Reference Material | Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ instruction

Reference Material

It is recommended that the following Regulations and

Standards be followed when installing Marine

Generator Sets.

Pleasure Craft

Designed and manufactured to meet U.S. Coast Guard Title 33.

U.S. Coast Guard Code of Federal Regulations

Title 33

Subparts I--Electrical Systems

Subparts J--Fuel Systems

Title 46

Subchapter F--Marine Engineering

Part 58--Main and Auxiliary Machinery and Related

Systems

Order the above publications from: Superintendent of Documents U.S. Government Printing Office Washington, DC 20402 1-202-783-3238

Boating Safety Circular Commandant (G-BC) Boating Statistics (G-BP-1)

U.S. Coast Guard Headquarters

2100 Second Street, S.W.

Washington, DC 20593-0001

Boating Safety Hotline: 1-800-368-5647

American Bureau of Shipping

“Rules for Building and Classing Steel Vessels” 45 Eisenhower Drive

Paramus, N.J. 07652 201-368-9100

Lloyds Registry of Shipping “Rules for Classification of Ships” 17 Battery Place

New York, N.Y. 10004 212-425-8050

Underwriters Laboratories, Inc. (UL)

Publications Stock

333 Pfingsten Road

Northbrook, IL 60062

Marine Department: 1-919-549-1400

NFPA 302

National Fire Protection Association

60 Batterymarch Park

Quincy, MA 02269

Customer Service

Society of Automotive Engineer’s (SAE) 400 Commonwealth Drive Warrendale, PA 15096 1-412-776-4970

American Boat and Yacht Council, Inc. (ABYC) 3069 Solomon’s Island Rd.

Edgewater, MD 21037 1-410-956-1050 1-410-974-8112

1-410-956-2737 FAX

IEEE 45

The Institute of Electrical and

Electronics Engineer’s Inc.

345 East 47th Street

New York, NY 10017

viii Reference Material

TP-5695 12/93

Image 11

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Reference Material, Pleasure Craft

Contents

5CZ Marine Generator SetsModels 5CFZ California Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide can cause severe nausea Carbon monoxide Can cause severe nausea, fainting, or death Sulfuric acid in batteries can cause severe injury or Sulfuric acid in batteries Can cause severe injury or death Explosive fuel vapors can cause severe injury or Explosive fuel vapors Can cause severe injury or death Flying 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 death Hazardous 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 death 246242 Pleasure Craft Reference Material Additional References Commercial Vessels Part Description Kohler Part No Routine Service Parts Abbreviation Description Glossary of Abbreviations NEC Introduction SpecificationsSpecifications General Specifications 5CFZ/4CZ 5CFZ/6.5CZ Generator GX360EV Engine BPR4HS NGK Accessories Service Views typical Service Views Prestart Checks Operation Controller Controller Stopping Starting Circuit Protection Engine Safety Shutdown Switches High Water Temperature Shutdown Switch Remote Panels Optional Remote Panel Features Remote Start and Four-Meter Panel Kit Remote Start and Four-Meter Features Scheduled Maintenance Or 2 Years Service Schedule Generator Lubrication System Specifications Oil Change/Oil Filter Change Adding Oil Removing Oil Filter Fuel System Fuel Pump Screen Fuel Pump Screen Carburetor/Choke Lubrication Carburetor Adjustments Spark Plugs Ignition System ServiceIgnition System Carbon fouled Problem Means of Identification Possible Cause NormalGap bridged Oil fouled 12. 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 Zinc Servicing Mixing Elbow Air Cleaner Mixing ElbowServicing Air Cleaner Pressure Cap Checking Specific Gravity BatteryCleaning Checking Electrolyte Level Charging 21. Specific Gravity Temperature Correction Valve Adjustment 22. Determining Top Dead Center Lubrication Governor AdjustmentGovernor General Generator ServiceWattage Requirements Storage Procedure Not start TroubleshootingEngine Unit cranks but will Operates erratically Problem Possible Cause Corrective Action Stops suddenlyLacks power Electrical System Generator Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring Diagrams 4CZ Diagrams To Load Wire Generator SetsTo Generator To Shore Set Power 60 Hz LO Neutral GroundLoad Side Line Side Without Jumper Lead L1--L3Page Motor Loads InstallationGenerator Selection and Wattage Requirements Kilowatt Derating Appliance Loads Typical Location and Mounting Air Requirements CFM L/min Model Combustion Cooling LocationVentilationSpace Mounting Fuel Supply Fuel Systems Max. Lift ft. m In. mm Anti-Siphon ProvisionsFuel Lines Fuel Pump Lift Capabilities Fuel Consumption 11. Intake Strainer Cooling Systems 13. Seawater Strainer Closed/Heat Exchanger 15. Closed/Heat Exchanger Cooling System Exhaust Systems Carbon monoxide 17. Typical Above Waterline Installation Mid/Below Waterline Above Waterline AC Voltage Connections Installation in Steel or Aluminum VesselsElectrical Systems Wiring Battery Lead Designations Pin Function Remote Start Switch Connection Section Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Standard on 5CFZ and 6.5CZ Sound Shield--Optional on 3.5CFZ and 4CZ Parts Ordering Instructions For Sales & Service in U.S.A. & Canada Phone Operating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone