Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Diagrams

Page 58

5-2	ENGINE					THERMAL		FUEL PUMP															CONTROLLER
	ENGINE					SWITCH	N										J4						CONTROLLER
Wiring						SWITCH											J4
				CHOKE
				CHOKE
			ANTI--DIESEL
	GREEN/WHITE		SOLENOID				70						P4
							70				1		P4				1
											1						1		2
					7N				2				3			3			2
									2		BC		3			3	BC
										5	BC	70				70	BC		5
Diagrams				GREEN	8N	P8			4	5		70		8	8	70			5	4
				GREEN					4					8	8					4
				73		N			71				73			73				71											INPUT
				73					9					14	14					9								START		STOP	INPUT
			45	73					45	P		7C		73	73	7C	P			45											P	10A					120 V. CONNECTION
									45	P		7C		73	73	7C	P			45
																																						L0
									15 72	BC		37	8N	19		8N	37	BC		72																	LO	L0
									15 72	BC		37	8N	19	19	8N	37	BC		72																	LO	GRD
																				15																	GRD	L2
										N		N				N			N									43										L2
									20	N	BC	N	21			N	BC		N	20								43	N N 47				P					L1
Figure									20		BC		21			21	BC			20									N N 47				P
				BATTERY							22						22															BC
				BATTERY							22																					BC
																															BC						CIRCUIT BREAKERS
																																					CIRCUIT BREAKERS
				N																								HOUR METER									FOR AMPERAGE
				GROUND																																	RATING SEE
				GROUND																																	OWNERS MANUAL
				NUT																												BC					OWNERS MANUAL
				NUT	N
	STARTER				N
5-	STARTER			N	N																										BATT.
	MOTOR			N	N																										CHRG.
				N	N																							73		N		10A		4	3	2	1
2.	STARTER			BC																																	120/240 V. CONNECTION
	STARTER			P																																	120/240 V. CONNECTION
	SOLENOID			P
Point				71																																	LO	L0
					HIGH ENGINE																																LO	GRD
					HIGH ENGINE																																GRD	GRD
					TEMPERATURE																																GRD	L2
					TEMPERATURE																																	L2
					SWITCH																																	L1
	BATTERY		2	GREEN
	CHARGING		2			YELLOW																															CIRCUIT BREAKERS
	CHARGING		1		N	YELLOW																															CIRCUIT BREAKERS
-	ALTERNATOR		1		N
to-																																					FOR AMPERAGE
			37																																		RATING SEE
				37						BC																											OWNERS MANUAL
Point					37
	EXHAUST								VOLTAGE		BC	N														70								4	3	2	1
	TEMPERATURE								VOLTAGE																B1		73
	TEMPERATURE								REGULATOR																B1		73										220 V. CONNECTION
	SWITCHES		37						REGULATOR																												220 V. CONNECTION
	SWITCHES		37																																		LO (NEUTRAL)	L0
																																					LO (NEUTRAL)
																												71
Wiring										5	4	3													3	2	1	71									GRD	GRD
										2	4	1											N		6	5	4	45		GROUND								L1
																									9	8	7	72		LUG
																									9	8	7
																								B2	12 11 10						N
																					43 N		37		15 14 13			P1				N					CIRCUIT BREAKERS
																					43 N							P1									CIRCUIT BREAKERS
				7C																							P										FOR AMPERAGE
				7C																	P2																FOR AMPERAGE
Diagram				37																	9	6	3														RATING SEE
				37																	9	6	3														OWNERS MANUAL
				37																	8	5	2	73
				37																N	8	5	2	73
				37	5															N	7	4	1	76			75
																					43													4	3	2	1
																					47		47			RELAY BOARD			B2 B1					4	3	2	1
	37	37					IGNITION		72																			P6
	7C	37			(OPTIONAL)		SYSTEM		72																76		4	P3
		37		OIL	WATER																				76		4	1
				OIL	WATER																				47		5	2
				PRESSURE	TEMPERATURE																				47		5	2									73	N
	G WK			SWITCH	SENDING UNIT																				43		6	3									P5
--				SWITCH	SENDING UNIT
--																												N									2	1
3.																												7C									4	3
3.				TAPE LEADS ”5”OR ”7C”																								5
5CFZ,	(OPTIONAL)			WHEN NOT USED.																																	75
	OIL PRESSURE																																				8N
	SENDING UNIT/																									55											HOT CHOKE
	SENDING UNIT/																				EXCITATION					55											CIRCUIT BOARD
	LOW OIL PRESSURE																				EXCITATION																CIRCUIT BOARD
	LOW OIL PRESSURE																				CAPACITOR
	SWITCH																				CAPACITOR					66
	SWITCH																									66

4CZ,						REMOTE PANEL									NOTE :																						GENERATOR
															CONNECTOR SHOWN FROM
															PIN INSERTION END.
5CFZ,														LT BLUE
						VIOLET
					HOUR																								B2	B1	66	55	4	3	2		1
									OIL
and 6.									OIL
				BLK	+		VIOLET																								55	4		3
																																		3
																														66				2
								BLK				VIOLET					YEL/RED																	2
								BLK	S																					B1
																																		1
				BLK
																	VIOLET
																	VIOLET													B2
5CZ									+								J3													B2
									+								J3
					VOLT		VIOLET	BLK	TEMP			VIOLET			BLACK		1	4
				BLK	VOLT			BLK	TEMP								2	5
				BLK
														START
														START
																	3	6
							VIOLET																								ALTERNATOR
								BLK	S			VIOLET			GREY/BLK
					+				S						GREY/BLK
TP-5695 12/93				BLK	+
	246482-D								+					STOP
												VIOLET
												BLK
					BACK VIEW OF PANEL									TAN
					BACK VIEW OF PANEL
					(2 AND 4 GAUGE REMOTE PANEL)

Image 58

Contents 5CFZ Marine Generator SetsModels 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 orRotating parts Can cause severe injury or death Accidental starting Can cause severe injury or deathAccidental starting can cause severe injury or Flying projectiles can cause severe injury or deathSudden flash fire can cause severe injury or death Fire Can cause severe injury or deathSudden backfire 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 General Specifications SpecificationsSpecifications 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 Oil fouled Problem Means of Identification Possible Cause NormalGap bridged 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 ZincPressure Cap Air Cleaner Mixing ElbowServicing Air Cleaner Servicing Mixing ElbowChecking Electrolyte Level BatteryCleaning Checking Specific Gravity21. Specific Gravity Temperature Correction ChargingValve Adjustment 22. Determining Top Dead Center Governor Governor AdjustmentLubrication Wattage Requirements Generator ServiceGeneral Storage Procedure Unit cranks but will TroubleshootingEngine 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 Line Side LO Neutral GroundLoad Side 60 HzL1--L3 Without Jumper LeadPage Generator Selection and Wattage Requirements InstallationMotor Loads Appliance Loads Kilowatt DeratingTypical Location and Mounting Mounting LocationVentilationSpace Air Requirements CFM L/min Model Combustion CoolingFuel Systems Fuel SupplyFuel Pump Lift Capabilities Fuel Consumption Anti-Siphon ProvisionsFuel Lines 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