Kohler 3 5Cfz 4Cz 6 5Cz Users Manual Operation Manual, 4/6.5CZ 3.5/5CFZ Spec 125217 (TP 5695)

3.5CFZ, 4CZ, 5CFZ, 6.5CZ Kohler-TP-5695

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Operation and

Installation Manual

MarineGenerator Sets

Models:

3.5CFZ

4CZ

5CFZ

6.5CZ

TP-5695 12/93

Engine exhaust fromthisproductcontains

chemicalsknowntotheStateofCaliforniatocause

cancer,birth defects,orother reproductive harm.

WARNING

CaliforniaProposition 65

TP-5695 12/93 Table ofContents

TableofContents

SUBJECTPAGE SUBJECTPAGE

SafetyPrecautions and Instructionsi.......

Reference Materialviii.......................

Routine ServiceParts x......................

GlossaryofAbbreviations xi................

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

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

Specifications1-1.............................

GeneralSpecifications1-1...................

Generator1-2..............................

Engine 1-3.................................

Accessories1-5..............................

ServiceViews1-6.............................

Section 2.Operation 2-1......................

PrestartChecks 2-1...........................

Controller2-2................................

Starting 2-3..................................

Stopping 2-3.................................

CircuitProtection 2-4..........................

Engine SafetyShutdownSwitches2-4...........

RemotePanels(Optional)2-6..................

Section 3.ScheduledMaintenance 3-1.........

ServiceSchedule 3-2..........................

Lubrication System3-4........................

Specifications3-4...........................

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

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

Oil Change/Oil FilterChange 3-5..............

FuelSystem3-6..............................

Specifications3-6...........................

FuelPumpScreen 3-7.......................

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

CarburetorAdjustments3-8..................

Ignition System3-9............................

Ignition SystemService 3-9..................

SparkPlugs3-9............................

Cooling Systems—Closed/HeatExchanger3-12...

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

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

Anticorrosion Zinc3-16.......................

PressureCap 3-17...........................

Siphon Break3-17...........................

AirCleanerand Mixing Elbow3-17...............

Servicing AirCleaner3-17....................

Servicing Mixing Elbow3-17...................

Battery3-18...................................

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

Checking Electrolyte Level3-18................

Checking SpecificGravity3-18................

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

ValveAdjustment3-20..........................

Governor3-22.................................

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

GovernorAdjustment3-22....................

Wattage Requirements3-23.....................

GeneratorService 3-23.........................

General3-23................................

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

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

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

ElectricalSystem4-3..........................

Generator4-4................................

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

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

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

GeneratorSelection and

Wattage Requirements6-1.....................

Lighting Load 6-1...........................

MotorLoads6-1............................

Appliance Loads6-2........................

Kilowatt Derating 6-2........................

Location 6-4..................................

General6-4................................

Space 6-4.................................

Mounting 6-4...............................

Ventilation 6-4................................

FuelSystems6-5.............................

FuelSupply6-5............................

Anti-Siphon Provisions6-6...................

FuelLines6-6..............................

FuelPump Lift Capabilitiesand

FuelConsumption 6-6.......................

Cooling Systems6-7..........................

General6-7................................

Closed/HeatExchanger6-8..................

ExhaustSystems6-9..........................

General6-9................................

AboveWaterline 6-11........................

Mid/BelowWaterline 6-11.....................

ElectricalSystems6-12.........................

ACVoltage Connections6-12..................

Installation inSteelorAluminumVessels6-12...

Battery6-13.................................

Wiring 6-13.................................

RemoteStartSwitchConnection 6-14..........

Section 7. Installation Drawings 7-1...........

Section 8.PartsOrdering Instructions 8-1.....

Section 9.Operating HourService Log 9-1.....

TP-5695 12/93 SafetyPrecautionsand Instructionsi

Safety Precautions and Instructions

Ageneratorset, like anyotherelectro-mechanical

device,can pose potentialdangerstolife and limbif

improperlymaintained orimprudentlyoperated.The

bestwayto preventaccidentsisto be aware of the

potentialdangersand to always use good common

sense. Inthe interestofsafety,some general

precautionsrelating tothe operation ofa generatorset

follow.Keep theseinmind.Thismanualcontains

severaltypesofsafetyprecautionswhich are explained

below.

DANGER

Dangerisusedtoindicatethepresenceofahazardthat

will causeseverepersonal injury,death,orsubstantial

propertydamage if the warning isignored.

WARNING

Warning isused toindicatethe presence ofa hazard

thatcan causeseverepersonal injury,death,or

substantialpropertydamage if the warning isignored.

CAUTION

Cautionisused toindicatethepresence ofahazardthat

will orcan causeminorpersonal injuryorproperty

damage if the warning isignored.

Safetydecalsare affixed tothe generatorsetin

prominentplacesto advisethe operatororservice

technician ofpotentiallyhazardous situations.The

decalsarereproduced heretoimprove operator

recognition and therebyincrease decaleffectiveness.

Forafurtherexplanationofdecalinformation,reference

theaccompanying safetyprecautions.Beforeoperating

orservicing the generatorset, be sureyou understand

the message of these decals.Replace decalsifmissing

ordamaged.

NOTE

Noteisusedto notifypeople ofinstallation,operation,or

maintenanceinformation thatisimportantbutnot

hazard-related.

HAZARDOUS VOLTAGE/

ELECTRICALSHOCK

WARNING

Hazardous voltage.

Do notoperate generatorsetwithoutall guards

and electricalenclosuresin place.

Moving rotor.

Cancause severeinjuryordeath.

Hazardous voltage cancause severeinjuryor

death.Whereverelectricityispresent, thereisthe

hazardofelectrocution.Takethesameprecautionswith

electricalappliancesinyourcraft thatyou would

observeinyourhome.Open maincircuitbreakeron all

powersourcesbeforeservicing equipment. Makesure

unqualified persons,especially children,cannotgain

access toyourset—keep the compartmentdoorlocked

orsecurelylatchedatall times.Besurethatgeneratoris

properlygrounded.Nevertouch electrical leadsor

applianceswithwethands,when standing inwater,or

on wetground asthe chance ofelectrocution is

especiallyprevalentundersuchconditions.

Hazardous voltage cancause severeinjuryor

death.Usecaution when handling the capacitor;

possible electricalshock can result. Discharge

capacitorby shorting terminalstogether.

Hazardous voltage cancause severeinjuryor

death.Shortcircuits can cause bodilyinjuryand/or

equipmentdamage.Do notcontactelectrical

connectionswithtoolsorjewelrywhile adjustmentsare

made.Removewristwatch,rings,and jewelrythatcan

causeshortcircuits.

Hazardous“backfeed”voltage cancause severe

injuryordeath.Do notconnect to anybuilding/marina

electricalsystemwithoutconnecting through an

approved device and afterbuilding mainswitchisopen.

Backfeedconnectionscancauseseriousinjuryordeath

to utilitypersonnelworking torepaira poweroutage

and/orpersonnel inthe vicinity.Unauthorized

connection maybe unlawful insomestatesand/or

localities.Aship-to-shoretransferswitchmustbe

installed to preventinterconnection ofgeneratorset

powerand shore power.

TP-5695 12/93ii SafetyPrecautionsand Instructions

EXHAUSTSYSTEM

WARNING

Carbon monoxide.

Cancause severenausea,fainting,ordeath.

The exhaustsystem mustbe leakproofand

routinelyinspected.

Carbon monoxide cancause severenausea,

fainting,ordeath.Usethe following precautionswhen

installing and operating generatorset. Carbon

monoxide isparticularlythreatening inthatitisan

odorless,colorless, tasteless,nonirritating gas.Be

especially careful ifoperating the generatorwhen

moored oranchored undercalmconditionsasgases

mayaccumulate.Ifoperating the setdockside,moor

yourcraftsothatthe exhaustdischargesonthe leeside

(the side sheltered fromthe wind),and always be

mindfulofothers—makesureyourexhaustisdirected

awayfromotherboatsand occupied buildings.Do not

install exhaustoutletwhere exhaustcan be drawn

through portholes,vents,orairconditioners. If

generatorset’sexhaustdischarge holeisneartoyour

craft’swaterline,DONOTOVERLOADCRAFTso asto

close or restrictexhaustdischarge hole.

Carbon monoxide cancause severenausea,

fainting,ordeath.In addition toroutine inspection of

theexhaustsystem,acarbonmonoxidedetectorshould

be considered.Consultyourboatbuilderormarina for

installation ofapproved detectors.Itisessentialthatall

detectorsbe routinelyinspected forproperoperation.

TP-5695 12/93 SafetyPrecautionsand Instructionsiii

BATTERY

WARNING

Sulfuric acidin batteries.

Cancause severeinjuryordeath.

Use protective gogglesand clothes.Can cause

permanentdamage to eyes,burnskin,and eatholes

inclothing.

Sulfuric acidin batteries cancause severeinjuryor

death.Sulfuricacidin battery can cause permanent

damage to eyes,burnskin,and eatholesinclothing.

Alwayswearsplash-proofsafetygoggleswhenworking

around the battery.Ifbatteryelectrolyteis splashed in

the eyesoron skin,immediatelyflushthe affected area

for15minuteswithlarge quantitiesofclean water.Inthe

caseofeyecontact,seekimmediatemedicalaid.Never

addacidtoabatteryoncethebatteryhasbeenplacedin

service.Doing somayresultin hazardous spattering of

electrolyte.

Explosion cancause severeinjuryordeath.Battery

gases can cause an explosion.Do notsmoke orpermit

flame orsparkto occurneara batteryatanytime,

particularlywhen itisbeing charged.Avoidcontacting

terminalswithtools,etc.topreventburnsand to prevent

sparks thatcouldcause an explosion.Remove

wristwatch,rings,andanyotherjewelrybeforehandling

battery.Neverconnectnegative(--) battery cableto

positive(+)connection terminalofstartersolenoid.Do

not testbattery condition by shorting terminalstogether

orsparks couldignite batterygasesorfuelvapors.Any

compartmentcontaining batteriesmustbe well

ventilated to preventaccumulation ofexplosive gases.

To avoidsparks,do notdisturb battery charger

connectionswhile batteryisbeing charged and always

turnchargeroff before disconnecting battery

connections.When disconnecting battery,remove

negativelead firstand reconnectitlast.

TP-5695 12/93ivSafetyPrecautionsand Instructions

FUELSYSTEM

WARNING

Explosion.

Gasoline vapors cancause explosion and

severeinjuryordeath.

Beforestarting generatorset, operate blower4

minutesand check engine compartment for

gasoline vapors.

WARNING

Explosive fuelvapors.

Cancause severeinjuryordeath.

Useextremecarewhen handling,storing,

and using fuels.

Explosive fuelvapors cancause severeinjuryor

death.Allfuelsarehighlyexplosiveinavaporstate.Use

extremecarewhen handling,storing,and using fuels.

Storefuel inawell-ventilated area awayfrom

spark-producing equipmentand outof the reach of

children.Neveradd fueltothe tankwhilethe engine is

running sincespilled fuelmayignite on contactwith hot

partsorfromignition spark.Do notsmoke orpermit

flame orsparkto occurnearpotentialsourcesofspilled

fuelorfuelvapors.Keepfuellinesand connectionstight

and in good condition—don’treplaceflexiblefuel lines

withrigidlines.Flexiblesectionsare used to avoid

breakage due tovibration.Should anyfuel leakage,fuel

accumulation,orelectricalsparks be noted,DONOT

OPERATEGENERATORSET.Havesystemsrepaired

beforeresuming generatoroperation.

Explosive fuelvapors cancause severeinjuryor

death.Additionalprecautionsmustbe taken when

using the following fuels:

Gasoline—Store gasoline onlyin approved red

containers clearlymarked GASOLINE.Do notstore

gasoline in anyoccupied building.

Explosive fuelvapors cancause severeinjuryor

death.Gasoline vapors can explode and can cause

death orsevereinjury.USCGRegulation 33CFR183

requiresall electricaldevices(ship-to-shoretransfer

switch,remotestartpanel,etc.)tobe“ignitionprotected”

whenusedinagasoline(gaseous)-fueledenvironment.

These electricaldevicesare not“ignition protected”and

are notcertified to operatein a gasoline

(gaseous)-fueled environmentsuch asengine roomor

nearfueltanks.Acceptablelocationswould be

wheelhouseorotherlivingareasshelteredfromrainand

watersplash.

Explosive fuelvapors cancause severeinjuryor

death.Spilled fuelcan cause an explosion.Use a

containertocatchfuelwhen draining fuelsystem.Wipe

up all spilled fuelafterdraining system.

Explosive fuelvapors cancause severeinjuryor

death.Fuel leakage can cause an explosion.Do not

modifythe tankorpropulsion engine fuelsystem.Craft

mustbe equipped withatankallowing one of the two

pickup arrangementsdescribed.Tankand installation

mustconformtoU.S.C.G.Regulations.

Explosive fuelvapors cancause severeinjuryor

death.Fuel leakage can cause an explosion.To

prevent fuel leakage,use pipe sealanton all threaded

fittings.Pipe sealantmustbe suitableforuseinmarine

applicationshaving oil and gasoline environments.

TP-5695 12/93 SafetyPrecautionsand Instructions v

ACCIDENTALSTARTING

WARNING

Accidentalstarting.

Cancause severeinjuryordeath.

Disconnectbattery cablesbeforeworking on

generatorset(negativelead firstand reconnectit

last).

Accidentalstarting cancause severeinjuryor

death.Disconnectbattery cables(remove negative

lead firstand reconnectitlast)to disable generatorset

beforeworking on anyequipmentconnected to

generator.The generatorsetcan be started byremote

start/stop switch unless thisprecaution isfollowed.

MOVINGPARTS

WARNING

Rotating parts.

Cancause severeinjuryordeath.

Do notoperate generatorsetwithoutall guards,

screens,orcoversin place.

Flying projectiles cancause severeinjuryordeath.

Retorque all crankshaft and rotorhardware after

servicing.When making adjustmentsorservicing

generatorset, do notloosen crankshaft hardware or

rotorthru-bolt. If rotating crankshaft manually,direction

shouldbeclockwise only.Turning crankshaft boltor

rotorthru-boltcounterclockwisecan loosen hardware

and resultinseriouspersonal injuryfromhardware or

pulleyflying off engine while unitisrunning.

Exposedmoving parts cancause severeinjuryor

death.AdditionalPrecautionsRegarding Sound Shield

Equipped Models:

Somescheduled maintenance proceduresrequirethe

generatorset to be running while performing service. If

the sound shield hasbeen removed leaving beltsand

pulleys exposed,be especially carefulof thisarea.

Exposedmoving parts cancause severeinjuryor

death.Keep hands, feet, hair,clothing,and testleads

awayfrombeltsand pulleys when unitisrunning.

Replace guards,covers,and screensbefore operating

generatorset.

HOTPARTS

WARNING

Hotengine and exhaustsystem.

Cancause severeinjuryordeath.

Donotworkongeneratorsetuntilunitisallowedto

cool.

Hotparts cancause severeinjuryordeath.Do not

touchhotengine parts.Anengine getshotwhilerunning

and exhaustsystemcomponentsgetextremelyhot.

WARNING

Hotcoolantand steam.

Cancause severeinjuryordeath.

Beforeremoving pressurecap stop generator,

allowtocooland loosen pressurecap torelieve

pressure.

Hotcoolantcancause severeinjuryordeath.Allow

engine tocooland release pressurefromcooling

systembefore opening pressurecap.Torelease

pressure,coverthe pressurecap with a thick cloththen

turnitslowly counterclockwisetothe firststop.After

pressure hasbeen completelyreleased and the engine

has cooled,removecap. If generatorsetisequipped

withacoolantrecoverytank,checkcoolantlevelattank.

TP-5695 12/93viSafetyPrecautionsand Instructions

ENGINEBACKFIRE/FLASHFIRE

WARNING

Fire.

Cancause severeinjuryordeath.

Do notsmoke orpermit flame orsparkto occur

nearfuelorfuelsystem.

Aflashfire cancause severeinjuryordeath.Donot

smokeorpermitflameorsparktooccurnearcarburetor,

fuel line, fuelfilter, fuelpump,orotherpotentialsources

ofspilled fuelorfuelvapors.When removing fuel line or

carburetor,useapropercontainertocatch all fuel.

Asuddenbackfire cancause severeinjuryordeath.

Do notoperatewith backfireflame arrestor removed.

Asuddenbackfirecancausesevereinjuryordeath.

Do notoperatewith aircleaner/silencer removed.

Asuddenflashfirecancausesevereinjuryordeath.

Donotsmokeorpermitflameorsparktooccurnearfuel

system.Keepthecompartmentandgeneratorsetclean

and free ofdebristominimizechancesof fire.Wipe up

all spilled fueland engine oil.

HAZARDOUSNOISE

CAUTION

Hazardousnoise.

Cancause loss ofhearing.

Neveroperate generatorwithoutamufflerorwith

faultyexhaustsystem.

TP-5695 12/93 SafetyPrecautionsand Instructions vii

NOTES NOTE

HARDWAREDAMAGE!Engine and generatormay

make use ofbothAmerican Standard and metric

hardware.Besureto usethe correctsizetoolsto

preventrounding ofboltheadsand nuts.

NOTE

Specialattention should be given when checking for

propercoolantlevel.Afterthecoolanthasbeendrained,

itnormallyrequires sometime beforecompleterefill of

the engine waterjacket takesplace.

NOTE

Whenreplacing hardware,do notsubstitutewith

inferiorgradehardware.Screwsand nutsare

availablein differenthardness ratings.American

Standard hardware usesaseriesofmarkingsand

metrichardware usesa numeric systemtoindicate

hardness.Check markingson bolthead and nutsfor

properidentification.

NOTE

When a fusereplacementisrequired,be surefuse has

the same ampererating and isthe sametype (for

example:ABCor3AB,ceramic).Do notsubstitute

“clear”glass-type fusesforceramicfuses. If ampere

rating isunknown orquestionable,see Wiring Diagram.

NOTE

High-mineralcontentsea water (saltwater) can cause

rapid destruction ofall metals.Wipe up all saltwater

spillage on and around generatorsetand keep metal

surfacesfree fromaccumulated saltdeposits.

NOTICE

Thisgeneratorsethas beenrewiredfromits

nameplate voltageto:

246242

NOTICE

Thisisapositive terminalonly.

Do notattach negative lead!

NOTICE

Checkzincanode every100 hoursor3months.

NOTICE

Do notuse as a step.

Standing on gensetcouldimpairoperation ofunit.

NOTE

Splitlock washersmaybe supplied withsomekits. If

splitlock washersaresupplied withkit, theiruseis

optional.

TP-5695 12/93viii ReferenceMaterial

Reference Material

It isrecommended that the following Regulationsand

Standardsbe followed when installing Marine

GeneratorSets.

PleasureCraft

Designed and manufactured tomeetU.S.CoastGuard

Title 33.

U.S.CoastGuardCode ofFederalRegulations

Title 33

SubpartsI--ElectricalSystems

Subparts J--FuelSystems

Title 46

SubchapterF--Marine Engineering

Part58--Main and AuxiliaryMachineryand Related

Systems

Orderthe above publicationsfrom:

SuperintendentofDocuments

U.S.GovernmentPrinting Office

Washington,DC 20402

1-202-783-3238

Boating SafetyCircularCommandant(G-BC)

Boating Statistics (G-BP-1)

U.S.CoastGuardHeadquarters

2100 Second Street, S.W.

Washington,DC 20593-0001

Boating SafetyHotline:1-800-368-5647

American Bureau ofShipping

“RulesforBuilding and Classing SteelVessels”

45 EisenhowerDrive

Paramus,N.J.07652

201-368-9100

LloydsRegistryofShipping

“RulesforClassification ofShips”

17 BatteryPlace

NewYork,N.Y.10004

212-425-8050

UnderwritersLaboratories, Inc.(UL)

PublicationsStock

333 Pfingsten Road

Northbrook, IL 60062

Marine Department: 1-919-549-1400

NFPA 302

NationalFireProtection Association

60 BatterymarchPark

Quincy,MA02269

CustomerService

SocietyofAutomotiveEngineer’s(SAE)

400 CommonwealthDrive

Warrendale,PA 15096

1-412-776-4970

American Boatand YachtCouncil, Inc.(ABYC)

3069 Solomon’sIsland Rd.

Edgewater,MD21037

1-410-956-1050

1-410-974-8112

1-410-956-2737 FAX

IEEE 45

The Institute ofElectricaland

Electronics Engineer’sInc.

345 East47thStreet

NewYork,NY10017

TP-5695 12/93 ReferenceMaterial ix

CommercialVessels

In orderto usethese generatorsetsforcommercial

applicationswhereU.S.CoastGuardTitle46Certificate

isrequired,additionalmodificationswill be necessary.

U.S.CoastGuardCode ofFederalRegulations

Title 46

SubchapterF--Marine Engineering

Part58--Main and AuxiliaryMachineryand Related

Systems

SubchapterJ--ElectricalEngineering

Part111--ElectricalSystems--GeneralRequirements

Part112--Emergency Lighting and PowerSystems

SubchapterT--Small PassengerVessels

(Under100 Gross Tons)

Part182--MachineryInstallation

Part183--ElectricalInstallation

Orderthe above publicationsfrom:

SuperintendentofDocuments

U.S.GovernmentPrinting Office

Washington,DC 20402

1-202-783-3238

American Bureau ofShipping (ABS)

65 Broadway

NewYork,NY10006

OrderABS publicationsfrom:

American Bureau ofShipping

BookOrderSection

45 EisenhowerDrive

P.O.Box910

Paramus,NJ97653-0910

Lloyd’sRegisterofShipping

71 FenchurchStreet

London,EC3M4BS England

MidwestOffice:

Lloyd’sRegisterofShipping

100 SouthYorkStreet, Room226

Elmhurst, IL 60126

1-312-279-5414

AdditionalReferences

The following organizationsprovide a servicewhich

maybe usefultothe generatorsetinstaller.These

organizationsare notregulatoryin nature butrather

provide guidelinesand assistance.Theyarelisted only

asasourceforadditional information.Nosolicitation or

representation isherebygiven.

YachtCorrosion Consultants, Inc.

2970 SeaborgAve.

Ventura,CA93003

1-805-644-1886

Ward’sMarine Electric, Inc.

630 S.W.FlaglerAve.

Ft. Lauderdale,FL 33301

1-305-523-2815

1-800-545-9273

1-305-523-1967 FAX

xRoutine ServicePartsTP-5695 12/93

RoutineService Parts

ContactyourKohlergeneratordealer/distributorfora

completelisting ofservice partsforyourgeneratorset.

PartDescription KohlerPartNo.

Engine:

AirFilter278612

Oil Filter267714

Belt, Timing 267722

Ignition System:

SparkPlug 267713

Sea WaterPumpImpeller229826

ZincAnode 267928

WhiteSprayPaint221318

TP-5695 12/93 GlossaryofAbbreviations xi

GlossaryofAbbreviations

Abbreviationsare used throughout thismanual.Normallyinthe text theywill appearincompleteformwiththe

abbreviation following in parenthesisthe first timetheyare used.Afterthat theywill appearinthe abbreviated form.

The commonlyused abbreviationsareshown below.

Abbreviation Description

ACalternating current

AHWTanticipatoryhigh watertemp.

ALOPanticipatorylowoil pressure

AMamplitude modulation

Amp ampere

Ampsamperes

ANSIAmerican NationalStandardInstitute

APIAmerican PetroleumInstitute

approx.approximate,approximately

A/Rasrequired,asrequested

A/Sas supplied,as stated,as suggested

ASA American StandardsAssociation

assy.assembly

ASTMAmerican SocietyforTesting Materials

ATDC aftertop dead center

ATSautomatictransferswitch

aux.auxiliary

AWGAmerican WireGauge

AWMappliancewiring material

bhp brake horsepower

bmep brakemean effective power

BtuBritishthermalunit

°C Celsiusdegree

cc cubic centimeter

CCAcoldcranking Amps.

CEC Canadian ElectricalCode

cfhcubicfeetperhour

cfmcubicfeetperminute

CIDcubicinch displacement

cmcentimeter,centimeters

cmm cubicmetersperminute

co.company

cont’d.continued

C.S.A.Canadian StandardsAssociation

cu.in.cubicinch,cubicinches

cyl.cylinder

dBA decibels

DC directcurrent

DCR directcurrentresistance

deg.degree

dept. department

dia.diameter

e.g.example given

EMIelectromagneticinterference

etc.etcetera,(and soforth)

ext. external

°F Fahrenheitdegree

fl.oz. fluid ounce, fluid ounces

Abbreviation Description

FMfrequency modulation

fsfull scale

ft. foot, feet

ft. lbs. footpound, footpounds

ga.gauge

gal., gals.gallon,gallons

gal./hr.gallonsperhour

gph gallonsperhour

gpmgallonsperminute

gr.grade

grd.ground

HCHThigh cylinderhead temperature

HEThigh exhaust temperature

Hgmercury(element)

H2Owater

hp horsepower

hr,hrshour

HWThigh watertemperature

Hzhertz(cyclespersecond)

IDinside diameter

in.inch(es)

inc.incorporated

in.lbs.inch pounds

int. internal

int.-ext. internal-external

ISOInternationalStandardsOrganization

Jjoule,joules

JISJapaneseIndustryStandard

kgkilogram,kilograms

kg/cm2kilogramspersquarecentimeter

kgmkilogram meter(s)

kmkilometer,kilometers

kPakiloPascal,kiloPascals

kph kilometersperhour

kVkilovolt

kVA kilovoltamperes

kWkilowatt, kilowatts

kWHkilowatt hour

Lliter,liters

LxWxHlengthxwidthxheight

LED,LEDslightemitting diode

lb., lbs.pound,pounds

L/hr.literperhour,litersperhour

L/min.liter(s)perminutes

LOPlowoil pressure

LPliquefied petroleum

LWTlow watertemperature

m meter,meters

xii GlossaryofAbbreviationsTP-5695 12/93

Abbreviation Description

m3cubicmeter,cubicmeters

max.maximum

MCMone thousand circularmils.

mi.mile,miles

mil one one-thousandth ofan inch

min.minimum

mJmillijoule,millijoules

MJmega joule,mega joules

mm millimeter,millimeters

m3/mincubicmetersperminute

MPamegaPascal

mph milesperhour

MSmilitary standard

mWmilliwatt, milliwatts

MWmegawatt, megawatts

N/Anotavailable

NEC NationalElectricalCode

NEMANationalElectrical

ManufacturersAssociation

NFPA NationalFireProtection Association

NmNewton meter,Newton meters

no., nos.number,numbers

NPTNationalStandardtaperpipe

thread pergeneraluse

N/Rnotrequired

OCovercrank

ODoutside diameter

OEMoriginalequipmentmanufacturer

OSoverspeed,oversize

OVovervoltage

oz.ounce,ounces

Abbreviation Description

PFpowerfactor

pot. potentiometer

ppmpartspermillion

psipoundspersquareinch

pt., pts.pint, pints

qt., qts.quart, quarts

qty.quantity

ref. reference

RFIradiofrequency interference

rmsrootmean square

rpmrevolutionsperinch

SAE SocietyofAutomotiveEngineers

sec.second,seconds

SCR silicon controlled rectifier

spec,specs specification

sq.square

sq.cmsquarecentimeters

sq.in.squareinch,squareinches

tachtachometer

TDC top dead center

temp. temperature

TIFtelephone influencefactor

turbo turbocharger

UNC Unified coarsethread (wasNC)

UNFUnified fine thread (wasNF)

ULUnderwriter’sLaboratories, Inc.

USundersize

Vvolt, volts

VACVoltsalternating current

VDC voltsdirectcurrent

Wwatt, watts

TP-5695 12/93 Specifications1-1

Section 1.Specifications

Introduction

The craft isequipped with a dependable 110 volt

(reconnectableto 110/220 volt),50 Hz;or120 volt

(reconnectableto 120/240 volt),60 Hz single-phase

alternating currentmarine generatorset. Service

requirementsareminimalbutareveryimportant tothe

safe and efficientoperation of the generatorset;

therefore,inspectassociated partsoften. It is

recommended thatan authorized service

dealer/distributorperformrequired servicing to assure

the unitcontinuestomeetU.S.C.G.requirements.

Pleasetakeafewmomentstoread thismanual, then

carefullyfollowallservicerecommendationstokeepthe

setintop condition.Keep thismanualaboardthe craft

forfuturereference.See Figure 1-1foridentification

and location ofcomponents.

Specifications

GeneralSpecifications

3.5CFZ 5CFZ

Dimensions--LxWxH--in.(mm)27.87 x17.50 x16.60

(708 x445 x422)31.07 x18.10 x17.50

(789 x460 x445)

withSound Shield 31.07 x18.10 x17.50

(789 x460 x445)31.07 x18.10 x17.50

(789 x460 x445)

Weight--(wet),lbs.(kg)208 (94)231 (104)

withSound Shield 231 (104)231 (104)

AirRequirements--cfm(L/min.)18 (510)18 (510)

FuelConsumption U.S.gal./hr.(L/hr.)

Load

25%0.42 (1.59)0.44 (1.67)

50%0.50 (1.89)0.54 (2.04)

75%0.59 (2.23)0.66 (2.50)

100%0.68 (2.57)0.80 (3.03)

4CZ6.5CZ

Dimensions--LxWxH--in.(mm)27.87 x17.50 x16.60

(708 x445 x422)31.07 x18.10 x17.50

(789 x460 x445)

withSound Shield 31.07 x18.10 x17.50

(789 x460 x445)31.07 x18.10 x17.50

(789 x460 x445)

Weight--(wet),lbs.(kg)190 (86)231 (104)

withSound Shield 213 (96)231 (104)

AirRequirements--cfm(L/min.)18 (510)18 (510)

FuelConsumption U.S.gal./hr.(L/hr.)

Load

25%0.48 (1.81)0.53 (2.00)

50%0.55 (2.08)0.62 (2.34)

75%0.62 (2.34)0.86 (3.25)

100%0.68 (2.57)1.02 (3.86)

TP-5695 12/931-2Specifications

Generator

3.5CFZ 5CFZ

Rated kW3.5 5

Frequency--Hz50 50

Rated Voltage 110 Volt, 2&3Wire,SinglePhase or110/220 Volt, 3Wire,SinglePhase

Rated Amps(110 Volt)31.8 45.5

Rated Amps(220 Volt)15.9 22.7

RotorResistance(cold) (ohms)4--5 4--5

StatorResistance(cold) (ohms)*

Leads:

1--2,3--4 0.8 0.8

55--66 4.2 4.2

B1--B2 0.08 0.08

4CZ6.5CZ

Rated kW4 6.5

Frequency--Hz60 60

Rated Voltage 120 Volt, 2&3Wire,SinglePhase or120/240 Volt, 3Wire,SinglePhase

Rated Amps(120 Volt)33.3 54.2

Rated Amps(240 Volt)16.7 27.1

RotorResistance(cold) (ohms)3--4 4--5

StatorResistance(cold) (ohms)*

Leads:

1--2,3--4 0.06 0.04

55--66 1.9 2.4

B1--B2 0.09 0.06

3.5CFZ/4CZ5CFZ/6.5CZ

GeneratorType Two-Pole,Rotating Field

Voltage Regulation ±5%

Frequency Regulation ±5%

AngularOperation (Max.)

(in all directions)20° Continuous

Excitation Method Brushless,ExciterWinding/Capacitor

Coupling Type Tapered Shaft--Thru-Bolt

StatorBoltTorque in.lbs.(Nm)260 (29)

Thru-BoltTorque ft. lbs.(Nm)37 (50)

NumberofOutputLeads4,Reconnectable

Insulation (Rotorand Stator) Class F,Epoxy Varnish,VacuumImpregnated

Winding MaterialCopper

Bearing,Numberand Type 1,ReplaceableBall

CircuitProtection:

ControllerReplaceable 10-AmpFuse

BatteryCharging Replaceable 10-AmpFuse

AC CircuitBreakersOptional

*Mostohmmeterswill notgive accuratereadingswhen measuring less than 1 ohm.The statorcan be

considered good ifalowresistancereading (continuity)isobtained and thereisno evidence ofshorted

windings(discoloration).Do notconfusealowresistancereading withareading indicatingashorted winding.

TP-5695 12/93 Specifications1-3

DERATING:All unitsarerated1.0powerfactor.Derateapproximately3.5%per1000 ft.(300 m)above500ft.(150m)

abovesea level.

3.5CFZ,50 Hz:3.5kWat77° F(25° C)and 3.5kWat122° F(50° C).

4CFZ,60 Hz:4kWat77° F(25° C)and 3.5kWat122° F(50° C).

5CFZ,50 Hz:5kWat77° F(25° C)and 4.85 kWat122° F(50° C).

6.5CZ,60 Hz:6.5kWat77° F(25° C)and 6 kWat122° F(50° C).

Engine

Some generalengine specificationsarelisted below.Refertothe appropriateservicesection and the engine service

manualforspecific service details.

3.5CFZ/4CZ5CFZ/6.5CZ

ManufacturerHonda

ModelGX360EV

Cycle 4

NumberCylinders2

Compression Ratio 8:5:1

Displacement--cu.in.(L)21.9(359)

Rated Horsepower--50 Hz10.7(3.5CFZ)10.7(5CFZ)

--60 Hz12.8(4CZ)12.8(6.5CZ)

RPM--50 Hz3000 (3.5CFZ)3000 (5CFZ)

--60 Hz3600 (4CZ)3600 (6.5CZ)

BorexStroke--in.(mm)2.28 x2.68 (58 x68)

ValveMaterialSteelAlloy(JIS SUH3)

ValveClearance--in.(mm) (cold)0.004--0.006 (0.10--0.14)

CylinderBlock MaterialAluminum

CylinderHead CoverTightening

Torque--ft. lbs.(Nm)7(10)

CylinderHead MaterialAluminum

Connecting Rod MaterialSteel

Piston Rings2Compression/1Oil Control

Crankshaft BearingsReplaceableInserts

GovernorGear-Driven Centrifugal

Lubrication SystemPressure

Oil Capacity(withfilter)--U.S.qts.(L)1.48 (1.4)

Oil Type (API)SF,SF/CC,orSF/CD

Oil Pressure--psi(kPa)30--50 (207--345)

FuelType Gasoline,86 orHigher,Octane Unleaded

FuelSystemSingle-Barrel,HorizontalCarburetor

CarburetorChokeAutomatic,Electric

FuelPumpElectric

FuelPump Lift (max.)3ft. (0.9m)

BatteryVoltage 12

BatteryGround Negative

BatteryRecommendation 250 ColdCranking Amps(Min.)

TP-5695 12/931-4Specifications

Engine(Continued)

3.5CFZ/4CZ5CFZ/6.5CZ

SparkPlug Type Resistor,RadioSuppression,14 mm

BPR4HS(NGK)

KohlerPartNumberL92YC(Champion)

R43CFS(AC-Delco)

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

SparkPlug Tightening Torque--

ft. lbs.(Nm)15--22 (20--30)

Ignition SystemTransistorized,Breakerless

StarterMotorBendixAutomotiveType

Cooling SystemWater-Cooled,Closed/HeatExchanger

Cooling SystemCapacity--U.S.qts.(L)1.10 (1.00)

CoolantRecoveryTank--U.S.qts.(L)0.38 (0.35)

Thermostat180 °F(82° C)

PressureCap Rating 15 psi(103 kPa)

Engine Firing Order1--2

Ignition Timing B.T.D.C.24° ±2 degrees

ExhaustManifoldtoCylinder

Head Torque 16 ft. lbs.(22 Nm)

WaterPumpAssemblyto

CylinderBlock Torque 7ft. lbs.(10 Nm)

Cooling Fan Torque 16 ft. lbs.(22 Nm)

AirCleanerElbowtoCarburetor

Stud Torque 6ft. lbs.(8.5Nm)

Timing BeltCoverTorque 6 ft. lbs.(8Nm)

GovernorArmShaft NutTorque 7 ft. lbs.(10 Nm)

GovernorCasetoCylinderHead

Torque 7ft. lbs.(10 Nm)

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

BatteryCharging Winding

Resistance--10 Amp0.16--0.24 Ohms

Ignition Coil PrimaryWire

Resistance0.9--1.1Ohms

Ignition Coil Secondary

(SparkPlug WireSide)Resistance0.9--1.1Ohms

(WithSparkPlug Boot/Cap Removed)

Transistorized Ignition AirGap 0.016 ±0.008 in.(0.4±0.2mm)

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

TP-5695 12/93 Specifications1-5

Accessories

Severalaccessoriesare availabletofinalizethe

installation orto add convenienceto operation and

service.Allthemostcurrentinformationcanbeobtained

by contacting the localauthorized Kohler

dealer/distributor.Available accessoriesat the time of

printof thispublication are asfollows.

Sound Shield

(Optionalon 3.5CFZ/4CZ;

Standardon5CFZ/6.5CZ)

Providesforhighlyeffectivesilencing,ease ofaccess

forengine/generatorservicing,lowmaintenance,

excellentdurability,and safety.

SeawaterStrainer

The seawaterstrainerwithclearviewing container,

allowseasy cleaning and maintenance.Threaded for

1/2NPTfittings.

Ship-to-ShoreTransferSwitch

The ship-to-shoretransferswitch allowsimmediate

switching to generatorsetpowerorshore power

protecting the electricalsystemfromthe possibilityof

simultaneous connection ofboth powersources.

RemoteStartPanel

Allows starting/stopping fromalocation remote of the

generatorset. Supplied with 15 foot(4.6m)connection

harness.Overall mounting dimensionsare41/16 in.

(103mm)by2 1/8in.(54mm)witha minimum mounting

depth of2 1/4in.(57 mm).

SenderKit

Providesgauge sendersforthe remotestartand

two-meterpanelkitand the remotestartand four-meter

panelkit. The gauge senderkitisrequired tomakethe

oil pressure and watertemperature gaugesfunctional.

CircuitBreakers

See pricelistordealer/distributorforproperapplication

ofcircuitbreakers.

ModelAmpsPoles

4CZ/3.5CFZ 18 2

4CZ/3.5CFZ 35 1

4CZ/3.5CFZ 20 1

6CZ/5CFZ 30 2

6CZ/5CFZ 55 1

6CZ/5CFZ 25 2

6CZ/5CFZ 20 1

RemoteStartand

Four-MeterPanelKit

Allows starting/stopping fromalocation remote of the

generatorset. The illuminated meters/gaugesinclude a

DC voltmeter,engine oil pressure gauge,water

temperature gauge,and an hourmeterwhichrecords

totalgeneratorsetoperating hours.Overall dimensions

are9in.(229 mm)by6in.(152 mm)with a minimum

mounting depth of4in.(102 mm).Requiresremote

connection/extension harness and senderkit.

RemoteStartand

Two-MeterPanelKit

Allows starting/stopping fromalocation remote of the

generatorset.The illuminatedgaugesincludeengineoil

pressure gauge and watertemperature gauge.Overall

dimensionsare6in.(152 mm)by6in.(152 mm)with a

minimum mounting depth of2 3/4in.(70 mm).Requires

remoteconnection/extension harness and senderkit.

RemoteConnection/

Extension Harness

Providesadditionalwiring between all remote panels

and controllerconnector.One required foreachremote

meterpanelkit. Availablein15ft. (46 m)and 25 ft.

(76 m)lengths.Extension limited to a totalof fourkits

and 75 ft. (23 m).

12-InchRemoteWiring Harness

Thisone foot(0.3m)wiring harness hasa 6-pin

connectoron one end whichis keyed tocontrollerbox

connector.The otherend haspigtailsforconnection to

customer-supplied startswitch,generator“on”light,

hourmeter,etc.

Siphon Break

Preventsthe siphoning ofwaterintothe engine on

generatorsetsinstalled belowthe waterline.

TP-5695 12/931-6Specifications

Service Views

TOTALHOURS

00 0

E

00 1/10

10A

FUSE

BATT.

CHRG.

INPUT

2

9

45

36

35

30

29 28 27 26 25 24 23

21

19

33

258000-D

1

34

STOP START

10 17

16131211 14

31 15

18

20

67

8

32

3

22

Figure 1-1.Service Views(typical)

1.MixerElbow(ExhaustWaterOutlet)

2.BeltGuard

3.ElectricChokeRotarySolenoid

4.Carburetor

5.GovernorLinkage

6.GovernorArm

7.Lifting Eye

8.Speed Adjustment(IdleSpeed)

9.Antidieseling Solenoid

10.Controller

11.BatteryChargerVoltage Regulator

12.CoolantOverflow Hose

13.Cooling SystemPressureCap

14.High WaterTemperatureSafetyShutdown

Switch

15.Thermostat

16.High ExhaustTemperatureShutdown

Switches(2)

17.SparkPlugs

18.SeawaterPump

19.Oil Drain

20.WaterTemperatureSender (Optional)

21.HeatExchanger

22. Ignition Coil/Module

23.LowOil PressureShutdownSwitch/Sender

(SenderOptional)

24.Oil Dipstick (Oil Check/Oil Fill)

25.Oil Filter

26.Anticorrosion Zinc

27.ElectricFuelPump

28.RemotePanelConnector

29.PositiveBatteryLead Connection

30.CoolantRecoveryTank

31.AirFilter

32.Nameplate

33.NegativeBatteryLead Connection

34.EquipmentGround Lug

35.StarterSolenoid

36.StarterMotor

TP-5695 12/93 Operation 2-1

Section 2. Operation

PrestartChecks

Toinsurecontinued satisfactoryoperation, the following

items shouldbechecked before eachstart-up.

BACKFIREFLAMEARRESTOR:Aircleanermustbe

cleanandproperlyinstalledtopreventunfilteredairfrom

entering engine.See Maintenance--AirCleaner.

BATTERY:Removecapsand check the electrolyte

levelofeachcell (batterieswithfillercapsonly);add

distilled waterifnecessary.Check tomakesureitis

connected correctly.Batteryinstallation and

connectionsmustmeetCoastGuardStandards.

Battery shouldbeserviced byauthorized personnel

only.See Maintenance--Battery.

COMPARTMENT:Keep the engine roomor

compartmentclean and dry.Check forfueloroil leaks.

Check the condition of fuelsystem,exhaustpiping,

hoses,and muffler;have anyfaulty components

repaired before getting underway.Open hatchto airout

compartmentand use“ignition-protected”bilge

blowers,ifrequired, toclearfumesfromarea before

eachstart-up. If fuel leaks, fumes,exhaustgases,or

electricalsparks are noted,arrange forqualified

personneltomake necessaryrepairsbefore operating

generatorset.

FUEL LEVEL:Makesurethe fueltanks arefull and the

fuelsystemprimed foroperation.See

Maintenance--FuelSystem.

OIL LEVEL:Should be atornearMax.mark.Add oil as

neededtobringleveluptothisrange.SeeMaintenance

Lubrication System.

COOLING:The coolantlevelon closed-type heat

exchangersystems can be checked using the coolant

recoverytank,ifused.TheMINmarkindicatesfull when

coldandtheMAXmarkindicatesfullwhen hot. Maintain

the coolantlevelbetween thesemarks. It is

recommended thatcoolantlevelon closed systemsbe

periodically checked byremoving pressurecap.Do not

solelyrelyon level incoolantrecoverytank.

Add freshcoolantuntil level isjustbelowoverflowtube

opening.See Maintenance--Cooling Systems.

SEAWATERPUMP PRIMING:The seawaterpump

mustbe primed beforeinitialstart-up.To prime pump,

closeseacock and removethe hosefromwaterfilter

outlet. Fill hose and pumpwithclean water.Replace

hose and open seacock.Check forpump operating on

start-up byobserving waterdischarge fromexhaust

outlet.

TP-5695 12/932-2Operation

Controller

Foridentification and location ofcontrolleroperating

features,refertothe textbelowand Figure 2-1.

1.BatteryCharging Fuse protectsbattery charging

circuitryfromshortcircuits.

2.Input (Controller)Fuse protects controller

circuitryfromshortcircuits.

3.Start/Stop Switchisused tostop and start

generatorset. Rock tostartorstop position and

holdtostartorstop engine.Switch automatically

returnsto neutralcenterposition when released.

4.Hourmeterrecordstotalgeneratorsetoperating

hours.Use asareferencetoschedule

maintenance.

5.RemoteStartConnectorprovides connection

point foroptionalremotestartkits.

6.OptionalAC CircuitBreaker(s)protects

generatorset fromshortcircuitsinload.Also used

to disconnectgeneratorset fromloadsduring

maintenance.Toclosecircuitbreaker,placeinON

position.

1

3

5

2

4

6

1.BatteryCharging Fuse

2. Input(Controller) Fuse

3.Start/Stop Switch

4.Hourmeter

5.RemoteStartConnector

6.OptionalAC Circuit

Breaker(s)

A-246486-D

Figure 2-1.Controller

TP-5695 12/93 Operation 2-3

Starting

WARNING

Explosion.

Gasoline vapors cancause explosion and

severeinjuryordeath.

Beforestarting generatorset, operate blower4

minutesand check engine compartment for

gasoline vapors.

NOTE

For reliablestarting,allowatleast30 secondsafter

shutdown beforerestarting a hotengine.

Ensurethatthe manualfuelshutoffvalve(ifequipped)is

open.Then rock the masterStart/Stop Switch on

controller (oruseStart/Stop Switch on remote panel)to

theStartpositionforamaximumof7secondsoruntilthe

engine starts.

NOTE

Do notcrankthe engine continuouslyformorethan 7

secondsatatime.Allowa 5-second period between

starting attemptsif the engine doesnotstart. If the

engine failstostartafterthree attempts,contactan

authorized Kohlerdealer/distributorfor repair.Failureto

followthese guidelinesmayresultin burn-outof the

startermotorfromoverheating.

Iftheenginefailstostartafterthe firstattempt, closethe

seacock before a second start-up attempt. Thisaction

will help preventseawaterfromentering the engine

cylindersthrough the exhaustvalve.Oncethe engine

starts,the seacock mustbe re-openedtoallowpassage

ofcooling water.

NOTE

Failureto open the seacock afterthe generatorsetis

running will resultinseriousengine damage due to

overheating.

NOTE

Ensurethat the marine ship-to-shoretransferswitch,if

used,isin properposition.

Stopping

Disconnecttheloadfromthegeneratorsetandallowthe

generatorset torun atno-load for5minutestocool

downthe engine.Then rock the masterStart/Stop

switchonthe controller (orthe Start/Stop Switch on a

remotepanel)totheStoppositionandholditintheStop

position until the generatorsetcomesto a complete

stop.

NOTE

Allowunit tocometoacompletestop before attempting

tostart the generatorsetagain.

TP-5695 12/932-4Operation

CircuitProtection

AC CircuitBreaker(Optional)

The optionalACcircuitbreaker(s)located on the front

panelof the controllerprotect the generatoroutput

windings.Ifaload circuitlosespower,the causemaybe

atrippedACcircuitbreaker.Ifatripped circuitbreakeris

resetand then tripsagain, find and correct the shortin

the load circuit thatis causing the problem.

Input (Controller)Fuse (10 Amp)

The input fuse protectsthe controllercircuitry. If the

generatorsetengine will notcrankand the batteryand

battery connectionsappearokay, the input fusemaybe

blown. If thisfuse,located on the frontpanelof the

controller,isreplaced and then blowsagain, find and

correct the short thatis causing the problem.

Battery-Charging Fuse (10 Amp)

The battery-charging fuse protectsthebattery-charging

circuit. If the batterygoesdead and the batteryand

battery-charging alternatorare otherwise normal, the

battery-chargingfusemaybeblown. If thisfuse,located

onthefrontpanelof thecontroller,isreplacedandblows

again, find and correct the shortinthe charging circuit

thatis causing the problem.

NOTE

When a fusereplacementisrequired,be surefuse has

the same ampererating and isthe sametype (for

example:ABCor3AB,ceramic).Do notsubstitute

“clear”glass-type fusesforceramicfuses. If ampere

rating isunknown orquestionable,see Wiring Diagram.

WARNING

Accidentalstarting.

Cancause severeinjuryordeath.

Disconnectbattery cablesbeforeworking on

generatorset(negativelead firstand reconnectit

last).

Accidentalstarting cancause severeinjuryor

death.Disconnectbattery cables(remove negative

lead firstand reconnectitlast)to disable generatorset

beforeworking on anyequipmentconnected to

generator.The generatorsetcan be started byremote

start/stop switch unless thisprecaution isfollowed.

EngineSafety

ShutdownSwitches

The engine isprotected bythree engine safety

shutdownswitches.Activating anyof theseswitches

whilethe generatorsetisrunning,resultsin an

immediate,automatic shutdown.During start-up, the

engine safety shutdownfeatureisinhibited until a

generatoroutputissensedinordertoallowtheoilpump

output toreach normaloperating pressure.

Low Oil PressureShutdownSwitch

The lowoil pressureshutdownswitch protectsthe

engineagainstinternaldamage,iftheoilpressuredrops

below20psi(138kPa),duetoanengineoilpumpfailure

orotherengine malfunction.The location of the lowoil

pressureshutdownswitchis showninFigure 2-2.

NOTE

The lowoil pressureshutdownswitch doesnotactasa

lowoil levelswitch.The onlywayto protectagainst

engine damage due tolowoil level istocheck the oil

levelregularly.

1

258000-D

1.LowOil PressureShutdownSwitch

Figure 2-2.Low Oil PressureShutdownSwitch

TP-5695 12/93 Operation 2-5

High WaterTemperature

ShutdownSwitch

The high watertemperatureshutdownswitch protects

the engine againstinternaldamage if the cooling water

temperatureinthe engine block istoo high due to

cooling waterorcoolantcirculation problems.The

switchis set totrip at248--266°F(120--130°C).The

location of the high watertemperatureshutdownswitch

is showninFigure 2-3.

TOTALHOURS

00 000 1/10

10A

FUSE

STARTSTOP

BATT.

CHRG.

INPUT

258000-D

1(hidden)

1.High WaterTemperatureShutdownSwitch

Figure 2-3.High WaterTemperature

ShutdownSwitch

High ExhaustTemperature

ShutdownSwitches

The two high exhaust temperatureshutdownswitches

protect the engine againstinternaldamage due to

excessive exhaust temperatures.The switchesareset

at210--220°F(99--105°C).The locationsof the high

exhaust temperatureshutdownswitchesareshownin

Figure 2-4.

TOTALHOURS

00 000 1/10

10A

FUSE

STARTSTOP

BATT.

CHRG.

INPUT

258000-D

1

1.High ExhaustTemperatureShutdownSwitches

(one located on eachmanifold)

Figure 2-4.High ExhaustTemperature

ShutdownSwitches

TP-5695 12/932-6Operation

RemotePanels(Optional)

RemoteStartPanel

Remotestartpanelallows starting-stopping froma

locationremoteofthegeneratorset.Generatorsetsare

equippedwitha6-pinconnectoron controllerbottomfor

connection of the kit. See Figure 2-5.

2

1

1.“ON”Light2.Start/Stop Switch1-656

KOHLER

GENERATOR

START

STOP

Figure 2-5.RemotePanelFeatures

RemoteStartand

Two-MeterPanelKit

Allows starting-stopping fromalocation remote of the

generatorset. The illuminated gaugesinclude an

engine oil pressure gauge and a watertemperature

gauge.Generatorsets come equipped with a 6-pin

connectoron controllerbottomforconnection of the kit.

See Figure 2-6for remotestartand meterpanelkit.

1

2

4 3

1.Engine Oil Pressure

2.WaterTemperature3.Start/Stop Switch

4.“On”Light

1-762

Figure 2-6.RemoteStartand Two-Meter

PanelFeatures

Start/Stop Switchisarocker-type switchwith“ON”

lightused tostartand stop generatorset.

EngineOil PressureGaugemeasuresengine oil

pressure.Normalengine operating range is30--50 psi

(207--345 kPa).

NOTE

During the engine break-in period,itisnormalforthe

engine to produce higheroil pressurereadings.

WaterTemperatureGaugemeasuresengine coolant

temperature.Normalengine operating range is

170--195_ F(77--91_ C).

TP-5695 12/93 Operation 2-7

RemoteStartand Four-Meter

PanelKit

Allows starting-stopping fromalocation remote of the

generatorset. The illuminated gaugesinclude a DC

voltmeter,engine oil pressure gauge,water

temperature gauge,and generator running time

hourmeter.Generatorsets come equipped with a 6-pin

connectoron controllerbottomforconnection of the kit.

See Figure 2-7for remotestartand four-meterpanel

features.

Start/Stop Switchisarocker-type switchwith“ON”

lightused tostartand stop the generatorset.

DC Voltmetermeasures voltage ofstarting battery(ies).

Normalbatteryoperating range is12--14 volts.

EngineOil PressureGaugemeasuresengine oil

pressure.Normalengine operating range is30--50 psi

(207--345 kPa).

NOTE

During the engine break-in period,itisnormalforthe

engine to produce higheroil pressurereadings.

WaterTemperatureGaugemeasuresengine coolant

temperature.Normalengine operating range is

170--195_ F(77--91_ C).

Hourmeterrecordstotalgeneratorsetoperating hours

for referenceinmaintenancescheduling.

12

6

53

4

1.Engine Oil Pressure

2.Hourmeter

3.Voltmeter

4.WaterTemperature

5.Start/Stop Switch

6.“ON”Light

1-830

Figure 2-7.RemoteStartand Four-MeterFeatures

TP-5695 12/93 Scheduled Maintenance 3-1

Section 3.ScheduledMaintenance

Usethe following serviceschedule and the hourmeter

on the controllertoscheduleroutine maintenance. In

addition tothe routine serviceslisted inthismanual,

there are otherimportantstepsthatshould be taken to

keep a generatorsetintop condition.Usuallytoolsand

instrumentsrequired forthese additionalstepsare not

availabletothegeneratorsetowner.Forthisreason,the

setshouldbereturned periodicallyto an authorized

service dealer/distributorforcompleteservicing and

tune-up.The benefitsofsuchservicewill be improved

performance and continuous satisfactoryoperation

duringalongtrouble-freeservicelife.UsetheOperating

HourServiceLoginthebackofthismanualtodocument

servicesperformed.

Serviceintervalsarelocated on the top rowsof the

ServiceSchedulechart. It indicateshowoften

maintenancetasks need to be done.Eachserviceitem

istoberepeated at the specified interval.Forexample,

an itemrequired at50 hourswill again need to be

performed at100 hours,150 hours,etc.

Forcontinuedsatisfactoryoperationandlongevityofthe

engine and generatorset, propermaintenance and

eventualoverhaulbyacompetentmechanic/technician

are essential.Whileitisnotpossibleto anticipate

component failure,rough operation,metallicnoises,

and excessive oil loss are among the indicatorsof

potentialproblems.Do notignoretheseconditions!

NOTE

Operatethe generatorsetwithload applied atleast

onceamonth.Allowgeneratorsettorunaboutonehour

toreach operating temperature.Thispreventsthe

formation ofcorrosion on internalengine components

when exposed tothe breakdown ofexhaustgasesand

seawaterforlongperiodsofgeneratorinactivity.Ifunitis

to be outofserviceforseveralmonths,see Storage

Procedure.

WARNING

Accidentalstarting.

Cancause severeinjuryordeath.

Disconnectbattery cablesbeforeworking on

generatorset(negativelead firstand reconnectit

last).

Accidentalstarting cancause severeinjuryor

death.Disconnectbattery cables(remove negative

lead firstand reconnectitlast)to disable generatorset

beforeworking on anyequipmentconnected to

generator.The generatorsetcan be started byremote

start/stop switch unless thisprecaution isfollowed.

NOTE

HARDWAREDAMAGE!Engine and generatormake

useofbothAmericanStandardandmetrichardware.Be

sureto usethe correctsizetoolsto preventrounding of

boltheadsand nuts.

NOTE

High-mineralcontentseawater (saltwater) can cause

rapid destruction ofmetals.Wipe up all saltwater

spillage on and around generatorsetand keep metal

surfacesfree fromaccumulated saltdeposits.

TP-5695 12/933-2Scheduled Maintenance

Service Schedule

Before

Starting

After20

Hrs.or

One

Month

Every 50

Hrs.or3

Months

Every

100 Hrs.

or6

Months

Every

200 Hrs.

orYearly

Every

300 Hrs.

or2Years

LUBRICATIONSYSTEM

Check oil levelX

Change oil X(Break-in

Period)X

Change oil filterX

FUELSYSTEM

Check the fuel levelX

Fill fueltankX

Lubricatecarburetorand choke

linkage X(Break-in

Period)X

Clean fuelscreen X

Servicefuel linesX

IGNITIONSYSTEM

ReplacesparkplugsX

COOLINGSYSTEM

Check coolantlevelX

Check seawateroutletX(During

Operation)

Inspectexhaustsystem

componentsforcracks and

corrosion (exhaustmanifold,

mixing elbow,exhaustline,

hoseclamps,silencer,and

outlet flapper)

X X

Check function ofsiphon break

(ifequipped)X

Check condition ofheat

exchangeranticorrosion zincX(100 Hrs.

or3

Months)

Replace heatexchanger

anticorrosion zincX

Replacethe impellerof

seawaterpumpX

Check thermostat function X

INTAKE/EXHAUSTSYSTEM

Check exhaustgas condition X(During

Operation)

Clean the exhaust/watermixing

elbowX

Clean airfilterelementX

TP-5695 12/93 Scheduled Maintenance 3-3

Service Schedule(Continued)

Before

Starting

After20

Hrs.or

One

Month

Every 50

Hrs.or3

Months

Every

100 Hrs.

or6

Months

Every

200 Hrs.

orYearly

Every

300 Hrs.

or2Years

ELECTRICALSYSTEM

Check electrolytelevel

(Batterieswithfillercapsonly)X X

Check and tighten electrical

connectionsX

Check specificgravity

(Batterieswithfillercapsonly)X

Clean battery cablesX

ENGINEAND MOUNTING

Check forleakage ofwater, fuel,

oroil X X

Lubricate governorlinkage X(Break-in

Period)X

Retighten all majornutsand

boltsX(Break-in

Period)X

Check and tighten mounting

boltsand vibromountsX

Check intake/exhaust

valveclearanceX

REMOTECONTROLSYSTEM,

ETC.

Check compartmentcondition

(fuel,oil,orwaterleaks)X

Check the remotecontrol

operation X(Break-in

Period)

Testrun generatorsetX

(Monthly)

GENERATOR

BlowdustoutofgeneratorX

TP-5695 12/933-4Scheduled Maintenance

Lubrication System

Specifications

Use high qualitydetergentoil ofAPI(American

PetroleumInstitute)serviceclassSF,SF/CC,orSF/CD.

Thisinformation can be found on mostoil containers,

see Figure 3-1.The symbol illustrated identifiesthe API

serviceclass inthe upperportion.The centerindicates

the SAE (SocietyofAutomotiveEngineers)viscosity

grade.The bottomportion (when used)signifiesthe oil

isintended toimprovefueleconomyand displays the

phrase“EnergyConserving.” Selectviscositybased on

the airtemperature at the time ofoperation.(See

Figure 3-2.)

SAE 10W40 isthe preferred oil forgeneralusewhere

temperaturespermit.

1--792

Figure 3-1.Oil Service Class and

SAE ViscosityGradeSymbol

WhenOutsideTemperature

isConsistently:Use SAE

ViscosityGrade:

Below5_ F(--15_ C)5W30

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

90_ F(32_ C)10W30

Above 15_ F(--10_ C)20W40 or20W50

Above--5_ F(--21_ C)10W40 (Preferred)

Figure 3-2.RecommendedSAE

ViscosityGrades

Using otherthan the appropriateserviceclass oil or

extended oil change intervals couldcause engine

damage whichisnotcovered bythe engine warranty.

Do notmixoilsofdifferentviscosities. It isalso bestnot

tomixdifferentbrandsofoils.Possibleincompatibility

couldcauseabreakdown oflubricating ingredientsand

reduce engine protection.

Oil Check

Checkoillevelincrankcasedailyorbefore eachstartup

toinsurethat the level isinthe saferange.

NOTE

Do notcheck oil levelwhen unitisrunning.Generator

setmustbe stopped and levelto getan accurate

reading.

If generatorsethasjustbeen run,allowafewminutes

forthe oil toreturntothe oil pan beforechecking level.

Tocheck oil level,remove dipstick and wipe the end

clean,place bottomthread ofdipstick againstoil fill hole

and remove.Do notscrewin dipstick when checking oil

level.Levelshould be between MINand MAX marks on

dipstick.See Figure 3-3.

NOTE

Do notoperatethe setif the level isbelowthe MINmark

orabovethe MAX mark.Oil abovethe MAX markis

wasted due toincreased oil consumption.

12

3

1.MAX Limit

2.MINLimit3.SafeRange

1-826

Figure 3-3.Checking Oil Level

TP-5695 12/93 Scheduled Maintenance 3-5

Adding Oil

It isnormalto add some oil between oil changes.The

amountwillvarywiththe usage.Openfillcap and poura

small amountofoil using a funnelorothersuitable

pouring device.See Figure 3-4.Waitafewminutesand

check level. If necessary,add more oil and then check

again.Eachtime be sureto add small quantitiesand

check to preventoverfilling.

1-826

Figure 3-4.Adding Oil

Oil Change/Oil FilterChange

Change oil and oil filterevery200 hoursoryearly.

Change oil morefrequentlyunderdirty,dusty

conditions.Changeoilwhiletheengineisstillwarm.See

Figure 3-5 and usethe following procedure.

TOTALHOURS

00 000 1/10

10A

FUSE

STARTSTOP

BATT.

CHRG.

INPUT

1

258000-D

1.Oil DrainCap

Figure 3-5.Oil DrainCap

1.Place oil drain hosein a propercontainer.Remove

oil draincap.Ifa drain pumpisused,remove oil

draincapand connectoildrainhoseto drainpump.

2.Allowampletimeforall oil to drainintocontainer. If

drain pumpisused,activate pump until oil is

removed.

3.Loosen oil filterbyturning in a counterclockwise

direction.Oil filteris2 1/2in.(64 mm)dia.with 14

flutes.Use oil filterwrench,ifnecessary.See

Figure 3-6.Useragsto handle hotoil filterand

clean up spilled oil.Removefilterfromoil filter

adapteron engine and discard oil filterin a proper

container.

4.Clean contactsurface ofoil filteradapter.

5.Lightlylubricatethe gasketsurface ofnewoil filter

withfresh engine oil.Thread oil filteronto oil filter

adapteruntil gasketmakes contact; then

hand-tighten oil filteran additional3/4turn.

NOTE

If an automaticoil drain/oil fill pumpisused,omit

Step 6.Fill with properamountand type ofoil,see

Step 6.When complete,replacecap and

disconnectpump.

6.Replace oil draincap.Remove oil fill cap.Add oil

usingafunnelorothersuitablepouringdevice.See

Specifications—Engine foroil capacityand

Lubrication System—Specificationsforproper

serviceclass and SAE viscosityofoil.Replace oil

fill cap.

7.Startgeneratorsetand check forleaks atoil drain

cap and oil filter.

8.Stop generatorset. Waitafewminutesforoil to

returnto oil pan.Remove dipstick and wipe clean,

reinsertasfaraspossible and removetocheck oil

level.Add oil,asnecessary, to bring levelup to

MAX mark.

TP-5695 12/933-6Scheduled Maintenance

11-826

1.Oil FilterWrench21/2in.(64 mm)Dia.

Figure 3-6.Removing Oil Filter

FuelSystem

Specifications

Forbestresults,use only clean fresh,regulargrade

unleaded gasoline.Usefuelwith a minimumoctane

rating asdesignated bythe following:

Antiknock Index(Average ofResearch 86

Octane Numberand MotorOctane Number)

Unleaded fuel isrecommended sinceitleavesless

combustion chamberdeposits.Oil mustnotbe mixed

withfuel.

If using a gasolinecontaining alcohol(gasohol),be sure

the octane rating isatleast86 (Antiknock Index).There

aretwotypesofgasohol:one containing ethanol,and

anothercontaining methanol.

Do notuse gasoholthatcontainsmorethan 10%

ethanol.Do notuse gasoholcontaining methanol

(methylorwood alcohol)thatdoesnotalsocontain

cosolventsand corrosion inhibitorsformethanol.Never

usegasoline containingmorethan5%methanol,evenif

ithas cosolventsand corrosion inhibitors.

NOTE

Fuelsystemdamage and engine performance

problemsresulting fromthe use ofsuchfuelsare not

coveredunderWarranty.Hondacannotendorsetheuse

offuelscontainingmethanolsinceevidenceofsuitability

isas yetincomplete.Before purchasing fuelfroman

unfamiliarstation, trytoconfirmwhetherthe fuel

containsalcohol,and towhatpercentage.Ifany

undesirableoperating symptomsarenoticedafterusing

a gasoline thatcontainsalcohol,orone thatcontains

alcohol,switchto a gasoline thatdoesnotcontain

alcohol.

NOTE

Discontinue use ofanygasoholoralcohol/gasoline

blend ifengine performance orfuelsystemproblems

occur.Do notusesuchfuelunless itisUNLEADED.

Usefreshgasoline toensureitisblendedforthe season

and to prevent the formation ofgumdepositswhich

couldclog the fuelsystem.Do notuse gasoline left over

fromthe previous season.

TP-5695 12/93 Scheduled Maintenance 3-7

FuelPumpScreen

WARNING

Explosive fuelvapors.

Cancause severeinjuryordeath.

Useextremecarewhen handling,storing,

and using fuels.

Explosive fuelvapors cancause severeinjuryor

death.Allfuelsarehighlyexplosiveinavaporstate.Use

extremecarewhen handling,storing,and using fuels.

Storefuel inawell-ventilated area awayfrom

spark-producing equipmentand outof the reach of

children.Neveradd fueltothe tankwhilethe engine is

running sincespilled fuelmayignite on contactwith hot

partsorfromignition spark.Do notsmoke orpermit

flame orsparkto occurnearpotentialsourcesofspilled

fuelorfuelvapors.Keepfuellinesand connectionstight

and in good condition—don’treplaceflexiblefuel lines

withrigidlines.Flexiblesectionsare used to avoid

breakage due tovibration.Should anyfuel leakage,fuel

accumulation,orelectricalsparks be noted,DONOT

OPERATEGENERATORSET.Havesystemsrepaired

beforeresuming generatoroperation.

Gasoline—Store gasoline onlyin approved red

containers clearlymarked GASOLINE.Do notstore

gasoline in anyoccupied building.

The electricfuelpumpincludesascreen.(See

Figure 3-7.)At the recommended intervalorwhen

clogging is suspected,inspectand clean the screen as

follows:

1.Shutoff fuelflowto electricfuelpump at tankorat

in-line shutoff valve.Disconnectharness plug (see

Figure 3-7forlocation).

2.Disconnect fuel linesfromelectricfuelpump,

drainingfuelfromthelinesandpumpintoasuitable

containerto preventspillage intothe bilge.

3.Removethe three nutsthatsecurethe electricfuel

pumptothe mounting bracket.

4.Removethe three mounting studsfromtheelectric

fuelpump.

5.Removethe coverplate and inspect the screen.

Remove anydebrisor residue.Besurethe screen

isintact. If the screen isdamaged,replacethe fuel

pump.

6.Check the O-ring seal.Replacethe O-ring ifitis

nicked oreroded.

7.Reinstall the coverplate and secureit tothe fuel

pump byreinstalling the three mounting studs.

8. Insert the three mounting studson the fuelpump

through the mating holesinthe mounting bracket.

Reinstall the three nutstosecurethe fuelpumpin

place.

9.Reconnect the fuel linestothe fuelpump.

10.Open fuel line at tankorin-line shutoff valve and

check forleaks fromthe fuelpump at fuel line

connectionsand coverplate.

258000-D

2(enclosed)

1.Harness Plug 2.FuelPumpScreen

1

Figure 3-7.FuelPumpScreen

TP-5695 12/933-8Scheduled Maintenance

Carburetor/Choke Lubrication

Theonlymaintenancerequiredistolubricatecarburetor

and chokelinkage at the specified intervalusing white

lithiumgrease orlubriplate.

CarburetorAdjustments

The carburetorisasingle-barrel,horizontaldesign and

usesan electric choke.

Lack ofpowerusuallyindicatesthat the fuelmixtureis

too rich.An overrichmixturemayalso be caused bya

clogged airintake(backfireflame arrestor)—check this

beforereadjusting carburetor.Fuelmixturemaybe too

lean ifengine skipsorbackfires.Minorcarburetor

adjustmentmaybe necessarytocompensatefor

differencesin altitude, fuel,and temperature.

1.WithENGINE STOPPED, turnfuelmixturescrew

in(clockwise)until itseatslightly.DONOT

FORCE!Turnfuelmixturescrewout2to

2 1/2turns.See Figure 3-8.

2.Startengine and letitrun atno load forabout5

minutes.Beforemaking adjustmentsengine

shouldbethoroughlywarmed up running at

governed speed,and connected tofull load.

3.Turnlowspeed mixturescrewin until engine

instability(hunting)developsand then screwout

until engine instabilityisagain apparent. Turn

screwbackin untilitispositioned halfwaybetween

the pointsofincreasing stability.When properly

adjusted,engine will operatewithsteadygovernor

action.

4.To adjusttheidlespeed,runthegeneratorsetatno

load.Pushthe throttlelevercounterclockwise until

ithitsthe idlespeed screw.Holding the throttle

leveragainstthescrew,adjusttheidlespeedscrew

untilunitrunsat55Hz(3300rpm)for60Hzmodels

or45 Hz(2700 rpm)for50 Hzmodels.

NOTE

If engine runspoorlyafteradjusting carburetorand

doing scheduled maintenance,return generator

set to an authorized service dealer/distributorto

have problemcorrected.

WARNING

Fire.

Cancause severeinjuryordeath.

Do notsmoke orpermit flame orsparkto occur

nearfuelorfuelsystem.

Asuddenflashfirecancausesevereinjuryordeath.

Donotsmokeorpermitflameorsparktooccurnearfuel

system.Keepthecompartmentandgeneratorsetclean

and free ofdebristominimizechancesof fire.Wipe up

all spilled fueland engine oil.

2

1

3

1.GovernorArm

2.LowSpeed

MixtureScrew

3. IdleSpeed Screw

1-829

1-829

Figure 3-8.FuelMixtureAdjustment

TP-5695 12/93 Scheduled Maintenance 3-9

Ignition System

Ignition SystemService

The ignition systemistransistorized and breakerless.

Undernormalconditions,onlythe sparkplugsneed

serviceonaregularbasis.The electronicignition

modulerequiresno maintenance and should giveyears

of trouble-free service.Ifamodule problemis

suspected,haveservice performed byan authorized

service dealer/distributor.

SparkPlugs

At the recommended interval(showninthe service

schedule)servicesparkplugs.

1.Removesparkplug wiresbygrasping bootand

turning slightlywhile pulling.Do notpull wire.See

Figure 3-9.

NOTE

Pullingwireratherthanbootmaycausedamageto

wire orterminal.

2.Wherepossible,usecompressed airtoremovedirt

fromaround eachsparkplug beforeremoval.This

procedurewillpreventdirtparticlesfromfallinginto

combustion chamber.Loosen sparkplug with a

ratchetandsparkplugsocketwitharubberinsertto

preventdamage tosparkplug.See Figure 3-10.

Removesparkplugsone atatime and examine.

See Figure 3-11 to evaluate engine conditionsby

color/condition ofsparkplugs.

3.Cleansparkplugsbywiping with a ragandthenfile

the centerelectrode sothatitisparalleltothe side

electrode.Shouldreplacementbe necessary,see

“Specifications”forsparkplug type.

NOTE

Do notsandblast, wire brush,scrape,orotherwise

servicesparkplug in poorcondition.Bestresults

are obtained with a newplug.

1-827

Figure 3-9.Removing SparkPlug Wires

11-827

1.13/16 in.SparkPlug Socket

Figure 3-10.Removing SparkPlug

TP-5695 12/933-10 Scheduled Maintenance

ProblemMeansofIdentification PossibleCause

NormalLight tan orgraydepositon the

firing tip.Good operating conditionsand

maintenance.

Gap bridgedDepositsbuilt-up and closing gap

between electrodes.Oil orcarbon fouling.Clean and

regap.

Oil fouledWetblack depositson the insulator

shell bore electrode.Excessive oil entering combustion

chamberthrough wornringsand

pistons,excessiveclearance

between valve guidesand stems,

orworn orloose bearings.

Replace plug.

Carbon fouledBlack,dryfluffy carbon deposits

on insulatortips,exposed shell

surfaces,and electrodes.

Using too coldrange plug,weak

ignition,clogged airintake or

impropercarburetoradjustments,

defectivefuelpump,overrichfuel

mixture,orexcessivenoload

operation.Clean and regap.

LeadfouledDarkgray,black,yellow,ortan

deposits;ora glazed coating on

the insulatortip.

Caused byhighlyleaded fuel.

Replace plug.

Pre-ignition Melted electrodesand possibly

blistered insulator.Metallicdeposits

on insulatorsuggestsinternal

engine damage.

Wrong type of fuel,incorrect timing

oradvance, too hotofa plug,burnt

valves,orengine overheating.

Replace and plug.

Overheating White orlightgrayinsulatorwith

small black orgray/brownspots

with bluish(burnt)appearance on

electrodes.

Engine overheating,wrong type of

fuel,loosesparkplugs, too hota

plug,lowfuelpump pressure or

incorrectignition timing.Replace

plug.

WornSeverelyeroded orworn

electrodes.Caused bynormalwearand failure

toreplace atproperinterval.

Replace plug.

Figure 3-11.SparkPlug Condition

4.Beforeinstalling any sparkplug,check the gap.

See Figure 3-12.The propergap isattained when

the feeler (orwire)gauge justpassesbetween the

sparkplug electrodes.Itshould pass easily,but

withsomeresistance ordrag.The correctgap is

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

5.Toreadjust the sparkplug gap,use gapping toolto

gentlybend the side electrode closerto orfurther

fromthe centerelectrode.See Figure 3-13.The

side electrode mustbe centered overthe center

electrode.

6.Being carefulnot to bumpthe electrode,hand

threadsparkplug clockwiseintocylinderheaduntil

resistanceisfelt.

7.Usingatorquewrench,tighteneachsparkplugtoa

torque of18--22 ft. lbs.(20--30 Nm).Ifatorque

wrenchisnotavailable,hand-tighten sparkplug

until resistanceisfeltand then use a ratchet

wrenchtotighten the plug an additional1/2turn(if

installing a newplug)or1/8--1/4turn(ifreinstalling

a used plug).DoNOTovertighten asthismay strip

threadsoralterelectrode gap setting.

8.Check sparkplug wireconnectorin boot for

accumulated dirt, grease,etc., and clean as

necessary.Firmlypushsparkplug connectorand

bootontosparkplug.

TP-5695 12/93 Scheduled Maintenance 3-11

1

2

1.0.028--0.031 in.

(0.7--0.8mm)Gap 2.SparkPlug Electrodes

1-514

Figure 3-12.Checking SparkPlug Gap

1-511

Figure 3-13.Adjusting SparkPlug Gap

TP-5695 12/933-12 Scheduled Maintenance

Cooling Systems—

Closed/HeatExchanger

Inaclosed cooling system, the seawaterdoesnot

circulatethrough the engine butcirculatesthrough

separatechamberswithinthe heatexchangertocool

the engine coolant. The seawateristhen mixed with

engine exhaustand ejected out the exhaustoutlet. The

coolantis circulated through cooling passagestocool

theengine.All modelsmakeuseofacoolant thermostat

andacoolantrecoverytank.Thecoolantcapacityofthe

engine with heatexchangeris0.72 U.S.qts.(0.68 L)for

all models.Asolution of50%ethylene glycoland 50%

clean,softened waterisrecommended toinhibit

rust/corrosion.Acoolantsolutionof50%ethyleneglycol

will provide freezing protection to--34°F(--37°C)and

overheating protection to 265°F(129°C).Acoolant

solution withless than 50%ethylene glycolmaynot

provide adequatefreezing and overheating protection.

Acoolantsolution withmorethan 50%ethylene glycol

can cause damage to engine and components.Do not

use alcoholormethanolantifreeze ormixthemwiththe

coolant.

Filling and Checking

WARNING

Hotcoolantand steam.

Cancause severeinjuryordeath.

Beforeremoving pressurecap stop generator,

allowtocooland loosen pressurecap torelieve

pressure.

Hotcoolantcancause severeinjuryordeath.Allow

engine tocooland release pressurefromcooling

systembefore opening pressurecap.Torelease

pressure,coverthe pressurecap with a thick cloththen

turnitslowly counterclockwisetothe firststop.After

pressure hasbeen completelyreleased and the engine

has cooled,removecap. If generatorsetisequipped

withacoolantrecoverytank,checkcoolantlevelattank.

NOTE

ENGINEDAMAGE!Failureto bleed airfromcooling

system may cause overheating and subsequent

damage to engine.

NOTE

Specialattention should be given when checking for

propercoolantlevel.Afterthecoolanthasbeendrained,

itnormallyrequires sometime beforecompleterefill of

the engine waterjacket takesplace.

Beforefilling the cooling system,verifythatall hose

clampsaretight. Loosen air-bleed screwlocated on top

of the engine to allowtrapped airto escape.See

Figure 3-14.Place a rag around the screwto prevent

coolantspillage ontothe block.Remove pressurecap

locatedonthetopoftheengine(seeFigure 3-15)andfill

withthe recommended coolantuntil level isjustbelow

overflowtube opening.Tighten air-bleed screw when

coolant, free ofairbubbles,startstoflow.Replace

pressurecap.Startgeneratorsetand allowtorun for

about20--30seconds.STOPgeneratorsetandrecheck

coolantlevelbyremoving pressurecap.Repeat

procedure,asnecessary,until coolantcan no longerbe

added.

Acoolantoverflowbottleisprovided.Fill bottletojust

belowthe MAX mark.See Figure 3-16.Maintain proper

coolantlevel incoolantoverflowbottle.The MINmark

indicatesfull when cold and the MAX markindicatesfull

when hot. Coolantlevelshould always be between

thesemarks.The coolantlevelcan be checked using

the overflowbottlemarkings,butitisrecommended to

periodicallyremovethecoolantpressurecap and check

coolantlevel.

TP-5695 12/93 Scheduled Maintenance 3-13

1

1-828

1.Air-Bleed Screw;Use12mm Wrench

Figure 3-14.Air-BleedScrew

TOTALHOURS

00 000 1/10

10A

FUSE

STARTSTOP

BATT.

CHRG.

INPUT

3

2

1

1.CoolantRecoveryTank

2.Overflow Hose3.CoolantPressureCap

258000-D

Figure 3-15.CoolantPressureCap

TOTALHOURS

00 000 1/10

10A

FUSE

STARTSTOP

BATT.

CHRG.

INPUT

1

2

1.MAX.Mark2.MIN.Mark

258000-D

Figure 3-16.Checking CoolantLevel

TP-5695 12/933-14 Scheduled Maintenance

Flushing and Cleaning

If required, flushcoolant fromgeneratorset. To properly

flushcoolant, obtainKit#267999 and usethe following

procedure:

WARNING

Accidentalstarting.

Cancause severeinjuryordeath.

Disconnectbattery cablesbeforeworking on

generatorset(negativelead firstand reconnectit

last).

Accidentalstarting cancause severeinjuryor

death.Disconnectbattery cables(remove negative

lead firstand reconnectitlast)to disable generatorset

beforeworking on anyequipmentconnected to

generator.The generatorsetcan be started byremote

start/stop switch unless thisprecaution isfollowed.

WARNING

Hotcoolantand steam.

Cancause severeinjuryordeath.

Beforeremoving pressurecap stop generator,

allowtocooland loosen pressurecap torelieve

pressure.

Hotcoolantcancause severeinjuryordeath.Allow

engine tocooland release pressurefromcooling

systembefore opening pressurecap.Torelease

pressure,coverthe pressurecap with a thick cloththen

turnitslowly counterclockwisetothe firststop.After

pressure hasbeen completelyreleased and the engine

has cooled,removecap. If generatorsetisequipped

withacoolantrecoverytank,checkcoolantlevelattank.

1.Disconnect the battery,negativelead first.

2.With engine cooled,removethe air-bleed screw

and the high watertemperaturesafety shutdown

switchfromthe thermostathousing.

3.Connectkithosefittingstothe engine. Install kit

hosestofittings(ifnotalreadydone).

4.Connecta garden hosetothe femaleconnectorof

large kithose.Placethe free end of the small kit

hoseina1--2 gal.(min.)bucket.

NOTE

Heatexchangerpressurecap MUSTbe installed.

5.Turnonwatersupplytoflushcoolant fromengine

block.Turn off watersupplywhen clean wateris

observed coming fromhosein bucket.

6.Disconnectgardenhose.Placefreeendoflargekit

hoseintobucketandconnectanairhosetothefree

end of the smallerkithose.Applyairpressure(40

psi[276kPa]min.)until waterstopsflowingfromkit

hosein bucket. Thiswill remove about16 fl.oz.

(0.47 L)ofwaterfromengine block.

NOTE

Engine coolantcapacityis23 fl.oz.(0.68 L).

NOTE

Somesmall aircompressorsmaynotmaintain

pressure underthe required flowconditions. In

thesecases,itisrecommended that the end of the

kithoseinthe bucketbe closed off momentarily

until pressureisallowed to build up.Afterpressure

hasaccumulated,open end to allow watertoflow

into bucket. Repeatclosing and opening end ofkit

hose,asrequired.

7.Removekithoseswith hosefittingsfromengine.

8.Applypipe sealant tothreadsofhigh water

temperaturesafety shutdownswitch and install

switchinthermostathousing.Reconnectwiring

harness lead toswitch.

9.Applypipesealanttotheair-bleedscrewandinstall

screwinto engine.Do not finaltighten!

10.Removecap ofcoolantoverflowbottle and pour

contentsinto a suitablecontainer.Reinstall bottle

on unit.

11.Add freshcoolant tocoolantoverflowbottle.A

solution of50%ethylene glycoland 50%clean,

softened waterisrecommended toinhibitrust/

corrosion and provide freezing protection.Fill to

MINmark. Install coolantoverflowbottlecap.

12.Remove heatexchangerpressurecap and add

about5fl.oz.(0.15 L)ofclean,softened water.

Then fill remainderofengine withstraightcoolant

(100%)until level isjustbelowthe overflowtube

opening.Finaltighten the air-bleed screw when

coolant,free ofairbubbles,startstoflow.Installthe

heatexchangerpressurecap.

TP-5695 12/93 Scheduled Maintenance 3-15

13.Reconnectbattery,negativelead last.

14.Startgeneratorsetand allowthe set torun for

about20--30 seconds.Stop generatorsetand

recheck coolantlevelbyremoving heatexchanger

pressurecap.Add straightcoolant, ifnecessary,

until level isjustbelowthe overflowtube opening,

then reinstall pressurecap.Repeat this step until

coolantcan no longerbe added.Thisprocedure

should give an approximatemixture of50%

ethylene glycoland 50%water.

15.Wipe up spilled coolantand waterwithrags.

Dispose ofragsinapropercontainer.

16.Testrun generatorset forabout fiveminutesand

check forcoolantleaks.Thiswill allowthe coolant

mixturetomix completely.Stop generatorset.

17.Rinsecoolantflushkithosesandfittingswithclean

water.Storekit forfuture use.

18.Dispose ofused coolantinapropermanner.Do

NOTpollutewaterways!

TP-5695 12/933-16 Scheduled Maintenance

Anticorrosion Zinc

An anticorrosion zincanode isinstalled inthe heat

exchangertopreventelectrolyticcorrosionbyseawater.

When differentmetals,such asiron and copper,are

placed in a highly conductiveliquid(seawater), the iron

graduallyrusts.The zinchas chemicalpropertieswhich

causethe seawatertoreact toitratherthan the engine

components.

The anticorrosion zincanode shouldbechecked every

100 hoursorthree monthsand replaced every200

hoursoryearly.Depending upon operating conditions

and seawaterproperties, the anticorrosion zincanode

mayhavetobereplaced morefrequently.See

Figure 3-17 and usethe following procedure.

TOTALHOURS

00 000 1/10

10A

FUSE

STARTSTOP

BATT.

CHRG.

INPUT

1.HeatExchanger2.Anticorrosion Zinc

21258000-D

Figure 3-17.Removing Anticorrosion Zinc

1.With generatorsetcooled,drainthe cooling

seawatersystem.Closeseacock,remove

anticorrosion zincanode fromheatexchanger.

2.Useawire brushtoremovethe loosecorrosion on

the anticorrosion zincanode.Replacethe anode

when less than 50%of the 11/32 in.(9mm)dia.by

9/16 in.(14 mm)long portion ofzincremains.

3.Clean threaded hole ofheatexchangerand coat

threadsofanticorrosion zincanode with pipe

sealant(suitableformarine applications). Install

anticorrosion zincanode into heatexchanger.

4.Open seacock.Startgeneratorsetand check for

leaks at the anticorrosion zincanode location.

Check forseawaterflowbyobserving water

discharge fromexhaustoutlet.

TP-5695 12/93 Scheduled Maintenance 3-17

PressureCap

Closed-loop cooling systemsincorporate a pressurized

captoraisetheboilingpointofthecoolantandmakeuse

ofhigheroperating temperatures. If leakage or

malfunction occurs,replacethe pressurized cap with

one supplied byKohlerCo.partnumber229958.

1

2

3

1.Mounting Base

2.Retaining Cap 3.Reed ValveAssembly

1-779

Figure 3-18.Siphon Break

Siphon Break

An optionalsiphon breakisused to preventseawater

entryintothe engine when the generatorsetis shut

down.Corrosionbuildup maynotallowthesiphonbreak

tofunctionproperly.Therefore,ifused,the siphonbreak

mustbe inspected and cleaned periodically.

NOTE

To preventsiphoning ofseawater,run the generator

while performing thisinspection.

Removetheretainingcap toinspect the reed valve.See

Figure 3-18.Clean the reed valvetoremoveresidue

and oxidation.Check that the reed valve(opening)is

clear.Replacethe siphon breakif the materialhas

hardened ordeteriorated. Install the reed valvewiththe

valvedownwardintothemountingbase.Installretaining

cap and tighten finger-tightonly.DoNOTovertighten.

AirCleanerand

Mixing Elbow

Servicing AirCleaner

The engine isequipped with a dry-type aircleaner.

Every50 hours(more often ifoperating underdustyor

dirtyconditions) removeelementandservicebytapping

elementlightlyagainst flatsurfaceto dislodge loose

surface dirt. Do notclean in anyliquid orblowoutwith

compressedairasthiswillruinfiltermaterial inelement.

Service aircleaneraftereach 50 hoursofoperation. If

dirty,bent, ordamaged replace elementwith genuine

Kohler replacement. See Figure 3-19.

1-905

Figure 3-19.AirCleanerService

Servicing Mixing Elbow

The mixing elbowcombineshigh temperature exhaust

and cooling seawater.Theseconditionsareconducive

torapid deterioration and,combined with engine

vibrations,prematurefailuresifnotproperlymaintained.

Check the mixing elbowforcarbon buildup and

corrosion inside the pipe.Clean or replacethe mixing

elbowasnecessary. Inspect the exhaustmanifold

mounting threadsforcracking and corrosion.

TP-5695 12/933-18 Scheduled Maintenance

Battery

The starting battery should be a 12-voltunitwith a

minimum250 CCA(coldcranking Amps)at0_ F(--18_

C).When usingamaintenance-free batteryitisnot

necessarytocheck the specificgravityorelectrolyte

level.Otherwise, these procedures should be done at

the intervals specified inthe ServiceSchedule.

WARNING

Sulfuric acidin batteries.

Cancause severeinjuryordeath.

Use protective gogglesand clothes.Can cause

permanentdamage to eyes,burnskin,and eatholes

inclothing.

Sulfuric acidin batteries cancause severeinjuryor

death.Sulfuricacidin battery can cause permanent

damage to eyes,burnskin,and eatholesinclothing.

Alwayswearsplash-proofsafetygoggleswhenworking

around the battery.Ifbatteryelectrolyteis splashed in

the eyesoron skin,immediatelyflushthe affected area

for15minuteswithlarge quantitiesofclean water.Inthe

caseofeyecontact,seekimmediatemedicalaid.Never

addacidtoabatteryoncethebatteryhasbeenplacedin

service.Doing somayresultin hazardous spattering of

electrolyte.

Explosion cancause severeinjuryordeath.Battery

gases can cause an explosion.Do notsmoke orpermit

flame orsparkto occurneara batteryatanytime,

particularlywhen itisbeing charged.Avoidcontacting

terminalswithtools,etc.topreventburnsand to prevent

sparks thatcouldcause an explosion.Remove

wristwatch,rings,andanyotherjewelrybeforehandling

battery.Neverconnectnegative(--) battery cableto

positive(+)connection terminalofstartersolenoid.Do

not testbattery condition by shorting terminalstogether

orsparks couldignite batterygasesorfuelvapors.Any

compartmentcontaining batteriesmustbe well

ventilated to preventaccumulation ofexplosive gases.

To avoidsparks,do notdisturb battery charger

connectionswhile batteryisbeing charged and always

turnchargeroff before disconnecting battery

connections.When disconnecting battery,remove

negativelead firstand reconnectitlast.

Cleaning

Keep battery clean bywiping itwith a dampcloth.Keep

all electricalconnectionsdryand tight. If corrosion is

present, disconnectcablesfrombatteryand remove

corrosion withawire brush.Clean batteryand cables

withasolution ofbaking soda and water.Becarefulthat

cleaning solution doesnotenterbattery cells.When

cleaningiscomplete,flushbatteryandcableswithclean

waterand wipe withadry cloth.Afterthe battery cables

arereconnected,coat terminalswith petroleumjelly,

silicon grease,orothernonconductive grease.

Checking ElectrolyteLevel

Check the levelofelectrolyte before eachstartup.

Removefillercapsand check tosee thatelectrolyte

level isup to bottomsof fillerholes,see Figure 3-20.

Refill asnecessarywith distilled waterorclean tap

water.DONOTadd fresh electrolyte!Then reinstalland

tighten fillercaps.Ifwaterisadded during freezing

temperatures,run generatorset20--30 minutesto allow

mixing ofadded waterand electrolyte.Thiswill prevent

damage to batterydue tofreezing.

1

2

1.FilterCaps2.Electrolyte Level

1-046

Figure 3-20.Checking ElectrolyteLevel

Checking SpecificGravity

Useabatteryhydrometertocheckthespecificgravityof

the electrolytein each battery cell.Correctactual

hydrometer readingsfortemperature. If the hydrometer

used doesnothaveacorrection table,usethe one in

Figure 3-21.The batteryisfully charged if the specific

gravityis1.260 atan electrolytetemperature of80_ F

(26.7_ C).The difference between specificgravitiesof

TP-5695 12/93 Scheduled Maintenance 3-19

eachcell should notexceed ±0.01.The battery should

be charged if the specificgravityisbelow1.215 atan

electrolytetemperature of80_ F(26.7_ C).

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

-- 12.2

-- 6.7

-- 1.1

4.4

10

21.1

26.7

32.2

37.8

43.3

48.9

54.4

60.0

65.6

71.1

15.6

+.032

+.030

+.028

+.026

+.024

+.022

+.020

+.018

+.016

+.014

+.012

+.010

+.008

+.006

+.004

+.002

0

-- .002

-- .004

--. 006

-- .008

-- .010

-- .012

-- .014

-- .016

-- .018

-- .020

-- .022

-- .024

-- .026

-- .028

°C°F

EXAMPLENO.1—

Temperaturebelow80°F(26.7°C)

HydrometerReading 1.250

Acid Temperature 20°F(--6.7°C)

Subtract.024 SpecificGravity

CorrectedSpecificGravityis 1.226

EXAMPLENO.2—

Temperature above 80°F(26.7°C)

HydrometerReading 1.235

Acid Temperature 100°F(37.8°C)

Add .008 SpecificGravity

CorrectedSpecificGravityis

1.243

The temperaturecorrection amountsto about.004 (4“points”)

ofspecificgravityforeach10°F(5.5°C)changeintemperature.

Correction

1-787

Figure 3-21.SpecificGravity

TemperatureCorrection

NOTE

Some batterytesters simplyhavefourorfive beadsin a

tube.Drawelectrolyteintothe tube.Useinstructions

withtester;otherwisesee the following chart.

FiveBeadsFloating—Overcharged

FourBeadsFloating—FullyCharged

Three BeadsFloating—AGood Charge

One orTwoBeadsFloating—ALow Charge

NoBeadsFloating—ADead Battery

Charging

Theenginebatterychargingcircuitwillprovide a charge

of12 voltsatup to 10 amps.

NOTE

If the batteryisused whilethe craft isdocked and the

generatorsetisnotrunningi.e.,auxiliarylights,two-way

radio,etc., the batterywill be drained and maynothave

enoughpowertostartthegeneratorsetlater.Therefore,

itmaybe necessarytoconnecta battery chargerwhile

the craft isdocked and running on shore power.

TP-5695 12/933-20 Scheduled Maintenance

Valve Adjustment

With overhead camengines,eachvalveis spring-held

inthe closed position until forced open bythe action of

the rockerarmincontactwiththe camshaft. Rocker

armshave adjusting screwsand locknutsforadjusting

valvestem-to-rockerarmclearance.Check clearance

withthe engine cold.See Specifications—Engine for

intake and exhaustvalveclearances.

WARNING

Rotating parts.

Cancause severeinjuryordeath.

Do notoperate generatorsetwithoutall guards,

screens,orcoversin place.

Exposedmoving parts cancause severeinjuryor

death.Keep hands, feet, hair,clothing,and testleads

awayfrombeltsand pulleys when unitisrunning.

Replace guards,covers,and screensbefore operating

generatorset.

Flying projectiles cancause severeinjuryordeath.

Retorque all crankshaft and rotorhardware after

servicing.When making adjustmentsorservicing

generatorset, do notloosen crankshaft hardware or

rotorthru-bolt. If rotating crankshaft manually,direction

shouldbeclockwise only.Turning crankshaft boltor

rotorthru-boltcounterclockwisecan loosen hardware

and resultinseriouspersonal injuryfromhardware or

pulleyflying off engine while unitisrunning.

1.Removerockerarmcoverscrewsusing a 10 mm

wrench.Carefullypryrockerarmcoveroff cylinder

cover.Wipe excess oil fromcomponentsusing a

clean rag.

2.Exposetiming belt:

a.Closeseacock and drainseawaterfromhoses.

Removeseawaterpump hosesatseawater

pump.

b.Removetwoscrewstoreleaseseawaterpump

bracket.

c.Remove housing enclosing ignition coil.

d.Removeseawaterpumpfromcamshaft pulley.

e.Removetiming beltcover (beltguard).

NOTE

Toreduceforce needed torotatecrankshaft,

removethe sparkplugs.

3.Using a ratchetwrench on the crankshaft nut,

rotatethe crankshaft clockwise(as viewed from

engine end)until No.1cylinderisat the top ofits

compression stroke and the ‘T’ markon flywheel is

aligned withthe trianglesymbolon the engine

block.See Figure 3-22.The compression strokeis

the period between the closing of the intakevalve

and the opening of the exhaustvalve.The marks

define the TDC (top dead center) pointwhere both

intake and exhaustvalveswill be closed.

4. Insert feelergauge between rockerarmand

exhaustvalveforNo.1cylinder. If necessary,

adjustscrewsothatvery slightdrag isfelton the

feelergauge asitiswithdrawn.Loosen the

adjusting screwlocknutand turnthe adjusting

screwto obtainthe specified clearance.Retighten

the locknutwhile holding the adjusting screw.See

Figure 3-23.Recheck the valveclearance after

tightening the locknut. Repeatstep forintakevalve

ofNo.1cylinder.

5.Rotatecrankshaft 360 degrees clockwise and set

valveclearanceson No.2cylinder.

6.Reassemblyof timing beltcomponents:

a. Install timing beltcover (beltguard).

b. Install seawaterpumptocamshaft pulley.

c. Install housing forignition coil.

d.Mountseawaterpump bracketusing two

screws.

e. Installseawaterpumphosestoseawaterpump.

Open seacock.

7.Withmating surfaces clean and gasketproperly

aligned,install rockerarmcoverand screws.

Removeratchetwrenchfromcrankshaft nut.

TP-5695 12/93 Scheduled Maintenance 3-21

1.“Y”Mark2.“T”Mark

2

1

1-827

Figure 3-22.Determining Top DeadCenter

12

3

1.FeelerGauge

2.Adjusting Screw3mm

SquareHead

3.Locknut; Use9mm

Wrench

1-831

Figure 3-23.Valve Adjustment

TP-5695 12/933-22 Scheduled Maintenance

Governor

The gear-driven centrifugaltype governorservesto

keep engine speed constantbyautomaticallyadjusting

the amountof fuelsupplied tothe engine according to

changesinload.

Lubrication

Lubricate governorlinkage at the specified interval

using whitelithiumgrease orlubriplate.

GovernorAdjustment

The gear-driven centrifugaltype governorservesto

keep engine speed constantbyautomaticallyadjusting

the amountof fuelsupplied tothe engine according to

changesinload.Noregularserviceisrequired on the

unit. The governorisadjusted during run-in at the

factoryand furtheradjustmentshould notbe needed

unless greatly varying load conditionsare encountered

orifpoorgovernorcontroldevelopsafterextended

usage.See Figure 3-25 forcorrectplacementof

governorlinkage (modelsmay vary).

60 Hzgeneratorsetsare designed to operate at60-63

Hz,3600 rpmunderfull load and 3780 rpmunderno

load.50 Hzgeneratorsetsare designed to operate at

50--52.5Hz,3000 rpmunderfull load and 3150 rpm

undernoload.Tocheckspeed,usehand tachometeror

frequency meter.Usethe following procedureto adjust

governor.

1.Loosen governorarmlocking nut. See

Figure 3-24.

2.Movethe governorarmend fullyinthe direction

shown(towardthe electric chokesolenoid)and

readjustgovernorscrew.Tighten locking nut.

3.Startengine and run toreach operating

temperature.

4.Applyfull load and turn engine speed adjustment

screwto 3600 rpmfor60 Hzgeneratorset, 3000

rpmfor50 Hz set.

5.Check regulation byapplying and removing full

load.

6.STOPgeneratorset.

1

2

1.MixtureScrew

2. IdleSpeed Screw3.GovernorAdjustment

1-829

3

Figure 3-24.GovernorAdjustment

Carburetor

Governor

Adjustment

Screw

ThrottleRod/Spring

GovernorSpring

GovernorCross Shaft

GovernorRod OuterHole

HoleNearest

toPivotPoint

PivotPoint

Locknut

Figure 3-25.GovernorLinkage

TP-5695 12/93 Scheduled Maintenance 3-23

WattageRequirements

Iftheratedcapacityofthegeneratorsetisexceeded,the

circuitbreakerlocatedonthecontrollerwilltriptoprotect

the generatoragainstdamage.Tripping could be

caused byashortinthe ACcircuitinthe craft orsimply

byhaving too manyapplianceson at the sametime

resulting in an overload condition. If the circuitbreaker

trips, the setmay continue running but therewill be no

ACoutput tothe protected circuit. Beforeresetting the

circuitbreaker,turnoffsomeoftheappliancesandlights

inside the craft to bring the load downwithinthe rated

limitsoftheset.Ifthisisdoneandthecircuitbreakertrips

again afterbeing reset, see a qualified electrician.

Formoreinformation regarding generatorsetcapacity,

see Installation—GeneratorSelection and Wattage

Requirements.

GeneratorService

General

Undernormalconditionsgeneratorservicewill notbe

requiredonaregularbasis.Ifoperatingunderdustyand

dirty conditions,useDRYcompressed airto blowdust

outofthegeneratoratfrequentintervals.Dothiswiththe

generatorsetoperating and direct the streamofairin

through the cooling slotsat the end of the generator.

The end bracketbearing should be replaced every

10,000 hoursofoperation.Have bearing replaced

soonerifbearing inspection indicatesexcessiverotor

end playorbearing damage fromcorrosion orheat

buildup.The end bracketbearing issealed and requires

no additional lubrication.All generatorservicemustbe

performed byan authorized service dealer/distributor.

TP-5695 12/933-24 Scheduled Maintenance

StorageProcedure

It isrecommended that the craft be afloatwhen the

generatorsetisprepared forstorage sincethe engine

mustbe started.

1.Add fuelstabilizertofueltank.Use

recommendationsof fuelstabilizermanufacturer.

2.Startgeneratorsetand run until operating

temperatureisreached orabout15 minutes.Stop

generatorset. Drain oil fromcrankcasewhile

engine is still warm.Replace oil filter.Refill

crankcasewithspecified weightoil.

NOTE

Forstorage,seawatermustbe replaced with

antifreezeasdescribed insteps3a--cordrainedas

described insteps4a--c.

3.Closeseacockandremovehoseatseacock.Place

hosein a containerofcoolant/antifreeze.

Containershould have approximately1--2U.S.

gallons(3.7--7.5 L)ofantifreeze.Amixture of50%

ethylene glycoland 50%clean,softened wateris

sufficient.

a.With a suitablecontaineratexhaustoutlet, run

generatorsetuntil coolantdischarge is

observed atexhaustoutletoruntil coolant

mixtureisusedup.Donotallowcoolantmixture

toflowintowaterways.Stop generatorset.

b.Connecthosetoseacock.Leaveseacock

closed.

c.Check coolantlevelofheatexchangerand add

ifnecessary.

NOTE

If steps3a--cwere performed toreplace

seawaterwith antifreeze,omitsteps4a--c.

4.Closeseacockanddrainallseawateroutofcooling

system.

a.Drainseawaterfromstrainerand seawater

pump.

b.Removezincanode orend cap on heat

exchanger,whicheverismoreconvenient, to

drainonlyseawater.Useanairhosetoblowout

anyremaining seawater,ifnecessary.Check

coolantlevelofheatexchangerand add if

necessary.

c.Drainseawaterfromexhaustwaterline.

NOTE

Iffreezingtemperatureswillbeencounteredduring

storage,be sure engine coolantis capable of

withstanding the lowestpossibletemperatures.

Generally,amixture of50%ethylene glycoland

50%clean,softened wateris sufficient.

5.Removesparkplugsand pourone teaspoon of

engine oil into eachcylinder.Crankthe engine

severaltimestocoat the cylinderwallswith oil.

Reinstall the sparkplugs.

6. If fuelstabilizerwasnotadded tofueltank,drain

fuelcompletelyfromfueltank.Gumdepositswill

develop ifgasoline is stored forthe season.

7.Clean exteriorofgeneratorsetand spread a light

filmofoil orsilicon sprayoveranyexposed

surfaceswhichmaybesubjecttorustorcorrosion.

8.Using tape,sealairinlet, exhaustpipe,and fuel

tank cap.

9.Disconnectand remove battery.Battery should be

placedinawarm,drylocation forperiodofstorage.

Recharge batteryonceamonthtomaintainfull

charge.

10.Coverentire unitwith a dustcover.

TP-5695 12/93 Troubleshooting 4-1

Section 4.Troubleshooting

When troublesoccur,do notoverlook simplecauses.A

starting problem, forexample,could be caused by

improperfueloranemptyfueltank.The followingcharts

listsomecommon problems. If proceduresinthis

manualdo notexplain howtocorrect the problem, take

the generatorset to an authorized service

dealer/distributor.Tellthe dealerexactlywhathappened

when the problemoccurred and ofanyadjustments

made tothe set.

Engine

ProblemPossibleCause Corrective Action

Unitwill notcrankWeakordead batteryRecharge or replace battery

U

n

i

t

w

i

l

l

n

o

t

c

r

a

n

k

Reversed orpoorbattery connections.

Poorground.Check connections

Fuse blownincontrollerReplacefuse

Defectivestart/stop switchCheck function,replace asnecessary.

DefectivestartersolenoidCheck startersolenoid and wiring.Replace

asnecessary.

DefectivestarterAttemptstarting bydirectconnection to

battery.Replace/repairasnecessary.

Unitcranks butwill

n

o

t

s

t

a

r

t

Outof fuelReplenish

U

n

i

t

c

r

a

n

k

s

b

u

t

w

i

l

l

notstartClogged fuelscreen Clean fuelscreen

n

o

t

s

t

a

r

t

Faultyantidieseling solenoidReplacesolenoid

Airintakeclogged Clean or replace

Faulty sparkplug(s)Replace(and regap)sparkplug(s)

Loosesparkplug connection Reconnectwires

Faultyground (--) connection Clean and retighten

Carburetoradjustmentwrong Adjustcarburetor

Defective electricfuelpumpCheck pressure.Replace asnecessary.

Shorted oropen ignition coil Replacecoil

Weakordead batteryRecharge or replace

Bad fuelmixtureReplacefuel;clean carburetor

Flooded carburetorWaitafewminutesand attemptrestart

Engine malfunction See authorized Kohlerservice

dealer/distributor

Engine starts,but

d

o

e

s

n

o

t

c

o

n

t

i

n

u

e

t

o

No generatoroutputvoltage Check ACvoltage

E

n

g

i

n

e

s

t

a

r

t

s

,

b

u

t

does notcontinueto

r

u

n

a

f

t

e

r

s

t

a

r

t

s

w

i

t

c

h

No/lowoil pressureCheck oil pressure and pump

d

o

e

s

n

o

t

c

o

n

t

i

n

u

e

t

o

run afterstartswitch

isreleasedDefectivelowoil pressure(LOP)safety

shutdownswitchCheck LOPshutdownswitch

High temperatureshutdownCheck cooling system

Defective high exhaust temp.(HET)and/or

high watertemp.(HWT)safety shutdown

switch(es)

Check HETand/orHWTshutdown

switch(es)

Hardstarting Stale orbad fuelReplacefuel

H

a

r

d

s

t

a

r

t

i

n

g

Fuelvaporlock Check fuel line routing

Faulty sparkplug(s)Replace(and regap)plug(s)

Weakignition coil Replace

Carburetoradjustmentwrong Adjustcarburetor

Airintakeclogged Clean

TP-5695 12/934-2Troubleshooting

Engine(Continued)

ProblemPossibleCause Corrective Action

Stops suddenlyOutof fuelReplenish

S

t

o

p

s

s

u

d

d

e

n

l

y

Airintakeclogged Clean

Fuse blownincontrollerReplacefuse

DefectiveseawaterpumpimpellerReplace

Clogged seawaterstrainerClean strainer

Ignition coil failureCheck forspark

Fuel line restriction Check fuel linesand tank

Fuelvaporlock Check fuel line routing

Defective electricfuelpumpCheck pump

Dirtyfuelscreen Clean fuelscreen

Faulty sparkplug(s)Replacesparkplug(s)

No/lowoil pressureCheck oil pressure and pump

Defectivelowoil pressure(LOP)safety

shutdownswitchCheck LOPshutdownswitch

High temperatureshutdownCheck engine coolantsystem

Defective high exhaust temp.(HET)and/or

high watertemp.(HWT)safety shutdown

switch(es)

Check HETand HWTshutdownswitch(es)

Loss ofACoutputSee authorized Kohlerservice

dealer/distributor

Faultyantidieseling solenoidReplacesolenoid

Lacks powerAirintakeclogged Clean

L

a

c

k

s

p

o

w

e

r

Bad orstalefuelReplacefuel

Faulty sparkplug(s)Replace(and regap)plug(s)

Impropertiming Check timing

Chokesolenoid defectiveCheck and/orchange

Engine notoperating atrated RPMCheck governor

GovernoradjustmentsincorrectAdjustgovernor

Carbon build-up Clean carbon fromcylinderheads

Impropercooling Inspectcooling system

Dirtyfuelscreen Clean screen

Defectiveignition coil Replacecoil

Fuel line restricted Check fuel lines

Engine overloaded Reduceload

Carburetoradjustmentwrong Adjustcarburetor

Operates erraticallyAirintakeclogged Clean

O

p

e

r

a

t

e

s

e

r

r

a

t

i

c

a

l

l

y

Stale orbad fuelReplacefuel

Fuelpumpvaporlock Allowunit tocooland attemptrestart

Clogged fuelscreen Clean screen

Faulty sparkplug(s)Replacesparkplug(s)

CarburetoradjustmentincorrectAdjustcarburetor

TP-5695 12/93 Troubleshooting 4-3

Engine(Continued)

ProblemPossibleCause Corrective Action

OverheatsImpropercooling Check intake and outletopenings.Check

coolantleveland pressurecap.Check raw

waterstrainer.

ThermostatdefectiveReplace

Sea strainerclogged Clean sea strainer

Carburetoradjustment too lean Adjustcarburetormixture

Engine ignition timing incorrectAdjust timing

Unitisnoisy ExhaustsystemleakCheck exhaustsystem

U

n

i

t

i

s

n

o

i

s

y

Exhaustsystemnotsecurelyinstalled Check forloose parts

Broken ordamaged vibromountsCheck vibromounts

Noinstallation clearance(unithits craft

structure orcompartment)Check clearances

Nocompartmentsound insulation Install approved insulation

Excessivevibration engine/generator

(internal imbalance)See authorized Kohlerservice

dealer/distributor

Loose orvibrating sheetmetalCheck shrouds

ElectricalSystem

ProblemPossibleCause Corrective Action

Batterywill not

c

h

a

r

g

e

Loose orcorroded connectionsClean and tighten connections

B

a

t

t

e

r

y

w

i

l

l

n

o

t

chargeSulfated orworn-outbatteryCheck electrolyteleveland specificgravity

(batterieswithfillercapsonly)

Defective battery charging systemCheck charging system

Battery charging fuse blownReplacefuse. If fuse blowsagainsee

authorized Kohlerservice dealer/distributor

Starterdoes not

w

o

r

k

p

r

o

p

e

r

l

y

Loose orcorroded connectionsClean and tighten looseconnections

S

t

a

r

t

e

r

d

o

e

s

n

o

t

workproperlyLowbatteryoutputCheck electrolyteleveland specificgravity

(batterieswithfillercapsonly).Check

battery voltage.

DefectivestartersolenoidReplacestartersolenoid

Defectivestart/stop switchReplaceswitch

Defectivewiring Check wiring

Startercranks

slowlyLowbatteryoutputCheck electrolyteleveland specificgravity

(batterieswithfillercapsonly)

s

l

o

w

l

y

Too heavy viscositylube oil Use properviscosityoil

Loose orcorroded wiring Clean and tighten looseconnections

High startercurrentdraw Rebuild or replacestarter

Battery cable undersizeSee Installation Section--Electrical

Systems

TP-5695 12/934-4Troubleshooting

Generator

ProblemPossibleCause Corrective Action

NoAC outputCircuitbreakerinOFF position ResetbreakertoONposition

N

o

A

C

o

u

t

p

u

t

Circuitbreakertripped due to overload on

generatorsetReduceload.See Wattage Requirements.

ResetbreakertoONposition.

Ship-to-shoretransferswitchin“OFF”or

“SHORE”position Turnswitchto generatorpower

NoDC powertocontrollerCheck battery connections

Controllerfuse blownReplacefuse

Generatormalfunction such as capacitor

orotherinternalfaultSee authorized Kohlerservice

dealer/distributor

Lowoutputor

e

x

c

e

s

s

i

v

e

d

r

o

p

i

n

Engine speed too lowAdjustgovernor

L

o

w

o

u

t

p

u

t

o

r

excessive drop in

v

o

l

t

a

g

e

Generatoroverloaded Reduceload.See Wattage Requirements.

v

o

l

t

a

g

e

Engine in poorcondition If routine servicesare performed and

condition persists,see authorized Kohler

dealer/distributor

DefectivecapacitorSee authorized Kohlerservice

dealer/distributor

High generator

outputvoltageDefectivecapacitorand/orpoorwiring

connectionsSee authorized Kohlerservice

dealer/distributor

o

u

t

p

u

t

v

o

l

t

a

g

e

Excessivespeed orfrequency Adjustgovernor.Check governorlinkage

and spring fordamage orbinding.

Will notcrankNoDC powertocontrollerCheck battery connections

W

i

l

l

n

o

t

c

r

a

n

k

Controllercircuit fuse blownReplacefuse and attemptstart-up. If fuse

blowsagain,contactauthorized Kohler

service dealer/distributor.

TP-5695 12/93 Wiring Diagrams5-1

Section 5.Wiring Diagrams

THERMALSWITCH

BATTERY VOLTMETER

WATERTEMPERATUREGAUGE

OILPRESSUREGAUGE

WATERTEMP.SENDER

HOURMETER

ANTI--DIESELSOLENOID

CHOKE

FUELPUMP

STARTERMOTOR

FAULTSHUTDOWN RELAY

ENGINECRANKRELAY

ENGINERUN RELAY

AC CRANKDISCONNECTRELAY

L1

LO

120/240 V.CONNECTION

L2

GROUND

HAZARD

1

2

3

4

WTSOILPRESSURE SENDER

TS

BV

WT

OP

OPS

HR

AD

CH

FP

S

K4

K3

K2

K1

BOARD

CHOKE

HOT

P5--2

P5--4P4--3

8N

N

P1--8

5

7C

BV

BC N

N

BC

K2

HR

7N

VIOLET

P

N

SCHEMATIC

BLACK

1

2

3

4

55

66

B1

B2

OWNERSMANUAL

RATINGSEE

FORAMPERAGE

LEGEND

AUXILIARYWINDING

BATTERYCHARGING

WINDING

AUXILIARYCAPACITOR

EXCITATION

ALTERNATOR

FAULTSHUTDOWNTIMEDELAY RELAY

C1

2

1

B1P1--3

P1--6

B2

+12V

VR1

K5

K1

LED1R1

BR1

3

+--

5

4

1A

REGULATOR

VOLTAGE

ALTERNATOR

CHARGING

BATTERY

ON

GEN

WTS

P3--2

TAN

OPS

P3--3

BLUE

LT

WT

OP

P3--4

76

P2--3

K1

D4

73

P2--1HR

5A

D8

FN

P1--12

5A

D5

75

K1START

REMOTE

STOP

P3--6

43

P3--5

47

43

P2--8

P2--7

START

P1--15

37

37

37

37

LOWOILPRESSURE

HIGHEXHAUST TEMP.

HIGHENGINETEMP.

STOP

P2--4

P2--5

P1--9

47

N

N

K1

70

P3--1

K4

P1--471 P2--9

K3S

FP

CH TS

K4

1A

D7

P1--10

72

SYSTEM

IGNITION

P1--7

AD4573

P2--6

N

5A

1A

D3

D6

30

P1--13

1A

D1

13

P2--2

K1

K4

LED4R4

K1

D9

K2

K3

LED3R3

M

12 VOLT

+C2

LED2

R2

K2

1A

D2

S

P1--14

P1--1

1A

K1

PTC1N

P1--2

P4--16

BC

37 HIGHEXHAUST TEMP.

10A

10A

CONTROLLER

P

ENGINE

N

NN

P4--20

P4--21

P4--18

45

72

P4--8

P4--15

P4--1P4--11

P4--22

P4--9

7N

P4--1473 P5--3

P5--1

73

73

71

P4--4

N70

P4--13

P4--2

P1--5

P8--1P8--2

P4--19

P6--1P6--2

246482-D

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

5-2Wiring DiagramsTP-5695 12/93

FOR AMPERAGE

RATING SEE

OWNERS MANUAL

CIRCUIT BREAKERS

220 V. CONNECTION

L0

GRD

4 3 2 1

LO (NEUTRAL)

GRD L1

BC

72378N

45

73

71

5

2

4

9

15

20

22

21

19

BC

14

8

31

L1

GRD

LO

1234

L2

GRD

L0

120/240 V. CONNECTION

GRD

LO

1234

L2

GRD

CIRCUIT BREAKERS

75

8N

P6

N73

34

2 1

CIRCUIT BOARD

HOT CHOKE

75

8N

N

J3

HOUR

BLK

VIOLET

VIOLET

BLK

TEMP

OIL

LT BLUE

VIOLET

VIOLET

BLK

BLK

BLK

BLK

PIN INSERTION END.

CONNECTOR SHOWN FROM

NOTE :

VOLT

TAN

BLACK

VIOLET

GREY/BLK

6

5

3

2

41

YEL/RED

(2 AND 4GAUGE REMOTE PANEL)

BACK VIEW OF PANEL

STOP

START

REGULATOR

VOLTAGE

1

2

ALTERNATOR

CHARGING

BATTERY

NBC

3

12

54

BC

N

N

7N

76

BC

7C

S

S

++

+

+

VIOLETVIOLET

VIOLETVIOLET

BLK

BLK

SWITCH

TEMPERATURE

HIGH ENGINE

N

N

SOLENOID

ANTI--DIESEL

SWITCH

THERMAL

CHOKE

70

73

72

SYSTEM

IGNITION

73

45

37

SWITCHES

TEMPERATURE

EXHAUST

N

NUT

GROUND

SENDING UNIT

TEMPERATURE

WATER

(OPTIONAL)

SWITCH

LOW OIL PRESSURE

SENDING UNIT/

OIL PRESSURE

(OPTIONAL)

FUEL PUMP

5

L0

5

120 V. CONNECTION

123

L1

B2 B1

7C

45566

55

66

B2

N

37 P1

N

P2

43

47

73

47 RELAY BOARD

43

1

2

3

4

55

66

B1

B2

N

SOLENOID

STARTER

76

73

43

N

47

P

P

P

N

10A

INPUT

STOPSTART

HOUR METER

N

BC

LUG

GROUND

J4

CAPACITOR

EXCITATION

ALTERNATOR

15 14 13

12 11 10

9 8 7

6 5 4

3 2 1

9

10A

CHRG.

BATT.

8

7

6

5

4

3

2

1

3

B1

2

6

47

514

N

43

37

P

71

N

ENGINE CONTROLLER

REMOTE PANEL GENERATOR

CIRCUIT BREAKERS

GREEN

GREEN/WHITE

OWNERS MANUAL

RATING SEE

FOR AMPERAGE

OWNERS MANUAL

RATING SEE

FOR AMPERAGE

45

71

70

BC

BC BC

BC

WHEN NOT USED.

TAPE LEADS ”5”OR ”7C”

7C

37 37

37

37

37

37

37

37

SWITCH

PRESSURE

OIL

G

GREEN YELLOW

B2 B1

N

N

N

7070

P4

P8

P3

73

P5

72

WK

N

BC

8N3772

73

45

73

53

8

14

19

21

22

20

15

BC

9

4

21

NN

P 7C

71

MOTOR

STARTER

BATTERY

NN

P7C

73

246482-D

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

TP-5695 12/93 Wiring Diagrams5-3

Electro Switch

L1

L2

ToGenerator

SetToShore

Power

To Load

2-WireGeneratorSets

L1

L2

ToGenerator

SetToShore

Power

To Load

2-WireGeneratorSets

2-WireGeneratorSets

KrausNaimler/AmericanSolenoid

(Early RectangularDesign)

KrausNaimler/AmericanSolenoid

(NewerRound Design)

2 1 3 4

6 5 7 8

1 2 6 5

3 4 8 7

L1

L2

ToGenerator

SetToShore

Power

To Load

3 2 4 1

7 6 8 5

L1

L2

ToGenerator

SetToShore

Power

To Load

3-WireGeneratorSets

2 1 3 4

6 5 7 8

L0 10 9 11 12

1 2 6 5

3 4 8 7

9 10 14 13

L1

L2

ToGenerator

SetToShore

Power

To Load

3-WireGeneratorSets

L0

3 2 4 1

7 6 8 5

11 10 12 9

L1

L2

ToGenerator

SetToShore

Power

To Load

3-WireGeneratorSets

L0

Figure 5-3.MarineManual(Ship-to-Shore)TransferSwitch

5-4Wiring DiagramsTP-5695 12/93

Four-LeadReconnectable(Single-Phase)GeneratorSetsWhereGenerator

OutputCanBeReconnected For120 voltor120/240 volt,60 Hz,

110 voltor110/220 volt,50 Hz

NOTE

When a generatorsetisreconnected to a voltage

different than nameplatevoltage,noticeshould be

placed on the unitindicating this change.Decalsforthis

purpose are availablefromauthorized Kohler

dealers/distributors.

120-or 110-Volt3-Wire 2-Pole

Configuration--Figure 5-4

Jumperlead to be placed on line side ofcircuitbreaker.

LeadsL1 and L2 can eitherbe left as separateleadsor

can be connected togetherdepending upon whichis

practicalforthe given application.Regardless of the

numberofphase(black)leadsused inthe application,

bothcircuitbreakersmusthaveleadsattached tothe

load side.Itisrecommended thatjumperlead be

maintainedforallstraight120-or110-voltsystemssince

ithelpsbalancethe load of the generatorset.

4321

StatorLeads

LO

GRD.

L2

L1

LO(Neutral)

Ground

LoadSide

LineSide

Circuit

Breaker

Jumper

Lead

60 Hz50 Hz

L0--L1120 volt110 volt

L0--L2120 volt110 volt

Figure 5-4.WithJumperLead

120-or 110-Volt2-WireConfiguration

Figure 5-5(Single Pole)

If the installation requiresa 120 or110 volt, 2-wire

system,asingle-polecircuitbreakermustbe used.See

Figure 5-5.When connecting statorphaseleads

together,theoutputlead(L1)mustbesizedaccordingly.

4321

StatorLeads

LO

GRD.

LO(Neutral)

Ground

Load

Side

Line

Side

1-Pole

Circuit

Breaker

L1

60 Hz50 Hz

L0--L1100-120 volt100-120 volt

Figure 5-5.120 Volt,2-Wire

TP-5695 12/93 Wiring Diagrams5-5

120/240-or 110/220-Volt

Configuration--Figure 5-6

Jumperlead notused. If unitwasoriginallywired for

straight120 or110 volt, be surejumperlead isremoved

(see Figure 5-6forlocation).LeadsL1 and L2 are

differentphasesandmustneverbeconnectedtogether.

4321

StatorLeads

LO

GRD.

L2

L1

LO(Neutral)

LoadSide

LineSide

Circuit

Breaker

Ground

60 Hz50 Hz

L0--L1120 volt110 volt

L0--L2120 volt110 volt

L1--L3240 volt220 volt

Figure 5-6.WithoutJumperLead

6

TP-5695 12/93 Installation 6-1

Section 6. Installation

Introduction

Usethis section asa guide when installing the Marine

generatorset, then refertoSection 2.Operation for

specific serviceinstructions.Reliable and safe

generatorsetoperation dependslargelyupon proper

installation.Rememberthat the generatorsetwill

probablybe the craft’s solesource ofelectricalpower.

When installingamarine generatorset, itis

recommended that the installation complywith all

applicableRegulationsand Standards.See Reference

Materialfordocumentsissued bygoverning agencies.

Information presented hereshouldbefollowed in

planning and making installations.Specificationsgiven

should be used onlyininitialplanning.Usecurrent

dimension drawingsand wiring diagrams.

NOTE

Awood block islocated undersome generatorsetend

bracketsto preventdamage during shipment. Forthe

samereason,metalbracketsare used to attachsome

generatorsetstotheirwood shipping bases.These

itemsMUSTbe removed priortoinstallation in orderto

provide adequatevibration clearance during generator

setoperation.Checkthatallpacking material,literature,

and loose accessoriesareremoved fromgeneratorset

priorto operation.

GeneratorSelection and

WattageRequirements

Totalwattage requirements(lights,motors,appliances)

mustbe considered when selecting a generatorset, or

when sizing wattage usage where availablespace and

construction limit the size of the generatorset. The

4-lead reconnectable generatorsetcan be connected

for120 voltor120/240 volt60 Hz(110 voltor110/220

volt50 Hz),see Section 5.Wiring Diagrams.

NOTE

When a generatorsetisreconnected to produce a

voltage different than nameplatevoltage,noticeshould

beplacedontheunitindicatingthischange.Decals(part

number246242)forthispurpose are availablefrom

authorized Kohlerdealers/distributors.

Lighting Load

The lighting load isusuallyeasiest tocalculate. Inmost

cases,simplyadd the wattage ofeachlampto be

operated off the generatorset. Notethatinmany

applications,notall of the lightsorlampsareinthe

generatorsetACcircuit—some areDC powered bythe

12-voltbatteryinthe craft. Makesurethe total includes

onlylightsactuallyon the generatorsetACcircuit.

MotorLoads

When figuring generatorsetcapacityrequirementsthat

include electricmotors,do notoverlookthe high current

demanded bythe motorsduring start-up.The in-rush or

starting currentistypically2--3timeshigherthan that

required when the motor reachesnormaloperating

speed.Reservecapacitymustbe allowed forin-rush

demandsplusotherloadswhichcould be on the line as

the electricmotorstarts.

Airconditioning unitsare perhapsthe mostcommon

type ofmotorload forgeneratorsetsinmarine

applications.The starting characteristics of the different

varietiesofairconditioners varygreatly—one particular

12,000 Btu unithas, forexample,lowerstarting

requirementsthan a 10,000 Btu unitofanothermake.

When onlyone unitisinvolved, thereisusuallyno

starting problem,provided the lighting and appliance

load isnot too high when the unitis started.

Simultaneous starting of two airconditioning units,

however,can presentproblemsif the capacityis

marginal.Because of the variation instarting

characteristics of the variousmakesofairconditioners,

no definitestatementsaremade inthispublication

regarding multiple-motorstarting capabilitiesof the

marine generatorsetcovered.Delayed starting oruse

ofeasy-starting deviceson airconditionerunits should

be considered wheneversimultaneous starting ofmore

than one motorisinvolved.

The starting and running requirementsofsomemotor

loads common tomarine applicationsarelisted in

Figure 6-1;usethisasaguidewhenselectinggenerator

setcapacityrequirementsinvolving motorloads.See

Figure 6-2forgeneratorsetcapabilitiesregarding air

conditioners.

TP-5695 12/936-2Installation

Capabilitieswill varyaccording toKilowatt Derating

following.

Motor

Requirements

(HP)

Starting

(In-Rush)

WattsRunning

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.MotorRequirements

ModelWattage

Will OperateAir

Conditionerof

SizeIndicated

“Powerto

Spare”for

Lighting

Appliances,

Tools

4CZ4000 One 13,500 Btu 2100

6.5CZ6500 One 13,500 Btu 4600

Two 13,500 Btu 2700

Figure 6-2.AirConditionerRequirements

(50 Hzunitswill have slightlylower“power

tospare”figures thanthose indicated)

Appliance Loads

Marine generatorsetsare often used tofurnishACfor

appliances such asTV,stereo,electricwaterheaters,

etc.Withthe exception of the resistance-type loads

such asthe waterheater,requirementsforappliances

are usuallylow.Suchloadsmustnot, however,be

overlooked when figuring totalrequirements.Reserve

capacity should be availableforanticipated appliance

loadsto avoid overloading ofaset. The average power

requirementsofsomecommon electricalappliances

are given inFigure 6-3.

Kilowatt Derating

Unitsarerated aslisted belowat1.0 powerfactor.

Deratethelisted ratingbyapproximately3.5%per1000

ft.(300m)whentheunitisoperatedataltitudesof500ft.

(150 m)ormore abovesea level.

3.5CFZ,50 Hz:3.5kWat77_F(25_C)and 3.5kWat

122_F(50_C).

4CZ,60 Hz:4kWat77_F(25_C)and 3.5kWat122_F

(50_C).

5CFZ,50 Hz:5kWat77_F(25_C)and 4.85 kWat

122_F(50_C).

6.5CZ,60Hz:6.5kWat77_F(25_C)and6kWat122_F

(50_C).

Electrical

Appliance

Motor

Starting

WattsRunning

Watts

AutomaticPilot-- 150--250

Blanket, Electric-- 50--250

Blender800 600

Broiler -- 1350

Depthometer -- 25--1000

Drill,3/8”600 350

Dryer,Hair -- 850--1200

Fan,Air

Circulating 50--200 25--100

Food,Mixer400 235

Heater,Space-- 750--1500

Heater,Water -- 1500

Iron -- 900--1200

LightBulbs-- (asindicated)

Pan,Frying -- 1200

Percolator,

Coffee -- 650

Radar -- 750--1500

Radio-- 50--100

Radiophone -- 100--200

Range,Electric

(perelement)-- 1000--1500

Soldering Gun -- 250

Television -- 300--750

Toaster -- 750--1200

WaterSystem500--1500 300--1250

Figure 6-3.Appliance AverageWattageRatings

(60 Hz)

TP-5695 12/93 Installation 6-3

TOTALHOURS

00 000 1/10

10A

FUSE

BATT.

CHRG.

INPUT

NOTE

Usetwo hoseclampson each end of

all flexible exhausthoseconnections.

*Indicated componentsmustconformtoU.S.C.G.Regulations.

4

*5

6

7

8

*9

10

11

STOP/START

258000-D

2

1

13

*14 12

3

1.HeatExchanger

2.Siphon Break(See Instruction SheetTT-927 for

ProperInstallation.)

3.ExhaustMixer

4.Engine-Driven SeawaterPump

5.ExhaustHose

6.SeawaterStrainer

7.RawWaterline

8. IntakeThrough-Hull Strainer

9.Seacock

10.Mounting Base

11.Mounting Tray

12.CoolantRecoveryTank

13.HoseClamp

14.FuelLine

Figure 6-4.TypicalLocation and Mounting

TP-5695 12/936-4Installation

Location

General

Considerthe following inselecting orconstructing a

generatorsetlocation.

Compartment/location mustallowadequatespacefor

ventilation,cooling and exhaustsysteminstallation,

service access tothe engine and generator,and proper

fuelsysteminstallation.

Engine stringersorotheravailablestructuralmembers

mustprovide adequatesupport forthe generatorset

weight.

Ageneratorsetcompartmentmustbesealed to prevent

exhaustgasesand fuelvaporsfromentering cabins.

Generatorsetslocated above deck musthave a

protectivecoverto preventdamage fromrain and water

splash.This covermustnotaffectcooling airflowand

serviceability.

SeeFigure 6-4foratypicalinstallationandSection1.for

dimensionsand weights.

Space

Locationshouldalloweasyaccesstothegeneratorset’s

engine,controller,cooling,andfuelsystemcomponents

forroutineservice.Enginecompartmentsareoftenideal

generatorsetlocations,butaccess should notbe

obstructed bypropulsion enginesorgeneratorand

controller.Also allowclearanceforvibration during

operation.Minimumrecommended clearancefor

vibration and cooling of top, front, rear,and sidesof

generatorsetis1 1/2in.(38 mm).

Mounting

Enginestringersgenerallyprovidethebestsupport fora

generatorset. Any structuralmembers considered for

mounting mustsupport the generatorsetweightand

withstand engine vibration.The generatorsetincludes

vibration mountsand mounting trays;additional

vibration isolating padsmaybe installed between trays

and bases.

Ageneratorsetshould be mounted ashigh aspossible

to avoid bilge splash and lower-lying vaporsand alsoto

allowdownward pitch of the exhaustline.Forangular

installation, the maximumoperation angle of the

engine/generatorsetis20_ (in all directions).

Ventilation

Ventilation isrequired tosupportengine combustion,

generatorcooling,and expulsion of flammable and

lethalfumes.Ventilation provisionsmustcomplywith

U.S.C.G.Regulationsgoverning sizing ofventsand

operator requirements.

Asarule,inletand outletventareas should each be

sizedtoaminimumof2sq.in.perft.(13sq.cm/30.5cm)

ofcraft’sbeam.Shouldthisrulein anyinstanceconflict

withU.S.C.G.Regulations,appropriateRegulations

shouldbefollowed.Ifany screening isused ininlets,

size ofhull/deck openings should be doubled.Vent

ducts should extend to bilgesto expelheavier-than-air

fumes.Ifthegeneratorsetistobemountedintheengine

compartment, airflowmustbe increased to allowfor

generatorset’srequirements.UL-listed ignition-

protected blowers should be installed in outletvents,

and wired to operate before engine(s)arestarted.

Snifferdevicesmayalsobe optionallyinstalled tocause

alarm,warning,orengine shutdownshould dangerous

fumesaccumulateinthe compartment.

WARNING

Explosion.

Gasoline vapors cancause explosion and

severeinjuryordeath.

Beforestarting generatorset, operate blower4

minutesand check engine compartment for

gasoline vapors.

Air requirementsforvariousmodelsare given in

Figure 6-5.The airintakesilencerprovides combustion

airtothe engine.Itisimperativethat the recommended

minimumclearance of1 1/2in.(38 mm)between duct

opening and anyenclosurewall notbe compromised.

Engine/generatorperformancewill be affected

adverselyif these guidelinesare not followed.

AirRequirements

CFM(L/min.)

ModelCombustion Cooling

3.5CFZ 18 (510)323 (9145)

4CZ18 (510)323 (9145)

5CFZ 18 (510)600 (16988)

6.5CZ18 (510)600 (16988)

Figure 6-5.AirRequirements

TP-5695 12/93 Installation 6-5

FuelSystems

FuelSupply

Generatorsets,inmostcases,mustdrawfuelfromthe

sametankasthe propulsion engines. If the tank’sfuel

pickup opening allows,amultiple diptube arrangement

(Figure 6-6)maybe used.An alternatetank,ifused,

shouldhaveasmallerseparatepickup openingallowing

asingle diptube (Figure 6-7).

1

2

1-788

1.FuelLine toPropulsion

Engine 2.FuelLine toGenerator

Set

Figure 6-6.DualDip Tubes

Forinstallationswherethe highestpointof the gasoline

source(fueltank)isabovethegeneratorsetcarburetor,

an auxiliaryfuelshutoff valveisrequired.Thisfuel

shutoffvalveshouldbeclosedwhenthegeneratorisnot

in useto prevent fuel leakage resulting fromfuelflow

throughthe fuelpumpandintothecarburetorshouldthe

floatvalve notseatproperly.

NOTE

FuelsystemsmustconformtoU.S.C.GRegulationsand

tests.

WARNING

Explosive fuelvapors.

Cancause severeinjuryordeath.

Useextremecarewhen handling,storing,

and using fuels.

Explosive fuelvapors cancause severeinjuryor

death.Fuel leakage can cause an explosion.Do not

modifythe tankorpropulsion engine fuelsystem.Craft

mustbe equipped withatankallowing one of the two

pickup arrangementsdescribed.Tankand installation

mustconformtoU.S.C.G.Regulations.

1

1-788

1.FuelLine toGeneratorSet

Figure 6-7.SingleDip Tube

TP-5695 12/936-6Installation

Anti-Siphon Provisions

Anti-siphon devicesmustbe installed ifany section of

fuel line liesbelowthe highestpointof the fueltank.The

anti-siphon deviceshould be eitheraspring-loaded

check valve(tested tofunction withthe particular

installation’s siphon head),oran electricallyoperated

shutoff valve(ULignition-protected, tested toU.S.C.G.

Regulations)whichmaybe operated manually.Acheck

valveshouldbeinstalled ata pointabovefueltank’s

highestpoint, secured tocraft’s structure,and be

accessiblewithoutremoving anypermanentstructure.

The fuel line section between the tankand check valve

mustbe located abovethe tank’shighestpoint. An

electric shutoff valveshouldbeinstalled at the tank’s

fuelwithdrawalfitting,and be wired to open when the

generatorsetengine is cranking or running.

Anti-siphon holesdrilled infueldiptubeswithinthe tank

are notreliable anti-siphon devicesastheybecome

ineffectivewhen restricted bydirtorgum.

FuelLines

Metalliclines should be used fromthe tankto a flexible

hosesection connecting metallicline tothe engine fuel

pump.Metalliclinesmusthavewall thicknessofatleast

0.029 in.(0.74 mm).Seamless annealed nickelcopper,

copper-nickel,orcoppertubing mustbe used.The

flexiblesection(necessaryto allowvibrationalmotionof

the generatorsetduring operation)mustbe U.S.C.G.

TYPE A HOSE,marked and tagged according to

Regulations.Metallicline mustbe supported within 4 in.

(102 mm)ofits connection tothe flexiblesection.See

Figure 6-8forfuelpumpinletconnection.

1.1/4in.NPT Female

Pipe Thread 2.ElectricFuelPump

1

2258000-D

Figure 6-8.FuelPumpInletConnection

Anyin-line fuelfiltersorstrainersmustconformto

U.S.C.G.Regulations,mustbe independentlymounted

tothe craft’s structure,and mustbe accessiblefor

servicing withoutremoving anypermanentstructures.

NOTE

If afuelstrainerisinstalled,eachfuelfilterand strainer

mustbe supported on the engine orboatstructure

independent fromitsfuel line connections,unless the

fuelfilterorstrainerisinsideafueltank.

FuelPump Lift Capabilities and

FuelConsumption

Figure 6-9listselectricfuelpumplift capabilitiesand

fuel line sizes.Figure 6-10 showsgeneratorset fuel

consumption rates.

ModelFuelPump

Max.Lift ft.(m)Fuel InletSize

I.D. in.(mm)

3.5CFZ 3(0.9)3/8(9.5)

4CZ3(0.9)3/8(9.5)

5CFZ 3(0.9)3/8(9.5)

6.5CZ3(0.9)3/8(9.5)

Figure 6-9.FuelPump Lift and FuelLineSize

Loadand GPH(L/hr.)

Model1/4 1/2 3/4Full

3.5CFZ 0.42

(1.59)0.50

(1.89)0.59

(2.23)0.68

(2.57)

4CZ0.48

(1.81)0.55

(2.08)0.62

(2.34)0.68

(2.57)

5CFZ 0.44

(1.67)0.54

(2.04)0.66

(2.50)0.80

(3.03)

6.5CZ0.53

(2.00)0.62

(2.34)0.86

(3.25)1.02

(3.86)

Figure 6-10.FuelConsumption

TP-5695 12/93 Installation 6-7

Cooling Systems

General

The following featuresare necessaryinthe cooling

system.

Anintake thru-hull strainer(seacock cover) mustbe

screened to prevententryof foreign objectsand must

notbe aligned (inrelation to direction of travel)withthe

propulsion engine intake.See Figure 6-11.The

recommended thru-hull strainershould be flush

mounted.Strainerswithslotted holesmustbe installed

withtheirslotsparalleltothe direction ofvessel

movement. The area of the straineropening(s)mustbe

equalto orgreaterthan the inside diameterof the

waterline hosetothe seawaterpump.

Anintakethru-hull strainermustnotbe of the scoop or

cup design.This stylecan causearamming effectand

forcewaterupward,past the seawaterpump,and into

the engine cylinderswhen the vessel ismoving and the

generatorsetis shutdown.Hull designsincorporating

sea chestsare also notsuitableforintakethru-hull

strainers.Asea chestisaconcavemolded-in-the-hull

chamberthatisalso aligned tothe direction of travel.A

sea chestconfiguration appliesa positive pressure

similartoascoop-type thru-hull strainer.

Aseacock isto be mountedto hull,assembled ontothe

intake and accessibleforoperation.Figure 6-12 shows

atypical installation. Install the canvason the outside of

the hull,and the canvasor rubberpacking on the inside

of the hull.

If caulking isused tosealthe seacock,be sure not to

applyan excessive amount. Excess caulk can cause

improperwaterflowand insomecasesdevelop a

barrierwhichcanforcewaterupward,pasttheseawater

pump,and intothe engine cylinderswhen the vessel is

moving and generatorsetis shutdown.

NOTE

Intakesare positioned inrelation tovesseltravel

so neitherwill be inthe wake of the other.

1

2

4 3

1-789

1.GeneratorSet Intake

2.Propulsion Engine

Intake

3.Aft

4.Fore

Figure 6-11. Intake Strainer

1

2

3

4

1. Inside Packing

2.Outside Packing

3.Seacock Cover

4.Direction ofVessel

Movement

5.TypicalIntakeThru-Hull

Strainers

51-789

Figure 6-12.Seacock Installation

TP-5695 12/936-8Installation

Aseawaterstrainerofsufficientcapacity should be

mounted tothe seacock orpermanentstructure ata

pointnothigherthan the seawaterpump.The strainer

shouldbeaccessibleforservicing.SeeFigure 6-13fora

typical installation.The optionalKohlerseawater

straineristhreaded for1/2NPTfittings.

1

2

3

1-789

1.SeawaterPump

2.SeawaterStrainer3.Seacock

Figure 6-13.SeawaterStrainer

NOTE

Someseawaterstrainersinclude seacock and intake

thru-hull strainer.

Waterlines fromthe seacock tothe engine-driven

seawaterpumpcan be coppertubing orflexible hose.A

flexiblesection ofhoseisused forthe actualconnection

tothe seawaterpumpto allowvibrationalmotion of the

generatorsetduring operation.The hoseshould have

aninsidediameterof3/4in.(19mm).Copperlineshould

be supported within4in.(102 mm)ofits connection to

the flexiblesection.

NOTE

A5/8in.(16 mm)waterline hosecan be substituted for

the recommended 3/4in.waterline hose.

Piping shouldbekeptstraightand as shortaspossible.

See Figure 6-14 forthe seawaterconnection tothe

seawaterpumpinlet. The seawateroutletis combined

with engine exhaustgases.(Onsound shielded units,a

small section ofmolded hoseisrequired forthe

seawaterinletconnection.)

1

ADV-5792-D

1.3/4in.SeawaterPumpInlet

Figure 6-14.SeawaterInletConnection

Closed/HeatExchanger

Aclosed,heatexchangercooling system, the best

alternativeformostapplicationsespeciallyifcraft isto

be operated insaltwatersorwaterswith high silt

content, isprovided aspartof the generatorset.

Service accessibilitymustbe provided forthe heat

exchangerpressurecap.See Figure 6-15.

TP-5695 12/93 Installation 6-9

TOTALHOURS

00 000 1/10

10A

FUSE

BATT.

CHRG.

INPUT

NOTE

Usetwohoseclampsoneach

end ofall flexible exhaust

hoseconnections.

1.ExhaustManifold

2.3ft. (1m)Max.

3.Engine-Driven SeawaterPump

4.HeatExchanger

5.Waterline

6.SeawaterStrainer

7. IntakeStrainer

8.Engine Coolant

9.Seawater

10.Seacock

11.CoolantRecoveryTank

123

4

5

6

78

9

10

11

STOP/START

258000-D

Figure 6-15.Closed/HeatExchangerCooling System

ExhaustSystems

General

Water-cooledexhaustlinesshouldbeusedin all marine

installations.The hose used forthe lines should have a

2in.(51 mm)inside diameter.Keep the linesas short

andstraightaspossible.Theuseof two hoseclampson

each end of flexible exhausthoseconnectionsishighly

recommended.ABYCSafetyStandardsP-1.6.c

recommend a pitch ofatleast1/2in.(12.8mm)per

running foot(30.5cm).Useflexiblesteamhose

conforming toULStandard 1129 for“Engine wet

exhaustcomponents”between the mixing elbowand

the exhaustoutlet. Asilencershould be independently

mounted to eliminate any stress on the exhaustsystem

and exhaustmanifold/mixerelbow.See Figure 6-16 for

the exhaustconnection tothe mixerelbow.

11-894

1.Seawater/ExhaustOutlet

Figure 6-16.MixerElbow/ExhaustConnection

TP-5695 12/936-10 Installation

Locatetheexhaustoutletatleast4in.(10cm)abovethe

waterlinewhenthecraftisloadedtomaximumcapacity.

Usuallyaflapperisinstalled atexhaust(transom)outlet

topreventwaterbackup infollowing seasorwhen going

astern(backward).

WARNING

Carbon monoxide.

Cancause severenausea,fainting,ordeath.

The exhaustsystem mustbe leakproofand

routinelyinspected.

Carbon monoxide cancause severenausea,

fainting,ordeath.Usethe following precautionswhen

installing and operating generatorset. Carbon

monoxide isparticularlythreatening inthatitisan

odorless,colorless, tasteless,nonirritating gas.Be

especially careful ifoperating the generatorwhen

moored oranchored undercalmconditionsasgases

mayaccumulate.Ifoperating the setdockside,moor

yourcraftsothatthe exhaustdischargesonthe leeside

(the side sheltered fromthe wind),and always be

mindfulofothers—makesureyourexhaustisdirected

awayfromotherboatsand occupied buildings.Do not

install exhaustoutletwhere exhaustcan be drawn

through portholes,vents,orairconditioners. If

generatorset’sexhaustdischarge holeisneartoyour

craft’swaterline,DONOTOVERLOAD CRAFTso asto

close or restrictexhaustdischarge hole.

TOTALHOURS

00 000 1/10

10A

FUSE

BATT.

CHRG.

INPUT

NOTE

Usetwo hoseclampson each end of

all flexible exhausthoseconnections.

1.HeatExchanger

2.ExhaustManifold

3.Engine-Driven SeawaterPump

4.3ft. (1m)Max.Lift ofSeawaterPump

5.Silencer (CustomerSupplied)

6.ExhaustHoseSlope 0.5in.(1.3cm)perft. (30.5cm)

7.SlightLift ImprovesSilencing (Keep BelowLevel

ofExhaustManifoldOutlet)

8.4in.(10 cm)Min.ofExhaustLine AboveWaterline

9.Waterline

10.SeawaterStrainer

11. IntakeStrainer

12.10 ft. (3m)Max.Between ExhaustOutletand Silencer

13.Seacock

14.CoolantRecoveryTank

11

NOTE

Data givenisapplicableto

side-exhaustinstallations.

12

5

6

7

8

9

10

4

12

STOP/START

14 13

3

258000-D

Figure 6-17.TypicalAbove WaterlineInstallation

Exhaustsystemguidelinesforvariousgeneratorset

locationsfollow.Where exhaustlineswouldrequire

passage through bulkheads,itmaybe more practicalto

use port(left)orstarboard(right)side exhaustoutlets.

Thiswould be especiallytrue wherelong exhaustlines

tothe transom(rear) couldcause excessive back

pressure. Information and illustrationsofstern(rear)

exhaustinstallationsalso applytoside exhaust

installations.Should anyinformation regarding

installation conflictwithU.S.C.G.Regulations,

appropriateRegulations shouldbefollowed.

TP-5695 12/93 Installation 6-11

Above Waterline

In addition toconsiderationsdescribed earlier,a

customer-supplied silencershouldbeinstalled withits

outletatamaximumof10 horizontalft. (3m)fromthe

centerof the engine’sexhaustoutlet(see Figure 6-17).

Atypicalsilencershouldbemounted withthe inletand

outletleveland withthe drain plug down.The silencer

mayrequiretwosupporting bracketsorhangerstraps

forinstallation tostringersorothersuitablestructure.

Any“lift”inthe exhaustlinetoimprovesilencingmustbe

belowthe engine exhaustmanifold outlet.

Mid/BelowWaterline

U.S.C.G.Regulationsrequirethatan anti-siphoning

provision be used to preventraw waterentryintothe

engineiftheexhaustmanifoldoutletislocated lessthan

9in.(23cm)abovethewaterlinewhenthecraftisloaded

tomaximumcapacity. Install asiphon break,see

Figure 6-18,atleast1ft. (31 cm)abovewaterline as

showninFigure 6-19.

1

2

3

1.Mounting Base

2.Retaining Cap 3.Reed ValveAssembly

1-779

Figure 6-18.Siphon Break Components

The siphon breakmustbe located atleast1footabove

the waterline atmaximumvesselcapacitybetween the

heatexchangerand waterelbow(three-wayfittings).

The siphon breakand fitting mustbe supported to

maintainproperpositionandfunction.Thesiphonbreak

shouldbemounted directly verticalofits connection to

generatorsetwhere possible.Otherwise,aslightoffset

isallowabletoclearstringersorotherpermanent

structures.

1.Siphon Break

2.ExhaustManifold

3.HeatExchanger

4.4ft. (1.2m)Max.

5.ExhaustHoseSlope 0.5in.(1.3cm)perft. (30.5cm)

6.4in.(10 cm)Min.

7.Waterline

8.Silencer (CustomerSupplied)

9.10 ft. (3m)Max.

10. Install OptionalWaterLock Here

11.CoolantRecoveryTank

12.1ft. (30.5cm)Min.

TOTALHOURS

00 000 1/10

10A

FUSE

BATT.

CHRG.

INPUT

NOTE

Usetwo hoseclampson

each end ofall flexible

exhausthoseconnections.

NOTE

Data given isalso applicable

toside-exhaustinstallations.

4

5

6

7

8

9

10

11

12

STOP/START

123

258000-D

Figure 6-19.TypicalMidand BelowWaterlineInstallation

TP-5695 12/936-12 Installation

Atypicalsilencershouldbemounted no morethan 4 ft.

(1.2m)belowthe highestpointinthe exhaustline.

Attachaseparatewood mounting baseto hull stringers

orothersuitablestructure.Then securethe silencerto

hull using silencermanufacturer’srecommendation.Be

surethe silenceroutletisnotmorethan 10 horizontalft.

(3m)fromthe engine exhaustmanifold outlet. UL

marine exhausthoseshould be used.

ElectricalSystems

AC VoltageConnections

WARNING

Explosion.

Gasoline vapors cancause explosion and

severeinjuryordeath.

Beforestarting generatorset, operate blower4

minutesand check engine compartment for

gasoline vapors.

Explosive fuelvapors cancause severeinjuryor

death.Gasoline vapors can explode and can cause

death orsevereinjury.USCGRegulation 33CFR183

requiresall electricaldevices(ship-to-shoretransfer

switch,remotestartpanel,etc.)tobe“ignitionprotected”

whenusedinagasoline(gaseous)-fueledenvironment.

These electricaldevicesare not“ignition protected”and

are notcertified to operatein a gasoline

(gaseous)-fueled environmentsuch asengine roomor

nearfueltanks.Acceptablelocationswould be

wheelhouseorotherlivingareasshelteredfromrainand

watersplash.

WARNING

Hazardous voltage.

Do notoperate generatorsetwithoutall guards

and electricalenclosuresin place.

Moving rotor.

Cancause severeinjuryordeath.

Hazardous“backfeed”voltage cancause severe

injuryordeath.Do notconnect to anybuilding/marina

electricalsystemwithoutconnecting through an

approved device and afterbuilding mainswitchisopen.

Backfeedconnectionscancauseseriousinjuryordeath

to utilitypersonnelworking torepaira poweroutage

and/orpersonnel inthe vicinity.Unauthorized

connection maybe unlawful insomestatesand/or

localities.Aship-to-shoretransferswitchmustbe

installed to preventinterconnection ofgeneratorset

powerand shore power.

ACconnectionsto generatorsetaremade inside the

controllerbox.Thegeneratorsetisusually connectedto

aship-to-shoretransferswitchwhich allowsthe use of

shore/utilitypowerwhendocked orgeneratorsetpower

whendockedoratsea.Thewiringisthenconnectedtoa

maincircuitbreakerbox(panelboard)which distributes

branchcircuitsthroughout the craft. See Section 5.

Wiring Diagramsfor reconnectabilityofgeneratorset.

Installation inSteelor

AluminumVessels

Installation ofa generatorsetinavesselconstructed of

amaterialcapable ofconducting current(e.g.: steelor

aluminum)is subject toconsiderationsnotnormally

encountered infiberglass orwood vessels.These

differencesinclude equipmentgrounding,grounding of

neutralconductors,ground faultprotection,and

isolation ofgalvanic currents.

Whilethe scope of thesetopics istoo extensiveto be

fullydiscussed here,referencestothe appropriate

governing bodieswill be identified forfurther

investigation.

The information provided hereisintended toserve asa

guideline to boatmanufacturersand generatorset

installers.Thisinformation isnotintended orimplied to

be limited tothesesourcesand is subject torevision by

the appropriate governing bodies.

Priortoinstalling the generatorset, check the wiring

diagramsto becomefamiliarwiththe electricalsystem.

Generatorsetsinstalled in pleasurecraft are governed

bythe U.S.CoastGuard and the American Boatand

YachtCouncil, Inc.CompliancewithU.S.CoastGuard

RegulationsgiveninTitle33,Part183mustbefollowed.

Generatorsetsinstalled in pleasurecraft require a

grounded neutralsystemas specified inABYCE-8.4.b.

Variouswiring configurationsareillustrated inABYC

StandardsE-8.22 through E-8.29.Grounding of

appliancesand equipmentis covered inABYCE-8.12.

Galvanic corrosion prevention bymeansofgalvanic

TP-5695 12/93 Installation 6-13

isolatororisolation transformerisreferenced inABYC

E-8.20 and ABYCE-8.11.

Generatorsetsinstalled incommercialvesselsare

governedbyU.S.CoastGuardRegulations,Title46,the

American Bureau ofShipping,and Lloyd’sRegisterof

Shipping.Grounding ofequipmentis covered inABS

35.9.6 and Lloyd’sPart6,Chapter2-1,Section 1.3.The

typesofpermissible neutralgrounding ofgenerating

equipmentarereferenced inABS 35.125 and 35.95.1

andin Lloyd’sPart6,Chapter2-1,Section14.4.Ground

faultprotection information can be found in Lloyd’sPart

6,Chapter2-1,Section 14.5 and Part6,Chapter2-2,

Section 13.6.

Battery

BatteriesandtheirinstallationmustconformtoU.S.C.G.

Regulations183.420 (a)through (g).Generatorsets

should use batteries separatefromthe propulsion

engineswheneverpossible.Boththe generatorsetand

the propulsion engines’ starting/charging systemsmust

haveacommon negative(--) ground.

U.S.C.GRegulation 183.415,Grounding,requiresa

common conductortobeconnected to each grounded

crankingmotorcircuit.Thisconductorshouldbesizedto

matchthe largerof the engines’two battery cables.

(Cablesizesforgeneratorsetbattery connectionsare

given inFigure 6-20.)Thisrequirementpreventsthe

starting motorcurrent fromusing alternative electrical

paths shouldthe cranking motorground circuitbe

restricted oropen due to oxidation orloose hardware.

These alternative electricalpathsinclude metallicfuel

lineswhichcan poseafire hazard.See Figure 6-21 for

battery connectionsto generatorset.

Distance Between

GeneratorSetand

BatteryAt0° F

(--18° C)

Cable

Size

(AWG)

At32° F

(0° C)At75° F

(24° C)

40 ft. (12.2m)00 0 1

30 ft. (9.1m)012

25 ft. (7.6m)124

20 ft. (6.1m)226

15 ft. (4.6m)246

10 ft. (3.0m)468

5ft. (1.5m)668

2.5ft. (0.8m)888

Figure 6-20.BatteryCableSizes

1.BatteryPositive(+)

Connection 2.BatteryNegative(--)

Connection

1

2

ADV-5792-D

Figure 6-21.BatteryConnection Bracket

Wiring

All wiring mustbe stranded copper.Wire gaugesand

insulation,conductortemperatureratings,sheath

stripping,conductorsupportand protection,conductor

terminalsand splices,and overcurrentprotection

(circuitbreakers, fuses)mustconformtoU.S.C.G.

Regulations183.425 through 183.460.Userubber

grommetsand cableties,asnecessary, to protectand

securewiring fromsharp objects,exhaustsystem,and

anymoving parts.

TP-5695 12/936-14 Installation

RemoteStartSwitchConnection

Kohleroffers severalremote panelsforconnection to

the generatorset. See Accessoriesforfurtherdetailed

description.Awiring harness withaconnectorkeyed to

the controllerbox connectorisavailabletoconnect

these panelstothe generatorset. The otherend of this

harness haspigtailswhichcan be used if the installer

electsto usejustastart-stop switch orseparatelights

and hourmeter.See Figure 6-22.

NOTE

If gaugesareto be used, theremustalso be generator

setsenders.Sendersare optionalon these generator

sets.Gaugesand sendersare available as service

itemsfroman authorized Kohlerservice

dealer/distributor.

WT

OP

123

456

J3

LeadDesignations

Pin Lead Function

J3-1Black Ground (--)

J3-2Tan WaterTemp.Ga.

J3-3 Lt. Blue Oil PressureGa.

J3-4VioletGen.“ON”(+)

J3-5Yellow/Red Start

J3-6Grey/Black Stop

NOTE

All wireis16 gauge.

Tape toinsulate all

unused lead ends.

1

23

4

6

7

5

1.UseInsulinkorSolderConnection (Tape toInsulate)

2.Hourmeter

3.“ON”Light

4.Stop

5.Start

6.RockerSwitch

7.GaugesSenders

Figure 6-22.RemoteControlPanelWiring

TP-5695 12/93 Installation Drawings7-1

Section 7. Installation Drawings

ADV-5792-D

VIEW A--A

MOUNTING PATTERN

EQUIVALENT.

ARE MILLIMETER

DIMENSIONS IN ( )

NOTE:

WITH HUSH COVER.

5/6.5 SUPPLIED STANDARD

WITH HEAT EXCHANGER

WATER--COOLED

IGNITION PROTECTED

4/6.5KW 60HZ. GASOLINE MARINE

3.5/5KW 50HZ. GASOLINE

A

A

REMOTE

CONNECTION

SEA WATER INLET

.75 (.19) I.D. HOSE

1/4 STUD FOR

BATTERY CONNECTION

(POSITIVE)

5/16 STUD FOR

BATTERY CONNECTION

(NEGATIVE).

1.65

(42)

.62

(16)

2.69

(68)

9.13

(232)

21.20

(538)

1.0

(25)

1.0

(25)

15.50

(394)

GROUND LUG

WATER COOLED EXHAUST

OUTLET FOR 2.0 (51) I.D.

RUBBER HOSE

14.19

(360)

6.34

(161)

FUEL INLET

1/4 N.P.T. 15.43

(392)

17.50

(445)

OIL DRAIN

8.77

(223)

27.87

(708)

26.44

(672)

.44

(11)

16.60

(422)

5.89

(150)

24.44

(621)

ENGINE

.406 DIA. (4) HOLES

(10)

CIRCUIT BREAKERS (OPTIONAL)

START/STOP SWITCH

ENGINE COOLANT

CHECK AND FILL

ENGINE OIL

CHECK AND FILL

OIL FILTER

C

L

Sheet 1

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

TP-5695 12/937-2Installation Drawings

ADV-5792-D

A A

VIEW A--A

KIT # 267994 (4 PIECE COVER).

SOUND SHIELD SERVICE

WITH SOUND SHIELD.

5/6.5KW SUPPLIED STANDARD

MILLIMETER EQUIV.

DIMENSIONS IN ( ) ARE

NOTE:

31.07

(789)

1.75

(44)8.67

(220)12.82

(326)

3.12 DIA. (79)

EXHAUST

OUTLET

OPENING

1.92

(49)

1.57

(40)

.51

(13) TYP.

CLEARANCE REQ’D FOR

LATCH OPENING

3.07

(78)

17.86

(454)

.50 R.

(13)

OPENING FOR FUEL

INLET HOSE AND

BATTERY CONNECTIONS

OPENING FOR

A.C. LOAD LEADS

.625 R. (16)

SEA WATER INLET

MOUNTING LOCATION FOR

SIPHON BREAK ASSEMBLY.

DRILL (2) 1.00”DIA. HOLES

USING INDENTATIONS FOR

LOCATION. (OPTIONAL)

30.06

(764)

26.76

(680)

1.65

(42)

2 PLACES

18.10

(460)

.50 R. (13)

2.75

(70)

2.12

(54)

17.50

(445)

Do not use as a step.

267957

Standing on genset could

impair operation of unit.

CAUTION

15.62

(397)

4.00

(102)5.45

(138)

1.75

(44)

Sheet 2

Figure 7-2.Sound Shield--Optionalon 3.5CFZ and 4CZ;Standardon5CFZ and 6.5CZ

TP-5695 12/93 PartsOrdering Instructions8-1

Section 8.PartsOrdering Instructions

Forserviceorinformation,checktheyellowpagesofthe

telephone directoryunderthe heading

GENERATORS--ELECTRICorcontact the localmarina

fortheauthorizedKohlerservicedealer/distributorinthe

area.

KOHLER CO.KOHLER,WISCONSIN53044

PHONE414-565-3381

FAX 414-459-1646 (NorthAmerican Sales),

414-459-1614 (International)

FORSALES&SERVICEINU.S.A.&CANADAPHONE

1-800-544-2444

Amajorservicemanualand parts catalog maybe

ordered through an authorized Kohlerservice

dealer/distributor.When ordering,stateMODEL and

SPEC.numbersfromthe GeneratorNameplate.(See

NOTAG.)

In any communicationsregarding thisgeneratorset,

pleasereporttheMODEL,SPEC.andSERIALnumbers

asfound on the nameplate attached tothe generator

and engine.Enternumbersinspacesprovided below.

Thisinformation will enablethe authorized Kohler

service dealer/distributortosupplythe correctpartor

dataforthisparticularmodel.

ModelNo. ......................................

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

SerialNo. ......................................

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

TP-5695 12/93 Operating HourService Log 9-1

Section 9. Operating Hour Service Log

The following isprovided to helpyou keep a cumulative

record ofoperating hourson yourgeneratorsetand the datesrequiredserviceswere performed.Enterhoursto

the nearestquarterhour.

OPERATINGHOURS SERVICERECORD

DATEHOURSRUN CUMULATIVE DATE SERVICE

TP-5695 12/93

PRINTEDIN U.S.A.

KOHLER CO. KOHLER,WISCONSIN53044

PHONE 414-565-3381

FAX 414-459-1646 (NorthAmerican Sales), 414-459-1614 (International)

FOR SALES & SERVICE IN U.S.A.& CANADA PHONE 1-800-544-2444