacity. Install a siphon break, seeFigure 6-18, at least 1 ft. (31 cm) above waterline asshown in Figure 6-19.

1

2

3

1. Mounting Base2. Retaining Cap

3. Reed Valve Assembly

1-779

Figure 6-18. Siphon Break ComponentsThe siphon break must be located at least 1 foot abovethe waterline at maximum vessel capacity between theheat exchanger and water elbow (three-way fittings).The siphon break and fitting must be supported tomaintain proper position and function. The siphon breakshould be mounted directly vertical of its connection togenerator set where possible. Otherwise, a slight offsetis allowable to clear stringers or other permanentstructures.

1. Siphon Break2. Exhaust Manifold3. Heat Exchanger4. 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.

7. Waterline8. Silencer (Customer Supplied)9. 10 ft. (3 m) Max.

10. Install Optional Water Lock Here11. Coolant Recovery Tank12. 1 ft. (30.5 cm) Min.


10AFUSE

BATT.CHRG.

INPUT

NOTEUse two hose clamps oneach end of all flexibleexhaust hose connections.

NOTEData given is also applicableto side-exhaust installations.

4

5

6

7

89

1011

12

STOP/START

12

3

258000-D

Figure 6-19. Typical Mid and Below Waterline Installation


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 stringersor other suitable structure. Then secure the silencer tohull using silencer manufacturer’s recommendation. Besure the silencer outlet is not more than 10 horizontal ft.(3 m) from the engine exhaust manifold outlet. ULmarine exhaust hose should be used.

Electrical SystemsAC Voltage Connections

WARNING


Explosive fuel vapors can cause severe injury ordeath. Gasoline vapors can explode and can causedeath or severe injury. USCG Regulation 33CFR183requires all electrical devices (ship-to-shore transferswitch, remote start panel, etc.) to be “ignition protected”when used in a gasoline (gaseous)-fueled environment.These electrical devices are not “ignition protected”andare not certified to operate in a gasoline(gaseous)-fueled environment such as engine room ornear fuel tanks. Acceptable locations would bewheelhouse or other living areas sheltered from rain andwater splash.

WARNING

Hazardous voltage.

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

Moving rotor.

Can cause severe injury or death.

Hazardous “backfeed” voltage can cause severeinjury or death. Do not connect to any building/marinaelectrical system without connecting through anapproved device and after building main switch is open.Backfeed connections can cause serious injury or deathto utility personnel working to repair a power outageand/or personnel in the vicinity. Unauthorizedconnection may be unlawful in some states and/orlocalities. A ship-to-shore transfer switch must beinstalled to prevent interconnection of generator setpower and shore power.

AC connections to generator set are made inside thecontroller box. The generator set is usually connected toa ship-to-shore transfer switch which allows the use ofshore/utility power when docked or generator set powerwhen docked or at sea. The wiring is then connected to amain circuit breaker box (panelboard) which distributesbranch circuits throughout the craft. See Section 5.Wiring Diagrams for reconnectability of generator set.

Installation in Steel orAluminum Vessels

Installation of a generator set in a vessel constructed ofa material capable of conducting current (e.g.: steel oraluminum) is subject to considerations not normallyencountered in fiberglass or wood vessels. Thesedifferences include equipment grounding, grounding ofneutral conductors, ground fault protection, andisolation of galvanic currents.

While the scope of these topics is too extensive to befully discussed here, references to the appropriategoverning bodies will be identified for furtherinvestigation.

The information provided here is intended to serve as aguideline to boat manufacturers and generator setinstallers. This information is not intended or implied tobe limited to these sources and is subject to revision bythe appropriate governing bodies.

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

Generator sets installed in pleasure craft are governedby the U.S. Coast Guard and the American Boat andYacht Council, Inc. Compliance with U.S. Coast GuardRegulations given in Title 33, Part 183 must be followed.Generator sets installed in pleasure craft require agrounded neutral system as specified in ABYC E-8.4.b.Various wiring configurations are illustrated in ABYCStandards E-8.22 through E-8.29. Grounding ofappliances and equipment is covered in ABYC E-8.12.Galvanic corrosion prevention by means of galvanic


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

Generator sets installed in commercial vessels aregoverned by U.S. Coast Guard Regulations, Title 46, theAmerican Bureau of Shipping, and Lloyd’s Register ofShipping. Grounding of equipment is covered in ABS35.9.6 and Lloyd’s Part 6, Chapter 2-1, Section 1.3. Thetypes of permissible neutral grounding of generatingequipment are referenced in ABS 35.125 and 35.95.1and in Lloyd’s Part 6, Chapter 2-1, Section 14.4. Groundfault protection information can be found in Lloyd’s Part6, Chapter 2-1, Section 14.5 and Part 6, Chapter 2-2,Section 13.6.

BatteryBatteries and their installation must conform to U.S.C.G.Regulations 183.420 (a) through (g). Generator setsshould use batteries separate from the propulsionengines whenever possible. Both the generator set andthe propulsion engines’starting/charging systems musthave a common negative (--) ground.

U.S.C.G Regulation 183.415, Grounding, requires acommon conductor to be connected to each groundedcranking motor circuit. This conductor should be sized tomatch the larger of the engines’two battery cables.(Cable sizes for generator set battery connections aregiven in Figure 6-20.) This requirement prevents thestarting motor current from using alternative electricalpaths should the cranking motor ground circuit berestricted or open due to oxidation or loose hardware.These alternative electrical paths include metallic fuellines which can pose a fire hazard. See Figure 6-21 forbattery connections to generator set.

Distance BetweenGenerator Set andBattery

At 0°F(--18°C)

CableSize

(AWG)At 32°F

(0°C)At 75°F(24°C)

40 ft. (12.2 m) 00 0 130 ft. (9.1 m) 0 1 225 ft. (7.6 m) 1 2 420 ft. (6.1 m) 2 2 615 ft. (4.6 m) 2 4 610 ft. (3.0 m) 4 6 85 ft. (1.5 m) 6 6 82.5 ft. (0.8 m) 8 8 8

Figure 6-20. Battery Cable Sizes

1. Battery Positive (+)Connection

2. Battery Negative (--)Connection

1

2

ADV-5792-D

Figure 6-21. Battery Connection Bracket

WiringAll wiring must be stranded copper. Wire gauges andinsulation, conductor temperature ratings, sheathstripping, conductor support and protection, conductorterminals and splices, and overcurrent protection(circuit breakers, fuses) must conform to U.S.C.G.Regulations 183.425 through 183.460. Use rubbergrommets and cable ties, as necessary, to protect andsecure wiring from sharp objects, exhaust system, andany moving parts.


Remote Start Switch Connection

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

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

NOTEIf gauges are to be used, there must also be generatorset senders. Senders are optional on these generatorsets. Gauges and senders are available as serviceitems from an authorized Kohler servicedealer/distributor.

WT

OP

1 2 3

4 5 6

J3

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 StartJ3-6 Grey/Black Stop

NOTEAll wire is 16 gauge.Tape to insulate allunused lead ends.

1

2 3

4

6

7

5

1. Use Insulink or Solder Connection (Tape to Insulate)2. Hourmeter3. “ON”Light4. Stop

5. Start6. Rocker Switch7. Gauges Senders

Figure 6-22. Remote Control Panel Wiring

TP-5695 12/93 Installation Drawings 7-1

Section 7. Installation Drawings

ADV-

5792

-D

VIEW

A--A

MO

UN

TIN

GPA

TTER

N

EQU

IVAL

ENT.

ARE

MIL

LIM

ETER

DIM

ENSI

ON

SIN

()N

OTE

:

WIT

HH

USH

CO

VER

.5/

6.5

SUPP

LIED

STAN

DAR

D

WIT

HH

EAT

EXC

HAN

GER

WAT

ER--C

OO

LED

IGN

ITIO

NPR

OTE

CTE

D4/

6.5K

W60

HZ.

GAS

OLI

NE

MAR

INE

3.5/

5KW

50H

Z.G

ASO

LIN

E

A A

REM

OTE

CO

NN

ECTI

ON

SEA

WAT

ERIN

LET

.75

(.19)

I.D.H

OSE

1/4

STU

DFO

RBA

TTER

YC

ON

NEC

TIO

N(P

OSI

TIVE

)5/

16ST

UD

FOR

BATT

ERY

CO

NN

ECTI

ON

(NEG

ATIV

E).

1.65

(42)

.62

(16)

2.69(68)

9.13

(232

)

21.2

0(5

38)

1.0

(25)

1.0(25)

15.50(394)

GR

OU

ND

LUG

WAT

ERC

OO

LED

EXH

AUST

OU

TLET

FOR

2.0

(51)

I.D.

RU

BBER

HO

SE

14.19(360)

6.34

(161

)FU

ELIN

LET

1/4

N.P

.T.

15.4

3(3

92)

17.5

0(4

45)

OIL

DR

AIN

8.77(223)

27.8

7(7

08)

26.4

4(6

72)

.44

(11)

16.60(422)

5.89(150)

24.4

4(6

21)

ENG

INE

.406

DIA

.(4)

HO

LES

(10)

CIR

CU

ITBR

EAKE

RS

(OPT

ION

AL)

STAR

T/ST

OP

SWIT

CH

ENG

INE

CO

OLA

NT

CH

ECK

AND

FILL

ENG

INE

OIL

CH

ECK

AND

FILL

OIL

FILT

ER

C L

Shee

t1

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

TP-5695 12/937-2 Installation Drawings

ADV-

5792

-D

AA

VIEW

A--A

KIT

#26

7994

(4PI

ECE

CO

VER

).SO

UN

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IELD

SERV

ICE

WIT

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6.5K

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AND

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MIL

LIM

ETER

EQU

IV.

DIM

ENSI

ON

SIN

()AR

EN

OTE

:

31.0

7(7

89)

1.75(44)

8.67(220)

12.82(326)

3.12

DIA

.(79

)EX

HAU

STO

UTL

ETO

PEN

ING

1.92

(49)

1.57

(40)

.51

(13)

TYP.CLE

ARAN

CE

REQ

’DFO

RLA

TCH

OPE

NIN

G

3.07

(78)

17.8

6(4

54)

.50

R.

(13)

OPE

NIN

GFO

RFU

ELIN

LET

HO

SEAN

DBA

TTER

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ON

NEC

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NS

OPE

NIN

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S

.625

R.(

16)

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FOR

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ILL

(2)1

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OPT

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30.0

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64)

26.7

6(6

80)

1.65

(42)

2PL

ACES

18.1

0(4

60).5

0R

.(13

)

2.75

(70)

2.12

(54)

17.50(445)

Dono

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. 2679

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coul

dim

pair

oper

atio

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unit.

CAUT

ION

15.6

2(3

97)

4.00(102)

5.45(138)

1.75(44)

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

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

Section 8. Parts Ordering InstructionsFor service or information, check the yellow pages of thetelephone directory under the headingGENERATORS--ELECTRIC or contact the local marinafor the authorized Kohler service dealer/distributor in thearea.

KOHLER CO. KOHLER, WISCONSIN 53044PHONE 414-565-3381FAX 414-459-1646 (North American Sales),414-459-1614 (International)FOR SALES & SERVICE IN U.S.A. & CANADA PHONE1-800-544-2444

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

SPEC. numbers from the Generator Nameplate. (SeeNO TAG.)

In any communications regarding this generator set,please report the MODEL, SPEC. and SERIAL numbersas found on the nameplate attached to the generatorand engine. Enter numbers in spaces provided below.This information will enable the authorized Kohlerservice dealer/distributor to supply the correct part ordata for this particular model.

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

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

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

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

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

Section 9. Operating Hour Service LogThe following is provided to help you keep a cumulativerecord of operating hours on your generator set and the

dates required services were performed. Enter hours tothe nearest quarter hour.

OPERATING HOURS SERVICE RECORD

DATE HOURS RUN CUMULATIVE DATE SERVICE

TP-5695 12/93

PRINTED IN U.S.A.

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