Kohler 32EOZ Service Manual
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Kohler 32EOZ Service Manual

Kohler 32EOZ Service Manual

Marine generator sets
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See also: Operating Manual , Instruction and Installation Manual
Service
Marine Generator Sets
Models:
32EOZ
27EFOZ
TP-5936 7/04d

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Summary of Contents for Kohler 32EOZ

  • Page 1 Service Marine Generator Sets Models: 32EOZ 27EFOZ TP-5936 7/04d...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ..Section 7 Generator Troubleshooting ..General ........Introduction .
  • Page 4 Notes Table of Contents TP-5936 7/04...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting Battery electrolyte is a diluted INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear...
  • Page 6 Battery short circuits. Explosion Combustible materials. A fire can Copper tubing exhaust systems. cause severe injury or death. Carbon monoxide can cause severe can cause severe injury or death. Generator set engine fuels and fuel nausea, fainting, or death. Do not Short circuits can cause bodily injury vapors are flammable and explosive.
  • Page 7 Fuel System Pipe sealant. Explosive fuel vapors Hazardous Voltage can cause severe injury or death. Fuel leakage can cause an explosion. WARNING Use pipe sealant on all threaded fittings WARNING to prevent fuel leakage. Use pipe sealant that resists gasoline, grease, lubrication oil, common bilge solvents, salt deposits, and water.
  • Page 8 Disconnecting the electrical load. Electrical backfeed to the utility. Hot Parts Hazardous voltage cause Hazardous backfeed voltage can severe injury or death. Disconnect cause severe injury or death. WARNING the generator set from the load by Connect the generator set to the opening the line circuit breaker or by building/marina electrical system only disconnecting the generator set output...
  • Page 9 Moving Parts Servicing the generator set when it NOTICE is operating. Exposed moving parts When replacing hardware, do not can cause severe injury or death. substitute with inferior grade WARNING Keep hands, feet, hair, clothing, and hardware. Screws and nuts are test leads away from the belts and available in different hardness ratings.
  • Page 10 Notes Safety Precautions and Instructions TP-5936 7/04...

  • Page 11: Introduction

    Maintenance work must be performed by appropriately Information in this publication represents data available skilled and suitably-trained maintenance personnel at the time of print. Kohler Co. reserves the right to familiar with generator set operation and service. change this publication and the products represented...
  • Page 12 Product 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. Engine Identification Record the product identification information from the engine nameplate.

  • Page 13: Section 1 Specifications

    Section 1 Specifications 1.1 General The 32EOZ/27EFOZ units are powered by a Yanmar conditions of 25_C (77_F) and pressure of 29.2 in. Hg 4TNE98 four-cylinder, water-cooled, four-cycle diesel dry barometer. ISO 3046 and ISO 8528-1 include engine with heat exchanger.

  • Page 14: Generator

    1.3 Generator 32EOZ/27EFOZ—4 Lead, 1 Phase Generator 32EOZ/27EFOZ—12 Lead, 3 Phase Generator Component Specification Value Component Specification Value Hot exciter field voltage/current Hot exciter field voltage/current readings at rated voltage* readings at rated voltage* No load (63 Hz) No load (63 Hz) 18.0/0.7...

  • Page 15: Service View

    1.4 Service View 1 2 3 4 11 12 13 14 15 16 GB-250000 1. Controller 18. High water temperature switch 2. Start/Stop switch 19. Seawater pump (water inlet) 3. Hourmeter 20. Coolant overflow bottle 4. DC circuit breaker 21. Oil filter 5.
  • Page 16 Notes Section 1 Specifications TP-5936 7/04...

  • Page 17: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance 2.1 General 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. WARNING Be especially careful if the sound shield has been removed, leaving the belts and pulleys exposed.

  • Page 18: Lubrication System

    2.2 Lubrication System 4. Drain the seawater from the heat exchanger by removing the coolant drain plug. following paragraphs describe the engine 5. Close the seacock and remove the hose at the lubrication system. seacock. Place the hose in a container having approximately 3.7--7.5 L (1--2 gal.) of marine 2.2.1 Oil Specifications...

  • Page 19: Section 3 Intake And Exhaust System

    Section 3 Intake and Exhaust System 3.1 Air Intake Silencer/Cleaner Check the hoses for softness, cracks, leaks, or dents. Replace the hoses as needed. At the interval specified in the service schedule, clean or Check for corroded or broken metal parts and replace replace the air intake silencer.
  • Page 20 Notes Section 3 Intake Exhaust System TP-5936 7/04...

  • Page 21: Section 4 Fuel System

    Section 4 Fuel System 4.1 General 4.2 Fuel Specifications In most installations, both the generator set and the Use a clean, good quality diesel fuel oil with a cetane propulsion engine operate from a common fuel tank with number of 45 or greater. Clean fuel prevents diesel fuel a dual dip tube arrangement.

  • Page 22: Bleed The Fuel System

    4.4 Bleed the Fuel System 5. Loosen vent screw C at the fuel filter. Figure 4-2. Bleed the air from the fuel system to prevent starting 6. Toggle the start/stop switch until fuel, free of air failures and/or erratic operation. One or more of the bubbles, flows from vent screw C.

  • Page 23: Fuel Solenoid

    4.5 Fuel Solenoid Reading 12V System 24V System Fuel Solenoid The fuel solenoid pulls the injector pump lever to the fuel Pull-In 50 amps 22 amps on position when energized. The fuel solenoid is spring loaded to return the injector pump lever to the fuel off Hold 1.0 amps 0.37 amps...

  • Page 24: Fuel Pump

    4.6 Fuel Pump 60 Hz generator sets are designed to operate at 57--63 Hz, 1800 rpm under full load and 1890 rpm under The fuel pump transfers fuel from a source to the fuel no load. injection pump. 50 Hz generator sets are designed to operate at 47--53 Hz, 1500 rpm under full load and 1590 rpm under Fuel Pump Test Procedure no load.

  • Page 25: Section 5 Cooling System

    Section 5 Cooling System 5.1 General 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 The heat exchanger cooling system consists of a heat release pressure, cover the pressure cap with a thick cloth and exchanger with a coolant recovery tank, a thermostat, a then slowly turn the cap counterclockwise to the first stop.

  • Page 26: Water-Cooled Exhaust Manifold

    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. Model Bolt Torque 32EOZ/27EFOZ 19 Nm (14 ft. lbs. ) 5.5 Flush and Fill the Cooling Figure 5-2 Water-Cooled Exhaust Manifold Bolt System...

  • Page 27: Siphon Break

    5.6 Siphon Break 3. Use a light detergent to clean the reed valve to remove the residue and oxidation. A siphon break prevents seawater entry into the engine 4. Check that the reed valve opening is clear. when the engine exhaust manifold outlet is less than 23 cm (9 in.) above the waterline of a fully-loaded craft.

  • Page 28: Impeller Inspection And Replacement

    5.7 Impeller Inspection and Replacement The belt-driven seawater pump is located on the service side of the generator set. Check and change the seawater pump impeller at the interval specified in the service schedule. Follow instructions in the impeller kit. If the instructions are not included with the kit use the following procedure.

  • Page 29: Anticorrosion Zinc Anode

    Replace When Percent of Zinc New Anode Models Remaining is: Dimensions mm (in.) <50% of 32EOZ/27EFOZ 9 (0.34) x 19 (0.75) length/diameter Figure 5-8 Anticorrosion Zinc Anode Measurements TP-5586-3 1. Diameter: 9 mm (0.34 in.) 2. Length: 19 mm (0.75 in.)
  • Page 30 Notes Section 5 Cooling System TP-5936 7/04...

  • Page 31: Section 6 Controller Troubleshooting

    Section 6 Controller Troubleshooting 6.1 Controller 6.2 Controller Sequence of Operation This section covers the controller troubleshooting procedure for generator sets equipped with a relay The following describes the controller sequence of controller and related engine components. Refer to operation during generator start, run, stop, and fault Section identify controller external...

  • Page 32: Run

    6.2.2 6.2.3 Stop The K1 relay energizes (LED1 lights) when the B1 and Close the start/stop switch between N and 43 (local or B2 windings receive AC output from the stator main remote). field. After a 5--10 second time delay, the K5 relay The K4 relay is energized (LED4 lights).

  • Page 33: High Water Temperature (Hwt) And High Exhaust Temperature (Het) Shutdown Switch

    6.3.2 High Water Temperature (HWT) and High Exhaust Temperature (HET) Shutdown Switch When a high temperature is encountered at one (or both) of these sources, the shutdown switch contacts close and energize the K4 relay (LED4 lights). The normally closed K4 contacts open to deenergize the K25 relay.

  • Page 34: Troubleshooting

    6.3.4 Troubleshooting Use the following flow chart as an aid in troubleshooting prescribed remedy does not correct the problem, the the main circuit board and the entire generator set. If the circuit board may have to be replaced. Press the start switch Go to A Does the engine crank? (Local or remote)
  • Page 35 Go to B Does the engine start? (next page) Is the K4 relay LED lit? Is there continuity between P4-5 and N? Is 12 volts DC Is the fuel present at the pump working? (P9-2)? Is there continuity Is there continuity between between P1-9 and P9-1? P2-8 and N? - Diagnose engine safety...
  • Page 36 Does the engine continue Can the engine be stopped to run after the start by using the stop switch? switch is released? Generator set checks out okay Did the K4 relay LED light? Does the K1 relay LED light? Is the fuel solenoid functioning? Go to C Do the local and...
  • Page 37 Is there AC output when the start button Is the voltage Is AC output at the regulator is HELD and the unit correct voltage, e.g. fuse okay? is running? 120 volts AC? Replace the fuse Is there 12VDC at the exciter field? Test the voltage regulator Refer to Section 7...
  • Page 38 Notes Section 6 Controller Troubleshooting TP-5936 7/04...

  • Page 39: Section 7 Generator Troubleshooting

    Section 7 Generator Troubleshooting 7.1 General 7.2 General Troubleshooting Before beginning the troubleshooting procedures, read To determine the cause of no- or low-AC output , refer to all the safety precautions at the beginning of this the following steps and the troubleshooting flow chart manual.

  • Page 40: Separate Excitation

    7.3 Separate Excitation Note: See Section 1, Specifications, for the stator output voltages (with separately excited By separately exciting the generator to determine the generator). These specifications are based on a battery voltage of 12. Should the battery voltage presence of a faulty voltage regulator, it is possible to vary (11--14 volts), the resulting stator output determine if a running fault exists in the rotor and/or values will also vary.
  • Page 41 The following components will be needed to test the 3. Plug the power cord into the outlet. voltage regulator: 4. Turn the power supply on. The AC voltmeter should indicate a power supply voltage of Step-up transformer, 1:2, 120 volts to 240 volts 200--240 volts.

  • Page 42: Voltage Regulator Adjustment

    7.5 Voltage Regulator Adjustment Note: The voltage regulator is located inside the generator set controller. The voltage regulator is factory set and, under normal Voltage Adjustment Pot. Pot adjusts the generator circumstances, requires further adjustment. output. However, if the voltage regulator has been replaced, or tampered with, or if voltage/frequency reconnection has Stability Pot.

  • Page 43: Exciter Field

    7.6 Exciter Field Direct current from the battery magnetizes the exciter field. When the exciter armature rotates within the magnetized exciter field windings, an electrical current develops within the exciter armature. Test the exciter field according to the following procedure. Exciter Field Test Procedure 1.

  • Page 44: Exciter Armature

    7.7 Exciter Armature The exciter armature supplies excitation current to the generator main field through the rectifier module. Test the exciter armature as described in the following steps. Exciter Armature Test Procedure 1. Disassemble the alternator. Refer to Section 9. 2.

  • Page 45: Rectifier Module

    7.8 Rectifier Module The rectifier module converts the AC from the exciter armature to DC, which magnetizes the generator main field. Test the rectifier module as described in the following steps. Rectifier Module Test Procedure 1. Disconnect the exciter armature and the main field leads from the rectifier module.

  • Page 46: Stator

    7.10 Stator The stator consists of a series of coils of wire laid in a laminated steel frame. The stator leads supply voltage to the AC load and exciter regulator. Before testing the stator, inspect it for heat discoloration and visible damage to the housing lead wires and exposed and varnished areas of the frame laminations.
  • Page 47 5. Contact the ohmmeter leads and readjust the ohmmeter to zero ohms. Check the cold resistance of the stator windings by connecting the meter leads to the stator leads 1-2, 3-4, etc. See Section 1, Specifications, for the stator resistance values.
  • Page 48 Notes Section 7 Generator Troubleshooting TP-5936 7/04...

  • Page 49: Section 8 Component Troubleshooting

    Section 8 Component Troubleshooting 8.1 General 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 WARNING connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. See Figure 8-1 through Figure 8-2 for component testing.
  • Page 50 Note: Before performing ohmmeter checks, disconnect plugs from the controller circuit board. Use an the generator set battery to prevent damage to ohmmeter to check the continuity of the components the ohmmeter. and to isolate inoperative components. Refer to Figure 8-2. To further check the generator set components, disconnect the battery and remove the wiring harness Component...

  • Page 51: Remote Panels (Optional)

    Refer to Figure 8-3 and Figure 8-4 for resistance values. Refer Figure 8-5 Kohler Co. offers three remote panels for connection to troubleshooting information on the remote start panels. the generator set: 2-Meter and 4-Meter Panels A panel with a start/stop switch...
  • Page 52 Notes Section 8 Component Troubleshooting TP-5936 7/04...

  • Page 53: Section 9 Generator Disassembly/Reassembly

    Section 9 Generator Disassembly/Reassembly 9.1 Disassembly In some installations, it is not possible to remove the generator set from the craft. Disconnect the external connections—battery cables (negative lead first), AC-output leads in the controller, remote start panel at the controller P3 connector, water line at the seawater pump, fuel line at the fuel pump filter inlet, and exhaust line at the mixing elbow.
  • Page 54 5936 1. Bolt (3/8 x 16 x 1.25) 2. Plate 4” x 1/4” min. 558864 3. Washers (4) 1. 3/8 in. nut (4) and plain washer (4) 4. Alternator 2. End bracket cover 5. Rotor 3. Vibromount hardware Figure 9-5 Securing the Rotor Figure 9-3 Alternator, End View 11.
  • Page 55 16. Support the alternator assembly and remove the 8 23. Remove the 4 alternator end bracket bolts. See bolts, washers, and spacers securing the rotor Figure 9-8. assembly to the engine flywheel. See Figure 9-6. 24. Carefully remove the end bracket with the exciter 17.

  • Page 56: Reassembly

    9.2 Reassembly 1. Reinstall the alternator end bracket with the exciter field. Feed the exciter leads into the hole in the top of the stator housing. Torque the mounting bolts to 38.0 Nm (28 ft. lbs.). See Figure 9-9. 2. Gently insert the rotor into the stator housing. Be careful to avoid damaging the rotor assembly or the stator during installation.

  • Page 57: Diagrams

    Section 10 Voltage Reconnection and Wiring Diagrams 10.1 4-Lead Reconnection L0 (Neutral) The following information illustrates the reconnection of GRD. Ground 4-lead generator sets. In all cases, follow the National Electrical Code (NEC). Load Side NOTICE Single-Pole Voltage reconnection. Affix a notice to the generator set after Circuit reconnecting the set to a voltage different from the voltage on Breaker...

  • Page 58: Configurations

    Figure 10-1 for location). Select a two-pole circuit L0 (Neutral) breaker. Application of two single-pole circuit breakers does not conform to NEC requirements for supplying a GRD. Ground 200--240-volt load, even breakers mechanically attached together. Leads L1 and L2 are Load for different phases;...

  • Page 59: Two And Three Wire Manual (Ship-To-Shore) Transfer Switch

    10.3 Two and Three Wire Manual (Ship-to-Shore) Transfer Switch Electro Switch 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load To Load Kraus Naimler/American Solenoid (Early Rectangular Design) 2-Wire Generator Sets 3-Wire Generator Sets To Shore To Generator...

  • Page 60: Four Wire Manual (Ship-To-Shore) Transfer Switch

    10.4 Four Wire Manual (Ship-to-Shore) Transfer Switch Kraus Naimer/American Solenoid 4-Wire, 3-phase Generator Sets To Generator Set To Shore Power To Load I-940 10.5 Generator Reconnection Generator Connections 3-Phase WYE Single-Phase 3-Phase Delta Some sets not rated for single phase, see manuals Used 190-208 Volt 50 Hz 110/220 Volt 50 Hz...
  • Page 61 Notes TP-5936 7/04 Section 10 Voltage Reconnection and Wiring Diagrams...

  • Page 62: Single-Phase Wiring Diagram-Schematic

    10.6 Single-Phase Wiring Diagram—Schematic 229937-G Section 10 Voltage Reconnection and Wiring Diagrams TP-5936 7/04...

  • Page 63: Single-Phase Wiring Diagram-Point-To-Point

    10.7 Single-Phase Wiring Diagram—Point-to-Point 229937-G TP-5936 7/04 Section 10 Voltage Reconnection and Wiring Diagrams...

  • Page 64: Three-Phase Wiring Diagram-Schematic

    10.8 Three-Phase Wiring Diagram—Schematic 229938-D Section 10 Voltage Reconnection and Wiring Diagrams TP-5936 7/04...

  • Page 65: Three-Phase Wiring Diagram-Point-To-Point

    10.9 Three-Phase Wiring Diagram—Point-to-Point 229938-D TP-5936 7/04 Section 10 Voltage Reconnection and Wiring Diagrams...

  • Page 66: Remote Start Panel

    10.10Remote Start Panel 10.11 Remote Start and Two-Meter Panel Stop Stop Local 10-amp P1-9 Local switch P1-9 10-amp fuse switch fuse Start Start W.T. O.P. P1-14 P2-4 P2-5 P2-6 sender sender P1-14 P2-4 P2-5 P2-6 Relay Relay circuit circuit board board P2-3 P2-7...

  • Page 67: Remote Start And Four-Meter Panel

    10.12Remote Start and Four-Meter Panel Stop Local P1-9 10-amp switch fuse Start O.P. W.T. P1-14 P2-4 P2-5 P2-6 sender sender Relay circuit board P2-3 P4-2 P4-3 P2-8 P2-9 P2-7 Grey/ P3-4 P3-5 P3-1 P3-2 P3-3 P3-6 Black J3-4 J3-5 J3-1 J3-2 J3-3 Violet...
  • Page 68 Notes Section 10 Voltage Reconnection and Wiring Diagrams TP-5936 7/04...

  • Page 69: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute exh. exhaust ABDC after bottom dead center center of gravity ext. external alternating current cubic inch displacement Fahrenheit, female analog to digital centerline fglass.
  • Page 70 kilo (1000) MTBF mean time between failure round head machine (screw) kelvin MTBO mean time between overhauls rly. relay kiloampere mtg. mounting root mean square kilobyte (2 bytes) megawatt rnd. round kilogram milliwatt read only memory µF kg/cm kilograms per square microfarad rot.

  • Page 71: Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 72: Appendix C General Torque Specifications

    Appendix C General Torque Specifications Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated literature instructions give no specific torque values. threads. All torque values are +0%/--10%. The charts list values for new plated, zinc phosphate, or American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel...

  • Page 73: Identification

    Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)

  • Page 74: Appendix E Common Hardware List

    Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
  • Page 75 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Full Thread), Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), continued continued M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M933-12016-60...
  • Page 76 Metric, continued Part No. Dimensions Type Hex Nuts M934-03-50 M3-0.50 Standard M934-04-50 M4-0.70 Standard M934-04-B M4-0.70 Brass M934-05-50 M5-0.80 Standard M934-06-60 M6-1.00 Standard M934-06-64 M6-1.00 Std. (green) M6923-06-80 M6-1.00 Spiralock M982-06-80 M6-1.00 Elastic Stop M934-08-60 M8-1.25 Standard M6923-08-80 M8-1.25 Spiralock M982-08-80 M8-1.25 Elastic Stop...
  • Page 80 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-5936 7/04d 7 Jurong Pier Road Singapore 619159 E 2000, 2001, and 2004 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...

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