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TP-5936 7/04

Section 6 Controller Troubleshooting

Does the engine start?

Yes

Is the K4 relay LED lit?

Yes

Is there continuity across the
P1, P4, and P9 connectors?

Go to B
(next page)

Is there continuity
between P1-9 and P9-1?

Check wiring
for opens

Is there continuity
between P9-2 and P1-8?

Is there continuity
between P1-8 and P1-14?

Yes

Is 12 volts DC
present at the
(P9-2)?

Is the fuel
pump working?

Replace fuel pump

Yes

Is there continuity between
P4-5 and N?

Yes

- Diagnose engine safety

shutdown switches
(LOP, LCS, HET).

- Engine fault (check the

fuel supply, carburetion,
ignition, compression)
See engine service
manual.

Is there continuity between
P2-8 and N?

Disconnect the P2 connector.
Is there continuity between
P2-5 and N?

Replace the remote
start/stop switch

Yes

Replace the
start/stop switch

Yes

Figure 6-4

Troubleshooting the Run Relay Controller Circuit (2 of 4)

Содержание 27EFOZ

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

Страница 2: ......

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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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