Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Circuit Protection, Engine Safety Shutdown Switches

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Circuit Protection

AC Circuit Breaker (Optional)

The optional AC circuit breaker(s) located on the front panel of the controller protect the generator output windings. If a load circuit loses power, the cause may be a tripped AC circuit breaker. If a tripped circuit breaker is reset and then trips again, find and correct the short in the load circuit that is causing the problem.

Input (Controller) Fuse (10 Amp)

The input fuse protects the controller circuitry. If the generator set engine will not crank and the battery and battery connections appear okay, the input fuse may be blown. If this fuse, located on the front panel of the controller, is replaced and then blows again, find and correct the short that is causing the problem.

Battery-Charging Fuse (10 Amp)

The battery-charging fuse protects the battery-charging circuit. If the battery goes dead and the battery and battery-charging alternator are otherwise normal, the battery-charging fuse may be blown. If this fuse, located on the front panel of the controller, is replaced and blows again, find and correct the short in the charging circuit that is causing the problem.

NOTE

When a fuse replacement is required, be sure fuse has the same ampere rating and is the same type (for example: ABC or 3AB, ceramic). Do not substitute “clear” glass-type fuses for ceramic fuses. If ampere rating is unknown or questionable, see Wiring Diagram.

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect battery cables before working on generator set (negative lead first and reconnect it last).

Accidental starting can cause severe injury or

death. Disconnect battery cables (remove negative lead first and reconnect it last) to disable generator set

before working on any equipment connected to generator. The generator set can be started by remote start/stop switch unless this precaution is followed.

Engine Safety

Shutdown Switches

The engine is protected by three engine safety shutdown switches. Activating any of these switches while the generator set is running, results in an immediate, automatic shutdown. During start-up, the engine safety shutdown feature is inhibited until a generator output is sensed in order to allow the oil pump output to reach normal operating pressure.

Low Oil Pressure Shutdown Switch

The low oil pressure shutdown switch protects the engine against internal damage, if the oil pressure drops below 20 psi (138 kPa), due to an engine oil pump failure or other engine malfunction. The location of the low oil pressure shutdown switch is shown in Figure 2-2.

NOTE

The low oil pressure shutdown switch does not act as a low oil level switch. The only way to protect against engine damage due to low oil level is to check the oil level regularly.

1

258000-D

1. Low Oil Pressure Shutdown Switch

Figure 2-2. Low Oil Pressure Shutdown Switch

2-4 Operation

TP-5695 12/93

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Contents Models Marine Generator Sets5CFZ 5CZCalifornia Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide can cause severe nausea Carbon monoxide Can cause severe nausea, fainting, or deathSulfuric acid in batteries can cause severe injury or Sulfuric acid in batteries Can cause severe injury or deathExplosive fuel vapors can cause severe injury or Explosive fuel vapors Can cause severe injury or deathAccidental starting can cause severe injury or Accidental starting Can cause severe injury or deathRotating parts Can cause severe injury or death Flying projectiles can cause severe injury or deathSudden backfire can cause severe injury or death Fire Can cause severe injury or deathSudden flash fire can cause severe injury or death Hazardous noise Can cause loss of hearing246242 Pleasure Craft Reference MaterialAdditional References Commercial VesselsPart Description Kohler Part No Routine Service PartsAbbreviation Description Glossary of AbbreviationsNEC Specifications SpecificationsGeneral Specifications Introduction5CFZ/4CZ 5CFZ/6.5CZ GeneratorGX360EV EngineBPR4HS NGK Accessories Service Views typical Service ViewsPrestart Checks OperationController ControllerStopping StartingCircuit Protection Engine Safety Shutdown SwitchesHigh Water Temperature Shutdown Switch Remote Panels Optional Remote Panel FeaturesRemote Start and Four-Meter Panel Kit Remote Start and Four-Meter FeaturesScheduled Maintenance Or 2 Years Service ScheduleGenerator Lubrication System SpecificationsOil Change/Oil Filter Change Adding OilRemoving Oil Filter Fuel SystemFuel Pump Screen Fuel Pump ScreenCarburetor/Choke Lubrication Carburetor AdjustmentsIgnition System Ignition System ServiceSpark Plugs Gap bridged Problem Means of Identification Possible Cause NormalOil fouled 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 17. Removing Anticorrosion Zinc Anticorrosion ZincServicing Air Cleaner Air Cleaner Mixing ElbowPressure Cap Servicing Mixing ElbowCleaning BatteryChecking Electrolyte Level Checking Specific GravityCharging 21. Specific Gravity Temperature CorrectionValve Adjustment 22. Determining Top Dead Center Governor Governor AdjustmentLubrication Wattage Requirements Generator ServiceGeneral Storage Procedure Engine TroubleshootingUnit cranks but will Not startLacks power Problem Possible Cause Corrective Action Stops suddenlyOperates erratically Electrical System Generator Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring Diagrams4CZ DiagramsTo Generator To Shore Set Power Wire Generator SetsTo Load Load Side LO Neutral GroundLine Side 60 HzWithout Jumper Lead L1--L3Page Generator Selection and Wattage Requirements InstallationMotor Loads Kilowatt Derating Appliance LoadsTypical Location and Mounting Space LocationVentilationMounting Air Requirements CFM L/min Model Combustion CoolingFuel Supply Fuel SystemsFuel Lines Anti-Siphon ProvisionsFuel Pump Lift Capabilities Fuel Consumption Max. Lift ft. m In. mm11. Intake Strainer Cooling Systems13. Seawater Strainer Closed/Heat Exchanger15. Closed/Heat Exchanger Cooling System Exhaust SystemsCarbon monoxide 17. Typical Above Waterline InstallationMid/Below Waterline Above WaterlineElectrical Systems Installation in Steel or Aluminum VesselsAC Voltage Connections Wiring BatteryLead Designations Pin Function Remote Start Switch ConnectionSection Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZStandard on 5CFZ and 6.5CZ Sound Shield--Optional on 3.5CFZ and 4CZParts Ordering Instructions For Sales & Service in U.S.A. & Canada PhoneOperating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone
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