Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Valve Adjustment, Rotating parts Can cause severe injury or death

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Valve Adjustment

With overhead cam engines, each valve is spring-held in the closed position until forced open by the action of the rocker arm in contact with the camshaft. Rocker arms have adjusting screws and locknuts for adjusting valve stem-to-rocker arm clearance. Check clearance with the engine cold. See Specifications— Engine for intake and exhaust valve clearances.

WARNING

Rotating parts.

Can cause severe injury or death.

Do not operate generator set without all guards, screens, or covers in place.

Exposed moving parts can cause severe injury or

death. Keep hands, feet, hair, clothing, and test leads away from belts and pulleys when unit is running. Replace guards, covers, and screens before operating generator set.

Flying projectiles can cause severe injury or death.

Retorque all crankshaft and rotor hardware after servicing. When making adjustments or servicing generator set, do not loosen crankshaft hardware or rotor thru-bolt. If rotating crankshaft manually, direction should be clockwise only. Turning crankshaft bolt or rotor thru-bolt counterclockwise can loosen hardware and result in serious personal injury from hardware or pulley flying off engine while unit is running.

1.Remove rocker arm cover screws using a 10 mm wrench. Carefully pry rocker arm cover off cylinder cover. Wipe excess oil from components using a clean rag.

2.Expose timing belt:

a.Close seacock and drain seawater from hoses. Remove seawater pump hoses at seawater pump.

b.Remove two screws to release seawater pump bracket.

c.Remove housing enclosing ignition coil.

d.Remove seawater pump from camshaft pulley.

e.Remove timing belt cover (belt guard).

NOTE

To reduce force needed to rotate crankshaft, remove the spark plugs.

3.Using a ratchet wrench on the crankshaft nut, rotate the crankshaft clockwise (as viewed from engine end) until No. 1 cylinder is at the top of its compression stroke and the ‘T’mark on flywheel is aligned with the triangle symbol on the engine block. See Figure 3-22. The compression stroke is the period between the closing of the intake valve and the opening of the exhaust valve. The marks define the TDC (top dead center) point where both intake and exhaust valves will be closed.

4.Insert feeler gauge between rocker arm and exhaust valve for No. 1 cylinder. If necessary, adjust screw so that very slight drag is felt on the feeler gauge as it is withdrawn. Loosen the adjusting screw locknut and turn the adjusting screw to obtain the specified clearance. Retighten the locknut while holding the adjusting screw. See Figure 3-23. Recheck the valve clearance after tightening the locknut. Repeat step for intake valve of No. 1 cylinder.

5.Rotate crankshaft 360 degrees clockwise and set valve clearances on No. 2 cylinder.

6.Reassembly of timing belt components:

a.Install timing belt cover (belt guard).

b.Install seawater pump to camshaft pulley.

c.Install housing for ignition coil.

d.Mount seawater pump bracket using two screws.

e.Install seawater pump hoses to seawater pump. Open seacock.

7.With mating surfaces clean and gasket properly aligned, install rocker arm cover and screws. Remove ratchet wrench from crankshaft nut.

3-20 Scheduled Maintenance

TP-5695 12/93

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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 Service Ignition SystemSpark Plugs Problem Means of Identification Possible Cause Normal Gap bridgedOil fouled Carbon 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 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 Adjustment GovernorLubrication Generator Service Wattage RequirementsGeneral Storage Procedure Troubleshooting EngineUnit cranks but will Not startProblem Possible Cause Corrective Action Stops suddenly Lacks powerOperates erratically Electrical System Generator Wiring Diagrams Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZDiagrams 4CZWire Generator Sets To Generator To Shore Set PowerTo Load LO Neutral Ground Load SideLine Side 60 HzL1--L3 Without Jumper LeadPage Installation Generator Selection and Wattage RequirementsMotor 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 WaterlineInstallation in Steel or Aluminum Vessels Electrical SystemsAC 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
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