Manuals / Kohler / Lawn and Garden / Portable Generator

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Remote Panels Optional, 5. Remote Panel Features

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

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Remote Panels (Optional)

Remote Panels (Optional)

Remote Start Panel

Remote start panel allows starting-stopping from a location remote of the generator set. Generator sets are equipped with a 6-pin connector on controller bottom for connection of the kit. See Figure 2-5.

KOHLER

GENERATOR

START	2

1

STOP

1-656

1. “ON”Light

2. Start/Stop Switch

Figure 2-5. Remote Panel Features

Remote Start and

Two-Meter Panel Kit

Allows starting-stopping from a location remote of the generator set. The illuminated gauges include an engine oil pressure gauge and a water temperature gauge. Generator sets come equipped with a 6-pin connector on controller bottom for connection of the kit. See Figure 2-6 for remote start and meter panel kit.

		1
		2
	4	3		1-762
				1-762
1.	Engine Oil Pressure		3.	Start/Stop Switch
2.	Water Temperature		4.	“On”Light

Figure 2-6. Remote Start and Two-Meter

Panel Features

Start/Stop Switch is a rocker-type switch with “ON” light used to start and stop generator set.

Engine Oil Pressure Gauge measures engine oil pressure. Normal engine operating range is 30--50 psi (207--345 kPa).

NOTE

During the engine break-in period, it is normal for the engine to produce higher oil pressure readings.

Water Temperature Gauge measures engine coolant temperature. Normal engine operating range is 170--195_F(77--91_C).

2-6 Operation

TP-5695 12/93

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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Remote Panels Optional, 5. Remote Panel Features, Remote Start Panel

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 nauseaBATTERY Sulfuric acid in batteries Can cause severe injury or deathSulfuric acid in batteries can cause severe injury or 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 VesselsRoutine Service Parts Part DescriptionKohler Part No 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/6.5CZEngine Continued 3.5CFZ/4CZ5CFZ/6.5CZ 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 SwitchFigure 2-4. High Exhaust Temperature Shutdown Switches Shutdown SwitchShutdown Switches Figure 2-3. High Water Temperature Shutdown SwitchRemote Start Panel Figure 2-5. Remote Panel FeaturesFigure 2-6. Remote Start and Two-Meter Panel Features Remote Panels OptionalFigure 2-7. Remote Start and Four-Meter Features Remote Start and Four-Meter Panel KitWater Temperature Section 3. Scheduled Maintenance Accidental starting Can cause severe injury or deathAccidental starting can cause severe injury or 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 OilFuel System Figure 3-6. Removing Oil FilterSpecifications 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 MaintenanceCooling Systems- Closed/Heat Exchanger Filling and CheckingHot coolant and steam Can cause severe injury or death 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 LevelFigure 3-21. Specific Gravity Temperature Correction ChargingFlying 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 GovernorGenerator Service Wattage RequirementsGeneral 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 StrainerClosed/Heat Exchanger Figure 6-13. Seawater StrainerFigure 6-14. Seawater Inlet Connection 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