Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Commercial Vessels, Additional References

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Commercial Vessels

In order to use these generator sets for commercial applications where U.S. Coast Guard Title 46 Certificate is required, additional modifications will be necessary.

U.S. Coast Guard Code of Federal Regulations

Title 46

Subchapter F--Marine Engineering

Part 58--Main and Auxiliary Machinery and Related

Systems

Subchapter J--Electrical Engineering

Part 111--Electrical Systems--General Requirements

Part 112--Emergency Lighting and Power Systems

Subchapter T--Small Passenger Vessels

(Under 100 Gross Tons)

Part 182--Machinery Installation

Part 183--Electrical Installation

Order the above publications from: Superintendent of Documents U.S. Government Printing Office Washington, 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, NJ 97653-0910

Lloyd’s Register of Shipping

71 Fenchurch Street

London, EC3M 4BS England

Midwest Office:

Lloyd’s Register of Shipping

100 South York Street, Room 226 Elmhurst, IL 60126 1-312-279-5414

Additional References

The following organizations provide a service which	Yacht Corrosion Consultants, Inc.
may be useful to the generator set installer. These	2970 Seaborg Ave.
organizations are not regulatory in nature but rather	Ventura, CA 93003
provide guidelines and assistance. They are listed only	1-805-644-1886
as a source for additional information. No solicitation or
representation is hereby given.	Ward’s Marine Electric, Inc.
	630 S.W. Flagler Ave.
	Ft. Lauderdale, FL 33301
	1-305-523-2815
	1-800-545-9273
	1-305-523-1967 FAX

TP-5695 12/93

Reference Material ix

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Contents Marine Generator Sets Models5CFZ 5CZCalifornia Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide Can cause severe nausea, fainting, or death Carbon monoxide can cause severe nauseaSulfuric acid in batteries Can cause severe injury or death Sulfuric acid in batteries can cause severe injury orExplosive fuel vapors Can cause severe injury or death Explosive fuel vapors can cause severe injury orAccidental starting Can cause severe injury or death Accidental starting can cause severe injury orRotating parts Can cause severe injury or death Flying projectiles can cause severe injury or deathFire Can cause severe injury or death Sudden backfire can cause severe injury or deathSudden flash fire can cause severe injury or death Hazardous noise Can cause loss of hearing246242 Reference Material Pleasure CraftCommercial Vessels Additional ReferencesRoutine Service Parts Part Description Kohler Part NoGlossary of Abbreviations Abbreviation DescriptionNEC Specifications SpecificationsGeneral Specifications IntroductionGenerator 5CFZ/4CZ 5CFZ/6.5CZEngine GX360EVBPR4HS NGK Accessories Service Views Service Views typicalOperation Prestart ChecksController ControllerStarting StoppingEngine Safety Shutdown Switches Circuit ProtectionHigh Water Temperature Shutdown Switch Remote Panel Features Remote Panels OptionalRemote Start and Four-Meter Features Remote Start and Four-Meter Panel KitScheduled Maintenance Service Schedule Or 2 YearsGenerator Specifications Lubrication SystemAdding Oil Oil Change/Oil Filter ChangeFuel System Removing Oil FilterFuel Pump Screen Fuel Pump ScreenCarburetor Adjustments Carburetor/Choke LubricationIgnition System Service Ignition SystemSpark Plugs Problem Means of Identification Possible Cause Normal Gap bridgedOil fouled Carbon fouled12. Checking Spark Plug Gap Cooling Systems- Closed/Heat Exchanger Filling and CheckingHot coolant and steam Can cause severe injury or death 14. Air-Bleed Screw Flushing and Cleaning TP-5695 12/93 Scheduled Maintenance Anticorrosion Zinc 17. Removing Anticorrosion ZincAir Cleaner Mixing Elbow Servicing Air CleanerPressure Cap Servicing Mixing ElbowBattery CleaningChecking Electrolyte Level Checking Specific Gravity21. Specific Gravity Temperature Correction ChargingValve Adjustment 22. Determining Top Dead Center Governor Adjustment GovernorLubrication Generator Service Wattage RequirementsGeneral Storage Procedure Troubleshooting EngineUnit cranks but will Not startProblem Possible Cause Corrective Action Stops suddenly Lacks powerOperates erratically Electrical System Generator Wiring Diagrams Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZDiagrams 4CZWire Generator Sets To Generator To Shore Set PowerTo Load LO Neutral Ground Load SideLine Side 60 HzL1--L3 Without Jumper LeadPage Installation Generator Selection and Wattage RequirementsMotor Loads Appliance Loads Kilowatt DeratingTypical Location and Mounting LocationVentilation SpaceMounting Air Requirements CFM L/min Model Combustion CoolingFuel Systems Fuel SupplyAnti-Siphon Provisions Fuel LinesFuel Pump Lift Capabilities Fuel Consumption Max. Lift ft. m In. mmCooling Systems 11. Intake StrainerClosed/Heat Exchanger 13. Seawater StrainerExhaust Systems 15. Closed/Heat Exchanger Cooling System17. Typical Above Waterline Installation Carbon monoxideAbove Waterline Mid/Below WaterlineInstallation in Steel or Aluminum Vessels Electrical SystemsAC Voltage Connections Battery WiringRemote Start Switch Connection Lead Designations Pin FunctionDimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ SectionSound Shield--Optional on 3.5CFZ and 4CZ Standard on 5CFZ and 6.5CZFor Sales & Service in U.S.A. & Canada Phone Parts Ordering InstructionsOperating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone