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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Reconnect battery, negative lead last

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

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13.Reconnect battery, negative lead last.

14.Start generator set and allow the set to run for about 20--30 seconds. Stop generator set and recheck coolant level by removing heat exchanger pressure cap. Add straight coolant, if necessary, until level is just below the overflow tube opening, then reinstall pressure cap. Repeat this step until coolant can no longer be added. This procedure should give an approximate mixture of 50% ethylene glycol and 50% water.

15.Wipe up spilled coolant and water with rags. Dispose of rags in a proper container.

16.Test run generator set for about five minutes and check for coolant leaks. This will allow the coolant mixture to mix completely. Stop generator set.

17.Rinse coolant flush kit hoses and fittings with clean water. Store kit for future use.

18.Dispose of used coolant in a proper manner. Do NOT pollute waterways!

TP-5695 12/93

Scheduled Maintenance 3-15

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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Reconnect battery, negative lead last

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 death BATTERYSulfuric 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 VesselsPart Description Routine Service PartsKohler 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/6.5CZ3.5CFZ/4CZ Engine Continued5CFZ/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 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 OptionalWater 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 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 OilFigure 3-6. Removing Oil Filter Fuel SystemSpecifications 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 MaintenanceFilling and Checking Cooling Systems- Closed/Heat ExchangerHot 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 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 GovernorWattage Requirements Generator ServiceGeneral 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 6-13. Seawater Strainer Closed/Heat ExchangerFigure 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