Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual LocationVentilation, Space, Mounting

Page 66

LocationVentilation

General

Consider the following in selecting or constructing a generator set location.

Compartment/location must allow adequate space for ventilation, cooling and exhaust system installation, service access to the engine and generator, and proper fuel system installation.

Engine stringers or other available structural members must provide adequate support for the generator set weight.

A generator set compartment must be sealed to prevent exhaust gases and fuel vapors from entering cabins.

Generator sets located above deck must have a protective cover to prevent damage from rain and water splash. This cover must not affect cooling air flow and serviceability.

See Figure 6-4 for a typical installation and Section 1. for dimensions and weights.

Space

Location should allow easy access to the generator set’s engine, controller, cooling, and fuel system components for routine service. Engine compartments are often ideal generator set locations, but access should not be obstructed by propulsion engines or generator and controller. Also allow clearance for vibration during operation. Minimum recommended clearance for vibration and cooling of top, front, rear, and sides of generator set is 1 1/2 in. (38 mm).

Mounting

Engine stringers generally provide the best support for a generator set. Any structural members considered for mounting must support the generator set weight and withstand engine vibration. The generator set includes vibration mounts and mounting trays; additional vibration isolating pads may be installed between trays and bases.

A generator set should be mounted as high as possible to avoid bilge splash and lower-lying vapors and also to allow downward pitch of the exhaust line. For angular installation, the maximum operation angle of the engine/generator set is 20_(in all directions).

Ventilation is required to support engine combustion, generator cooling, and expulsion of flammable and lethal fumes. Ventilation provisions must comply with U.S.C.G. Regulations governing sizing of vents and operator requirements.

As a rule, inlet and outlet vent areas should each be sized to a minimum of 2 sq. in. per ft. (13 sq. cm/30.5 cm) of craft’s beam. Should this rule in any instance conflict with U.S.C.G. Regulations, appropriate Regulations should be followed. If any screening is used in inlets, size of hull/deck openings should be doubled. Vent ducts should extend to bilges to expel heavier-than-air fumes. If the generator set is to be mounted in the engine compartment, air flow must be increased to allow for generator set’s requirements. UL-listed ignition- protected blowers should be installed in outlet vents, and wired to operate before engine(s) are started. Sniffer devices may also be optionally installed to cause alarm, warning, or engine shutdown should dangerous fumes accumulate in the compartment.

WARNING

Explosion.

Gasoline vapors can cause explosion and severe injury or death.

Before starting generator set, operate blower 4 minutes and check engine compartment for gasoline vapors.

Air requirements for various models are given in Figure 6-5. The air intake silencer provides combustion air to the engine. It is imperative that the recommended minimum clearance of 1 1/2 in. (38 mm) between duct opening and any enclosure wall not be compromised. Engine/generator performance will be affected adversely if these guidelines are not followed.

Air Requirements

CFM (L/min.)

Model

Combustion

 

Cooling

3.5CFZ

18 (510)

323

(9145)

4CZ

18 (510)

323

(9145)

5CFZ

18 (510)

600 (16988)

6.5CZ

18 (510)

600 (16988)

Figure 6-5. Air Requirements

6-4 Installation

TP-5695 12/93

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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 Service Ignition SystemSpark Plugs Oil fouled Problem Means of Identification Possible Cause NormalGap bridged 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 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 Adjustment GovernorLubrication Generator Service Wattage RequirementsGeneral Storage Procedure Unit cranks but will TroubleshootingEngine 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 Line Side LO Neutral GroundLoad Side 60 HzL1--L3 Without Jumper LeadPage Installation Generator Selection and Wattage RequirementsMotor 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 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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