Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Scheduled Maintenance

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Section 3. Scheduled Maintenance

Use the following service schedule and the hourmeter on the controller to schedule routine maintenance. In addition to the routine services listed in this manual, there are other important steps that should be taken to keep a generator set in top condition. Usually tools and instruments required for these additional steps are not available to the generator set owner. For this reason, the set should be returned periodically to an authorized service dealer/distributor for complete servicing and tune-up. The benefits of such service will be improved performance and continuous satisfactory operation during a long trouble-free service life. Use the Operating Hour Service Log in the back of this manual to document services performed.

Service intervals are located on the top rows of the Service Schedule chart. It indicates how often maintenance tasks need to be done. Each service item is to be repeated at the specified interval. For example, an item required at 50 hours will again need to be performed at 100 hours, 150 hours, etc.

For continued satisfactory operation and longevity of the engine and generator set, proper maintenance and eventual overhaul by a competent mechanic/technician are essential. While it is not possible to anticipate component failure, rough operation, metallic noises, and excessive oil loss are among the indicators of potential problems. Do not ignore these conditions!

NOTE

Operate the generator set with load applied at least once a month. Allow generator set to run about one hour to reach operating temperature. This prevents the formation of corrosion on internal engine components when exposed to the breakdown of exhaust gases and seawater for long periods of generator inactivity. If unit is to be out of service for several months, see Storage Procedure.

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.

NOTE

HARDWARE DAMAGE! Engine and generator make use of both American Standard and metric hardware. Be sure to use the correct size tools to prevent rounding of bolt heads and nuts.

NOTE

High-mineral content seawater (salt water) can cause rapid destruction of metals. Wipe up all salt water spillage on and around generator set and keep metal surfaces free from accumulated salt deposits.

TP-5695 12/93

Scheduled Maintenance 3-1

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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 AdjustmentsSpark Plugs Ignition System ServiceIgnition System Gap bridged Problem Means of Identification Possible Cause NormalOil fouled Carbon fouled12. Checking Spark Plug Gap Hot coolant and steam Can cause severe injury or death Cooling Systems- Closed/Heat ExchangerFilling and Checking 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 Lubrication Governor AdjustmentGovernor General Generator ServiceWattage Requirements Storage Procedure Engine TroubleshootingUnit cranks but will Not startOperates erratically Problem Possible Cause Corrective Action Stops suddenlyLacks power Electrical System Generator Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring Diagrams4CZ DiagramsTo Load Wire Generator SetsTo Generator To Shore Set Power Load Side LO Neutral GroundLine Side 60 HzWithout Jumper Lead L1--L3Page Motor Loads InstallationGenerator Selection and Wattage Requirements 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 WaterlineAC Voltage Connections Installation in Steel or Aluminum VesselsElectrical Systems 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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