Manuals / Kohler / Lawn and Garden / Portable Generator

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Output Can Be Reconnected For 120 volt or 120/240 volt, 60 Hz

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

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Four-Lead Reconnectable (Single-Phase) Generator Sets Where Generator

Four-Lead Reconnectable (Single-Phase) Generator Sets Where Generator

Output Can Be Reconnected For 120 volt or 120/240 volt, 60 Hz,

110 volt or 110/220 volt, 50 Hz

NOTE

When a generator set is reconnected to a voltage different than nameplate voltage, notice should be placed on the unit indicating this change. Decals for this purpose are available from authorized Kohler dealers/distributors.

120- or 110- Volt 2-Wire Configuration

Figure 5-5 (Single Pole)

If the installation requires a 120 or 110 volt, 2-wire system, a single-pole circuit breaker must be used. See Figure 5-5. When connecting stator phase leads together, the output lead (L1) must be sized accordingly.

120- or 110-Volt 3-Wire 2-Pole

Configuration--Figure 5-4

Jumper lead to be placed on line side of circuit breaker. Leads L1 and L2 can either be left as separate leads or can be connected together depending upon which is practical for the given application. Regardless of the number of phase (black) leads used in the application, both circuit breakers must have leads attached to the load side. It is recommended that jumper lead be maintained for all straight 120- or 110-volt systems since it helps balance the load of the generator set.

LO (Neutral)

		LO
	Ground	GRD.
	Ground	L2
		L2
		L1
		Load Side
		Circuit
		Breaker
		Line Side

Stator Leads

4 3 2 1

Line

Side

	Load
	Side
	Ground
	LO (Neutral)
	60 Hz
L0--L1	100-120 volt

1-Pole Circuit Breaker

L1

GRD.

LO

50 Hz

100-120 volt

				Jumper
				Lead
4	3	2	1
Stator Leads
			60 Hz	50 Hz
L0--L1			120 volt	110 volt
L0--L2			120 volt	110 volt

Figure 5-4. With Jumper Lead

Figure 5-5. 120 Volt, 2-Wire

5-4 Wiring Diagrams

TP-5695 12/93

Image 60

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Four-Lead Reconnectable Single-Phase Generator Sets Where Generator, LO Neutral, Ground

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 nauseaBATTERY Sulfuric acid in batteries Can cause severe injury or deathSulfuric 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 ReferencesRoutine Service Parts Part DescriptionKohler 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 xEngine Continued 3.5CFZ/4CZ5CFZ/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 PanelFigure 2-7. Remote Start and Four-Meter Features Water TemperatureRemote Start and Four-Meter Panel Kit Section 3. Scheduled Maintenance Accidental starting Can cause severe injury or deathAccidental 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 CapFuel System Figure 3-6. Removing Oil FilterSpecifications 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 inCooling Systems- Closed/Heat Exchanger Filling and CheckingHot 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 LubricationGenerator Service Wattage RequirementsGeneral 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 GeneralClosed/Heat Exchanger Figure 6-13. Seawater StrainerFigure 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