Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Specification sheet

Operation and
Installation Manual
MarineGenerator Sets
Models:
3.5CFZ
4CZ
5CFZ
6.5CZ
TP-5695 12/93

Engine exhaust fromthisproductcontains
chemicalsknowntotheStateofCaliforniatocause
cancer,birth defects,orother reproductive harm.
WARNING
CaliforniaProposition 65

TP-5695 12/93 Table ofContents
TableofContents
SUBJECTPAGE SUBJECTPAGE
SafetyPrecautions and Instructionsi.......
Reference Materialviii.......................
Routine ServiceParts x......................
GlossaryofAbbreviations xi................
Section 1.Specifications 1-1..................
Introduction 1-1...............................
Specifications1-1.............................
GeneralSpecifications1-1...................
Generator1-2..............................
Engine 1-3.................................
Accessories1-5..............................
ServiceViews1-6.............................
Section 2.Operation 2-1......................
PrestartChecks 2-1...........................
Controller2-2................................
Starting 2-3..................................
Stopping 2-3.................................
CircuitProtection 2-4..........................
Engine SafetyShutdownSwitches2-4...........
RemotePanels(Optional)2-6..................
Section 3.ScheduledMaintenance 3-1.........
ServiceSchedule 3-2..........................
Lubrication System3-4........................
Specifications3-4...........................
Oil Check 3-4..............................
Adding Oil 3-5..............................
Oil Change/Oil FilterChange 3-5..............
FuelSystem3-6..............................
Specifications3-6...........................
FuelPumpScreen 3-7.......................
Carburetor/Choke Lubrication 3-8.............
CarburetorAdjustments3-8..................
Ignition System3-9............................
Ignition SystemService 3-9..................
SparkPlugs3-9............................
Cooling Systems—Closed/HeatExchanger3-12...
Filling and Checking 3-12.....................
Flushing and Cleaning 3-14...................
Anticorrosion Zinc3-16.......................
PressureCap 3-17...........................
Siphon Break3-17...........................
AirCleanerand Mixing Elbow3-17...............
Servicing AirCleaner3-17....................
Servicing Mixing Elbow3-17...................
Battery3-18...................................
Cleaning 3-18...............................
Checking Electrolyte Level3-18................
Checking SpecificGravity3-18................
Charging 3-19...............................
ValveAdjustment3-20..........................
Governor3-22.................................
Lubrication 3-22.............................
GovernorAdjustment3-22....................
Wattage Requirements3-23.....................
GeneratorService 3-23.........................
General3-23................................
Storage Procedure 3-24........................
Section 4.Troubleshooting 4-1................
Engine 4-1...................................
ElectricalSystem4-3..........................
Generator4-4................................
Section 5.Wiring Diagrams 5-1...............
Section 6. Installation 6-1.....................
Introduction 6-1...............................
GeneratorSelection and
Wattage Requirements6-1.....................
Lighting Load 6-1...........................
MotorLoads6-1............................
Appliance Loads6-2........................
Kilowatt Derating 6-2........................
Location 6-4..................................
General6-4................................
Space 6-4.................................
Mounting 6-4...............................
Ventilation 6-4................................
FuelSystems6-5.............................
FuelSupply6-5............................
Anti-Siphon Provisions6-6...................
FuelLines6-6..............................
FuelPump Lift Capabilitiesand
FuelConsumption 6-6.......................
Cooling Systems6-7..........................
General6-7................................
Closed/HeatExchanger6-8..................
ExhaustSystems6-9..........................
General6-9................................
AboveWaterline 6-11........................
Mid/BelowWaterline 6-11.....................
ElectricalSystems6-12.........................
ACVoltage Connections6-12..................
Installation inSteelorAluminumVessels6-12...
Battery6-13.................................
Wiring 6-13.................................
RemoteStartSwitchConnection 6-14..........
Section 7. Installation Drawings 7-1...........
Section 8.PartsOrdering Instructions 8-1.....
Section 9.Operating HourService Log 9-1.....

TP-5695 12/93 SafetyPrecautionsand Instructionsi
Safety Precautions and Instructions
Ageneratorset, like anyotherelectro-mechanical
device,can pose potentialdangerstolife and limbif
improperlymaintained orimprudentlyoperated.The
bestwayto preventaccidentsisto be aware of the
potentialdangersand to always use good common
sense. Inthe interestofsafety,some general
precautionsrelating tothe operation ofa generatorset
follow.Keep theseinmind.Thismanualcontains
severaltypesofsafetyprecautionswhich are explained
below.
DANGER
Dangerisusedtoindicatethepresenceofahazardthat
will causeseverepersonal injury,death,orsubstantial
propertydamage if the warning isignored.
WARNING
Warning isused toindicatethe presence ofa hazard
thatcan causeseverepersonal injury,death,or
substantialpropertydamage if the warning isignored.
CAUTION
Cautionisused toindicatethepresence ofahazardthat
will orcan causeminorpersonal injuryorproperty
damage if the warning isignored.
Safetydecalsare affixed tothe generatorsetin
prominentplacesto advisethe operatororservice
technician ofpotentiallyhazardous situations.The
decalsarereproduced heretoimprove operator
recognition and therebyincrease decaleffectiveness.
Forafurtherexplanationofdecalinformation,reference
theaccompanying safetyprecautions.Beforeoperating
orservicing the generatorset, be sureyou understand
the message of these decals.Replace decalsifmissing
ordamaged.
NOTE
Noteisusedto notifypeople ofinstallation,operation,or
maintenanceinformation thatisimportantbutnot
hazard-related.
HAZARDOUS VOLTAGE/
ELECTRICALSHOCK
WARNING
Hazardous voltage.
Do notoperate generatorsetwithoutall guards
and electricalenclosuresin place.
Moving rotor.
Cancause severeinjuryordeath.
Hazardous voltage cancause severeinjuryor
death.Whereverelectricityispresent, thereisthe
hazardofelectrocution.Takethesameprecautionswith
electricalappliancesinyourcraft thatyou would
observeinyourhome.Open maincircuitbreakeron all
powersourcesbeforeservicing equipment. Makesure
unqualified persons,especially children,cannotgain
access toyourset—keep the compartmentdoorlocked
orsecurelylatchedatall times.Besurethatgeneratoris
properlygrounded.Nevertouch electrical leadsor
applianceswithwethands,when standing inwater,or
on wetground asthe chance ofelectrocution is
especiallyprevalentundersuchconditions.
Hazardous voltage cancause severeinjuryor
death.Usecaution when handling the capacitor;
possible electricalshock can result. Discharge
capacitorby shorting terminalstogether.
Hazardous voltage cancause severeinjuryor
death.Shortcircuits can cause bodilyinjuryand/or
equipmentdamage.Do notcontactelectrical
connectionswithtoolsorjewelrywhile adjustmentsare
made.Removewristwatch,rings,and jewelrythatcan
causeshortcircuits.
Hazardous“backfeed”voltage cancause severe
injuryordeath.Do notconnect to anybuilding/marina
electricalsystemwithoutconnecting through an
approved device and afterbuilding mainswitchisopen.
Backfeedconnectionscancauseseriousinjuryordeath
to utilitypersonnelworking torepaira poweroutage
and/orpersonnel inthe vicinity.Unauthorized
connection maybe unlawful insomestatesand/or
localities.Aship-to-shoretransferswitchmustbe
installed to preventinterconnection ofgeneratorset
powerand shore power.

TP-5695 12/93ii SafetyPrecautionsand Instructions
EXHAUSTSYSTEM
WARNING
Carbon monoxide.
Cancause severenausea,fainting,ordeath.
The exhaustsystem mustbe leakproofand
routinelyinspected.
Carbon monoxide cancause severenausea,
fainting,ordeath.Usethe following precautionswhen
installing and operating generatorset. Carbon
monoxide isparticularlythreatening inthatitisan
odorless,colorless, tasteless,nonirritating gas.Be
especially careful ifoperating the generatorwhen
moored oranchored undercalmconditionsasgases
mayaccumulate.Ifoperating the setdockside,moor
yourcraftsothatthe exhaustdischargesonthe leeside
(the side sheltered fromthe wind),and always be
mindfulofothers—makesureyourexhaustisdirected
awayfromotherboatsand occupied buildings.Do not
install exhaustoutletwhere exhaustcan be drawn
through portholes,vents,orairconditioners. If
generatorset’sexhaustdischarge holeisneartoyour
craft’swaterline,DONOTOVERLOADCRAFTso asto
close or restrictexhaustdischarge hole.
Carbon monoxide cancause severenausea,
fainting,ordeath.In addition toroutine inspection of
theexhaustsystem,acarbonmonoxidedetectorshould
be considered.Consultyourboatbuilderormarina for
installation ofapproved detectors.Itisessentialthatall
detectorsbe routinelyinspected forproperoperation.

TP-5695 12/93 SafetyPrecautionsand Instructionsiii
BATTERY
WARNING
Sulfuric acidin batteries.
Cancause severeinjuryordeath.
Use protective gogglesand clothes.Can cause
permanentdamage to eyes,burnskin,and eatholes
inclothing.
Sulfuric acidin batteries cancause severeinjuryor
death.Sulfuricacidin battery can cause permanent
damage to eyes,burnskin,and eatholesinclothing.
Alwayswearsplash-proofsafetygoggleswhenworking
around the battery.Ifbatteryelectrolyteis splashed in
the eyesoron skin,immediatelyflushthe affected area
for15minuteswithlarge quantitiesofclean water.Inthe
caseofeyecontact,seekimmediatemedicalaid.Never
addacidtoabatteryoncethebatteryhasbeenplacedin
service.Doing somayresultin hazardous spattering of
electrolyte.
Explosion cancause severeinjuryordeath.Battery
gases can cause an explosion.Do notsmoke orpermit
flame orsparkto occurneara batteryatanytime,
particularlywhen itisbeing charged.Avoidcontacting
terminalswithtools,etc.topreventburnsand to prevent
sparks thatcouldcause an explosion.Remove
wristwatch,rings,andanyotherjewelrybeforehandling
battery.Neverconnectnegative(--) battery cableto
positive(+)connection terminalofstartersolenoid.Do
not testbattery condition by shorting terminalstogether
orsparks couldignite batterygasesorfuelvapors.Any
compartmentcontaining batteriesmustbe well
ventilated to preventaccumulation ofexplosive gases.
To avoidsparks,do notdisturb battery charger
connectionswhile batteryisbeing charged and always
turnchargeroff before disconnecting battery
connections.When disconnecting battery,remove
negativelead firstand reconnectitlast.

TP-5695 12/93ivSafetyPrecautionsand Instructions
FUELSYSTEM
WARNING
Explosion.
Gasoline vapors cancause explosion and
severeinjuryordeath.
Beforestarting generatorset, operate blower4
minutesand check engine compartment for
gasoline vapors.
WARNING
Explosive fuelvapors.
Cancause severeinjuryordeath.
Useextremecarewhen handling,storing,
and using fuels.
Explosive fuelvapors cancause severeinjuryor
death.Allfuelsarehighlyexplosiveinavaporstate.Use
extremecarewhen handling,storing,and using fuels.
Storefuel inawell-ventilated area awayfrom
spark-producing equipmentand outof the reach of
children.Neveradd fueltothe tankwhilethe engine is
running sincespilled fuelmayignite on contactwith hot
partsorfromignition spark.Do notsmoke orpermit
flame orsparkto occurnearpotentialsourcesofspilled
fuelorfuelvapors.Keepfuellinesand connectionstight
and in good condition—don’treplaceflexiblefuel lines
withrigidlines.Flexiblesectionsare used to avoid
breakage due tovibration.Should anyfuel leakage,fuel
accumulation,orelectricalsparks be noted,DONOT
OPERATEGENERATORSET.Havesystemsrepaired
beforeresuming generatoroperation.
Explosive fuelvapors cancause severeinjuryor
death.Additionalprecautionsmustbe taken when
using the following fuels:
Gasoline—Store gasoline onlyin approved red
containers clearlymarked GASOLINE.Do notstore
gasoline in anyoccupied building.
Explosive fuelvapors cancause severeinjuryor
death.Gasoline vapors can explode and can cause
death orsevereinjury.USCGRegulation 33CFR183
requiresall electricaldevices(ship-to-shoretransfer
switch,remotestartpanel,etc.)tobe“ignitionprotected”
whenusedinagasoline(gaseous)-fueledenvironment.
These electricaldevicesare not“ignition protected”and
are notcertified to operatein a gasoline
(gaseous)-fueled environmentsuch asengine roomor
nearfueltanks.Acceptablelocationswould be
wheelhouseorotherlivingareasshelteredfromrainand
watersplash.
Explosive fuelvapors cancause severeinjuryor
death.Spilled fuelcan cause an explosion.Use a
containertocatchfuelwhen draining fuelsystem.Wipe
up all spilled fuelafterdraining system.
Explosive fuelvapors cancause severeinjuryor
death.Fuel leakage can cause an explosion.Do not
modifythe tankorpropulsion engine fuelsystem.Craft
mustbe equipped withatankallowing one of the two
pickup arrangementsdescribed.Tankand installation
mustconformtoU.S.C.G.Regulations.
Explosive fuelvapors cancause severeinjuryor
death.Fuel leakage can cause an explosion.To
prevent fuel leakage,use pipe sealanton all threaded
fittings.Pipe sealantmustbe suitableforuseinmarine
applicationshaving oil and gasoline environments.

TP-5695 12/93 SafetyPrecautionsand Instructions v
ACCIDENTALSTARTING
WARNING
Accidentalstarting.
Cancause severeinjuryordeath.
Disconnectbattery cablesbeforeworking on
generatorset(negativelead firstand reconnectit
last).
Accidentalstarting cancause severeinjuryor
death.Disconnectbattery cables(remove negative
lead firstand reconnectitlast)to disable generatorset
beforeworking on anyequipmentconnected to
generator.The generatorsetcan be started byremote
start/stop switch unless thisprecaution isfollowed.
MOVINGPARTS
WARNING
Rotating parts.
Cancause severeinjuryordeath.
Do notoperate generatorsetwithoutall guards,
screens,orcoversin place.
Flying projectiles cancause severeinjuryordeath.
Retorque all crankshaft and rotorhardware after
servicing.When making adjustmentsorservicing
generatorset, do notloosen crankshaft hardware or
rotorthru-bolt. If rotating crankshaft manually,direction
shouldbeclockwise only.Turning crankshaft boltor
rotorthru-boltcounterclockwisecan loosen hardware
and resultinseriouspersonal injuryfromhardware or
pulleyflying off engine while unitisrunning.
Exposedmoving parts cancause severeinjuryor
death.AdditionalPrecautionsRegarding Sound Shield
Equipped Models:
Somescheduled maintenance proceduresrequirethe
generatorset to be running while performing service. If
the sound shield hasbeen removed leaving beltsand
pulleys exposed,be especially carefulof thisarea.
Exposedmoving parts cancause severeinjuryor
death.Keep hands, feet, hair,clothing,and testleads
awayfrombeltsand pulleys when unitisrunning.
Replace guards,covers,and screensbefore operating
generatorset.
HOTPARTS
WARNING
Hotengine and exhaustsystem.
Cancause severeinjuryordeath.
Donotworkongeneratorsetuntilunitisallowedto
cool.
Hotparts cancause severeinjuryordeath.Do not
touchhotengine parts.Anengine getshotwhilerunning
and exhaustsystemcomponentsgetextremelyhot.
WARNING
Hotcoolantand steam.
Cancause severeinjuryordeath.
Beforeremoving pressurecap stop generator,
allowtocooland loosen pressurecap torelieve
pressure.
Hotcoolantcancause severeinjuryordeath.Allow
engine tocooland release pressurefromcooling
systembefore opening pressurecap.Torelease
pressure,coverthe pressurecap with a thick cloththen
turnitslowly counterclockwisetothe firststop.After
pressure hasbeen completelyreleased and the engine
has cooled,removecap. If generatorsetisequipped
withacoolantrecoverytank,checkcoolantlevelattank.

TP-5695 12/93viSafetyPrecautionsand Instructions
ENGINEBACKFIRE/FLASHFIRE
WARNING
Fire.
Cancause severeinjuryordeath.
Do notsmoke orpermit flame orsparkto occur
nearfuelorfuelsystem.
Aflashfire cancause severeinjuryordeath.Donot
smokeorpermitflameorsparktooccurnearcarburetor,
fuel line, fuelfilter, fuelpump,orotherpotentialsources
ofspilled fuelorfuelvapors.When removing fuel line or
carburetor,useapropercontainertocatch all fuel.
Asuddenbackfire cancause severeinjuryordeath.
Do notoperatewith backfireflame arrestor removed.
Asuddenbackfirecancausesevereinjuryordeath.
Do notoperatewith aircleaner/silencer removed.
Asuddenflashfirecancausesevereinjuryordeath.
Donotsmokeorpermitflameorsparktooccurnearfuel
system.Keepthecompartmentandgeneratorsetclean
and free ofdebristominimizechancesof fire.Wipe up
all spilled fueland engine oil.
HAZARDOUSNOISE
CAUTION
Hazardousnoise.
Cancause loss ofhearing.
Neveroperate generatorwithoutamufflerorwith
faultyexhaustsystem.

TP-5695 12/93 SafetyPrecautionsand Instructions vii
NOTES NOTE
HARDWAREDAMAGE!Engine and generatormay
make use ofbothAmerican Standard and metric
hardware.Besureto usethe correctsizetoolsto
preventrounding ofboltheadsand nuts.
NOTE
Specialattention should be given when checking for
propercoolantlevel.Afterthecoolanthasbeendrained,
itnormallyrequires sometime beforecompleterefill of
the engine waterjacket takesplace.
NOTE
Whenreplacing hardware,do notsubstitutewith
inferiorgradehardware.Screwsand nutsare
availablein differenthardness ratings.American
Standard hardware usesaseriesofmarkingsand
metrichardware usesa numeric systemtoindicate
hardness.Check markingson bolthead and nutsfor
properidentification.
NOTE
When a fusereplacementisrequired,be surefuse has
the same ampererating and isthe sametype (for
example:ABCor3AB,ceramic).Do notsubstitute
“clear”glass-type fusesforceramicfuses. If ampere
rating isunknown orquestionable,see Wiring Diagram.
NOTE
High-mineralcontentsea water (saltwater) can cause
rapid destruction ofall metals.Wipe up all saltwater
spillage on and around generatorsetand keep metal
surfacesfree fromaccumulated saltdeposits.
NOTICE
Thisgeneratorsethas beenrewiredfromits
nameplate voltageto:
246242
NOTICE
Thisisapositive terminalonly.
Do notattach negative lead!
NOTICE
Checkzincanode every100 hoursor3months.
NOTICE
Do notuse as a step.
Standing on gensetcouldimpairoperation ofunit.
NOTE
Splitlock washersmaybe supplied withsomekits. If
splitlock washersaresupplied withkit, theiruseis
optional.

TP-5695 12/93viii ReferenceMaterial
Reference Material
It isrecommended that the following Regulationsand
Standardsbe followed when installing Marine
GeneratorSets.
PleasureCraft
Designed and manufactured tomeetU.S.CoastGuard
Title 33.
U.S.CoastGuardCode ofFederalRegulations
Title 33
SubpartsI--ElectricalSystems
Subparts J--FuelSystems
Title 46
SubchapterF--Marine Engineering
Part58--Main and AuxiliaryMachineryand Related
Systems
Orderthe above publicationsfrom:
SuperintendentofDocuments
U.S.GovernmentPrinting Office
Washington,DC 20402
1-202-783-3238
Boating SafetyCircularCommandant(G-BC)
Boating Statistics (G-BP-1)
U.S.CoastGuardHeadquarters
2100 Second Street, S.W.
Washington,DC 20593-0001
Boating SafetyHotline:1-800-368-5647
American Bureau ofShipping
“RulesforBuilding and Classing SteelVessels”
45 EisenhowerDrive
Paramus,N.J.07652
201-368-9100
LloydsRegistryofShipping
“RulesforClassification ofShips”
17 BatteryPlace
NewYork,N.Y.10004
212-425-8050
UnderwritersLaboratories, Inc.(UL)
PublicationsStock
333 Pfingsten Road
Northbrook, IL 60062
Marine Department: 1-919-549-1400
NFPA 302
NationalFireProtection Association
60 BatterymarchPark
Quincy,MA02269
CustomerService
SocietyofAutomotiveEngineer’s(SAE)
400 CommonwealthDrive
Warrendale,PA 15096
1-412-776-4970
American Boatand YachtCouncil, Inc.(ABYC)
3069 Solomon’sIsland Rd.
Edgewater,MD21037
1-410-956-1050
1-410-974-8112
1-410-956-2737 FAX
IEEE 45
The Institute ofElectricaland
Electronics Engineer’sInc.
345 East47thStreet
NewYork,NY10017

TP-5695 12/93 ReferenceMaterial ix
CommercialVessels
In orderto usethese generatorsetsforcommercial
applicationswhereU.S.CoastGuardTitle46Certificate
isrequired,additionalmodificationswill be necessary.
U.S.CoastGuardCode ofFederalRegulations
Title 46
SubchapterF--Marine Engineering
Part58--Main and AuxiliaryMachineryand Related
Systems
SubchapterJ--ElectricalEngineering
Part111--ElectricalSystems--GeneralRequirements
Part112--Emergency Lighting and PowerSystems
SubchapterT--Small PassengerVessels
(Under100 Gross Tons)
Part182--MachineryInstallation
Part183--ElectricalInstallation
Orderthe above publicationsfrom:
SuperintendentofDocuments
U.S.GovernmentPrinting Office
Washington,DC 20402
1-202-783-3238
American Bureau ofShipping (ABS)
65 Broadway
NewYork,NY10006
OrderABS publicationsfrom:
American Bureau ofShipping
BookOrderSection
45 EisenhowerDrive
P.O.Box910
Paramus,NJ97653-0910
Lloyd’sRegisterofShipping
71 FenchurchStreet
London,EC3M4BS England
MidwestOffice:
Lloyd’sRegisterofShipping
100 SouthYorkStreet, Room226
Elmhurst, IL 60126
1-312-279-5414
AdditionalReferences
The following organizationsprovide a servicewhich
maybe usefultothe generatorsetinstaller.These
organizationsare notregulatoryin nature butrather
provide guidelinesand assistance.Theyarelisted only
asasourceforadditional information.Nosolicitation or
representation isherebygiven.
YachtCorrosion Consultants, Inc.
2970 SeaborgAve.
Ventura,CA93003
1-805-644-1886
Ward’sMarine Electric, Inc.
630 S.W.FlaglerAve.
Ft. Lauderdale,FL 33301
1-305-523-2815
1-800-545-9273
1-305-523-1967 FAX

xRoutine ServicePartsTP-5695 12/93
RoutineService Parts
ContactyourKohlergeneratordealer/distributorfora
completelisting ofservice partsforyourgeneratorset.
PartDescription KohlerPartNo.
Engine:
AirFilter278612
Oil Filter267714
Belt, Timing 267722
Ignition System:
SparkPlug 267713
Sea WaterPumpImpeller229826
ZincAnode 267928
WhiteSprayPaint221318

TP-5695 12/93 GlossaryofAbbreviations xi
GlossaryofAbbreviations
Abbreviationsare used throughout thismanual.Normallyinthe text theywill appearincompleteformwiththe
abbreviation following in parenthesisthe first timetheyare used.Afterthat theywill appearinthe abbreviated form.
The commonlyused abbreviationsareshown below.
Abbreviation Description
ACalternating current
AHWTanticipatoryhigh watertemp.
ALOPanticipatorylowoil pressure
AMamplitude modulation
Amp ampere
Ampsamperes
ANSIAmerican NationalStandardInstitute
APIAmerican PetroleumInstitute
approx.approximate,approximately
A/Rasrequired,asrequested
A/Sas supplied,as stated,as suggested
ASA American StandardsAssociation
assy.assembly
ASTMAmerican SocietyforTesting Materials
ATDC aftertop dead center
ATSautomatictransferswitch
aux.auxiliary
AWGAmerican WireGauge
AWMappliancewiring material
bhp brake horsepower
bmep brakemean effective power
BtuBritishthermalunit
°C Celsiusdegree
cc cubic centimeter
CCAcoldcranking Amps.
CEC Canadian ElectricalCode
cfhcubicfeetperhour
cfmcubicfeetperminute
CIDcubicinch displacement
cmcentimeter,centimeters
cmm cubicmetersperminute
co.company
cont’d.continued
C.S.A.Canadian StandardsAssociation
cu.in.cubicinch,cubicinches
cyl.cylinder
dBA decibels
DC directcurrent
DCR directcurrentresistance
deg.degree
dept. department
dia.diameter
e.g.example given
EMIelectromagneticinterference
etc.etcetera,(and soforth)
ext. external
°F Fahrenheitdegree
fl.oz. fluid ounce, fluid ounces
Abbreviation Description
FMfrequency modulation
fsfull scale
ft. foot, feet
ft. lbs. footpound, footpounds
ga.gauge
gal., gals.gallon,gallons
gal./hr.gallonsperhour
gph gallonsperhour
gpmgallonsperminute
gr.grade
grd.ground
HCHThigh cylinderhead temperature
HEThigh exhaust temperature
Hgmercury(element)
H2Owater
hp horsepower
hr,hrshour
HWThigh watertemperature
Hzhertz(cyclespersecond)
IDinside diameter
in.inch(es)
inc.incorporated
in.lbs.inch pounds
int. internal
int.-ext. internal-external
ISOInternationalStandardsOrganization
Jjoule,joules
JISJapaneseIndustryStandard
kgkilogram,kilograms
kg/cm2kilogramspersquarecentimeter
kgmkilogram meter(s)
kmkilometer,kilometers
kPakiloPascal,kiloPascals
kph kilometersperhour
kVkilovolt
kVA kilovoltamperes
kWkilowatt, kilowatts
kWHkilowatt hour
Lliter,liters
LxWxHlengthxwidthxheight
LED,LEDslightemitting diode
lb., lbs.pound,pounds
L/hr.literperhour,litersperhour
L/min.liter(s)perminutes
LOPlowoil pressure
LPliquefied petroleum
LWTlow watertemperature
m meter,meters

xii GlossaryofAbbreviationsTP-5695 12/93
Abbreviation Description
m3cubicmeter,cubicmeters
max.maximum
MCMone thousand circularmils.
mi.mile,miles
mil one one-thousandth ofan inch
min.minimum
mJmillijoule,millijoules
MJmega joule,mega joules
mm millimeter,millimeters
m3/mincubicmetersperminute
MPamegaPascal
mph milesperhour
MSmilitary standard
mWmilliwatt, milliwatts
MWmegawatt, megawatts
N/Anotavailable
NEC NationalElectricalCode
NEMANationalElectrical
ManufacturersAssociation
NFPA NationalFireProtection Association
NmNewton meter,Newton meters
no., nos.number,numbers
NPTNationalStandardtaperpipe
thread pergeneraluse
N/Rnotrequired
OCovercrank
ODoutside diameter
OEMoriginalequipmentmanufacturer
OSoverspeed,oversize
OVovervoltage
oz.ounce,ounces
Abbreviation Description
PFpowerfactor
pot. potentiometer
ppmpartspermillion
psipoundspersquareinch
pt., pts.pint, pints
qt., qts.quart, quarts
qty.quantity
ref. reference
RFIradiofrequency interference
rmsrootmean square
rpmrevolutionsperinch
SAE SocietyofAutomotiveEngineers
sec.second,seconds
SCR silicon controlled rectifier
spec,specs specification
sq.square
sq.cmsquarecentimeters
sq.in.squareinch,squareinches
tachtachometer
TDC top dead center
temp. temperature
TIFtelephone influencefactor
turbo turbocharger
UNC Unified coarsethread (wasNC)
UNFUnified fine thread (wasNF)
ULUnderwriter’sLaboratories, Inc.
USundersize
Vvolt, volts
VACVoltsalternating current
VDC voltsdirectcurrent
Wwatt, watts

TP-5695 12/93 Specifications1-1
Section 1.Specifications
Introduction
The craft isequipped with a dependable 110 volt
(reconnectableto 110/220 volt),50 Hz;or120 volt
(reconnectableto 120/240 volt),60 Hz single-phase
alternating currentmarine generatorset. Service
requirementsareminimalbutareveryimportant tothe
safe and efficientoperation of the generatorset;
therefore,inspectassociated partsoften. It is
recommended thatan authorized service
dealer/distributorperformrequired servicing to assure
the unitcontinuestomeetU.S.C.G.requirements.
Pleasetakeafewmomentstoread thismanual, then
carefullyfollowallservicerecommendationstokeepthe
setintop condition.Keep thismanualaboardthe craft
forfuturereference.See Figure 1-1foridentification
and location ofcomponents.
Specifications
GeneralSpecifications
3.5CFZ 5CFZ
Dimensions--LxWxH--in.(mm)27.87 x17.50 x16.60
(708 x445 x422)31.07 x18.10 x17.50 (789 x460 x445)
withSound Shield 31.07 x18.10 x17.50
(789 x460 x445)31.07 x18.10 x17.50 (789 x460 x445)
Weight--(wet),lbs.(kg)208 (94)231 (104)
withSound Shield 231 (104)231 (104)
AirRequirements--cfm(L/min.)18 (510)18 (510)
FuelConsumption U.S.gal./hr.(L/hr.)
Load
25%0.42 (1.59)0.44 (1.67)
50%0.50 (1.89)0.54 (2.04)
75%0.59 (2.23)0.66 (2.50)
100%0.68 (2.57)0.80 (3.03)
4CZ6.5CZ
Dimensions--LxWxH--in.(mm)27.87 x17.50 x16.60
(708 x445 x422)31.07 x18.10 x17.50 (789 x460 x445)
withSound Shield 31.07 x18.10 x17.50
(789 x460 x445)31.07 x18.10 x17.50 (789 x460 x445)
Weight--(wet),lbs.(kg)190 (86)231 (104)
withSound Shield 213 (96)231 (104)
AirRequirements--cfm(L/min.)18 (510)18 (510)
FuelConsumption U.S.gal./hr.(L/hr.)
Load
25%0.48 (1.81)0.53 (2.00)
50%0.55 (2.08)0.62 (2.34)
75%0.62 (2.34)0.86 (3.25)
100%0.68 (2.57)1.02 (3.86)

TP-5695 12/931-2Specifications
Generator
3.5CFZ 5CFZ
Rated kW3.5 5
Frequency--Hz50 50
Rated Voltage 110 Volt, 2&3Wire,SinglePhase or110/220 Volt, 3Wire,SinglePhase
Rated Amps(110 Volt)31.8 45.5
Rated Amps(220 Volt)15.9 22.7
RotorResistance(cold) (ohms)4--5 4--5
StatorResistance(cold) (ohms)*
Leads:
1--2,3--4 0.8 0.8
55--66 4.2 4.2
B1--B2 0.08 0.08
4CZ6.5CZ
Rated kW4 6.5
Frequency--Hz60 60
Rated Voltage 120 Volt, 2&3Wire,SinglePhase or120/240 Volt, 3Wire,SinglePhase
Rated Amps(120 Volt)33.3 54.2
Rated Amps(240 Volt)16.7 27.1
RotorResistance(cold) (ohms)3--4 4--5
StatorResistance(cold) (ohms)*
Leads:
1--2,3--4 0.06 0.04
55--66 1.9 2.4
B1--B2 0.09 0.06
3.5CFZ/4CZ5CFZ/6.5CZ
GeneratorType Two-Pole,Rotating Field
Voltage Regulation ±5%
Frequency Regulation ±5%
AngularOperation (Max.)
(in all directions)20° Continuous
Excitation Method Brushless,ExciterWinding/Capacitor
Coupling Type Tapered Shaft--Thru-Bolt
StatorBoltTorque in.lbs.(Nm)260 (29)
Thru-BoltTorque ft. lbs.(Nm)37 (50)
NumberofOutputLeads4,Reconnectable
Insulation (Rotorand Stator) Class F,Epoxy Varnish,VacuumImpregnated
Winding MaterialCopper
Bearing,Numberand Type 1,ReplaceableBall
CircuitProtection:
ControllerReplaceable 10-AmpFuse
BatteryCharging Replaceable 10-AmpFuse
AC CircuitBreakersOptional
*Mostohmmeterswill notgive accuratereadingswhen measuring less than 1 ohm.The statorcan be
considered good ifalowresistancereading (continuity)isobtained and thereisno evidence ofshorted
windings(discoloration).Do notconfusealowresistancereading withareading indicatingashorted winding.

TP-5695 12/93 Specifications1-3
DERATING:All unitsarerated1.0powerfactor.Derateapproximately3.5%per1000 ft.(300 m)above500ft.(150m)
abovesea level.
3.5CFZ,50 Hz:3.5kWat77° F(25° C)and 3.5kWat122° F(50° C).
4CFZ,60 Hz:4kWat77° F(25° C)and 3.5kWat122° F(50° C).
5CFZ,50 Hz:5kWat77° F(25° C)and 4.85 kWat122° F(50° C).
6.5CZ,60 Hz:6.5kWat77° F(25° C)and 6 kWat122° F(50° C).
Engine
Some generalengine specificationsarelisted below.Refertothe appropriateservicesection and the engine service
manualforspecific service details.
3.5CFZ/4CZ5CFZ/6.5CZ
ManufacturerHonda
ModelGX360EV
Cycle 4
NumberCylinders2
Compression Ratio 8:5:1
Displacement--cu.in.(L)21.9(359)
Rated Horsepower--50 Hz10.7(3.5CFZ)10.7(5CFZ)
--60 Hz12.8(4CZ)12.8(6.5CZ)
RPM--50 Hz3000 (3.5CFZ)3000 (5CFZ)
--60 Hz3600 (4CZ)3600 (6.5CZ)
BorexStroke--in.(mm)2.28 x2.68 (58 x68)
ValveMaterialSteelAlloy(JIS SUH3)
ValveClearance--in.(mm) (cold)0.004--0.006 (0.10--0.14)
CylinderBlock MaterialAluminum
CylinderHead CoverTightening
Torque--ft. lbs.(Nm)7(10)
CylinderHead MaterialAluminum
Connecting Rod MaterialSteel
Piston Rings2Compression/1Oil Control
Crankshaft BearingsReplaceableInserts
GovernorGear-Driven Centrifugal
Lubrication SystemPressure
Oil Capacity(withfilter)--U.S.qts.(L)1.48 (1.4)
Oil Type (API)SF,SF/CC,orSF/CD
Oil Pressure--psi(kPa)30--50 (207--345)
FuelType Gasoline,86 orHigher,Octane Unleaded
FuelSystemSingle-Barrel,HorizontalCarburetor
CarburetorChokeAutomatic,Electric
FuelPumpElectric
FuelPump Lift (max.)3ft. (0.9m)
BatteryVoltage 12
BatteryGround Negative
BatteryRecommendation 250 ColdCranking Amps(Min.)

TP-5695 12/931-4Specifications
Engine(Continued)
3.5CFZ/4CZ5CFZ/6.5CZ
SparkPlug Type Resistor,RadioSuppression,14 mm
BPR4HS(NGK)
KohlerPartNumberL92YC(Champion)
R43CFS(AC-Delco)
SparkPlug Gap--in.(mm)0.028--0.031 (0.7--0.8)
SparkPlug Tightening Torque--
ft. lbs.(Nm)15--22 (20--30)
Ignition SystemTransistorized,Breakerless
StarterMotorBendixAutomotiveType
Cooling SystemWater-Cooled,Closed/HeatExchanger
Cooling SystemCapacity--U.S.qts.(L)1.10 (1.00)
CoolantRecoveryTank--U.S.qts.(L)0.38 (0.35)
Thermostat180 °F(82° C)
PressureCap Rating 15 psi(103 kPa)
Engine Firing Order1--2
Ignition Timing B.T.D.C.24° ±2 degrees
ExhaustManifoldtoCylinder
Head Torque 16 ft. lbs.(22 Nm)
WaterPumpAssemblyto
CylinderBlock Torque 7ft. lbs.(10 Nm)
Cooling Fan Torque 16 ft. lbs.(22 Nm)
AirCleanerElbowtoCarburetor
Stud Torque 6ft. lbs.(8.5Nm)
Timing BeltCoverTorque 6 ft. lbs.(8Nm)
GovernorArmShaft NutTorque 7 ft. lbs.(10 Nm)
GovernorCasetoCylinderHead
Torque 7ft. lbs.(10 Nm)
FuelPumpPressureRating 2.0--3.5 psi(13.8--24.1kPa)
BatteryCharging Winding
Resistance--10 Amp0.16--0.24 Ohms
Ignition Coil PrimaryWire
Resistance0.9--1.1Ohms
Ignition Coil Secondary
(SparkPlug WireSide)Resistance0.9--1.1Ohms (WithSparkPlug Boot/Cap Removed)
Transistorized Ignition AirGap 0.016 ±0.008 in.(0.4±0.2mm)
Timing BeltDeflection 0.16--0.20 in.(4.5mm)@4.4lbs.(2kg)

TP-5695 12/93 Specifications1-5
Accessories
Severalaccessoriesare availabletofinalizethe
installation orto add convenienceto operation and
service.Allthemostcurrentinformationcanbeobtained
by contacting the localauthorized Kohler
dealer/distributor.Available accessoriesat the time of
printof thispublication are asfollows.
Sound Shield
(Optionalon 3.5CFZ/4CZ;
Standardon5CFZ/6.5CZ)
Providesforhighlyeffectivesilencing,ease ofaccess
forengine/generatorservicing,lowmaintenance,
excellentdurability,and safety.
SeawaterStrainer
The seawaterstrainerwithclearviewing container,
allowseasy cleaning and maintenance.Threaded for
1/2NPTfittings.
Ship-to-ShoreTransferSwitch
The ship-to-shoretransferswitch allowsimmediate
switching to generatorsetpowerorshore power
protecting the electricalsystemfromthe possibilityof
simultaneous connection ofboth powersources.
RemoteStartPanel
Allows starting/stopping fromalocation remote of the
generatorset. Supplied with 15 foot(4.6m)connection
harness.Overall mounting dimensionsare41/16 in.
(103mm)by2 1/8in.(54mm)witha minimum mounting
depth of2 1/4in.(57 mm).
SenderKit
Providesgauge sendersforthe remotestartand
two-meterpanelkitand the remotestartand four-meter
panelkit. The gauge senderkitisrequired tomakethe
oil pressure and watertemperature gaugesfunctional.
CircuitBreakers
See pricelistordealer/distributorforproperapplication
ofcircuitbreakers.
ModelAmpsPoles
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
RemoteStartand
Four-MeterPanelKit
Allows starting/stopping fromalocation remote of the
generatorset. The illuminated meters/gaugesinclude a
DC voltmeter,engine oil pressure gauge,water
temperature gauge,and an hourmeterwhichrecords
totalgeneratorsetoperating hours.Overall dimensions
are9in.(229 mm)by6in.(152 mm)with a minimum
mounting depth of4in.(102 mm).Requiresremote
connection/extension harness and senderkit.
RemoteStartand
Two-MeterPanelKit
Allows starting/stopping fromalocation remote of the
generatorset.The illuminatedgaugesincludeengineoil
pressure gauge and watertemperature gauge.Overall
dimensionsare6in.(152 mm)by6in.(152 mm)with a
minimum mounting depth of2 3/4in.(70 mm).Requires
remoteconnection/extension harness and senderkit.
RemoteConnection/
Extension Harness
Providesadditionalwiring between all remote panels
and controllerconnector.One required foreachremote
meterpanelkit. Availablein15ft. (46 m)and 25 ft.
(76 m)lengths.Extension limited to a totalof fourkits
and 75 ft. (23 m).
12-InchRemoteWiring Harness
Thisone foot(0.3m)wiring harness hasa 6-pin
connectoron one end whichis keyed tocontrollerbox
connector.The otherend haspigtailsforconnection to
customer-supplied startswitch,generator“on”light,
hourmeter,etc.
Siphon Break
Preventsthe siphoning ofwaterintothe engine on
generatorsetsinstalled belowthe waterline.