Genset service - Kohler 3.5 CFZ (circa 1993)

[rcon]

More questions.

Strongly suspect my Kohler 3.5CFZ has not been serviced in many a year (what was that about used boats and delayed maintenance?).

I've found what purports to be te manual for it, but there are subtle (and very confusing to newbie like me) differences.

First up, is a genset service something I can attempt myself? Is there anything that I could take off/apart, then not be able to call in the experts if I went wrong?

Assuming we're all good to attempt this, I'm thinking this screw leaking the brown gunk is a good place to start. Any ideas what it is? Is it the zinc?

Next, was getting a bit bogged down last time I ran it, even with small load. Checked and water was being expelled. Fuel filter? Impeller? I have no idea where these two might be.

And lastly for this post, oil. When I checked the oil, you can see the edge of the dip stick in the bottom right of photo, it came gushing out (was cold), is this a problem?

Thanks again.

 

[rcon]

Maybe the thermostat?

 

[rcon]

No one has one of these old girls?

 

[rcon]

Ok, anyone have an old, Kohler at all?

Started her up this afternoon, realised id left seacock closed

Stopped, opened sea cock,
Started again, checked water was exiting the hull - all ok, warm-ish and a little oily.
gave it a run for 5 min and it died

Now it dies when I release the start switch.

Thoughts?


On a similar tack, is the pic attached likely to the a zinc? I think that is the heat exchanger.

 

[rcon]

More questions - starting to suspect something has gone wrong with the A/C output.

Would I expect to see voltage on my main switchboard if I start the generator with the generator breaker on? Or would the genset not produce output whilst in start mode?

 

[rcon]

Whilst there are so many people posting, bump.

 

[rcon]

Ok, one more question then I'l buy some answers...


When the service manual says "check low oil pressure shutdown switch", what exactly am I looking for? I can see a wire on something I assume to be a sensor, but it doesn't look like a "switch I could throw/toggle".

Same thing for high exhaust/water temp switches....

 

[rcon]

Ok, have a petrol mech/auto electrician with experience on boats coming out tomorrow. Finding the right skill set for genset work has proved challenging. Unfortunately he isn't certified to do 240v, but at least we can diagnose and make a more informed decision before pulling the whole thing.

He is suggesting I don't need an anode in my heat exchanger if we just put one elsewhere - doesn't the anode need to be in water, more specifically, sea water? Or will other metals work in contact with air and still pull the corrosion?


Also, a $10.80 oil filter from iboats over in the US, which they wont ship to me due to weight restrictions, is going to cost me $96, wowwee

 

[JerryS]

I'm guessing that your generator uses the 2 cyclinder Honda engine. The oil filter should be Honda part #15400-PFB-014

 

[JerryS]

If it starts and then quits when you release the start button, it may be a relay on the control board. Or it could be the excitation capacitor.
I believe that the excitation capacitor is the main culprit when the engine will start, but, not continue to run and you get no 120V reading on the panel.
Here is a source for parts: http://www.partsfortechs.com/asapcart/

Kohler: http://www.kohlerengines.com/manuals/landing.htm

 

[rcon]

That's great, cheers.

 

[JerryS]

I had trouble with both my excitation capacitor and control board. I will see if I can find those threads and post them for you.

 

[JerryS]

Here is a link to one thread - No output from generator:
http://clubsearay.com/showthread.php/33184-No-Output-from-Generator?highlight=

(The pictures are missing, I'll see if I can find some and post them)

Here is a link to second thread, the generator crapped out again after I fixed it the first time:
http://clubsearay.com/showthread.php/34738-MY-Kohler-4KW-died-again?highlight=

 

[JerryS]

Can't find the pictures, must have sh*tcanned them! But, I will give you some ASAP (partsfortechs.com) parts numbers.
These are for my Kohler 4KW generator, but, I would bet that they are the same for your 3.5KW model. (Check their website)

Kohler 250872 Impeller for Sea Water Pump - ASAP part Number 250872 ($35.15)
Kohler gasket 252475 for sea water pump - ASAP part number 252475 (3.08)
Kohler Fuel Filter 249433 _ ASAP part number 249433 ($5.72)
Kohler Zinc Anode 260085 - ASAP part number 260085 ($5.39)
Excitation Capacitor - 25UF, 440V - ASAP part number 267968 (42.90)
Kohler Control Board - ASAP part number H-239563 ($229.00)
Kohler Choke Board - ASAP part number B-267448 ($67.90)

Good Luck!

Also, I have a trouble shooting guide that is about fifteen (15) pages long. It details how to troubleshoot the control board, choke board and general problems. If you want a copy, I will send one to you. Just PM me with your mailing address and I will send a copy down there. You will have to turn the pages upside down, however, since it is not printed for use by down under people!

 

[rcon]

Thank you, Jerry.

I'll give the tech a call in the morning and clue him in and order as needed.

Where is the excitation capacitor located, is it in the control box?

Cheers
Mathew.

 

[JerryS]

On my generator, the excitation capacitor is located under the control box. I was not able to get it out. I finally cut the wires and spliced them to the new capacitor that I remotely located on the transom. If I make it over to the boat today, I will take a picture or two for you.
BTW, I will have to snail mail the troubleshooting guide to you, My wife has an Iphone, but, I don't and I am a technot.

 

[rcon]

Ah, news from the frontline.

Petrol in the crank case, probably leading to low oil pressure as petrol seeps in. This would possibly explain the oil gushing out when I popped the oil cap.

Hopefully it's just a matter of draining, topping off, bypassing low oil pressure switch and getting her going.

Of course ths begs the question, have the rings gone.... Engine has only 120ish hours on it, but it is a 1993 original. Rebuild, rings, or replace.

Hopefully he calls me this morning and tells me we've got summer with a genset so I can sit out on the hook and contemplate this deep question in aircon'd comfort.

Now back to exam study


Jerry, many thanks, that is uncommonly good of you.

 

[rcon]

Well that is disappointing.

He cracked open the control box and found some LEDs that should have been lit up if it was a switch such as low oil pressure.

Has suggested ordering the control circuit boards (apparently there are two that you can replace) and an excitation capacitor - ill also get some spare filters (air/oil) and zincs sent over.

Now, where was that application form for the hole in the water club?

 

[rcon]

Received Jerry's troubleshooting guide in the post last Friday, very generous to take the time out to have a copy made and post internationally, so I made a scan of it at work today for posting.

Realising I'd I was extremely limited in my attachment capacity I thought I'd better sign up to support the site so I could post it - but I'm being told .pdf files can only be 20kb or so. Any ideas on how to post the scan I've made?

Thanks again, Jerry. Very kind of you to help a fellow kohler troubleshooter out

Regards
Mathew

 

[rcon]

Success.

Sparky replaced both control board and choke board, no go. I asked if he'd found the capacitor useful - PartsForTechs hadn't listed it as a part for that model and I was suspicious I'd bought a superfluous part. Sparky said he had no idea where it went so we went to the manual.

Capacitor found, new one wired in and away we went.

He'll be back tomorrow to wire/brace it in properly as he can't access the exist one properly. I've read others have had this issue too.

Condition report of the boards was poor tho, lots of problems, as you'd expect with 20yo circuitry, and as for the anode, well that was in little bits.

More than just a little excited about up coming trip to KI now