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Kohler 5ECD Service Manual
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TP-6391
9/08
2
1
3
Table of Contents
Table of Contents
3
Table of Contents
4
Safety Precautions and Instructions
5
Introduction
9
Service Assistance
10
Section 1 Specifications
11
Introduction
11
Generator Set Ratings
11
Controller Specifications
11
Alternator Specifications
11
Alternator Specifications, Continued
12
Torque Specifications
12
Engine Specifications
13
Service View
14
Section 2 Scheduled Maintenance
15
General
15
Service Schedule
16
Section 3 Troubleshooting
17
Introduction
17
Initial Checks
17
Troubleshooting Chart
17
Section 4 Controller
23
Introduction
23
Controller Display and Keypad
24
Master Switch
24
Sequence of Operation
25
Starting the Generator Set
25
Running Sequence
25
Stopping the Generator Set
25
Faults
25
Shutdowns
25
Warnings
25
SECM Fault Codes and Diagnostics
29
Relay Interface Board (RIB)
35
CO Sensor Module
35
K5 Main Power Relay
35
Silicon Controlled Rectifier (SCR) Module
36
Controller Replacement
37
Controller Configuration and Adjustment
38
Voltage Adjustments
38
Controller Configuration
41
Controller Configuration Mode
43
Section 5 Component Testing and Adjustment
45
Theory of Operation
45
Separate Excitation
45
Stator
47
Main Field (Rotor)
48
Rotor Continuity and Resistance Tests
48
Slip Rings
50
Brushes
50
Voltage
51
Voltage Regulation
51
Voltage Adjustment
51
Voltage Reconnection
52
Governor System
52
Fault Shutdown Tests
52
Controller Fault Shutdown Functions
52
Fault Shutdown Switches
53
Electronic Throttle Assembly
57
Fuses
57
Continuity Checks
58
Section 6 Generator Disassembly/Reassembly
59
Disassembly
59
Collector Ring and Bearing Replacement
62
Reassembly
63
Section 7 Wiring Diagrams
65
Point-To-Point Wiring Diagram
66
Appendix A Abbreviations
79
Appendix B Common Hardware Application Guidelines
81
Appendix C General Torque Specifications
82
Appendix D Common Hardware Identification
83
Appendix E Common Hardware List
84
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Kohler 5ECD Specifications
General
Power Output
5 kW
Frequency
60 Hz
Fuel Type
Diesel
Cylinders
2
Engine Type
4-cycle
Starter System
Electric
Phase
Single
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