Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Problem Possible Cause Corrective Action Stops suddenly

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Engine (Continued)

Problem	Possible Cause	Corrective Action
Stops suddenly	Out of fuel	Replenish
	Air intake clogged	Clean
	Fuse blown in controller	Replace fuse
	Defective seawater pump impeller	Replace
	Clogged seawater strainer	Clean strainer
	Ignition coil failure	Check for spark
	Fuel line restriction	Check fuel lines and tank
	Fuel vapor lock	Check fuel line routing
	Defective electric fuel pump	Check pump
	Dirty fuel screen	Clean fuel screen
	Faulty spark plug(s)	Replace spark plug(s)
	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 engine coolant system
	Defective high exhaust temp. (HET) and/or	Check HET and HWT shutdown switch(es)
	high water temp. (HWT) safety shutdown
	switch(es)
	Loss of AC output	See authorized Kohler service
		dealer/distributor
	Faulty antidieseling solenoid	Replace solenoid
Lacks power	Air intake clogged	Clean
	Bad or stale fuel	Replace fuel
	Faulty spark plug(s)	Replace (and regap) plug(s)
	Improper timing	Check timing
	Choke solenoid defective	Check and/or change
	Engine not operating at rated RPM	Check governor
	Governor adjustments incorrect	Adjust governor
	Carbon build-up	Clean carbon from cylinder heads
	Improper cooling	Inspect cooling system
	Dirty fuel screen	Clean screen
	Defective ignition coil	Replace coil
	Fuel line restricted	Check fuel lines
	Engine overloaded	Reduce load
	Carburetor adjustment wrong	Adjust carburetor
Operates erratically	Air intake clogged	Clean
	Stale or bad fuel	Replace fuel
	Fuel pump vapor lock	Allow unit to cool and attempt restart
	Clogged fuel screen	Clean screen
	Faulty spark plug(s)	Replace spark plug(s)
	Carburetor adjustment incorrect	Adjust carburetor

4-2 Troubleshooting

TP-5695 12/93

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Contents 5CFZ Marine Generator SetsModels 5CZCalifornia Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide Can cause severe nausea, fainting, or death Carbon monoxide can cause severe nauseaSulfuric acid in batteries Can cause severe injury or death Sulfuric acid in batteries can cause severe injury orExplosive fuel vapors Can cause severe injury or death Explosive fuel vapors can cause severe injury orRotating parts Can cause severe injury or death Accidental starting Can cause severe injury or deathAccidental starting can cause severe injury or Flying projectiles can cause severe injury or deathSudden flash fire can cause severe injury or death Fire Can cause severe injury or deathSudden backfire can cause severe injury or death Hazardous noise Can cause loss of hearing246242 Reference Material Pleasure CraftCommercial Vessels Additional ReferencesRoutine Service Parts Part Description Kohler Part NoGlossary of Abbreviations Abbreviation DescriptionNEC General Specifications SpecificationsSpecifications IntroductionGenerator 5CFZ/4CZ 5CFZ/6.5CZEngine GX360EVBPR4HS NGK Accessories Service Views Service Views typicalOperation Prestart ChecksController ControllerStarting StoppingEngine Safety Shutdown Switches Circuit ProtectionHigh Water Temperature Shutdown Switch Remote Panel Features Remote Panels OptionalRemote Start and Four-Meter Features Remote Start and Four-Meter Panel KitScheduled Maintenance Service Schedule Or 2 YearsGenerator Specifications Lubrication SystemAdding Oil Oil Change/Oil Filter ChangeFuel System Removing Oil FilterFuel Pump Screen Fuel Pump ScreenCarburetor Adjustments Carburetor/Choke LubricationIgnition System Service Ignition SystemSpark Plugs Oil fouled Problem Means of Identification Possible Cause NormalGap bridged Carbon fouled12. Checking Spark Plug Gap Cooling Systems- Closed/Heat Exchanger Filling and CheckingHot coolant and steam Can cause severe injury or death 14. Air-Bleed Screw Flushing and Cleaning TP-5695 12/93 Scheduled Maintenance Anticorrosion Zinc 17. Removing Anticorrosion ZincPressure Cap Air Cleaner Mixing ElbowServicing Air Cleaner Servicing Mixing ElbowChecking Electrolyte Level BatteryCleaning Checking Specific Gravity21. Specific Gravity Temperature Correction ChargingValve Adjustment 22. Determining Top Dead Center Governor Adjustment GovernorLubrication Generator Service Wattage RequirementsGeneral Storage Procedure Unit cranks but will TroubleshootingEngine Not startProblem Possible Cause Corrective Action Stops suddenly Lacks powerOperates erratically Electrical System Generator Wiring Diagrams Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZDiagrams 4CZWire Generator Sets To Generator To Shore Set PowerTo Load Line Side LO Neutral GroundLoad Side 60 HzL1--L3 Without Jumper LeadPage Installation Generator Selection and Wattage RequirementsMotor Loads Appliance Loads Kilowatt DeratingTypical Location and Mounting Mounting LocationVentilationSpace Air Requirements CFM L/min Model Combustion CoolingFuel Systems Fuel SupplyFuel Pump Lift Capabilities Fuel Consumption Anti-Siphon ProvisionsFuel Lines Max. Lift ft. m In. mmCooling Systems 11. Intake StrainerClosed/Heat Exchanger 13. Seawater StrainerExhaust Systems 15. Closed/Heat Exchanger Cooling System17. Typical Above Waterline Installation Carbon monoxideAbove Waterline Mid/Below WaterlineInstallation in Steel or Aluminum Vessels Electrical SystemsAC Voltage Connections Battery WiringRemote Start Switch Connection Lead Designations Pin FunctionDimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ SectionSound Shield--Optional on 3.5CFZ and 4CZ Standard on 5CFZ and 6.5CZFor Sales & Service in U.S.A. & Canada Phone Parts Ordering InstructionsOperating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone