Kohler 5e problem

B

brizwizz

New Member
Aug 22, 2012
24
Australia
Boat Info
2001 amberjack 290
Engines
2x 5.7lt efi mercruisers
Hello All

I bought and exported a 2001 amberjack 290 with a fully functional westerbeke 4kw generator. Unfortunately after I bought the boat and before the shipping the seller/shipper (whom I am having a lot of trouble with) ) swapped out the generator with a used kohler 5e gas model, (They connected the plumbing) but left the wiring unconnected and now I have the problem of reconnecting this to see if it works. It turns over but I haven't started it as yet. I am hoping someone can help to finish the wiring before starting.

Left to connect is the white round searay plug (cant see where this would go on this unit) which would go to the electrical panel in the cabin and the 110 volt wiring (white, green and black) to be connected into the control box on the unit. Can somebody point me in the right direction to connect these up and to get it going. Pics would be great in the control box.

There is also a wire down near the fuel pump (which looks dodgy) that is not connected.


Thanks for your help

Wayne

2.jpg
 
Wow good luck with this. Sounds like a mess. Sounds like you were not expecting this change.
 
skolbe said:
Wow good luck with this. Sounds like a mess. Sounds like you were not expecting this change.
Click to expand...

Yes the whole situation has been a huge mess. I wish I didn't do it now, but I do like this model.
Apparently the gen had a $400 service and was running perfectly. I can only guess they pulled it for a new boat they were purchasing.

cheers
 
brizwizz said:
Yes the whole situation has been a huge mess. I wish I didn't do it now, but I do like this model.
Apparently the gen had a $400 service and was running perfectly. I can only guess they pulled it for a new boat they were purchasing.

cheers
Click to expand...
Do you have the Kohler 5E Service Manual? There may be enough in there to help you out. I has both internal wiring diagrams and external connection wiring diagrams. The manual number is TP-5986 and I found it in PDF online.
 
ZZ13 said:
Do you have the Kohler 5E Service Manual? There may be enough in there to help you out. I has both internal wiring diagrams and external connection wiring diagrams. The manual number is TP-5986 and I found it in PDF online.
Click to expand...

Thanks heaps for that Bill. I had tried looking for one but only found a brief one online, made it simple with the number.

cheers
 
KP49 said:
TP-5982 is the installation manual and may be of help, its out there on the internet.
Click to expand...

Not being real savvy with electrical drawings. :)

From the boat there is the 110v wiring (green, black, white) to be connected into the black electrical box.

Im guessing here....

...there is a stud in the box with green wires connected, so i will connect the green from the boat input to it.
...there is a stud in the box with black wires connected, so i will connect the black from the boat input to it.
...i will connect the white from the boat input to the breaker switch.

Does that sound right to you guys?

Spark plugs have plenty of spark.

I also tested the fuel pump and couldn't get it to work, so I have ordered a new one, oil filter and other bits for it from the USA. So hopefully this will get it working.

cheers
 
brizwizz said:
From the boat there is the 110v wiring (green, black, white) to be connected into the black electrical box.

Im guessing here....

...there is a stud in the box with green wires connected, so i will connect the green from the boat input to it.
...there is a stud in the box with black wires connected, so i will connect the black from the boat input to it.
...i will connect the white from the boat input to the breaker switch
Click to expand...

Hmmmm, where is this black electrical box located? I have a 280, but with same generator. I might be able to look in mine and verify connections, but I'm unfamiliar where this box may be?

Your guesses don't seem quite right to me. The white wire is a neutral wire in a 110v circuit (black being the hot wire, green being the ground). A neutral wire doesn't normally connect to a breaker switch, a black wire does. Not so say your are wrong or I am right, just that I'd find another way to verify it before you proceed.

Tom
 
Gunn said:
Hmmmm, where is this black electrical box located? I have a 280, but with same generator. I might be able to look in mine and verify connections, but I'm unfamiliar where this box may be?

Your guesses don't seem quite right to me. The white wire is a neutral wire in a 110v circuit (black being the hot wire, green being the ground). A neutral wire doesn't normally connect to a breaker switch, a black wire does. Not so say your are wrong or I am right, just that I'd find another way to verify it before you proceed.

Tom
Click to expand...

LOL....sorry for being Aussie, our wiring over here is different colors and that's the confusing thing. The black box is where the start button, fuses and the breaker switch is at the right of the engine... I cant load a pic for some reason, but it is the black box in the upper right corner of this pic off the web, sorry.

http://www.google.com.au/imgres?num...w=187&start=0&ndsp=10&ved=1t:429,r:0,s:0,i:73

Thanks
 
brizwizz said:
LOL....sorry for being Aussie, our wiring over here is different colors and that's the confusing thing. The black box is where the start button, fuses and the breaker switch is at the right of the engine... I cant load a pic for some reason, but it is the black box in the upper right corner of this pic off the web, sorry.

http://www.google.com.au/imgres?num...w=187&start=0&ndsp=10&ved=1t:429,r:0,s:0,i:73

Thanks
Click to expand...

I apologize too; I had vaguely recalled that you may have been the one who purchased a U.S.A. boat with U.S.A. wiring and receptacles. Sorry about that.

Ok I do know where the black box is. But now I doubt I'll be able to help due to the wire coloring now!
 
Gunn said:
I apologize too; I had vaguely recalled that you may have been the one who purchased a U.S.A. boat with U.S.A. wiring and receptacles. Sorry about that.

Ok I do know where the black box is. But now I doubt I'll be able to help due to the wire coloring now!
Click to expand...

No need...You are correct... it is the USA wiring (white, green and black) I am connecting to the 110v of the kohler. I am leaving it at these volts to run the USA electricals. Just pretend you are rewiring it back into your own boat.. :)

These color wires come from the boat and I just need to know where to connect in the box.

I think I am safe connecting the greens, it is just the black and white I am worrying about. I wish I was an electrician..... marine mechanic.... rich.... more careful when I buy things.... :)

cheers
 
Hi All.

I have had a bit of a win....

The gen wouldn't fire at all..

Tested the fuel pump and it was dead. So I replaced it, spark plugs, oil and filter. Then I pulled the carbi off and cleaned it, when I thought I would check the automatic choke. Pulled it apart and the linkage inside is seized. I tried to free it but no luck and it doesn't want to start without the choke.

I then manually used the choke and it fired. Unfortunately I had to hold the start button in the on position, but it ran until it was released and seemed to run well apart from this. Half way there, just need to find out what is stopping it from running now with out the start switch on..

It seems these chokes are discontinued and you cant get rebuild kits for it. The following seems to be mostly the same, will it suit??

http://www.partsfortechs.com/asapcart/gm12236-choke-rep-kit-kawas-kohler-p-1092.html

Thanks

Wayne
 
scoflaw said:
That's the one, just did mine this season
Click to expand...

Thanks for that. I have ordered one and a new impeller.

Just need to check the kohler troubleshooting flow chart as to why it doesn't continue to run.... Any one have any ideas as to the likely culprit?

cheers
 
scoflaw said:
That's the one, just did mine this season
Click to expand...

Wow, is that a rebuild kit or a whole new choke assembly?! Because if that's just a rebuild kit, it the most expensive one I've ever seen...by $100.00!! Ouch.

You may have a failed sensor issue causing your gen to shutdown, even though it is actually running fine.

Tom
 
Gunn said:
Wow, is that a rebuild kit or a whole new choke assembly?! Because if that's just a rebuild kit, it the most expensive one I've ever seen...by $100.00!! Ouch.

You may have a failed sensor issue causing your gen to shutdown, even though it is actually running fine.

Tom
Click to expand...

Hi Tom.

Received it today and it is the whole pump in kit form.

I will be checking all the sensors on the weekend also, but the choke was seized so I had to replace it.

regards
 
When it runs by holding down the start switch, what is the voltage being put out on the AC side?
 
steelheder said:
When it runs by holding down the start switch, what is the voltage being put out on the AC side?
Click to expand...

Hi.

There doesn't seem to be any now, but there was. Would the circuit board cause this, or is it the stator etc..

It still does not run when the sensors were disconnected. I think it is not going to be a cheap easy fix.
 
First check is excitation capacitor I believe.

Ive got the same issue, and I've just ordered all control boards + excitation capacitor from US.
 
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