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TP-5695 12/93

Troubleshooting 4-1

Section 4. Troubleshooting

When troubles occur, do not overlook simple causes. A
starting problem, for example, could be caused by
improper fuel or an empty fuel tank. The following charts
list some common problems. If procedures in this
manual do not explain how to correct the problem, take

the

generator

set

authorized

service

dealer/distributor. Tell the dealer exactly what happened
when the problem occurred and of any adjustments
made to the set.

Engine

Problem

Possible Cause

Corrective Action

Unit will not crank

Weak or dead battery

Recharge or replace battery

Unit will not crank

Reversed or poor battery connections.
Poor ground.

Check connections

Fuse blown in controller

Replace fuse

Defective start/stop switch

Check function, replace as necessary.

Defective starter solenoid

Check starter solenoid and wiring. Replace
as necessary.

Defective starter

Attempt starting by direct connection to
battery. Replace/repair as necessary.

Unit cranks but will
not start

Out of fuel

Replenish

Unit cranks but will
not start

Clogged fuel screen

Clean fuel screen

not start

Faulty antidieseling solenoid

Replace solenoid

Air intake clogged

Clean or replace

Faulty spark plug(s)

Replace (and regap) spark plug(s)

Loose spark plug connection

Reconnect wires

Faulty ground (--) connection

Clean and retighten

Carburetor adjustment wrong

Adjust carburetor

Defective electric fuel pump

Check pressure. Replace as necessary.

Shorted or open ignition coil

Replace coil

Weak or dead battery

Recharge or replace

Bad fuel mixture

Replace fuel; clean carburetor

Flooded carburetor

Wait a few minutes and attempt restart

Engine malfunction

See authorized Kohler service
dealer/distributor

Engine starts, but
does not continue to

No generator output voltage

Check AC voltage

Engine starts, but
does not continue to
run after start switch

No/low oil pressure

Check oil pressure and pump

does not continue to
run after start switch
is released

Defective low oil pressure (LOP) safety
shutdown switch

Check LOP shutdown switch

High temperature shutdown

Check cooling system

Defective high exhaust temp. (HET) and/or
high water temp. (HWT) safety shutdown
switch(es)

Check HET and/or HWT shutdown
switch(es)

Hard starting

Stale or bad fuel

Replace fuel

Hard starting

Fuel vapor lock

Check fuel line routing

Faulty spark plug(s)

Replace (and regap) plug(s)

Weak ignition coil

Replace

Carburetor adjustment wrong

Adjust carburetor

Air intake clogged

Clean

Содержание 3.5CFZ, 4CZ, 5CFZ, 6.5CZ

Страница 1: ...Operation and Installation Manual Marine Generator Sets Models 3 5CFZ 4CZ 5CFZ 6 5CZ TP 5695 12 93...

Страница 2: ...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...

Страница 3: ...d Mixing Elbow 3 17 Servicing Air Cleaner 3 17 Servicing Mixing Elbow 3 17 Battery 3 18 Cleaning 3 18 Checking Electrolyte Level 3 18 Checking Specific Gravity 3 18 Charging 3 19 Valve Adjustment 3 20...

Страница 4: ...ed HAZARDOUS VOLTAGE ELECTRICAL SHOCK WARNING Hazardous voltage Do not operate generator set without all guards and electrical enclosures in place Moving rotor Can cause severe injury or death Hazardo...

Страница 5: ...side moor your craft so that the exhaust discharges on the lee side the side sheltered from the wind and always be mindful of others make sure your exhaust is directed away from other boats and occupi...

Страница 6: ...t in hazardous spattering of electrolyte Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flame or spark to occur near a battery at any time parti...

Страница 7: ...be taken when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Do not store gasoline in any occupied building Explosive fuel vapors can cause...

Страница 8: ...re injury or death Additional Precautions Regarding Sound Shield Equipped Models Some scheduled maintenance procedures require the generator set to be running while performing service If the sound shi...

Страница 9: ...r use a proper container to catch all fuel A sudden backfire can cause severe injury or death Do not operate with backfire flame arrestor removed A sudden backfire can cause severe injury or death Do...

Страница 10: ...s on bolt head and nuts for proper identification NOTE When a fuse replacement is required be sure fuse has the same ampere rating and is the same type for example ABC or 3AB ceramic Do not substitute...

Страница 11: ...Second Street S W Washington DC 20593 0001 Boating Safety Hotline 1 800 368 5647 American Bureau of Shipping Rules for Building and Classing Steel Vessels 45 Eisenhower Drive Paramus N J 07652 201 36...

Страница 12: ...DC 20402 1 202 783 3238 American Bureau of Shipping ABS 65 Broadway New York NY 10006 Order ABS publications from American Bureau of Shipping Book Order Section 45 Eisenhower Drive P O Box 910 Paramus...

Страница 13: ...or dealer distributor for a complete 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...

Страница 14: ...mpany cont d continued C S A Canadian Standards Association cu in cubic inch cubic inches cyl cylinder dBA decibels DC direct current DCR direct current resistance deg degree dept department dia diame...

Страница 15: ...not required OC overcrank OD outside diameter OEM original equipment manufacturer OS overspeed oversize OV overvoltage oz ounce ounces Abbreviation Description PF power factor pot potentiometer ppm pa...

Страница 16: ...tification and location of components Specifications General Specifications 3 5CFZ 5CFZ Dimensions L x W x H in mm 27 87 x 17 50 x 16 60 708 x 445 x 422 31 07 x 18 10 x 17 50 789 x 460 x 445 with Soun...

Страница 17: ...o Pole Rotating Field Voltage Regulation 5 Frequency Regulation 5 Angular Operation Max in all directions 20 Continuous Excitation Method Brushless Exciter Winding Capacitor Coupling Type Tapered Shaf...

Страница 18: ...3 5CFZ 10 7 5CFZ 60 Hz 12 8 4CZ 12 8 6 5CZ RPM 50 Hz 3000 3 5CFZ 3000 5CFZ 60 Hz 3600 4CZ 3600 6 5CZ Bore x Stroke in mm 2 28 x 2 68 58 x 68 Valve Material Steel Alloy JIS SUH3 Valve Clearance in mm...

Страница 19: ...1 2 Ignition Timing B T D C 24 2 degrees Exhaust Manifold to Cylinder Head Torque 16 ft lbs 22 Nm Water Pump Assembly to Cylinder Block Torque 7 ft lbs 10 Nm Cooling Fan Torque 16 ft lbs 22 Nm Air Cle...

Страница 20: ...rice list or dealer distributor for proper application of circuit breakers Model Amps Poles 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 Remo...

Страница 21: ...arger Voltage Regulator 12 Coolant Overflow Hose 13 Cooling System Pressure Cap 14 High Water Temperature Safety Shutdown Switch 15 Thermostat 16 High Exhaust Temperature Shutdown Switches 2 17 Spark...

Страница 22: ...uel leaks fumes exhaust gases or electrical sparks are noted arrange for qualified personnel to make necessary repairs before operating generator set FUEL LEVEL Make sure the fuel tanks are full and t...

Страница 23: ...ch automatically returns to neutral center position when released 4 Hourmeter records total generator set operating hours Use as a reference to schedule maintenance 5 Remote Start Connector provides c...

Страница 24: ...to follow these guidelines may result in burn out of the starter motor from overheating If the engine fails to start after the first attempt close the seacock before a second start up attempt This ac...

Страница 25: ...e fuses for ceramic fuses If ampere rating is unknown or questionable see Wiring Diagram WARNING Accidental starting Can cause severe injury or death Disconnect battery cables before working on genera...

Страница 26: ...ART STOP BATT CHRG INPUT 258000 D 1 hidden 1 High Water Temperature Shutdown Switch Figure 2 3 High Water Temperature Shutdown Switch High Exhaust Temperature Shutdown Switches The two high exhaust te...

Страница 27: ...nd a water temperature gauge Generator sets come equipped with a 6 pin connector on controller bottom for connection of the kit See Figure 2 6 for remote start and meter panel kit 1 2 4 3 1 Engine Oil...

Страница 28: ...op the generator set DC Voltmeter measures voltage of starting battery ies Normal battery operating range is 12 14 volts Engine Oil Pressure Gauge measures engine oil pressure Normal engine operating...

Страница 29: ...hnician are essential While it is not possible to anticipate component failure rough operation metallic noises and excessive oil loss are among the indicators of potential problems Do not ignore these...

Страница 30: ...es X IGNITION SYSTEM Replace spark plugs X COOLING SYSTEM Check coolant level X Check seawater outlet X During Operation Inspect exhaust system components for cracks and corrosion exhaust manifold mix...

Страница 31: ...specific gravity Batteries with filler caps only X Clean battery cables X ENGINE AND MOUNTING Check for leakage of water fuel or oil X X Lubricate governor linkage X Break in Period X Retighten all m...

Страница 32: ...sing other than the appropriate service class oil or extended oil change intervals could cause engine damage which is not covered by the engine warranty Do not mix oils of different viscosities It is...

Страница 33: ...l filter by turning in a counterclockwise direction Oil filter is 2 1 2 in 64 mm dia with 14 flutes Use oil filter wrench if necessary See Figure 3 6 Use rags to handle hot oil filter and clean up spi...

Страница 34: ...nd corrosion inhibitors for methanol Never use gasoline containing more than 5 methanol even if it has cosolvents and corrosion inhibitors NOTE Fuel system damage and engine performance problems resul...

Страница 35: ...building The electric fuel pump includes a screen See Figure 3 7 At the recommended interval or when clogging is suspected inspect and clean the screen as follows 1 Shut off fuel flow to electric fuel...

Страница 36: ...screw in until engine instability hunting develops and then screw out until engine instability is again apparent Turn screw back in until it is positioned halfway between the points of increasing sta...

Страница 37: ...or terminal 2 Where possible use compressed air to remove dirt from around each spark plug before removal This procedure will prevent dirt particles from falling into combustion chamber Loosen spark...

Страница 38: ...bluish burnt appearance on electrodes Engine overheating wrong type of fuel loose spark plugs too hot a plug low fuel pump pressure or incorrect ignition timing Replace plug Worn Severely eroded or wo...

Страница 39: ...TP 5695 12 93 Scheduled Maintenance 3 11 1 2 1 0 028 0 031 in 0 7 0 8 mm Gap 2 Spark Plug Electrodes 1 514 Figure 3 12 Checking Spark Plug Gap 1 511 Figure 3 13 Adjusting Spark Plug Gap...

Страница 40: ...turn it slowly counterclockwise to the first stop After pressure has been completely released and the engine has cooled remove cap If generator set is equipped with a coolant recovery tank check coola...

Страница 41: ...ew TOTAL HOURS 0 0 0 0 0 1 10 10A FUSE START STOP BATT CHRG INPUT 3 2 1 1 Coolant Recovery Tank 2 Overflow Hose 3 Coolant Pressure Cap 258000 D Figure 3 15 Coolant Pressure Cap TOTAL HOURS 0 0 0 0 0 1...

Страница 42: ...anger pressure cap MUST be installed 5 Turn on water supply to flush coolant from engine block Turn off water supply when clean water is observed coming from hose in bucket 6 Disconnect garden hose Pl...

Страница 43: ...ssure cap Repeat this step until coolant can no longer be added This procedure should give an approximate mixture of 50 ethylene glycol and 50 water 15 Wipe up spilled coolant and water with rags Disp...

Страница 44: ...and use the following procedure TOTAL HOURS 0 0 0 0 0 1 10 10A FUSE START STOP BATT CHRG INPUT 1 Heat Exchanger 2 Anticorrosion Zinc 2 1 258000 D Figure 3 17 Removing Anticorrosion Zinc 1 With generat...

Страница 45: ...erial has hardened or deteriorated Install the reed valve with the valve downward into the mounting base Install retaining cap and tighten finger tight only Do NOT overtighten Air Cleaner and Mixing E...

Страница 46: ...y compartment containing batteries must be well ventilated to prevent accumulation of explosive gases To avoid sparks do not disturb battery charger connections while battery is being charged and alwa...

Страница 47: ...s 1 243 The temperature correction amounts to about 004 4 points of specific gravity for each10 F 5 5 C change intemperature Correction 1 787 Figure 3 21 Specific Gravity Temperature Correction NOTE S...

Страница 48: ...seawater pump b Remove two screws to release seawater pump bracket c Remove housing enclosing ignition coil d Remove seawater pump from camshaft pulley e Remove timing belt cover belt guard NOTE To re...

Страница 49: ...Scheduled Maintenance 3 21 1 Y Mark 2 T Mark 2 1 1 827 Figure 3 22 Determining Top Dead Center 1 2 3 1 Feeler Gauge 2 Adjusting Screw 3 mm Square Head 3 Locknut Use 9 mm Wrench 1 831 Figure 3 23 Valv...

Страница 50: ...ry 60 Hz generator sets are designed to operate at 60 63 Hz 3600 rpm under full load and 3780 rpm under no load 50 Hz generator sets are designed to operate at 50 52 5 Hz 3000 rpm under full load and...

Страница 51: ...ain after being reset see a qualified electrician For more information regarding generator set capacity see Installation Generator Selection and Wattage Requirements Generator Service General Under no...

Страница 52: ...s 3a c were performed to replace seawater with antifreeze omit steps 4a c 4 Close seacock and drain all seawater out of cooling system a Drain seawater from strainer and seawater pump b Remove zinc an...

Страница 53: ...ng solenoid Replace solenoid Air intake clogged Clean or replace Faulty spark plug s Replace and regap spark plug s Loose spark plug connection Reconnect wires Faulty ground connection Clean and retig...

Страница 54: ...Check HET and HWT shutdown switch es Loss of AC output See authorized Kohler service dealer distributor Faulty antidieseling solenoid Replace solenoid Lacks power Air intake clogged Clean Lacks power...

Страница 55: ...on Battery will not charge Loose or corroded connections Clean and tighten connections Battery will not charge Sulfated or worn out battery Check electrolyte level and specific gravity batteries with...

Страница 56: ...rop in Engine speed too low Adjust governor Low output or excessive drop in voltage Generator overloaded Reduce load See Wattage Requirements voltage Engine in poor condition If routine services are p...

Страница 57: ...N TIME DELAY RELAY C1 2 1 B1 P1 3 P1 6 B2 12V VR1 K5 K1 LED1 R1 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 1 HR 5A D...

Страница 58: ...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 1 2 3 L1 B2 B1...

Страница 59: ...merican Solenoid Newer Round Design 2 1 3 4 6 5 7 8 1 2 6 5 3 4 8 7 L1 L2 To Generator Set To Shore Power To Load 3 2 4 1 7 6 8 5 L1 L2 To Generator Set To Shore Power To Load 3 Wire Generator Sets 2...

Страница 60: ...of the number of phase black leads used in the application both circuit breakers must have leads attached to the load side It is recommended that jumper lead be maintained for all straight 120 or 110...

Страница 61: ...or 110 volt be sure jumper lead is removed see Figure 5 6 for location Leads L1 and L2 are different phases and must never be connected together 4 3 2 1 Stator Leads LO GRD L2 L1 LO Neutral Load Side...

Страница 62: ...6...

Страница 63: ...ers distributors Lighting Load The lighting load is usually easiest to calculate In most cases simply add the wattage of each lamp to be operated off the generator set Note that in many applications n...

Страница 64: ...loads to avoid overloading of a set The average power requirements of some common electrical appliances are given in Figure 6 3 Kilowatt Derating Units are rated as listed below at 1 0 power factor D...

Страница 65: ...lations 4 5 6 7 8 9 10 11 STOP START 258000 D 2 1 13 14 12 3 1 Heat Exchanger 2 Siphon Break See Instruction Sheet TT 927 for Proper Installation 3 Exhaust Mixer 4 Engine Driven Seawater Pump 5 Exhaus...

Страница 66: ...so to allow downward pitch of the exhaust line For angular installation the maximum operation angle of the engine generator set is 20_ in all directions Ventilation Ventilation is required to support...

Страница 67: ...l shutoff valve is required This fuel shutoff valve should be closed when the generator is not in use to prevent fuel leakage resulting from fuel flow through the fuel pump and into the carburetor sho...

Страница 68: ...bing must be used The flexible section necessary to allow vibrational motion of the generator set during operation must be U S C G TYPE A HOSE marked and tagged according to Regulations Metallic line...

Страница 69: ...ke thru hull strainers A sea chest is a concave molded in the hull chamber that is also aligned to the direction of travel A sea chest configuration applies a positive pressure similar to a scoop type...

Страница 70: ...eration The hose should have an inside diameter of 3 4 in 19 mm Copper line should be supported within 4 in 102 mm of its connection to the flexible section NOTE A 5 8 in 16 mm waterline hose can be s...

Страница 71: ...installations The hose used for the lines should have a 2 in 51 mm inside diameter Keep the lines as short and straight as possible The use of two hose clamps on each end of flexible exhaust hose con...

Страница 72: ...ine DO NOT OVERLOAD CRAFT so as to close or restrict exhaust discharge hole 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 connec...

Страница 73: ...in Figure 6 19 1 2 3 1 Mounting Base 2 Retaining Cap 3 Reed Valve Assembly 1 779 Figure 6 18 Siphon Break Components The siphon break must be located at least 1 foot above the waterline at maximum ves...

Страница 74: ...localities A ship to shore transfer switch must be installed to prevent interconnection of generator set power and shore power AC connections to generator set are made inside the controller box The g...

Страница 75: ...d be sized to match the larger of the engines two battery cables Cable sizes for generator set battery connections are given in Figure 6 20 This requirement prevents the starting motor current from us...

Страница 76: ...ee Figure 6 22 NOTE If gauges are to be used there must also be generator set senders Senders are optional on these generator sets Gauges and senders are available as service items from an authorized...

Страница 77: ...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...

Страница 78: ...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 USI...

Страница 79: ...VICE IN U S A CANADA PHONE 1 800 544 2444 A major service manual and parts catalog may be ordered through an authorized Kohler service dealer distributor When ordering state MODEL and SPEC numbers fro...

Страница 80: ...ervice Log The following is provided to help you keep a cumulative record of operating hours on your generator set and the dates required services were performed Enter hours to the nearest quarter hou...

Страница 81: ...P 5695 12 93 PRINTED IN U S A KOHLER CO KOHLER WISCONSIN 53044 PHONE 414 565 3381 FAX 414 459 1646 North American Sales 414 459 1614 International FOR SALES SERVICE IN U S A CANADA PHONE 1 800 544 244...

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