Page 2 - WARNING; California Proposition 65
Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING California Proposition 65
Page 3 - Table of Contents
TP-5695 12/93 Table of Contents Table of Contents SUBJECT PAGE SUBJECT PAGE Safety Precautions and Instructions i . . . . . . . Reference Material viii . . . . . . . . . . . . . . . . . . . . . . . Routine Service Parts x . . . . . . . . . . . . . . . . . . . . . . Glossary of Abbreviations xi . . ....
Page 4 - Safety Precautions and Instructions
TP-5695 12/93 Safety Precautions and Instructions i Safety Precautions and Instructions A generator set, like any other electro-mechanicaldevice, can pose potential dangers to life and limb ifimproperly maintained or imprudently operated. Thebest way to prevent accidents is to be aware of thepotenti...
Page 5 - EXHAUST SYSTEM
TP-5695 12/93 ii Safety Precautions and Instructions EXHAUST SYSTEM WARNING Carbon monoxide.Can cause severe nausea, fainting, or death. The exhaust system must be leakproof androutinely inspected. Carbon monoxide can cause severe nausea,fainting, or death. Use the following precautions when install...
Page 6 - BATTERY
TP-5695 12/93 Safety Precautions and Instructions iii BATTERY WARNING Sulfuric acid in batteries.Can cause severe injury or death. Use protective goggles and clothes. Can causepermanent damage to eyes, burn skin, and eat holesin clothing. Sulfuric acid in batteries can cause severe injury ordeath. S...
Page 7 - FUEL SYSTEM
TP-5695 12/93 iv Safety Precautions and Instructions FUEL SYSTEM WARNING Explosion.Gasoline vapors can cause explosion andsevere injury or death. Before starting generator set, operate blower 4minutes and check engine compartment forgasoline vapors. WARNING Explosive fuel vapors.Can cause severe inj...
Page 8 - ACCIDENTAL STARTING; MOVING PARTS; HOT PARTS
TP-5695 12/93 Safety Precautions and Instructions v ACCIDENTAL STARTING WARNING Accidental starting.Can cause severe injury or death. Disconnect battery cables before working ongenerator set (negative lead first and reconnect itlast). Accidental starting can cause severe injury ordeath. Disconnect b...
Page 9 - ENGINE BACKFIRE/FLASH FIRE; HAZARDOUS NOISE
TP-5695 12/93 vi Safety Precautions and Instructions ENGINE BACKFIRE/FLASH FIRE WARNING Fire.Can cause severe injury or death. Do not smoke or permit flame or spark to occurnear fuel or fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flame or spark to occur near ca...
Page 10 - NOTES; NOTICE
TP-5695 12/93 Safety Precautions and Instructions vii NOTES NOTE HARDWARE DAMAGE! Engine and generator may make use of both American Standard and metrichardware. Be sure to use the correct size tools toprevent rounding of bolt heads and nuts. NOTE Special attention should be given when checking forp...
Page 11 - Reference Material; Pleasure Craft
TP-5695 12/93 viii Reference Material Reference Material It is recommended that the following Regulations andStandards be followed when installing MarineGenerator Sets. Pleasure Craft Designed and manufactured to meet U.S. Coast GuardTitle 33. U.S. Coast Guard Code of Federal RegulationsTitle 33Subp...
Page 12 - Commercial Vessels; Additional References
TP-5695 12/93 Reference Material ix Commercial Vessels In order to use these generator sets for commercialapplications where U.S. Coast Guard Title 46 Certificateis required, additional modifications will be necessary. U.S. Coast Guard Code of Federal RegulationsTitle 46Subchapter F--Marine Engineer...
Page 13 - Routine Service Parts
x Routine Service Parts TP-5695 12/93 Routine Service Parts Contact your Kohler generator dealer/distributor for acomplete listing of service parts for your generator set. Part Description Kohler Part No. Engine: Air Filter 278612 Oil Filter 267714 Belt, Timing 267722 Ignition System: Spark Plug 267...
Page 14 - Glossary of Abbreviations
TP-5695 12/93 Glossary of Abbreviations xi Glossary of Abbreviations Abbreviations are used throughout this manual. Normally in the text they will appear in complete form with theabbreviation following in parenthesis the first time they are used. After that they will appear in the abbreviated form.T...
Page 16 - Section 1. Specifications; Introduction; General Specifications
TP-5695 12/93 Specifications 1-1 Section 1. Specifications Introduction The craft is equipped with a dependable 110 volt(reconnectable to 110/220 volt), 50 Hz; or 120 volt(reconnectable to 120/240 volt), 60 Hz single-phasealternating current marine generator set. Servicerequirements are minimal but ...
Page 17 - Generator
TP-5695 12/93 1-2 Specifications Generator 3.5CFZ 5CFZ Rated kW 3.5 5 Frequency--Hz 50 50 Rated Voltage 110 Volt, 2&3 Wire, Single Phase or 110/220 Volt, 3 Wire, Single Phase Rated Amps (110 Volt) 31.8 45.5 Rated Amps (220 Volt) 15.9 22.7 Rotor Resistance (cold) (ohms) 4--5 4--5 Stator Resistanc...
Page 18 - Engine
TP-5695 12/93 Specifications 1-3 DERATING: All units are rated 1.0 power factor. Derate approximately 3.5% per 1000 ft. (300 m) above 500 ft. (150 m) above sea level. 3.5CFZ, 50 Hz: 3.5 kW at 77 ° F (25 ° C) and 3.5 kW at 122 ° F (50 ° C). 4CFZ, 60 Hz: 4 kW at 77 ° F (25 ° C) and 3.5 kW at 122 ° F (...
Page 20 - Accessories
TP-5695 12/93 Specifications 1-5 Accessories Several accessories are available to finalize theinstallation or to add convenience to operation andservice. All the most current information can be obtainedby contacting the local authorized Kohler dealer/distributor. Available accessories at the time of...
Page 21 - Service Views
TP-5695 12/93 1-6 Specifications Service Views TOTAL HOURS 0 0 0 E 0 0 1/10 10A FUSE BATT. CHRG. INPUT 2 9 4 5 36 35 30 29 28 27 26 25 24 23 21 19 33 258000-D 1 34 STOP START 10 17 16 13 12 11 14 31 15 18 20 6 7 8 32 3 22 Figure 1-1. Service Views (typical) 1. Mixer Elbow (Exhaust Water Outlet) 2. B...
Page 22 - Prestart Checks
TP-5695 12/93 Operation 2-1 Section 2. Operation Prestart Checks To insure continued satisfactory operation, the followingitems should be checked before each start-up. BACKFIRE FLAME ARRESTOR: Air cleaner must be clean and properly installed to prevent unfiltered air fromentering engine. See Mainten...
Page 23 - Controller
TP-5695 12/93 2-2 Operation Controller For identification and location of controller operatingfeatures, refer to the text below and Figure 2-1. 1. Battery Charging Fuse protects battery charging circuitry from short circuits. 2. Input (Controller) Fuse protects controller circuitry from short circui...
Page 24 - Stopping
TP-5695 12/93 Operation 2-3 Starting WARNING Explosion.Gasoline vapors can cause explosion andsevere injury or death. Before starting generator set, operate blower 4minutes and check engine compartment forgasoline vapors. NOTE For reliable starting, allow at least 30 seconds aftershutdown before res...
Page 25 - Circuit Protection; Engine Safety
TP-5695 12/93 2-4 Operation Circuit Protection AC Circuit Breaker (Optional) The optional AC circuit breaker(s) located on the frontpanel of the controller protect the generator outputwindings. If a load circuit loses power, the cause may bea tripped AC circuit breaker. If a tripped circuit breaker ...
Page 26 - High Exhaust Temperature
TP-5695 12/93 Operation 2-5 High Water Temperature Shutdown Switch The high water temperature shutdown switch protectsthe engine against internal damage if the cooling watertemperature in the engine block is too high due tocooling water or coolant circulation problems. Theswitch is set to trip at 24...
Page 29 - Section 3. Scheduled Maintenance
TP-5695 12/93 Scheduled Maintenance 3-1 Section 3. Scheduled Maintenance Use the following service schedule and the hourmeteron the controller to schedule routine maintenance. Inaddition to the routine services listed in this manual,there are other important steps that should be taken tokeep a gener...
Page 30 - Service Schedule
TP-5695 12/93 3-2 Scheduled Maintenance Service Schedule Before Starting After 20 Hrs. or One Month Every 50 Hrs. or 3 Months Every 100 Hrs. or 6 Months Every 200 Hrs. or Yearly Every 300 Hrs. or 2 Years LUBRICATION SYSTEM Check oil level X Change oil X (Break-in Period) X Change oil filter X FUEL S...
Page 32 - Lubrication System; Specifications; Oil Check
TP-5695 12/93 3-4 Scheduled Maintenance Lubrication System Specifications Use high quality detergent oil of API (AmericanPetroleum Institute) service class SF, SF/CC, or SF/CD.This information can be found on most oil containers,see Figure 3-1. The symbol illustrated identifies the APIservice class ...
Page 33 - Adding Oil
TP-5695 12/93 Scheduled Maintenance 3-5 Adding Oil It is normal to add some oil between oil changes. Theamount will vary with the usage. Open fill cap and pour asmall amount of oil using a funnel or other suitablepouring device. See Figure 3-4. Wait a few minutes andcheck level. If necessary, add mo...
Page 34 - Fuel System
TP-5695 12/93 3-6 Scheduled Maintenance 1 1-826 1. Oil Filter Wrench 2 1/2 in. (64 mm) Dia. Figure 3-6. Removing Oil Filter Fuel System Specifications For best results, use only clean fresh, regular gradeunleaded gasoline. Use fuel with a minimum octanerating as designated by the following:Antiknock...
Page 35 - Fuel Pump Screen
TP-5695 12/93 Scheduled Maintenance 3-7 Fuel Pump Screen WARNING Explosive fuel vapors.Can cause severe injury or death. Use extreme care when handling, storing,and using fuels. Explosive fuel vapors can cause severe injury ordeath. All fuels are highly explosive in a vapor state. Use extreme care w...
Page 36 - Carburetor/Choke Lubrication
TP-5695 12/93 3-8 Scheduled Maintenance Carburetor/Choke Lubrication The only maintenance required is to lubricate carburetorand choke linkage at the specified interval using whitelithium grease or lubriplate. Carburetor Adjustments The carburetor is a single-barrel, horizontal design anduses an ele...
Page 37 - Ignition System; Ignition System Service
TP-5695 12/93 Scheduled Maintenance 3-9 Ignition System Ignition System Service The ignition system is transistorized and breakerless.Under normal conditions, only the spark plugs needservice on a regular basis. The electronic ignitionmodule requires no maintenance and should give yearsof trouble-fr...
Page 40 - Cooling Systems—; Filling and Checking
TP-5695 12/93 3-12 Scheduled Maintenance Cooling Systems— Closed/Heat Exchanger In a closed cooling system, the seawater does notcirculate through the engine but circulates throughseparate chambers within the heat exchanger to coolthe engine coolant. The seawater is then mixed withengine exhaust and...
Page 42 - Flushing and Cleaning
TP-5695 12/93 3-14 Scheduled Maintenance Flushing and Cleaning If required, flush coolant from generator set. To properlyflush coolant, obtain Kit #267999 and use the followingprocedure: WARNING Accidental starting.Can cause severe injury or death. Disconnect battery cables before working ongenerato...
Page 45 - Pressure Cap; Siphon Break; Air Cleaner and; Servicing Air Cleaner
TP-5695 12/93 Scheduled Maintenance 3-17 Pressure Cap Closed-loop cooling systems incorporate a pressurizedcap to raise the boiling point of the coolant and make useof higher operating temperatures. If leakage ormalfunction occurs, replace the pressurized cap withone supplied by Kohler Co. part numb...
Page 46 - Cleaning
TP-5695 12/93 3-18 Scheduled Maintenance Battery The starting battery should be a 12-volt unit with aminimum 250 CCA (cold cranking Amps) at 0 _ F (--18 _ C). When using a maintenance-free battery it is notnecessary to check the specific gravity or electrolytelevel. Otherwise, these procedures shoul...
Page 47 - Charging
TP-5695 12/93 Scheduled Maintenance 3-19 each cell should not exceed ± 0.01. The battery should be charged if the specific gravity is below 1.215 at anelectrolyte temperature of 80 _ F (26.7 _ C). 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 -- 12.2 -- 6.7 -- 1.1 4.4 10 21.1 26.7 32.2 37.8...
Page 48 - Valve Adjustment
TP-5695 12/93 3-20 Scheduled Maintenance Valve Adjustment With overhead cam engines, each valve is spring-heldin the closed position until forced open by the action ofthe rocker arm in contact with the camshaft. Rockerarms have adjusting screws and locknuts for adjustingvalve stem-to-rocker arm clea...
Page 50 - Governor; Lubrication
TP-5695 12/93 3-22 Scheduled Maintenance Governor The gear-driven centrifugal type governor serves tokeep engine speed constant by automatically adjustingthe amount of fuel supplied to the engine according tochanges in load. Lubrication Lubricate governor linkage at the specified intervalusing white...
Page 51 - Wattage Requirements; General
TP-5695 12/93 Scheduled Maintenance 3-23 Wattage Requirements If the rated capacity of the generator set is exceeded, thecircuit breaker located on the controller will trip to protectthe generator against damage. Tripping could becaused by a short in the AC circuit in the craft or simplyby having to...
Page 52 - Storage Procedure
TP-5695 12/93 3-24 Scheduled Maintenance Storage Procedure It is recommended that the craft be afloat when thegenerator set is prepared for storage since the enginemust be started. 1. Add fuel stabilizer to fuel tank. Use recommendations of fuel stabilizer manufacturer. 2. Start generator set and ru...
Page 53 - Section 4. Troubleshooting
TP-5695 12/93 Troubleshooting 4-1 Section 4. Troubleshooting When troubles occur, do not overlook simple causes. Astarting problem, for example, could be caused byimproper fuel or an empty fuel tank. The following chartslist some common problems. If procedures in thismanual do not explain how to cor...
Page 55 - Electrical System
TP-5695 12/93 Troubleshooting 4-3 Engine (Continued) Problem Possible Cause Corrective Action Overheats Improper cooling Check intake and outlet openings. Checkcoolant level and pressure cap. Check rawwater strainer. Thermostat defective Replace Sea strainer clogged Clean sea strainer Carburetor adj...
Page 57 - Section 5. Wiring Diagrams
TP-5695 12/93 Wiring Diagrams 5-1 Section 5. Wiring Diagrams THERMAL SWITCH BATTERY VOLTMETER WATER TEMPERATURE GAUGE OIL PRESSURE GAUGE WATER TEMP. SENDER HOURMETER ANTI--DIESEL SOLENOID CHOKE FUEL PUMP STARTER MOTOR FAULT SHUTDOWN RELAY ENGINE CRANK RELAY ENGINE RUN RELAY AC CRANK DISCONNECT RELAY...
Page 59 - Electro Switch; To Load; Kraus Naimler/American Solenoid
TP-5695 12/93 Wiring Diagrams 5-3 Electro Switch L1 L2 To Generator Set To Shore Power To Load 2-Wire Generator Sets L1 L2 To Generator Set To Shore Power To Load 2-Wire Generator Sets 2-Wire Generator Sets Kraus Naimler/American Solenoid (Early Rectangular Design) Kraus Naimler/American Solenoid (N...
Page 63 - Section 6. Installation; Generator Selection and; Lighting Load
TP-5695 12/93 Installation 6-1 Section 6. Installation Introduction Use this section as a guide when installing the Marinegenerator set, then refer to Section 2. Operation forspecific service instructions. Reliable and safegenerator set operation depends largely upon properinstallation. Remember tha...
Page 66 - Location; Ventilation
TP-5695 12/93 6-4 Installation Location General Consider the following in selecting or constructing agenerator set location. Compartment/location must allow adequate space forventilation, cooling and exhaust system installation,service access to the engine and generator, and properfuel system instal...
Page 67 - Fuel Systems; Fuel Supply
TP-5695 12/93 Installation 6-5 Fuel Systems Fuel Supply Generator sets, in most cases, must draw fuel from thesame tank as the propulsion engines. If the tank’s fuelpickup opening allows, a multiple dip tube arrangement(Figure 6-6) may be used. An alternate tank, if used,should have a smaller separa...
Page 68 - Fuel Pump Lift Capabilities and
TP-5695 12/93 6-6 Installation Anti-Siphon Provisions Anti-siphon devices must be installed if any section offuel line lies below the highest point of the fuel tank. Theanti-siphon device should be either a spring-loadedcheck valve (tested to function with the particularinstallation’s siphon head), ...
Page 69 - Cooling Systems
TP-5695 12/93 Installation 6-7 Cooling Systems General The following features are necessary in the coolingsystem. An intake thru-hull strainer (seacock cover) must be screened to prevent entry of foreign objects and mustnot be aligned (in relation to direction of travel) with thepropulsion engine in...
Page 70 - Closed/Heat Exchanger
TP-5695 12/93 6-8 Installation A seawater strainer of sufficient capacity should be mounted to the seacock or permanent structure at apoint not higher than the seawater pump. The strainershould be accessible for servicing. See Figure 6-13 for atypical installation. The optional Kohler seawaterstrain...
Page 71 - Exhaust Systems
TP-5695 12/93 Installation 6-9 TOTAL HOURS 0 0 0 0 0 1/10 10A FUSE BATT. CHRG. INPUT NOTE Use two hose clamps on each end of all flexible exhaust hose connections. 1. Exhaust Manifold2. 3 ft. (1 m) Max.3. Engine-Driven Seawater Pump4. Heat Exchanger5. Waterline 6. Seawater Strainer7. Intake Strainer...
Page 73 - Above Waterline
TP-5695 12/93 Installation 6-11 Above Waterline In addition to considerations described earlier, acustomer-supplied silencer should be installed with itsoutlet at a maximum of 10 horizontal ft. (3 m) from thecenter of the engine’s exhaust outlet (see Figure 6-17).A typical silencer should be mounted...
Page 74 - Electrical Systems; AC Voltage Connections; Installation in Steel or
TP-5695 12/93 6-12 Installation A typical silencer should be mounted no more than 4 ft.(1.2 m) below the highest point in the exhaust line.Attach a separate wood mounting base to hull stringersor other suitable structure. Then secure the silencer tohull using silencer manufacturer’s recommendation. ...
Page 75 - Wiring
TP-5695 12/93 Installation 6-13 isolator or isolation transformer is referenced in ABYCE-8.20 and ABYC E-8.11. Generator sets installed in commercial vessels aregoverned by U.S. Coast Guard Regulations, Title 46, theAmerican Bureau of Shipping, and Lloyd’s Register ofShipping. Grounding of equipment...
Page 76 - Remote Start Switch Connection
TP-5695 12/93 6-14 Installation Remote Start Switch Connection Kohler offers several remote panels for connection tothe generator set. See Accessories for further detaileddescription. A wiring harness with a connector keyed tothe controller box connector is available to connectthese panels to the ge...
Page 77 - Section 7. Installation Drawings
TP-5695 12/93 Installation Drawings 7-1 Section 7. Installation Drawings A D V- 57 92 -D V IE W A --A M O U N T IN G PA T T E R N E Q U IV A LE N T. A R E M IL LI M E T E R D IM E N S IO N S IN ( ) N O T E : W IT H H U S H C O V E R . 5/ 6. 5 S U P P LI E D S TA N D A R D W IT H H E AT E X C H A N G...
Page 79 - Section 8. Parts Ordering Instructions
TP-5695 12/93 Parts Ordering Instructions 8-1 Section 8. Parts Ordering Instructions For service or information, check the yellow pages of thetelephone directory under the heading GENERATORS--ELECTRIC or contact the local marinafor the authorized Kohler service dealer/distributor in thearea. KOHLER ...
Page 80 - Section 9. Operating Hour Service Log
TP-5695 12/93 Operating Hour Service Log 9-1 Section 9. Operating Hour Service Log The following is provided to help you keep a cumulativerecord of operating hours on your generator set and the dates required services were performed. Enter hours tothe nearest quarter hour. OPERATING HOURS SERVICE RE...
