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Kohler 5E Service Manual

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Marine Generator Sets
TP-5986 4/03b



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  Summary of Contents for Kohler 5E

  • Page 1 Service Marine Generator Sets Models: 5E/4EF 7.3E/6EF TP-5986 4/03b...
  • Page 2: Product Identification Information

    Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.
  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ..Engine Safety Shutdown Switches ... 6.2.1 Low Oil Pressure (LOP) Shutdown . . . Introduction .
  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Battery electrolyte is a diluted Accidental Starting INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear...
  • Page 6 Battery short circuits. Explosion Combustible materials. A fire can Inspecting the exhaust system. can cause severe injury or death. cause severe injury death. Carbon monoxide can cause severe Generator set engine fuels and fuel nausea, fainting, or death. For the Short circuits can cause bodily injury vapors are flammable and explosive.
  • Page 7: Fuel System

    Explosive fuel vapors can cause Fuel System Hazardous Noise severe injury or death. Take additional precautions when using the WARNING CAUTION following fuels: Gasoline—Store gasoline only in approved containers clearly marked GASOLINE. Draining the fuel system. Explosive Explosion. fuel vapors can cause severe injury Hazardous noise.
  • Page 8: Hot Parts

    Grounding electrical equipment. Testing voltage regulator. Hot Parts Hazardous voltage cause Hazardous voltage cause severe injury or death. Electrocution severe injury or death. High voltage is WARNING is possible whenever electricity is present at the voltage regulator heat present. Open the main circuit sink.
  • Page 9 NOTICE Tightening the hardware. Flying Moving Parts projectiles can cause severe injury Voltage reconnection. Affix a notice or death. Loose hardware can cause to the generator set after reconnecting WARNING the hardware or pulley to release from the set to a voltage different from the the generator set engine and can voltage on the nameplate.
  • Page 10 Notes VI Safety Precautions and Instructions TP-5986 4/03...
  • Page 11: Introduction

    Information in this publication represents data available Maintenance work must be performed by appropriately- at the time of print. Kohler Co. reserves the right to skilled and suitably-trained maintenance personnel, change this publication and the products represented familiar with generator set operation and service.
  • Page 12: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product...
  • Page 13: Service Parts/Publications

    The following table identifies literature available for the spare parts. Contact your Kohler generator generator sets covered in this manual. Only qualified distributor/dealer for a complete list of service parts for persons should install or service the generator set. your generator set.
  • Page 14 Notes iv Introduction TP-5986 4/03...
  • Page 15: Section 1 Specifications

    Section 1 Specifications 1.1 General 1.3 Fuel The 7.3E/6EF and 5E/4EF units are powered by a Fuel recommendation Unleaded 87 octane two-cylinder, water-cooled, four-cycle gasoline engine Fuel pump Electric with heat exchanger. Fuel pump operating, 13.8--24.1 (2.0--3.5) kPa (psi) Kohler Co. develops all Kohler marine generator set...
  • Page 16: Generator

    1.5 Generator 1.6 Torque Component Specification Value Component Torque Nm (in. lbs.) Rotor field voltage/current readings at rated voltage (hot) Rotor bolt 23.1 (204) No load (63 Hz) (volts/amps) 13/3.82 Generator overbolts 13.6 (120) Full load (60 Hz) (volts/amps) 47/13.82 Mounting plate to end bracket (60) bolts...
  • Page 17: Service Views

    1.7 Service Views SERVICE VIEW ADV-6395-A GY-250000-A ENGINE-END VIEW 1. Electric choke (on carburetor) 18. Hourmeter 2. Carburetor/choke linkage 19. Heat exchanger 3. Spark plug (also one on nonservice side) 20. Anticorrosion zinc anode 4. Oil fill 21. Seawater drain (remove zinc anode) 5.
  • Page 18 Notes Section 1 Specifications TP-5986 4/03...
  • Page 19: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance 2.1 General Sound shield removal. Exposed moving parts can cause severe injury or death. The generator set must be operating in order to perform some scheduled maintenance procedures. WARNING Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.
  • Page 20 Notes Section 2 Scheduled Maintenance TP-5986 4/03...
  • Page 21: Section 3 Intake And Exhaust System

    Section 3 Intake and Exhaust System 3.1 Backfire Flame Arrestor Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and At the interval specified in the service schedule, inspect, check for tight exhaust system connections. clean or replace the backfire flame arrestor.
  • Page 22 Notes Section 3 Intake and Exhaust System TP-5986 4/03...
  • Page 23: Section 4 Fuel System

    Section 4 Fuel System 4.1 General WARNING In most installations, both the generator set and the vehicle’s engine operate from a common fuel tank with a dual dip tube arrangement. The generator set’s dip tube may be shorter than the vehicle engine’s dip tube. With this arrangement, fuel may not be available to the Explosive fuel vapors.
  • Page 24: Fuel Pump Troubleshooting

    4.4 Fuel Pump Troubleshooting 4.5 Carburetor Troubleshooting The fuel pump transfers fuel from a source to the This section is for fuel-related problems only. Use for carburetor. basic carburetor troubleshooting. Note: When troubleshooting the fuel system, it is Fuel Pump Test Procedure important to have an adequate fuel supply.
  • Page 25: Flooding

    4.5.3 Flooding Note: Never tamper with the governor settings to increase the generator output. Overspeeding Flooding occurs from a float level set too high, can cause equipment parts to exceed design improperly adjusted fuel pressure, improperly installed limitations, resulting in component failure. fuel pump, a sticking choke plate or float, or a fuel inlet needle held off its seat either by improper seating or dirt Governor 60 Hz to 50 Hz Conversion Procedure...
  • Page 26 Notes Section 4 Fuel System TP-5986 4/03...
  • Page 27: Section 5 Cooling System

    Section 5 Cooling System 5.1 General The heat exchanger cooling system consists of a heat engine circulating pump, a water-cooled exhaust exchanger with a coolant recovery tank, a thermostat, a manifold, and an exhaust mixer. See Figure 5-1 for rubber impeller seawater pump, a centrifugal-type cooling system components.
  • Page 28: Closed Heat Exchanger

    5.2 Closed Heat Exchanger Do not add coolant to a hot engine. Adding coolant to a hot engine can cause the cylinder block or cylinder head In a closed cooling system, the seawater circulates to crack. Wait until the engine has cooled. through separate chambers within the heat exchanger Note: Coolant solution.
  • Page 29: Impeller

    5.5 Impeller This model uses a direct-driven seawater pump located on the generator end. Check and change the seawater pump impeller at the interval specified in the service schedule. Follow the instructions included with the impeller kit. If the instructions are not included with the kit, use the following procedure.
  • Page 30: Siphon Break

    5.6 Siphon Break 4. Check that the reed valve opening is clear. 5. Replace the siphon break if it is cracked or if the A siphon break prevents seawater entry into the engine reed valve material has hardened or deteriorated. when the engine exhaust manifold outlet is less than 23 cm (9 in.) above waterline.
  • Page 31: Anticorrosion Zinc Anode

    5.7 Anticorrosion Zinc Anode 4. Install the zinc anode into the heat exchanger. 5. Open the seacock. The heat exchanger contains an anticorrosion zinc anode (plug) to prevent electrolytic corrosion by 6. Refill the cooling system. seawater. 7. Start the generator set and check for leaks at the Check and replace the zinc anode at intervals zinc anode location.
  • Page 32: Generator Storage

    Place the hose in a container having approximately 3.7--7.5 L (1--2 gal.) of marine 15. Reinstall the spark plugs and torque them to antifreeze. Kohler Co. recommends using an specifications. environmentally friendly potable antifreeze such as PeakR RV/marine propylene glycol/water mix or 16.
  • Page 33: Section 6 Controller Troubleshooting

    Section 6 Controller Troubleshooting 6.1 Sequence of Operation The K6 relay energizes. The normally-open K6 contacts close, latching itself on. The normally-closed K6 This section describes the controller sequence of contacts open, preventing inadvertent starter operation during the generator start, run, stop, and fault engagement by disabling the the K3 relay.
  • Page 34: Stop

    At the same time the K1 relay is energized, the time generator shuts down, described delay for the K5 relay starts. After 5--10 seconds, the K5 Section 6.1.3. relay is energized (LED 5 lights). Note: During cranking, the low oil pressure shutdown switch deactivates until the K5 relay energizes.
  • Page 35: Troubleshooting

    6.2.5 Troubleshooting Use the following flowchart as an aid in troubleshooting circuit board may have to be replaced. Use this chart for the main circuit board and the entire generator set. If the component testing only. Always check the continuity of prescribed remedy does not correct the problem, the the wires between components.
  • Page 36 Go to B Does the engine start? (next page). Is the K4 relay LED lit? Is there continuity between P4-5 and N? Is there12 volts DC Is the fuel present at the fuel pump working? pump (P9-2)? Is there continuity between P1-9 and P9-1? Troubleshoot the engine.
  • Page 37 Does the engine continue Does using the stop switch to run after the start stop the engine? switch is released? The generator set is functioning properly? Did the K4 relay LED light? Does the K1 relay LED light? Is the LOP switch functional? Replace Does the K5 relay LED...
  • Page 38 Is there AC output when the start button is held and the unit is running? Is there approximately 12VDC at the exciter field? Replace the Is there 12 volts AC output at circuit board. the B1/B2 stator winding? Separately excite the generator set to determine if other components are...
  • Page 39: Section 7 Generator Troubleshooting

    Section 7 Generator Troubleshooting 7.1 General 7.1.1 Troubleshooting To determine the cause of no- or low-AC output , refer to Before beginning following troubleshooting the following steps and the troubleshooting flowchart procedures, read all the safety precautions at the (Figure 7-1). Verify the operation of the alternator beginning of this manual.
  • Page 40: Separate Excitation

    7.1.2 Separate Excitation 7. Remove the jumper wire and reverse the positive (+) and negative (--) leads on the rotor. By separately exciting the generator to determine the Repeat step 5. If the ammeter is stable, ground the presence of a faulty voltage regulator, it is possible to negative (--) lead at its new location on the rotor to determine if a running fault exists in the rotor and/or the engine block.
  • Page 41: Powerboost Iiie Voltage Regulators

    7.2 PowerBoosttIIIE Voltage Regulator Test Procedure Regulators 1. Connect the components as shown in Figure 7-4. The generator set is equipped with a PowerBoostt IIIE 2. Turn the variable transformer setting to zero. Plug voltage regulator. See Figure 7-3. in the variable transformer. 3.
  • Page 42: Voltage Regulator Adjustment

    7.2.2 Voltage Regulator Adjustment Voltage Regulator Adjustment Procedure 1. Stop the generator set. The factory sets the voltage regulator and under normal circumstances the regulator requires no further 2. Turn the remote rheostat, if equipped, to the adjustment. However, if the voltage regulator has been midpoint.
  • Page 43: Rotor

    11. Set engine speed to 47.5 Hz for 50 Hz generator Note: Use the values in Section 1 as a reference for sets and 57.5 Hz for 60 Hz generator sets for the rotor resistance readings. Take readings at room desired cut-in frequency.
  • Page 44 Stator Test Procedure Note: The stator resistance varies directly with increased temperature. 1. Place the generator start/stop switch in the STOP position. If the stator readings vary considerably during the previous checks, repair or replace the stator. 2. Disconnect the generator set engine starting battery, negative (--) lead first.
  • Page 45: Brushes

    7.5 Brushes Use a retainer wire (such as a paper clip) to contain the brushes during disassembly and reassembly. Push the The brushes provide a current path from the voltage brushes into the brush holder until the retainer wire can regulator to the collector rings.
  • Page 46 Notes Section 7 Generator Troubleshooting TP-5986 4/03...
  • Page 47: Section 8 Component Troubleshooting

    Section 8 Component Troubleshooting 8.1 Engine/Generator Components See Figure 8-1 through Figure 8-3 for engine/generator listed in the following tables. Check each component component testing. using a multimeter to verify that the switches function and that voltage is present at each component. With the generator set battery connected, check the wiring harness and the engine/generator components Component...
  • Page 48 To further check the generator set components, WARNING disconnect the battery and remove the wiring harness plugs from the controller circuit board. Use an ohmmeter to check the continuity of the components and to isolate inoperative components. Refer to Figure 8-2 and Figure 8-3. Moving rotor.
  • Page 49: Remote Panels (Optional)

    Troubleshooting Remote Start Panels 8.2 Remote Panels (Optional) Generally, if the sender changes its resistance values as Kohler Co. offers three remote panels for connection to its respective pressure/temperature changes, it is the generator set. working correctly. An inoperative sender will either be open or shorted.
  • Page 50 Refer to Figure 8-6 for troubleshooting information on the remote start panels. Component Ohmmeter Connections Procedure Results Remote switch: yellow/red Place the ohmmeter on the Continuity, the switch is Remote start/stop switch wire terminal and black wire R x 1 scale. Press the rocker functional.
  • Page 51: Section 9 Generator Disassembly/Reassembly

    Section 9 Generator Disassembly/Reassembly 9.1 Disassembly Disconnect the external connections—battery cables at the battery (negative (--) lead first), AC-output leads in the controller, remote start panel at the controller P3 connector, water line at the seawater pump, fuel line at the fuel pump filter inlet, and exhaust line at the mixing elbow.
  • Page 52 3, 4, 5 201-191-1 1. Generator adapter plate bolt, quantity 4 12. Bracket, brush holder 2. Generator adapter 13. Fan guard bolts, quantity 2 3. Spring 14. Fan guard 4. Brush holder 15. End bracket 5. Brush, quantity 2 16. Pipe plug 6.
  • Page 53: Collector Ring And Bearing Replacement

    9.2 Collector Ring and Bearing 9. Install the sound shield enclosure. Replacement 10. Install the fuel line and fuel pump. 1. Unsolder the collector ring leads from the collector 11. Reconnect the water inlet hose to the water pump. ring terminals. 12.
  • Page 54 Notes Section 9 Generator Disassembly/Reassembly TP-5986 4/03...
  • Page 55: Reconnection

    Section 10 Wiring Diagrams and Voltage Reconnection WARNING WARNING Moving rotor. Hazardous voltage. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working on the generator set.
  • Page 56: Schematic Wiring Diagram

    10.1 Schematic Wiring Diagram 359343-J Section 10 Wiring Diagrams and Voltage Reconnection TP-5986 4/03...
  • Page 57: Point-To-Point Wiring Diagram

    10.2 Point-to-Point Wiring Diagram 359343-J TP-5986 4/03 Section 10 Wiring Diagrams and Voltage Reconnection...
  • Page 58: Reconnection Diagram 100--120 V, 60 & 50 Hz

    10.3 Reconnection Diagram 10.5 Reconnection Diagram 100- -120 V, 60 & 50 Hz 220- -240 V, 50 Hz ADV-5857 ADV-5857 10.4 Reconnection Diagram 10.6 Remote Start Panel 100- -120/200- -240 V, 60 & 50 Hz Stop Local 10-amp P1-9 switch Fuse Start P1-14...
  • Page 59: Remote Start And Two-Meter Panel

    10.7 Remote Start and Two-Meter 10.8 Remote Start and Four-Meter Panel Panel Stop Stop Local Local P1-9 10-amp P1-9 10-amp switch switch fuse fuse Start O.P. W.T. Start W.T. O.P. P1-14 P2-4 P2-5 P2-6 sender sender sender sender P1-14 P2-4 P2-5 P2-6 Relay...
  • Page 60 Notes Section 10 Wiring Diagrams and Voltage Reconnection TP-5986 4/03...
  • Page 61: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex.
  • Page 62 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter μF microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat.
  • Page 63: Appendix B Common Hardware Application Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.
  • Page 64 Appendix C General Torque Specifications Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated literature instructions give no specific torque values. threads. All torque values are +0%/--10%. The charts list values for new plated, zinc phosphate, or American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into...
  • Page 65: Appendix D Common Hardware Identification

    Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)
  • Page 66: Appendix E Common Hardware List

    Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
  • Page 67 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Full Thread), Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), continued continued M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M961-14025-60...
  • Page 68 Metric, continued Part No. Dimensions Type Hex Nuts M934-03-50 M3-0.50 Standard M934-04-50 M4-0.70 Standard M934-05-50 M5-0.80 Standard M982-05-60 M5-0.80 Elastic Stop M934-06-60 M6-1.00 Standard M934-06-64 M6-1.00 Std. (green) M6923-06-80 M6-1.00 Spiralock M982-06-80 M6-1.00 Elastic Stop M934-08-60 M8-1.25 Standard M6923-08-80 M8-1.25 Spiralock M982-08-80 M8-1.25...
  • Page 72 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 Kohler Power Systems Asia Pacific Headquarters TP-5986 4/03b 7 Jurong Pier Road Singapore 619159 E2000, 2003 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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