Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Troubleshooting, Engine, Unit cranks but will, Not start

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Section 4. Troubleshooting

When troubles occur, do not overlook simple causes. A starting problem, for example, could be caused by improper fuel or an empty fuel tank. The following charts list some common problems. If procedures in this manual do not explain how to correct the problem, take

the generator set to an authorized service dealer/distributor. Tell the dealer exactly what happened when the problem occurred and of any adjustments made to the set.

Engine

Problem	Possible Cause	Corrective Action
Unit will not crank	Weak or dead battery	Recharge or replace battery
	Reversed or poor battery connections.	Check connections
	Poor ground.
	Fuse blown in controller	Replace fuse
	Defective start/stop switch	Check function, replace as necessary.
	Defective starter solenoid	Check starter solenoid and wiring. Replace
		as necessary.

Defective starter

Attempt starting by direct connection to battery. Replace/repair as necessary.

Unit cranks but will	Out of fuel	Replenish
not start	Clogged fuel screen	Clean fuel screen
	Faulty antidieseling 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 retighten
	Carburetor adjustment wrong	Adjust carburetor
	Defective electric fuel pump	Check pressure. Replace as necessary.
	Shorted or open ignition coil	Replace coil
	Weak or dead battery	Recharge or replace
	Bad fuel mixture	Replace fuel; clean carburetor
	Flooded carburetor	Wait a few minutes and attempt restart
	Engine malfunction	See authorized Kohler service
		dealer/distributor

Engine starts, but does not continue to run after start switch is released

No generator output voltage	Check AC voltage
No/low oil pressure	Check oil pressure and pump
Defective low oil pressure (LOP) safety	Check LOP shutdown switch
shutdown switch
High temperature shutdown	Check cooling system
Defective high exhaust temp. (HET) and/or	Check HET and/or HWT shutdown
high water temp. (HWT) safety shutdown	switch(es)
switch(es)

Hard starting

Stale or bad fuel	Replace fuel
Fuel vapor lock	Check fuel line routing
Faulty spark plug(s)	Replace (and regap) plug(s)
Weak ignition coil	Replace
Carburetor adjustment wrong	Adjust carburetor
Air intake clogged	Clean

TP-5695 12/93

Troubleshooting 4-1

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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 AdjustmentsSpark Plugs Ignition System ServiceIgnition System Gap bridged Problem Means of Identification Possible Cause NormalOil fouled Carbon fouled12. Checking Spark Plug Gap Hot coolant and steam Can cause severe injury or death Cooling Systems- Closed/Heat ExchangerFilling and Checking 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 Lubrication Governor AdjustmentGovernor General Generator ServiceWattage Requirements Storage Procedure Engine TroubleshootingUnit cranks but will Not startOperates erratically Problem Possible Cause Corrective Action Stops suddenlyLacks power Electrical System Generator Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring Diagrams4CZ DiagramsTo Load Wire Generator SetsTo Generator To Shore Set Power Load Side LO Neutral GroundLine Side 60 HzWithout Jumper Lead L1--L3Page Motor Loads InstallationGenerator Selection and Wattage Requirements 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 WaterlineAC Voltage Connections Installation in Steel or Aluminum VesselsElectrical Systems 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