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

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

Image 55

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

Contents

5CZ Marine Generator SetsModels 5CFZ California Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide can cause severe nausea Carbon monoxide Can cause severe nausea, fainting, or death Sulfuric acid in batteries can cause severe injury or Sulfuric acid in batteries Can cause severe injury or death Explosive fuel vapors can cause severe injury or Explosive fuel vapors Can cause severe injury or death Flying 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 death Hazardous 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 death 246242 Pleasure Craft Reference Material Additional References Commercial Vessels Part Description Kohler Part No Routine Service Parts Abbreviation Description Glossary of Abbreviations NEC Introduction SpecificationsSpecifications General Specifications 5CFZ/4CZ 5CFZ/6.5CZ Generator GX360EV Engine BPR4HS NGK Accessories Service Views typical Service Views Prestart Checks Operation Controller Controller Stopping Starting Circuit Protection Engine Safety Shutdown Switches High Water Temperature Shutdown Switch Remote Panels Optional Remote Panel Features Remote Start and Four-Meter Panel Kit Remote Start and Four-Meter Features Scheduled Maintenance Or 2 Years Service Schedule Generator Lubrication System Specifications Oil Change/Oil Filter Change Adding Oil Removing Oil Filter Fuel System Fuel Pump Screen Fuel Pump Screen Carburetor/Choke Lubrication Carburetor Adjustments Ignition System Ignition System ServiceSpark Plugs Carbon fouled Problem Means of Identification Possible Cause NormalGap bridged Oil fouled 12. 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 Zinc Servicing Mixing Elbow Air Cleaner Mixing ElbowServicing Air Cleaner Pressure Cap Checking Specific Gravity BatteryCleaning Checking Electrolyte Level Charging 21. Specific Gravity Temperature Correction Valve Adjustment 22. Determining Top Dead Center Governor Governor AdjustmentLubrication Wattage Requirements Generator ServiceGeneral Storage Procedure Not start TroubleshootingEngine Unit cranks but will Lacks power Problem Possible Cause Corrective Action Stops suddenlyOperates erratically Electrical System Generator Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Wiring Diagrams 4CZ Diagrams To Generator To Shore Set Power Wire Generator SetsTo Load 60 Hz LO Neutral GroundLoad Side Line Side Without Jumper Lead L1--L3Page Generator Selection and Wattage Requirements InstallationMotor Loads Kilowatt Derating Appliance Loads Typical Location and Mounting Air Requirements CFM L/min Model Combustion Cooling LocationVentilationSpace Mounting Fuel Supply Fuel Systems Max. Lift ft. m In. mm Anti-Siphon ProvisionsFuel Lines Fuel Pump Lift Capabilities Fuel Consumption 11. Intake Strainer Cooling Systems 13. Seawater Strainer Closed/Heat Exchanger 15. Closed/Heat Exchanger Cooling System Exhaust Systems Carbon monoxide 17. Typical Above Waterline Installation Mid/Below Waterline Above Waterline Electrical Systems Installation in Steel or Aluminum VesselsAC Voltage Connections Wiring Battery Lead Designations Pin Function Remote Start Switch Connection Section Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Standard on 5CFZ and 6.5CZ Sound Shield--Optional on 3.5CFZ and 4CZ Parts Ordering Instructions For Sales & Service in U.S.A. & Canada Phone Operating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone