Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Electrical System

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Engine (Continued)

Problem	Possible Cause	Corrective Action
Overheats	Improper cooling	Check intake and outlet openings. Check
		coolant level and pressure cap. Check raw
		water strainer.
	Thermostat defective	Replace
	Sea strainer clogged	Clean sea strainer
	Carburetor adjustment too lean	Adjust carburetor mixture
	Engine ignition timing incorrect	Adjust timing
Unit is noisy	Exhaust system leak	Check exhaust system
	Exhaust system not securely installed	Check for loose parts
	Broken or damaged vibromounts	Check vibromounts
	No installation clearance (unit hits craft	Check clearances
	structure or compartment)
	No compartment sound insulation	Install approved insulation
	Excessive vibration engine/ generator	See authorized Kohler service
	(internal imbalance)	dealer/distributor
	Loose or vibrating sheet metal	Check shrouds

Electrical System

Problem	Possible Cause	Corrective Action
Battery will not	Loose or corroded connections	Clean and tighten connections
charge
charge	Sulfated or worn-out battery	Check electrolyte level and specific gravity
		(batteries with filler caps only)
	Defective battery charging system	Check charging system
	Battery charging fuse blown	Replace fuse. If fuse blows again see
		authorized Kohler service dealer/distributor
Starter does not	Loose or corroded connections	Clean and tighten loose connections
work properly
work properly	Low battery output	Check electrolyte level and specific gravity
		(batteries with filler caps only). Check
		battery voltage.
	Defective starter solenoid	Replace starter solenoid
	Defective start/stop switch	Replace switch
	Defective wiring	Check wiring
Starter cranks	Low battery output	Check electrolyte level and specific gravity
slowly		(batteries with filler caps only)
	Too heavy viscosity lube oil	Use proper viscosity oil
	Loose or corroded wiring	Clean and tighten loose connections
	High starter current draw	Rebuild or replace starter
	Battery cable undersize	See Installation Section--Electrical
		Systems

TP-5695 12/93

Troubleshooting 4-3

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Contents 5CZ Marine Generator SetsModels 5CFZCalifornia 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 deathFlying projectiles can cause severe injury or death Accidental starting Can cause severe injury or deathAccidental starting can cause severe injury or Rotating parts Can cause severe injury or deathHazardous noise Can cause loss of hearing Fire Can cause severe injury or deathSudden backfire can cause severe injury or death Sudden flash fire can cause severe injury or death246242 Pleasure Craft Reference MaterialAdditional References Commercial VesselsPart Description Kohler Part No Routine Service PartsAbbreviation Description Glossary of AbbreviationsNEC Introduction SpecificationsSpecifications General Specifications5CFZ/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 Carbon fouled Problem Means of Identification Possible Cause NormalGap bridged Oil 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 Mixing Elbow Air Cleaner Mixing ElbowServicing Air Cleaner Pressure CapChecking Specific Gravity BatteryCleaning Checking Electrolyte LevelCharging 21. Specific Gravity Temperature CorrectionValve Adjustment 22. Determining Top Dead Center Governor Governor AdjustmentLubrication Wattage Requirements Generator ServiceGeneral Storage Procedure Not start TroubleshootingEngine Unit cranks but willLacks 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 60 Hz LO Neutral GroundLoad Side Line SideWithout Jumper Lead L1--L3Page Generator Selection and Wattage Requirements InstallationMotor Loads Kilowatt Derating Appliance LoadsTypical Location and Mounting Air Requirements CFM L/min Model Combustion Cooling LocationVentilationSpace MountingFuel Supply Fuel SystemsMax. Lift ft. m In. mm Anti-Siphon ProvisionsFuel Lines Fuel Pump Lift Capabilities Fuel Consumption11. 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