Manuals / Kohler / Lawn and Garden / Portable Generator

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ 14. Air-Bleed Screw, 15. Coolant Pressure Cap, Overflow Hose

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

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1. Air-Bleed Screw; Use 12 mm Wrench

Figure 3-14. Air-Bleed Screw

1		3
1		2
INPUT	STOP	START
10A
FUSE
	00 0 0 0	1/10
	TOTAL HOURS
BATT.
CHRG.
		258000-D

1.	Coolant Recovery Tank	3. Coolant Pressure Cap
2.	Overflow Hose

Figure 3-15. Coolant Pressure Cap

1
INPUT	STOP	START
10A
FUSE
	00 0 0 0	1/10
	TOTAL HOURS
BATT.
CHRG.
2		258000-D
		258000-D

1. MAX. Mark

2. MIN. Mark

Figure 3-16. Checking Coolant Level

TP-5695 12/93

Scheduled Maintenance 3-13

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Image 41

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ 14. Air-Bleed Screw, 15. Coolant Pressure Cap, 16. Checking Coolant Level, Overflow Hose

Contents

Models Marine Generator Sets3.5CFZ 4CZ 5CFZ 6.5CZ TP-5695 12/93California Proposition Safety Precautions and Instructions Table of ContentsSection 3. Scheduled Maintenance Section 4. TroubleshootingHAZARDOUS VOLTAGE ELECTRICAL SHOCK Safety Precautions and InstructionsDANGER Moving rotorCarbon monoxide Can cause severe nausea, fainting, or death EXHAUST SYSTEMCarbon monoxide can cause severe nausea Carbon monoxide can cause severe nauseaSulfuric acid in batteries can cause severe injury or BATTERYSulfuric acid in batteries Can cause severe injury or death Explosion FUEL SYSTEMGasoline vapors can cause explosion and severe injury or death Explosive fuel vapors Can cause severe injury or deathMOVING PARTS ACCIDENTAL STARTINGHOT PARTS Accidental starting Can cause severe injury or deathHAZARDOUS NOISE ENGINE BACKFIRE/FLASH FIREFire Can cause severe injury or death A sudden backfire can cause severe injury or deathThis is a positive terminal only Do not attach negative lead This generator set has been rewired from its nameplate voltage toCheck zinc anode every 100 hours or 3 months Do not use as a stepPleasure Craft Reference MaterialAdditional References Commercial VesselsKohler Part No Routine Service PartsPart Description Abbreviation Glossary of AbbreviationsDescription AbbreviationDescription AbbreviationAbbreviation DescriptionSpecifications Section 1. SpecificationsGeneral Specifications Introduction3.5CFZ/4CZ Generator5CFZ/6.5CZ 3.5CFZ3.5CFZ/4CZ Engine5CFZ/6.5CZ 2.28 x5CFZ/6.5CZ Engine Continued3.5CFZ/4CZ Ship-to-Shore Transfer Switch Accessories12-Inch Remote Wiring Harness Sound ShieldFigure 1-1. Service Views typical Service ViewsPrestart Checks Section 2. OperationFigure 2-1. Controller ControllerStopping StartingExplosion Gasoline vapors can cause explosion and severe injury or deathBattery-Charging Fuse 10 Amp Engine Safety Shutdown SwitchesLow Oil Pressure Shutdown Switch Figure 2-2. Low Oil Pressure Shutdown SwitchHigh Exhaust Temperature High Water TemperatureShutdown Switch Shutdown SwitchesFigure 2-6. Remote Start and Two-Meter Panel Features Figure 2-5. Remote Panel FeaturesRemote Panels Optional 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 After Service ScheduleEvery BeforeREMOTE CONTROL SYSTEM Service Schedule ContinuedELECTRICAL SYSTEM ENGINE AND MOUNTINGFigure 3-1. Oil Service Class and SAE Viscosity Grade Symbol SpecificationsWhen Outside Temperature Lubrication SystemOil Change/Oil Filter Change Adding OilFigure 3-4. Adding Oil Figure 3-5. Oil Drain CapSpecifications Fuel SystemFigure 3-6. Removing Oil Filter Figure 3-7. Fuel Pump Screen Fuel Pump ScreenExplosive fuel vapors Can cause severe injury or death Explosive fuel vapors can cause severe injury orFigure 3-8. Fuel Mixture Adjustment Carburetor AdjustmentsCarburetor/Choke Lubrication Fire Can cause severe injury or deathFigure 3-9. Removing Spark Plug Wires Ignition System ServiceIgnition System Spark PlugsMeans of Identification ProblemPossible Cause NormalFigure 3-12. Checking Spark Plug Gap Figure 3-13. Adjusting Spark Plug GapScheduled Maintenance 0.028--0.031 inHot coolant and steam Can cause severe injury or death Cooling Systems- Closed/Heat ExchangerFilling and Checking Figure 3-15. Coolant Pressure Cap Figure 3-14. Air-Bleed ScrewFigure 3-16. Checking Coolant Level Coolant Recovery TankAccidental starting Can cause severe injury or death Flushing and CleaningAccidental starting can cause severe injury or Hot coolant and steam Can cause severe injury or death13. Reconnect battery, negative lead last Figure 3-17. Removing Anticorrosion Zinc Anticorrosion ZincServicing Air Cleaner Air Cleaner and Mixing ElbowFigure 3-19. Air Cleaner Service Pressure CapCleaning BatteryChecking Electrolyte Level Checking Specific GravityCharging Figure 3-21. Specific Gravity Temperature CorrectionRotating parts Can cause severe injury or death Valve AdjustmentExposed moving parts can cause severe injury or Flying projectiles can cause severe injury or deathFigure 3-22. Determining Top Dead Center Figure 3-23. Valve AdjustmentAdjusting Screw 3 mm Scheduled MaintenanceFigure 3-24. Governor Adjustment Governor AdjustmentGovernor LubricationGeneral Generator ServiceWattage Requirements Storage Procedure Engine Section 4. TroubleshootingCorrective Action Unit will not crankEngine Continued Lacks powerStops suddenly Operates erraticallyElectrical System Battery will notOverheats Unit is noisyNo AC output GeneratorLow output or excessive drop inFigure 5-1. Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Section 5. Wiring DiagramsWiring Diagrams TP-5695 12/93Diagram WiringWiring DiagramsKraus Naimler/American Solenoid Electro SwitchEarly Rectangular Design Kraus Naimler/American Solenoid120- or 110- Volt 2-Wire Configuration Figure 5-5 Single Pole Four-Lead Reconnectable Single-Phase Generator Sets Where Generator120- or 110-Volt 3-Wire 2-Pole Configuration--Figure Figure 5-5. 120 Volt, 2-WireL1--L3 120/240- or 110/220-Volt Configuration--FigureFigure 5-6. Without Jumper Lead LO NeutralPage Generator Selection and Wattage Requirements Section 6. InstallationMotor Loads Lighting LoadAppliance Loads “Power toKilowatt Derating MotorINPUT STOP/START 10A FUSE 00000 1/10 TOTAL HOURS BATT CHRG Figure 6-4. Typical Location and MountingSpace LocationVentilationMounting Air Requirements CFM L/minFuel Supply Fuel SystemsFigure 6-6. Dual Dip Tubes Figure 6-7. Single Dip TubeFuel Lines Anti-Siphon ProvisionsFuel Pump Lift Capabilities and Fuel Consumption Figure 6-8. Fuel Pump Inlet ConnectionCooling Systems Figure 6-12. Seacock InstallationFigure 6-11. Intake Strainer GeneralFigure 6-14. Seawater Inlet Connection Closed/Heat ExchangerFigure 6-13. Seawater Strainer Figure 6-15. Closed/Heat Exchanger Cooling System Exhaust SystemsFigure 6-16. Mixer Elbow/Exhaust Connection GeneralCarbon monoxide Figure 6-17. Typical Above Waterline InstallationCan cause severe nausea, fainting, or death Carbon monoxide can cause severe nauseaAbove Waterline Figure 6-19. Typical Mid and Below Waterline InstallationMid/Below Waterline Figure 6-18. Siphon Break ComponentsElectrical Systems Installation in Steel or Aluminum VesselsAC Voltage Connections ExplosionWiring BatteryBattery Figure 6-20. Battery Cable SizesFigure 6-22. Remote Control Panel Wiring Remote Start Switch ConnectionLead Designations Lead7. Installation Drawings 7-1. Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZInstallation Drawings SectionStandard on 5CFZ and 6.5CZ Sound Shield--Optional on 3.5CFZ and 4CZInstallation Drawings 12/93Section 8. Parts Ordering Instructions SERVICE RECORD Section 9. Operating Hour Service LogSERVICE DATEKOHLER CO. KOHLER, WISCONSIN 53044 PHONE TP-5695 12/93 PRINTED IN U.S.A

1. Air-Bleed Screw; Use 12 mm Wrench

Figure 3-14. Air-Bleed Screw

Coolant Recovery Tank

3. Coolant Pressure Cap

Overflow Hose

Figure 3-15. Coolant Pressure Cap

1. MAX. Mark

2. MIN. Mark

Figure 3-16. Checking Coolant Level