Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Ignition System Service, Spark Plugs

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Ignition System

Ignition System Service

The ignition system is transistorized and breakerless. Under normal conditions, only the spark plugs need service on a regular basis. The electronic ignition module requires no maintenance and should give years of trouble-free service. If a module problem is suspected, have service performed by an authorized service dealer/distributor.

Spark Plugs

At the recommended interval (shown in the service schedule) service spark plugs.

1.Remove spark plug wires by grasping boot and turning slightly while pulling. Do not pull wire. See Figure 3-9.

NOTE

Pulling wire rather than boot may cause damage to wire 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 plug with a ratchet and spark plug socket with a rubber insert to prevent damage to spark plug. See Figure 3-10. Remove spark plugs one at a time and examine. See Figure 3-11 to evaluate engine conditions by color/condition of spark plugs.

3.Clean spark plugs by wiping with a rag and then file the center electrode so that it is parallel to the side electrode. Should replacement be necessary, see “Specifications”for spark plug type.

NOTE

Do not sandblast, wire brush, scrape, or otherwise service spark plug in poor condition. Best results are obtained with a new plug.

1-827

Figure 3-9. Removing Spark Plug Wires

1

1-827

1. 13/16 in. Spark Plug Socket

Figure 3-10. Removing Spark Plug

TP-5695 12/93

Scheduled Maintenance 3-9

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Contents Models Marine Generator Sets5CFZ 5CZCalifornia Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide can cause severe nausea Carbon monoxide Can cause severe nausea, fainting, or deathSulfuric acid in batteries can cause severe injury or Sulfuric acid in batteries Can cause severe injury or deathExplosive fuel vapors can cause severe injury or Explosive fuel vapors Can cause severe injury or deathAccidental starting can cause severe injury or Accidental starting Can cause severe injury or deathRotating parts Can cause severe injury or death Flying projectiles can cause severe injury or deathSudden backfire can cause severe injury or death Fire Can cause severe injury or deathSudden flash fire can cause severe injury or death Hazardous noise Can cause loss of hearing246242 Pleasure Craft Reference MaterialAdditional References Commercial VesselsPart Description Kohler Part No Routine Service PartsAbbreviation Description Glossary of AbbreviationsNEC Specifications SpecificationsGeneral Specifications Introduction5CFZ/4CZ 5CFZ/6.5CZ GeneratorGX360EV EngineBPR4HS NGK Accessories Service Views typical Service ViewsPrestart Checks OperationController ControllerStopping StartingCircuit Protection Engine Safety Shutdown SwitchesHigh Water Temperature Shutdown Switch Remote Panels Optional Remote Panel FeaturesRemote Start and Four-Meter Panel Kit Remote Start and Four-Meter FeaturesScheduled Maintenance Or 2 Years Service ScheduleGenerator Lubrication System SpecificationsOil Change/Oil Filter Change Adding OilRemoving Oil Filter Fuel SystemFuel Pump Screen Fuel Pump ScreenCarburetor/Choke Lubrication Carburetor AdjustmentsIgnition System Ignition System ServiceSpark Plugs Gap bridged Problem Means of Identification Possible Cause NormalOil fouled Carbon fouled12. Checking Spark Plug Gap Filling and Checking Cooling Systems- Closed/Heat ExchangerHot coolant and steam Can cause severe injury or death 14. Air-Bleed Screw Flushing and Cleaning TP-5695 12/93 Scheduled Maintenance 17. Removing Anticorrosion Zinc Anticorrosion ZincServicing Air Cleaner Air Cleaner Mixing ElbowPressure Cap Servicing Mixing ElbowCleaning BatteryChecking Electrolyte Level Checking Specific GravityCharging 21. Specific Gravity Temperature CorrectionValve Adjustment 22. Determining Top Dead Center Governor Governor AdjustmentLubrication Wattage Requirements Generator ServiceGeneral Storage Procedure Engine TroubleshootingUnit cranks but will Not startLacks power Problem Possible Cause Corrective Action Stops suddenlyOperates erratically Electrical System Generator Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring Diagrams4CZ DiagramsTo Generator To Shore Set Power Wire Generator SetsTo Load Load Side LO Neutral GroundLine Side 60 HzWithout Jumper Lead L1--L3Page Generator Selection and Wattage Requirements InstallationMotor Loads Kilowatt Derating Appliance LoadsTypical Location and Mounting Space LocationVentilationMounting Air Requirements CFM L/min Model Combustion CoolingFuel Supply Fuel SystemsFuel Lines Anti-Siphon ProvisionsFuel Pump Lift Capabilities Fuel Consumption Max. Lift ft. m In. mm11. Intake Strainer Cooling Systems13. Seawater Strainer Closed/Heat Exchanger15. Closed/Heat Exchanger Cooling System Exhaust SystemsCarbon monoxide 17. Typical Above Waterline InstallationMid/Below Waterline Above WaterlineElectrical Systems Installation in Steel or Aluminum VesselsAC Voltage Connections Wiring BatteryLead Designations Pin Function Remote Start Switch ConnectionSection Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZStandard on 5CFZ and 6.5CZ Sound Shield--Optional on 3.5CFZ and 4CZParts Ordering Instructions For Sales & Service in U.S.A. & Canada PhoneOperating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone