TP-5695 12/93
Marine Generator Sets
Models
3.5CFZ 4CZ 5CFZ 6.5CZ
California Proposition
Section 4. Troubleshooting
Table of Contents
Safety Precautions and Instructions
Section 3. Scheduled Maintenance
Moving rotor
Safety Precautions and Instructions
HAZARDOUS VOLTAGE ELECTRICAL SHOCK
DANGER
Carbon monoxide can cause severe nausea
EXHAUST SYSTEM
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
BATTERY
Sulfuric acid in batteries can cause severe injury or
Explosive fuel vapors Can cause severe injury or death
FUEL SYSTEM
Explosion
Gasoline vapors can cause explosion and severe injury or death
Accidental starting Can cause severe injury or death
ACCIDENTAL STARTING
MOVING PARTS
HOT PARTS
A sudden backfire can cause severe injury or death
ENGINE BACKFIRE/FLASH FIRE
HAZARDOUS NOISE
Fire Can cause severe injury or death
Do not use as a step
This generator set has been rewired from its nameplate voltage to
This is a positive terminal only Do not attach negative lead
Check zinc anode every 100 hours or 3 months
Pleasure Craft
Reference Material
Additional References
Commercial Vessels
Part Description
Routine Service Parts
Kohler Part No
Abbreviation
Glossary of Abbreviations
Abbreviation
Description
Description
Abbreviation
Description
Abbreviation
Introduction
Section 1. Specifications
Specifications
General Specifications
3.5CFZ
Generator
3.5CFZ/4CZ
5CFZ/6.5CZ
2.28 x
Engine
3.5CFZ/4CZ
5CFZ/6.5CZ
3.5CFZ/4CZ
Engine Continued
5CFZ/6.5CZ
Sound Shield
Accessories
Ship-to-Shore Transfer Switch
12-Inch Remote Wiring Harness
Figure 1-1. Service Views typical
Service Views
Prestart Checks
Section 2. Operation
Figure 2-1. Controller
Controller
Gasoline vapors can cause explosion and severe injury or death
Starting
Stopping
Explosion
Figure 2-2. Low Oil Pressure Shutdown Switch
Engine Safety Shutdown Switches
Battery-Charging Fuse 10 Amp
Low Oil Pressure Shutdown Switch
Shutdown Switches
High Water Temperature
High Exhaust Temperature
Shutdown Switch
Remote Start Panel
Figure 2-5. Remote Panel Features
Figure 2-6. Remote Start and Two-Meter Panel Features
Remote Panels Optional
Water Temperature
Figure 2-7. Remote Start and Four-Meter Features
Remote Start and Four-Meter Panel Kit
Accidental starting Can cause severe injury or death
Section 3. Scheduled Maintenance
Accidental starting can cause severe injury or
Before
Service Schedule
After
Every
ENGINE AND MOUNTING
Service Schedule Continued
REMOTE CONTROL SYSTEM
ELECTRICAL SYSTEM
Lubrication System
Specifications
Figure 3-1. Oil Service Class and SAE Viscosity Grade Symbol
When Outside Temperature
Figure 3-5. Oil Drain Cap
Adding Oil
Oil Change/Oil Filter Change
Figure 3-4. Adding Oil
Figure 3-6. Removing Oil Filter
Fuel System
Specifications
Explosive fuel vapors can cause severe injury or
Fuel Pump Screen
Figure 3-7. Fuel Pump Screen
Explosive fuel vapors Can cause severe injury or death
Fire Can cause severe injury or death
Carburetor Adjustments
Figure 3-8. Fuel Mixture Adjustment
Carburetor/Choke Lubrication
Spark Plugs
Ignition System Service
Figure 3-9. Removing Spark Plug Wires
Ignition System
Normal
Problem
Means of Identification
Possible Cause
0.028--0.031 in
Figure 3-13. Adjusting Spark Plug Gap
Figure 3-12. Checking Spark Plug Gap
Scheduled Maintenance
Filling and Checking
Cooling Systems- Closed/Heat Exchanger
Hot coolant and steam Can cause severe injury or death
Coolant Recovery Tank
Figure 3-14. Air-Bleed Screw
Figure 3-15. Coolant Pressure Cap
Figure 3-16. Checking Coolant Level
Hot coolant and steam Can cause severe injury or death
Flushing and Cleaning
Accidental starting Can cause severe injury or death
Accidental starting can cause severe injury or
13. Reconnect battery, negative lead last
Figure 3-17. Removing Anticorrosion Zinc
Anticorrosion Zinc
Pressure Cap
Air Cleaner and Mixing Elbow
Servicing Air Cleaner
Figure 3-19. Air Cleaner Service
Checking Specific Gravity
Battery
Cleaning
Checking Electrolyte Level
Charging
Figure 3-21. Specific Gravity Temperature Correction
Flying projectiles can cause severe injury or death
Valve Adjustment
Rotating parts Can cause severe injury or death
Exposed moving parts can cause severe injury or
Scheduled Maintenance
Figure 3-23. Valve Adjustment
Figure 3-22. Determining Top Dead Center
Adjusting Screw 3 mm
Lubrication
Governor Adjustment
Figure 3-24. Governor Adjustment
Governor
Wattage Requirements
Generator Service
General
Storage Procedure
Unit will not crank
Section 4. Troubleshooting
Engine
Corrective Action
Operates erratically
Lacks power
Engine Continued
Stops suddenly
Unit is noisy
Battery will not
Electrical System
Overheats
excessive drop in
Generator
No AC output
Low output or
TP-5695 12/93
Section 5. Wiring Diagrams
Figure 5-1. Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ
Wiring Diagrams
Diagrams
Wiring
Diagram
Wiring
Kraus Naimler/American Solenoid
Electro Switch
Kraus Naimler/American Solenoid
Early Rectangular Design
Figure 5-5. 120 Volt, 2-Wire
Four-Lead Reconnectable Single-Phase Generator Sets Where Generator
120- or 110- Volt 2-Wire Configuration Figure 5-5 Single Pole
120- or 110-Volt 3-Wire 2-Pole Configuration--Figure
LO Neutral
120/240- or 110/220-Volt Configuration--Figure
L1--L3
Figure 5-6. Without Jumper Lead
Page
Lighting Load
Section 6. Installation
Generator Selection and Wattage Requirements
Motor Loads
Motor
“Power to
Appliance Loads
Kilowatt Derating
INPUT STOP/START 10A FUSE 00000 1/10 TOTAL HOURS BATT CHRG
Figure 6-4. Typical Location and Mounting
Air Requirements CFM L/min
LocationVentilation
Space
Mounting
Figure 6-7. Single Dip Tube
Fuel Systems
Fuel Supply
Figure 6-6. Dual Dip Tubes
Figure 6-8. Fuel Pump Inlet Connection
Anti-Siphon Provisions
Fuel Lines
Fuel Pump Lift Capabilities and Fuel Consumption
General
Figure 6-12. Seacock Installation
Cooling Systems
Figure 6-11. Intake Strainer
Figure 6-13. Seawater Strainer
Closed/Heat Exchanger
Figure 6-14. Seawater Inlet Connection
General
Exhaust Systems
Figure 6-15. Closed/Heat Exchanger Cooling System
Figure 6-16. Mixer Elbow/Exhaust Connection
Carbon monoxide can cause severe nausea
Figure 6-17. Typical Above Waterline Installation
Carbon monoxide
Can cause severe nausea, fainting, or death
Figure 6-18. Siphon Break Components
Figure 6-19. Typical Mid and Below Waterline Installation
Above Waterline
Mid/Below Waterline
Explosion
Installation in Steel or Aluminum Vessels
Electrical Systems
AC Voltage Connections
Figure 6-20. Battery Cable Sizes
Battery
Wiring
Battery
Lead
Remote Start Switch Connection
Figure 6-22. Remote Control Panel Wiring
Lead Designations
Section
7-1. Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ
7. Installation Drawings
Installation Drawings
12/93
Sound Shield--Optional on 3.5CFZ and 4CZ
Standard on 5CFZ and 6.5CZ
Installation Drawings
Section 8. Parts Ordering Instructions
DATE
Section 9. Operating Hour Service Log
SERVICE RECORD
SERVICE
KOHLER CO. KOHLER, WISCONSIN 53044 PHONE
TP-5695 12/93 PRINTED IN U.S.A