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1. spes yeys jou seop yng 30219 Yue o you suiojdui AS 26 Section 4 Troubleshooting Section 5 Wiring Diagrams WARNING KS Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator setasfollows 1 Placethe generator setstart stop switch in the STOP position 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch TP 5985 10 02 WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installati
2. ii Section 1 Service VIEWS 2 2 22 ee eee ees 1 Section2 Operation A RR be eG RG eee tee 3 2 1 PrestartiCheckliSt dico re 3 2 2 Marine Inspection 3 2 3 Angular Operation 3 2 4 Operation in European Union Member Countries 4 2 5 Exercising the Generator Set 4 2 6 Starting and Stopping 4 2 6 1 Controls and Indicators 4 2 6 2 Starting the Generator 5 2 6 3 Remote Panel Gauge 5 2 6 4 Stopping the Generator 5 Section 3 Scheduled 7 3 1 General Maintenance 7 3 2 Service Schedule u uns en wet bes bode eee Wey Ed ada 8 3 3 Lubrication System 10 3 3 1 Oil Specifications 10 332 Oil CHECK RP hie Uere nd ol quet et 10 3 39 OMACGITIONS a been 10 3 34 Ol Ghiange i oh
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4. 10 3 85 Oil Filter Change 11 34 0 ceu seem ede 12 3 4 1 Fuel Specifications sso a ed 12 3 4 2 Lubrication 12 3 4 3 Carburetor Adjustment 12 3 5 Backfire Flame Arrestor 13 3 6 Exhaust System nn een ner ren 13 3 72 Cooling System curo IR do abate Cede seus 14 3 7 1 Closed Heat Exchanger 14 3 7 2 Pressure Caps css opos ERE 14 373 gt 5 uber ee Ea E EHE RES 15 34 4 Siphon Break A 16 3 75 Anticorrosion Zinc 18 37 6 Seawater Outlet A E RES 18 3 8 Ignition System xps ae bes dude 19 3 9 Balto tas tans omis eae bau seine epus huma Shape EA M teur 21 3 10 Generator Storage 22 Section 4 Troubleshooting 22 I RAM eee ee IR ge 23 Section 5 Wiring Diagrams 27 Appendix A Abbreviations A 1 Appendix B Operating Hour Service 00
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6. A 3 Table of Contents TP 5985 10 02 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 5985 10 02 Accidental Starting A WARNING KS x Accidental sta
7. National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier S Sec second SI Systeme international d unites Int
8. OPTIONAL a 10 INSULINK 1 WIS OPTIONAL MARINE ONLY OPTIONAL MOBILE ONLY MARINE ONLY BATTERY TIA P4 4 V R A4P P4 12 BCP P4 22 MP P4 11 4 P4 12 y BCP Pa 20 Paca 71 MOBILE ONLY 4 1 PIN N P9 CONNECTIONS CHTR 2 70 INSULINK1 J13 CONNECTIONS LCS P4 8 LOS Pa 1 INSULINK 1 PIN 37 12 37 BC 70 a7 2 sol ro Figure 5 2 Point to Point Wiring Diagram TP 5985 10 02 GENERATOR LEGEND ADS ANTI DIESEL SOLENOID BV BATTERY VOLTMETER CHTR CHOKE HEATER D f DIODE EBG ENGINE BLOCK GROUND F 4 FUSE FP FUEL PUMP GND CONTROLLER BOX GROUND HET HIGH ENGINE TEMPERATURE SWITCH HR HOURMETER IGN IGNITION Jf CONNECTOR JACK K1 AC CRANK DISCONNECT RELAY K2 ENGINE START RUN RELAY ENGINE CRANK RELAY Ka FAULT SHUTDOWN RELAY K5 FAULT SHUTDOWN TIME DELAY RELAY K6 CRANK INTERLOCK RELAY 98 P10 3 44 P10 4 11 2 gt 5 81 11 1 re pii 9 EN P11 4 F2 P10 2 1 10 1 FOR VOLT RECONNECTABLE CONFIGURATIONS SEE ADV 5857 K20 STARTER SOLENOID RELAY LCS LOSS OF
9. Position the side electrode directly over the center electrode 20 Section 3 Scheduled Maintenance TP 5985 10 02 3 9 Battery Consult the battery manufacturer s regarding battery care and maintenance instructions WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid TP 5985 10 02 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge stati
10. Reed valve Figure 3 8 Siphon Break m sm 003 007 TP 5985 10 02 Waterline TP 5586 3 Mounting base 12 Seawater strainer Retaining cap 13 Seacock Reed valve assembly 14 Intake strainer Silencer vertical lift 1 2 m 4 ft max 15 Engine driven seawater pump Exhaust mixer elbow distance above waterline If less than 16 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min 23 cm 9 in siphon break is required 17 Water lock optional Siphon break distance above waterline 30 5 cm 1 ft min 18 Silencer distance from exhaust mixer elbow 3 m 10 ft max Siphon break 19 Silencer customer supplied Exhaust mixer elbow 20 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min Heat exchanger locations vary by model 21 Exhaust outlet distance above waterline 10 cm 4 in min Coolant recovery tank 22 Seawater outlet Locate coolant recovery tank at same height as heat exchanger Figure 3 9 Siphon Break Plastic U Type Installation Note Consult the installation manual for complete explanation of dimensions and other installation considerations TP 5985 10 02 Section 3 Scheduled Maintenance 17 3 7 5 Anticorrosion Zinc Anode The heat exchanger on these models contains an anticorrosion zinc anode plug to prevent electrolytic corrosion by seawater Check and replace the anticorrosion zinc anode at intervals recommended in the service schedu
11. seacock closed 22 Section 3 Scheduled Maintenance 8 10 11 12 13 14 15 Check the coolant level of the heat exchanger and add coolant if necessary Note Use antifreeze capable of withstanding the lowest possible temperatures Drain fuel completely from the fuel tank Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs Seal the air inlet exhaust pipe and fuel tank cap with tape Disconnect and remove the battery Place the battery in a warm dry location for the storage period Recharge the battery once a month to maintain a full charge Select a well ventilated not humid or dusty location to store the generator Cover the entire unit with a dust cover Note Run the generator set once a month whenever possible TP 5985 10 02 This section contains generator set troubleshooting diagnostic and repair information Use the following chart as a quick troubleshooting reference The table groups generator set faults and suggests likely causes and remedies The table also refers you to more detailed information including sections of this manual the generator set service manual S M the generator set installation manual 1 M and the engine service manual Engine S M to correct the indicate
12. the compartment and the generator set clean and free of debris to minimize the risk of fire Wipe up spilled fuels and engine oil l Safety Precautions and Instructions Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others
13. 91 104 C 195 219 F DC voltmeter 12 14 volts 50 Hz models show a slightly lower pressure range 2 6 4 Stopping the Generator Set The following table describes the actions required to stop the generator set Step Action Cooldown Run generator set at no load for 5 minutes to ensure adequate engine cooldown Stopping Place controller start stop switch or remote start stop switch in the stop position and wait until the generator set comes to a complete stop Fuel shut off valve Close the manual fuel shut off valve if equipped Section 2 Operation 5 Notes 6 Section 2 Operation TP 5985 10 02 3 1 General Maintenance WARNING KS Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator setasfollows 1 Placethe generator setstart stop switch in the STOP position 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the gene
14. Ibm ft pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm MQ milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg mounting A 2 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT pp PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code
15. Maintenance 19 5 Clean spark plugs by wiping them with a rag File the center electrode to keep it parallel to the side electrode Note Do not sandblast wire brush scrape or otherwise service spark plug in poor condition Obtain a new plug for best results 6 Check the spark plug gap before installing any spark plug See Figure 3 13 Attain a correct gap when the feeler or wire passes between the spark plug electrode It should pass easily but with some resistance or drag otherwise adjust as necessary The correct gap is 0 6 0 7 mm 0 024 0 028 in Figure 3 14 Spark Plug Gap Adjustment 8 Reinstall the spark plug Do not bump the electrode against the cylinder head Rotate the spark plug clockwise until feeling resistance 9 Use a torque wrench to torque each spark plug to 12 17 Nm 9 12 ft lbs Otherwise hand tighten spark plug until feeling resistance 10 Use a ratchet wrench to final tighten an additional 1 4 turn Do not overtighten as doing so may strip threads or alter electrode gap setting 11 Check spark plug wire connector in boot for accumulated dirt grease and other debris and clean as necessary 1 0 6 0 7 mm 0 024 0 028 in gap 2 Spark plug electrodes Figure 3 13 Spark Plug Gap Inspection 12 Firmly push spark plug boot onto spark plug 7 Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap See Figure 3 14
16. components as necessary 8 Lubricate the gasket with silicon grease and attach the gasket and coverplate to the seawater pump housing 9 Open the seacock 10 Start the generator set and check for leaks 11 Stop the generator set and repair leaks or replace damaged or worn components m sm 003 008 Section 3 Scheduled Maintenance 15 3 7 4 Siphon Break A siphon break prevents seawater entry into the generator set s engine when the engine exhaust manifold outlet is less than 230 mm 9 in above the waterline of a fully loaded docked or stationary craft See Figure 3 9 The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater Use the following procedure to inspect the siphon break at the intervals listed in the service schedule Siphon Break Inspection 1 Stop the generator set 2 Remove the retaining cap and remove the reed valve for inspection See Figure 3 8 3 Use a mild detergent to remove residue and oxidation from the reed valve 4 Clear blockage from the reed valve opening 5 Replace the siphon break if the reed valve is cracked or if the reed valve material has hardened or deteriorated 16 Section 3 Scheduled Maintenance 6 Install the reed valve into the mounting base with the valve downward See Figure 3 8 item 3 7 Install and only finger tighten the retaining cap Do not overtighten it 1 Mounting base 2 Retaining cap 3
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18. schedule and the Section 3 3 5 procedure in Fill crankcase with oil Section 1 shows the oil fill location See Figure 3 1 for oil selection and Figure 3 3 for oil capacity Replace the oil fill cap Start the generator set and check for oil leaks Stop the generator set Check the oil level Add oil as necessary to bring the level up to the Full mark Note Too high an oil level causes high oil consumption and engine carbonizing Too low a level damages the engine Note Do not pollute the environment Dispose of used engine oil and other contaminants in a safe approved manner TP 5985 10 02 3 3 5 Oil Filter Change Replace the oil filter at the interval specified in the service schedule Change the oil filter more frequently if the generator set operates under dirty dusty conditions Refer to the following procedure See Section 1 for oil filter location Oil Filter Change Procedure 1 Loosen the oil filter by turning it counterclockwise Remove the oil filler and use rags to clean up spilled oil Dispose of the oil filter in an approved manner Clean the contact surface of the oil filter adapter Lightly lubricate the gasket surface of the new filter with fresh engine oil Thread the filter on the adapter until the gasket makes contact and hand tighten the filter an additional one half turn Wash hands after any contact with engine oil Note If also performing an oil change skip steps 4 a
19. set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks x 0p 001 005 2 6 Starting and Stopping Procedure Note Opening seacock Before starting the generator set open the seacock to allow cooling water passage Failure to do so could damage the seawater pump impeller and cause serious engine overheating damage Note Transfer switch Check that the marine ship to shore transfer switch if equipped is in the ship position Note Close seacock if engine fails to start If the engine fails to start after the first attempt close the seacock before the next starting attempt Failure to close the seacock may cause seawater to enter the exhaust piping silencer and or engine water filled exhaust piping and silencer may further hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valve Water ingested into the engine may cause major engine damage that the Kohler Co warranty does not cover Note Close seacock if water enters the exhaust system f water enters the exhaust system close the seacock and drain the water from the exhaust system atthe silencer s drain plug before attempting to start the generator set If excessive cranking is a chronic problem have the unit including the exhaust system serviced by an author
20. 2 remove the hose from the water filter outlet 3 fill the hose and seawater pump with clean water 4 reconnect the hose to the water filter outlet and 5 open the seacock Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet 2 2 Marine Inspection Kohler Co recommends that all boat owners have their vessels especially the exhaust system attached to the generator set inspected at the start of each boating season by the local Coast Guard Auxiliary If there is no Coast Guard Auxiliary in the area contact an authorized Kohler distributor dealer for the inspection m op 001 003 2 3 Angular Operation See Figure 2 1 for angular operation limits for units covered in this manual Intermittent Continuous 3 minutes or less 25 30 Maximum value for all directions Figure 2 1 Angular Operation m op 001 004 Section 2 Operation 3 2 4 Operation in European Union Member Countries This generator set is specifically intended and approved for operation below the deck in the engine compartment Operation above the deck and or outdoors would constitute a violation of European Union Directive 2000 4 EC noise emission standard 2 5 Exercising the Generator Set Operate the generator set under load once each week for one hour with an operator present The operator should perform all of the prestart checks before starting the exercise procedure Start the generator
21. 6002 359979 Service Manual Supplement Engine TP 6008 Spark Plug For Engine Model BS 04 Spray Paint White Touch Up Paint White NGK BPR4ES 221335 GM19490 223316 267928 Voltage Regulator Fuse 10 amp Zinc Anode Figure 1 Maintenance and Service Parts x in 001 004 ii Maintenance and Service Parts Related Literature One manual combines Generator and Engine information Figure 2 Generator Set Literature x in 001 005 TP 5985 10 02 Section 1 Service Views SERVICE VIEW m ENGINE END VIEW ADV 6395 A GY 250000 A Electric choke on carburetor 18 Anticorrosion zinc anode Carburetor choke linkage 19 Seawater drain remove plate Spark plugs also one on nonservice side 20 Seawater pump water inlet Oil fill 21 Cooling air inlet Overflow tube 22 Mixing elbow water outlet exhaust outlet nonservice side Pressure cap coolant fill location after draining coolant 23 Fuel feed pump fuel inlet Controller 24 Oil check Start Stop switch 25 Coolant drain remove hose clamp to drain coolant 26 Oil drain valve 27 Lube oil filter 28 Antidieseling solenoid on carburetor 29 Air intake silencer backfire flame arrestor 30 Coolant overflow bottle daily coolant check fill location
22. 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 X in 008 001a Introduction i Maintenance and Service Parts Related Literature Maintenance and Service Parts Figure 1 identifies maintenance and service parts for your generator set Obtain a complete list of maintenance and service parts from your authorized generator distributor dealer List of Related Literature Figure 2 identifies related literature available for the generator sets covered in this manual Only trained and qualified personnel should install or service the generator set Part Description Part Number Literature Type Part Number Battery Charging Fuse 25 amp 262389 Installation Manual TP 5982 Input Fuse 10 amp 223316 Operation Manual Generator TP 5985 Oil Filter 359771 Operation Manual Engine TP 6001 Seawater Pump Impeller Kit 359978 Parts Catalog TP 5987 Spark Plug 359796 Service Manual Generator TP 5986 For Engine Model AS 04 BMR6A Service Manual Engine TP
23. COOLANT SWITCH LOP LOW OIL PRESSURE SWITCH M STARTER MOTOR OPG OIL PRESSURE GAUGE OPS OIL PRESSURE SENDER P PLUG P CONNECTOR PLUG SM STARTER MOTOR SR STARTER RELAY MARINE ONLY SS STARTER SOLENOID MOBILE ONLY SSS STOP START SWITCH E VADJ VOLTAGE ADJUST WTG WATER TEMPERATURE GAUGE WTS WATER TEMPERATURE SENDER POINT TO POINT CODE LEAD NUMBER DEVICE TO POSITION ON DEVICE 359343 F Section 5 Wiring Diagrams 29 Notes 30 Section 5 Wiring Diagrams TP 5985 10 02 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cc CCA ccw CEC cfh cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supp
24. Full and Add marks on the dipstick as shown in Figure 3 2 See Section 1 Service Views for the dipstick location 10 Section 3 Scheduled Maintenance 1 Full mark 2 Add mark Figure 3 2 Oil Level Check Note Do not operate the set if the oil level is below the Add mark on the dipstick or above the Full mark on the dipstick 3 3 3 Oil Additions Adding some oil between oil changes is normal The amount varies with generator set usage Open the oil fill cap and pour in a small amount of oil using a funnel or other suitable pouring device See Section 1 Service Views for the oil check and oil fill locations 3 3 4 Oil Change Change the oil according to the service schedule or before generator set storage Change the oil more frequently if the generator set operates under dirty dusty conditions Change the oil while the engine is still warm See Figure 3 3 for oil capacity See Section 1 Service Views for oil fill oil check and oil filter locations Model All models L Qts 1 36 1 44 Figure 3 3 Oil Capacity with Filter TP 5985 10 02 Oil Change Procedure 1 2 10 Stop the generator set To drain the oil open the oil drain valve See Section 1 for the valve location Drain the oil into a suitable container Allow ample time for all oil to drain Close the oil drain valve Remove the oil fill cap Replace the engine oil filter according to the service
25. ILE ONLY 5 CHARGING V COIL Os j LCS INSULINK 1 IGNITER PIN 1 SIT AI C Yer fa NS 97 EAT VA VA TENEN 70 gu Noy EY BATTERY CHARGING REGULATOR 1 P2 CONNECTIONS coso aso P1 CONNECTIONS 12 Bi 71 24 8 11 1 K20 86 FP 113 B2 011 2 NC 70 J4 13 N NC NIC FN J11 4 NIC J11 CONNECTIONS PO 37 4 5 PIN 1 Bt P1 3 B2 P1 6 70 HM FP P1 5 2 3 4 37 70 112 2 P3 4 FN P1 12 47 SSS 43 658 P11 CONNECTIONS N SSS P3 5 3 6 N 3 1 J4 CONNECTIONS 5 P3 2 P3 3 K20 30 P1 18 Pi K20 87 PIN 1 14 14 11 87 2 4 N K20 85 8 87 85 J4 4 VOLTAGE REGULATOR De LULU Y Ser FN ES Ly n vas STAB 2 B J10 CONNECTIONS PIN BLK WHT P10 CONNECTIONS PINE 1 2 2 333 444 5 55 F3 6N C YEL RED ORG GRY F1 P1 8 GND TX 43 P2 5 mio m Li LINE SEE GENERATOR CONNECTIONS P4 3 OPS
26. Note Consult installation drawings in Spec Sheet or Installation Manual for fuel and battery connection points oo oNOUPOD Nameplate top AC load lead connector nonservice side Input fuse Battery charging fuse AC circuit breaker Remote start connector nonservice side Voltage regulator fuse Hourmeter Note Consult distributor dealer or Service Manual for items Heat exchanger not shown LE L L LX ck 24 1 NOOR WON O Figure 1 1 Service Views TP 5985 10 02 Section 1 Service Views 1 Notes 2 Section 1 Service Views TP 5985 10 02 2 1 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Inlets Check for clean and unobstructed air inlets Air Shrouding Check for securely installed and positioned air shrouding Backfire Flame Arrester Check for a clean and installed backfire flame arrester to prevent unfiltered air from entering the engine Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Exhaust System Check for exhaust leaks and blockages Check the silencer and piping c
27. OP LOW OIL PRESSURE SWITCH M STARTER MOTOR OPG OIL PRESSURE GAUGE OPS OIL PRESSURE SENDER P PLUG P CONNECTOR PLUG SM STARTER MOTOR SR STARTER RELAY MARINE ONLY SS STARTER SOLENOID MOBILE ONLY SSS STOP START SWITCH VADJ VOLTAGE ADJUST WTG WATER TEMPERATURE GAUGE WTS WATER TEMPERATURE SENDER VOLTAGE REGULATOR PB 3E BERS ORG GRY BLK WHT ver 0 1 P10 2 y Fi F2 FP AP11 3 Schematic Wiring Diagram 359343 F TP 5985 10 02 REMOTE PANEL OPTIONAL BACK VIEW OF PANEL 2 AND 4 GAUGE REMOTE PANEL UT BLUE CONTROLLER P3 CONNECTIONS PIN N P2 9 5 4 2 7C 4 3 70 P2 3 PIN 1 YEURED VIOLET 47 P2 7 43 P2 8 N Ja LK 47 5 7 jt rer 3 J12 CONNECTIONS GREY BLK NOTE CONNECTOR SHOWN FROM PIN INSERTION END 4 P HALON OPTIONAL PIN N GRD 2 37 P2 2 70 HM F1 PIN 1 ENGINE P4 CONNECTIONS PN 013 4 5 WTS 7C 5 SR OR SS 37 LCS g G 13 2 24 SR OR SS SR OR SS INSULINK 1 CHTR SR OR SS Ni tar p M PG 15 7887 7877 78 78 78 TO KAWASAKI ENGINE HARNESS 37 INSULINK 2 MOB
28. Operation Marine Generator Sets Models 5E 4EF 7 3E 6EF ISO KOHLER POWER SYSTEMS NATIONALLY REGISTERED KOHLER POWER SYSTEMS TP 5985 10 02d California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number x in 007 001 Table of Contents Product Identification Information Inside front cover Safety Precautions and Instructions Introduction tii ne re ADR a TN RC RU i Service Assistance ccce coils e Rag a i Maintenance and Service Parts Related Literature
29. TP 5985 10 02 Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Installing the fuel system Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Do not modify the tank or the propulsion engine fuel system Equip the craft with a tank that allows one of the two pickup arrangements described in the installation section The tank and installation must conform to USCG Regulations Pipe sealant Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Use pipe sealanton all threaded fittings to prevent fuel leakage Use pipe sealant that resists gasoline grease lubrication oil common bilge solvents salt deposits and water Ignition protected equipment Explosive fuel vapors can cause severe injury or death Gasoline vapors can cause an explosion USCG Regulation 33CFR183 requires thatall electrical devices ship to shore transfer switch remote start panel etc must be ignition protected when used in a gasoline and gaseous fueled environment The electrical devices listed abov
30. a eui eonpeu euiBu3 W s 8u3 4 uoisseJdujoo eui 2949 yesm uoisseJduio 2 uonoes juaWaje 191 11 ay eoejde1 Jo 1y Uonoeuuoo eui pue UeE D uonoeuuoo 4 G M 40 W S YOUMS eAnejedour y eoejdeu eAneJedout y9 iMs JejeM YBIH w s piouejos Jeueis Jo Jeueijs eAneJedout piouejos 1euejs 1euels G M 10 W S USD uoyMs eAnejedoui eui eoejdeu eAneJedout youms 1sneuxe uBiH 2 uonoes eui 100use qnoJi pue SAYIJIMS 1eseH UMOpINys 4 G M eui 01 12euuoo81 UA s 10j9euuoo sseujeu ay 10euuoosiq 1451 paxoo jou s 1019euuoo sseujeu S S uonoes Bulges WOO jeeus oeds y leyeq au eoe dei Jo Jo uonoeg juBn pue ueejo 4931109 suonoeuuoo fuepmeq y Py JO esoo suonoeuuoo leeg x x JO suonoy sosne ajqeqoid esiou euJouqe 10 uonduunsuoo Jen eunsseJd sjesyla
31. bling higher operating temperatures If the cap leaks replace it with a cap ofthe same rating Find the pressure cap rating in Figure 3 5 TP 5985 10 02 3 7 3 Seawater Pump The direct driven seawater pump is located on the generator end of the generator set Check and change the seawater pump impeller at the interval specified in the service schedule Follow the instructions included with the impeller kit If the instructions are not included with the kit use the following procedure Impeller Inspection and Replacement Procedure 1 Close the seacock 2 Remove the seawater pump coverplate See Figure 3 6 3 Remove the impeller 4 Inspectthe impeller for damaged cracked broken missing or flattened vanes The impeller vanes should be straight and flexible See Figure 3 7 Replace the impeller if it is damaged Seawater pump Coverplate Gasket 7 Pulley 8 Drive shaft 9 Washer 10 Nut 11 Mechanical seal if equipped Impeller Bearing Housing Figure 3 6 Seawater Pump Typical TP 5985 10 02 1 Flattened vane 2 Crack 3 Broken vane Figure 3 7 Worn Impeller 5 Lubricate the impeller with soapy water before installation 6 Install the impeller Note During installation push and rotate the impeller in the same direction as the engine rotation until it is thoroughly seated in the impeller housing 7 Inspect the coverplate and gasket for corrosion and or damage Replace
32. c electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Section 3 Scheduled Maintenance 21 3 10 Generator Storage Procedure Keep the craft afloat for generator operation during the storage procedure Follow the procedure below when storing your generator set for a long period 3 months or more 1 Connect the hose to the seacock Start and run the generator set until it reaches operating temperature or about 15 minutes Stop the generator set Change the oil and oil filter see Section 3 3 4 Oil Change and Section 3 3 5 Oil Filter Change Close the seacock and remove the hose at the seacock Place the hose in a container having approximately 3 7 7 5 L 1 2U S gallons of coolant antifreeze Kohler Co recommends using an environmentally friendly potable antifreeze such as Peak RV marine propylene glycol water mix or equivalent With a suitable container at the exhaust outlet run the generator set until coolant discharges at the exhaust outlet or until depleting the coolant mixture Do not allow coolant mixture to flow into waterways Stop the generator set Leave the
33. d problem Corrective action and testing often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service distributor dealer perform service TP 5985 10 02 Section 4 Troubleshooting NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown or questionable Maintain a record of repairs and adjustments performed on the equipment If the procedures in this manual do not explain how to correct the problem contact an authorized distributor dealer Use the record to help describe the problem and repairs or adjustments made to the equipment x gt 001 002a Section 4 Troubleshooting 23 w s eui SIY uuojied jepeep 4o01nquisip 398S ue 1 32945 oeds s s enue enuey uoejed o 4W O enuen uone eisu W 195 5 ues YMS 6 v jenueuu sy jo uonoes 9 y jeuuou juejooo ay 8 101594 JUe OOD
34. e are not ignition protected and are not certified to operate in a gasoline and gaseous fueled environment such as an engine room or near fuel tanks Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Electrical Shock WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increa
35. encer and piping condition and check for tight exhaust system connections e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed e Ensure that the carbon monoxide detector is 1 in the craft 2 functional and 3 energized whenever the generator set operates Section 3 Scheduled Maintenance 13 3 7 Cooling System 3 7 1 Closed Heat Exchanger In a closed cooling system the seawater circulates through separate chambers within the heat exchanger to cool the engine water The seawater then mixes with engine exhaust and ejects out the exhaust outlet See Figure 3 4 for coolant capacity include coolant recovery tank capacity of 0 8L 0 85 qts See Figure 3 5 for thermostat and pressure cap ratings Model All models L Qts 2 84 3 0 Figure 3 4 Coolant Capacity WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure C
36. ernational System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s Sq square sq cm square centimeter Sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 5985 10 02 Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed Enter hours to the operating hours on your generator set and the dates nearest quarter h
37. hecking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure fromthe cooling system before removing the pressure cap To release pressure coverthe pressure cap with athick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released andthe engine has cooled Checkthe coolant level atthe tank if the generator set has a coolant recovery tank NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Checking and Filling Coolant Maintain the coolant level in coolant recovery tank at approximately 1 4 full Before filling the cooling system close all petcocks and tighten all hose clamps Use a solution of 5096 ethylene glycol and 5096 clean softened water to inhibit rust corrosion and prevent freezing Add additional coolant as necessary to the coolant recovery tank Periodically check the coolant level on closed systems by removing the pressure cap Do not rely solely on level in coolant recovery tank Add fresh coolant until the level is just below the overflow tube opening 14 Section 3 Scheduled Maintenance Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until engine has cooled Note Coolant solution A coolant solution of 50 et
38. hylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F A coolant solution with less than 5096 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 5096 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Consult the engine manufacturer s operation manual for engine coolant specifications 5 7E 96 5 kPa 14 psi 71 C 160 F Pressure Cap Rating Thermostat Rating Figure 3 5 Pressure Cap and Thermostat Rating Procedure for Flushing and Cleaning Cooling System For optimum protection drain flush and refill the cooling system at the interval listed in the service schedule Pay special attention to the coolant level After the coolant drains allow time for complete refill of the engine water jacket Check the coolant level as described earlier 1 Remove the hose clamp at the coolant hose See Section 1 for location of the hose 2 Remove the pressure cap to make draining easier 3 Drain clean and flush the coolant recovery tank 4 Flush the system with clean water 5 Replace the hose clamp to secure the coolant hose 6 Fill the system with the recommended coolant 7 Replace the pressure cap 3 7 2 Pressure Cap Closed heat exchanger systems utilize a pressure cap to raise the boiling point of the coolant ena
39. ice Log Use the Operating Hour Service Log located in the back of this manual to document performed services Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set For example an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months 300 hours or 9 months and so on x sm 004 001 Perform Service at Intervals Indicated X Reference Section Before Starting After 50 Hrs or 1 Month Every 100 Hrs or 3 Months Every 300 Hrs or 6 Months Every 500 Hrs or Yearly FUEL SYSTEM Check the fuel level and fill as necessary 2 1 X Lubricate carburetor and choke linkage 3 4 2 X 200 hrs Check fuel lines and replace as necessary LUBRICATION SYSTEM Check crankcase oil level and add as necessary 3 3 2 X X Replace the oil in crankcase 3 3 4 X 20 hrs break in period Replace the lube oil filter element COOLING SYSTEM Check coolant level and fill as necessary 3 7 1 X 20 hrs X break in 200 hrs period X Check seawater outlet and clean as necessary 3 7 6 X during operation 3 7 4 Check function of siphon break if equipped 3 7 3 Replace seawater pump impeller Check heat exchanger anticorrosion zinc condition 3 7 5 Replace heat exchanger anticorrosion zinc 3 7 5 Flush cooling syste
40. itical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft ft lbs ft min 9 gal gen genset GFI GND gov gph gpm gr GRD gr wt fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hou
41. ized Kohler distributor dealer 4 Section 2 Operation Note Starter motor cooldown Do not crank the engine continuously for more than 10 seconds at a time Allow a 60 second cooldown period between cranking attempts if the engine does not start If the unit fails to start after 3 attempts contact an authorized Kohler distributor dealer for repair Failure to follow these guidelines may result in starter motor burnout The following table describes the allowable cranking time Cranking Attempts Seacock Cranking Position Time Open up to 10 seconds Close up to 10 seconds Close up to 10 seconds Allow a 60 second cooldown period between cranking attempts If the units fails to start after 3 attempts contact an authorized Kohler distributor dealer for repair Once unit is running immediately open the seacock 2 6 1 Controls and Indicators The following table describes the controls and indicators located at the controller Name Description Start Stop Switch Use switch to start and stop the generator set Press the switch to the START position to start generator set Press the switch to the STOP position to stop the generator set AC Circuit Breaker optional Circuit breaker trips when a fault occurs in the output circuit During maintenance of craft wiring the circuit breaker disconnects the generator set Place the circuit breaker s in the ON position to close circui
42. lace a damaged flame arrestor Use only USCG approved Kohler replacement parts Follow the procedure described below Backfire Flame Arrestor Cleaning Procedure 1 Loosen the hose clamp at the breather hose at the air silencer fitting and remove the hose 2 Loosen the hose clamp attaching the air silencer assembly to the carburetor 3 Lift off the air silencer assembly 4 Clean the assembly in evaporative solvent and wipe clean Allow to dry 5 Reassemble using the reverse sequence TP 5985 10 02 3 6 Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the crafts occupants install a carbon monoxide detector Consult the boat builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times Atthe interval specified in the service schedule inspect the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper for cracks leaks and corrosion Exhaust System Inspection Points Check for exhaust leaks and blockages Check the sil
43. le Depending upon operating conditions and seawater properties the anticorrosion zinc anode may require more frequent replacement See Section 1 Service Views for location and use the following procedure Anticorrosion Zinc Anode Replacement Procedure 1 With the generator set cooled close the seacock remove the anticorrosion zinc plug from the heat exchanger and drain the coolant into a suitable container 2 Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode Replace the anode according to Figure 3 10 and Figure 3 11 Anticorrosion Zinc Anode Replacement Replace When New Anode Percent of Zinc Models Dimensions mm in Remaining Is 5 7 3E and lt 50 of 4 6EF 9 0 34 x 43 1 7 length diameter Figure 3 10 Anticorrosion Zinc Anode Plug Measurements 18 Section 3 Scheduled Maintenance 1 Diameter 9 mm 0 34 in 2 Length 48 mm 1 7 in Figure 3 11 Anticorrosion Zinc Anode Plug 3 Clean the threaded hole of the heat exchanger and coat the threads of the anticorrosion zinc anode plug with pipe sealant suitable for marine applications Install the anticorrosion zinc anode into the heat exchanger 4 Open the seacock Refill the cooling system 5 Start the generator set and check for leaks at the anticorrosion zinc anode location The pump is operating if cooling water flows from the exhaust outlet If water is not discharging at the exhaust o
44. lied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute TP 5985 10 02 CG CID CL cm CMOS cogen Com conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port connection continued chlorinated polyvinyl chloride cr
45. losive gases Safety Precautions and Instructions Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING 7 d 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Servicing the backfire flame arrester A sudden backfire can cause severe injury or death Do not operate the generator set with the backfire flame arrester removed Combustible materials A sudden flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the fuel system Keep
46. ls to prevent rounding of the bolt heads and nuts Annual Inspection Kohler Co recommends that all boat owners have their vessels especially the exhaust system attached to the generator set inspected at the start of each boating season by their local Coast Guard Auxiliary Ifthere is no Coast Guard Auxiliary in the area contact an authorized Kohler distributor dealer for the inspection See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized distributor dealer perform generator set service Section 3 Scheduled Maintenance 7 Engine Service Perform generator set engine service at the intervals specified by the engine operation manual Generator Set Service Perform generator set service at the intervals specified by the generator set operation manual If the generator set operates under dusty or dirty conditions use dry compressed air to blow dust out of the alternator With the generator set running direct the stream of air in through the cooling slots atthe alternator end Routine Maintenance Refer to the following generator set service schedule the engine service schedule and 3 2 Service Schedule the hourmeter located on the generator set controller to determine when to schedule routine maintenance Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions Serv
47. m 3 7 1 IGNITION SYSTEM Clean and regap spark plugs 3 8 400 hrs X Replace spark plugs 3 8 Requires removal of sound shield if installed Consult your local distributor dealer for service 8 Section 3 Scheduled Maintenance TP 5985 10 02 Service Schedule continued Perform Service at Intervals Indicated X Reference Section Before Starting After 50 Hrs or 1 Month Every 100 Hrs or 3 Months Every 300 Hrs or 6 Months Every 500 Hrs or Yearly INTAKE EXHAUST SYSTEM Inspect exhaust system components Check the exhaust gas condition x during operation Service backfire flame arrestor X Clean the exhaust water mixing elbow X 200 hrs Check the crankcase breather pipe for obstructions Inspect the complete exhaust system ELECTRICAL SYSTEM Keep battery charged and in good condition Check and tighten electrical connections Clean battery cables X 200 hrs ENGINE AND MOUNTING Check for water fuel coolant and oil leakage Retighten all nuts and bolts Check tightness of mounting bolts vibromounts X 200 hrs Check and adjust valve clearance Clean combustion chamber REMOTE CONTROL SYSTEM Check remote control operation 2 6 3 TEST in period X GENERATOR Test run generator set Blow dust out of generator Requires remo
48. nd 5 and go back to oil change procedure Start the generator set and check for oil leaks Stop the generator set Check oil level Add oil as necessary to bring level up to Full mark Section 3 Scheduled Maintenance 11 3 4 Fuel System 341 Fuel Specifications Use a clean good quality unleaded fuel with an octane number of 87 Use fresh gasoline to ensure itis blended for the season and to reduce the possibility of the formation of gum deposits that could clog the fuel system Do not use gasoline left over from the previous season Kohler Co recommends unleaded fuel because it leaves fewer combustion chamber deposits Never mix oil with fuel Note Consult the engine owner s manual for oxygenated fuel recommendations 12 Section 3 Scheduled Maintenance 3 4 2 Carburetor Choke Lubrication At the interval specified in the service schedule lubricate the carburetor and choke linkage using a light oil See Section 1 for the linkage s location 3 4 3 Carburetor Adjustment The carburetor is factory set possible No adjustments are TP 5985 10 02 3 5 Backfire Flame Arrestor At the interval specified in the service schedule inspect clean or replace the backfire flame arrestor Clean the arrestor more frequently if the generator set operates in dirty dusty conditions Check the mesh element for accumulated oil or dirt that could clog the element and cause poor performance See Section 1 for location Rep
49. ng Wet black deposits on the insulator shell bore and electrodes Problem Condition Gap bridged spark plug Oil fouled spark plug Carbon fouled spark plug Black dry fluffy carbon deposits on insulator tips exposed shell surfaces and electrodes Incorrect spark plug weak ignition clogged air intake defective fuel pump overrich fuel mixture or excessive no load operation Clean and regap the spark plug Lead fouled spark plug Dark gray black yellow or tan deposits or a glazed coating on the insulator tip Caused by highly leaded fuel Replace the spark plug Preignition damaged spark plug Melted electrodes and possibly blistered insulator Metallic deposits on insulator suggest internal engine damage Wrong type of fuel incorrect timing or advance too hot a plug burned valves or engine overheating Replace the spark plug Overheated spark plug White or light gray insulator with small black or gray brown spots with bluish burned 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 the spark plug Worn spark plug Severely eroded or worn electrodes Figure 3 12 Engine Evaluation Using Spark Plug Condition TP 5985 10 02 Caused by normal wear and failure to replace spark plug at prescribed interval Replace the spark plug Section 3 Scheduled
50. no Jewod sx9e7 1ndino JO ON Ja uwajs s 891119913 sueis yeys jou seop yng syuelD yueso seoq swojdwAs Section 4 Troubleshooting 25 TP 5985 10 02 goes siu uuoped Jepeep 1ojnquisip pezuouine ue 1 weu erg BuulW Q M 3eeus eds s s enuen 391MSS N S enuen uonej ed o 4W O enuen uomneleisu W I 38S 1 c ues Buy YAMS 1eJsueJ oneulogny S v siy jo uonoes peuequinu uomnoeS 98S x TP 5985 10 02 eu 104 ejqeyns Ay soos n e asf y JO palloou ed eseoxueJo yojims 407 eui eAneJedout yoyms 407 eunsseJd 0 eui xoeuo UMOpinus eJnsseJd MOT SXee JO jos joedsu 0 eui eJojseH IIO W S Ue Joye nba ay urbe swo q ayy esny eui soeldeH eBeyoA W S Uan eBeyoA ay 1sn fpy jo 1no eDeyoA 4 sjueuoduJoo esoo ue1ui W S uan 4 J0Je s ay eoe deJ Jo pue 159 pepunoi6 10 uedo
51. on at the beginning of this manual Keep this manual with the equipment for future reference Introduction The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe prescribed intervals Obtain service from authorized service distributor dealer to keep equipment in top condition Before installing a marine generator set obtain the most current installation manual from your local distributor dealer Only qualified persons should install the generator set x in 001 002 a Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPowerSystems com e Lookatthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Africa Europe Middle East London Regional Office Langley Slough England Phone 44 1753 580 771 Fax 44 1753 580 036 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 TP 5985 10 02 China North China Regional Office Beijing Phone
52. on to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Section 5 Wiring Diagrams 27 SCHEMATIC CRANKING BATTERY SR OR 55 lt 2 2 37 lt J12 2 P13 3 HET 37 o gt AY ks R3 P1 13 e lt 5 D45A Ma 1 7 Po P1 10 Pp D31A e4K20 AP4 18 __ P4 14 2 lt gt 9 2 P9 1 Figure 5 1 28 Section 5 Wiring Diagrams BATTERY CHARGING COIL BATTERY CHARGING SENSE VOLTAGE REGULATOR ac GND B2 B 1 FN 4P11 4 P11 2 A 11 1 YELo LEGEND ADS ANTI DIESEL SOLENOID BV BATTERY VOLTMETER CHTR CHOKE HEATER D DIODE EBG ENGINE BLOCK GROUND F FUSE FP FUEL PUMP GND CONTROLLER BOX GROUND HET HIGH ENGINE TEMPERATURE SWITCH HR HOURMETER IGN IGNITION J CONNECTOR JACK AC CRANK DISCONNECT RELAY K2 ENGINE START RUN RELAY K3 ENGINE CRANK RELAY FAULT SHUTDOWN RELAY K5 FAULT SHUTDOWN TIME DELAY RELAY K6 CRANK INTERLOCK RELAY K20 STARTER SOLENOID RELAY LCS LOSS OF COOLANT SWITCH L
53. ondition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper for cracks leaks and corrosion e Checkthe hoses for softness cracks leaks or dents Replace the hoses as needed e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed e Ensure that the carbon monoxide detector s is 1 in the craft 2 functional and 3 energized whenever the generator set operates Note Never operate the generator set without a functioning carbon monoxide detector TP 5985 10 02 Section 2 Operation Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set Seawater Pump Priming Prime the seawater pump before initial startup To prime the pump 1 close the seacock
54. otor thrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware TP 5985 10 02 Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Sound shield removal Exposed moving parts can cause severe injury or death The generator set must be operating in order to perform some scheduled maintenance procedures Be especially careful ifthe sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nu
55. our OPERATING HOURS SERVICE RECORD DATE TOTAL SERVICE RUN HOURS DATE SERVICE TP5985 10 02 Appendix A 3 TP 5985 10 02d 1999 2001 and 2002 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
56. r gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext 1 0 IP ISO J JIS k K kA KB hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 219 bytes Appendix A 1 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m8 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm KQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height lb pound pounds
57. rator set by the remote start stop switch A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation TP 5985 10 02 Section 3 Scheduled Maintenance WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Sound shield removal Exposed moving parts can cause severe injury or death The generator set must be operating in orderto perform some scheduled maintenance procedures Be especially careful if the sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped models only NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Usethe correct size too
58. rting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Place the generator set start stop switch in the STOP position 2 Disconnectthe power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seekimmediate medical aid inthe case of eye con
59. se the risk of electrocution Safety Precautions and Instructions III Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is present at the voltage regulator heat sink To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator PowerBoost PowerBoost III and PowerBoost V voltage regulator models only Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building marina electrical system only through an approved device and after
60. t breaker Input Fuse Protects the controller circuitry Battery Charging Fuse circuitry Protects the battery charging Voltage Regulator Protects the voltage regulator Fuse circuitry Remote Start Connector A 6 pin connector on controller back panel allows connection of optional remote start kits Hourmeter Meter records total generator set operating hours for reference in maintenance scheduling TP 5985 10 02 2 6 2 Starting the Generator Set The following table describes the actions required to start the generator set WARNING Explosion Gasoline vapors can cause explosion and severe injury or death Before starting the generator set operate the blower 4 minutes and check the engine compartment for gasoline vapors Action Operate the blower Operate the blower 4 minutes and check the engine compartment for gasoline vapors Fuel shut off valve Open the manual fuel shut off valve if equipped Starting Place the generator set controller start stop switch or the remote start stop switch in the START position TP 5985 10 02 2 6 3 Remote Panel Gauge Operation If the generator set has an optional remote panel with gauges observe the gauges upon engine start up If gauge readings are not within the ranges specified contact an authorized service distributor dealer Gauge Normal Operating Range Oil pressure 276 414 kPa 40 60 psi Water temperature
61. t can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Checkthe coolant level atthe tank ifthe generator set has a coolant recovery tank Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Moving Parts A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place TP 5985 10 02 WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place WARNING 2 Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator setengine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen the crankshaft hardware or r
62. tact Never add acid to a battery after placing the battery in service asthis may resultin hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicingthe equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away fromthe battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of exp
63. the building marina main switch is opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a ship to shore transfer switch to prevent interconnection of the generator set power and shore power IV Safety Precautions and Instructions Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on adry approved electrically insulated mat 8 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under Hot Parts A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Checking the coolant level Hot coolan
64. the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats and buildings Avoid overloading the craft TP 5985 10 02 Fuel System A WARNING v Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels A WARNING Explosion Gasoline vapors can cause explosion and severe injury or death Before starting the generator set operate the blower 4 minutes and check the engine compartment for gasoline vapors The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donotoperatethe generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation
65. to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Consultthe boat builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times Operating the generator set Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Use the following precautions when installing andoperating the generator set Do not installthe exhaustoutlet where exhaust can be drawn in through portholes vents or air conditioners If the generator set exhaust discharge outlet is near the waterline water could enter the exhaust discharge outlet and close or restrict the flow of exhaust Never operate the generator set without a functioning carbon monoxide detector Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate operating the generator set dockside moor
66. ts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown or questionable NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Safety Precautions and Instructions Notes VI Safety Precautions and Instructions TP 5985 10 02 This manual provides operation instructions for 5 7 3E and 4 6EF model generator sets Refer to the engine operation manual for generator set engine scheduled maintenance information This manual may be used for models not listed on the front cover Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions secti
67. utlet see Prestart Checklist Seawater Pump Priming 3 7 6 Seawater Outlet Check the seawater outlet at the interval specified in the service schedule See Figure 3 9 for location Remove any obstructions to keep the outlet clear TP 5985 10 02 3 8 Service spark plugs at the interval specified in the service schedule using the following procedure 3 Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling into the combustion chamber Ignition System 4 Remove spark plugs one at a time and examine Identify a normal spark plug in good operating condition by observing a lighttan or gray deposit on the firing tip See Figure 3 12 to evaluate engine condition by color condition of a problem spark plug Spark Plug Service Procedure 1 Remove spark plug wires by grasping the spark plug boot and turning slightly while pulling Do not pull the wire Pulling on the wire rather than the boot may damage the wire or terminal 2 Loosen the spark plug with a ratchet and 5 8 in spark plug socket with a rubber insert to prevent spark plug damage Possible Cause Solution Oil or carbon fouling Clean and regap the spark plug Excessive oil entering combustion chamber through worn rings and pistons excessive clearance between valve guides and stems or worn or loose bearings Replace the spark plug Means of Identification Built up deposits and gap between electrodes closi
68. val of sound shield if installed Consult your local distributor dealer for service Read WARNING found at the beginning of manual regarding moving parts Should be performed by your local distributor dealer Consult battery manufacturer s instructions TP 5985 10 02 Section 3 Scheduled Maintenance 9 3 3 Lubrication System 3 3 1 Use oil that meets the American Petroleum Institute API classification of SC SD SE SF SG or SH Using unsuitable oil or neglecting an oil change may result in engine damage that is not covered by the engine warranty Figure 3 1 shows the recommended Society of Automotive Engineers SAE viscosity designation for given operating temperature ranges Cil Specifications Do not mix different oil brands Incompatibility could cause a breakdown of lubricating ingredients and reduce engine protection Recommended SAE Viscosity Grades SAE10W 30 SAE 10W 40 F 4 14 32 C 20 10 0 Using multigrade oil causes greater oil consumption Figure 3 1 Engine Oil Selection 3 3 2 Oil Check Check the oil level in the crankcase daily or before each start up to ensure that the level is in the safe range Do not check the oil level while operating the unit Stop the generator set and keep the generator set level to get an accurate reading To check the oil level remove the dipstick and wipe the end clean reinsert and remove Maintain the oil level between the

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