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

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

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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

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

Contents

TP-5695 12/93 Marine Generator SetsModels 3.5CFZ 4CZ 5CFZ 6.5CZCalifornia Proposition Section 4. Troubleshooting Table of ContentsSafety Precautions and Instructions Section 3. Scheduled MaintenanceMoving rotor Safety Precautions and InstructionsHAZARDOUS VOLTAGE ELECTRICAL SHOCK DANGERCarbon 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 BATTERYSulfuric acid in batteries Can cause severe injury or death Explosive fuel vapors Can cause severe injury or death FUEL SYSTEMExplosion Gasoline vapors can cause explosion and severe injury or deathAccidental starting Can cause severe injury or death ACCIDENTAL STARTINGMOVING PARTS HOT PARTSA sudden backfire can cause severe injury or death ENGINE BACKFIRE/FLASH FIREHAZARDOUS NOISE Fire Can cause severe injury or deathDo not use as a step This generator set has been rewired from its nameplate voltage toThis is a positive terminal only Do not attach negative lead Check zinc anode every 100 hours or 3 monthsPleasure Craft Reference MaterialAdditional References Commercial VesselsKohler Part No Routine Service PartsPart Description Abbreviation Glossary of AbbreviationsAbbreviation DescriptionDescription AbbreviationDescription AbbreviationIntroduction Section 1. SpecificationsSpecifications General Specifications3.5CFZ Generator3.5CFZ/4CZ 5CFZ/6.5CZ2.28 x Engine3.5CFZ/4CZ 5CFZ/6.5CZ5CFZ/6.5CZ Engine Continued3.5CFZ/4CZ Sound Shield AccessoriesShip-to-Shore Transfer Switch 12-Inch Remote Wiring HarnessFigure 1-1. Service Views typical Service ViewsPrestart Checks Section 2. OperationFigure 2-1. Controller ControllerGasoline vapors can cause explosion and severe injury or death StartingStopping ExplosionFigure 2-2. Low Oil Pressure Shutdown Switch Engine Safety Shutdown SwitchesBattery-Charging Fuse 10 Amp Low Oil Pressure Shutdown SwitchShutdown Switches High Water TemperatureHigh Exhaust Temperature Shutdown SwitchRemote Start Panel Figure 2-5. Remote Panel FeaturesFigure 2-6. Remote Start and Two-Meter Panel Features Remote Panels OptionalRemote Start and Four-Meter Panel Kit Figure 2-7. Remote Start and Four-Meter FeaturesWater Temperature Accidental starting can cause severe injury or Section 3. Scheduled MaintenanceAccidental starting Can cause severe injury or death Before Service ScheduleAfter EveryENGINE AND MOUNTING Service Schedule ContinuedREMOTE CONTROL SYSTEM ELECTRICAL SYSTEMLubrication System SpecificationsFigure 3-1. Oil Service Class and SAE Viscosity Grade Symbol When Outside TemperatureFigure 3-5. Oil Drain Cap Adding OilOil Change/Oil Filter Change Figure 3-4. Adding OilSpecifications Fuel SystemFigure 3-6. Removing Oil Filter Explosive fuel vapors can cause severe injury or Fuel Pump ScreenFigure 3-7. Fuel Pump Screen Explosive fuel vapors Can cause severe injury or deathFire Can cause severe injury or death Carburetor AdjustmentsFigure 3-8. Fuel Mixture Adjustment Carburetor/Choke LubricationSpark Plugs Ignition System ServiceFigure 3-9. Removing Spark Plug Wires Ignition SystemNormal ProblemMeans of Identification Possible Cause0.028--0.031 in Figure 3-13. Adjusting Spark Plug GapFigure 3-12. Checking Spark Plug Gap Scheduled MaintenanceHot coolant and steam Can cause severe injury or death Cooling Systems- Closed/Heat ExchangerFilling and Checking Coolant Recovery Tank Figure 3-14. Air-Bleed ScrewFigure 3-15. Coolant Pressure Cap Figure 3-16. Checking Coolant LevelHot coolant and steam Can cause severe injury or death Flushing and CleaningAccidental starting Can cause severe injury or death Accidental starting can cause severe injury or13. Reconnect battery, negative lead last Figure 3-17. Removing Anticorrosion Zinc Anticorrosion ZincPressure Cap Air Cleaner and Mixing ElbowServicing Air Cleaner Figure 3-19. Air Cleaner ServiceChecking Specific Gravity BatteryCleaning Checking Electrolyte LevelCharging Figure 3-21. Specific Gravity Temperature CorrectionFlying projectiles can cause severe injury or death Valve AdjustmentRotating parts Can cause severe injury or death Exposed moving parts can cause severe injury orScheduled Maintenance Figure 3-23. Valve AdjustmentFigure 3-22. Determining Top Dead Center Adjusting Screw 3 mmLubrication Governor AdjustmentFigure 3-24. Governor Adjustment GovernorGeneral Generator ServiceWattage Requirements Storage Procedure Unit will not crank Section 4. TroubleshootingEngine Corrective ActionOperates erratically Lacks powerEngine Continued Stops suddenlyUnit is noisy Battery will notElectrical System Overheatsexcessive drop in GeneratorNo AC output Low output orTP-5695 12/93 Section 5. Wiring DiagramsFigure 5-1. Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring DiagramsDiagrams WiringDiagram WiringKraus Naimler/American Solenoid Electro SwitchKraus Naimler/American Solenoid Early Rectangular DesignFigure 5-5. 120 Volt, 2-Wire Four-Lead Reconnectable Single-Phase Generator Sets Where Generator120- or 110- Volt 2-Wire Configuration Figure 5-5 Single Pole 120- or 110-Volt 3-Wire 2-Pole Configuration--FigureLO Neutral 120/240- or 110/220-Volt Configuration--FigureL1--L3 Figure 5-6. Without Jumper LeadPage Lighting Load Section 6. InstallationGenerator Selection and Wattage Requirements Motor LoadsMotor “Power toAppliance Loads Kilowatt DeratingINPUT STOP/START 10A FUSE 00000 1/10 TOTAL HOURS BATT CHRG Figure 6-4. Typical Location and MountingAir Requirements CFM L/min LocationVentilationSpace MountingFigure 6-7. Single Dip Tube Fuel SystemsFuel Supply Figure 6-6. Dual Dip TubesFigure 6-8. Fuel Pump Inlet Connection Anti-Siphon ProvisionsFuel Lines Fuel Pump Lift Capabilities and Fuel ConsumptionGeneral Figure 6-12. Seacock InstallationCooling Systems Figure 6-11. Intake StrainerFigure 6-14. Seawater Inlet Connection Closed/Heat ExchangerFigure 6-13. Seawater Strainer General Exhaust SystemsFigure 6-15. Closed/Heat Exchanger Cooling System Figure 6-16. Mixer Elbow/Exhaust ConnectionCarbon monoxide can cause severe nausea Figure 6-17. Typical Above Waterline InstallationCarbon monoxide Can cause severe nausea, fainting, or deathFigure 6-18. Siphon Break Components Figure 6-19. Typical Mid and Below Waterline InstallationAbove Waterline Mid/Below WaterlineExplosion Installation in Steel or Aluminum VesselsElectrical Systems AC Voltage ConnectionsFigure 6-20. Battery Cable Sizes BatteryWiring BatteryLead Remote Start Switch ConnectionFigure 6-22. Remote Control Panel Wiring Lead DesignationsSection 7-1. Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ7. Installation Drawings Installation Drawings12/93 Sound Shield--Optional on 3.5CFZ and 4CZStandard on 5CFZ and 6.5CZ Installation DrawingsSection 8. Parts Ordering Instructions DATE Section 9. Operating Hour Service LogSERVICE RECORD SERVICEKOHLER CO. KOHLER, WISCONSIN 53044 PHONE TP-5695 12/93 PRINTED IN U.S.A