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Kohler 3.5CFZ User's Manual

1. 258000 D Figure 1 1 Service Views typical Mixer Elbow Exhaust Water Outlet Belt Guard Electric Choke Rotary Solenoid Carburetor Governor Linkage Governor Arm Lifting Eye Speed Adjustment Idle Speed Antidieseling Solenoid Controller Battery Charger Voltage Regulator Coolant Overflow Hose Cooling S ystem Pressure Cap High Water Temperature Safety Shutdown Switch Thermostat High Exhaust Temperature Shutdown S witches 2 Spark Plugs Seawater P ump 1 6 Specifications Oil Drain Water Temperature Gender O ptional Heat Exchanger Ignition Coil M odule Low Oil Pressure Shutdown S witch S ender Sender Optional Oil Dipstick Oil Check Oil Fill Oil Filter Anticorrosion Zinc Electric Fuel Pump Remote Panel Connector Positive Battery Lead Connection Coolant Recovery Tank Air Filter Nameplate Negative Battery Lead Connection Equipment Ground Lug Starter Solenoid Starter Motor TP 5695 12 93 Section 2 Operation Prestart Checks To insure continued satisfactory operation the
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5. 1 258000 D 1 High Exhaust Temperature Shutdown Switches one located on each manifold Figure 2 4 High Exhaust Temperature Shutdown Switches Operation 2 5 Remote Panels Optional Remote Start Panel Remote start panel allows starting stopping from a location remote of the generator set Generator sets are equipped with a 6 pin connector on controller bottom for connection of the kit See Figure 2 5 1 ON Light 2 Start Stop Switch Figure 2 5 Remote Panel Features Remote Start and Two Meter Panel Kit Allows starting stopping from a location remote of the generator set The illuminated gauges include an engine oil pressure gauge and a water temperature gauge Generator sets come equipped with a 6 pin connector on controller bottom for connection of the kit See Figure 2 6 for remote start and meter panel kit 2 6 Operation KOHLER MARINE GENERATORS 1 Engine Oil Pressure 2 Water Temperature 3 Start Stop S witch 4 On Light Figure 2 6 Remote Start and Two Meter Panel Features Start Stop Switch is a rocker type switch with ON light used to start and stop generator set
6. 6 5 Fuel Supply 2a eR de mc Res 6 5 Anti Siphon Provisions 6 6 FuelLines ii aaa 6 6 Fuel Pump Lift Capabilities and Fuel Consumption 6 6 Cooling Systems 6 7 General 6 7 Closed Heat Exchanger 6 8 Exhaust Systems 6 9 General u a aces AUER deed wan sas 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 is br iii LE aa 6 13 WING uuo sed Ls ERU a de 6 13 Remote Start Switch Connection 6 14 Section 7 Installation Drawings 7 1 Section 8 Parts Ordering Instructions 8 1 Operating Hour Service Log 9 1 Safety Precautions and Instructions HAZARDOUS VOLTAGE ELECTRICAL SHOCK A WARNING A generator set like any other electro mechanical device can pose potential dangers to life and limb if improperly maintained or imprudently operated The best way to prevent accidents is to be aware of the potential dangers and to always use good common sense In the interest of safety some general precautions relating to the operation of a generator set follow Keep these in mind This manual contains several types of safety precautions which are explained below
7. 1 Harness Plug 2 Fuel Pump Screen Figure 3 7 Fuel Pump Screen Scheduled Maintenance 3 7 Carburetor Choke Lubrication The only maintenance reguired is to lubricate carburetor and choke linkage at the specified interval using white lithium grease or lubriplate Carburetor Adjustments The carburetor is a single barrel horizontal design and uses an electric choke Lack of power usually indicates that the fuel mixture is too rich An overrich mixture may also be caused by a clogged air intake backfire flame arrestor check this before readjusting carburetor Fuel mixture may be too lean if engine skips or backfires Minor carburetor adjustment may be necessary to compensate for differences in altitude fuel and temperature 1 With ENGINE STOPPED turn fuel mixture screw in clockwise until it seats lightly DO NOT FORCE Turn fuel mixture screw out 2 to 2 1 2 turns See Figure 3 8 2 Start engine and let it run at no load for about 5 minutes Before making adjustments engine should be thoroughly warmed up running at governed speed and connected to full load 3 Turn low speed mixture screw in until engine instability hunting develops and then screw out until engine instability is again apparent Turn screw back in until itis positioned halfway between the points of increasing stability When properly adjusted engine will operate with steady governor action 4 To adjust the idle speed run the generatorseta
8. A generator set should be mounted as high as possible to avoid bilge splash and lower lying vapors and also to allow downward pitch of the exhaust line For angular installation the maximum operation angle of the engine generator setis 20 in all directions 64 Ventilation Ventilation is required to support engine combustion generator cooling and expulsion of flammable and lethal fumes Ventilation provisions must comply with U S C G Regulations governing sizing of vents and operator requirements As a rule inlet and outlet vent areas should each be sized 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 conflict with U S C G Regulations appropriate Regulations should be followed If any screening is used in inlets size of hull deck openings should be doubled Vent ducts should extend to bilges to expel heavier than air fumes Ifthe generator setis to be mounted in the engine compartment air flow must be increased to allow for generator sets 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 cause alarm warning or engine shutdown should dangerous fumes accumulate in the compartment WARNING Explosion Gasoline vapors can cause explosion and severe injury or death Before starting generator set operate blower 4 minu
9. Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode Replace the anode when less than 5096 of the 11 32 in 9 mm dia by 9 16 in 14 mm long portion of zinc remains Clean threaded hole of heat exchanger and coat threads of anticorrosion zinc anode with pipe sealant suitable for marine applications Install anticorrosion zinc anode into heat exchanger Open seacock Start generator set and check for leaks at the anticorrosion zinc anode location Check for seawater flow by observing water discharge from exhaust outlet TP 5695 12 93 Pressure Cap Closed loop cooling systems incorporate a pressurized capto raise the boiling pointofthe coolantand make use of higher operating temperatures If leakage or malfunction occurs replace the pressurized cap with one supplied by Kohler Co part number 229958 1 Mounting Base 2 Retaining Cap 3 Reed Valve Assembly Figure 3 18 Siphon Break Siphon Break An optional siphon break is used to prevent seawater entry into the engine when the generator set is shut down Corrosion buildup may notallow the siphon break to function properly Therefore if used the siphon break must be inspected and cleaned periodically NOTE To prevent siphoning of seawater run the generator while performing this inspection Remove the retaining cap to inspect the reed valve See Figure 3 18 Clean the reed valve to remove residue and oxidation
10. A DANGER Danger is used to indicate the presence of a hazard that will cause severe personal injury death or substantial property damage if the warning is ignored A WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored A CAUTION Caution is used to indicate the presence ofa hazard that will or can cause minor personal injury or property damage if the warning is ignored Safety decals are affixed to the generator set in prominent places to advise the operator or service technician of potentially hazardous situations The decals are reproduced here to improve operator recognition and thereby increase decal effectiveness Fora further explanation of decal information reference the accompanying safety precautions Before operating or servicing the generator set be sure you understand the message of these decals Replace decals if missing or damaged NOTE Note is used to notify people oflinstallation operation or maintenance information that is important but not hazard related TP 5695 12 93 Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place Hazardous voltage can cause severe injury or death Wherever electricity is present there is the hazard of electrocution Take the same precautions with elec
11. 18_ C When using a maintenance free battery it is not necessary to check the specific gravity or electrolyte level Otherwise these procedures should be done at the intervals specified in the Service Schedule A WARNING Sulfuric acid in batteries Can cause severe injury or death Use protective goggles and clothes Can cause permanent damage to eyes burn skin and eat holes in clothing Sulfuric acid in batteries can cause severe injury or death Sulfuric acid in battery can cause permanent damage to eyes burn skin and eat holes in clothing Always wear splash proof safety goggles when working around the battery If battery electrolyte is splashed in the eyes or on skin immediately flush the affected area for 15 minutes with large quantities of clean water In the case of eye contact seek immediate medical aid Never add acid to a battery once the battery has been placed in service Doing so may result in hazardous spattering of electrolyte Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flame or spark to occur near a battery at any time particularly when it is being charged Avoid contacting terminals with tools etc to prevent burns and to prevent sparks that could cause an explosion Remove wristwatch rings and any other jewelry before handling battery Never connect negative battery cable to positive connection terminal of starter solenoid Do no
12. Engine Oil Pressure Gauge measures engine oil pressure Normal engine operating range is 30 50 psi 207 345 kPa NOTE During the engine break in period it is normal for the engine to produce higher oil pressure readings Water Temperature Gauge measures engine coolant temperature Normal engine operating range is 170 195 F 77 91 C TP 5695 12 93 Remote Start and Four Meter Panel Kit Allows starting stopping from a location remote of the generator set The illuminated gauges include a DC voltmeter engine oil pressure gauge water temperature gauge and generator running time hourmeter Generator sets come equipped with a 6 pin connector on controller bottom for connection of the kit See Figure 2 7 for remote start and four meter panel features 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 oil pressure Normal engine operating range is 30 50 psi 207 345 kPa NOTE During the engine break in period it is normal for the engine to produce higher oil pressure readings Water Temperature Gauge measures engine coolant temperature Normal engine operating range is 170 195 F 77 91 C Hourmeter records total generator set operating hours for reference in maintenance scheduling KOHLER MARINE
13. Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion To prevent fuel leakage use pipe sealant on all threaded fittings Pipe sealant must be suitable for use in marine applications having oil and gasoline environments TP 5695 12 93 ACCIDENTAL STARTING anne dok Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental starting can cause severe injury or death Disconnect battery cables remove negative lead first and reconnect it last to disable generator set before working on any equipment connected to generator The generator set can be started by remote start stop switch unless this precaution is followed MOVING PARTS A WARNING i lt Wer Ko Rotating parts Can cause severe injury or death Do not operate generator set without all guards screens or covers in place Flying projectiles can cause severe injury or death Retorque all crankshaft and rotor hardware after servicing When making adjustments or servicing generator set do not loosen crankshaft hardware or rotor thru bolt If rotating crankshaft manually direction should be clockwise only Turning crankshaft bolt or rotor thru bolt counterclockwise can loosen hardware and result in serious personal injury from hardware or pulley flying off engine while unit is running Exposed moving parts
14. 90 F 32 C Above 15 F 10 C 20W40 or 20W 50 Above 5 F 21 C 10W40 Preferred Figure 3 2 Recommended SAE Viscosity Grades Using other than the appropriate service class oil or extended oil change intervals could cause engine damage which is not covered by the engine warranty Do not mix oils of different viscosities Itis also bestnot to mix different brands of oils Possible incompatibility could cause a breakdown of lubricating ingredients and reduce engine protection 3 4 Scheduled Maintenance Oil Check Check oil level in crankcase daily or before each startup to insure that the level is in the safe range NOTE Do not check oil level when unit is running Generator set must be stopped and level to get an accurate reading If generator set has just been run allow a few minutes for the oil to return to the oil pan before checking level To check oil level remove dipstick and wipe the end Clean place bottom thread of dipstick againstoil fill hole and remove Do notscrew in dipstick when checking oil level Level should be between MIN and MAX marks on dipstick See Figure 3 3 NOTE Do not operate the set ifthe level is below the MIN mark or above the MAX mark Oil above the MAX mark is wasted due to increased oil consumption 1 MAX Limit 2 MIN Limit 3 Safe Range Figure 3 3 Checking Oil Level TP 5695 12 93 Adding Oil 1 Place oil drain hose in a proper container Remove oil
15. Check that the reed valve opening is clear Replace the siphon break if the material has hardened or deteriorated Install the reed valve with the TP 5695 12 93 valve downward into the mounting base Install retaining cap and tighten finger tight only Do NOT overtighten Air Cleaner and Mixing Elbow Servicing Air Cleaner The engine is equipped with a dry type air cleaner Every 50 hours more often if operating under dusty or dirty conditions remove element and service by tapping element lightly against flat surface to dislodge loose surface dirt Do not clean in any liquid or blow out with compressed air as this will ruin filter material in element Service air cleaner after each 50 hours of operation If dirty bent or damaged replace element with genuine Kohler replacement See Figure 3 19 Figure 3 19 Air Cleaner Service Servicing Mixing Elbow The mixing elbow combines high temperature exhaust and cooling seawater These conditions are conducive to rapid deterioration and combined with engine vibrations premature failures if not properly maintained Check the mixing elbow for carbon buildup and corrosion inside the pipe Clean or replace the mixing elbow as necessary Inspect the exhaust manifold mounting threads for cracking and corrosion Scheduled Maintenance 3 17 Battery The starting battery should be a 12 volt unit with a minimum 250 CCA cold cranking Amps at 0_ F
16. and isolation of galvanic currents While the scope of these topics is too extensive to be fully discussed here references to the appropriate governing bodies will be identified for further investigation The information provided here is intended to serve as a guideline to boat manufacturers and generator set installers This information is not intended or implied to be limited to these sources and is subjectto revision by the appropriate governing bodies Prior to installing the generator set check the wiring diagrams to become familiar with the electrical system Generator sets installed in pleasure craft are governed by the U S Coast Guard and the American Boat and Yacht Council Inc Compliance with U S Coast Guard Regulations given in Title 33 Part 183 mustbe followed Generator sets installed in pleasure craft require a grounded neutral system as specified in ABY C E 8 4 b Various wiring configurations are illustrated in ABYC Standards E 8 22 through E 8 29 Grounding of appliances and equipment is covered in ABYC E 8 12 Galvanic corrosion prevention by means of galvanic TP 5695 12 93 isolator or isolation transformer is referenced in ABYC E 8 20 and ABYC E 8 11 Generator sets installed in commercial vessels are governed by U S CoastGuard Regulations Title 46 the American Bureau of Shipping and Lloyd s Register of Shipping Grounding of equipment is covered in ABS 35 9 6 and Lloyd s Part6 Chapter 2 1 Section 1
17. engine exhaust and ejected out the exhaust outlet The coolant is circulated through cooling passages to cool the engine All models make use of a coolant thermostat anda coolant recovery tank The coolant capacity ofthe engine with heat exchanger is 0 72 U S qts 0 68 L for all models A solution of 50 ethylene glycol and 50 clean softened water is recommended to inhibit rust corrosion A coolantsolution of 50 ethylene glycol will provide freezing protection to 34 379 and overheating protection to 2650 1299 A coolant solution with less than 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause damage to engine and components Do not use alcohol or methanol antifreeze or mix them with the coolant Filling and Checking A WARNING Hot coolant and steam Can cause severe injury or death Before removing pressure cap stop generator allow to cool and loosen pressure cap to relieve pressure Hot coolant can cause severe injury or death Allow engine to cool and release pressure from cooling system before opening pressure cap To release pressure cover the pressure cap with a thick cloth then turn it slowly counterclockwise to the first stop After pressure has been completely released and the engine has cooled remove cap If generator set is equipped with a coolantrecovery tank check coolantlevel attank 3 12 Scheduled Ma
18. locations follow Where exhaust lines would require passage through bulkheads it may be more practical to use port left or starboard right side exhaust outlets This would be especially true where long exhaust lines to the transom rear could cause excessive back 6 10 Installation pressure Information and illustrations of stern rear exhaust installations also apply to side exhaust installations Should any information regarding installation conflict with U S C G Regulations appropriate Regulations should be followed TP 5695 12 93 Above Waterline In addition to considerations described earlier a customer supplied silencer should be installed with its outlet ata maximum of 10 horizontal ft 3 m from the center of the engine s exhaust outlet see Figure 6 17 A typical silencer should be mounted with the inlet and outlet level and with the drain plug down The silencer may reguire two supporting brackets or hanger straps ERE stringers or other suitable structure Any lift in the exhaust line to improve silencing must be below the engine exhaust manifold outlet Mid Below Waterline U S C G Regulations require that an anti siphoning provision be used to prevent raw water entry into the engine if the exhaust manifold outlet is located less than 9 in 23 cm above the waterline when the craftis loaded to maximum capacity Install a siphon break see Figure 6 18 at least 1 ft 31 cm above waterline as sh
19. 0 16 0 24 Ohms Resistance 10 Amp Ignition Coil Primary Wire 0 9 1 1 Ohms Resistance Ignition Coil Secondary 0 9 1 1 Ohms Spark Plug Wire Side Resistance With Spark Plug Boot Cap Removed Transistorized Ignition Air Gap 0 016 30 008 in 0 4 30 2 mm Timing Belt Deflection 0 16 0 20 in 4 5 mm 4 4 Ibs 2 kg 1 4 Specifications TP 5695 12 93 Accessories Several accessories are available to finalize the or to add convenience to operation and service Allthe mostcurrentinformation can be obtained by contacting the local authorized Kohler dealer distributor Available accessories at the time of print of this publication are as follows Sound Shield Optional on 3 5CFZ ACZ Standard on 5CFZ 6 5CZ Provides for highly effective silencing ease of access for engine generator servicing low maintenance excellent durability and safety Seawater Strainer The seawater strainer with clear viewing container allows easy cleaning and maintenance Threaded for 1 2 NPT fittings Ship to Shore Transfer Switch The ship to shore transfer switch allows immediate switching to generator set power or shore power protecting the electrical system from the possibility of simultaneous connection of both power sources Remote Start Panel Allows starting stopping from a location remote of the generator set Supplied with 15 foot 4 6 m connection harness Overall mounting dimensions are 4 1 16 in 103 mm by 2 1 8 in 54 mm w
20. 10 8 To Shore Power O gt To Load To Load Kraus Naimler American Solenoid Early Rectangular Design 3 Wire Generator Sets ee ger 1 2 6 5 O gt O gt 7 To Generator 710 Shore Set Power Lo lt O O O 9 10 ail 13 Y To Load 5 To Shore Power To Load Kraus Naimler American Solenoid Newer Round Design 3 Wire Generator Sets l ToShore Power O gt L2 O 5 ToGenerator 7 Set Lo 0 11 5 To Shore Power To Load To Load Figure 5 3 Marine Manual Ship to Shore Transfer Switch Wiring Diagrams 5 3 Four Lead Reconnectable Single Phase Generator Sets Where Generator Output Can Be Reconnected For 120 volt or 120 240 volt 60 Hz 110 volt or 110 220 volt 50 Hz NOTE When a generator set is reconnected to a voltage different than nameplate voltage notice should be placed on the unit indicating this change Decals for this purpose are available from authorized Kohler dealers distributors 120 or 110 Volt 3 Wire 2 Pole Configuration Figure 5 4 J umper lead to be placed on line side of circuit breaker Leads L1 and L2 can either be leftas separate leads or can be connected together depending upon which is practical for the given application Regardless of the number of phase black leads used in the application both circuit breakers must have leads attached to the load side It is recommended that jumper lead be maintained for all straight 120 or 110 voltsystems s
21. Gun 250 Television 300 750 Toaster 750 1200 Water System 500 1500 300 1250 Figure 6 3 Appliance Average Wattage Ratings 60 Hz TP 5695 12 93 INPUT STOP START Sei ej Erdem NOTE Use two hose clamps on each end of all flexible exhaust hose connections Indicated components must conform to U S C G Regulations 1 Heat Exchanger Siphon Break See Instruction Sheet TT 927 for P roper Installation Exhaust Mixer Engine Driven S eawater Pump Exhaust Hose Seawater Strainer Raw Waterline N zl Sr En a A LO 10 11 12 13 14 258000 D Intake Through Hull Strainer Seacock Mounting Base Mounting Tray Coolant Recovery Tank Hose Clamp Fuel Line Figure 6 4 Typical Location and Mounting TP 5695 12 93 63 Location General Consider the following in selecting or constructing a generator set location Compartment location
22. and test leads away from belts and pulleys when unit is running Replace guards covers and screens before operating generator set Flying projectiles can cause severe injury or death Retorque all crankshaft and rotor hardware after servicing When making adjustments or servicing generator set do not loosen crankshaft hardware or rotor thru bolt If rotating crankshaft manually direction should be clockwise only Turning crankshaft bolt or rotor thru bolt counterclockwise can loosen hardware and result in serious personal injury from hardware or pulley flying off engine while unit is running 1 Remove rocker arm cover screws using a 10 mm wrench Carefully pry rocker arm cover off cylinder cover Wipe excess oil from components using a clean rag 2 Expose timing belt a Close seacock and drain seawater from hoses Remove seawater pump hoses at seawater pump 3 20 Scheduled Maintenance b Remove two screws to release seawater pump bracket c Remove housing enclosing ignition coil d Remove seawater pump from camshaft pulley e Remove timing belt cover belt guard NOTE To reduce force needed to rotate crankshaft remove the spark plugs Using a ratchet wrench on the crankshaft nut rotate the crankshaft clockwise as viewed from engine end until No 1 cylinder is at the top of its compression stroke and the T mark on flywheel is aligned with the triangle symbol on the engine block See Figure 3 22 The
23. and use the following procedure amme Dr AOS Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental starting can cause severe injury or death Disconnect battery cables remove negative lead first and reconnect it last to disable generator set before working on any equipment connected to generator The generator set can be started by remote start stop switch unless this precaution is followed A WARNING Hot coolant and steam Can cause severe injury or death Before removing pressure cap stop generator allow to cool and loosen pressure cap to relieve pressure Hot coolant can cause severe injury or death Allow engine to cool and release pressure from cooling system before opening pressure cap To release pressure cover the pressure cap with a thick cloth then turn it slowly counterclockwise to the first stop After pressure has been completely released and the engine has cooled remove cap If generator set is equipped with a coolantrecovery tank check coolantlevel attank 1 Disconnect the battery negative lead first 2 With engine cooled remove the air bleed screw and the high water temperature safety shutdown switch from the thermostat housing 3 Connect kit hose fittings to the engine Install kit hoses to fittings if not already done 3 14 Scheduled Maintenance 10 11 12
24. authorized Kohler service WE Engine stars but does not continue to run after start switch Defective low oil pressure LOP safety Check LOP shutdown switch is released shutdown switch High temperature shutdown Check cooling system Defective high exhaust temp HET and or Check HET and or HWT shutdown high water temp HWT safety shutdown switch es switch es Replace and regap plug s Unit cranks but will not start Hard starting TP 5695 12 93 Troubleshooting 4 1 Engine Continued Stops suddenly Faulty spark plug s Replace spark plug s No low oil pressure Check oil pressure and pump Defective low oil pressure LOP safety Check LOP shutdown switch shutdown switch High temperature shutdown Check engine coolant system Defective high exhaust temp HET and or Check HET and HWT shutdown switch es high water temp HWT safety shutdown switch es dealer distributor Lacks power Faulty spark plug s Replace and regap plug s Operates erratically 4 2 Troubleshooting TP 5695 12 93 Engine Continued Overheats Improper cooling Check intake and outlet openings Check coolant level and pressure cap Check raw water strainer Unitis noisy Nolinstallation clearance unit hits craft Check clearances structure or compartment pe Excessive vibration engine generator See authorized Kohler service Loose or vibrating sheet metal Check shrouds Electrical System Possible Cause Corrective
25. cap and check coolant level TP 5695 12 93 1 Air Bleed Screw Use 12 mm Wrench Figure 3 14 Air Bleed Screw 3 2 258000 D 1 Coolant Recovery Tank 3 Coolant Pressure Cap 2 Overflow Hose Figure 3 15 Coolant Pressure Cap TP 5695 12 93 INPur STOP START aid oO ARE vam es g FE q z 7 L J 1 MAX Mark 258000 D 2 MIN Mark Figure 3 16 Checking Coolant Level Scheduled Maintenance 3 13 Flushing and Cleaning If required flush coolant from generator set To properly flush coolant obtain Kit 267999
26. compression stroke is the period between the closing of the intake valve and the opening of the exhaust valve The marks define the TDC top dead center point where both intake and exhaust valves will be closed Insert feeler gauge between rocker arm and exhaust valve for No 1 cylinder If necessary adjust screw so that very slight drag is felt on the feeler gauge as it is withdrawn Loosen the adjusting screw locknut and turn the adjusting screw to obtain the specified clearance Retighten the locknut while holding the adjusting screw See Figure 3 23 Recheck the valve clearance after tightening the locknut R epeat step for intake valve of No 1 cylinder Rotate crankshaft 360 degrees clockwise and set valve clearances on No 2 cylinder 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 two Screws e Install seawater pump hoses to seawater pump Open seacock With mating surfaces clean and gasket properly aligned install rocker arm cover and screws Remove ratchet wrench from crankshaft nut TP 5695 12 93 1 Feeler Gauge 3 Locknut Use 9 mm 2 Adjusting Screw 3 mm Wrench 1 Y Mark 2 T Mark Square Head Figure 3 22 Determining Top Dead Center Figure 3 23 Valve Adjustment TP 5695 12 93 Scheduled Maintenance 3 21 Gove
27. depends largely upon proper Remember that the generator set will probably be the craft s sole source of electrical power When installing a marine generator set it is recommended that the comply with all applicable Regulations and Standards See Reference Material for documents issued by governing agencies Information presented here should be followed in planning and making installations Specifications given should be used only in initial planning Use current dimension drawings and wiring diagrams NOTE A wood block is located under some generator set end brackets to prevent damage during shipment For the same reason metal brackets are used to attach some generator sets to their wood shipping bases These items MUST be removed EC eien order to provide adequate vibration clearance during generator set operation Check thatall packing material literature and loose accessories are removed from generator set prior to operation Generator Selection and Wattage Requirements Total wattage requirements lights motors appliances must be considered when selecting a generator set or when sizing wattage usage where available space and construction limit the size of the generator set The 4 lead reconnectable generator set can be connected for 120 volt or 120 240 volt 60 Hz 110 volt or 110 220 volt 50 Hz see Section 5 Wiring Diagrams NOTE When a generator set is reconnected to produce a voltage different than nameplate vol
28. disconnect pump conditions Change oil while the engine is still warm S ee Figure 3 5 and use the following procedure 6 Replace oil drain cap Remove oil fill cap Add oil using a funnelorother suitable pouring device See Specifications Engine for oil capacity and Lubrication System Specifications for proper service class and SAE viscosity of oil Replace oil fill cap 7 Start generator set and check for leaks at oil drain cap and oil filter 8 Stop generator set Wait a few minutes for oil to return to oil pan Remove dipstick and wipe clean reinsert as far as possible and remove to check oil 1 Oil Drain Cap level Add oil as necessary to bring level up to Figure 3 5 Oil Drain Cap MAX mark TP 5695 12 93 Scheduled Maintenance 3 5 a IN nn LTM CROS ES I O 1 Oil Filter Wrench 2 1 2 in 64 mm Dia Figure 3 6 Removing Oil Filter 3 6 Scheduled Maintenance Fuel System Specifications For best results use only clean fresh regular gra
29. hull strainers A sea chest is a concave molded in the hull chamber thatis also aligned to the direction of travel A sea chest configuration applies a positive pressure similar to a scoop type thru hull strainer A seacock is to be mounted to hull assembled onto the intake and accessible for operation Figure 6 12 shows a typicallinstallation Installthe canvas on the outside of the hull and the canvas or rubber packing on the inside of the hull If caulking is used to seal the seacock be sure not to apply an excessive amount Excess caulk can cause improper water flow and in some cases develop a barrier which can force water upward past the seawater pump and into the engine cylinders when the vessel is moving and generator set is shut down TP 5695 12 93 NOTE Intakes are positioned in relation to vessel travel So neither will be in the wake of the other 1 789 1 Generator Set Intake 3 Aft 2 Propulsion Engine 4 Fore Intake Figure 6 11 Intake Strainer 4 Direction of Vessel 1 Inside Packing 2 Outside Packing Movement 3 Seacock Cover 5 Typical Intake Thru Hull Strainers Figure 6 12 Seacocklinstallation 6 7 A seawater strainer of sufficient capacity should be mounted to the seacock or permanent structure ata point not higher than the seawater pump The strainer should be accessible for servicing See Figure 6 13 fora typical The opti
30. must allow adeguate space for ventilation cooling and exhaust system installation service access to the engine and generator and proper fuel systemlinstallation Engine stringers or other available structural members must provide adequate support for the generator set weight A generator set compartment must be sealed to prevent exhaust gases and fuel vapors from entering cabins Generator sets located above deck must have a protective cover to prevent damage from rain and water splash This cover must not affect cooling air flow and serviceability See Figure 6 4 fora typicallinstallation and S ection 1 for dimensions and weights Space Location should allow easy access to the generator set s engine controller cooling and fuel system components for routine service Engine compartments are often ideal generator set locations but access should not be obstructed by propulsion engines or generator and controller Also allow clearance for vibration during operation Minimum recommended clearance for vibration and cooling of top front rear and sides of generator set is 1 1 2 in 38 mm Mounting Engine stringers generally provide the bestsupportfor a generator set Any structural members considered for mounting must support the generator set weight and withstand engine vibration The generator set includes vibration mounts and mounting trays additional vibration isolating pads may be installed between trays and bases
31. of used coolant in a proper manner Do NOT pollute waterways Scheduled Maintenance 3 15 Anticorrosion Zinc An anticorrosion zinc anode is installed in the heat exchanger to preventelectrolytic corrosion by seawater When different metals such as iron and copper are placed in a highly conductive liquid seawater the iron gradually rusts The zinc has chemical properties which cause the seawater to react to it rather than the engine components The anticorrosion zinc anode should be checked every 100 hours or three months and replaced every 200 hours or yearly Depending upon operating conditions and seawater properties the anticorrosion zinc anode may have to be replaced more frequently See Figure 3 17 and use the following procedure 258000 D 2 Anticorrosion Zinc 1 Heat Exchanger Figure 3 17 Removing Anticorrosion Zinc 3 16 Scheduled Maintenance With generator set cooled drain the cooling seawater system Close seacock remove anticorrosion zinc anode from heat exchanger
32. recommended that the following Regulations and Standards be followed when installing Marine Generator Sets Pleasure Craft Designed and manufactured to meet U S Coast Guard Title 33 U S Coast Guard Code of Federal Regulations Title 33 Subparts I Electrical Systems Subparts J Fuel Systems Title 46 Subchapter F Marine Engineering Part 58 Main and Auxiliary Machinery and Related Systems Order the above publications from Superintendent of Documents U S Government Printing Office Washington DC 20402 1 202 783 3238 Boating Safety Circular Commandant G BC Boating Statistics G BP 1 U S Coast Guard Headquarters 2100 Second Street S W Washington DC 20593 0001 Boating Safety Hotline 1 800 368 5647 American Bureau of Shipping Rules for Building and Classing Steel Vessels 45 Eisenhower Drive Paramus N J 07652 201 368 9100 viii Reference Material Lloyds Registry of Shipping Rules for Classification of Ships 17 Battery Place New York N Y 10004 212 425 8050 Underwriters Laboratories Inc UL Publications Stock 333 Pfingsten Road Northbrook IL 60062 Marine Department 1 919 549 1400 NFPA 302 National Fire P rotection Association 60 Batterymarch P ark Quincy MA 02269 Customer Service Society of Automotive Engineer s SAE 400 Commonwealth Drive Warrendale PA 15096 1 412 776 4970 American Boat and Yacht Council Inc ABYC 3069 Solomon s Island Rd Edgewater MD 210
33. the coolanthas been drained it normally requires some time before complete refill of the engine water jacket takes place NOTE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings American Standard hardware uses a series of markings and metric hardware uses a numeric system to indicate hardness Check markings on bolt head and nuts for proper identification NOTE When a fuse replacementis required be sure fuse has the same ampere rating and is the same type for example ABC or 3AB ceramic Do not substitute clear glass type fuses for ceramic fuses If ampere rating is unknown or questionable see Wiring Diagram NOTE High mineral content sea water salt water can cause rapid destruction of all metals Wipe up all salt water spillage on and around generator set and keep metal surfaces free from accumulated salt deposits TP 5695 12 93 NOTICE This generator set has been rewired from its nameplate voltage to 246242 NOTICE This is a positive terminal only Do not attach negative lead NOTICE Check zinc anode every 100 hours or 3 months NOTICE Do not use as a step Standing on genset could impair operation of unit NOTE Split lock washers may be supplied with some kits If split lock washers are supplied with kit their use is optional Safety Precautions and Instructions vii Reference Material Itis
34. 2 93 NOTE Fuelsystems mustconform to U S C G Regulations and tests aa v A WARNING W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Do not modify the tank or propulsion engine fuel system Craft must be equipped with a tank allowing one of the two pickup arrangements described Tank and installation must conform to U S C G Regulations 1 Fuel Line to Generator Set Figure 6 7 Single Dip Tube 65 Anti Siphon Provisions Anti siphon devices must be installed if any section of fuelline lies below the highest pointofthe fuel tank The anti siphon device should be either a spring loaded check valve tested to function with the particular installation s siphon head or an electrically operated shutoff valve UL ignition protected tested to U S C G Regulations which may be operated manually A check valve should be installed ata point above fuel tank s highest point secured to craft s structure and be accessible without removing any permanent structure The fuel line section between the tank and check valve must be located above the tank s highest point An electric shutoff valve should be installed at the tank s fuel withdrawal fitting and be wired to open when the generator set engine is cranking or running Anti siphon holes drilled in f
35. 3 The types of permissible neutral grounding of generating equipment are referenced in ABS 35 125 and 35 95 1 and in Lloyd s Part6 Chapter 2 1 Section 14 4 Ground fault protection information can be found in Lloyd s Part 6 Chapter 2 1 Section 14 5 and Part 6 Chapter 2 2 Section 13 1316 6 Battery Batteries and theininstallationjimustconform to U S C G Regulations 183 420 a through g Generator sets should use batteries separate from the propulsion engines whenever possible Both the generator setand the propulsion engines starting charging systems must have a common negative ground U S C G Regulation 183 415 Grounding requires a common conductor to be connected to each grounded cranking motor circuit This conductor should be sized to match the larger of the engines two battery cables Cable sizes for generator set battery connections are given in Figure 6 20 This requirement prevents the starting motor current from using alternative electrical paths should the cranking motor ground circuit be restricted or open due to oxidation or loose hardware These alternative electrical paths include metallic fuel lines which can pose a fire hazard See Figure 6 21 for battery connections to generator set TP 5695 12 93 Cable Size Distance Between AWG Generator Set and AtO F At32 F At75 F Battery 18xC 0C 24 C 40 ft 12 2 m 00 0 1 30 ft 9 1 m 0 1 2 25 ft 7 6 m 1 2 4 20 ft 6 1 m 2 2
36. 37 1 410 956 1050 1 410 974 8112 1 410 956 2737 FAX IEEE 45 The Institute of Electrical and Electronics Engineer s Inc 345 East 47th Street New York NY 10017 TP 5695 12 93 Commercial Vessels In order to use these generator sets for commercial applications where U S Coast Guard Title 46 Certificate is required additional modifications will be necessary U S Coast Guard Code of Federal Regulations Title 46 Subchapter F Marine Engineering Part 58 Main and Auxiliary Machinery and Related Systems Subchapter J Electrical Engineering Part 111 Electrical S ystems G eneral R equirements Part 112 Emergency Lighting and Power S ystems Subchapter T S mall Passenger Vessels Under 100 Gross Tons Part 182 Machinery Installation Part 183 E lectrical Installation Order the above publications from Superintendent of Documents U S Government Printing Office Washington DC 20402 1 202 783 3238 American Bureau of Shipping ABS 65 Broadway New York NY 10006 Order ABS publications from American Bureau of Shipping Book Order Section 45 Eisenhower Drive P O Box 910 Paramus NJ 97653 0910 Lloyd s Register of Shipping 71 Fenchurch Street London EC3M 4BS England Midwest Office Lloyd s Register of Shipping 100 South York Street Room 226 Elmhurst IL 60126 1 312 279 5414 Additional References The following organizations provide a service which may be useful to the generator set installer These O
37. 4 0 86 3 25 25 Em SSCS how 10096 0 68 2 57 1 02 3 86 TP 5695 12 93 Specifications 1 1 Generator scr Rotor Resistance cold ohms Stator Resistance co rest Leit e eo eee RE see 0 EC RER FmmexyHz BE BEE EEE BEE Stator Resistance ces ei EE REEL 3 55 66 31 82 ow t women or 3 5CFZ 4CZ 5CFZ 6 5CZ Generator Type Two Pole Rotating Field Voltage Regulation Frequency Regulation Ee in all directions i Reconnecable iwtPmiedom CCC Most ohmmeters will not give accurate readings when measuring less than 1 ohm The stator can be considered good if a low resistance reading continuity is obtained and there is no evidence of shorted windings discoloration Do not confuse a low resistance reading with a reading indicating a shorted winding 2 Thru Bolt Torque ft lbs Nm 37 50 1 2 Specifications TP 5695 12 93 DERATING All units are rated 1 0 power factor Derate approximately 3 5 per 1000 ft 300 m above 500 ft 150 m above sea level 3 5CFZ 50 Hz 3 5 kW at 77 oF 25 C and 3 5 kW at 122eF 50 C ACFZ 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 250C and 4 85 kW at 122 F 50 C 6 5CZ 60 Hz 6 5 kW at 77 F 250C and 6 kW at 122eF 50 C Engine Some general engine specifications are listed below Refer to the appropriate service section and the engine service manual for specific service de
38. 6 15 ft 4 6 m 2 4 6 10 ft 3 0 m 4 6 8 5 ft 1 5 m 6 6 8 2 5 ft 0 8 m 8 8 8 Figure 6 20 Battery Cable Sizes gt ADV 5792 D 1 Battery Positive Connection 2 Battery Negative Connection Figure 6 21 Battery Connection Bracket Wiring All wiring must be stranded copper Wire gauges and insulation conductor temperature ratings Sheath stripping conductor support and protection conductor terminals and splices and overcurrent protection circuit breakers fuses must conform to U S C G Regulations 183 425 through 183 460 Use rubber grommets and cable ties as necessary to protect and secure wiring from sharp objects exhaust system and any moving parts 6 13 Remote Start Switch Connection Kohler offers several remote panels for connection to the generator set See Accessories for further detailed description A wiring harness with a connector keyed to the controller box connector is available to connect these panels to the generator set The other end of this harness has pigtails which can be used if the installer Lead Desi gnations Pim Lead Function Black Ground Tan Water Temp Ga Lt Blue Oil Pressure Ga Violet Gen ON Yellow R ed Start Grey Black Stop elects to use just a start stop switch or separate lights and hourmeter See Figure 6 22 NOTE If gauges are to be used there mu
39. 695 12 93 NOTE Some battery testers simply have four or five beads ina tube Draw electrolyte into the tube Use instructions with tester otherwise see the following chart Five Beads Floating O vercharged Four Beads Floating Fully Charged Three Beads Floating A Good Charge One or Two Beads Floating A Low Charge No Beads Floating A Dead Battery Charging The engine battery charging circuit will provide a charge of 12 volts at up to 10 amps NOTE If the battery is used while the craft is docked and the generator setis notrunning i e auxiliary lights two way radio etc the battery will be drained and may nothave enough power to start the generator set later Therefore it may be necessary to connect a battery charger while the craft is docked and running on shore power Scheduled Maintenance 3 19 Valve Adjustment With overhead cam engines each valve is spring held in the closed position until forced open by the action of the rocker arm in contact with the camshaft Rocker arms have adjusting screws and locknuts for adjusting valve stem to rocker arm clearance Check clearance with the engine cold See Specifications Engine for intake and exhaust valve clearances A WARNING Rotating parts Can cause severe injury or death Do not operate generator set without all guards screens or covers in place Exposed moving parts can cause severe injury or death Keep hands feet hair clothing
40. Action Battery will not Loose or corroded connections Clean and tighten connections batteries with filler caps only Battery charging fuse blown Replace fuse If fuse blows again see TT Leer Starter does not work properly Low battery output Check electrolyte level and specific gravity batteries with filler caps only Check battery voltage Starter cranks Low battery output Check electrolyte level and specific gravity Loose or corroded wiring Clean and tighten loose connections High starter current draw Rebuild or replace starter Battery cable undersize See nstallation Section E lectrical Systems TP 5695 12 93 Troubleshooting 4 3 Generator Possible Cause Corrective Action No AC output Circuit breakerin OFF position Resetbreaker to ON position Circuit breaker tripped due to overload on Reduce load See Wattage Requirements generator set Reset breaker to ON position Ship to shore transfer switch in OFF or Turn switch to generator power SHORE position No DC power to controller Check battery connections Controller fuse blown Replace fuse Generator malfunction such as capacitor See authorized Kohler service Eu LLL other internal fault UT REI Low output or Engine Engine speed too low too low Adustgovenr sd excessive drop in Generator overloaded Reduce load See Wattage Requirements voltage RI 9 Engine in poor condition If routine services are performed and condition persists see authorized
41. Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place 6 12 Hazardous backfeed voltage can cause severe injury or death Do not connect to any building marina electrical system without connecting through an approved device and after building main switch is open Backfeed connections can cause Serious injury or death to utility personnel working to repair a power outage and or personnel in the vicinity Unauthorized connection may be unlawful in some states and or localities A ship to shore transfer switch must be installed to prevent interconnection of generator set power and shore power AC connections to generator set are made inside the controller box The generator setis usually connected to a ship to shore transfer switch which allows the use of shore utility power when docked or generator set power when docked oratsea The wiring is then connected to a main circuit breaker box panelboard which distributes branch circuits throughout the craft See Wiring Diagrams for reconnectability of generator set Installation in Steel or Aluminum Vessels Installation of a generator set in a vessel constructed of a material capable of conducting current e g steel or aluminum is subject to considerations not normally encountered in fiberglass or wood vessels These differences include equipment grounding grounding of neutral conductors ground fault protection
42. Connecta garden hose to the female connector of large kit hose Place the free end of the small kit hose in a 1 2 gal min bucket NOTE Heat exchanger pressure cap MUST be installed Turn on water supply to flush coolant from engine block Turn off water supply when clean water is observed coming from hose in bucket Disconnectgarden hose Place free end oflarge kit hose into bucketand connectan airhose to the free end of the smaller kit hose Apply air pressure 40 psi 276 kPa min until water stops flowing from kit hose in bucket This will remove about 16 fl oz 0 47 L of water from engine block NOTE Engine coolant capacity is 23 fl oz 0 68 L NOTE Some small air compressors may not maintain pressure under the required flow conditions In these cases itis recommended thatthe end ofthe kit hose in the bucket be closed off momentarily until pressure is allowed to build up After pressure has accumulated open end to allow water to flow into bucket Repeat closing and opening end of kit hose as required Remove kit hoses with hose fittings from engine Apply pipe sealant to threads of high water temperature safety shutdown switch and install switch in thermostat housing Reconnect wiring harness lead to switch Apply pipe sealantto the air bleed screw and install screw into engine Do not final tighten Remove cap of coolant overflow bottle and pour contents into a suitable container Rei
43. GE WATER TEMPERATURE GAUGE BATTERY VOLTMETER voa T L t J THERMAL SWITCH ALTERNATOR S OIL PRESSURE SENDER 120 240 V CONNECTION WATER TEMP SENDER 246482 D Figure 5 1 Schematic Wiring Diagram 3 5CFZ 4CZ 5CFZ and 6 5CZ TP 5695 12 93 Wiring Diagrams 5 1 MOLYNYSLIV DEE EN 13Nvd 310w3u 39nv9 v ONY Z 13NV4 40 MIIA iov DIER na GEET dois amon aaunaA 1310144 anon aman QN3 NOLLU3SNI Nid WOH NMOHS YOLI INNOD 310N Tanya aLowau favo unawd SOHO LOH i 97 76 L veer Nouvuoxa E y E O Iren SYINMO 335 ONLY aOvUadWY HOS SECHER T NJ ou ag 2 9 6 ne en Ovulnaw OF NOLL23NNO2 A Ozz quvos Avia SL IVANY Su 3NMO 33s ONLY 39vu3dnv uO4 zua eg LINDY nl ama oo ea wo il NOLL23NNO2 A Ovz ozt o TEE IWnNVW SYINMO 33s ONLY Soeur HOS CH na 21 ag auo quo lt i noa T NOLLO3NNOO A ozt
44. GENERATORS a a NEA N 1 Engine Oil Pressure 2 Hourmeter 3 Voltmeter 4 Water Temperature 5 Start Stop Switch 6 ON Light Figure 2 7 Remote Start and Four Meter Features TP 5695 12 93 Operation 2 7 Section 3 Scheduled Maintenance Use the following service schedule and the hourmeter on the controller to schedule routine maintenance In addition to the routine services listed in this manual there are other important steps that should be taken to keep a generator set in top condition Usually tools and instruments required for these additional steps are not available to the generator setowner For this reason the set should be returned periodically to an authorized service dealer distributor for complete servicing and tune up The benefits of such service will be improved performance and continuous satisfactory operation during a long trouble free service life Use the Operating Hour Service Log in the back of this manual to document services performed Service intervals are located on the top rows of the Service Schedule chart It indicates how often maintenance tasks need to be done Each service item is to be repeated at the specified interval For example an item required at 50 hours will again need to be performed at 100 hours 150 hours etc Forcontinued satisfactory o
45. If a torque the feeler or wire gauge just passes between the wrench is not available hand tighten spark plug spark plug electrodes It should pass easily but until resistance is felt and then use a ratchet with some resistance or drag The correct gap is wrench to tighten the plug an additional 1 2 turn if 0 028 0 031 in 0 7 0 8 mm installing a new plug or 1 8 1 4 turn if reinstalling 5 To readjustthe spark plug gap use gapping tool to a used plug Do NOT overtighten as this may strip gently bend the side electrode closer to or further threads or alter electrode gap setting from the center electrode See Figure 3 13 The 8 Check spark plug wire connector in boot for side electrode must be centered over the center accumulated dirt grease etc and clean as electrode necessary Firmly push spark plug connector and 6 Being careful not to bump the electrode hand boot onto spark plug thread spark plug clockwise into cylinder head until resistance is felt 3 10 Scheduled Maintenance TP 5695 12 93 1 0 028 0 031 in 2 Spark Plug Electrodes 0 7 0 8 mm Gap Figure 3 13 Adjusting Spark Plug Gap Figure 3 12 Checking Spark Plug Gap TP 5695 12 93 Scheduled Maintenance 3 11 Cooling Systems Closed Heat Exchanger In a closed cooling system the seawater does not circulate through the engine but circulates through separate chambers within the heat exchanger to cool the engine coolant The seawater is then mixed with
46. Kohler dealer distributor Defective capacitor See authorized Kohler service dealer distributor High generator Defective capacitor and or poor wiring See authorized Kohler service output voltage connections dealer distributor Excessive speed or frequency Adjust governor Check governor linkage and spring for damage or binding No DC power to controller Check battery connections Controller circuit fuse blown Replace fuse and attempt start up If fuse blows again contact authorized Kohler service dealer distributor 4 4 Troubleshooting TP 5695 12 93 Wiring Diagrams SCHEMATIC P4 21 12 VOLT prae Jiji CONTROLLER ME 1 ENGINE HIGH ENGINE TEMP o o P1 13 P4718 HIGH EKHAUST TEMP HIGH EXHAUST TEMP LOW OIL PRESSURE 5 IGNITION gt 7 A SYSTEM P4 3 70 75 Gei 1A VIOLET R1 LED VOLTAGE gt REGULATOR K 1 des 3 4 5 2 LEGEND AC CRANK DISCONNECT RELAY ENGINE RUN RELAY p ENGINE CRANK RELAY BATTERY t FAULT SHUTDOWN RELAY KE AND FAULT SHUTDOWN TIME DELAY RELAY P6 13 Pe XCITATION STARTER MOTOR p CAPACITOR 2 FUEL PUMP AUXILIARY CHOKE WINDING ANTI DIESEL SOLENOID HOURMETER OIL PRESSURE GAU
47. Operation and Installation Manual Marine Generator Sets KOHLER POWER SYSTEMS LO California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Table of Contents SUBJ ECT Safety Precautions and Instructions Reference Material EEN nn Routine Service Parts Glossary of Abbreviations Specifications Introduction a cnra dead eed rra Rh Specifications General Specifications Gerieratot coi eet d ev e a Engine era MEUSE Accessories Service VIEWS sss n Operation sssansansa Prestart Check Controller Starting Stopping Circuit Protection Engine Safety Shutdown Switches Remote Panels Optional Scheduled Maintenance Service Schedule Lubrication S ystem Specifications Oil Check Adding Oil ces crs nce ee RR DURAS Oil Change Oil Filter Change Fuel System iis imus Sech Den d aen ea Specifications Fuel Pump SCcreen Carburetor Choke Lubrication Carburetor Adjustments IgnitionSystem Ignition System Service Spark Plugs Cooling Systems Closed Heat Exchanger Filling and Checking Flushin
48. RATOR SET Have systems repaired before resuming generator operation iv Safety Precautions and Instructions Explosive fuel vapors can cause severe injury or death Additional precautions must be taken when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Do not store gasoline in any occupied building Explosive fuel vapors can cause severe injury or death Gasoline vapors can explode and can cause death or severe injury USCG Regulation 33CFR183 requires all electrical devices ship to shore transfer Switch remote start panel etc to be ignition protected when used in a gasoline gaseous fueled environment These electrical devices are not ignition protected and are not certified to operate in a gasoline gaseous fueled environment such as engine room or near fuel tanks Acceptable locations would be wheelhouse or other living areas sheltered from rain and water splash Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining fuel system Wipe up all spilled fuel after draining system Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Do not modify the tank or propulsion engine fuel system Craft must be equipped with a tank allowing one of the two pickup arrangements described Tank and installation must conform to U S C G Regulations
49. aced with antifreeze as described in steps 3a c or drained as described in steps 4a c Closeseacock and remove hose atseacock Place hose in a container of coolant antifreeze Container should have approximately 1 2 U S gallons 3 7 7 5 L of antifreeze A mixture of 50 ethylene glycol and 50 clean softened water is sufficient a With a suitable container at exhaust outlet run generator set until coolant discharge is observed at exhaust outlet or until coolant mixture is used up Do notallow coolant mixture to flow into waterways Stop generator set b Connect hose to seacock Leave seacock closed c Check coolantlevel of heat exchanger and add if necessary NOTE If steps 3a c were performed to replace seawater with antifreeze omit steps 4a c 3 24 Scheduled Maintenance 10 drain only seawater Use an airhose to blow out any remaining seawater if necessary Check coolant level of heat exchanger and add if necessary c Drain seawater from exhaust waterline NOTE Iffreezing temperatures will be encountered during storage be sure engine coolant is capable of withstanding the lowest possible temperatures Generally a mixture of 5096 ethylene glycol and 5096 clean softened water is sufficient Remove spark plugs and pour one teaspoon of engine oil into each cylinder Crank the engine several times to coat the cylinder walls with oil Reinstall the spark plugs If fuel stabilizer was not added to
50. ameplate See NO TAG In any communications regarding this generator set please reportthe MODEL SPEC and SERIAL numbers as found on the nameplate attached to the generator and engine Enter numbers in spaces provided below This information will enable the authorized Kohler service dealer distributor to supply the correct part or data for this particular model Model NO iere des Rer REEL AN Specification NO SENGA WA ar Engine MO EEN ise yee eee beep E SEN gee RES Parts Ordering Instructions 8 1 Section 9 Operating Hour Service Log The following is provided to help you keep a cumulative dates required services were performed Enter hours to record of operating hours on your generator set and the the nearest quarter hour OPERATING HOURS SERVICE RECORD HOURS RUN CUMULATIVE DATE SERVICE TP 5695 12 93 Operating Hour Service Log 9 1 TP 5695 12 93 PRINTED IN U S A KOHLER POWER SYSTEMS KOHLER CO KOHLER WISCONSIN 53044 PHONE 414 565 3381 FAX 414 459 1646 North American Sales 414 459 1614 International FOR SALES amp SERVICE IN U S A amp CANADA PHONE 1 800 544 2444
51. appliances such as TV stereo electric water heaters etc With the exception of the resistance type loads such as the water heater requirements for appliances are usually low Such loads must not however be overlooked when figuring total requirements Reserve capacity should be available for anticipated appliance loads to avoid overloading of a set The average power requirements of some common electrical appliances are given in Figure 6 3 Kilowatt Derating Units are rated as listed below at 1 0 power factor Derate the listed rating by approximately 3 596 per 1000 ft 300 m when the unitis operated ataltitudes of 500 ft 150 m or more above sea level 6 2 installation 3 5CFZ 50 Hz 3 5 kW at 77 F 25 C and 3 5 kW at 122 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 at 122 F 50 C 6 5CZ 60 Hz 6 5 kW at77 F 25 C and6kW at122 F 50 C Motor Electrical Starting Running Appliance Watts Watts Automatic Pilot 150 250 Blanket Electric 50 250 Blender 800 600 Broiler 1350 Depthometer 25 1000 Drill 3 8 600 350 Dryer Hair 850 1200 Fan Air 50 200 25 100 Circulating Food Mixer 400 235 Heater Space 750 1500 Heater Water 1500 Iron 900 1200 Light Bulbs as indicated Pan Frying 1200 Percolator 650 Coffee Radar 750 1500 Radio 50 100 Radiophone 100 200 Range Electric 1000 1500 per element Soldering
52. ater can cause rapid destruction of metals Wipe up all salt water spilage on and around generator set and keep metal surfaces free from accumulated salt deposits Scheduled Maintenance 3 1 Service Schedule Every Every Every Before i or 6 200 Hrs 300 Hrs Starting Months or Yearly or 2 Years LUBRICATION SYSTEM Check oil level Change oil Change oil filter FUEL SYSTEM Check the fuel level Fill fuel tank Lubricate carburetor and choke linkage Service fuel lines checkcoolantevel X X During Check seawater outlet Operation TI Inspect exhaust system components for cracks and corrosion exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper Check function of siphon break X if equipped Check condition of heat x GN exchanger anticorrosion zinc Months Replace heat exchanger X anticorrosion zinc Replace the impeller of X seawater pump Check thermostat function J X INTAKEEXHAUSTSYSTEM z X During Checkorhaustgascondion Clean the exhaust water mixing X elbow Clean air fiter element ppp uie p Em E NE p E E E D D 3 2 Scheduled Maintenance TP 5695 12 93 Service Schedule Continued Every 100 Hrs Every Every Before or 6 200 Hrs 300 Hrs Starting Months or Yearly or 2 Years Check electrolyte level X Batteries with filler caps only Check and tighten electrical connections Check speci
53. can cause severe injury or death Additional P recautions Regarding Sound Shield Equipped Models Some scheduled maintenance procedures require the generator setto be running while performing service If the sound shield has been removed leaving belts and pulleys exposed be especially careful of this area TP 5695 12 93 Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from belts and pulleys when unit is running Replace guards covers and screens before operating generator set HOT PARTS WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on generator set until unitis allowed to cool Hot parts can cause severe injury or death Do not touch hotengine parts An engine gets hot while running and exhaust system components get extremely hot WARNING Hot coolant and steam Can cause severe injury or death Before removing pressure cap stop generator allow to cool and loosen pressure cap to relieve pressure Hot coolant can cause severe injury or death Allow engine to cool and release pressure from cooling system before opening pressure cap To release pressure cover the pressure cap with a thick cloth then turn it slowly counterclockwise to the first stop After pressure has been completely released and the engine has cooled remove cap If generator set is equipped with a coolantrecovery tank check coolantlevel at
54. ction of generator set power and shore power Safety Precautions and Instructions i EKHAUST SYSTEM A WARNING Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected Carbon monoxide can cause severe nausea fainting or death Use the following precautions when installing and operating generator set Carbon monoxide is particularly threatening in that it is an odorless colorless tasteless nonirritating gas Be especially careful if operating the generator when moored or anchored under calm conditions as gases may accumulate If operating the set dockside moor your craft so thatthe exhaust discharges on the lee side the side sheltered from the wind and always be mindful of others make sure your exhaust is directed away from other boats and occupied buildings Do not install exhaust outlet where exhaust can be drawn through portholes vents or air conditioners If generator set s exhaust discharge hole is near to your crafts water line DO NOT OVERLOAD CRAFT soas to close or restrict exhaust discharge hole ii Safety Precautions and Instructions Carbon monoxide can cause severe nausea fainting or death In addition to routine inspection of the exhaustsystem a carbon monoxide detector should be considered Consult your boat builder or marina for installationjof approved detectors Itis essential that all detectors be routinely inspected for pr
55. d interval or when clogging is suspected inspect and clean the screen as follows 1 Shut off fuel flow to electric fuel pump attank or at in line shutoff valve Disconnectharness plug see Figure 3 7 for location 2 Disconnect fuel lines from electric fuel pump draining fuel from the lines and pump into a suitable container to prevent spillage into the bilge TP 5695 12 93 3 Remove the three nuts that secure the electric fuel pump to the mounting bracket 4 Remove the three mounting studs from the electric fuel pump 5 Remove the cover plate and inspect the screen Remove any debris or residue Be sure the screen is intact If the screen is damaged replace the fuel pump 6 Check the O ring seal Replace the O ring if it is nicked or eroded 7 Reinstall the cover plate and secure it to the fuel pump by reinstalling the three mounting studs 8 Insert the three mounting studs on the fuel pump through the mating holes in the mounting bracket Reinstall the three nuts to secure the fuel pump in place 9 Reconnectthe fuel lines to the fuel pump 10 Open fuel line at tank or in line shutoff valve and check for leaks from the fuel pump at fuel line connections and cover plate 2 enclosed Ep 258000 D
56. de unleaded gasoline Use fuel with a minimum octane rating as designated by the following Antiknock Index Average of Research 86 Octane Number and Motor Octane Number Unleaded fuel is recommended since it leaves less combustion chamber deposits Oil must not be mixed with fuel If using a gasoline containing alcohol gasohol be sure the octane rating is atleast 86 Antiknock Index There are two types of gasohol one containing ethanol and another containing methanol Do not use gasohol that contains more than 1096 ethanol Do not use gasohol containing methanol methyl or wood alcohol that does not also contain cosolvents and corrosion inhibitors for methanol Never use gasoline containing more than 596 methanol even if ithas cosolvents and corrosion inhibitors NOTE Fuel system damage and engine performance problems resulting from the use of such fuels are not covered under Warranty Honda cannotendorse the use of fuels containing methanol since evidence of suitability is as yet incomplete Before purchasing fuel from an unfamiliar station try to confirm whether the fuel contains alcohol and to what percentage If any undesirable operating symptoms are noticed after using a gasoline that contains alcohol or one that contains alcohol switch to a gasoline that does not contain alcohol NOTE Discontinue use of any gasohol or alcohol gasoline blend if engine performance or fuel system problems occur Do not use such f
57. drain cap If a drain pump is used remove oil It is normal to add some oil between oil changes The drain cap and connect oil drain hose to drain pump amountwill vary with the usage Open fillcap and poura small amount of oil using a funnel or other suitable pouring device See Figure 3 4 Wait a few minutes and 2 Allow ample time for all oil to drain into container If check level If necessary add more oil and then check drain pump is used activate pump until oil is again Each time be sure to add small quantities and removed check to prevent overfilling 3 Loosen oil filter by turning in a counterclockwise direction Oil filter is 2 1 2 in 64 mm dia with 14 flutes Use oil filter wrench if necessary See Figure 3 6 Use rags to handle hot oil filter and clean up spilled oil Remove filter from oil filter adapter on engine and discard oil filter in a proper container 4 Clean contact surface of oil filter adapter 5 Lightly lubricate the gasket surface of new oil filter with fresh engine oil Thread oil filter onto oil filter adapter until gasket makes contact then hand tighten oil filter an additional 3 4 turn NOTE Figure 3 4 Adding Oil If an automatic oil drain oil fill pump is used omit Oil Change Oil Filter Change Step 6 Fill with proper amount and type of oil see Change oil and oil filter every 200 hours or yearly Step 6 When complete replace cap and Change oil more frequently under dirty dusty
58. e wet exhaust components between the mixing elbow and the exhaust outlet A silencer should be independently mounted to eliminate any stress on the exhaust system and exhaust manifold mixer elbow See Figure 6 16 for the exhaust connection to the mixer elbow Figure 6 16 Mixer Elbow E xhaust Connection 1 Seawater E xhaust Outlet TP 5695 12 93 Installation 6 9 Locate the exhaustoutletatleast4 in 10 cm above the waterline when the craftis loaded to maximum capacity Usually a flapper is installed at exhaust transom outlet to prevent water backup in following seas or when going astern backward A WARNING Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected NOTE Data given is applicable to side exhaustinstallations C esp e e E tomer Carbon monoxide can cause severe nausea fainting or death Use the following precautions when installing and operating generator
59. ed Engine Safety Shutdown Switches The engine is protected by three engine safety shutdown switches Activating any of these switches while the generator set is running results in an immediate automatic shutdown During start up the engine safety shutdown feature is inhibited until a generator outputis sensed in orderto allow the oil pump output to reach normal operating pressure Low Oil Pressure Shutdown Switch The low oil pressure shutdown switch protects the engine againstinternal damage ifthe oil pressure drops below 20 psi 138 kP a dueto an engine oil pump failure or other engine malfunction The location of the low oil pressure shutdown switch is shown in Figure 2 2 NOTE The low oil pressure shutdown switch does notactas a low oil level switch The only way to protect against engine damage due to low oil level is to check the oil level regularly 258000 D 1 Low Oil Pressure Shutdown Switch Figure 2 2 Low Oil Pressure Shutdown Switch TP 5695 12 93 High Water Temperature Shutdown Switch The high water temperature shutdown s
60. ed parts often It is recommended that an authorized service dealer distributor perform required servicing to assure the unit continues to meet U S C G requirements Please take a few moments to read this manual then carefully follow all service recommendations to keep the set in top condition Keep this manual aboard the craft for future reference See Figure 1 1 for identification and location of components Specifications General Specifications Dimensions L x W x H in mm with Sound Shield Weight wet lbs kg with Sound Shield Air Requirements cfm L min Fuel Consumption U S gal hr L hr 3 5CFZ 5CFZ 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 445 208 94 231 104 18 510 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 445 231 104 231 104 18 510 TH EEE EEE 25 0 42 1 59 50 0 50 1 89 0 59 2 23 100 0 68 2 57 4CZ 6 5CZ 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 445 190 86 213 96 18 510 Dimensions L x W x H in mm with Sound Shield Weight wet lbs kg with Sound Shield Air Requirements cfm L min 0 66 2 50 0 80 3 03 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 445 231 104 231 104 18 510 Fuel Consumption U S gaar um E had ll 25 0 48 1 81 0 53 2 00 7596 0 62 2 3
61. fic gravity Batteries with filler caps only Clean battery cables WG ENGINE AND MOUNTING nl JI Lil EENG e Check for leakage of water fuel X X or oi d X Retighten all major nuts and X i X olts Period Check and tighten mounting X bolts and vibromounts Check intake exhaust valve clearance REMOTE CONTROL SYSTEM ETC Break i oy LI X Check compartment condition X fuel oil or water leaks Check the remote control X operation I Test run generator set mmi Monthly GENERATOR Lass Blow dust out of generator P A TP 5695 12 93 Scheduled Maintenance 3 3 Lubrication System Specifications Use high guality detergent oil of API American Petroleum 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 API service class in the upper portion The center indicates the SAE Society of Automotive Engineers viscosity grade The bottom portion when used signifies the oil is intended to improve fuel economy and displays the phrase Energy Conserving Select viscosity based on the air temperature at the time of operation See Figure 3 2 SAE 10W40 is the preferred oil for general use where temperatures permit Figure 3 1 Oil Service Class and SAE Viscosity Grade Symbol When Outside Temperature Use SAE is Consistently Viscosity Grade Below 5 F 15 C 5W30 5 F 21 C to
62. following items should be checked before each startup BACKFIRE FLAME ARRESTOR Air cleaner must be clean and properly installed to preventunfiltered air from entering engine See Maintenance Air Cleaner BATTERY Remove caps and check the electrolyte level of each cell batteries with filler caps only add distilled water if necessary Check to make sure it is connected correctly Battery and connections must meet Coast Guard Standards Battery should be serviced by authorized personnel only See Maintenance Battery COMPARTMENT Keep the engine room or compartment clean and dry Check for fuel or oil leaks Check the condition of fuel system exhaust piping hoses and muffler have any faulty components repaired before getting underway Open hatch to air out compartment and use ignition protected bilge blowers if required to clear fumes from area before each start up If fuel leaks fumes exhaust gases or electrical sparks are noted arrange for qualified personnel to make necessary repairs before operating generator set TP 5695 12 93 FUEL LEVEL Make sure the fuel tanks are full and the fuel system primed for operation See Maintenance F uel System OIL LEVEL Should be at or near Max mark Add oil as needed to bring level up to this range See Maintenance Lubrication System COOLING The coolant level on closed type heat exchanger systems can be checked using the coolant recovery tank if used The MIN mark i
63. fuel tank drain fuel completely from fuel tank Gum deposits will develop if gasoline is stored for the season Clean exterior of generator set and spread a light film of oil or silicon spray over any exposed surfaces which may be subjectto rustor corrosion Using tape seal air inlet exhaust pipe and fuel tank cap Disconnect and remove battery Battery should be placed in a warm dry location for period of storage Recharge battery once a month to maintain full charge Cover entire unit with a dust cover TP 5695 12 93 Section 4 Troubleshooting When troubles occur do notoverlook simple causes A starting problem for example could be caused by improper fuel or an empty fuel tank The following charts list some common problems If procedures in this the generator set to an authorized service dealer distributor Tell the dealer exactly what happened when the problem occurred and of any adjustments made to the set manual do not explain how to correct the problem take Engine Possible Cause Corrective Action Weak or dead battery Recharge or replace battery Reversed or poor battery connections Check connections Poor ground Fuse blown in controller Replace fuse Defective start stop switch Check function replace as necessary Defective starter solenoid Check starter solenoid and wiring Replace E Kiss battery Replace repair as necessary Replace and regap spark plug s Engine malfunction See
64. g and Cleaning Anticorrosion Zinc PressureCap Siphon Break Air Cleaner and Mixing Elbow Servicing Air Cleaner Servicing Mixing Elbow sssseeesee Battery 2 nh ries Mant DR ERR PRU RARE ROG Cleaning Checking Electrolyte Level Checking Specific Gravity Charging i mme red Valve Adjustment TP 5695 12 93 PAGE SUBJ ECT PAGE GoVernOl une 3 22 L brieation 522525 ill eR GG meh add de 3 22 Governor Adjustment 3 22 Wattage Requirements 3 23 Generator Service 3 23 General sasi aso dare aiaia iara A a ik dich a dads 3 23 Storage Procedure 3 24 Troubleshooting ise 4 1 Engine ice oc exa ERRARE ER RE ERG 4 1 Electrical System 4 3 ER Ee re 4 4 Wiring Diagrams 5 1 Installation 6 1 Introduction ever ec are 6 1 Generator Selection and Wattage Requirements 6 1 Lighting Load NEEN 6 1 Motor Loads 6 1 Appliance Loads 6 2 Kilowatt Derating 6 2 L EE Aessen See beats Maa 6 4 General 6 4 SPACE marashi PT 6 4 Mounting 6 4 Ventilation 6 4 FuelSystems
65. hell bore electrode chamber through worn rings and pistons excessive clearance between valve guides and stems or worn or loose bearings Replace plug Carbon fouled Black dry fluffy carbon deposits Using too cold range plug weak on insulator tips exposed shell ignition clogged air intake or surfaces and electrodes improper carburetor adjustments defective fuel pump overrich fuel mixture or excessive no load operation Clean and regap Lead fouled Dark gray black yellow or tan Caused by highly leaded fuel deposits or a glazed coating on Replace plug the insulator tip Pre ignition Melted electrodes and possibly Wrong type of fuel incorrect timing blistered insulator Metallic deposits or advance too hot of a plug burnt on insulator suggests internal valves or engine overheating engine damage Replace and plug Overheating White or light gray insulator with Engine overheating wrong type of small black or gray brown spots fuel loose spark plugs too hot a with bluish burnt appearance on plug low fuel pump pressure or electrodes incorrect ignition timing Replace plug Severely eroded or worn Caused by normal wear and failure electrodes to replace at proper interval Replace plug Figure 3 11 Spark Plug Condition 4 Before installing any spark plug check the gap 7 Usinga torque wrench tighten each spark plug to a See Figure 3 12 The proper gap is attained when torque of 18 22 ft lbs 20 30 Nm
66. ince it helps balance the load of the generator set LO Neutral gt Ground gt gt GRD Circuit Breaker Line Side 4 3 2 Stator Leads 60 Hz 120 volt 120 volt 50 Hz 110 volt 110 volt LO L1 LO L2 Figure 5 4 With J umper Lead 5 4 Wiring Diagrams 120 or 110 Volt 2 Wire Configuration Figure 5 5 Single Pole If the requires a 120 or 110 volt 2 wire system a single pole circuit breaker must be used See Figure 5 5 When connecting stator phase leads together the outputlead L1 mustbe sized accordingly Stator Leads 3 2 Circuit Breaker Ground gt GRD y LO LO Neutral 60 Hz 100 120 volt 50 Hz 100 120 volt Figure 5 5 120 Volt 2 Wire TP 5695 12 93 120 240 or 110 220 Volt Configuration Figure 5 6 J umper lead not used If unit was originally wired for straight 120 or 110 volt be sure jumper lead is removed see Figure 5 6 for location Leads L1 and L2 are different phases and mustnever be connected together Load Side Circuit Breaker Line Side 4 3 2 Stator Leads 60 Hz 50 Hz LO L1 120 volt 110 volt LO L2 120 volt 110 volt L1 L3 240 volt 220 volt Figure 5 6 Without J umper Lead TP 5695 12 93 Wiring Diagrams 5 5 Introduction Use this section as a guide when installing the Marine generator set then refer to Operation for specific service instructions Reliable and safe generator set operation
67. intenance NOTE ENGINE DAMAGE Failure to bleed air from cooling system may cause overheating and subsequent damage to engine NOTE Special attention should be given when checking for proper coolant level After the coolanthas been drained it normally requires some time before complete refill of the engine water jacket takes place Before filling the cooling system verify that all hose clamps are tight Loosen air bleed screw located on top of the engine to allow trapped air to escape See Figure 3 14 Place a rag around the screw to prevent coolant spillage onto the block Remove pressure cap located on the top of the engine see Figure 3 15 and fill with the recommended coolant until level is just below overflow tube opening Tighten air bleed screw when coolant free of air bubbles starts to flow Replace pressure cap Start generator set and allow to run for about 20 30 seconds STOP generator set and recheck coolant level by removing pressure cap Repeat procedure as necessary until coolantcan no longer be added A coolant overflow bottle is provided Fill bottle to just below the MAX mark See Figure 3 16 Maintain proper coolant level in coolant overflow bottle The MIN mark indicates full when cold and the MAX mark indicates full when hot Coolant level should always be between these marks The coolant level can be checked using the overflow bottle markings but it is recommended to periodically remove the coolant pressure
68. is started Simultaneous starting of two air conditioning units however can present problems if the capacity is marginal Because of the variation in starting characteristics of the various makes of air conditioners no definite statements are made in this publication regarding multiple motor starting capabilities of the marine generator set covered Delayed starting or use of easy starting devices on air conditioner units should be considered whenever simultaneous starting of more than one motor is involved The starting and running requirements of some motor loads common to marine applications are listed in Figure 6 1 usethis as a guide when selecting generator set capacity requirements involving motor loads See Figure 6 2 for generator set capabilities regarding air conditioners 61 Capabilities will vary according to Kilowatt Derating following Motor Starting Requirements In Rush Running HP Watts Watts 1 4 750 330 1 3 1000 400 1 2 1500 600 3 4 2000 750 1 3300 1100 2 4000 2000 3 5000 3000 Figure 6 1 Motor Requirements Power to Spare for Will Operate Air Lighting Conditioner of Appliances Model Wattage Size Indicated Tools 4CZ 4000 One 13 500 Btu 2100 6 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 Loads Marine generator sets are often used to furnish AC for
69. ith a minimum mounting depth of 2 1 4 in 57 mm Sender Kit Provides gauge senders for the remote start and two meter panel kit and the remote start and four meter panel kit The gauge sender kit is required to make the oil pressure and water temperature gauges functional Circuit Breakers See price list or dealer distributor for proper application of circuit breakers TP 5695 12 93 Inc m 3 aczBscez 35 azas 20 1 jeczmcrz o gt jeczmcrz 3 1 ezz 5 2 jeczmcrz 3 1 Remote Start and Four Meter Panel Kit Allows starting stopping from a location remote of the generator set The illuminated meters gauges include a DC voltmeter engine oil pressure gauge water temperature gauge and an hourmeter which records total generator set operating hours Overall dimensions are 9 in 229 mm by 6 in 152 mm with a minimum mounting depth of 4 in 102 mm Requires remote connection extension harness and sender kit Remote Start and Two Meter Panel Kit Allows starting stopping from a location remote of the generator set The illuminated gauges include engine oil pressure gauge and water temperature gauge Overall dimensions are 6 in 152 mm by 6 in 152 mm with a minimum mounting depth of 2 3 4 in 70 mm Requires remote connection extension harness and sender kit Remote Connection Extension Harness Provides additional wiring between all re
70. l oz TP 5695 12 93 alternating current anticipatory high water temp anticipatory low oil pressure amplitude modulation ampere amperes American National Standard Institute American P etroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Standards Association assembly American Society for Testing Materials after top dead center automatic transfer switch auxiliary American Wire Gauge appliance wiring material brake horsepower brake mean effective power British thermal unit Celsius degree cubic centimeter cold cranking Amps Canadian Electrical Code cubic feet per hour cubic feet per minute cubic inch displacement centimeter centimeters cubic meters per minute company continued Canadian Standards Association cubic inch cubic inches cylinder decibels direct current direct current resistance degree department diameter example given electromagnetic interference etcetera and so forth external Fahrenheit degree fluid ounce fluid ounces Abbreviation Description FM fs ft ft Ibs ga gal gals gal hr gph gpm gr grd HCHT HET Hg H20 hp hr hrs HWT Hz ID in inc in Ibs int int ext ISO J JIS kg kg cm kgm km kPa kph kV kVA kW kWH L LxWxH LED LEDs lb Ibs L hr L min LOP LP LWT m frequency modulation full scale foot feet foot pound foot pound
71. l ventilated to prevent accumulation of explosive gases To avoid sparks do not disturb battery charger connections while battery is being charged and always turn charger off before disconnecting battery connections When disconnecting battery remove negative lead first and reconnect it last Safety Precautions and Instructions iii FUEL SYSTEM A WARNING Explosion Gasoline vapors can cause explosion and severe injury or death Before starting generator set operate blower 4 minutes and check engine compartment for gasoline vapors A WARNING W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Explosive fuel vapors can cause severe injury or death All fuels are highly explosive in a vapor state Use extreme care when handling storing and using fuels Store fuel in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running since spilled fuel may ignite on contact with hot parts or from ignition spark Do not smoke or permit flame or spark to occur near potential sources of spilled fuel or fuel vapors Keep fuel lines and connections tight and in good condition don t replace flexible fuel lines with rigid lines Flexible sections are used to avoid breakage due to vibration Should any fuel leakage fuel accumulation or electrical sparks be noted DO NOT OPERATE GENE
72. lenoid and readjust governor screw Tighten locking nut 3 Start engine and run to reach operating temperature 4 Apply full load and turn engine speed adjustment screw to 3600 rpm for 60 Hz generator set 3000 rpm for 50 Hz set 5 Check regulation by applying and removing full load 6 STOP generator set 1 Mixture Screw 2 Idle Speed Screw 3 Governor Adjustment Figure 3 24 Governor Adjustment Throttle Rod S pring A Governor Cross Shaft O Governor Spring Outer Hole O O Figure 3 25 Governor Linkage 3 22 Scheduled Maintenance TP 5695 12 93 Wattage Requirements Ifthe rated capacity of the generator setis exceeded the circuit breaker located on the controller will trip to protect the generator against damage Tripping could be caused by a short in the AC circuit in the craft or simply by having too many appliances on at the same time resulting in an overload condition If the circuit breaker trips the set may continue running but there will be no AC output to the protected circuit Before resetting the circuit breaker turn off some of the appliances and lights inside the craft to bring the load down within the rated limits of the set If this is done and the circuit breaker trips again after being reset see a qualified electrician For more information regarding generator set capacity see Installation Generator Selection and Wattage Requirements TP 5695 12 93 Generator Ser
73. m overheating TP 5695 12 93 If the engine fails to start after the first attempt close the seacock before a second start up attempt This action will help prevent seawater from entering the engine cylinders through the exhaust valve Once the engine starts the seacock mustbe re opened to allow passage of cooling water NOTE Failure to open the seacock after the generator set is running will result in serious engine damage due to overheating NOTE Ensure that the marine ship to shore transfer switch if used is in proper position Stopping Disconnect the load from the generator setand allow the generator set to run at no load for 5 minutes to cool down the engine Then rock the master Start Stop switch on the controller or the Start Stop Switch on a remote panel to the Stop position and hold itin the Stop position until the generator set comes to a complete stop NOTE Allow unitto come to a complete stop before attempting to start the generator set again Operation 2 3 Circuit Protection AC Circuit Breaker Optional The optional AC circuit breaker s located on the front panel of the controller protect the generator output windings Ifa load circuitloses power the cause may be a tripped AC circuit breaker If a tripped circuit breaker is reset and then trips again find and correct the short in the load circuit that is causing the problem Input Controller Fuse 10 Amp The input fuse protects the co
74. mote panels and controller connector One required for each remote meter panel kit Available in 15 ft 46 m and 25 ft 76 m lengths Extension limited to a total of four kits and 75 ft 23 m 12 Inch Remote Wiring Harness This one foot 0 3 m wiring harness has a 6 pin connector on one end which is keyed to controller box connector The other end has pigtails for connection to customer supplied start switch generator on light hourmeter etc Siphon Break Prevents the siphoning of water into the engine on generator sets installed below the waterline Specifications 1 5 Service Views RR oH Ul 17 18 HA Hd HB BWNESCONOUARWNE
75. n load Also used to disconnect generator set from loads during maintenance To close circuit breaker place in ON position 2 2 Operation A 246486 D 1 Battery Charging Fuse 4 Hourmeter 2 Input Controller Fuse 5 Remote Start Connector 3 Start Stop S witch 6 Optional AC Circuit Breaker s Figure 2 1 Controller TP 5695 12 93 Starting A WARNING Explosion Gasoline vapors can cause explosion and severe injury or death Before starting generator set operate blower 4 minutes and check engine compartment for gasoline vapors NOTE For reliable starting allow at least 30 seconds after shutdown before restarting a hot engine Ensure thatthe manual fuel shutoff valve if equipped is open Then rock the master Start Stop Switch on controller or use Start S top S witch on remote panel to the Start position fora maximum of 7 seconds or until the engine starts NOTE Do not crank the engine continuously for more than 7 seconds at a time Allow a 5 second period between starting attempts if the engine does not start If the engine fails to start after three attempts contact an authorized Kohler dealer distributor for repair Failure to follow these guidelines may result in burn out of the starter motor fro
76. ndicates full when cold and the MAX mark indicates full when hot Maintain the coolant level between these marks It is recommended that coolant level on closed systems be periodically checked by removing pressure cap Do not solely rely on level in coolant recovery tank Add fresh coolant until level is just below overflow tube opening See Maintenance Cooling Systems SEAWATER PUMP PRIMING The seawater pump must be primed before initial start up To prime pump close seacock and remove the hose from water filter outlet Fill hose and pump with clean water Replace hose and open seacock Check for pump operating on start up by observing water discharge from exhaust outlet Operation 2 1 Controller For identification and location of controller operating features refer to the text below and Figure 2 1 1 Battery Charging Fuse protects battery charging circuitry from short circuits Input Controller Fuse protects controller circuitry from short circuits Start Stop Switch is used to stop and start generator set Rock to start or stop position and hold to start or stop engine Switch automatically returns to neutral center position when released Hourmeter records total generator set operating hours Use as a reference to schedule maintenance Remote Start Connector provides connection point for optional remote start kits Optional AC Circuit Breaker s protects generator set from short circuits i
77. nstall bottle on unit Add fresh coolant to coolant overflow bottle A solution of 5096 ethylene glycol and 5096 clean softened water is recommended to inhibit rust corrosion and provide freezing protection Fill to MIN mark Install coolant overflow bottle cap Remove heat exchanger pressure cap and add about 5 fl oz 0 15 L of clean softened water Then fill remainder of engine with straight coolant 10096 until level is just below the overflow tube opening Final tighten the air bleed screw when coolant free of air bubbles starts to flow Install the heat exchanger pressure cap TP 5695 12 93 13 Reconnect battery negative lead last 14 Start generator set and allow the set to run for about 20 30 seconds Stop generator set and recheck coolant level by removing heat exchanger pressure cap Add straight coolant if necessary until level is just below the overflow tube opening then reinstall pressure cap Repeat this step until coolant can no longer be added This procedure should give an approximate mixture of 50 ethylene glycol and 50 water TP 5695 12 93 15 16 17 18 Wipe up spilled coolant and water with rags Dispose of rags in a proper container Test run generator set for about five minutes and check for coolant leaks This will allow the coolant mixture to mix completely Stop generator set Rinse coolant flush kithoses and fittings with clean water Store kit for future use Dispose
78. ntroller circuitry If the generator set engine will not crank and the battery and battery connections appear okay the input fuse may be blown If this fuse located on the front panel of the controller is replaced and then blows again find and correct the short that is causing the problem Battery Charging Fuse 10 Amp The battery charging fuse protects the battery charging circuit If the battery goes dead and the battery and battery charging alternator are otherwise normal the battery charging fuse may be blown If this fuse located on the front panel of the controller is replaced and blows again find and correct the short in the charging circuit that is causing the problem NOTE When a fuse replacement is required be sure fuse has the same ampere rating and is the same type for example ABC or 3AB ceramic Do not substitute clear glass type fuses for ceramic fuses If ampere rating is unknown or questionable see Wiring Diagram PIS Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental starting can cause severe injury or death Disconnect battery cables remove negative lead first and reconnect it last to disable generator set 2 4 Operation before working on any equipment connected to generator The generator set can be started by remote start stop switch unless this precaution is follow
79. on meter Newton meters number numbers National Standard taper pipe thread per general use not required overcrank outside diameter original equipment manufacturer overspeed oversize overvoltage ounce ounces xii Glossary of Abbreviations Abbreviation PF pot ppm psi pt pts qt ats qty ref RFI rms rpm SAE sec SCR spec specs sq sq cm Sq in tach TDC temp TIF turbo UNC UNF UL US V VAC VDC W Description power factor potentiometer parts per million pounds per square inch pint pints quart quarts quantity reference radio frequency interference root mean square revolutions per inch Society of Automotive Engineers second seconds silicon controlled rectifier specification square square centimeters square inch square inches tachometer top dead center temperature telephone influence factor turbocharger Unified coarse thread was NC Unified fine thread was NF Underwriter s Laboratories Inc undersize volt volts Volts alternating current volts direct current watt watts TP 5695 12 93 Section 1 S pecifications The craft is equipped with a dependable 110 volt reconnectable to 110 220 volt 50 Hz or 120 volt reconnectable to 120 240 volt 60 Hz single phase alternating current marine generator set Service requirements are minimal but are very important to the safe and efficient operation of the generator set therefore inspect associat
80. onal Kohler seawater strainer is threaded for 1 2 NPT fittings 3 Seacock 1 Seawater Pump 2 Seawater Strainer Figure 6 13 Seawater Strainer NOTE Some seawater strainers include seacock and intake thru hull strainer Waterlines from the seacock to the engine driven seawater pump can be copper tubing or flexible hose A flexible section of hose is used for the actual connection to the seawater pump to allow vibrational motion of the generator set during operation The hose should have an inside diameter of 3 4 in 19 mm Copper line should be supported within 4 in 102 mm of its connection to the flexible section 6 8 NOTE A 5 8 in 16 mm waterline hose can be substituted for the recommended 3 4 in waterline hose Piping should be kept straight and as short as possible See Figure 6 14 for the seawater connection to the seawater pump inlet The seawater outlet is combined with engine exhaust gases On sound shielded units a small section of molded hose is required for the seawater inlet connection ADV 5792 D 1 3 4 in Seawater Pump Inlet Figure 6 14 Seawater Inlet Connection Closed Heat Exchanger A closed heat exchanger cooling system the best alternative for most applications especially if craft is to be operated in salt waters or waters with high silt content is provided as par
81. oper operation TP 5695 12 93 BATTERY A WARNING Sulfuric acid in batteries Can cause severe injury or death Use protective goggles and clothes Can cause permanent damage to eyes burn skin and eat holes in clothing Sulfuric acid in batteries can cause severe injury or death Sulfuric acid in battery can cause permanent damage to eyes burn skin and eat holes in clothing Always wear splash proof safety goggles when working around the battery If battery electrolyte is splashed in the eyes or on skin immediately flush the affected area for 15 minutes with large quantities of clean water In the case of eye contact seek immediate medical aid Never add acid to a battery once the battery has been placed in service Doing so may result in hazardous spattering of electrolyte TP 5695 12 93 Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flame or spark to occur near a battery at any time particularly when it is being charged Avoid contacting terminals with tools etc to prevent burns and to prevent sparks that could cause an explosion Remove wristwatch rings and any other jewelry before handling battery Never connect negative battery cable to positive 4 connection terminal of starter solenoid Do nottest battery condition by shorting terminals together or sparks could ignite battery gases or fuel vapors Any compartment containing batteries must be wel
82. own in Figure 6 19 1 Mounting Base 2 Retaining Cap 3 Reed Valve Assembly Figure 6 18 Siphon Break Components The siphon break must be located at least 1 foot above the waterline at maximum vessel capacity between the heat exchanger and water elbow three way fittings The siphon break and fitting must be supported to maintain proper position and function The siphon break should be mounted directly vertical of its connection to generator set where possible Otherwise a slight offset is allowable to clear stringers or other permanent structures NOTE NOTE Use two hose clamps on each end of all flexible exhaust hose connections 1 Siphon Break Exhaust Manifold Heat Exchanger 4 ft 1 2 m Max Exhaust Hose Slope 0 5 in 1 3 cm per ft 30 5 cm 4 in 10 cm Min Data given is also applicable to side exhaustinstallations 258000 D 7 Waterline 8 Silencer Customer S upplied 9 10 ft 3 m Max 10 Install Optional Wate
83. peration and longevity ofthe engine and generator set proper maintenance and eventual overhaul by a competent mechanic technician are essential While it is not possible to anticipate component failure rough operation metallic noises and excessive oil loss are among the indicators of potential problems Do not ignore these conditions NOTE Operate the generator set with load applied at least once a month Allow generator setto run aboutone hour to reach operating temperature This prevents the formation of corrosion on internal engine components when exposed to the breakdown of exhaust gases and seawater for long periods of generator inactivity If unitis to be out of service for several months see Storage Procedure TP 5695 12 93 Po Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental starting can cause severe injury or death Disconnect battery cables remove negative lead first and reconnect it last to disable generator set before working on any equipment connected to generator The generator set can be started by remote start stop switch unless this precaution is followed NOTE HARDWARE DAMAGE Engine and generator make use of both American Standard and metric hardware Be sure to use the correct size tools to prevent rounding of bolt heads and nuts NOTE High mineral content seawater salt w
84. plugs 1 Remove spark plug wires by grasping boot and turning slightly while pulling Do not pull wire See Figure 3 9 NOTE Pulling wire rather than boot may cause damage to wire or terminal Where possible use compressed air to remove dirt from around each spark plug before removal This procedure will prevent dirt particles from falling into combustion chamber Loosen spark plug with a ratchet and spark plug socket with a rubber insertto prevent damage to spark plug See Figure 3 10 Remove spark plugs one at a time and examine See Figure 3 11 to evaluate engine conditions by color condition of spark plugs Clean spark plugs by wiping with a rag and then file the center electrode so that itis parallel to the side electrode Should replacement be necessary see Specifications for spark plug type TP 5695 12 93 NOTE Do not sandblast wire brush scrape or otherwise service spark plug in poor condition Best results are obtained with a new plug 1 13 16 in Spark Plug Socket Figure 3 10 Removing Spark Plug Scheduled Maintenance 3 9 Means of Identification Possible Cause Light tan or gray deposit on the Good operating conditions and firing tip maintenance Gap bridged Deposits built up and closing gap Oil or carbon fouling Clean and between electrodes regap Oil fouled Wet black deposits on the insulator Excessive oil entering combustion s
85. ption rates Fuel Pump Fuel Inlet Size Model Max Lift ft m LD 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 0 50 0 59 0 68 1 59 1 89 2 23 2 57 4CZ 0 48 0 55 0 62 0 68 1 81 2 08 2 34 2 57 5CFZ 0 44 0 54 0 66 0 80 1 67 2 04 2 50 3 03 6 5CZ 0 53 0 62 0 86 1 02 2 00 2 34 3 25 3 86 Figure 6 10 Fuel Consumption TP 5695 12 93 Cooling Systems General The following features are necessary in the cooling system An intake thru hull strainer seacock cover must be screened to prevent entry of foreign objects and must not be aligned in relation to direction of travel with the propulsion engine intake See Figure 6 11 The recommended thru hull strainer should be flush mounted Strainers with slotted holes must be installed with their slots parallel to the direction of vessel movement The area of the strainer opening s must be equal to or greater than the inside diameter of the waterline hose to the seawater pump An intake thru hull strainer must not be of the scoop or cup design This style can cause a ramming effect and force water upward past the seawater pump and into the engine cylinders when the vessel is moving and the generator set is shut down Hull designs incorporating sea chests are also not suitable for intake thru
86. r Lock Here 11 Coolant Recovery Tank 12 1 ft 30 5 cm Min Figure 6 19 Typical Mid and Below Waterline Installation TP 5695 12 93 6 11 A typical silencer should be mounted no more than 4 ft 1 2 m below the highest point in the exhaust line Attach a separate wood mounting base to hull stringers or other suitable structure Then secure the silencer to hull using silencer manufacturer s recommendation Be sure the silencer outlet is not more than 10 horizontal ft 3 m from the engine exhaust manifold outlet UL marine exhaust hose should be used Electrical Systems AC Voltage Connections A WARNING Explosion Gasoline vapors can cause explosion and severe injury or death Before starting generator set operate blower 4 minutes and check engine compartment for gasoline vapors Explosive fuel vapors can cause severe injury or death Gasoline vapors can explode and can cause death or severe injury USCG Regulation 33CFR183 requires all electrical devices ship to shore transfer Switch remote start panel etc to be ignition protected when used in a gasoline gaseous fueled environment These electrical devices are not ignition protected and are not certified to operate in a gasoline gaseous fueled environment such as engine room or near fuel tanks Acceptable locations would be wheelhouse or other living areas sheltered from rain and water splash WARNING FR Hazardous voltage Moving rotor
87. rganizations are not regulatory in nature but rather provide guidelines and assistance They are listed only as a source for additional information No solicitation or representation is hereby given TP 5695 12 93 Yacht Corrosion Consultants Inc 2970 Seaborg Ave Ventura CA 93003 1 805 644 1886 Ward s Marine Electric Inc 630 S W Flagler Ave Ft Lauderdale FL 33301 1 305 523 2815 1 800 545 9273 1 305 523 1967 FAX Reference Material ix Routine Contact your Kohler generator dealer distributor for a complete listing De your generator Set Part Description Kohler Part No Engine Air Filter 278612 Oil Filter 267714 Belt Timing 267722 Ignition System Spark Plug 267713 Sea Water Pump Impeller 229826 Zinc Anode 267928 White Spray Paint 221318 x Routine Service Parts TP 5695 12 93 Glossary of Abbreviations Abbreviations are used throughout this manual Normally in the text they will appear in complete form with the abbreviation following in parenthesis the first time they are used After that they will appear in the abbreviated form The commonly used abbreviations are shown below Abbreviation Description AC AHWT ALOP AM Amp Amps ANSI API approx A R A S ASA assy ASTM ATDC ATS aux AWG AWM bhp bmep Btu of CC CCA CEC cfh cfm CID cm cmm CO contd C S A cu in cyl dBA DC DCR deg dept dia e g EMI etc ext ob f
88. rnor The gear driven centrifugal type governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in load Lubrication Lubricate governor linkage at the specified interval using white lithium grease or lubriplate Governor Adjustment The gear driven centrifugal type governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in load No regular service is required on the unit The governor is adjusted during run in at the factory and further adjustment should not be needed unless greatly varying load conditions are encountered or if poor governor control develops after extended usage See Figure 3 25 for correct placement of governor linkage models may vary 60 Hz generator sets are designed to operate at 60 63 Hz 3600 rpm under full load and 3780 rpm under no load 50 Hz generator sets are designed to operate at 50 52 5 Hz 3000 rpm under full load and 3150 rpm under no load To check speed use hand tachometer or frequency meter Use the following procedure to adjust governor 1 Loosen governor arm locking nut See Figure 3 24 Locknut Pivot Point TL DL DJ I Li Hole Nearest Governor to Pivot Point Adjustment Screw Governor Rod LI CH mm u Carburetor 2 Move the governor arm end fully in the direction shown toward the electric choke so
89. s gauge gallon gallons gallons per hour gallons per hour gallons per minute grade ground high cylinder head temperature high exhaust temperature mercury element water horsepower hour high water temperature hertz cycles per second inside diameter inch es incorporated inch pounds internal internal external International Standards Organization joule joules Japanese Industry Standard kilogram kilograms kilograms per sguare centimeter kilogram meter s kilometer kilometers kiloP ascal kiloPascals kilometers per hour kilovolt kilovolt amperes kilowatt kilowatts kilowatt hour liter liters length x width x height light emitting diode pound pounds liter per hour liters per hour liter s per minutes low oil pressure liquefied petroleum low water temperature meter meters Glossary of Abbreviations xi Abbreviation m3 max MCM mi mil min mj MJ mm m3 min MPa mph MS mw MW N A NEC NEMA NFPA Nm no nos NPT Description cubic meter cubic meters maximum one thousand circular mils mile miles one one thousandth of an inch minimum millijoule millijoules mega joule mega joules millimeter millimeters cubic meters per minute megaP ascal miles per hour military standard milliwatt milliwatts megawatt megawatts not available National Electrical Code National Electrical Manufacturers Association National Fire Protection Association Newt
90. set Carbon monoxide is particularly threatening in that it is an odorless colorless tasteless nonirritating gas Be especially careful if operating the generator when moored or anchored under calm conditions as gases may accumulate If operating the set dockside moor your craftso thatthe exhaustdischarges on the lee side the side sheltered from the wind and always be mindful of others make sure your exhaust is directed away from other boats and occupied buildings Do not install exhaust outlet where exhaust can be drawn through portholes vents or air conditioners If generator set s exhaust discharge hole is near to your crafts waterline DO NOT OVERLOAD CRAFT so as to close or restrict exhaust discharge hole NOTE Use two hose clamps on each end of all flexible exhaust hose connections Heat Exchanger Exhaust Manifold Engine Driven Seawater Pump 3 ft 1 m Max Lift of Seawater Pump Silencer Customer Supplied Exhaust Hose Slope 0 5 in 1 3 cm per ft 30 5 cm Slight Lift Improves Silencing Keep Below Level of Exhaust Manifold Outlet 258000 D 8 4 in 10 cm Min of Exhaust Line Above Waterline 9 Waterline 10 Seawater Strainer 11 Intake Strainer 12 10 ft 3 m Max Between Exhaust Outlet and Silencer 13 Seacock 14 Coolant Recovery Tank Figure 6 17 Typical Above Waterline Installation Exhaust system guidelines for various generator set
91. st also be generator set senders Senders are optional on these generator sets Gauges and senders are available as service items from an authorized Kohler service dealer distributor NOTE All wire is 16 gauge Tape to insulate all unused lead ends Use Insulink or Solder Connection Tape to Insulate Hourmeter ON Light Stop JA LA NJ HB 5 Start 6 Rocker Switch 7 Gauges Senders Figure 6 22 Remote Control Panel Wiring 6 14 TP 5695 12 93 Section 7 Installation Drawings T S d Z6LS AGV H3AO2 HSNH HLIM LNATWAINOA QuvaNvis aariddns SYS YILININ JYV U NI SNOISNAWIG H395NVHOX3 LVH HLIM Q31002 u31VA Q34123L0Wd NOLLINSI 3NIH VIN ANMOSV 9 ZHO9 Ae Ok 3NI1OSV9 ZHOS MAS S E ALON NOLLDANNOD 31O0wW3u LAN v T LIINI 13004 5frnaunou 3SOH ua88fid a TS 07 uod 1311nO ASNVHX3 Q31002 Y3lvM 1113 ANY JDIH y 710 3NISN3 yaa 10
92. t of the generator set Service accessibility must be provided for the heat exchanger pressure cap See Figure 6 15 TP 5695 12 93 6 NOTE Usetwo hose clamps on each end of all flexible exhaust hose connections 258000 D 1 Exhaust Manifold 6 Seawater Strainer 2 3 ft 1m Max 7 Intake Strainer 3 Engine Driven Seawater Pump S an 4 Heat Exchanger 10 Seacock 5 Waterline 11 Coolant Recovery Tank Figure 6 15 Closed Heat Exchanger Cooling System Exhaust Systems General Water cooled exhaustlines should be used in allmarine installations The hose used for the lines should have a 2 in 51 mm inside diameter Keep the lines as short and straightas possible The use oftwo hose clamps on each end of flexible exhaust hose connections is highly recommended ABYC Safety Standards P 1 6 c recommend a pitch of at least 1 2 in 12 8 mm per running foot 30 5 cm Use flexible steam hose conforming to UL Standard 1129 for Engin
93. t test battery condition by shorting terminals together or Sparks could ignite battery gases or fuel vapors Any compartment containing batteries must be well ventilated to prevent accumulation of explosive gases To avoid sparks do not disturb battery charger connections while battery is being charged and always turn charger off before disconnecting battery connections When disconnecting battery remove negative lead first and reconnect it last 3 18 Scheduled Maintenance Cleaning Keep battery clean by wiping it with a damp cloth Keep all electrical connections dry and tight If corrosion is present disconnect cables from battery and remove corrosion with a wire brush Clean battery and cables with a solution of baking soda and water Be careful that cleaning solution does not enter battery cells When cleaning is complete flush battery and cables with clean water and wipe with a dry cloth After the battery cables are reconnected coat terminals with petroleum jelly silicon grease or other nonconductive grease Checking Electrolyte Level Check the level of electrolyte before each startup Remove filler caps and check to see that electrolyte level is up to bottoms of filler holes see Figure 3 20 Refill as necessary with distilled water or clean tap water DO NOT add fresh electrolyte Then reinstall and tighten filler caps If water is added during freezing temperatures run generator set 20 30 minutes to allow mixing of added
94. tage notice should be placed on the unitindicating this change Decals part number 246242 for this purpose are available from authorized Kohler dealers distributors TP 5695 12 93 Lighting Load The lighting load is usually easiest to calculate In most cases simply add the wattage of each lamp to be operated off the generator set Note that in many applications not all of the lights or lamps are in the generator set AC circuit some are DC powered by the 12 volt battery in the craft Make sure the total includes only lights actually on the generator set AC circuit Motor Loads When figuring generator set capacity requirements that include electric motors do notoverlook the high current demanded by the motors during start up The in rush or starting current is typically 2 3 times higher than that required when the motor reaches normal operating speed Reserve capacity must be allowed for in rush demands plus other loads which could be on the line as the electric motor starts Air conditioning units are perhaps the most common type of motor load for generator sets in marine applications The starting characteristics of the different varieties of air conditioners vary greatly one particular 12 000 Btu unit has for example lower starting requirements than a 10 000 Btu unit of another make When only one unit is involved there is usually no starting problem provided the lighting and appliance load is nottoo high when the unit
95. tails 35CFZACZ Honda De 553 713 355 in Valve Material Steel Alloy J IS SUH3 Cylinder Block Materi Valve Clearance in mm cold 0 004 0 006 0 10 0 14 Cylinder Head Cover Tightening 7 10 Torque ft lbs Nm Cylinder Head Materi Connecting Rod Matera 2 Compression t Oil Control Crankshaft Bearings Replaceable Inserts Gear Driven Centrifugal 48 Lubrication System Oil Type API SF SF CC or SF CD Oil Pressure psi kPa 30 50 207 345 0 10 0 OT Capacity with fiter US qi D 345 TP 5695 12 93 Specifications 1 3 Engine Continued 35CFZAACZ SCFZI6 SCZ Spark Plug Type Resistor Radio Suppression 14 mm BPR4HS NGK Kohler Part Number L92YC Champion R43CFS AC Delco Spark Plug Gap in mm 0 028 0 031 0 7 0 8 Spark Plug Tightening Torque 15 22 20 30 ft Ibs Nm Ignition System Transistorized Breakerless Bendix Automotive Type Cooling System Capacity U S qts L 1 10 1 00 Coolant Recovery Tank U S qts L 0 38 0 35 Head Torque Cylinder Block Torque tud Torqu Air Cleaner Elbow to Carburetor 6 ft lbs 8 5 Nm S e 6 ft lbs 8 Nm Timing Belt Cover Torque Cooling System Water Cooled Closed Heat Exchanger Governor Arm Shaft Nut Torque 7 ft Ibs 10 Nm Governor Case to Cylinder Head 7 ft Ibs 10 Nm Torque Fuel Pump Pressure Rating 2 0 3 5 psi 13 8 24 1 kPa Battery Charging Winding
96. tank Safety P recautions and Instructions v ENGINE BACKFIRE FLASH FIRE A WARNING Gh d Fire Can cause severe injury or death Do not smoke or permit flame or spark to occur near fuel or fuel system A flash fire can cause severe injury or death Do not smoke or permit flame or spark to occur near carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuel or fuel vapors When removing fuel line or carburetor use a proper container to catch all fuel A sudden backfire can cause severe injury or death Do not operate with backfire flame arrestor removed vi Safety Precautions and Instructions 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 notsmoke or permit flame or spark to occur near fuel system Keep the compartmentand generator set clean and free of debris to minimize chances of fire Wipe up all spilled fuel and engine oil HAZARDOUS NOISE A caution Hazardous noise Can cause loss of hearing Never operate generator without a muffler or with faulty exhaust system TP 5695 12 93 NOTES NOTE HARDWARE DAMAGE Engine and generator may make use of both American Standard and metric hardware Be sure to use the correct size tools to prevent rounding of bolt heads and nuts NOTE Special attention should be given when checking for proper coolantlevel After
97. tes and check engine compartment for gasoline vapors Air requirements for various models are given in Figure 6 5 The air intake silencer provides combustion air to the engine It is imperative that the recommended minimum clearance of 1 1 2 in 38 mm between duct opening and any enclosure wall not be compromised Engine generator performance will be affected adversely if these guidelines are not followed Air Requirements CFM L min Model Combustion Cooling 3 5CFZ 18 510 323 9145 ACZ 18 510 323 9145 5CFZ 18 510 600 16988 6 5CZ 18 510 600 16988 Figure 6 5 Air Requirements TP 5695 12 93 Fuel Systems Fuel Supply Generator sets in most cases must draw fuel from the same tank as the propulsion engines If the tank s fuel pickup opening allows a multiple dip tube arrangement Figure 6 6 may be used An alternate tank if used should have a smaller separate pickup opening allowing a single dip tube Figure 6 7 2 Fuel Line to Generator 1 Fuel Line to Propulsion Engine Set Figure 6 6 Dual Dip Tubes For installations where the highest point of the gasoline source fuel tank is above the generator set carburetor an auxiliary fuel shutoff valve is required This fuel shutoff valve should be closed when the generator is not in use to prevent fuel leakage resulting from fuel flow through the fuel pump and into the carburetor should the float valve not seat properly TP 5695 1
98. tno load Push the throttle lever counterclockwise until it hits the idle speed screw Holding the throttle lever againstthe screw adjust the idle speed screw until unitruns at55 Hz 3300 rpm for 60 Hz models or 45 Hz 2700 rpm for 50 Hz models NOTE If engine runs poorly after adjusting carburetor and doing scheduled maintenance return generator set to an authorized service dealer distributor to have problem corrected 3 8 Scheduled Maintenance A WARNING Gh Fire Can cause severe injury or death Do not smoke or permit flame or spark to occur near fuel or fuel system A sudden flash fire can cause severe injury or death Do notsmoke or permit flame or spark to occur near fuel system Keep the compartmentand generator setclean and free of debris to minimize chances of fire Wipe up all spilled fuel and engine oil 1 Governor Arm 3 Idle Speed Screw 2 Low Speed Mixture Screw Figure 3 8 Fuel Mixture Adjustment TP 5695 12 93 Ignition System Ignition System Service The ignition system is transistorized and breakerless Under normal conditions only the spark plugs need service on a regular basis The electronic ignition module reguires no maintenance and should give years of trouble free service If a module problem is suspected have service performed by an authorized service dealer distributor Spark Plugs At the recommended interval shown in the service schedule service spark
99. trical appliances in your craft that you would observe in your home Open main circuit breaker on all power sources before servicing equipment Make sure unqualified persons especially children cannot gain access to your set keep the compartment door locked or securely latched at al times Be sure that generator is properly grounded Never touch electrical leads or appliances with wet hands when standing in water or on wet ground as the chance of electrocution is especially prevalent under such conditions Hazardous voltage can cause severe injury or death Use caution when handling the capacitor possible electrical shock can result Discharge capacitor by shorting terminals together Hazardous voltage can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while adjustments are made Remove wristwatch rings and jewelry that can cause short circuits Hazardous backfeed voltage can cause severe injury or death Do notconnectto any building marina electrical system without connecting through an approved device and after building main switch is open Backfeed connections can cause serious injury or death to utility personnel working to repair a power outage and or personnel in the vicinity Unauthorized connection may be unlawful in some states and or localities A ship to shore transfer switch must be installed to prevent interconne
100. uel dip tubes within the tank are not reliable anti siphon devices as they become ineffective when restricted by dirt or gum Fuel Lines Metallic lines should be used from the tank to a flexible hose section connecting metallic line to the engine fuel pump Metallic lines must have wall thickness of atleast 0 029 in 0 74 mm Seamless annealed nickel copper copper nickel or copper tubing must be used The flexible section necessary to allow vibrational motion of the generator set during operation must be U S C G TYPE A HOSE marked and tagged according to Regulations Metallic line must be supported within 4 in 102 mm of its connection to the flexible section See Figure 6 8 for fuel pump inlet connection 258000 D 2 Electric Fuel Pump 1 1 4 in NPT Female Pipe Thread Figure 6 8 Fuel Pump Inlet Connection 6 6 Any in line fuel filters or strainers must conform to U S C G Regulations must be independently mounted to the craft s structure and must be accessible for servicing without removing any permanent structures NOTE If a fuel strainer is installed each fuel filter and strainer must be supported on the engine or boat structure independent from its fuel line connections unless the fuel filter or strainer is inside a fuel tank Fuel Pump Lift Capabilities and Fuel Consumption Figure 6 9 lists electric fuel pump lift capabilities and fuel line sizes Figure 6 10 shows generator set fuel consum
101. uel unless itis UNLEADED Use fresh gasoline to ensure itis blended for the season and to prevent the formation of gum deposits which could clog the fuel system Do notuse gasoline left over from the previous season TP 5695 12 93 Fuel Pump Screen A WARNING W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Explosive fuel vapors can cause severe injury or death All fuels are highly explosive in a vapor state Use extreme care when handling storing and using fuels Store fuel in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running since spilled fuel may ignite on contact with hot parts or from ignition spark Do not smoke or permit flame or spark to occur near potential sources of spilled fuel or fuel vapors Keep fuel lines and connections tight and in good condition don t replace flexible fuel lines with rigid lines Flexible sections are used to avoid breakage due to vibration Should any fuel leakage fuel accumulation or electrical sparks be noted DO NOT OPERATE GENERATOR SET Have systems repaired before resuming generator operation Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Do not store gasoline in any occupied building The electric fuel pump includes a screen See Figure 3 7 At the recommende
102. vice General Under normal conditions generator service will not be required on a regular basis If operating under dusty and dirty conditions use DRY compressed air to blow dust out of the generator at frequent intervals Do this with the generator set operating and direct the stream of air in through the cooling slots at the end of the generator The end bracket bearing should be replaced every 10 000 hours of operation Have bearing replaced sooner if bearing inspection indicates excessive rotor end play or bearing damage from corrosion or heat buildup The end bracket bearing is sealed and requires no additional lubrication All generator service must be performed by an authorized service dealer distributor Scheduled Maintenance 3 23 S to rage P roc ed ure 4 Close seacock and drain all seawater out of cooling system It is recommended that the craft be afloat when the a Drain seawater from strainer and seawater generator set is prepared for storage since the engine pump must be started b Remove zinc anode or end cap on heat 1 Add fuel stabilizer to fuel tank Use exchanger whichever is more convenient to recommendations of fuel stabilizer manufacturer Start generator set and run until operating temperature is reached or about 15 minutes Stop generator set Drain oil from crankcase while engine is still warm Replace oil filter Refill crankcase with specified weight oil NOTE For storage seawater must be repl
103. water and electrolyte This will prevent damage to battery due to freezing 1 Filter Caps 2 Electrolyte Level Figure 3 20 Checking Electrolyte Level Checking Specific Gravity Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell Correct actual hydrometer readings for temperature If the hydrometer used does not have a correction table use the one in Figure 3 21 The battery is fully charged if the specific gravity is 1 260 at an electrolyte temperature of 80_ F 26 7_ C The difference between specific gravities of TP 5695 12 93 each cell should not exceed 20 01 The battery should be charged if the specific gravity is below 1 215 atan electrolyte temperature of 80_ F 26 7 C Correction 032 030 99 EXAMPLE NO 1 1 026 4 00 Temperature below 80 26 79 022 Hydrometer Reading 1 250 020 Acid Temperature 200F 6 70C 018 016 Subtract 024 Specific Gravity 014 Corrected Specific Gravity is 1 226 012 010 008 006 EXAMPLE NO 2 004 N Temperature above 800 26 79 0 Hydrometer Reading 1 235 Acid Temperature 100 37 89 Add 008 Specific Gravity Corrected Specific Gravity is 1 243 1 787 The temperature correction amounts to about 004 4 points of specific gravity for each L ck 5 50 change in temperature Figure 3 21 Specific Gravity Temperature Correction TP 5
104. witch protects the engine against internal damage if the cooling water temperature in the engine block is too high due to cooling water or coolant circulation problems The switch is set to trip at 248 266oF 120 130C The location of the high water temperature shutdown switch is shown in Figure 2 3 1 hidden 258000 D 1 High Water Temperature Shutdown S witch Figure 2 3 High Water Temperature Shutdown Switch TP 5695 12 93 High Exhaust Temperature Shutdown Switches The two high exhaust temperature shutdown switches protect the engine against internal damage due to excessive exhaust temperatures The switches are set at 210 2200F 99 105oC The locations of the high exhaust temperature shutdown switches are shown in Figure 2 4

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