Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ User Manual

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Operation and

Installation Manual

Marine Generator Sets

Models:

3.5CFZ

4CZ

5CFZ

6.5CZ

TP-5695 12/93

Table of Contents

Questions and Answers:

J
Jeffrey LopezAug 20, 2025
How to fix a Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ that will not crank?
- A
  amanda02Aug 20, 2025
  If your Kohler Inverter won't crank, here's what you can check: * A weak or dead battery: Recharge or replace the battery. * Reversed or poor battery connections, or a poor ground: Check the connections. * A blown fuse in the controller: Replace the fuse. * A defective start/stop switch: Check the function and replace it if necessary. * A defective starter solenoid: Check the starter solenoid and wiring, and replace if needed. * A defective starter: Attempt starting by direct connection to the battery and replace or repair as necessary.
J
Jorge MaddenAug 22, 2025
Why won't the battery charge on my Kohler Inverter?
- G
  gregory47Aug 22, 2025
  If the battery on your Kohler Inverter isn't charging, check the following: * Loose or corroded connections: Clean and tighten the connections. * Sulfated or worn-out battery: Check the electrolyte level and specific gravity (for batteries with filler caps only). * Defective battery charging system: Check the charging system. * Battery charging fuse blown: Replace the fuse.
S
Shirley BrockAug 25, 2025
What causes high generator output voltage in a Kohler Inverter?
- P
  phodgesAug 25, 2025
  If your Kohler Inverter has high generator output voltage, it could be due to excessive speed or frequency. Adjust the governor and check the governor linkage and spring for damage or binding.
S
Stephanie SnyderAug 26, 2025
Why will my Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ not crank?
- S
  Seth BonillaAug 26, 2025
  If your Kohler Inverter will not crank, check for: * No DC power to controller: Check battery connections. * Controller circuit fuse blown: Replace fuse and attempt start-up.
D
dwayne07Aug 30, 2025
Why is there no AC output from my Kohler Inverter?
- S
  Sarah Grant MDAug 30, 2025
  If you're not getting any AC output from your Kohler Inverter, check these items: 1. Circuit breaker: Ensure it's in the ON position. If it tripped, it could be due to an overload, so reduce the load before resetting. See Wattage Requirements. 2. Ship-to-shore transfer switch: Make sure it's set to generator power. 3. DC power to controller: Verify the battery connections. 4. Controller fuse: Replace it if it's blown.
S
Stephanie JohnstonSep 1, 2025
Why does my Kohler Inverter engine start, but not continue to run?
- J
  jeremiah21Sep 1, 2025
  If your Kohler Inverter's engine starts but doesn't continue running after releasing the start switch, here are potential causes: * No generator output voltage: Check the AC voltage. * No/low oil pressure: Check the oil pressure and pump. * Defective low oil pressure (LOP) safety shutdown switch: Check the LOP shutdown switch. * High temperature shutdown: Check the cooling system. * Defective high exhaust temp. (HET) and/or high water temp. (HWT) safety shutdown switch(es): Check the HET and/or HWT shutdown switch(es).
M
Michelle ClarkSep 3, 2025
How to troubleshoot a Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Inverter that lacks power?
- A
  Adam ThompsonSep 3, 2025
  If your Kohler Inverter lacks power, consider these potential causes: * Air intake clogged: Clean the air intake. * Bad or stale fuel: Replace the fuel. * Faulty spark plug(s): Replace (and regap) the spark plug(s). * Improper timing: Check the timing. * Choke solenoid defective: Check and/or change the choke solenoid. * Engine not operating at rated RPM: Check the governor. * Governor adjustments incorrect: Adjust the governor. * Carbon build-up: Clean carbon from cylinder heads. * Improper cooling: Inspect the cooling system. * Dirty fuel screen: Clean the screen. * Defective ignition coil: Replace the coil. * Fuel line restricted: Check the fuel lines. * Engine overloaded: Reduce the load. * Carburetor adjustment wrong: Adjust the carburetor.
T
Tara CarpenterSep 7, 2025
Why is my Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Inverter hard starting?
- G
  Gary WadeSep 7, 2025
  A Kohler Inverter may be hard to start due to: * Stale or bad fuel: Replace the fuel. * Fuel vapor lock: Check the fuel line routing. * Faulty spark plug(s): Replace (and regap) plug(s). * Weak ignition coil: Replace the coil. * Carburetor adjustment wrong: Adjust the carburetor. * Air intake clogged: Clean the air intake.
E
Erin LopezSep 9, 2025
What should I do if my Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ overheats?
- J
  jonespaulaSep 9, 2025
  If your Kohler Inverter is overheating, take these steps: * Improper cooling: Check intake and outlet openings, coolant level and pressure cap, and the raw water strainer. * Thermostat defective: Replace the thermostat. * Sea strainer clogged: Clean the sea strainer. * Carburetor adjustment too lean: Adjust the carburetor mixture. * Engine ignition timing incorrect: Adjust the timing.
M
Michael WelchSep 12, 2025
What causes a Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ to operate erratically?
- K
  Kimberly FullerSep 12, 2025
  If your Kohler Inverter operates erratically, check: * Air intake: Clean it if clogged. * Fuel: Replace it if it's stale or bad. * Fuel pump: Allow unit to cool if there is fuel pump vapor lock and attempt restart. * Fuel screen: Clean it if clogged. * Spark plugs: Replace if faulty. * Carburetor: Adjust if adjustment is incorrect.

Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Specifications

General

Brand	Kohler
Model	3.5CFZ, 4CZ, 5CFZ, 6.5CZ
Category	Inverter
Language	English

Summary

Safety Precautions and Instructions

Hazardous Voltage and Electrical Shock

Details hazards of electricity, grounding, and capacitors.

System-Specific Safety Hazards

Covers exhaust, fuel, battery, and noise hazards with safety warnings.

Mechanical and Operational Hazards

Specifications and Parts

Operation Procedures

Prestart Checks and Controller Functions

Starting, Stopping, and Circuit Protection

Engine Safety Shutdown Switches

High Temperature Shutdowns

Scheduled Maintenance

Service Schedule Overview

Provides a comprehensive maintenance task schedule by hours/months.

Lubrication System Maintenance

Covers oil checks, changes, and adding oil procedures.

Fuel System Maintenance

Recommends gasoline type, octane, and covers fuel pump screen.

Ignition System Service

Cooling System Maintenance

Guides on checking, filling, flushing, and cleaning the cooling system.

Battery Maintenance

Guides on cleaning battery terminals and checking levels/gravity.

Governor System Maintenance

Generator Performance and Storage

Troubleshooting Guide

Engine Troubleshooting

Lists common engine problems, causes, and corrective actions.

Electrical and Generator Troubleshooting

Covers battery, starter, and generator issues with solutions.

Wiring Diagrams and Installation

Schematic and Point-to-Point Wiring Diagrams

Provides overviews of the generator's electrical system connections.

Transfer Switch and Reconnectable Wiring

Shows wiring for transfer switches and voltage reconfiguration.

Section 6: Installation Introduction and Guidelines

Fuel, Cooling, Exhaust, and Electrical Installation

Installation Drawings

Dimension Drawing

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