Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Exhaust Systems, Closed/Heat Exchanger Cooling System

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INPUT STOP/START

10A FUSE

00 0 0 0 1/10

TOTAL HOURS

BATT.

CHRG.

11

1

2

10

3

4

5

6

NOTE

Use two hose clamps on each end of all flexible exhaust hose connections.

7

8

9

258000-D

	1.	Exhaust Manifold	6.	Seawater Strainer
	2.	3 ft. (1 m) Max.	7.	Intake Strainer
	3.	Engine-Driven Seawater Pump	8.	Engine Coolant
	3.	Engine-Driven Seawater Pump	9.	Seawater
	4.	Heat Exchanger	9.	Seawater
	4.	Heat Exchanger	10.	Seacock
	5.	Waterline	11.	Coolant Recovery Tank

Figure 6-15. Closed/Heat Exchanger Cooling System

Exhaust Systems

General

Water-cooled exhaust lines should be used in all marine installations. The hose used for the lines should have a 2 in. (51 mm) inside diameter. Keep the lines as short and straight as possible. The use of two hose clamps on each end of flexible exhaust hose connections is highly recommended. ABYC Safety Standards P-1.6.c recommend a pitch of at least 1/2 in. (12.8 mm) per running foot (30.5 cm). Use flexible steam hose conforming to UL Standard 1129 for “Engine wet exhaust components” between the mixing elbow and the exhaust outlet. A silencer should be independently mounted to eliminate any stress on the exhaust system and exhaust manifold/mixer elbow. See Figure 6-16 for the exhaust connection to the mixer elbow.

1	1-894
	1-894
1. Seawater/Exhaust Outlet

Figure 6-16. Mixer Elbow/Exhaust Connection

TP-5695 12/93

Installation 6-9

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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 AdjustmentsSpark Plugs Ignition System ServiceIgnition System Carbon fouled Problem Means of Identification Possible Cause NormalGap bridged Oil fouled12. Checking Spark Plug Gap Hot coolant and steam Can cause severe injury or death Cooling Systems- Closed/Heat ExchangerFilling and Checking 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 Lubrication Governor AdjustmentGovernor General Generator ServiceWattage Requirements Storage Procedure Not start TroubleshootingEngine Unit cranks but willOperates erratically Problem Possible Cause Corrective Action Stops suddenlyLacks power Electrical System Generator Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring Diagrams4CZ DiagramsTo Load Wire Generator SetsTo Generator To Shore Set Power 60 Hz LO Neutral GroundLoad Side Line SideWithout Jumper Lead L1--L3Page Motor Loads InstallationGenerator Selection and Wattage Requirements 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 WaterlineAC Voltage Connections Installation in Steel or Aluminum VesselsElectrical Systems 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