Format: PDF (Printable Document)
File Language: English
File Pages: 72
File Size: 2.20 MB (Speed Download Link)
Brand: Kohler
Model: 5E, 4EF7.3E, 6EF Marine
Book No: tp5986
Type of Document: Service Manual
$ 40
These Kohler marine gensets usually sit in a tight engine room, running hotel loads, air‑con, and electronics while the main engines are off. This service manual is what I grab when I need to trace a no-start, chase an uneven running issue, or verify a governor or frequency adjustment instead of just throwing parts at it. For example, if a 5E starts but won’t carry load without bogging down, this book walks you through checking fuel, exhaust, and electrical causes in a logical order before you condemn the generator end or control board.
Applications & Use Cases
FAQ
Q: Can I keep this manual on a tablet in the engine room?
A: Yes, it’s practical to use digitally; you can zoom in on diagrams and avoid getting a paper copy oily.
Q: Is it still worth printing sections of this manual?
A: Definitely—most techs print the pages for the job they’re doing, mark notes, and keep them with the work order.
Safety Note
Always lock out starting sources and verify ventilation before working on or near a running marine generator.
Safety Precautions and Instructions . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . ii
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Service Parts/Publications . . . . . . . . . . . . . . . . . . iii
Routine Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
List of Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . iii
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.7 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 2 Scheduled Maintenance . . . . . . . . . . . 5
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 3 Intake and Exhaust System . . . . . . . . 7
3.1 Backfire Flame Arrestor . . . . . . . . . . . . . . . . . . . . . 7
3.2 Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 4 Fuel System . . . . . . . . . . . . . . . . . . . . . 9
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Float Bowl Vent System . . . . . . . . . . . . . . . . . . . . . 9
4.3 Fuel Pump and Filter . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Fuel Pump Troubleshooting . . . . . . . . . . . . . . . . . 10
4.5 Carburetor Troubleshooting . . . . . . . . . . . . . . . . . 10
4.5.1 Hard Starting . . . . . . . . . . . . . . . . . . . . . . 10
4.5.2 Stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5.3 Flooding . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5.4 Hunting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5.5 Leaking Carburetor . . . . . . . . . . . . . . . . . 11
4.6 Governor 60 Hz to 50 Hz Conversion . . . . . . . . . 11
Section 5 Cooling System . . . . . . . . . . . . . . . . . . 13
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Closed Heat Exchanger . . . . . . . . . . . . . . . . . . . . . 14
5.3 Check and Fill Coolant . . . . . . . . . . . . . . . . . . . . . 14
5.4 Flush and Clean Cooling System . . . . . . . . . . . . . 14
5.5 Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.6 Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.7 Anticorrosion Zinc Anode . . . . . . . . . . . . . . . . . . . 17
5.8 Generator Storage . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section 6 Controller Troubleshooting . . . . . . . . 19
6.1 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . 19
6.1.1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.2 Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.3 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2 Engine Safety Shutdown Switches . . . . . . . . . . . 20
6.2.1 Low Oil Pressure (LOP) Shutdown . . . 20
6.2.2 Loss of Coolant Switch (LCS)
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.3 High Engine Temperature Switch
(HET) Shutdown . . . . . . . . . . . . . . . . . . . 20
6.2.4 Controller Circuit Board . . . . . . . . . . . . . 20
6.2.5 Troubleshooting . . . . . . . . . . . . . . . . . . . 21
Section 7 Generator Troubleshooting . . . . . . . . 25
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1.1 Troubleshooting . . . . . . . . . . . . . . . . . . . 25
7.1.2 Separate Excitation . . . . . . . . . . . . . . . . 26
7.2 PowerBoost IIIE Voltage Regulators . . . . . . . . . . 27
7.2.1 Voltage Regulator Test . . . . . . . . . . . . . . 27
7.2.2 Voltage Regulator Adjustment . . . . . . . 28
7.3 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.5 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Section 8 Component Troubleshooting . . . . . . 33
8.1 Engine/Generator Components . . . . . . . . . . . . . . 33
8.2 Remote Panels (Optional) . . . . . . . . . . . . . . . . . . . 35
Section 9 Generator Disassembly/
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2 Collector Ring and Bearing Replacement . . . . . . 39
9.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Section 10 Wiring Diagrams and Voltage
Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10.1 Schematic Wiring Diagram . . . . . . . . . . . . . . . . . . 42
10.2 Point-to-Point Wiring Diagram . . . . . . . . . . . . . . . 43
10.3 Reconnection Diagram 100–120 V,
60 & 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.4 Reconnection Diagram 100–120/200–240 V,
60 & 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.5 Reconnection Diagram 220–240 V, 50 Hz . . . . . 44
10.6 Remote Start Panel . . . . . . . . . . . . . . . . . . . . . . . . 44
10.7 Remote Start and Two-Meter Panel . . . . . . . . . . 45
10.8 Remote Start and Four-Meter Panel . . . . . . . . . . 45
Appendix A Abbreviations . . . . . . . . . . . . . . . . A-1
Appendix B Common Hardware Application
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix C General Torque
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Appendix D Common Hardware
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Appendix E Common Hardware List . . . . . . . A-6
