Manuals / Kohler / Lawn and Garden / Portable Generator

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Point, Wiring, Diagrams, TP-5695 12/93

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

1 81

Download 81 pages 39.68 Kb

Page 58

Wiring

5-2	ENGINE					THERMAL		FUEL PUMP															CONTROLLER
	ENGINE					SWITCH	N										J4						CONTROLLER
Wiring						SWITCH											J4
				CHOKE
				CHOKE
			ANTI--DIESEL
	GREEN/WHITE		SOLENOID				70						P4
							70				1		P4				1
											1						1		2
					7N				2				3			3			2
									2		BC		3			3	BC
										5	BC	70				70	BC		5
Diagrams				GREEN	8N	P8			4	5		70		8	8	70			5	4
				GREEN					4					8	8					4
				73		N			71				73	14		73				71											INPUT
				73					9					14	14					9								START		STOP	INPUT
			45	73					45	P		7C		73	73	7C	P			45											P	10A					120 V. CONNECTION
									45	P		7C		73	73	7C	P			45
																																						L0
									15 72	BC		37	8N	19		8N	37	BC		72																	LO	L0
									15 72	BC		37	8N	19	19	8N	37	BC		72																	LO	GRD
																				15																	GRD	L2
										N		N				N			N									43										L2
									20	N	BC	N	21			N	BC		N	20								43	N N 47				P					L1
Figure									20		BC		21			21	BC			20									N N 47				P
				BATTERY							22						22															BC
				BATTERY							22																					BC
																															BC						CIRCUIT BREAKERS
																																					CIRCUIT BREAKERS
				N																								HOUR METER									FOR AMPERAGE
				GROUND																																	RATING SEE
				GROUND																																	OWNERS MANUAL
				NUT																												BC					OWNERS MANUAL
				NUT	N
	STARTER				N
5-	STARTER			N	N																										BATT.
	MOTOR			N	N																										CHRG.
				N	N																							73		N		10A		4	3	2	1
2.	STARTER			BC																																	120/240 V. CONNECTION
	STARTER			P																																	120/240 V. CONNECTION
	SOLENOID			P
Point				71																																	LO	L0
					HIGH ENGINE																																LO	GRD
					HIGH ENGINE																																GRD	GRD
					TEMPERATURE																																GRD	L2
					TEMPERATURE																																	L2
					SWITCH																																	L1
	BATTERY		2	GREEN
	CHARGING		2			YELLOW																															CIRCUIT BREAKERS
	CHARGING		1		N	YELLOW																															CIRCUIT BREAKERS
-	ALTERNATOR		1		N
to-																																					FOR AMPERAGE
			37																																		RATING SEE
				37						BC																											OWNERS MANUAL
Point					37
	EXHAUST								VOLTAGE		BC	N														70								4	3	2	1
	TEMPERATURE								VOLTAGE																B1		73
	TEMPERATURE								REGULATOR																B1		73										220 V. CONNECTION
	SWITCHES		37						REGULATOR																												220 V. CONNECTION
	SWITCHES		37																																		LO (NEUTRAL)	L0
																																					LO (NEUTRAL)
																												71
Wiring										5	4	3													3	2	1	71									GRD	GRD
										2	4	1											N		6	5	4	45		GROUND								L1
																									9	8	7	72		LUG
																									9	8	7
																								B2	12 11 10						N
																					43 N		37		15 14 13			P1				N					CIRCUIT BREAKERS
																					43 N							P1									CIRCUIT BREAKERS
				7C																							P										FOR AMPERAGE
				7C																	P2																FOR AMPERAGE
Diagram				37																	9	6	3														RATING SEE
				37																	9	6	3														OWNERS MANUAL
				37																	8	5	2	73
				37																N	8	5	2	73
				37	5															N	7	4	1	76			75
																					43													4	3	2	1
																					47		47			RELAY BOARD			B2 B1					4	3	2	1
	37	37					IGNITION		72																			P6
	7C	37			(OPTIONAL)		SYSTEM		72																76		4	P3
		37		OIL	WATER																				76		4	1
				OIL	WATER																				47		5	2
				PRESSURE	TEMPERATURE																				47		5	2									73	N
	G WK			SWITCH	SENDING UNIT																				43		6	3									P5
--				SWITCH	SENDING UNIT
--																												N									2	1
3.																												7C									4	3
3.				TAPE LEADS ”5”OR ”7C”																								5
5CFZ,	(OPTIONAL)			WHEN NOT USED.																																	75
	OIL PRESSURE																																				8N
	SENDING UNIT/																									55											HOT CHOKE
	SENDING UNIT/																				EXCITATION					55											CIRCUIT BOARD
	LOW OIL PRESSURE																				EXCITATION																CIRCUIT BOARD
	LOW OIL PRESSURE																				CAPACITOR
	SWITCH																				CAPACITOR					66
	SWITCH																									66

4CZ,						REMOTE PANEL									NOTE :																						GENERATOR
															CONNECTOR SHOWN FROM
															PIN INSERTION END.
5CFZ,														LT BLUE
						VIOLET
					HOUR																								B2	B1	66	55	4	3	2		1
									OIL
and 6.									OIL
				BLK	+		VIOLET																								55	4		3
																																		3
																														66				2
								BLK				VIOLET					YEL/RED																	2
								BLK	S																					B1
																																		1
				BLK
																	VIOLET
																	VIOLET													B2
5CZ									+								J3													B2
									+								J3
					VOLT		VIOLET	BLK	TEMP			VIOLET			BLACK		1	4
				BLK	VOLT			BLK	TEMP								2	5
				BLK
														START
														START
																	3	6
							VIOLET																								ALTERNATOR
								BLK	S			VIOLET			GREY/BLK
					+				S						GREY/BLK
TP-5695 12/93				BLK	+
	246482-D								+					STOP
												VIOLET
												BLK
					BACK VIEW OF PANEL									TAN
					BACK VIEW OF PANEL
					(2 AND 4 GAUGE REMOTE PANEL)

Image 58

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Point, Wiring, Diagrams, TP-5695 12/93

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 death BATTERYSulfuric acid in batteries can cause severe injury or 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 ReferencesPart Description Routine Service PartsKohler Part No 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 x3.5CFZ/4CZ Engine Continued5CFZ/6.5CZ 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 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 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 CapFigure 3-6. Removing Oil Filter Fuel SystemSpecifications 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 inFilling and Checking Cooling Systems- Closed/Heat ExchangerHot coolant and steam Can cause severe injury or death 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 LubricationWattage Requirements Generator ServiceGeneral 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 6-13. Seawater Strainer Closed/Heat ExchangerFigure 6-14. Seawater Inlet Connection 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