Format: PDF (Printable Document)
File Language: English
File Pages: 80
File Size: 2.68 MB (Speed Download Link)
Brand: Kohler
Model: 32EOZ, 27EFOZ Marine
Book No: tp5936
Type of Document: Service Manual
$ 40
On a boat, these Kohler marine gensets sit in a hot, cramped engine room and are expected to make clean power every time you hit the start button. This service manual is what I’d pull out when the set won’t carry load right, hunts on speed, or keeps tripping off on a fault. It walks you through how to verify the problem, trace it through the fuel, electrical, and cooling systems, and then tear down and reassemble components in a logical order so you’re not just throwing parts at it.
Applications & Use Cases
FAQ
Q: Can I keep this manual on a tablet in the engine room?
A: Yes, it’s convenient to use digitally; you can zoom wiring and layout diagrams while working in tight spaces.
Q: Should I still print parts of it?
A: Many techs print key procedures or schematics so they can mark notes and keep them next to the unit during a job.
Safety Note
Always lock out the generator’s starting and AC output sources before opening covers or disconnecting components.
Safety Precautions and Instructions . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . i
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Service View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 2 Scheduled Maintenance . . . . . . . . . . . 5
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.1 Oil Specifications . . . . . . . . . . . . . . . . . . 6
2.2.2 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Generator Storage . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 3 Intake and Exhaust System . . . . . . . . 7
3.1 Air Intake Silencer/Cleaner . . . . . . . . . . . . . . . . . . 7
3.2 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Mixing Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 4 Fuel System . . . . . . . . . . . . . . . . . . . . . 9
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Bleed the Fuel System . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 5 Cooling System . . . . . . . . . . . . . . . . . . 13
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Water-Cooled Exhaust Manifold . . . . . . . . . . . . . . 14
5.3 Closed Heat Exchanger . . . . . . . . . . . . . . . . . . . . . 14
5.4 Check and Fill the Cooling System . . . . . . . . . . . 14
5.5 Flush and Fill the Cooling System . . . . . . . . . . . . 14
5.6 Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.7 Impeller Inspection and Replacement . . . . . . . . . 16
5.8 Anticorrosion Zinc Anode . . . . . . . . . . . . . . . . . . . 17
Section 6 Controller Troubleshooting . . . . . . . . 19
6.1 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Controller Sequence of Operation . . . . . . . . . . . . 19
6.2.1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2.2 Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.3 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Engine Safety Shutdown Switches . . . . . . . . . . . 20
6.3.1 Low Oil Pressure (LOP) Shutdown . . . 20
6.3.2 High Water Temperature (HWT) and High
Exhaust Temperature (HET) Shutdown
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3.3 Controller Circuit Board . . . . . . . . . . . . . 21
6.3.4 Troubleshooting . . . . . . . . . . . . . . . . . . . 22
Section 7 Generator Troubleshooting . . . . . . . . 27
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2 General Troubleshooting . . . . . . . . . . . . . . . . . . . . 27
7.3 Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4 PowerBoost V Voltage Regulators . . . . . . . . . . . . 28
7.5 Voltage Regulator Adjustment . . . . . . . . . . . . . . . 30
7.6 Exciter Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.7 Exciter Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.8 Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.9 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.10 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Section 8 Component Troubleshooting . . . . . . 37
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2 Remote Panels (Optional) . . . . . . . . . . . . . . . . . . . 39
Section 9 Generator Disassembly/
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Section 10 Voltage Reconnection and Wiring
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.1 4-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . 45
10.1.1 100–120-Volt Configurations . . . . . . . . . 45
10.1.2 100–120-/200–240-Volt
Configurations . . . . . . . . . . . . . . . . . . . . . 46
10.1.3 200–240-Volt Configurations . . . . . . . . . 46
10.2 12-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . 46
10.3 Two and Three Wire Manual (Ship-to-Shore)
Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.4 Four Wire Manual (Ship-to-Shore)
Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.5 Generator Reconnection . . . . . . . . . . . . . . . . . . . . 48
10.6 Single-Phase Wiring Diagram—Schematic . . . . 50
10.7 Single-Phase Wiring Diagram—Point-to-Point . 51
10.8 Three-Phase Wiring Diagram—Schematic . . . . . 52
10.9 Three-Phase Wiring Diagram—Point-to-Point . . 53
10.10 Remote Start Panel . . . . . . . . . . . . . . . . . . . . . . . . 54
10.11 Remote Start and Two-Meter Panel . . . . . . . . . . 54
10.12 Remote Start and Four-Meter Panel . . . . . . . . . . 55
Appendix A Abbreviations . . . . . . . . . . . . . . . . A-1
Appendix B Common Hardware Application
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix C General Torque
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Appendix D Common Hardware
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Appendix E Common Hardware List . . . . . . . A-6
