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Kohler 27EFOZ, Service Manual

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Kohler 27EFOZ Service Manual Download Page 12

TP-5936 7/04

ii

Introduction

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.

Manufacturer

Model Number

Serial Number

Generator Set Identification Numbers

Record the product identification numbers from the
generator set nameplate(s).

Model Number

Specification Number

Serial Number

Accessory Number

Accessory Description

Summary of Contents for 27EFOZ

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

Page 2: ......

Page 3: ...ch 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 Voltag...

Page 4: ...TP 5936 7 04 Table of Contents Notes...

Page 5: ...econnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery Sulfuric acid in batteries Can cause severe injury or death Wear p...

Page 6: ...ght headedness dizziness D Physical fatigue weakness in joints and muscles D Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision D Stomachache vomiting nausea If experie...

Page 7: ...lvents salt deposits and water Ignition protected equipment Explosive fuel vapors can cause severe injury or death Gasoline vapors can cause an explosion USCG Regulation 33CFR183 requires thatallelect...

Page 8: ...trical system only through an approved device and after the building marina main switch is opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and...

Page 9: ...oval Exposed moving parts can cause severe injury or death The generator set must be operating in order to perform some scheduled maintenance procedures Be especially careful if the sound shield has b...

Page 10: ...TP 5936 7 04 VI Safety Precautions and Instructions Notes...

Page 11: ...n and service x in 001 003 Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer D Consult the Y...

Page 12: ...adily available for future reference Record field installed kit numbers after installing the kits Engine Identification Record the product identification information from the engine nameplate Manufact...

Page 13: ...ty w filter L qts 4 7 5 0 Oil Recommendation API CC or CD Engine Firing Order 1 cylinder nearest to flywheel 1 3 4 2 Fuel Injection Timing BTDC 10 12_ Fuel Injection Pressure kPa psi 1517 1586 220 230...

Page 14: ...tor resistance 1 2 3 4 33 44 ohms 0 04 55 66 ohms 1 7 B1 B2 ohms 0 19 Exciter field circuit includes resistor 32EOZ 27EFOZ 12 Lead 3 Phase Generator Component Specification Value Hot exciter field vol...

Page 15: ...l fill 13 Fuel return or located behind valve cover and filter 14 Governor 15 Fuel injection pump 16 Pressure cap 17 Overflow tube 18 High water temperature switch 19 Seawater pump water inlet 20 Cool...

Page 16: ...TP 5936 7 04 4 Section 1 Specifications Notes...

Page 17: ...oving parts can cause severe injury or death The generator set must be operating in order to perform some scheduled maintenanceprocedures Be especially careful if the sound shield has been removed lea...

Page 18: ...oil and oil filter See the generator set operation manual 4 Drain the seawater from the heat exchanger by removing the coolant drain plug 5 Close the seacock and remove the hose at the seacock Place t...

Page 19: ...exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and outlet flapper for cracks leaks and corrosion D Check the hoses for softness cracks leaks or dents Replac...

Page 20: ...TP 5936 7 04 8 Section 3 Intake Exhaust System Notes...

Page 21: ...tor Set Propulsion Engine 1 2 4 3 To fuel pump 1 Fuel tank 2 Dual dip tubes 3 Fuel filter 4 Fuel feed pump Figure 4 1 Fuel System Schematic Typical 4 2 Fuel Specifications Use a clean good quality die...

Page 22: ...h in the START position for a few seconds and then placing the switch in the STOP position Close the seacock during bleeding Procedure to Bleed the Fuel System 1 Loosen vent screw A at the fuel filter...

Page 23: ...llow the solenoid plunger to fully compress Incorrect adjustment may cause burnout of the pull in coil If the fuel solenoid is removed see Figure 4 4 and use the following procedure Fuel Solenoid Test...

Page 24: ...engine according to changes in the load No regular service is required on the governor The factory adjusts the governor during run in and further adjustment should not be needed unless poor governor c...

Page 25: ...releasepressure coverthepressure capwith athick clothand then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has coole...

Page 26: ...res 5 4 Check and Fill the Cooling System Before filling the cooling system close all the petcocks and tighten all of the hose clamps Use a solution of 50 ethylene glycol and 50 fresh softened water t...

Page 27: ...nstall the retaining cap and finger tighten only Do not overtighten Waterline 1 2 3 7 8 9 19 10 11 12 13 14 15 16 17 18 21 20 6 5 4 TP 5586 3 1 Mounting holes 2 Retaining cap 3 Reed valve assembly 4 S...

Page 28: ...straight and flexible See Figure 5 6 5 Lubricate the impeller with soapy water before installation 6 While installing the impeller always rotate the drive shaft and the impeller together in the same d...

Page 29: ...er start stop switch in the STOP position 2 Disconnect the generator set engine starting battery negative lead first 3 With the generator set cooled close the seacock open the engine petcock and drain...

Page 30: ...TP 5936 7 04 18 Section 5 Cooling System Notes...

Page 31: ...rator start run stop and fault shutdown modes Use the LEDs on the controller circuit board to assist in the troubleshooting process An illuminated LED indicates that the respective relay is receiving...

Page 32: ...nergize the K20 relay The K20 contacts open to deenergize the S relay The S contacts open to deenergize the starter motor When the generator set is running the start switch contacts N and 47 are opene...

Page 33: ...Circuit Board Some controller circuit board components can be tested without removing the component from the circuit board Perform these checks prior to installing a new circuit board and attempting...

Page 34: ...start stop switch N 43 and 47 Check the battery condition and connections Check the connections at P1 14 Is K2 relay functioning No Yes Replace the circuit board K3 relay or K1 relay faulty Replace t...

Page 35: ...14 No Yes Is 12 volts DC present at the P9 2 Is the fuel pump working No Replace fuel pump Yes Yes No Is there continuity between P4 5 and N No Yes Diagnose engine safety shutdown switches LOP LCS HET...

Page 36: ...Replace the fuel solenoid No No Replace the circuit board K5 relay inoperative Does the low oil pressure LOP safety shutdown switch function No Replace the LOP safety shutdown switch Yes No Did the K4...

Page 37: ...e exciter field Yes Test the stator and main field No No Separately excite the generator set to determine if other components are inoperative Replace the controller circuit board Yes No Is AC output v...

Page 38: ...TP 5936 7 04 26 Section 6 Controller Troubleshooting Notes...

Page 39: ...Never contact electrical leads or appliances when standing in water oronwetgroundbecause theseconditions increasethe riskof electrocution Short circuits Hazardous voltage current can cause severe inj...

Page 40: ...ads and compare it to the values in Section 1 Specifications If the output varies considerably from those listed a faulty stator rotor rectifier module or armature is likely If the AC output is not wi...

Page 41: ...r set failure Voltage Regulator Test Procedure 1 Connect the components as shown in Figure 7 3 If a 200 240 volt power source is available the step up transformer is not required 2 Turn the volts pote...

Page 42: ...cker Volts Hz Pot Pot adjustment determines the engine speed Hz at which the generator output begins to drop Voltage Regulator Adjustment Procedure 1 Place the generator set controller start stop swit...

Page 43: ...the exciter field if the ohmmeter readings indicate a inoperative exciter field Refer to Section 9 for removal If the resistance test is inconclusive perform a megohmmeter test on the exciter field a...

Page 44: ...fer to Section 9 3 With an ohmmeter on the R x 1 scale check the resistance across the exciter armature leads See Figure 7 8 See Section 1 Specifications for the armature resistance No continuity indi...

Page 45: ...by connecting an ohmmeter across the main field F and F leads See Figure 7 11 See Section 1 for the resistance reading A low reading indicates an internal short and a high reading indicates an open wi...

Page 46: ...itch in the STOP position 2 Disconnect the generator set engine starting battery negative lead first 3 Check the generator output lead connections See Section 10 Voltage Reconnection and Wiring Diagra...

Page 47: ...nd Figure 7 17 Apply 500 volts DC to any stator lead from each winding and the stator frame Follow the megohmmeter manufacturer s instructions for using the megohmmeter Repeat the test on the other le...

Page 48: ...TP 5936 7 04 36 Section 7 Generator Troubleshooting Notes...

Page 49: ...multimeter to verify that the switches function and that voltage is present at each component Component Voltmeter Connections Procedure Results Hourmeter and wiring Connect the red test lead to the ho...

Page 50: ...ad Note The J4 and P4 leads must be connected to perform this test Place the ohmmeter on the R x 1000 scale If functional zero or very low ohms No reading infinity open circuit or circuit breaker trip...

Page 51: ...e the ohmmeter on the R x 1 scale Press the rocker switch to the START position Continuity the switch is functional Open replace switch Remote switch grey black wire terminal and black wire terminal P...

Page 52: ...TP 5936 7 04 40 Section 8 Component Troubleshooting Notes...

Page 53: ...ery the negative lead first 3 Loosen the 4 screws and lift off the controller cover 4 Disconnect the P4 22 pin connector from J4 See Figure 9 1 5 Remove the bolt and disconnect the ground strap See Fi...

Page 54: ...5 Securing the Rotor 11 Remove the vibromount mounting hardware See Figure 9 3 Note Use a hoist with a capacity rating of one half ton or greater 12 Remove the 4 nuts and washers securing the alterna...

Page 55: ...fully lift the rotor out of the stator housing 558866 1 2 6 7 8 9 11 13 5 4 10 12 14 15 16 3 1 Bolt 3 8 16 x 2 5 in and washer 2 Alternator side alternator adapter 3 Rotor 4 Rotor hub 5 Nut 10 32 6 Al...

Page 56: ...t lbs See Figure 9 6 558865 2 1 3 3 4 5 1 Alternator end bracket and exciter field 2 Stator 3 Stator mounting bolts 3 8 16 x 1 75 in and washers 6 4 Alternator adapter mounting bolts 3 8 16 x 2 5 in a...

Page 57: ...the load side terminals of the circuit breaker together See Figure 10 1 If the installation requires a 100 120 volt 2 wire system use a single pole circuit breaker See Figure 10 2 When connecting stat...

Page 58: ...figuration does not use a jumper lead If the unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 10 1 for location 10 2 12 Lead Reconnection The following reco...

Page 59: ...aus Naimler American Solenoid Early Rectangular Design Kraus Naimler American Solenoid Newer Round Design 2 1 3 4 6 5 7 8 1 2 6 5 3 4 8 7 L1 L2 To Generator Set To Shore Power To Load 3 2 4 1 7 6 8 5...

Page 60: ...Used Some sets not rated for single phase see manuals 110 220 Volt 50 Hz 120 240 Volt 60 Hz Remove V9 from terminal strip and tape 3 Phase Delta 110 220 Volt 50 Hz 120 240 Volt 60 Hz 3 Phase WYE 190 2...

Page 61: ...TP 5936 7 04 49 Section 10 Voltage Reconnection and Wiring Diagrams Notes...

Page 62: ...TP 5936 7 04 50 Section 10 Voltage Reconnection and Wiring Diagrams 10 6 Single Phase Wiring Diagram Schematic 229937 G...

Page 63: ...TP 5936 7 04 51 Section 10 Voltage Reconnection and Wiring Diagrams 10 7 Single Phase Wiring Diagram Point to Point 229937 G...

Page 64: ...TP 5936 7 04 52 Section 10 Voltage Reconnection and Wiring Diagrams 10 8 Three Phase Wiring Diagram Schematic 229938 D...

Page 65: ...TP 5936 7 04 53 Section 10 Voltage Reconnection and Wiring Diagrams 10 9 Three Phase Wiring Diagram Point to Point 229938 D...

Page 66: ...Grey Black Start Stop Stop 10 amp fuse P3 4 J3 4 J3 5 J3 1 J3 6 TP 5588 7 10 11Remote Start and Two Meter Panel P3 2 J3 2 Start P P 7C K1 70 47 43 N Oil pressure gauge Water temp gauge Gen ON light R...

Page 67: ...C voltmeter Oil pressure gauge Water temp gauge Gen ON light Remote switch 5 P3 5 P3 6 P3 1 P3 2 P3 3 P2 3 P2 7 P2 8 P2 9 P4 2 P4 3 K2 P1 14 47 P2 4 43 P2 5 P2 6 N P1 9 N Relay circuit board Local swi...

Page 68: ...TP 5936 7 04 56 Section 10 Voltage Reconnection and Wiring Diagrams Notes...

Page 69: ...rmer Cu copper cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct cur...

Page 70: ...optional OS oversize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor p...

Page 71: ...p of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut...

Page 72: ...0 32 68 0 50 95 0 70 1 2 13 Nm ft lb 60 0 44 92 0 68 130 0 96 1 2 20 Nm ft lb 66 0 49 103 0 76 146 0 108 9 16 12 Nm ft lb 81 0 60 133 0 98 187 0 138 9 16 18 Nm ft lb 91 0 67 148 0 109 209 0 154 5 8 11...

Page 73: ...al External Tooth Lock Hardness Grades American Standard Grade 2 Grade 5 Grade 8 Grade 8 9 Hex Socket Head Metric Number stamped on hardware 5 8 shown 5 8 Allent head screw is a trademark of Holo Krom...

Page 74: ...4 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2 13...

Page 75: ...00 x 160 M931 24200 60 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M4 0 70 x 6 M933 05030 60 M5 0 80 x 30 M933 05035 60 M5 0 80 x 35 M933 05050 60 M5 0 80 x 50 M933 06010 60 M6 1 00 x 10...

Page 76: ...12 1 75 Spiralock M982 12 80 M12 1 75 Elastic Stop M982 14 60 M14 2 00 Elastic Stop M6923 16 80 M16 2 00 Spiralock M982 16 80 M16 2 00 Elastic Stop M934 18 80 M18 2 5 Standard M982 18 60 M18 2 50 Elas...

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Page 80: ...ohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headqu...

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