Kohler 3.5CFZ User Manual

Operation andInstallation ManualMarine Generator SetsModels:3.5CFZ4CZ5CFZ6.5CZTP-5695 12/93

TP-5695 12/93 Safety Precautions and Instructions viiNOTESNOTEHARDWARE DAMAGE! Engine and generator maymake use of both American Standard and metricha

TP-5695 12/93viii Reference MaterialReference MaterialIt is recommended that the following Regulations andStandards be followed when installing Marine

TP-5695 12/93 Reference Material ixCommercial VesselsIn order to use these generator sets for commercialapplicationswhere U.S.CoastGuardTitle46Certifi

x Routine Service Parts TP-5695 12/93Routine Service PartsContact your Kohler generator dealer/distributor for acomplete listing of service parts for

TP-5695 12/93 Glossary of Abbreviations xiGlossary of AbbreviationsAbbreviations are used throughout this manual. Normally in the text they will appea

xii Glossary of Abbreviations TP-5695 12/93Abbreviation Descriptionm3cubic meter, cubic metersmax. maximumMCM one thousand circular mils.mi. mile, mil

TP-5695 12/93 Specifications 1-1Section 1. SpecificationsIntroductionThe craft is equipped with a dependable 110 volt(reconnectable to 110/220 volt),

TP-5695 12/931-2 SpecificationsGenerator3.5CFZ 5CFZRated kW 3.5 5Frequency--Hz 50 50Rated Voltage 110 Volt, 2&3 Wire, Single Phase or 110/220 Volt

TP-5695 12/93 Specifications 1-3DERATING: Allunitsare rated1.0power factor.Derateapproximately3.5%per1000ft.(300m)above500ft.(150m)above sea level.3.5

TP-5695 12/931-4 SpecificationsEngine (Continued)3.5CFZ/4CZ 5CFZ/6.5CZSpark Plug Type Resistor, Radio Suppression, 14 mmBPR4HS (NGK)Kohler Part Number

Engine exhaust from this product containschemicalsknowntotheState of Californiatocausecancer, birth defects, or other reproductive harm.WARNINGCalifor

TP-5695 12/93 Specifications 1-5AccessoriesSeveral accessories are available to finalize theinstallation or to add convenience to operation andservice

TP-5695 12/931-6 SpecificationsService ViewsTOTAL HOURS00 0E001/1010AFUSEBATT.CHRG.INPUT2945363530292827 26 25 24 23211933258000-D134STOP START1017161

TP-5695 12/93 Operation 2-1Section 2. OperationPrestart ChecksTo insure continued satisfactory operation, the followingitems should be checked before

TP-5695 12/932-2 OperationControllerFor identification and location of controller operatingfeatures, refer to the text below and Figure 2-1.1. Battery

TP-5695 12/93 Operation 2-3StartingWARNINGExplosion.Gasoline vapors can cause explosion andsevere injury or death.Before starting generator set, opera

TP-5695 12/932-4 OperationCircuit ProtectionAC Circuit Breaker (Optional)The optional AC circuit breaker(s) located on the frontpanel of the controlle

TP-5695 12/93 Operation 2-5High Water TemperatureShutdown SwitchThe high water temperature shutdown switch protectsthe engine against internal damage

TP-5695 12/932-6 OperationRemote Panels (Optional)Remote Start PanelRemote start panel allows starting-stopping from alocationremoteofthegeneratorset.

TP-5695 12/93 Operation 2-7Remote Start and Four-MeterPanel KitAllows starting-stopping from a location remote of thegenerator set. The illuminated ga

TP-5695 12/93 Scheduled Maintenance 3-1Section 3. Scheduled MaintenanceUse the following service schedule and the hourmeteron the controller to schedu

TP-5695 12/93 Table of ContentsTable of ContentsSUBJECT PAGE SUBJECT PAGESafety Precautions and Instructions i. . . . . . .Reference Material viii. .

TP-5695 12/933-2 Scheduled MaintenanceService ScheduleBeforeStartingAfter 20Hrs. orOneMonthEvery 50Hrs. or 3MonthsEvery100 Hrs.or 6MonthsEvery200 Hrs.

TP-5695 12/93 Scheduled Maintenance 3-3Service Schedule (Continued)BeforeStartingAfter 20Hrs. orOneMonthEvery 50Hrs. or 3MonthsEvery100 Hrs.or 6Months

TP-5695 12/933-4 Scheduled MaintenanceLubrication SystemSpecificationsUse high quality detergent oil of API (AmericanPetroleumInstitute) serviceclassS

TP-5695 12/93 Scheduled Maintenance 3-5Adding OilIt is normal to add some oil between oil changes. Theamountwill varywiththe usage.Openfill capandpour

TP-5695 12/933-6 Scheduled Maintenance11-8261. Oil Filter Wrench 2 1/2 in. (64 mm) Dia.Figure 3-6. Removing Oil FilterFuel SystemSpecificationsFor bes

TP-5695 12/93 Scheduled Maintenance 3-7Fuel Pump ScreenWARNINGExplosive fuel vapors.Can cause severe injury or death.Useextreme carewhenhandling,stori

TP-5695 12/933-8 Scheduled MaintenanceCarburetor/Choke LubricationTheonlymaintenancerequiredisto lubricatecarburetorand choke linkage at the specified

TP-5695 12/93 Scheduled Maintenance 3-9Ignition SystemIgnition System ServiceThe ignition system is transistorized and breakerless.Under normal condit

TP-5695 12/933-10 Scheduled MaintenanceProblem Means of Identification Possible CauseNormal Light tan or gray deposit on thefiring tip.Good operating

TP-5695 12/93 Scheduled Maintenance 3-11121. 0.028--0.031 in.(0.7--0.8 mm) Gap2. Spark Plug Electrodes1-514Figure 3-12. Checking Spark Plug Gap1-511Fi

TP-5695 12/93 Safety Precautions and Instructions iSafety Precautions and InstructionsA generator set, like any other electro-mechanicaldevice, can po

TP-5695 12/933-12 Scheduled MaintenanceCooling Systems—Closed/Heat ExchangerIn a closed cooling system, the seawater does notcirculate through the eng

TP-5695 12/93 Scheduled Maintenance 3-1311-8281. Air-Bleed Screw; Use 12 mm WrenchFigure 3-14. Air-Bleed ScrewTOTAL HOURS00 0001/1010AFUSESTARTSTOPBAT

TP-5695 12/933-14 Scheduled MaintenanceFlushing and CleaningIf required, flush coolant from generator set. To properlyflush coolant, obtain Kit #26799

TP-5695 12/93 Scheduled Maintenance 3-1513. Reconnect battery, negative lead last.14. Start generator set and allow the set to run forabout 20--30 sec

TP-5695 12/933-16 Scheduled MaintenanceAnticorrosion ZincAn anticorrosion zinc anode is installed in the heatexchangertopreventelectrolyticcorrosionby

TP-5695 12/93 Scheduled Maintenance 3-17Pressure CapClosed-loop cooling systems incorporate a pressurizedcaptoraisetheboilingpointofthecoolantandmakeu

TP-5695 12/933-18 Scheduled MaintenanceBatteryThe starting battery should be a 12-volt unit with aminimum 250 CCA (cold cranking Amps) at 0_ F (--18_C

TP-5695 12/93 Scheduled Maintenance 3-19each cell should not exceed ±0.01. The battery shouldbe charged if the specific gravity is below 1.215 at anel

TP-5695 12/933-20 Scheduled MaintenanceValve AdjustmentWith overhead cam engines, each valve is spring-heldin the closed position until forced open by

TP-5695 12/93 Scheduled Maintenance 3-211. “Y” Mark2. “T” Mark211-827Figure 3-22. Determining Top Dead Center1231. Feeler Gauge2. Adjusting Screw 3 mm

TP-5695 12/93ii Safety Precautions and InstructionsEXHAUST SYSTEMWARNINGCarbon monoxide.Can cause severe nausea, fainting, or death.The exhaust system

TP-5695 12/933-22 Scheduled MaintenanceGovernorThe gear-driven centrifugal type governor serves tokeep engine speed constant by automatically adjustin

TP-5695 12/93 Scheduled Maintenance 3-23Wattage RequirementsIftheratedcapacityofthegeneratorsetisexceeded,thecircuitbreakerlocatedonthecontrollerwillt

TP-5695 12/933-24 Scheduled MaintenanceStorage ProcedureIt is recommended that the craft be afloat when thegenerator set is prepared for storage since

TP-5695 12/93 Troubleshooting 4-1Section 4. TroubleshootingWhen troubles occur, do not overlook simple causes. Astarting problem, for example, could b

TP-5695 12/934-2 TroubleshootingEngine (Continued)Problem Possible Cause Corrective ActionStops suddenlyOut of fuel ReplenishStopssuddenlyAir intake c

TP-5695 12/93 Troubleshooting 4-3Engine (Continued)Problem Possible Cause Corrective ActionOverheatsImproper cooling Check intake and outlet openings.

TP-5695 12/934-4 TroubleshootingGeneratorProblem Possible Cause Corrective ActionNo AC outputCircuit breaker in OFF position Reset breaker to ON posit

TP-5695 12/93 Wiring Diagrams 5-1Section 5. Wiring DiagramsTHERMAL SWITCHBATTERY VOLTMETERWATER TEMPERATURE GAUGEOIL PRESSURE GAUGEWATER TEMP. SENDERH

5-2 Wiring Diagrams TP-5695 12/93FOR AMPERAGERATINGSEEOWNERS MANUALCIRCUIT BREAKERS220 V. CONNECTIONL0GRD4 3 2 1LO (NEUTRAL)GRDL1BC72378N4573715249152

TP-5695 12/93 Wiring Diagrams 5-3Electro SwitchL1L2To GeneratorSetTo ShorePowerTo Load2-Wire Generator SetsL1L2To GeneratorSetTo ShorePowerTo Load2-Wi

TP-5695 12/93 Safety Precautions and Instructions iiiBATTERYWARNINGSulfuric acid in batteries.Can cause severe injury or death.Use protective goggles

5-4 Wiring Diagrams TP-5695 12/93Four-Lead Reconnectable (Single-Phase) Generator Sets Where GeneratorOutput Can Be Reconnected For 120 volt or 120/24

TP-5695 12/93 Wiring Diagrams 5-5120/240- or 110/220-VoltConfiguration--Figure 5-6Jumper lead not used. If unit was originally wired forstraight 120 o

6

TP-5695 12/93 Installation 6-1Section 6. InstallationIntroductionUse this section as a guide when installing the Marinegenerator set, then refer to Se

TP-5695 12/936-2 InstallationCapabilities will vary according to Kilowatt Deratingfollowing.MotorRequirements(HP)Starting(In-Rush)WattsRunningWatts1/4

TP-5695 12/93 Installation 6-3TOTAL HOURS00 0001/1010AFUSEBATT.CHRG.INPUTNOTEUse two hose clamps on each end ofall flexible exhaust hose connections.*

TP-5695 12/936-4 InstallationLocationGeneralConsider the following in selecting or constructing agenerator set location.Compartment/location must allo

TP-5695 12/93 Installation 6-5Fuel SystemsFuel SupplyGenerator sets, in most cases, must draw fuel from thesame tank as the propulsion engines. If the

TP-5695 12/936-6 InstallationAnti-Siphon ProvisionsAnti-siphon devices must be installed if any section offuel line lies below the highest point of th

TP-5695 12/93 Installation 6-7Cooling SystemsGeneralThe following features are necessary in the coolingsystem.An intake thru-hull strainer (seacock co

TP-5695 12/93iv Safety Precautions and InstructionsFUEL SYSTEMWARNINGExplosion.Gasoline vapors can cause explosion andsevere injury or death.Before st

TP-5695 12/936-8 InstallationA seawater strainer of sufficient capacity should bemounted to the seacock or permanent structure at apoint not higher th

TP-5695 12/93 Installation 6-9TOTAL HOURS00 0001/1010AFUSEBATT.CHRG.INPUTNOTEUsetwohoseclampsoneachend of all flexible exhausthose connections.1. Exha

TP-5695 12/936-10 InstallationLocatetheexhaustoutletatleast4in.(10cm)abovethewaterlinewhenthecraftisloadedtomaximumcapacity.Usually a flapper is insta

TP-5695 12/93 Installation 6-11Above WaterlineIn addition to considerations described earlier, acustomer-supplied silencer should be installed with it

TP-5695 12/936-12 InstallationA typical silencer should be mounted no more than 4 ft.(1.2 m) below the highest point in the exhaust line.Attach a sepa

TP-5695 12/93 Installation 6-13isolator or isolation transformer is referenced in ABYCE-8.20 and ABYC E-8.11.Generator sets installed in commercial ve

TP-5695 12/936-14 InstallationRemote Start Switch ConnectionKohler offers several remote panels for connection tothe generator set. See Accessories fo

TP-5695 12/93 Installation Drawings 7-1Section 7. Installation DrawingsADV-5792-DVIEW A--AMOUNTING PATTERNEQUIVALENT.ARE MILLIMETERDIMENSIONS IN ( )NO

TP-5695 12/937-2 Installation DrawingsADV-5792-DA AVIEW A--AKIT # 267994 (4 PIECE COVER).SOUND SHIELD SERVICEWITH SOUND SHIELD.5/6.5KW SUPPLIED STANDA

TP-5695 12/93 Parts Ordering Instructions 8-1Section 8. Parts Ordering InstructionsForserviceorinformation,checktheyellowpagesofthetelephone directory

TP-5695 12/93 Safety Precautions and Instructions vACCIDENTAL STARTINGWARNINGAccidental starting.Can cause severe injury or death.Disconnect battery c

TP-5695 12/93 Operating Hour Service Log 9-1Section 9. Operating Hour Service LogThe following is provided to help you keep a cumulativerecord of oper

TP-5695 12/93PRINTED IN U.S.A.KOHLER CO. KOHLER, WISCONSIN 53044PHONE 414-565-3381FAX 414-459-1646 (North American Sales), 414-459-1614 (International

TP-5695 12/93vi Safety Precautions and InstructionsENGINE BACKFIRE/FLASH FIREWARNINGFire.Can cause severe injury or death.Do not smoke or permit flame