Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Table of Contents

Page 3

SUBJECT

PAGE

Safety Precautions and Instructions

i

Reference Material

viii

Routine Service Parts

x

Glossary of Abbreviations

xi

Section 1. Specifications

1-1

Introduction

1-1

Specifications

1-1

General Specifications

1-1

Generator

1-2

Engine

1-3

Accessories

1-5

Service Views

1-6

Section 2. Operation

2-1

Prestart Checks

2-1

Controller

2-2

Starting

2-3

Stopping

2-3

Circuit Protection

2-4

Engine Safety Shutdown Switches

2-4

Remote Panels (Optional)

2-6

Section 3. Scheduled Maintenance . . . . . . . . . 3-1

Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Oil Change/Oil Filter Change . . . . . . . . . . . . . . 3-5

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Fuel Pump Screen . . . . . . . . . . . . . . . . . . . . . . . 3-7

Carburetor/Choke Lubrication . . . . . . . . . . . . . 3-8

Carburetor Adjustments . . . . . . . . . . . . . . . . . . 3-8

Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Ignition System Service . . . . . . . . . . . . . . . . . . 3-9

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Cooling Systems— Closed/Heat Exchanger . . . 3-12

Filling and Checking . . . . . . . . . . . . . . . . . . . . . 3-12

Flushing and Cleaning . . . . . . . . . . . . . . . . . . . 3-14

Anticorrosion Zinc . . . . . . . . . . . . . . . . . . . . . . . 3-16

Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Air Cleaner and Mixing Elbow . . . . . . . . . . . . . . . 3-17

Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . 3-17

Servicing Mixing Elbow . . . . . . . . . . . . . . . . . . . 3-17

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Checking Electrolyte Level . . . . . . . . . . . . . . . . 3-18

Checking Specific Gravity . . . . . . . . . . . . . . . . 3-18

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

SUBJECT

PAGE

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Governor Adjustment . . . . . . . . . . . . . . . . . . . . 3-22

Wattage Requirements . . . . . . . . . . . . . . . . . . . . . 3-23

Generator Service . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Section 4. Troubleshooting . . . . . . . . . . . . . . . . 4-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Section 5. Wiring Diagrams . . . . . . . . . . . . . . . 5-1

Section 6. Installation . . . . . . . . . . . . . . . . . . . . . 6-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Generator Selection and

Wattage Requirements . . . . . . . . . . . . . . . . . . . . . 6-1 Lighting Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Motor Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Appliance Loads . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Kilowatt Derating . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Anti-Siphon Provisions . . . . . . . . . . . . . . . . . . . 6-6 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Fuel Pump Lift Capabilities and

Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . 6-6 Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Closed/Heat Exchanger . . . . . . . . . . . . . . . . . . 6-8 Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Above Waterline . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Mid/Below Waterline . . . . . . . . . . . . . . . . . . . . . 6-11 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 AC Voltage Connections . . . . . . . . . . . . . . . . . . 6-12 Installation in Steel or Aluminum Vessels . . . 6-12 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Remote Start Switch Connection . . . . . . . . . . 6-14

Section 7. Installation Drawings . . . . . . . . . . . 7-1 Section 8. Parts Ordering Instructions . . . . . 8-1 Section 9. Operating Hour Service Log . . . . . 9-1

TP-5695 12/93

Table of Contents

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Contents 5CZ Marine Generator SetsModels 5CFZCalifornia 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 deathFlying projectiles can cause severe injury or death Accidental starting Can cause severe injury or deathAccidental starting can cause severe injury or Rotating parts Can cause severe injury or deathHazardous noise Can cause loss of hearing Fire Can cause severe injury or deathSudden backfire can cause severe injury or death Sudden flash fire can cause severe injury or death246242 Pleasure Craft Reference MaterialAdditional References Commercial VesselsPart Description Kohler Part No Routine Service PartsAbbreviation Description Glossary of AbbreviationsNEC Introduction SpecificationsSpecifications General Specifications5CFZ/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 Service Ignition SystemSpark Plugs Carbon fouled Problem Means of Identification Possible Cause NormalGap bridged Oil 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 17. Removing Anticorrosion Zinc Anticorrosion ZincServicing Mixing Elbow Air Cleaner Mixing ElbowServicing Air Cleaner Pressure CapChecking Specific Gravity BatteryCleaning Checking Electrolyte LevelCharging 21. Specific Gravity Temperature CorrectionValve Adjustment 22. Determining Top Dead Center Governor Adjustment GovernorLubrication Generator Service Wattage RequirementsGeneral Storage Procedure Not start TroubleshootingEngine Unit cranks but willProblem Possible Cause Corrective Action Stops suddenly Lacks powerOperates erratically Electrical System Generator Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring Diagrams4CZ DiagramsWire Generator Sets To Generator To Shore Set PowerTo Load 60 Hz LO Neutral GroundLoad Side Line SideWithout Jumper Lead L1--L3Page Installation Generator Selection and Wattage RequirementsMotor Loads Kilowatt Derating Appliance LoadsTypical Location and Mounting Air Requirements CFM L/min Model Combustion Cooling LocationVentilationSpace MountingFuel Supply Fuel SystemsMax. Lift ft. m In. mm Anti-Siphon ProvisionsFuel Lines Fuel Pump Lift Capabilities Fuel Consumption11. 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 WaterlineInstallation in Steel or Aluminum Vessels Electrical SystemsAC 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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