KOHLER Generator SETS MASTER Shop Manual

Marine Generator Sets Models: 5E/4EF 7.3E/6EF TP-5986 4/03b Service

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. Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate(s). Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate. Manufacturer Model Designation Serial Number x:in:007:001a

TP-5986 4/03 Table of Contents Table of Contents 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 .......

TP-5986 4/03 Safety Precautions and Instructions I Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS. This manual has several types ofsafety precautions and instructions: Danger, Warning, Caution, and Notice. DANGER Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage. WARNING Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage. CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage. NOTICE Notice communicates installation, operation, or maintenance information that is safety related but not hazard related. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals. Accidental Starting Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. WARNING Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Place the generator set start/stop switch in the STOP position. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. Battery Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

II Safety Precautions and Instructions TP-5986 4/03 Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Engine Backfire/Flash Fire Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. WARNING Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Servicing the backfire flame arrester. A sudden backfire can cause severe injury or death. Do not operate the generator set with the backfire flame arrester removed. Combustible materials. A sudden flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the fuel system. Keep the compartment and the generator set clean and free of debris to minimize the risk of fire. Wipe up spilled fuels and engine oil. Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures. Exhaust System Carbon monoxide. Can cause severe nausea,fainting, or death. The exhaust system must be leakproof and routinely inspected. WARNING Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide poisoning symptoms include but are not limited to the following: D Light-headedness, dizziness D Physical fatigue, weakness in joints and muscles D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention ifthe condition of affected persons does not improve within minutes of breathing fresh air. Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of the craft’s occupants, install a carbon monoxide detector. Consultthe boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times. Operating the generator set. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Use the following precautions when installing and operating the generatorset. Do not install the exhaust outlet where exhaust can be drawn in through portholes, vents, or air conditioners. If the generator set exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow of exhaust. Never operate the generator set without a functioning carbon monoxide detector. Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate. If operating the generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always be aware of others, making sure your exhaust is directed away from other boats and buildings. Avoid overloading the craft.

TP-5986 4/03 Safety Precautions and Instructions III Fuel System Explosion. Gasoline vapors can cause explosion and severe injury or death. Before starting the generator set, operate the blower 4 minutes and check the engine compartment for gasoline vapors. WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. WARNING The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do notoperate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels: Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE. Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a containerto catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system. Installing the fuel system. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Do not modify the tank orthe propulsion engine fuel system. Equip the craft with a tank that allows one of the two pickup arrangements described in the installation section. The tank and installation must conform to USCG Regulations. Pipe sealant. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Use pipe sealant on all threaded fittings to prevent fuel leakage. Use pipe sealant that resists gasoline, grease, lubrication oil, common bilge solvents, salt deposits, and water. Ignition-protected equipment. Explosive fuel vapors can cause severe injury or death. Gasoline vapors can cause an explosion. USCG Regulation 33CFR183 requires that all electrical devices (ship-to-shore transfer switch, remote start panel, etc.) must be ignition protected when used in a gasoline and gaseous-fueled environment. The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous-fueled environment such as an engine room or near fuel tanks. Acceptable locations are the wheelhouse and other living areas sheltered from rain and water splash. Hazardous Noise Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. CAUTION Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set. Hazardous Voltage/Electrical Shock Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Moving rotor. WARNING Welding the generator set. Can cause severe electrical equipment damage. Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM). CAUTION

IV Safety Precautions and Instructions TP-5986 4/03 Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. Disconnecting the electrical load. Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads. High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load. Welding the generator set. Can cause severe electrical equipment damage. Before welding the generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine battery- charging alternator connections. (5) Attach the weld ground connection close to the weld location. Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. Testing the voltage regulator. Hazardous voltage can cause severe injury or death. High voltage is present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator. (PowerBoostt, PowerBoostt III, and PowerBoostt V voltage regulator models only) Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is opened. Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near the work area. Some states and localities prohibit unauthorized connection to the utility electrical system. Install a ship-to-shore transfer switch to prevent interconnection of the generator set power and shore power. Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under) Hot Parts Hot coolant and steam. Can cause severe injury or death. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. WARNING Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.

TP-5986 4/03 Safety Precautions and Instructions V Moving Parts Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Moving rotor. WARNING Rotating parts. Can cause severe injury or death. Operate the generator set only when all guards, screens, and covers are in place. WARNING Airborne particles. Can cause severe injury or blindness. Wear protective goggles and clothing when using power tools, hand tools, or compressed air. WARNING Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do notloosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware. Servicing the generator set when itis operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens,and covers before operating the generator set. 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. Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed. (Sound-shield-equipped models only) Notice NOTICE This generator set has been rewired from its nameplate voltage to 246242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer. NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts. NOTICE When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification. NOTICE Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic). Do not substitute clear glass-type fuses for ceramic fuses. Refer to the wiring diagram when the ampere rating is unknown or questionable. NOTICE Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.

VI Safety Precautions and Instructions TP-5986 4/03 Notes

KOHLER Generator SETS MASTER Shop Manual

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