Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Operation, Prestart Checks

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Section 2. Operation

Prestart Checks

To insure continued satisfactory operation, the following items should be checked before each start-up.

BACKFIRE FLAME ARRESTOR: Air cleaner must be clean and properly installed to prevent unfiltered air from entering engine. See Maintenance--Air Cleaner.

BATTERY: Remove caps and check the electrolyte level of each cell (batteries with filler caps only); add distilled water if necessary. Check to make sure it is connected correctly. Battery installation and connections must meet Coast Guard Standards. Battery should be serviced by authorized personnel only. See Maintenance--Battery.

COMPARTMENT: Keep the engine room or compartment clean and dry. Check for fuel or oil leaks. Check the condition of fuel system, exhaust piping, hoses, and muffler; have any faulty components repaired before getting underway. Open hatch to air out compartment and use “ignition-protected” bilge blowers, if required, to clear fumes from area before each start-up. If fuel leaks, fumes, exhaust gases, or electrical sparks are noted, arrange for qualified personnel to make necessary repairs before operating generator set.

FUEL LEVEL: Make sure the fuel tanks are full and the

fuel system primed for operation. See Maintenance--Fuel System.

OIL LEVEL: Should be at or near Max. mark. Add oil as needed to bring level up to this range. See Maintenance Lubrication System.

COOLING: The coolant level on closed-type heat exchanger systems can be checked using the coolant recovery tank, if used. The MIN mark indicates full when cold and the MAX mark indicates full when hot. Maintain the coolant level between these marks. It is recommended that coolant level on closed systems be periodically checked by removing pressure cap. Do not solely rely on level in coolant recovery tank.

Add fresh coolant until level is just below overflow tube opening. See Maintenance--Cooling Systems.

SEAWATER PUMP PRIMING: The seawater pump must be primed before initial start-up. To prime pump, close seacock and remove the hose from water filter outlet. Fill hose and pump with clean water. Replace hose and open seacock. Check for pump operating on start-up by observing water discharge from exhaust outlet.

TP-5695 12/93

Operation 2-1

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Contents 5CFZ Marine Generator SetsModels 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 orRotating parts Can cause severe injury or death Accidental starting Can cause severe injury or deathAccidental starting can cause severe injury or Flying projectiles can cause severe injury or deathSudden flash fire can cause severe injury or death Fire Can cause severe injury or deathSudden backfire 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 General Specifications SpecificationsSpecifications 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 Ignition System ServiceSpark Plugs Oil fouled Problem Means of Identification Possible Cause NormalGap bridged Carbon fouled12. Checking Spark Plug Gap Filling and Checking Cooling Systems- Closed/Heat ExchangerHot 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 ZincPressure Cap Air Cleaner Mixing ElbowServicing Air Cleaner Servicing Mixing ElbowChecking Electrolyte Level BatteryCleaning Checking Specific Gravity21. Specific Gravity Temperature Correction ChargingValve Adjustment 22. Determining Top Dead Center Governor Governor AdjustmentLubrication Wattage Requirements Generator ServiceGeneral Storage Procedure Unit cranks but will TroubleshootingEngine Not startLacks power Problem Possible Cause Corrective Action Stops suddenlyOperates erratically Electrical System Generator Wiring Diagrams Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZDiagrams 4CZTo Generator To Shore Set Power Wire Generator SetsTo Load Line Side LO Neutral GroundLoad Side 60 HzL1--L3 Without Jumper LeadPage Generator Selection and Wattage Requirements InstallationMotor Loads Appliance Loads Kilowatt DeratingTypical Location and Mounting Mounting LocationVentilationSpace Air Requirements CFM L/min Model Combustion CoolingFuel Systems Fuel SupplyFuel Pump Lift Capabilities Fuel Consumption Anti-Siphon ProvisionsFuel Lines 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 WaterlineElectrical Systems Installation in Steel or Aluminum VesselsAC 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