Manuals / Kohler / Lawn and Garden / Portable Generator

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ 7. Remote Start and Four-Meter Features, Water Temperature

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

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Water Temperature

Remote Start and Four-Meter

Panel Kit

Allows starting-stopping from a location remote of the generator set. The illuminated gauges include a DC voltmeter, engine oil pressure gauge, water temperature gauge, and generator running time hourmeter. Generator sets come equipped with a 6-pin connector on controller bottom for connection of the kit. See Figure 2-7 for remote start and four-meter panel features.

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

DC Voltmeter measures voltage of starting battery(ies). Normal battery operating range is 12--14 volts.

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).

Hourmeter records total generator set operating hours for reference in maintenance scheduling.

1	2
6
5	3
	3
	4
	1-830

1.	Engine Oil Pressure	4.	Water Temperature
2.	Hourmeter	5.	Start/Stop Switch
3.	Voltmeter	6.	“ON”Light

Figure 2-7. Remote Start and Four-Meter Features

TP-5695 12/93

Operation 2-7

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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ 7. Remote Start and Four-Meter Features, Remote Start and Four-Meter Panel Kit

Contents

Marine Generator Sets Models3.5CFZ 4CZ 5CFZ 6.5CZ TP-5695 12/93California Proposition Table of Contents Safety Precautions and InstructionsSection 3. Scheduled Maintenance Section 4. TroubleshootingSafety Precautions and Instructions HAZARDOUS VOLTAGE ELECTRICAL SHOCKDANGER Moving rotorEXHAUST SYSTEM Carbon monoxide Can cause severe nausea, fainting, or deathCarbon monoxide can cause severe nausea Carbon monoxide can cause severe nauseaSulfuric acid in batteries Can cause severe injury or death BATTERYSulfuric acid in batteries can cause severe injury or FUEL SYSTEM ExplosionGasoline vapors can cause explosion and severe injury or death Explosive fuel vapors Can cause severe injury or deathACCIDENTAL STARTING MOVING PARTSHOT PARTS Accidental starting Can cause severe injury or deathENGINE BACKFIRE/FLASH FIRE HAZARDOUS NOISEFire Can cause severe injury or death A sudden backfire can cause severe injury or deathThis generator set has been rewired from its nameplate voltage to This is a positive terminal only Do not attach negative leadCheck zinc anode every 100 hours or 3 months Do not use as a stepReference Material Pleasure CraftCommercial Vessels Additional ReferencesPart Description Routine Service PartsKohler Part No Glossary of Abbreviations AbbreviationDescription AbbreviationAbbreviation DescriptionAbbreviation DescriptionSection 1. Specifications SpecificationsGeneral Specifications IntroductionGenerator 3.5CFZ/4CZ5CFZ/6.5CZ 3.5CFZEngine 3.5CFZ/4CZ5CFZ/6.5CZ 2.28 x3.5CFZ/4CZ Engine Continued5CFZ/6.5CZ Accessories Ship-to-Shore Transfer Switch12-Inch Remote Wiring Harness Sound ShieldService Views Figure 1-1. Service Views typicalSection 2. Operation Prestart ChecksController Figure 2-1. ControllerStarting StoppingExplosion Gasoline vapors can cause explosion and severe injury or deathEngine Safety Shutdown Switches Battery-Charging Fuse 10 AmpLow Oil Pressure Shutdown Switch Figure 2-2. Low Oil Pressure Shutdown SwitchHigh Water Temperature High Exhaust TemperatureShutdown Switch Shutdown SwitchesFigure 2-5. Remote Panel Features Figure 2-6. Remote Start and Two-Meter Panel FeaturesRemote Panels Optional 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 Service Schedule AfterEvery BeforeService Schedule Continued REMOTE CONTROL SYSTEMELECTRICAL SYSTEM ENGINE AND MOUNTINGSpecifications Figure 3-1. Oil Service Class and SAE Viscosity Grade SymbolWhen Outside Temperature Lubrication SystemAdding Oil Oil Change/Oil Filter ChangeFigure 3-4. Adding Oil Figure 3-5. Oil Drain CapFigure 3-6. Removing Oil Filter Fuel SystemSpecifications Fuel Pump Screen Figure 3-7. Fuel Pump ScreenExplosive fuel vapors Can cause severe injury or death Explosive fuel vapors can cause severe injury orCarburetor Adjustments Figure 3-8. Fuel Mixture AdjustmentCarburetor/Choke Lubrication Fire Can cause severe injury or deathIgnition System Service Figure 3-9. Removing Spark Plug WiresIgnition System Spark PlugsProblem Means of IdentificationPossible Cause NormalFigure 3-13. Adjusting Spark Plug Gap Figure 3-12. Checking Spark Plug GapScheduled Maintenance 0.028--0.031 inFilling and Checking Cooling Systems- Closed/Heat ExchangerHot coolant and steam Can cause severe injury or death Figure 3-14. Air-Bleed Screw Figure 3-15. Coolant Pressure CapFigure 3-16. Checking Coolant Level Coolant Recovery TankFlushing and Cleaning Accidental starting Can cause severe injury or deathAccidental starting can cause severe injury or Hot coolant and steam Can cause severe injury or death13. Reconnect battery, negative lead last Anticorrosion Zinc Figure 3-17. Removing Anticorrosion ZincAir Cleaner and Mixing Elbow Servicing Air CleanerFigure 3-19. Air Cleaner Service Pressure CapBattery CleaningChecking Electrolyte Level Checking Specific GravityFigure 3-21. Specific Gravity Temperature Correction ChargingValve Adjustment Rotating parts Can cause severe injury or deathExposed moving parts can cause severe injury or Flying projectiles can cause severe injury or deathFigure 3-23. Valve Adjustment Figure 3-22. Determining Top Dead CenterAdjusting Screw 3 mm Scheduled MaintenanceGovernor Adjustment Figure 3-24. Governor AdjustmentGovernor LubricationWattage Requirements Generator ServiceGeneral Storage Procedure Section 4. Troubleshooting EngineCorrective Action Unit will not crankLacks power Engine ContinuedStops suddenly Operates erraticallyBattery will not Electrical SystemOverheats Unit is noisyGenerator No AC outputLow output or excessive drop inSection 5. Wiring Diagrams Figure 5-1. Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZWiring Diagrams TP-5695 12/93Wiring DiagramWiring DiagramsElectro Switch Kraus Naimler/American SolenoidEarly Rectangular Design Kraus Naimler/American SolenoidFour-Lead Reconnectable Single-Phase Generator Sets Where Generator 120- or 110- Volt 2-Wire Configuration Figure 5-5 Single Pole120- or 110-Volt 3-Wire 2-Pole Configuration--Figure Figure 5-5. 120 Volt, 2-Wire120/240- or 110/220-Volt Configuration--Figure L1--L3Figure 5-6. Without Jumper Lead LO NeutralPage Section 6. Installation Generator Selection and Wattage RequirementsMotor Loads Lighting Load“Power to Appliance LoadsKilowatt Derating MotorFigure 6-4. Typical Location and Mounting INPUT STOP/START 10A FUSE 00000 1/10 TOTAL HOURS BATT CHRGLocationVentilation SpaceMounting Air Requirements CFM L/minFuel Systems Fuel SupplyFigure 6-6. Dual Dip Tubes Figure 6-7. Single Dip TubeAnti-Siphon Provisions Fuel LinesFuel Pump Lift Capabilities and Fuel Consumption Figure 6-8. Fuel Pump Inlet ConnectionFigure 6-12. Seacock Installation Cooling SystemsFigure 6-11. Intake Strainer GeneralFigure 6-13. Seawater Strainer Closed/Heat ExchangerFigure 6-14. Seawater Inlet Connection Exhaust Systems Figure 6-15. Closed/Heat Exchanger Cooling SystemFigure 6-16. Mixer Elbow/Exhaust Connection GeneralFigure 6-17. Typical Above Waterline Installation Carbon monoxideCan cause severe nausea, fainting, or death Carbon monoxide can cause severe nauseaFigure 6-19. Typical Mid and Below Waterline Installation Above WaterlineMid/Below Waterline Figure 6-18. Siphon Break ComponentsInstallation in Steel or Aluminum Vessels Electrical SystemsAC Voltage Connections ExplosionBattery WiringBattery Figure 6-20. Battery Cable SizesRemote Start Switch Connection Figure 6-22. Remote Control Panel WiringLead Designations Lead7-1. Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ 7. Installation DrawingsInstallation Drawings SectionSound Shield--Optional on 3.5CFZ and 4CZ Standard on 5CFZ and 6.5CZInstallation Drawings 12/93Section 8. Parts Ordering Instructions Section 9. Operating Hour Service Log SERVICE RECORDSERVICE DATETP-5695 12/93 PRINTED IN U.S.A KOHLER CO. KOHLER, WISCONSIN 53044 PHONE