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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual California Proposition

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

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California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual California Proposition

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 BATTERYSulfuric acid in batteries Can cause severe injury or death 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 ReferencesKohler Part No Routine Service PartsPart Description 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 x5CFZ/6.5CZ Engine Continued3.5CFZ/4CZ 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 PanelRemote 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 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 CapSpecifications Fuel SystemFigure 3-6. Removing Oil Filter 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 inHot coolant and steam Can cause severe injury or death Cooling Systems- Closed/Heat ExchangerFilling and Checking 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 LubricationGeneral Generator ServiceWattage Requirements 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 6-14. Seawater Inlet Connection Closed/Heat ExchangerFigure 6-13. Seawater Strainer 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