Generator | Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ instruction

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

Image 56

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

Contents

Marine Generator Sets Models5CFZ 5CZ California Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide Can cause severe nausea, fainting, or death Carbon monoxide can cause severe nausea Sulfuric acid in batteries Can cause severe injury or death Sulfuric acid in batteries can cause severe injury or Explosive fuel vapors Can cause severe injury or death Explosive fuel vapors can cause severe injury or Accidental 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 death Fire 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 hearing 246242 Reference Material Pleasure Craft Commercial Vessels Additional References Routine Service Parts Part Description Kohler Part No Glossary of Abbreviations Abbreviation Description NEC Specifications SpecificationsGeneral Specifications Introduction Generator 5CFZ/4CZ 5CFZ/6.5CZ Engine GX360EV BPR4HS NGK Accessories Service Views Service Views typical Operation Prestart Checks Controller Controller Starting Stopping Engine Safety Shutdown Switches Circuit Protection High Water Temperature Shutdown Switch Remote Panel Features Remote Panels Optional Remote Start and Four-Meter Features Remote Start and Four-Meter Panel Kit Scheduled Maintenance Service Schedule Or 2 Years Generator Specifications Lubrication System Adding Oil Oil Change/Oil Filter Change Fuel System Removing Oil Filter Fuel Pump Screen Fuel Pump Screen Carburetor Adjustments Carburetor/Choke Lubrication Spark Plugs Ignition System ServiceIgnition System Problem Means of Identification Possible Cause Normal Gap bridgedOil fouled Carbon fouled 12. 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 Zinc Air Cleaner Mixing Elbow Servicing Air CleanerPressure Cap Servicing Mixing Elbow Battery CleaningChecking Electrolyte Level Checking Specific Gravity 21. Specific Gravity Temperature Correction Charging Valve Adjustment 22. Determining Top Dead Center Lubrication Governor AdjustmentGovernor General Generator ServiceWattage Requirements Storage Procedure Troubleshooting EngineUnit cranks but will Not start Operates erratically Problem Possible Cause Corrective Action Stops suddenlyLacks power Electrical System Generator Wiring Diagrams Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Diagrams 4CZ To Load Wire Generator SetsTo Generator To Shore Set Power LO Neutral Ground Load SideLine Side 60 Hz L1--L3 Without Jumper LeadPage Motor Loads InstallationGenerator Selection and Wattage Requirements Appliance Loads Kilowatt Derating Typical Location and Mounting LocationVentilation SpaceMounting Air Requirements CFM L/min Model Combustion Cooling Fuel Systems Fuel Supply Anti-Siphon Provisions Fuel LinesFuel Pump Lift Capabilities Fuel Consumption Max. Lift ft. m In. mm Cooling Systems 11. Intake Strainer Closed/Heat Exchanger 13. Seawater Strainer Exhaust Systems 15. Closed/Heat Exchanger Cooling System 17. Typical Above Waterline Installation Carbon monoxide Above Waterline Mid/Below Waterline AC Voltage Connections Installation in Steel or Aluminum VesselsElectrical Systems Battery Wiring Remote Start Switch Connection Lead Designations Pin Function Dimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ Section Sound Shield--Optional on 3.5CFZ and 4CZ Standard on 5CFZ and 6.5CZ For Sales & Service in U.S.A. & Canada Phone Parts Ordering Instructions Operating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone