Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Operating And Installation Manual Download Page 1

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Operation and

Installation Manual

Marine Generator Sets

Models:

3.5CFZ

4CZ

5CFZ

6.5CZ

TP-5695 12/93

Summary of Contents for 3.5CFZ, 4CZ, 5CFZ, 6.5CZ

Page 1: ...Operation and Installation Manual Marine Generator Sets Models 3 5CFZ 4CZ 5CFZ 6 5CZ TP 5695 12 93...

Page 2: ...Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING California Proposition 65...

Page 3: ...d Mixing Elbow 3 17 Servicing Air Cleaner 3 17 Servicing Mixing Elbow 3 17 Battery 3 18 Cleaning 3 18 Checking Electrolyte Level 3 18 Checking Specific Gravity 3 18 Charging 3 19 Valve Adjustment 3 20...

Page 4: ...ed HAZARDOUS VOLTAGE ELECTRICAL SHOCK WARNING Hazardous voltage Do not operate generator set without all guards and electrical enclosures in place Moving rotor Can cause severe injury or death Hazardo...

Page 5: ...side moor your craft so that the exhaust discharges on the lee side the side sheltered from the wind and always be mindful of others make sure your exhaust is directed away from other boats and occupi...

Page 6: ...t in hazardous spattering of electrolyte Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flame or spark to occur near a battery at any time parti...

Page 7: ...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...

Page 8: ...re injury or death Additional Precautions Regarding Sound Shield Equipped Models Some scheduled maintenance procedures require the generator set to be running while performing service If the sound shi...

Page 9: ...r use a proper container to catch all fuel A sudden backfire can cause severe injury or death Do not operate with backfire flame arrestor removed A sudden backfire can cause severe injury or death Do...

Page 10: ...s on bolt head and nuts for proper identification NOTE When a fuse replacement is required be sure fuse has the same ampere rating and is the same type for example ABC or 3AB ceramic Do not substitute...

Page 11: ...Second Street S W Washington DC 20593 0001 Boating Safety Hotline 1 800 368 5647 American Bureau of Shipping Rules for Building and Classing Steel Vessels 45 Eisenhower Drive Paramus N J 07652 201 36...

Page 12: ...DC 20402 1 202 783 3238 American Bureau of Shipping ABS 65 Broadway New York NY 10006 Order ABS publications from American Bureau of Shipping Book Order Section 45 Eisenhower Drive P O Box 910 Paramus...

Page 13: ...or dealer distributor for a complete listing of service parts for your generator set Part Description Kohler Part No Engine Air Filter 278612 Oil Filter 267714 Belt Timing 267722 Ignition System Spark...

Page 14: ...mpany cont d continued C S A Canadian Standards Association cu in cubic inch cubic inches cyl cylinder dBA decibels DC direct current DCR direct current resistance deg degree dept department dia diame...

Page 15: ...not required OC overcrank OD outside diameter OEM original equipment manufacturer OS overspeed oversize OV overvoltage oz ounce ounces Abbreviation Description PF power factor pot potentiometer ppm pa...

Page 16: ...tification and location of components Specifications General Specifications 3 5CFZ 5CFZ Dimensions L x W x H in mm 27 87 x 17 50 x 16 60 708 x 445 x 422 31 07 x 18 10 x 17 50 789 x 460 x 445 with Soun...

Page 17: ...o Pole Rotating Field Voltage Regulation 5 Frequency Regulation 5 Angular Operation Max in all directions 20 Continuous Excitation Method Brushless Exciter Winding Capacitor Coupling Type Tapered Shaf...

Page 18: ...3 5CFZ 10 7 5CFZ 60 Hz 12 8 4CZ 12 8 6 5CZ RPM 50 Hz 3000 3 5CFZ 3000 5CFZ 60 Hz 3600 4CZ 3600 6 5CZ Bore x Stroke in mm 2 28 x 2 68 58 x 68 Valve Material Steel Alloy JIS SUH3 Valve Clearance in mm...

Page 19: ...1 2 Ignition Timing B T D C 24 2 degrees Exhaust Manifold to Cylinder Head Torque 16 ft lbs 22 Nm Water Pump Assembly to Cylinder Block Torque 7 ft lbs 10 Nm Cooling Fan Torque 16 ft lbs 22 Nm Air Cle...

Page 20: ...rice list or dealer distributor for proper application of circuit breakers Model Amps Poles 4CZ 3 5CFZ 18 2 4CZ 3 5CFZ 35 1 4CZ 3 5CFZ 20 1 6CZ 5CFZ 30 2 6CZ 5CFZ 55 1 6CZ 5CFZ 25 2 6CZ 5CFZ 20 1 Remo...

Page 21: ...arger Voltage Regulator 12 Coolant Overflow Hose 13 Cooling System Pressure Cap 14 High Water Temperature Safety Shutdown Switch 15 Thermostat 16 High Exhaust Temperature Shutdown Switches 2 17 Spark...

Page 22: ...uel leaks fumes exhaust gases or electrical sparks are noted arrange for qualified personnel to make necessary repairs before operating generator set FUEL LEVEL Make sure the fuel tanks are full and t...

Page 23: ...ch automatically returns to neutral center position when released 4 Hourmeter records total generator set operating hours Use as a reference to schedule maintenance 5 Remote Start Connector provides c...

Page 24: ...to follow these guidelines may result in burn out of the starter motor from overheating If the engine fails to start after the first attempt close the seacock before a second start up attempt This ac...

Page 25: ...e fuses for ceramic fuses If ampere rating is unknown or questionable see Wiring Diagram WARNING Accidental starting Can cause severe injury or death Disconnect battery cables before working on genera...

Page 26: ...ART STOP BATT CHRG INPUT 258000 D 1 hidden 1 High Water Temperature Shutdown Switch Figure 2 3 High Water Temperature Shutdown Switch High Exhaust Temperature Shutdown Switches The two high exhaust te...

Page 27: ...nd a water temperature gauge Generator sets come equipped with a 6 pin connector on controller bottom for connection of the kit See Figure 2 6 for remote start and meter panel kit 1 2 4 3 1 Engine Oil...

Page 28: ...op the generator set DC Voltmeter measures voltage of starting battery ies Normal battery operating range is 12 14 volts Engine Oil Pressure Gauge measures engine oil pressure Normal engine operating...

Page 29: ...hnician are essential While it is not possible to anticipate component failure rough operation metallic noises and excessive oil loss are among the indicators of potential problems Do not ignore these...

Page 30: ...es X IGNITION SYSTEM Replace spark plugs X COOLING SYSTEM Check coolant level X Check seawater outlet X During Operation Inspect exhaust system components for cracks and corrosion exhaust manifold mix...

Page 31: ...specific gravity Batteries with filler caps only X Clean battery cables X ENGINE AND MOUNTING Check for leakage of water fuel or oil X X Lubricate governor linkage X Break in Period X Retighten all m...

Page 32: ...sing other than the appropriate service class oil or extended oil change intervals could cause engine damage which is not covered by the engine warranty Do not mix oils of different viscosities It is...

Page 33: ...l filter by turning in a counterclockwise direction Oil filter is 2 1 2 in 64 mm dia with 14 flutes Use oil filter wrench if necessary See Figure 3 6 Use rags to handle hot oil filter and clean up spi...

Page 34: ...nd corrosion inhibitors for methanol Never use gasoline containing more than 5 methanol even if it has cosolvents and corrosion inhibitors NOTE Fuel system damage and engine performance problems resul...

Page 35: ...building The electric fuel pump includes a screen See Figure 3 7 At the recommended interval or when clogging is suspected inspect and clean the screen as follows 1 Shut off fuel flow to electric fuel...

Page 36: ...screw in until engine instability hunting develops and then screw out until engine instability is again apparent Turn screw back in until it is positioned halfway between the points of increasing sta...

Page 37: ...or terminal 2 Where possible use compressed air to remove dirt from around each spark plug before removal This procedure will prevent dirt particles from falling into combustion chamber Loosen spark...

Page 38: ...bluish burnt appearance on electrodes Engine overheating wrong type of fuel loose spark plugs too hot a plug low fuel pump pressure or incorrect ignition timing Replace plug Worn Severely eroded or wo...

Page 39: ...TP 5695 12 93 Scheduled Maintenance 3 11 1 2 1 0 028 0 031 in 0 7 0 8 mm Gap 2 Spark Plug Electrodes 1 514 Figure 3 12 Checking Spark Plug Gap 1 511 Figure 3 13 Adjusting Spark Plug Gap...

Page 40: ...turn it slowly counterclockwise to the first stop After pressure has been completely released and the engine has cooled remove cap If generator set is equipped with a coolant recovery tank check coola...

Page 41: ...ew TOTAL HOURS 0 0 0 0 0 1 10 10A FUSE START STOP BATT CHRG INPUT 3 2 1 1 Coolant Recovery Tank 2 Overflow Hose 3 Coolant Pressure Cap 258000 D Figure 3 15 Coolant Pressure Cap TOTAL HOURS 0 0 0 0 0 1...

Page 42: ...anger pressure cap MUST be installed 5 Turn on water supply to flush coolant from engine block Turn off water supply when clean water is observed coming from hose in bucket 6 Disconnect garden hose Pl...

Page 43: ...ssure cap Repeat this step until coolant can no longer be added This procedure should give an approximate mixture of 50 ethylene glycol and 50 water 15 Wipe up spilled coolant and water with rags Disp...

Page 44: ...and use the following procedure TOTAL HOURS 0 0 0 0 0 1 10 10A FUSE START STOP BATT CHRG INPUT 1 Heat Exchanger 2 Anticorrosion Zinc 2 1 258000 D Figure 3 17 Removing Anticorrosion Zinc 1 With generat...

Page 45: ...erial has hardened or deteriorated Install the reed valve with the valve downward into the mounting base Install retaining cap and tighten finger tight only Do NOT overtighten Air Cleaner and Mixing E...

Page 46: ...y compartment containing batteries must be well ventilated to prevent accumulation of explosive gases To avoid sparks do not disturb battery charger connections while battery is being charged and alwa...

Page 47: ...s 1 243 The temperature correction amounts to about 004 4 points of specific gravity for each10 F 5 5 C change intemperature Correction 1 787 Figure 3 21 Specific Gravity Temperature Correction NOTE S...

Page 48: ...seawater pump b Remove two screws to release seawater pump bracket c Remove housing enclosing ignition coil d Remove seawater pump from camshaft pulley e Remove timing belt cover belt guard NOTE To re...

Page 49: ...Scheduled Maintenance 3 21 1 Y Mark 2 T Mark 2 1 1 827 Figure 3 22 Determining Top Dead Center 1 2 3 1 Feeler Gauge 2 Adjusting Screw 3 mm Square Head 3 Locknut Use 9 mm Wrench 1 831 Figure 3 23 Valv...

Page 50: ...ry 60 Hz generator sets are designed to operate at 60 63 Hz 3600 rpm under full load and 3780 rpm under no load 50 Hz generator sets are designed to operate at 50 52 5 Hz 3000 rpm under full load and...

Page 51: ...ain after being reset see a qualified electrician For more information regarding generator set capacity see Installation Generator Selection and Wattage Requirements Generator Service General Under no...

Page 52: ...s 3a c were performed to replace seawater with antifreeze omit steps 4a c 4 Close seacock and drain all seawater out of cooling system a Drain seawater from strainer and seawater pump b Remove zinc an...

Page 53: ...ng solenoid Replace solenoid Air intake clogged Clean or replace Faulty spark plug s Replace and regap spark plug s Loose spark plug connection Reconnect wires Faulty ground connection Clean and retig...

Page 54: ...Check HET and HWT shutdown switch es Loss of AC output See authorized Kohler service dealer distributor Faulty antidieseling solenoid Replace solenoid Lacks power Air intake clogged Clean Lacks power...

Page 55: ...on Battery will not charge Loose or corroded connections Clean and tighten connections Battery will not charge Sulfated or worn out battery Check electrolyte level and specific gravity batteries with...

Page 56: ...rop in Engine speed too low Adjust governor Low output or excessive drop in voltage Generator overloaded Reduce load See Wattage Requirements voltage Engine in poor condition If routine services are p...

Page 57: ...N TIME DELAY RELAY C1 2 1 B1 P1 3 P1 6 B2 12V VR1 K5 K1 LED1 R1 BR1 3 5 4 1A REGULATOR VOLTAGE ALTERNATOR CHARGING BATTERY ON GEN WTS P3 2 TAN OPS P3 3 BLUE LT WT OP P3 4 76 P2 3 K1 D4 73 P2 1 HR 5A D...

Page 58: ...73 45 37 SWITCHES TEMPERATURE EXHAUST N NUT GROUND SENDING UNIT TEMPERATURE WATER OPTIONAL SWITCH LOW OIL PRESSURE SENDING UNIT OIL PRESSURE OPTIONAL FUEL PUMP 5 L0 5 120 V CONNECTION 1 2 3 L1 B2 B1...

Page 59: ...merican Solenoid Newer Round Design 2 1 3 4 6 5 7 8 1 2 6 5 3 4 8 7 L1 L2 To Generator Set To Shore Power To Load 3 2 4 1 7 6 8 5 L1 L2 To Generator Set To Shore Power To Load 3 Wire Generator Sets 2...

Page 60: ...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...

Page 61: ...or 110 volt be sure jumper lead is removed see Figure 5 6 for location Leads L1 and L2 are different phases and must never be connected together 4 3 2 1 Stator Leads LO GRD L2 L1 LO Neutral Load Side...

Page 62: ...6...

Page 63: ...ers distributors Lighting Load The lighting load is usually easiest to calculate In most cases simply add the wattage of each lamp to be operated off the generator set Note that in many applications n...

Page 64: ...loads to avoid overloading of a set The average power requirements of some common electrical appliances are given in Figure 6 3 Kilowatt Derating Units are rated as listed below at 1 0 power factor D...

Page 65: ...lations 4 5 6 7 8 9 10 11 STOP START 258000 D 2 1 13 14 12 3 1 Heat Exchanger 2 Siphon Break See Instruction Sheet TT 927 for Proper Installation 3 Exhaust Mixer 4 Engine Driven Seawater Pump 5 Exhaus...

Page 66: ...so to allow downward pitch of the exhaust line For angular installation the maximum operation angle of the engine generator set is 20_ in all directions Ventilation Ventilation is required to support...

Page 67: ...l shutoff valve is required This fuel shutoff valve should be closed when the generator is not in use to prevent fuel leakage resulting from fuel flow through the fuel pump and into the carburetor sho...

Page 68: ...bing must be used The flexible section necessary to allow vibrational motion of the generator set during operation must be U S C G TYPE A HOSE marked and tagged according to Regulations Metallic line...

Page 69: ...ke thru hull strainers A sea chest is a concave molded in the hull chamber that is also aligned to the direction of travel A sea chest configuration applies a positive pressure similar to a scoop type...

Page 70: ...eration The hose should have an inside diameter of 3 4 in 19 mm Copper line should be supported within 4 in 102 mm of its connection to the flexible section NOTE A 5 8 in 16 mm waterline hose can be s...

Page 71: ...installations The hose used for the lines should have a 2 in 51 mm inside diameter Keep the lines as short and straight as possible The use of two hose clamps on each end of flexible exhaust hose con...

Page 72: ...ine DO NOT OVERLOAD CRAFT so as to close or restrict exhaust discharge hole TOTAL HOURS 0 0 0 0 0 1 10 10A FUSE BATT CHRG INPUT NOTE Use two hose clamps on each end of all flexible exhaust hose connec...

Page 73: ...in Figure 6 19 1 2 3 1 Mounting Base 2 Retaining Cap 3 Reed Valve Assembly 1 779 Figure 6 18 Siphon Break Components The siphon break must be located at least 1 foot above the waterline at maximum ves...

Page 74: ...localities A ship to shore transfer switch must be installed to prevent interconnection of generator set power and shore power AC connections to generator set are made inside the controller box The g...

Page 75: ...d be sized to match the larger of the engines two battery cables Cable sizes for generator set battery connections are given in Figure 6 20 This requirement prevents the starting motor current from us...

Page 76: ...ee Figure 6 22 NOTE If gauges are to be used there must also be generator set senders Senders are optional on these generator sets Gauges and senders are available as service items from an authorized...

Page 77: ...4 STUD FOR BATTERY CONNECTION POSITIVE 5 16 STUD FOR BATTERY CONNECTION NEGATIVE 1 65 42 62 16 2 69 68 9 13 232 21 20 538 1 0 25 1 0 25 15 50 394 GROUND LUG WATER COOLED EXHAUST OUTLET FOR 2 0 51 I D...

Page 78: ...3 07 78 17 86 454 50 R 13 OPENING FOR FUEL INLET HOSE AND BATTERY CONNECTIONS OPENING FOR A C LOAD LEADS 625 R 16 SEA WATER INLET MOUNTING LOCATION FOR SIPHON BREAK ASSEMBLY DRILL 2 1 00 DIA HOLES USI...

Page 79: ...VICE IN U S A CANADA PHONE 1 800 544 2444 A major service manual and parts catalog may be ordered through an authorized Kohler service dealer distributor When ordering state MODEL and SPEC numbers fro...

Page 80: ...ervice Log The following is provided to help you keep a cumulative record of operating hours on your generator set and the dates required services were performed Enter hours to the nearest quarter hou...

Page 81: ...P 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 1 800 544 244...

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Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ, Operating And Installation Manual

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