Manuals / Kohler / Lawn and Garden / Portable Generator

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ This generator set has been rewired from its nameplate voltage to

Models: 3.5CFZ, 4CZ, 5CFZ, 6.5CZ

1 81

Download 81 pages 39.68 Kb

Page 10

This generator set has been rewired from its nameplate voltage to:

NOTES

NOTE

HARDWARE DAMAGE! Engine and generator may make use of both American Standard and metric hardware. Be sure to use the correct size tools to prevent rounding of bolt heads and nuts.

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.

NOTE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different hardness ratings. American Standard hardware uses a series of markings and metric hardware uses a numeric system to indicate hardness. Check markings on bolt head and nuts for proper identification.

NOTE

When a fuse replacement is required, be sure fuse has the same ampere rating and is the same type (for example: ABC or 3AB, ceramic). Do not substitute “clear” glass-type fuses for ceramic fuses. If ampere rating is unknown or questionable, see Wiring Diagram.

NOTE

High-mineral content sea water (salt water) can cause rapid destruction of all metals. Wipe up all salt water spillage on and around generator set and keep metal surfaces free from accumulated salt deposits.

NOTICE

This generator set has been rewired from its nameplate voltage to:

246242

NOTICE

This is a positive terminal only.

Do not attach negative lead!

NOTICE

Check zinc anode every 100 hours or 3 months.

NOTICE

Do not use as a step.

Standing on genset could impair operation of unit.

NOTE

Split lock washers may be supplied with some kits. If split lock washers are supplied with kit, their use is optional.

TP-5695 12/93

Safety Precautions and Instructions vii

Image 10

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ This generator set has been rewired from its nameplate voltage to, Do not use as a step

Contents

3.5CFZ 4CZ 5CFZ 6.5CZ Marine Generator SetsModels TP-5695 12/93California Proposition Section 3. Scheduled Maintenance Table of ContentsSafety Precautions and Instructions Section 4. TroubleshootingDANGER Safety Precautions and InstructionsHAZARDOUS VOLTAGE ELECTRICAL SHOCK Moving rotorCarbon monoxide can cause severe nausea EXHAUST SYSTEMCarbon monoxide Can cause severe nausea, fainting, or death Carbon monoxide can cause severe nauseaSulfuric acid in batteries Can cause severe injury or death BATTERYSulfuric acid in batteries can cause severe injury or Gasoline vapors can cause explosion and severe injury or death FUEL SYSTEMExplosion Explosive fuel vapors Can cause severe injury or deathHOT PARTS ACCIDENTAL STARTINGMOVING PARTS Accidental starting Can cause severe injury or deathFire Can cause severe injury or death ENGINE BACKFIRE/FLASH FIREHAZARDOUS NOISE A sudden backfire can cause severe injury or deathCheck zinc anode every 100 hours or 3 months This generator set has been rewired from its nameplate voltage toThis is a positive terminal only Do not attach negative lead Do not use as a stepReference Material Pleasure CraftCommercial Vessels Additional ReferencesPart Description Routine Service PartsKohler Part No Description Glossary of AbbreviationsAbbreviation AbbreviationAbbreviation AbbreviationDescription DescriptionGeneral Specifications Section 1. SpecificationsSpecifications Introduction5CFZ/6.5CZ Generator3.5CFZ/4CZ 3.5CFZ5CFZ/6.5CZ Engine3.5CFZ/4CZ 2.28 x3.5CFZ/4CZ Engine Continued5CFZ/6.5CZ 12-Inch Remote Wiring Harness AccessoriesShip-to-Shore Transfer Switch Sound ShieldService Views Figure 1-1. Service Views typicalSection 2. Operation Prestart ChecksController Figure 2-1. ControllerExplosion StartingStopping Gasoline vapors can cause explosion and severe injury or deathLow Oil Pressure Shutdown Switch Engine Safety Shutdown SwitchesBattery-Charging Fuse 10 Amp Figure 2-2. Low Oil Pressure Shutdown SwitchShutdown Switch High Water TemperatureHigh Exhaust Temperature Shutdown SwitchesRemote Panels Optional Figure 2-5. Remote Panel FeaturesFigure 2-6. Remote Start and Two-Meter Panel Features Remote Start PanelWater Temperature Figure 2-7. Remote Start and Four-Meter FeaturesRemote Start and Four-Meter Panel Kit Accidental starting Can cause severe injury or death Section 3. Scheduled MaintenanceAccidental starting can cause severe injury or Every Service ScheduleAfter BeforeELECTRICAL SYSTEM Service Schedule ContinuedREMOTE CONTROL SYSTEM ENGINE AND MOUNTINGWhen Outside Temperature SpecificationsFigure 3-1. Oil Service Class and SAE Viscosity Grade Symbol Lubrication SystemFigure 3-4. Adding Oil Adding OilOil Change/Oil Filter Change Figure 3-5. Oil Drain CapFigure 3-6. Removing Oil Filter Fuel SystemSpecifications Explosive fuel vapors Can cause severe injury or death Fuel Pump ScreenFigure 3-7. Fuel Pump Screen Explosive fuel vapors can cause severe injury orCarburetor/Choke Lubrication Carburetor AdjustmentsFigure 3-8. Fuel Mixture Adjustment Fire Can cause severe injury or deathIgnition System Ignition System ServiceFigure 3-9. Removing Spark Plug Wires Spark PlugsPossible Cause ProblemMeans of Identification NormalScheduled Maintenance Figure 3-13. Adjusting Spark Plug GapFigure 3-12. Checking Spark Plug Gap 0.028--0.031 inFilling and Checking Cooling Systems- Closed/Heat ExchangerHot coolant and steam Can cause severe injury or death Figure 3-16. Checking Coolant Level Figure 3-14. Air-Bleed ScrewFigure 3-15. Coolant Pressure Cap Coolant Recovery TankAccidental starting can cause severe injury or Flushing and CleaningAccidental starting Can cause severe injury or death Hot coolant and steam Can cause severe injury or death13. Reconnect battery, negative lead last Anticorrosion Zinc Figure 3-17. Removing Anticorrosion ZincFigure 3-19. Air Cleaner Service Air Cleaner and Mixing ElbowServicing Air Cleaner Pressure CapChecking Electrolyte Level BatteryCleaning Checking Specific GravityFigure 3-21. Specific Gravity Temperature Correction ChargingExposed moving parts can cause severe injury or Valve AdjustmentRotating parts Can cause severe injury or death Flying projectiles can cause severe injury or deathAdjusting Screw 3 mm Figure 3-23. Valve AdjustmentFigure 3-22. Determining Top Dead Center Scheduled MaintenanceGovernor Governor AdjustmentFigure 3-24. Governor Adjustment LubricationWattage Requirements Generator ServiceGeneral Storage Procedure Corrective Action Section 4. TroubleshootingEngine Unit will not crankStops suddenly Lacks powerEngine Continued Operates erraticallyOverheats Battery will notElectrical System Unit is noisyLow output or GeneratorNo AC output excessive drop inWiring Diagrams Section 5. Wiring DiagramsFigure 5-1. Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ TP-5695 12/93Wiring WiringDiagram DiagramsEarly Rectangular Design Electro SwitchKraus Naimler/American Solenoid Kraus Naimler/American Solenoid120- or 110-Volt 3-Wire 2-Pole Configuration--Figure Four-Lead Reconnectable Single-Phase Generator Sets Where Generator120- or 110- Volt 2-Wire Configuration Figure 5-5 Single Pole Figure 5-5. 120 Volt, 2-WireFigure 5-6. Without Jumper Lead 120/240- or 110/220-Volt Configuration--FigureL1--L3 LO NeutralPage Motor Loads Section 6. InstallationGenerator Selection and Wattage Requirements Lighting LoadKilowatt Derating “Power toAppliance Loads MotorFigure 6-4. Typical Location and Mounting INPUT STOP/START 10A FUSE 00000 1/10 TOTAL HOURS BATT CHRGMounting LocationVentilationSpace Air Requirements CFM L/minFigure 6-6. Dual Dip Tubes Fuel SystemsFuel Supply Figure 6-7. Single Dip TubeFuel Pump Lift Capabilities and Fuel Consumption Anti-Siphon ProvisionsFuel Lines Figure 6-8. Fuel Pump Inlet ConnectionFigure 6-11. Intake Strainer Figure 6-12. Seacock InstallationCooling Systems GeneralFigure 6-13. Seawater Strainer Closed/Heat ExchangerFigure 6-14. Seawater Inlet Connection Figure 6-16. Mixer Elbow/Exhaust Connection Exhaust SystemsFigure 6-15. Closed/Heat Exchanger Cooling System GeneralCan cause severe nausea, fainting, or death Figure 6-17. Typical Above Waterline InstallationCarbon monoxide Carbon monoxide can cause severe nauseaMid/Below Waterline Figure 6-19. Typical Mid and Below Waterline InstallationAbove Waterline Figure 6-18. Siphon Break ComponentsAC Voltage Connections Installation in Steel or Aluminum VesselsElectrical Systems ExplosionBattery BatteryWiring Figure 6-20. Battery Cable SizesLead Designations Remote Start Switch ConnectionFigure 6-22. Remote Control Panel Wiring LeadInstallation Drawings 7-1. Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ7. Installation Drawings SectionInstallation Drawings Sound Shield--Optional on 3.5CFZ and 4CZStandard on 5CFZ and 6.5CZ 12/93Section 8. Parts Ordering Instructions SERVICE Section 9. Operating Hour Service LogSERVICE RECORD DATETP-5695 12/93 PRINTED IN U.S.A KOHLER CO. KOHLER, WISCONSIN 53044 PHONE