Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ instruction

BATTERY

WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.

Use protective goggles and clothes. Can cause permanent damage to eyes, burn skin, and eat holes in clothing.

Sulfuric acid in batteries can cause severe injury or

death. Sulfuric acid in battery can cause permanent damage to eyes, burn skin, and eat holes in clothing. Always wear splash-proof safety goggles when working around the battery. If battery electrolyte is splashed in the eyes or on skin, immediately flush the affected area for 15 minutes with large quantities of clean water. In the case of eye contact, seek immediate medical aid. Never add acid to a battery once the battery has been placed in service. Doing so may result in hazardous spattering of electrolyte.

Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flame or spark to occur near a battery at any time, particularly when it is being charged. Avoid contacting terminals with tools, etc. to prevent burns and to prevent sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling battery. Never connect negative (--) battery cable to positive (+) connection terminal of starter solenoid. Do not test battery condition by shorting terminals together or sparks could ignite battery gases or fuel vapors. Any compartment containing batteries must be well ventilated to prevent accumulation of explosive gases. To avoid sparks, do not disturb battery charger connections while battery is being charged and always turn charger off before disconnecting battery connections. When disconnecting battery, remove negative lead first and reconnect it last.

TP-5695 12/93

Safety Precautions and Instructions iii

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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Sulfuric acid in batteries Can cause severe injury or death

Contents

5CFZ Marine Generator SetsModels 5CZ California Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide Can cause severe nausea, fainting, or death Carbon monoxide can cause severe nausea Sulfuric acid in batteries Can cause severe injury or death Sulfuric acid in batteries can cause severe injury or Explosive fuel vapors Can cause severe injury or death Explosive fuel vapors can cause severe injury or Rotating parts Can cause severe injury or death Accidental starting Can cause severe injury or deathAccidental starting can cause severe injury or Flying projectiles can cause severe injury or death Sudden flash fire can cause severe injury or death Fire Can cause severe injury or deathSudden backfire can cause severe injury or death Hazardous noise Can cause loss of hearing 246242 Reference Material Pleasure Craft Commercial Vessels Additional References Routine Service Parts Part Description Kohler Part No Glossary of Abbreviations Abbreviation Description NEC General Specifications SpecificationsSpecifications Introduction Generator 5CFZ/4CZ 5CFZ/6.5CZ Engine GX360EV BPR4HS NGK Accessories Service Views Service Views typical Operation Prestart Checks Controller Controller Starting Stopping Engine Safety Shutdown Switches Circuit Protection High Water Temperature Shutdown Switch Remote Panel Features Remote Panels Optional Remote Start and Four-Meter Features Remote Start and Four-Meter Panel Kit Scheduled Maintenance Service Schedule Or 2 Years Generator Specifications Lubrication System Adding Oil Oil Change/Oil Filter Change Fuel System Removing Oil Filter Fuel Pump Screen Fuel Pump Screen Carburetor Adjustments Carburetor/Choke Lubrication Ignition System Service Ignition SystemSpark Plugs Oil fouled Problem Means of Identification Possible Cause NormalGap bridged Carbon fouled 12. Checking Spark Plug Gap Cooling Systems- Closed/Heat Exchanger Filling and CheckingHot coolant and steam Can cause severe injury or death 14. Air-Bleed Screw Flushing and Cleaning TP-5695 12/93 Scheduled Maintenance Anticorrosion Zinc 17. Removing Anticorrosion Zinc Pressure Cap Air Cleaner Mixing ElbowServicing Air Cleaner Servicing Mixing Elbow Checking Electrolyte Level BatteryCleaning Checking Specific Gravity 21. Specific Gravity Temperature Correction Charging Valve Adjustment 22. Determining Top Dead Center Governor Adjustment GovernorLubrication Generator Service Wattage RequirementsGeneral Storage Procedure Unit cranks but will TroubleshootingEngine Not start Problem Possible Cause Corrective Action Stops suddenly Lacks powerOperates erratically Electrical System Generator Wiring Diagrams Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Diagrams 4CZ Wire Generator Sets To Generator To Shore Set PowerTo Load Line Side LO Neutral GroundLoad Side 60 Hz L1--L3 Without Jumper LeadPage Installation Generator Selection and Wattage RequirementsMotor Loads Appliance Loads Kilowatt Derating Typical Location and Mounting Mounting LocationVentilationSpace Air Requirements CFM L/min Model Combustion Cooling Fuel Systems Fuel Supply Fuel Pump Lift Capabilities Fuel Consumption Anti-Siphon ProvisionsFuel Lines Max. Lift ft. m In. mm Cooling Systems 11. Intake Strainer Closed/Heat Exchanger 13. Seawater Strainer Exhaust Systems 15. Closed/Heat Exchanger Cooling System 17. Typical Above Waterline Installation Carbon monoxide Above Waterline Mid/Below Waterline Installation in Steel or Aluminum Vessels Electrical SystemsAC Voltage Connections Battery Wiring Remote Start Switch Connection Lead Designations Pin Function Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Section Sound Shield--Optional on 3.5CFZ and 4CZ Standard on 5CFZ and 6.5CZ For Sales & Service in U.S.A. & Canada Phone Parts Ordering Instructions Operating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone