Kohler 4EF Service Manual Download

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Marine Generator Sets

Models:

5E/4EF

7.3E/6EF

TP-5986 4/03b

Service

Summary of Contents for 4EF

Page 1: ...Marine Generator Sets Models 5E 4EF 7 3E 6EF TP 5986 4 03b Service ...

Page 2: ...r 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 D...

Page 3: ...tart 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 Vo...

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Page 5: ...ecting 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 bli...

Page 6: ... 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 presentin 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 ...

Page 7: ...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 ...

Page 8: ...eat 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 sev...

Page 9: ...d 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 reconnect...

Page 10: ...VI Safety Precautions and Instructions TP 5986 4 03 Notes ...

Page 11: ...s represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requi...

Page 12: ...l office Africa Europe Middle East London Regional Office Langley Slough England Phone 44 1753 580 771 Fax 44 1753 580 036 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Pho...

Page 13: ...k Plug For Engine Model BS 04 359979 Spray Paint White 221335 Touch Up Paint White GM19490 Voltage Regulator Fuse 10 amp 223316 Zinc Anode 267928 List of Related Literature The following table identifies literature available for the generator sets covered in this manual Only qualified persons should install or service the generator set Literature Type Part Number Installation Manual TP 5982 Operat...

Page 14: ...TP 5986 4 03 iv Introduction Notes ...

Page 15: ... 0 4 26 7 Compression ratio 9 3 1 Horsepower 60 50 Hz 16 13 8 RPM 60 50 Hz 3600 3000 Lubrication system Pressure mechanical Lube oil capacity L U S qts w filter 1 36 1 44 Low oil pressure shutdown kPa psi 96 5 14 Oil recommendation API SC SD SE SF SG SH or SJ Battery voltage 12 volt standard Battery recommendation minimum 260 CCA Battery charging 15 amps Starter motor Bendix automotive type 1 3 Fu...

Page 16: ... 1 2 3 4 33 44 VAC 145 55 66 VAC 190 B1 B2 VAC 14 Cold stator resistance 1 2 3 4 33 44 ohms 0 16 55 66 ohms 1 70 B1 B2 ohms 0 05 1 6 Torque Component Torque Nm in lbs Rotor bolt 23 1 204 Generator overbolts 13 6 120 Mounting plate to end bracket bolts 6 8 60 Lift eye bolts 19 0 168 Generator adapter to engine bolts 14 9 132 Engine oil drain boss inside generator adapter 47 5 420 Generator adapter ...

Page 17: ...12 Input fuse 13 Battery charging fuse 14 AC circuit breaker 15 Voltage regulator 16 Remote start connector nonservice side 17 Voltage regulator fuse 18 Hourmeter 19 Heat exchanger 20 Anticorrosion zinc anode 21 Seawater drain remove zinc anode 22 Seawater pump water inlet 23 Cooling air inlet 24 High exhaust temp switch on mixing elbow nonservice side 25 Fuel filter fuel inlet 26 Fuel feed pump 2...

Page 18: ...TP 5986 4 03 4 Section 1 Specifications Notes ...

Page 19: ...nd 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 maintenanceprocedures Be especially careful if the sound shield has been removed leaving the belts and pulleys exposed Sound shield equipped...

Page 20: ...TP 5986 4 03 6 Section 2 Scheduled Maintenance Notes ...

Page 21: ...ufacturer s instructions and keep the detector operational at all times Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper for cracks leaks and corrosion D Check the hoses for softness crack...

Page 22: ...TP 5986 4 03 8 Section 3 Intake and Exhaust System Notes ...

Page 23: ... 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 container to catch fuel whendraining thefuel system Wipe up spilled fuel after draining the system 4 1 General In most installations both the generator set and the vehicle s engine operate from a common fuel tank with a dual d...

Page 24: ... 5 Carburetor Troubleshooting This section is for fuel related problems only Use for basic carburetor troubleshooting Note When troubleshooting the fuel system it is important to have an adequate fuel supply A lean or rich fuel condition can reduce power output and cause poor acceleration Symptoms of a Lean Condition D Hard starting D Stalling D Rough idle D Surging above idle Symptoms of a Rich C...

Page 25: ...king Carburetor Loose fuel connections a cracked carburetor body a sticking fuel inlet needle or an inoperative float can cause a leaking carburetor Adjust repair or replace the affected components 4 6 Governor 60 Hz to 50 Hz Conversion Governors are adjusted at the factory and further adjustments should not be necessary Note Never tamper with the governor settings to increase the generator output...

Page 26: ...TP 5986 4 03 12 Section 4 Fuel System Notes ...

Page 27: ...ype engine circulating pump a water cooled exhaust manifold and an exhaust mixer See Figure 5 1 for cooling system components Seawater Coolant Antifreeze 1 2 3 4 5 6 7 8 9 10 11 12 1 Engine block 2 Exhaust manifold 3 Exhaust mixer elbow 4 Outlet flapper 5 Silencer 6 Thermostat 7 Heat exchanger 8 Engine seawater pump 9 Seawater strainer 10 Seacock 11 Intake strainer 12 Engine driven water pump Figu...

Page 28: ... and corrosion and to prevent freezing Add additional coolant mixture as necessary to the coolant recovery tank Periodically check the coolant level on closed systems by removing the pressure cap Do not rely solely on the level in the coolant recovery tank Add fresh coolant until the level is just below the overflow tube opening Do not add coolant to a hot engine Adding coolant to a hot engine can...

Page 29: ...p 2 Coverplate 3 Gasket 4 Impeller 5 Bearing 6 Housing 7 Pulley 8 Drive shaft 9 Washer 10 Nut 11 Mechanical seal if equipped 11 598652 Figure 5 2 Seawater Pump Typical 1 2 3 1 Flat spot 2 Crack 3 Broken vane 598653 Figure 5 3 Worn Impeller Note Impeller pieces can cause blockage and overheating Locate and remove all missing impeller pieces from the cooling system 5 Lubricate the impeller with soap...

Page 30: ...spect the reed assembly for leaks Replace the reed valve if leakage occurs Note Consult the installation manual for a complete explanation of the dimensions and other installation considerations Waterline 1 2 3 7 8 9 18 10 11 12 13 14 15 16 17 20 19 6 5 4 TP 5586 3 21 1 Mounting holes 2 Retaining cap 3 Reed valve assembly 4 Silencer vertical lift 1 2 m 4 ft max 5 Exhaust mixer elbow distance above...

Page 31: ...he percent of the zinc remaining is less than 50 of the length and diameter shown in Figure 5 5 3 Clean the threaded opening of the heat exchanger and coat the threads of the zinc anode with pipe sealant suitable for marine applications 4 Install the zinc anode into the heat exchanger 5 Open the seacock 6 Refill the cooling system 7 Start the generator set and check for leaks at the zinc anode loc...

Page 32: ...ropylene glycol water mix or equivalent 7 With a container at the exhaust outlet run the generator set until coolant discharges at the exhaust outlet or until depleting the coolant mixture Do not allow the coolant mixture to flow into waterways 8 Stop the generator set 9 Connect the hose to the seacock Leave the seacock closed 10 Check the coolant level of the heat exchanger and add coolant if nec...

Page 33: ...lay The normally open K20 contacts close energizing the starter relay and the starter motor Note The normally closed LOP contacts open when the engine builds oil pressure This may take a few seconds after engine cranking is initiated 6 1 2 Run The bridged rectifier BR1 receives AC voltage 12 15 volts through the B1 and B2 windings of the stator The K1 relay energizes LED1 lights The normally open ...

Page 34: ... shutdown switch contacts close energizing the K4 relay LED4 lights The generator shuts down as described in Section 6 1 3 Note During cranking the low oil pressure shutdown switch deactivates until the K5 relay energizes This delay allows the engine to reach normal operating oil pressure 6 2 2 Loss of Coolant Switch LCS Shutdown When the coolant level is low the LCS contacts close energizing the ...

Page 35: ...while cranking Yes No Is the K3 relay LED lit Yes No Yes No Is there continuity between N and 47 while pressing the start stop switch The K2 relay is faulty Replace the circuit board Is voltage present at the starter relay Yes Is voltage present at the starter No Yes Replace the starter relay Replace or repair the starter motor Go to A next page Replace the K20 relay Is voltage present at the K20 ...

Page 36: ... 8 and P1 14 No Yes Is there12 volts DC present at the fuel pump P9 2 Is the fuel pump working No Check the connectors for open circuits Yes Yes Is there continuity between P4 5 and N No Yes Is there continuity between P2 8 and N Disconnect the P2 connector Is there continuity between P2 5 and N No Replace the remote start stop switch Yes Replace the start stop switch Yes Go to C next page Yes Tro...

Page 37: ...ace the circuit board the K5 relay is inoperative Did the K4 relay LED light Replace the circuit board inoperative K4 relay B Is the temperature HET safety shutdown switch functional Replace the inoperative temperature switch Yes Yes Yes Is the K3 LED out Replace the circuit board the K6 relay is inoperative No Yes C Is the LOP switch functional Replace LOP switch No Yes No No Is the low coolant s...

Page 38: ...ine if other components are inoperative See Section 7 1 2 Separate Excitation Yes No Is the voltage regulator functional Is there AC output voltage Is the stator and rotor functional Is the voltage regulator fuse functional D No Yes Replace the voltage regulator Yes Replace the fuse No Replace inoperative components Yes Replace the circuit board Is the stator functional No No Replace the stator Ye...

Page 39: ...lated equipment and electrical circuits to comply with applicablecodes andstandards Never contact electrical leads or appliances when standing in water oronwetgroundbecause theseconditions increasethe riskof electrocution 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 wit...

Page 40: ...ading suggests a running open in the rotor If the ammeter is stable continue with step 6 6 With a jumper wire ground the negative lead from the rotor to the engine block An increased current reading or a fluctuating reading indicates a grounded rotor winding Replace the rotor if the ammeter reading fluctuates If the ammeter is stable continue with step 7 7 Remove the jumper wire and reverse the po...

Page 41: ...ct the components as shown in Figure 7 4 2 Turn the variable transformer setting to zero Plug in the variable transformer 3 Turn the variable transformer on Slowly increase the variable transformer voltage to 100 volts The test lamp should light If the lamp does not light turn the voltage adjustment potentiometer pot clockwise If the lamp still does not light the voltage regulator is inoperative R...

Page 42: ...ed on the generator causes the engine speed to fall below a predetermined RPM or frequency This reduction of voltage results in a decrease of starting kW load allowing the governor to recover the engine speed Voltage Regulator Adjustment Procedure 1 Stop the generator set 2 Turn the remote rheostat if equipped to the midpoint Turn the voltage and stabilizer pots fully counterclockwise Connect the ...

Page 43: ...See Section 1 5 Note When checking rotor resistance with the rotor installed brushes must not be in contact with rotor collector rings Use a brush retainer on brushes for accurate resistance readings Note Use the values in Section 1 as a reference for rotor resistance readings Take readings at room temperature or about 21 C 70 F Rotor resistance will vary directly with increase in temperature To c...

Page 44: ...e stator as described in step 7 Note Consider the stator functional if the resistance reading continuity is low and there is no evidence of shorted windings heat discoloration Note The stator resistance varies directly with increased temperature If the stator readings vary considerably during the previous checks repair or replace the stator 7 Check the stator for a grounded condition using a megoh...

Page 45: ... wear evenly Brushes must ride 100 on the collector rings or arcing will occur and cause burned rings or failure of the voltage regulator Figure 7 9 shows the correct positioning of the brushes Add or remove spacers as necessary to center brushes on collector rings Replace brushes if they show excessive or uneven wear TP 598657 1 2 3 4 1 Correct position 2 Brush holder 3 Incorrect position 4 Gener...

Page 46: ...TP 5986 4 03 32 Section 7 Generator Troubleshooting Notes ...

Page 47: ...ourmeter positive terminal Connect the black test lead to the hourmeter negative terminal Set the voltmeter to 12 volts DC or greater Start the generator set A 12 volt DC reading indicates the wiring harness is functional None see Procedure Disconnect the hourmeter leads and apply 12 volts DC to the hourmeter The hourmeter is polarity sensitive If functional hourmeter operates Stator auxiliary win...

Page 48: ...tch in the START position If the switch is functional zero ohms continuity Any resistance other than zero or very low ohms replace the switch Connect the ohmmeter to the P2 6 and P2 5 leads Place the ohmmeter on the R x 1000 scale Place the rocker switch in the STOP position If the switch is functional zero ohms continuity Any resistance other than zero or very low ohms replace the switch K20 rela...

Page 49: ...ct the ohmmeter to the P1 15 and engine block ground Note Remove and isolate the LOP switch lead Place the ohmmeter on the R x 1000 scale If functional open circuit Any continuity suggests an inoperative temperature switch es Disconnect individual leads to inoperative switch Figure 8 3 Engine Generator Component Testing Relay Controller 8 2 Remote Panels Optional Kohler Co offers three remote pane...

Page 50: ... switch to the START position Stop the generator set when the test is complete Voltmeter setting 12 volts or greater Generator set does not need to be running just cranking for this test Note If the hourmeter is not illuminated test by connecting it to a 12 volt battery Note The hourmeter is polarity sensitive Water temperature gauge Connect the red test lead to P3 4 socket side and black test lea...

Page 51: ...connect the generator output leads 1 2 3 and 4 from the circuit breaker and the neutral stud L0 7 Disconnect the P11 FP and FN and P10 F1 and F2 connectors 8 Remove the fuel inlet hose 9 Close the seacock and remove the water inlet hose from the water pump 10 Remove the sound shield enclosure if equipped 11 If the generator set is not equipped with a sound shield enclosure lift the controller from...

Page 52: ... fitting 18 End bracket bearing 19 O ring 20 Stator assembly 21 Rotor assembly 15 16 9 9 9 Figure 9 3 Alternator Assembly Components 2 1 1 Rotor bolt 2 Hammer 598692 Figure 9 4 Removing the Rotor 18 Remove the end bracket overbolts See Figure 9 3 Use a rubber mallet to separate the end bracket from the stator housing 19 Carefully remove the stator assembly from the generator adaptor plate 20 Remov...

Page 53: ... 1 Nm 204 in lbs 3 Carefully slide the stator assembly over the rotor 4 Replace the end bracket o ring 5 Install the end bracket and torque the overbolts to 13 6 Nm 120 in lbs 6 Feed the brush leads inside the stator housing up through the opening Secure the brush holder using the original screws 7 Remove the brush retainer and check the brush alignment See Section 7 5 8 Install the coverplate and...

Page 54: ...TP 5986 4 03 40 Section 9 Generator Disassembly Reassembly Notes ...

Page 55: ...attery 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 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 Grounding electrical equipment Hazardous vo...

Page 56: ...TP 5986 4 03 42 Section 10 Wiring Diagrams and Voltage Reconnection 10 1 Schematic Wiring Diagram 359343 J ...

Page 57: ...TP 5986 4 03 43 Section 10 Wiring Diagrams and Voltage Reconnection 10 2 Point to Point Wiring Diagram 359343 J ...

Page 58: ...200 240 V 60 50 Hz ADV 5857 10 5 Reconnection Diagram 220 240 V 50 Hz ADV 5857 10 6 Remote Start Panel Start P P K1 70 47 43 N Gen ON light Remote switch P3 5 P3 6 P3 1 P2 3 P2 7 P2 8 P2 9 K2 P1 14 47 P2 4 43 P2 5 P2 6 N P1 9 N Relay circuit board Local switch Violet Black Yellow Red Grey Black Start Stop Stop 10 amp Fuse P3 4 J3 4 J3 5 J3 1 J3 6 TP 5588 7 ...

Page 59: ...ack Yellow Red Grey Black L Blue Start Stop Stop 10 amp fuse P3 4 W T sender O P sender J3 4 J3 5 J3 6 J3 1 J3 3 TP 5588 7 10 8 Remote Start and Four Meter Panel Start P P 7C K1 70 47 43 N Hourmeter DC voltmeter Oil pressure gauge Water temp gauge Gen ON light Remote switch 5 P3 5 P3 6 P3 1 P3 2 P3 3 P2 3 P2 7 P2 8 P2 9 P4 2 P4 3 K2 P1 14 47 P2 4 43 P2 5 P2 6 N P1 9 N Relay circuit board Local swi...

Page 60: ...TP 5986 4 03 46 Section 10 Wiring Diagrams and Voltage Reconnection Notes ...

Page 61: ...ooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO dual inlet end outlet DIN Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss DIP dual inline package DPDT double pole double throw DPST double pole single throw DS disconnect ...

Page 62: ...nal OS oversize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase PHC Phillips head crimptite screw PHH Phillips hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per milli...

Page 63: ...Below top of nut Figure 1 Acceptable Bolt Lengths Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nu...

Page 64: ... 27 7 16 14 ft lbs Nm 29 39 44 60 63 85 7 16 20 ft lbs Nm 32 43 50 68 70 95 1 2 13 ft lbs Nm 44 60 68 92 96 130 1 2 20 ft lbs Nm 49 66 76 103 108 146 9 16 12 ft lbs Nm 60 81 98 133 138 187 9 16 18 ft lbs Nm 67 91 109 148 154 209 5 8 11 ft lbs Nm 83 113 135 183 191 259 5 8 18 ft lbs Nm 94 128 153 208 216 293 3 4 10 ft lbs Nm 147 199 240 325 338 458 3 4 16 ft lbs Nm 164 222 268 363 378 513 1 8 ft lb...

Page 65: ...nal External Tooth Lock Hardness Grades American Standard Grade 2 Grade 5 Grade 8 Grade 8 9 Hex Socket Head Metric Number stamped on hardware 5 8 shown 5 8 Allent head screw is a trademark of Holo Krome Co Phillipsr screw is a registered trademark of Phillips Screw Company Sample Dimensions 1 4 20 x 1 Major Thread Diameter In Fractional Inches Or Screw Number Size Length In Inches Screws and Bolts...

Page 66: ...24 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2 13 x 1 25 X 129 19 1 2 13 x 1 50 X 129 20 1 2 13 x 1 75 X 129 21 1 2 13 x 2 00 X 129 22 1 2 13 x 2 25 X 129 23 1 2 13 x 2 50 X 129 24 1 2 13 x 2 75 X 129 25 1 2 13 x 3 00 X 129 27 1 2 13 x 3 50 X 129 2...

Page 67: ...ead Bolts Full Thread M933 04006 60 M4 0 70 x 6 M933 05030 60 M5 0 80 x 30 M933 05035 60 M5 0 80 x 35 M933 05050 60 M5 0 80 x 50 M933 06010 60 M6 1 00 x 10 M933 06012 60 M6 1 00 x 12 M933 06014 60 M6 1 00 x 14 M933 06016 60 M6 1 00 x 16 M933 06020 60 M6 1 00 x 20 M933 06025 60 M6 1 00 x 25 M933 06040 60 M6 1 00 x 40 M933 06050 60 M6 1 00 x 50 M933 07025 60 M7 1 00 x 25 M933 08010 60 M8 1 25 x 10 M...

Page 68: ... 80 M12 1 75 Spiralock M982 12 80 M12 1 75 Elastic Stop M982 14 60 M14 2 00 Elastic Stop M6923 16 80 M16 2 00 Spiralock M982 16 80 M16 2 00 Elastic Stop M934 18 80 M18 2 5 Standard M982 18 60 M18 2 50 Elastic Stop M934 20 80 M20 2 50 Standard M982 20 80 M20 2 50 Elastic Stop M934 22 60 M22 2 50 Standard M934 24 80 M24 3 00 Standard M982 24 60 M24 3 00 Elastic Stop M934 30 80 M30 3 50 Standard Wash...

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Page 72: ...er Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455 ...

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