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

FUEL SYSTEM

WARNING

Explosion.

Gasoline vapors can cause explosion and severe injury or death.

Before starting generator set, operate blower 4 minutes and check engine compartment for gasoline vapors.

WARNING

Explosive fuel vapors.

Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

Explosive fuel vapors can cause severe injury or

death. All fuels are highly explosive in a vapor state. Use extreme care when handling, storing, and using fuels. Store fuel in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running since spilled fuel may ignite on contact with hot parts or from ignition spark. Do not smoke or permit flame or spark to occur near potential sources of spilled fuel or fuel vapors. Keep fuel lines and connections tight and in good condition— don’t replace flexible fuel lines with rigid lines. Flexible sections are used to avoid breakage due to vibration. Should any fuel leakage, fuel accumulation, or electrical sparks be noted, DO NOT OPERATE GENERATOR SET. Have systems repaired before resuming generator operation.

Explosive fuel vapors can cause severe injury or

death. Additional precautions must be taken when using the following fuels:

Gasoline— Store gasoline only in approved red containers clearly marked GASOLINE. Do not store gasoline in any occupied building.

Explosive fuel vapors can cause severe injury or

death. Gasoline vapors can explode and can cause death or severe injury. USCG Regulation 33CFR183 requires all electrical devices (ship-to-shore transfer switch, remote start panel, etc.) to be “ignition protected” when used in a gasoline (gaseous)-fueled environment. These electrical devices are not “ignition protected”and are not certified to operate in a gasoline (gaseous)-fueled environment such as engine room or near fuel tanks. Acceptable locations would be wheelhouse or other living areas sheltered from rain and water splash.

Explosive fuel vapors can cause severe injury or

death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining fuel system. Wipe up all spilled fuel after draining system.

Explosive fuel vapors can cause severe injury or

death. Fuel leakage can cause an explosion. Do not modify the tank or propulsion engine fuel system. Craft must be equipped with a tank allowing one of the two pickup arrangements described. Tank and installation must conform to U.S.C.G. Regulations.

Explosive fuel vapors can cause severe injury or

death. Fuel leakage can cause an explosion. To prevent fuel leakage, use pipe sealant on all threaded fittings. Pipe sealant must be suitable for use in marine applications having oil and gasoline environments.

iv Safety Precautions and Instructions

TP-5695 12/93

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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Explosive fuel vapors Can cause severe injury or death

Contents

5CZ Marine Generator SetsModels 5CFZ California Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide can cause severe nausea Carbon monoxide Can cause severe nausea, fainting, or death Sulfuric acid in batteries can cause severe injury or Sulfuric acid in batteries Can cause severe injury or death Explosive fuel vapors can cause severe injury or Explosive fuel vapors Can cause severe injury or death Flying projectiles can cause severe injury or death Accidental starting Can cause severe injury or deathAccidental starting can cause severe injury or Rotating parts Can cause severe injury or death Hazardous noise Can cause loss of hearing Fire Can cause severe injury or deathSudden backfire can cause severe injury or death Sudden flash fire can cause severe injury or death 246242 Pleasure Craft Reference Material Additional References Commercial Vessels Part Description Kohler Part No Routine Service Parts Abbreviation Description Glossary of Abbreviations NEC Introduction SpecificationsSpecifications General Specifications 5CFZ/4CZ 5CFZ/6.5CZ Generator GX360EV Engine BPR4HS NGK Accessories Service Views typical Service Views Prestart Checks Operation Controller Controller Stopping Starting Circuit Protection Engine Safety Shutdown Switches High Water Temperature Shutdown Switch Remote Panels Optional Remote Panel Features Remote Start and Four-Meter Panel Kit Remote Start and Four-Meter Features Scheduled Maintenance Or 2 Years Service Schedule Generator Lubrication System Specifications Oil Change/Oil Filter Change Adding Oil Removing Oil Filter Fuel System Fuel Pump Screen Fuel Pump Screen Carburetor/Choke Lubrication Carburetor Adjustments Ignition System Ignition System ServiceSpark Plugs Carbon fouled Problem Means of Identification Possible Cause NormalGap bridged Oil fouled 12. Checking Spark Plug Gap Filling and Checking Cooling Systems- Closed/Heat ExchangerHot coolant and steam Can cause severe injury or death 14. Air-Bleed Screw Flushing and Cleaning TP-5695 12/93 Scheduled Maintenance 17. Removing Anticorrosion Zinc Anticorrosion Zinc Servicing Mixing Elbow Air Cleaner Mixing ElbowServicing Air Cleaner Pressure Cap Checking Specific Gravity BatteryCleaning Checking Electrolyte Level Charging 21. Specific Gravity Temperature Correction Valve Adjustment 22. Determining Top Dead Center Governor Governor AdjustmentLubrication Wattage Requirements Generator ServiceGeneral Storage Procedure Not start TroubleshootingEngine Unit cranks but will Lacks power Problem Possible Cause Corrective Action Stops suddenlyOperates erratically Electrical System Generator Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring Diagrams 4CZ Diagrams To Generator To Shore Set Power Wire Generator SetsTo Load 60 Hz LO Neutral GroundLoad Side Line Side Without Jumper Lead L1--L3Page Generator Selection and Wattage Requirements InstallationMotor Loads Kilowatt Derating Appliance Loads Typical Location and Mounting Air Requirements CFM L/min Model Combustion Cooling LocationVentilationSpace Mounting Fuel Supply Fuel Systems Max. Lift ft. m In. mm Anti-Siphon ProvisionsFuel Lines Fuel Pump Lift Capabilities Fuel Consumption 11. Intake Strainer Cooling Systems 13. Seawater Strainer Closed/Heat Exchanger 15. Closed/Heat Exchanger Cooling System Exhaust Systems Carbon monoxide 17. Typical Above Waterline Installation Mid/Below Waterline Above Waterline Electrical Systems Installation in Steel or Aluminum VesselsAC Voltage Connections Wiring Battery Lead Designations Pin Function Remote Start Switch Connection Section Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Standard on 5CFZ and 6.5CZ Sound Shield--Optional on 3.5CFZ and 4CZ Parts Ordering Instructions For Sales & Service in U.S.A. & Canada Phone Operating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone