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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual TP-5695 12/93 PRINTED IN U.S.A

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

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TP-5695 12/93

PRINTED IN U.S.A.

KOHLER CO. KOHLER, WISCONSIN 53044 PHONE 414-565-3381

FAX 414-459-1646 (North American Sales), 414-459-1614 (International) FOR SALES & SERVICE IN U.S.A. & CANADA PHONE 1-800-544-2444

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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ TP-5695 12/93 PRINTED IN U.S.A, KOHLER CO. KOHLER, WISCONSIN 53044 PHONE

Contents

Models Marine Generator Sets3.5CFZ 4CZ 5CFZ 6.5CZ TP-5695 12/93California Proposition Safety Precautions and Instructions Table of ContentsSection 3. Scheduled Maintenance Section 4. TroubleshootingHAZARDOUS VOLTAGE ELECTRICAL SHOCK Safety Precautions and InstructionsDANGER Moving rotorCarbon monoxide Can cause severe nausea, fainting, or death EXHAUST SYSTEMCarbon 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 Explosion FUEL SYSTEMGasoline vapors can cause explosion and severe injury or death Explosive fuel vapors Can cause severe injury or deathMOVING PARTS ACCIDENTAL STARTINGHOT PARTS Accidental starting Can cause severe injury or deathHAZARDOUS NOISE ENGINE BACKFIRE/FLASH FIREFire Can cause severe injury or death A sudden backfire can cause severe injury or deathThis is a positive terminal only Do not attach negative lead This generator set has been rewired from its nameplate voltage toCheck zinc anode every 100 hours or 3 months Do not use as a stepPleasure Craft Reference MaterialAdditional References Commercial VesselsRoutine Service Parts Part DescriptionKohler Part No Abbreviation Glossary of AbbreviationsDescription AbbreviationDescription AbbreviationAbbreviation DescriptionSpecifications Section 1. SpecificationsGeneral Specifications Introduction3.5CFZ/4CZ Generator5CFZ/6.5CZ 3.5CFZ3.5CFZ/4CZ Engine5CFZ/6.5CZ 2.28 xEngine Continued 3.5CFZ/4CZ5CFZ/6.5CZ Ship-to-Shore Transfer Switch Accessories12-Inch Remote Wiring Harness Sound ShieldFigure 1-1. Service Views typical Service ViewsPrestart Checks Section 2. OperationFigure 2-1. Controller ControllerStopping StartingExplosion Gasoline vapors can cause explosion and severe injury or deathBattery-Charging Fuse 10 Amp Engine Safety Shutdown SwitchesLow Oil Pressure Shutdown Switch Figure 2-2. Low Oil Pressure Shutdown SwitchHigh Exhaust Temperature High Water TemperatureShutdown Switch Shutdown SwitchesFigure 2-6. Remote Start and Two-Meter Panel Features Figure 2-5. Remote 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 After Service ScheduleEvery BeforeREMOTE CONTROL SYSTEM Service Schedule ContinuedELECTRICAL SYSTEM ENGINE AND MOUNTINGFigure 3-1. Oil Service Class and SAE Viscosity Grade Symbol SpecificationsWhen Outside Temperature Lubrication SystemOil Change/Oil Filter Change Adding OilFigure 3-4. Adding Oil Figure 3-5. Oil Drain CapFuel System Figure 3-6. Removing Oil FilterSpecifications Figure 3-7. Fuel Pump Screen Fuel Pump ScreenExplosive fuel vapors Can cause severe injury or death Explosive fuel vapors can cause severe injury orFigure 3-8. Fuel Mixture Adjustment Carburetor AdjustmentsCarburetor/Choke Lubrication Fire Can cause severe injury or deathFigure 3-9. Removing Spark Plug Wires Ignition System ServiceIgnition System Spark PlugsMeans of Identification ProblemPossible Cause NormalFigure 3-12. Checking Spark Plug Gap Figure 3-13. Adjusting 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 3-15. Coolant Pressure Cap Figure 3-14. Air-Bleed ScrewFigure 3-16. Checking Coolant Level Coolant Recovery TankAccidental starting Can cause severe injury or death Flushing and CleaningAccidental starting can cause severe injury or Hot coolant and steam Can cause severe injury or death13. Reconnect battery, negative lead last Figure 3-17. Removing Anticorrosion Zinc Anticorrosion ZincServicing Air Cleaner Air Cleaner and Mixing ElbowFigure 3-19. Air Cleaner Service Pressure CapCleaning BatteryChecking Electrolyte Level Checking Specific GravityCharging Figure 3-21. Specific Gravity Temperature CorrectionRotating parts Can cause severe injury or death Valve AdjustmentExposed moving parts can cause severe injury or Flying projectiles can cause severe injury or deathFigure 3-22. Determining Top Dead Center Figure 3-23. Valve AdjustmentAdjusting Screw 3 mm Scheduled MaintenanceFigure 3-24. Governor Adjustment Governor AdjustmentGovernor LubricationGenerator Service Wattage RequirementsGeneral Storage Procedure Engine Section 4. TroubleshootingCorrective Action Unit will not crankEngine Continued Lacks powerStops suddenly Operates erraticallyElectrical System Battery will notOverheats Unit is noisyNo AC output GeneratorLow output or excessive drop inFigure 5-1. Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Section 5. Wiring DiagramsWiring Diagrams TP-5695 12/93Diagram WiringWiring DiagramsKraus Naimler/American Solenoid Electro SwitchEarly Rectangular Design Kraus Naimler/American Solenoid120- or 110- Volt 2-Wire Configuration Figure 5-5 Single Pole Four-Lead Reconnectable Single-Phase Generator Sets Where Generator120- or 110-Volt 3-Wire 2-Pole Configuration--Figure Figure 5-5. 120 Volt, 2-WireL1--L3 120/240- or 110/220-Volt Configuration--FigureFigure 5-6. Without Jumper Lead LO NeutralPage Generator Selection and Wattage Requirements Section 6. InstallationMotor Loads Lighting LoadAppliance Loads “Power toKilowatt Derating MotorINPUT STOP/START 10A FUSE 00000 1/10 TOTAL HOURS BATT CHRG Figure 6-4. Typical Location and MountingSpace LocationVentilationMounting Air Requirements CFM L/minFuel Supply Fuel SystemsFigure 6-6. Dual Dip Tubes Figure 6-7. Single Dip TubeFuel Lines Anti-Siphon ProvisionsFuel Pump Lift Capabilities and Fuel Consumption Figure 6-8. Fuel Pump Inlet ConnectionCooling Systems Figure 6-12. Seacock InstallationFigure 6-11. Intake Strainer GeneralClosed/Heat Exchanger Figure 6-13. Seawater StrainerFigure 6-14. Seawater Inlet Connection Figure 6-15. Closed/Heat Exchanger Cooling System Exhaust SystemsFigure 6-16. Mixer Elbow/Exhaust Connection GeneralCarbon monoxide Figure 6-17. Typical Above Waterline InstallationCan cause severe nausea, fainting, or death Carbon monoxide can cause severe nauseaAbove Waterline Figure 6-19. Typical Mid and Below Waterline InstallationMid/Below Waterline Figure 6-18. Siphon Break ComponentsElectrical Systems Installation in Steel or Aluminum VesselsAC Voltage Connections ExplosionWiring BatteryBattery Figure 6-20. Battery Cable SizesFigure 6-22. Remote Control Panel Wiring Remote Start Switch ConnectionLead Designations Lead7. Installation Drawings 7-1. Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZInstallation Drawings SectionStandard on 5CFZ and 6.5CZ Sound Shield--Optional on 3.5CFZ and 4CZInstallation Drawings 12/93Section 8. Parts Ordering Instructions SERVICE RECORD Section 9. Operating Hour Service LogSERVICE DATEKOHLER CO. KOHLER, WISCONSIN 53044 PHONE TP-5695 12/93 PRINTED IN U.S.A