Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Generator

Page 56

Generator

	Problem	Possible Cause	Corrective Action
	No AC output	Circuit breaker in OFF position	Reset breaker to ON position

		Circuit breaker tripped due to overload on	Reduce load. See Wattage Requirements.
		generator set	Reset breaker to ON position.
		Ship-to-shore transfer switch in “OFF”or	Turn switch to generator power
		“SHORE”position
		No DC power to controller	Check battery connections

		Controller fuse blown	Replace fuse

		Generator malfunction such as capacitor	See authorized Kohler service
		or other internal fault	dealer/distributor

	Low output or	Engine speed too low	Adjust governor
	excessive drop in
	excessive drop in	Generator overloaded	Reduce load. See Wattage Requirements.
	voltage	Generator overloaded	Reduce load. See Wattage Requirements.

		Engine in poor condition	If routine services are performed and
		Engine in poor condition	If routine services are performed and
			condition persists, see authorized Kohler
			dealer/distributor

		Defective capacitor	See authorized Kohler service
			dealer/distributor
	High generator	Defective capacitor and/or poor wiring	See authorized Kohler service
	output voltage	connections	dealer/distributor
		Excessive speed or frequency	Adjust governor. Check governor linkage
			and spring for damage or binding.

	Will not crank	No DC power to controller	Check battery connections

		Controller circuit fuse blown	Replace fuse and attempt start-up. If fuse
			blows again, contact authorized Kohler
			service dealer/distributor.

4-4 Troubleshooting

TP-5695 12/93

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Contents Marine Generator Sets Models5CFZ 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 orAccidental starting Can cause severe injury or death Accidental starting can cause severe injury orRotating parts Can cause severe injury or death Flying projectiles can cause severe injury or deathFire Can cause severe injury or death Sudden backfire can cause severe injury or deathSudden flash fire 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 Specifications SpecificationsGeneral Specifications 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 LubricationSpark Plugs Ignition System ServiceIgnition System Problem Means of Identification Possible Cause Normal Gap bridgedOil 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 Anticorrosion Zinc 17. Removing Anticorrosion ZincAir Cleaner Mixing Elbow Servicing Air CleanerPressure Cap Servicing Mixing ElbowBattery CleaningChecking Electrolyte Level Checking Specific Gravity21. Specific Gravity Temperature Correction ChargingValve Adjustment 22. Determining Top Dead Center Lubrication Governor AdjustmentGovernor General Generator ServiceWattage Requirements Storage Procedure Troubleshooting EngineUnit cranks but will Not startOperates erratically Problem Possible Cause Corrective Action Stops suddenlyLacks power Electrical System Generator Wiring Diagrams Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZDiagrams 4CZTo Load Wire Generator SetsTo Generator To Shore Set Power LO Neutral Ground Load SideLine Side 60 HzL1--L3 Without Jumper LeadPage Motor Loads InstallationGenerator Selection and Wattage Requirements Appliance Loads Kilowatt DeratingTypical Location and Mounting LocationVentilation SpaceMounting Air Requirements CFM L/min Model Combustion CoolingFuel Systems Fuel SupplyAnti-Siphon Provisions Fuel LinesFuel Pump Lift Capabilities Fuel Consumption 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 WaterlineAC Voltage Connections Installation in Steel or Aluminum VesselsElectrical Systems 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