Kohler 32EOZ Service Manual

TP-5936 7/04 Table of Contents
Table of Contents
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.......

Kohler 32EOZ Specifications

General

Brand	Kohler
Model	32EOZ
Category	Portable Generator
Language	English