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Posted on Feb 15, 2011

I have a kohler 5E marine generator It will blow the input fuse when cranking. If the voltage regulator is disconnected it will start but only run if the start switch is pressed. Any Ideas?

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  • Posted on Jun 16, 2011
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I have the same genset. Just fixed a similar prob with it. Mine would intermittently blow fuses at first then started blowing them as soon as trying to start. I also saw a puff of smoke from reg when it did run at one point. Carefully check stator wires for shorts to ground. Make sure to lift the stator wires that are grounded in control box. If no grounds replace control board and reg board. $400+. Cross your fingers and try it. Mine worked, thank God. The pc boards are marginally designed and built. The relays, diodes and other componants are way too undersized for the application and can not survive a lot of cycling
on and off. When starting genset make sure to slowly apply loads to it. Same thing when shutting it down. Dont shut it down with any load. It wont take it
Good luck

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My kohler 5e marine generator only runs when I hold the start button and only produces about 12vac. Is this a quick fix?

Sounds Like possibly the regulator is the issue.
Flightsystems Can test these to see if it is good or not.
also here is a link for the service manual
https://us.v-cdn.net/5020499/uploads/editor/0c/g1lx13xi2vyy.pdf
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I have a 1989 Kohler marine generator model 7.5R. It runs OK but not AC power.

The Kohler 7.5 R had a possible three different voltage regulators that could be used.
You need to check there first. Also if you can get it the service manual for these are tp-5110 Which will show you how to test the regulator o the bench. There was a 5 6 and 7 pin regulator that could have been used.
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I have a kohler 23eozd marine gen set thatwowouldn't crank. There's voltage 12.8vlts coming all the way to the sttarter but still wouldn't crank.

on the starter of the engine there are two teminals that should have 12volts to them while its cranking (or trying to) one has a 3/8 bolt stud and has a large wire/cable that should go to either the battery disconnect or direct to battery , the other one is 1/8" size and has a smaller wire to it , this is the trigger wire , it triggers the starter to operate , your going to need to look at those voltages when its trying to operate
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Why my generator shuts down and posts a message cc-1 crank cycle

Maybe the start motor is damaged. You can check it first.

Power generation: www.dieselgeneratortech.com
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Does the kohler generator have shut down sensors for low oil, exhaust temp and such? If so, check the sensors.


I checked the kohler website and noticed that one of the option was the siphon break. Does your genset has this? I had a similar problem like yours and my siphon break was blown. It was replaced.

What is more, do check the exhaust system of the generator and see if there is water flow.
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