Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Cooling Systems- Closed/Heat Exchanger, Filling and Checking

Page 40

Cooling Systems— Closed/Heat Exchanger

In a closed cooling system, the seawater does not circulate through the engine but circulates through separate chambers within the heat exchanger to cool the engine coolant. The seawater is then mixed with engine exhaust and ejected out the exhaust outlet. The coolant is circulated through cooling passages to cool the engine. All models make use of a coolant thermostat and a coolant recovery tank. The coolant capacity of the engine with heat exchanger is 0.72 U.S. qts. (0.68 L) for all models. A solution of 50% ethylene glycol and 50% clean, softened water is recommended to inhibit rust/corrosion. A coolant solution of 50% ethylene glycol will provide freezing protection to --34°F (--37°C) and overheating protection to 265°F (129°C). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can cause damage to engine and components. Do not use alcohol or methanol antifreeze or mix them with the coolant.

Filling and Checking

WARNING

Hot coolant and steam.

Can cause severe injury or death.

Before removing pressure cap stop generator, allow to cool and loosen pressure cap to relieve pressure.

Hot coolant can cause severe injury or death. Allow engine to cool and release pressure from cooling system before opening pressure cap. To release pressure, cover the pressure cap with a thick cloth then turn it slowly counterclockwise to the first stop. After pressure has been completely released and the engine has cooled, remove cap. If generator set is equipped with a coolant recovery tank, check coolant level at tank.

NOTE

ENGINE DAMAGE! Failure to bleed air from cooling system may cause overheating and subsequent damage to engine.

NOTE

Special attention should be given when checking for proper coolant level. After the coolant has been drained, it normally requires some time before complete refill of the engine water jacket takes place.

Before filling the cooling system, verify that all hose clamps are tight. Loosen air-bleed screw located on top of the engine to allow trapped air to escape. See Figure 3-14. Place a rag around the screw to prevent coolant spillage onto the block. Remove pressure cap located on the top of the engine (see Figure 3-15) and fill with the recommended coolant until level is just below overflow tube opening. Tighten air-bleed screw when coolant, free of air bubbles, starts to flow. Replace pressure cap. Start generator set and allow to run for about 20--30 seconds. STOP generator set and recheck coolant level by removing pressure cap. Repeat procedure, as necessary, until coolant can no longer be added.

A coolant overflow bottle is provided. Fill bottle to just below the MAX mark. See Figure 3-16. Maintain proper coolant level in coolant overflow bottle. The MIN mark indicates full when cold and the MAX mark indicates full when hot. Coolant level should always be between these marks. The coolant level can be checked using the overflow bottle markings, but it is recommended to periodically remove the coolant pressure cap and check coolant level.

3-12 Scheduled Maintenance

TP-5695 12/93

Page 39 Page 41
Image 40
Page 39 Page 41
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 Ignition System ServiceSpark Plugs Problem Means of Identification Possible Cause Normal Gap bridgedOil 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 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 Governor AdjustmentLubrication Wattage Requirements Generator ServiceGeneral Storage Procedure Troubleshooting EngineUnit cranks but will 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 LO Neutral Ground Load SideLine Side 60 HzL1--L3 Without Jumper LeadPage Generator Selection and Wattage Requirements InstallationMotor 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 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
Top Page Image Contents