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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ manual

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Table of contents for the manual

  • Page 1

    O p e r a t i on a nd I n s t alla t i on M a nu al M a r i n e Ge n e r a t or Se t s M od els : 3 . 5 C F Z 4 C Z 5 C FZ 6 . 5 C Z T P - 5695 12/93[...]

  • Page 2

    E ng i ne e x h au s t f r o m t h i s p r o du c t c o n t a i n s c he m i c a l s k no w n t o t he S t a t e o f C a li f o r n i a t o c au s e c an c e r , b i r t h de f e c t s , o r o t h e r r ep r odu c t i v e ha rm . W ARN I N G C a li f o r n i a P r opo s i t i on 65[...]

  • Page 3

    T P - 5695 12 / 93 T ab l e o f C on t en t s T a b l e o f C on t e n t s S UB J E C T P A G E S UB J E C T P A G E S a f e t y P r eca u t i on s a nd I n s t r u c t i on s i ....... R e f e r e n ce M a t e r i a l v i i i ....................... R ou t i ne S e r v i c e P a r t s x ...................... G l o ssa r y o f A bb r ev i a t i on[...]

  • Page 4

    T P - 5695 12 / 93 S a f e t y P r e c au t i on s and I n s t r u c t i on s i Sa f e t y P r eca u t i on s a nd I n s t ru c t i on s A gene r a t o r s e t, li k e an y o t he r e l e c t r o - m e c han i c a l de v i c e , c an po s e po t en t i a l dange r s t o li f e and li m b i f i m p r ope r l y m a i n t a i ned o r i m p r uden t l [...]

  • Page 5

    T P - 5695 12 / 93 ii S a f e t y P r e c au t i on s and I n s t r u c t i on s EX HAU S T SYS T E M W ARN I N G C a r bon m ono x i d e . C a n ca u se seve r e n a u sea , f a i n t i ng , o r d ea t h . T he e x hau s t sys t e m m u s t be l ea k p r oo f and r ou t i ne l y i n s pe c t ed . C a r bon m ono x i d e ca n ca u se seve r e n a u[...]

  • Page 6

    T P - 5695 12 / 93 S a f e t y P r e c au t i on s and I n s t r u c t i on s iii BA TT E R Y W ARN I N G S u l f u r i c ac i d i n b a tt e r i es . C a n ca u se seve r e i n j u r y o r d ea t h . U s e p r o t e c t i v e gogg l e s and c l o t he s . C an c au s e pe r m anen t da m age t o e y e s , bu r n sk i n , and ea t ho l e s i n c l [...]

  • Page 7

    T P - 5695 12 / 93 i v S a f e t y P r e c au t i on s and I n s t r u c t i on s F U E L SYS T E M W ARN I N G E x p l o s i on . G as o li n e va po r s ca n ca u se ex p l o s i on a nd seve r e i n j u r y o r d ea t h . B e f o r e s t a r t i ng gene r a t o r s e t, ope r a t e b l o w e r 4 m i nu t e s and c he ck eng i ne c o m pa r t m e[...]

  • Page 8

    T P - 5695 12 / 93 S a f e t y P r e c au t i on s and I n s t r u c t i on s v ACC I D E N T A L S T AR T I N G W ARN I N G A cc i d e n t a l s t a r t i ng . C a n ca u se seve r e i n j u r y o r d ea t h . D i sc onne c t ba tt e r y c ab l e s be f o r e w o r k i ng on gene r a t o r s e t ( nega t i v e l ead f i r s t and r e c onne c t i [...]

  • Page 9

    T P - 5695 12 / 93 v i S a f e t y P r e c au t i on s and I n s t r u c t i on s E N G I N E BACK F I R E / FL A S H F I R E W ARN I N G F i r e . C a n ca u se seve r e i n j u r y o r d ea t h . D o no t s m o k e o r pe r m i t f l a m e o r s pa r k t o o cc u r nea r f ue l o r f ue l sys t e m . A f l as h f i r e ca n ca u se seve r e i n j[...]

  • Page 10

    T P - 5695 12 / 93 S a f e t y P r e c au t i on s and I n s t r u c t i on s v ii N O T ES N O T E HARD W AR E DA M A G E ! E ng i ne and gene r a t o r m a y m a k e u s e o f bo t h A m e r i c an S t anda r d and m e t r i c ha r d w a r e . B e s u r e t o u s e t he c o rr e c t s i z e t oo l s t o p r e v en t r ound i ng o f bo l t head s [...]

  • Page 11

    T P - 5695 12 / 93 v iii R e f e r en c e M a t e r i a l R e f e r e n ce M a t e r i a l It i s r e c o mm ended t ha t t he f o ll o w i ng R egu l a t i on s and S t anda r d s be f o ll o w ed w hen i n s t a lli ng M a r i ne G ene r a t o r S e t s . P l eas u r e C r a ft D e s i gned and m anu f a c t u r ed t o m ee t U . S . C oa s t G u[...]

  • Page 12

    T P - 5695 12 / 93 R e f e r en c e M a t e r i a l i x C o mm e r c i a l V esse l s I n o r de r t o u s e t he s e gene r a t o r s e t s f o r c o mm e r c i a l app li c a t i on s w he r e U . S . C oa s t G ua r d T i t l e 46 C e r t i f i c a t e i s r equ i r ed , add i t i ona l m od i f i c a t i on s w ill be ne c e ss a r y . U . S . [...]

  • Page 13

    x R ou t i ne S e r v i c e P a r t s T P - 5695 12 / 93 R ou t i n e S e r v i ce P a r t s C on t a c t y ou r K oh l e r gene r a t o r dea l e r / d i s t r i bu t o r f o r a c o m p l e t e li s t i ng o f s e r v i c e pa r t s f o r y ou r gene r a t o r s e t. P a r t D esc r i p t i on K oh l e r P a r t N o . E ng i ne : A i r F il t e r[...]

  • Page 14

    T P - 5695 12 / 93 G l o ss a r y o f A bb r e v i a t i on s x i Gl o ssa r y o f A bbr ev i a t i on s A bb r e v i a t i on s a r e u s ed t h r oughou t t h i s m anua l . N o r m a ll y i n t he t e x t t he y w ill appea r i n c o m p l e t e f o r m w i t h t he abb r e v i a t i on f o ll o w i ng i n pa r en t he s i s t he f i r s t t i m[...]

  • Page 15

    x ii G l o ss a r y o f A bb r e v i a t i on s T P - 5695 12 / 93 A b b r e v i a t i o n D esc r i p t i on m 3 c ub i c m e t e r , c ub i c m e t e r s m a x . m a x i m u m M C M one t hou s and c i r c u l a r m il s . m i . m il e , m il e s m il one one - t hou s and t h o f an i n c h m i n . m i n i m u m m J m illij ou l e , m illij ou l[...]

  • Page 16

    T P - 5695 12 / 93 S pe c i f i c a t i on s 1 - 1 Sec t i on 1 . S p ec i f i ca t i on s I n t r odu c t i on T he c r a ft i s equ i pped w i t h a dependab l e 1 10 v o l t (r e c onne c t ab l e t o 1 10 / 220 v o l t ) , 50 H z ; o r 120 v o l t (r e c onne c t ab l e t o 120 / 240 v o l t ) , 60 H z s i ng l e - pha s e a l t e r na t i ng c[...]

  • Page 17

    T P - 5695 12 / 93 1 - 2 S pe c i f i c a t i on s G e n e r a t o r 3 . 5 C FZ 5 C FZ R a t ed k W 3 . 5 5 F r equen cy - - H z 50 50 R a t ed V o l t age 1 10 V o l t, 2 & 3 W i r e , S i ng l e P ha s e o r 1 10 / 220 V o l t, 3 W i r e , S i ng l e P ha s e R a t ed A m p s ( 1 10 V o l t ) 31 . 8 45 . 5 R a t ed A m p s ( 220 V o l t ) 15 [...]

  • Page 18

    T P - 5695 12 / 93 S pe c i f i c a t i on s 1 - 3 D E RA T I N G : A ll un i t s a r e r a t ed 1 . 0 po w e r f a c t o r . D e r a t e app r o x i m a t e l y 3 . 5 % pe r 1000 ft. ( 300 m ) abo v e 500 ft. ( 150 m ) abo v e s ea l e v e l . 3 . 5 C FZ , 50 H z : 3 . 5 k W a t 77 ° F ( 25 ° C ) and 3 . 5 k W a t 122 ° F ( 50 ° C ) . 4 C FZ ,[...]

  • Page 19

    T P - 5695 12 / 93 1 - 4 S pe c i f i c a t i on s E ng i n e ( C on t i nu e d ) 3 . 5 C FZ / 4 C Z 5 C FZ / 6 . 5 C Z S pa r k P l ug T y pe R e s i s t o r , R ad i o S upp r e ss i on , 14 mm BP R 4 H S ( N G K ) K oh l e r P a r t N u m be r L92 Y C ( C ha m p i on ) R 43 C F S ( A C - D e l c o ) S pa r k P l ug G ap - - i n . ( mm ) 0 . 028 [...]

  • Page 20

    T P - 5695 12 / 93 S pe c i f i c a t i on s 1 - 5 A ccess o r i es S e v e r a l a cc e ss o r i e s a r e a v a il ab l e t o f i na li z e t he i n s t a ll a t i on o r t o add c on v en i en c e t o ope r a t i on and s e r v i c e . A ll t he m o s t c u rr en t i n f o r m a t i on c an be ob t a i ned b y c on t a c t i ng t he l o c a l au[...]

  • Page 21

    T P - 5695 12 / 93 1 - 6 S pe c i f i c a t i on s S e r v i ce V i e w s T O T A L H O UR S 0 0 0 E 0 0 1 / 10 10 A F U SE BA TT . CHR G . I N P U T 2 9 4 5 36 35 30 29 28 27 26 25 24 23 21 19 33 258000 - D 1 34 S T O P S T A R T 10 17 16 13 12 1 1 14 31 15 18 20 6 7 8 32 3 22 F i gu r e 1 - 1 . S e r v i ce V i e w s (t y p i ca l ) 1 . M i x e r[...]

  • Page 22

    T P - 5695 12 / 93 O pe r a t i on 2 - 1 Sec t i on 2 . O p e r a t i on P r es t a r t C h ecks T o i n s u r e c on t i nued s a t i s f a c t o r y ope r a t i on , t he f o ll o w i ng i t e m s s hou l db e c he ck ed be f o r e ea c h s t a r t - up . BACK F I R E FL A M E ARR ES T O R : A i r c l eane r m u s t be c l ean and p r ope r l y i[...]

  • Page 23

    T P - 5695 12 / 93 2 - 2 O pe r a t i on C on t r o ll e r F o r i den t i f i c a t i on and l o c a t i on o f c on t r o ll e r ope r a t i ng f ea t u r e s , r e f e r t o t he t e x t be l o w and F i gu r e 2 - 1 . 1 . B a tt e r y C h a r g i ng Fu se p r o t e c t s ba tt e r y c ha r g i ng c i r c u i t r y f r o m s ho r t c i r c u i t[...]

  • Page 24

    T P - 5695 12 / 93 O pe r a t i on 2 - 3 S t a r t i ng W ARN I N G E x p l o s i on . G as o li n e va po r s ca n ca u se ex p l o s i on a nd seve r e i n j u r y o r d ea t h . B e f o r e s t a r t i ng gene r a t o r s e t, ope r a t e b l o w e r 4 m i nu t e s and c he ck eng i ne c o m pa r t m en t f o r ga s o li ne v apo r s . N O T E F[...]

  • Page 25

    T P - 5695 12 / 93 2 - 4 O pe r a t i on C i r c u i t P r o t ec t i on AC C i r c u i t B r eake r ( O p t i on a l ) T he op t i ona l A C c i r c u i t b r ea k e r( s ) l o c a t ed on t he f r on t pane l o f t he c on t r o ll e r p r o t e c t t he gene r a t o r ou t pu t w i nd i ng s .I f a l oad c i r c u i t l o s e s po w e r , t he c[...]

  • Page 26

    T P - 5695 12 / 93 O pe r a t i on 2 - 5 H i gh W a t e r T e m p e r a t u r e S hu t do w n S w i t c h T he h i gh w a t e r t e m pe r a t u r e s hu t do w n s w i t c h p r o t e c t s t he eng i ne aga i n s t i n t e r na l da m age i f t he c oo li ng w a t e r t e m pe r a t u r e i n t he eng i ne b l o ck i s t oo h i gh due t o c oo li[...]

  • Page 27

    T P - 5695 12 / 93 2 - 6 O pe r a t i on R e m o t e P a n e l s ( O p t i on a l ) R e m o t e S t a r t P a n e l R e m o t e s t a r t pane l a ll o w s s t a r t i ng - s t opp i ng f r o m a l o c a t i on r e m o t e o f t he gene r a t o r s e t. G ene r a t o r s e t s a r e equ i pped w i t ha6 - p i n c onne c t o r on c on t r o ll e r b[...]

  • Page 28

    T P - 5695 12 / 93 O pe r a t i on 2 - 7 R e m o t e S t a r t a nd Fou r - M e t e r P a n e l K i t A ll o w s s t a r t i ng - s t opp i ng f r o m a l o c a t i on r e m o t e o f t he gene r a t o r s e t. T he ill u m i na t ed gauge s i n c l ude a DC v o l t m e t e r , eng i ne o il p r e ss u r e gauge , w a t e r t e m pe r a t u r e gau[...]

  • Page 29

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 1 Sec t i on 3 . Sc h e du l e d M a i n t e n a n ce U s e t he f o ll o w i ng s e r v i c e sc hedu l e and t he hou r m e t e r on t he c on t r o ll e r t o sc hedu l e r ou t i ne m a i n t enan c e . I n add i t i on t o t he r ou t i ne s e r v i c e s li s t ed i n t h i s m anua l , [...]

  • Page 30

    T P - 5695 12 / 93 3 - 2 S c hedu l ed M a i n t enan c e S e r v i ce S c h e du l e B e f o r e S t a r t i ng A ft e r 20 H r s . o r O n e M on t h E ve r y 50 H r s . o r 3 M on t h s E ve r y 100 H r s . o r 6 M on t h s E ve r y 200 H r s . o r Y ea r l y E ve r y 300 H r s . o r 2 Y ea r s L UBR I CA T I O N SYS T E M C he ck o il l e v e l[...]

  • Page 31

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 3 S e r v i ce S c h e du l e ( C on t i nu e d ) B e f o r e S t a r t i ng A ft e r 20 H r s . o r O n e M on t h E ve r y 50 H r s . o r 3 M on t h s E ve r y 100 H r s . o r 6 M on t h s E ve r y 200 H r s . o r Y ea r l y E ve r y 300 H r s . o r 2 Y ea r s E L E C T R I CA L SYS T E M C [...]

  • Page 32

    T P - 5695 12 / 93 3 - 4 S c hedu l ed M a i n t enan c e Lub r i ca t i on S ys t e m S p ec i f i ca t i on s U s e h i gh qua li t y de t e r gen t o il o f AP I ( A m e r i c an P e t r o l eu m I n s t i t u t e ) s e r v i c e c l a ss S F , S F / CC , o r S F / CD . T h i s i n f o r m a t i on c an be f ound on m o s t o il c on t a i ne r [...]

  • Page 33

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 5 A dd i ng O il It i s no r m a l t o add s o m e o il be t w een o il c hange s . T he a m oun t w ill v a r y w i t h t he u s age . O pen f ill c ap and pou r a s m a ll a m oun t o f o il u s i ng a f unne l o r o t he r s u i t ab l e pou r i ng de v i c e . S ee F i gu r e 3 - 4 . W a i[...]

  • Page 34

    T P - 5695 12 / 93 3 - 6 S c hedu l ed M a i n t enan c e 1 1 - 826 1 . O il F il t e r W r en c h21 / 2 i n . ( 64 mm ) D i a . F i gu r e 3 - 6 . R e m o v i ng O il F il t e r Fu e l S ys t e m S p ec i f i ca t i on s F o r be s t r e s u l t s , u s e on l y c l ean f r e s h , r egu l a r g r ade un l eaded ga s o li ne . U s e f ue l w i t h[...]

  • Page 35

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 7 Fu e l P u m p S c r ee n W ARN I N G E x p l o s i ve f u e l va po r s . C a n ca u se seve r e i n j u r y o r d ea t h . U s e e x t r e m e c a r e w hen hand li ng , s t o r i ng , and u s i ng f ue l s . E x p l o s i ve f u e l va po r s ca n ca u se seve r e i n j u r y o r d ea t h[...]

  • Page 36

    T P - 5695 12 / 93 3 - 8 S c hedu l ed M a i n t enan c e C a r bu r e t o r / C ho ke Lub r i ca t i on T he on l y m a i n t enan c e r equ i r ed i s t o l ub r i c a t e c a r bu r e t o r and c ho k e li n k age a t t he s pe c i f i ed i n t e r v a l u s i ng w h i t e li t h i u m g r ea s e o r l ub r i p l a t e . C a r bu r e t o r A d j[...]

  • Page 37

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 9 I gn i t i on S ys t e m I gn i t i on S ys t e m S e r v i ce T he i gn i t i on sys t e m i s t r an s i s t o r i z ed and b r ea k e r l e ss . U nde r no r m a l c ond i t i on s , on l y t he s pa r k p l ug s need s e r v i c eo na r egu l a r ba s i s . T he e l e c t r on i c i gn i[...]

  • Page 38

    T P - 5695 12 / 93 3 - 10 S c hedu l ed M a i n t enan c e P r ob l e m M ea n s o f I d e n t i f i ca t i on P o ss i b l e C a u se N o r m a l L i gh t t an o r g r a y depo s i t on t he f i r i ng t i p . G ood ope r a t i ng c ond i t i on s and m a i n t enan c e . G a p b r i dg e d D epo s i t s bu il t - up and c l o s i ng gap be t w ee[...]

  • Page 39

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 1 1 1 2 1 . 0 . 028 - - 0 . 031 i n . ( 0 . 7 - - 0 . 8 mm ) G ap 2 . S pa r k P l ug E l e c t r ode s 1 - 514 F i gu r e 3 - 12 . C h eck i ng S p a r k P l ug G a p 1 - 51 1 F i gu r e 3 - 13 . A d j u s t i ng S p a r k P l ug G a p[...]

  • Page 40

    T P - 5695 12 / 93 3 - 12 S c hedu l ed M a i n t enan c e C oo li ng S ys t e m s — C l o se d / H ea t E xc h a ng e r I na c l o s ed c oo li ng sys t e m , t he s ea w a t e r doe s no t c i r c u l a t e t h r ough t he eng i ne bu t c i r c u l a t e s t h r ough s epa r a t e c ha m be r s w i t h i n t he hea t e xc hange r t o c oo l t h[...]

  • Page 41

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 13 1 1 - 828 1 . A i r- B l eed S c r e w ; U s e1 2 mm W r en c h F i gu r e 3 - 14 . A i r - B l ee d S c r e w T O T A L H O UR S 0 0 0 0 0 1 / 10 10 A F U SE S T A R T S T O P BA TT . CHR G . I N P U T 3 2 1 1 . C oo l an t R e c o v e r y T an k 2 . O v e r f l o w H o s e 3 . C oo l an t[...]

  • Page 42

    T P - 5695 12 / 93 3 - 14 S c hedu l ed M a i n t enan c e F l u s h i ng a nd C l ea n i ng If r equ i r ed , f l u s h c oo l an t f r o m gene r a t o r s e t. T o p r ope r l y f l u s h c oo l an t, ob t a i n K i t #267999 and u s e t he f o ll o w i ng p r o c edu r e : W ARN I N G A cc i d e n t a l s t a r t i ng . C a n ca u se seve r e i[...]

  • Page 43

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 15 13 . R e c onne c t ba tt e r y , nega t i v e l ead l a s t. 14 . S t a r t gene r a t o r s e t and a ll o w t he s e t t o r un f o r abou t 20 - - 30 s e c ond s . S t op gene r a t o r s e t and r e c he ck c oo l an t l e v e l b y r e m o v i ng hea t e xc hange r p r e ss u r e c ap[...]

  • Page 44

    T P - 5695 12 / 93 3 - 16 S c hedu l ed M a i n t enan c e A n t i c o rr o s i on Z i n c A n an t i c o rr o s i on z i n c anode i s i n s t a ll ed i n t he hea t e xc hange r t o p r e v en t e l e c t r o l y t i c c o rr o s i on b y s ea w a t e r . W hen d i ff e r en t m e t a l s , s u c h a s i r on and c oppe r , a r e p l a c ed i n a[...]

  • Page 45

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 17 P r ess u r e C a p C l o s ed - l oop c oo li ng sys t e m s i n c o r po r a t e a p r e ss u r i z ed c ap t o r a i s e t he bo ili ng po i n t o f t he c oo l an t and m a k e u s e o f h i ghe r ope r a t i ng t e m pe r a t u r e s . If l ea k age o r m a l f un c t i on o cc u r s ,[...]

  • Page 46

    T P - 5695 12 / 93 3 - 18 S c hedu l ed M a i n t enan c e B a tt e r y T he s t a r t i ng ba tt e r y s hou l d be a 12 - v o l t un i t w i t h a m i n i m u m 250 CC A ( c o l d c r an k i ng A m p s ) a t 0 _ F (- - 18 _ C ) . W hen u s i n ga m a i n t enan c e - f r ee ba tt e r y i t i s no t ne c e ss a r y t o c he ck t he s pe c i f i c [...]

  • Page 47

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 19 ea c h c e ll s hou l d no t e xc eed ± 0 . 01 . T he ba tt e r y s hou l d be c ha r ged i f t he s pe c i f i c g r a v i t y i s be l o w 1 . 215 a t an e l e c t r o l y t e t e m pe r a t u r e o f 80 _ F ( 26 . 7 _ C ) . 10 20 30 40 50 60 70 80 90 100 1 10 120 130 140 150 160 - - 12.[...]

  • Page 48

    T P - 5695 12 / 93 3 - 20 S c hedu l ed M a i n t enan c e V a l ve A d j u s t m e n t W i t h o v e r head c a m eng i ne s , ea c h v a l v e i s s p r i ng - he l d i n t he c l o s ed po s i t i on un t il f o r c ed open b y t he a c t i on o f t he r o ck e r a r m i n c on t a c t w i t h t he c a m s ha ft. R o ck e r a r m s ha v e ad j u[...]

  • Page 49

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 21 1 . “ Y ” M a r k 2 . “ T ” M a r k 2 1 1 - 827 F i gu r e 3 - 22 . D e t e r m i n i ng T op D ea d C e n t e r 1 2 3 1 . F ee l e r G auge 2 . A d j u s t i ng S c r e w 3 mm S qua r e H ead 3 . Lo ck nu t; U s e9 mm W r en c h 1 - 831 F i gu r e 3 - 23 . V a l ve A d j u s t m e [...]

  • Page 50

    T P - 5695 12 / 93 3 - 22 S c hedu l ed M a i n t enan c e G o ve r no r T he gea r- d r i v en c en t r i f uga l t y pe go v e r no r s e r v e s t o k eep eng i ne s peed c on s t an t b y au t o m a t i c a ll y ad j u s t i ng t he a m oun t o f f ue l s upp li ed t o t he eng i ne a cc o r d i ng t o c hange s i n l oad . Lub r i ca t i on Lu[...]

  • Page 51

    T P - 5695 12 / 93 S c hedu l ed M a i n t enan c e 3 - 23 W a tt a g e R e qu i r e m e n t s If t he r a t ed c apa c i t y o f t he gene r a t o r s e t i s e xc eeded , t he c i r c u i t b r ea k e r l o c a t ed on t he c on t r o ll e r w ill t r i p t o p r o t e c t t he gene r a t o r aga i n s t da m age . T r i pp i ng c ou l d be c au [...]

  • Page 52

    T P - 5695 12 / 93 3 - 24 S c hedu l ed M a i n t enan c e S t o r a g e P r o ce du r e It i s r e c o mm ended t ha t t he c r a ft be a f l oa t w hen t he gene r a t o r s e t i s p r epa r ed f o r s t o r age s i n c e t he eng i ne m u s t be s t a r t ed . 1 . A dd f ue l s t ab ili z e r t o f ue l t an k . U s e r e c o mm enda t i on s o[...]

  • Page 53

    T P - 5695 12 / 93 T r oub l e s hoo t i ng 4 - 1 Sec t i on 4 . T roub l es hoo t i ng W hen t r oub l e s o cc u r , do no t o v e r l oo k s i m p l e c au s e s . A s t a r t i ng p r ob l e m , f o r e x a m p l e , c ou l d be c au s ed b y i m p r ope r f ue l o r an e m p t y f ue l t an k . T he f o ll o w i ng c ha r t s li s t s o m e c [...]

  • Page 54

    T P - 5695 12 / 93 4 - 2 T r oub l e s hoo t i ng E ng i n e ( C on t i nu e d ) P r ob l e m P o ss i b l e C a u se C o rr ec t i ve A c t i on S t op s s udd e n l y O u t o f f ue l R ep l en i s h S t o p s s u d d e n l y A i r i n t a k e c l ogged C l ean F u s e b l o w n i n c on t r o ll e r R ep l a c e f u s e D e f e c t i v e s ea w [...]

  • Page 55

    T P - 5695 12 / 93 T r oub l e s hoo t i ng 4 - 3 E ng i n e ( C on t i nu e d ) P r ob l e m P o ss i b l e C a u se C o rr ec t i ve A c t i on O ve r h ea t s I m p r ope r c oo li ng C he ck i n t a k e and ou t l e t open i ng s . C he ck c oo l an t l e v e l and p r e ss u r e c ap . C he ck r a w w a t e r s t r a i ne r . T he r m o s t a [...]

  • Page 56

    T P - 5695 12 / 93 4 - 4 T r oub l e s hoo t i ng G e n e r a t o r P r ob l e m P o ss i b l e C a u se C o rr ec t i ve A c t i on N o AC ou t pu t C i r c u i t b r ea k e r i n O FF po s i t i on R e s e t b r ea k e r t o O N po s i t i on N o A C o u t p u t C i r c u i t b r ea k e r t r i pped due t o o v e r l oad on gene r a t o r s e t R[...]

  • Page 57

    T P - 5695 12 / 93 W i r i ng D i ag r a m s 5 - 1 Sec t i on 5 . W i r i ng D i a gr a m s T H E R M A L S W I T CH BA TT E R Y V O L T M E T E R W A T E R T E M PE R A T UR E G A U G E O I L P R ESS UR E G A U G E W A T E R T E M P . SE ND E R H O UR M E T E R A N T I - - D I ESE L S O L E N O I D CH O KE F U E L P U M P S T A R T E R M O T O R F[...]

  • Page 58

    5 - 2 W i r i ng D i ag r a m s T P - 5695 12 / 93 FOR AMPERAGE RATING SEE OWNERS MANUAL CIRCUIT BREAKERS 220 V. CONN ECTION L0 GRD 4 3 2 1 LO (NEUTRAL) GRD L1 BC 72 37 8N 45 73 71 5 2 4 9 15 20 22 21 19 BC 14 8 3 1 L1 GRD LO 1 2 3 4 L2 GRD L0 120/240 V. CONNECTIO N GRD LO 1 2 3 4 L2 GRD CIRCUIT BREAKERS 75 8N P6 N 73 3 4 2 1 CIRCUIT BOARD HOT CHOK[...]

  • Page 59

    T P - 5695 12 / 93 W i r i ng D i ag r a m s 5 - 3 Elec t ro Swi t c h L1 L2 T o G ene r a t o r S e t T o S ho r e P o w e r T o Load 2 - W i r e G e n e r a t o r S e t s L1 L2 T o G ene r a t o r S e t T o S ho r e P o w e r T o Load 2 - W i r e G e n e r a t o r S e t s 2 - W i r e G e n e r a t o r S e t s K r a u s N ai m le r / A m e r ica n[...]

  • Page 60

    5 - 4 W i r i ng D i ag r a m s T P - 5695 12 / 93 Fou r - L ea d R ec onn ec t a b l e ( S i ng l e - P h ase ) G e n e r a t o r S e t s W h e r e G e n e r a t o r O u t pu t C a n B e R ec onn ec t e d Fo r 120 v o l t o r 120 / 240 v o l t , 60 H z , 1 10 v o l t o r 1 10 / 220 v o l t , 50 H z N O T E W hen a gene r a t o r s e t i s r e c on[...]

  • Page 61

    T P - 5695 12 / 93 W i r i ng D i ag r a m s 5 - 5 120/240 - or 1 10/220 - V o l t C on f i gur a t i on - - F i gur e 5 - 6 J u m pe r l ead no t u s ed . If un i t w a s o r i g i na ll y w i r ed f o r s t r a i gh t 120 o r 1 10 v o l t, be s u r e j u m pe r l ead i s r e m o v ed ( s ee F i gu r e 5 - 6 f o r l o c a t i on ) . Lead s L1 and [...]

  • Page 62

    6[...]

  • Page 63

    T P - 5695 12 / 93 I n s t a ll a t i on 6 - 1 Sec t i on 6 . I n s t a ll a t i on I n t r odu c t i on U s e t h i s s e c t i on a s a gu i de w hen i n s t a lli ng t he M a r i ne gene r a t o r s e t, t hen r e f e r t o S e c t i on 2 . O pe r a t i on f o r s pe c i f i c s e r v i c e i n s t r u c t i on s . R e li ab l e and s a f e gene[...]

  • Page 64

    T P - 5695 12 / 93 6 - 2 I n s t a ll a t i on C apab ili t i e s w ill v a r y a cc o r d i ng t o K il o w a tt D e r a t i ng f o ll o w i ng . M o t o r R e qu i r e m e n t s ( H P ) S t a r t i ng ( I n - R u s h ) W a tt s R unn i ng W a tt s 1 / 4 750 330 1 / 3 1000 400 1 / 2 1500 600 3 / 4 2000 750 1 3300 1 100 2 4000 2000 3 5000 3000 F i [...]

  • Page 65

    T P - 5695 12 / 93 I n s t a ll a t i on 6 - 3 T O T A L H O UR S 0 0 0 0 0 1 / 10 10 A F U SE BA TT . CHR G . I N P U T N O T E U s e t w o ho s e c l a m p s on ea c h end o f a ll f l e x i b l e e x hau s t ho s e c onne c t i on s . * I nd i c a t ed c o m ponen t s m u s t c on f o r m t o U . S . C . G . R egu l a t i on s . 4 * 5 6 7 8 * 9 [...]

  • Page 66

    T P - 5695 12 / 93 6 - 4 I n s t a ll a t i on Lo ca t i on G e n e r a l C on s i de r t he f o ll o w i ng i n s e l e c t i ng o r c on s t r u c t i ng a gene r a t o r s e t l o c a t i on . C o m pa r t m en t/ l o c a t i on m u s t a ll o w adequa t e s pa c e f o r v en t il a t i on , c oo li ng and e x hau s t sys t e m i n s t a ll a t [...]

  • Page 67

    T P - 5695 12 / 93 I n s t a ll a t i on 6 - 5 Fu e l S ys t e m s Fu e l S upp l y G ene r a t o r s e t s , i n m o s t c a s e s , m u s t d r a w f ue l f r o m t he s a m e t an k a s t he p r opu l s i on eng i ne s . If t he t an k ’ s f ue l p i ck up open i ng a ll o w s , a m u l t i p l e d i p t ube a rr ange m en t ( F i gu r e 6 - 6[...]

  • Page 68

    T P - 5695 12 / 93 6 - 6 I n s t a ll a t i on A n t i - S i phon P r o v i s i on s A n t i - s i phon de v i c e s m u s t be i n s t a ll ed i f an y s e c t i on o f f ue l li ne li e s be l o w t he h i ghe s t po i n t o f t he f ue l t an k . T he an t i - s i phon de v i c e s hou l d be e i t he r a s p r i ng - l oaded c he ck v a l v e ([...]

  • Page 69

    T P - 5695 12 / 93 I n s t a ll a t i on 6 - 7 C oo li ng S ys t e m s G e n e r a l T he f o ll o w i ng f ea t u r e s a r e ne c e ss a r y i n t he c oo li ng sys t e m . A n i n t ake t h r u - hu ll s t r a i n e r ( s ea c o ck c o v e r) m u s t be sc r eened t o p r e v en t en t r y o f f o r e i gn ob j e c t s and m u s t no t be a li g[...]

  • Page 70

    T P - 5695 12 / 93 6 - 8 I n s t a ll a t i on A sea w a t e r s t r a i n e r o f s u ff i c i en t c apa c i t y s hou l d be m oun t ed t o t he s ea c o ck o r pe r m anen t s t r u c t u r e a t a po i n t no t h i ghe r t han t he s ea w a t e r pu m p . T he s t r a i ne r s hou l d be a cc e ss i b l e f o r s e r v i c i ng . S ee F i gu r[...]

  • Page 71

    T P - 5695 12 / 93 I n s t a ll a t i on 6 - 9 T O T A L H O UR S 0 0 0 0 0 1 / 10 10 A F U SE BA TT . CHR G . I N P U T N O T E U s e t w o ho s e c l a m p s on ea c h end o f a ll f l e x i b l e e x hau s t ho s e c onne c t i on s . 1 . E x hau s t M an i f o l d 2 . 3 ft. ( 1 m ) M a x . 3 . E ng i ne - D r i v en S ea w a t e r P u m p 4 . H[...]

  • Page 72

    T P - 5695 12 / 93 6 - 10 I n s t a ll a t i on Lo c a t e t he e x hau s t ou t l e t a t l ea s t 4 i n . ( 10 c m ) abo v e t he w a t e r li ne w hen t he c r a ft i s l oaded t o m a x i m u m c apa c i t y . U s ua ll y a f l appe r i s i n s t a ll ed a t e x hau s t ( t r an s o m ) ou t l e t t o p r e v en t w a t e r ba ck up i n f o ll [...]

  • Page 73

    T P - 5695 12 / 93 I n s t a ll a t i on 6 - 1 1 A bo ve W a t e r li n e I n add i t i on t o c on s i de r a t i on s de sc r i bed ea r li e r , a c u s t o m e r- s upp li ed s il en c e r s hou l db e i n s t a ll ed w i t h i t s ou t l e t a t a m a x i m u m o f 10 ho r i z on t a l ft. ( 3 m ) f r o m t he c en t e r o f t he eng i ne ’ [...]

  • Page 74

    T P - 5695 12 / 93 6 - 12 I n s t a ll a t i on A t y p i c a l s il en c e r s hou l db e m oun t ed no m o r e t han 4 ft. ( 1 . 2 m ) be l o w t he h i ghe s t po i n t i n t he e x hau s t li ne . A tt a c ha s epa r a t e w ood m oun t i ng ba s e t o hu ll s t r i nge r s o r o t he r s u i t ab l e s t r u c t u r e . T hen s e c u r e t he [...]

  • Page 75

    T P - 5695 12 / 93 I n s t a ll a t i on 6 - 13 i s o l a t o r o r i s o l a t i on t r an s f o r m e r i s r e f e r en c ed i n ABY C E - 8 . 20 and ABY C E - 8 . 1 1 . G ene r a t o r s e t s i n s t a ll ed i n c o mm e r c i a l v e ss e l s a r e go v e r ned b y U . S . C oa s t G ua r d R egu l a t i on s , T i t l e 46 , t he A m e r i c[...]

  • Page 76

    T P - 5695 12 / 93 6 - 14 I n s t a ll a t i on R e m o t e S t a r t S w i t c h C onn ec t i on K oh l e r o ff e r s s e v e r a l r e m o t e pane l s f o r c onne c t i on t o t he gene r a t o r s e t. S ee A cc e ss o r i e s f o r f u r t he r de t a il ed de sc r i p t i on . A w i r i ng ha r ne ss w i t ha c onne c t o r k e y ed t o t h[...]

  • Page 77

    T P - 5695 12 / 93 I n s t a ll a t i on D r a w i ng s 7 - 1 Sec t i on 7 . I n s t a ll a t i on D r a wi ng s ADV -5792-D VIEW A- -A MOUNTING P ATTER N EQUIV ALENT . ARE MILLIMETER DIMENSIONS IN ( ) NOTE: WITH HUSH COVER. 5/6.5 SUPPLIED ST ANDARD WITH HEA T EXCHAN GER WA TER- -COO LED IGNITIO N PROTECTED 4/6.5KW 60HZ. GASOLINE MARINE 3.5/5KW 50H[...]

  • Page 78

    T P - 5695 12 / 93 7 - 2 I n s t a ll a t i on D r a w i ng s ADV -5792-D A A VIEW A- -A KIT # 267994 (4 PIECE C OVER). SOUND SHIELD SE RVICE WITH SOUND SHIELD. 5/6.5KW SUPPLIED ST ANDARD MILLIMETER EQUIV . DIMENSIONS IN ( ) ARE NOTE: 31.07 (789) 1 . 75 ( 44 ) 8 . 67 ( 220 ) 12 . 82 ( 326 ) 3.12 DIA. (79) EXHAU ST OUTLET OPENING 1.92 (49) 1.57 (40)[...]

  • Page 79

    T P - 5695 12 / 93 P a r t s O r de r i ng I n s t r u c t i on s 8 - 1 Sec t i on 8 . Pa r t s O rd e r i ng I n s t ru c t i on s F o r s e r v i c e o r i n f o r m a t i on , c he ck t he y e ll o w page s o f t he t e l ephone d i r e c t o r y unde r t he head i ng G E N E R A T O R S - - E L E C T R I C o r c on t a c t t he l o c a l m a r [...]

  • Page 80

    T P - 5695 12 / 93 O pe r a t i ng H ou r S e r v i c e Log 9 - 1 Sec t i on 9 . O p e r a t i ng H our Se r v i ce Log T he f o ll o w i ng i s p r o v i ded t o he l p y ou k eep a c u m u l a t i v e r e c o r d o f ope r a t i ng hou r s on y ou r gene r a t o r s e t and t he da t e s r equ i r ed s e r v i c e s w e r e pe r f o r m ed . E n [...]

  • Page 81

    T P - 5695 12/93 P R I N T E D I N U .S . A . K O H L ER C O. K O H L ER , W I SC O NS I N 53044 PH O NE 414 - 565 - 3381 F AX 414 - 459 - 1646 ( N o r t h A m e r i c an S a l e s ), 414 - 459 - 1614 (I n t e r na t i ona l ) F O R SA L ES & SER V I CE I N U . S . A . & CANADA P H O NE 1 - 800 - 544 - 2444[...]