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