Kohler 14RES RESL, 20RES RESL Residential Generator Service Manual
RES 14RES, RESL 14RESL, RES 20RES, RESL 20RESL are residential/commercial generator sets rated for 14 or 20 kW. These units are designed for reliable standby power in the event of a utility power outage.
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Service
Residential/Commercial Generator Sets
Models:
14RES/RESL
20RES/RESL
Controllers:
RDC Residential Digital Control
DC Digital Control
TP-6735 9/10
Table of Contents
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
12
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5
Alternator Specifications
1.6
Torque Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7
Service View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
14
14
15
13
13
13
Section 2 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1
Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.3
Engine Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.4
Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.5
Oil Cooler, 14RES/RESL
2.2.6
Oil Cooler, 20RES/RESL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1
Air Cleaner, 14RES/RESL Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2
Air Cleaner, 20RES/RESL Models
2.5
Cooling System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6
Stepper Motor Coupling
2.7
Exhaust System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.1
Lubricating System
2.10.2
Fuel System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.3
Cylinder Lubrication
2.10.4
Exterior Preparation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
21
22
22
23
23
24
24
24
17
19
19
19
19
19
20
21
25
26
26
26
26
26
26
Section 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3
Controller Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5
Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
27
27
27
27
36
Section 4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
RDC and DC Generator Set/ Transfer Switch Controllers . . . . . . . . . . . . . . . . . . .
4.3
Controller Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1
LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2
Controller Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
37
37
38
39
39
40
TP-6735 9/10 Table of Contents
Table of Contents, continued
4.5
Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1
Engine Start Crank Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2
Local Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.3
Automatic Operation with Model RRT Transfer Switch . . . . . . . . . . . . . .
4.5.4
Automatic Operation with Model RDT or RSB Transfer Switches
4.6
Exercise
. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1
Unloaded Exercise with Diagnostic Test
4.6.2
Low-Speed Diagnostics
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.3
Loaded Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.4
Exerciser Reset and Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.5
Power Failure During Exercise Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.1
Unloaded Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2
Loaded Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.3
Power Failure During Test Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.2
Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.3
ATS Communication Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.4
Resetting the Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . .
4.9
Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Model RRT Transfer Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.1
Source Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.2
ATS Control Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.3
Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.4
Engine and Transfer Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.5
Load Control Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.6
Model RRT ATS Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11 Controller Configuration and Adjustment
4.11.1
SiteTech Software
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11.2
Controller Configuration
4.11.3
Controller Time Out
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11.4
Controller Firmware Version Number
4.11.5
Voltage and Frequency Adjustments
4.12 Calibration
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12.1
Calibrate Function
4.12.2
Calibration Factor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13 Controller Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13.1
Relays and LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13.2
Controller Fuse F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
51
51
51
51
51
52
52
52
52
49
49
49
49
50
50
43
43
44
44
45
45
45
45
45
48
41
41
41
41
41
42
42
42
42
43
43
54
54
54
55
Section 5 Component Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4
Main Field (Rotor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1
Rotor Continuity and Resistance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7
Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7.1
Voltage Connections, Single-Phase Models
5.7.2
Voltage Regulation
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
57
57
59
61
61
62
62
63
63
63
Table of Contents TP-6735 9/10
Table of Contents, continued
5.8
Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8.1
Voltage Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8.2
Volts per Hertz (Hz) Adjustments (Droop) . . . . . . . . . . . . . . . . . . . . . . . . .
5.9
Governor System
5.9.1
Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.2
Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.3
Hunting/Surging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.4
Governor System/Magnetic Pickup Operation Test . . . . . . . . . . . . . . . . .
5.9.5
Frequency Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10 Fault Shutdown Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.1
Controller Fault Shutdown Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.2
Fault Shutdown Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11 Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.1
Fuel Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.2
Digital Spark Advance Ignition (DSAI) Timing
5.11.3
Fuel Regulators
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.4
Fuel Conversion, 20RES/RESL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.5
Fuel Conversion, 14RES/RESL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11.6
Fuel Metering Valve Adjustment, 14RES/RESL Only . . . . . . . . . . . . . . .
5.12 Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.13 Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14 Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14.1
Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14.2
Fuses and Mini-Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
64
64
71
71
72
74
74
75
75
76
77
78
66
66
66
66
67
70
80
81
82
82
82
Section 6 Disassembly/Reassembly
6.1
Initial Steps
Section 7 Wiring Diagrams
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
83
84
90
95
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102
103
Appendix E Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
Appendix F Controller Parameters (SiteTech) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
TP-6735 9/10 Table of Contents
6 TP-6735 9/10
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.
Read and follow all safety precautions and instructions.
SAVE
THESE INSTRUCTIONS.
This manual has several types of safety precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a hazard that will cause severe personal injury, death, substantial property damage.
or
WARNING
Warning indicates the presence of a hazard that can cause severe personal injury, death, substantial property damage.
or
CAUTION
Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.
NOTICE
Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.
Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.
The decals are shown throughout this publication to improve operator recognition.
Replace missing or damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.
Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.
Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup. Battery acid can cause severe injury or death.
Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.
Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.
TP-6735 9/10 Safety Precautions and Instructions 7
Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.
Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits.
Explosion can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage.
Disconnect the battery before generator set installation or maintenance.
Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.
Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
Engine Backfire/Flash
Fire
Fire.
WARNING
Can cause severe injury or death.
Do not smoke or permit flames or sparks near fuels or the fuel system.
Servicing the fuel system. A flash fire can cause severe injury or death.
Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.
Catch fuels in an approved container when removing the fuel line or carburetor.
Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.
Combustible materials. A fire can cause severe injury or death.
Generator set engine fuels and fuel vapors are flammable and explosive.
Handle these materials carefully to minimize the risk of fire or explosion.
Equip the compartment or nearby area with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as recommended by the local fire code or an authorized agency.
Train all personnel on fire extinguisher operation and fire prevention procedures.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation.
Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building.
Carbon monoxide detectors.
Carbon monoxide can cause severe nausea, fainting, or death.
Install carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide.
Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according to the manufacturer’s instructions.
Carbon monoxide symptoms.
Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
D Light-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 experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.
Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
8 Safety Precautions and Instructions TP-6735 9/10
The fuel system.
Explosive fuel vapors can cause severe injury or death.
Vaporized fuels are highly explosive.
Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.
Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines.
Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming generator set operation.
Gas fuel leaks.
Explosive fuel vapors can cause severe injury or death.
Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.
LP liquid withdrawal fuel leaks.
Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi
(621 kPa). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.
Hazardous Voltage/
Moving Parts
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.
WARNING
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
WARNING
Hazardous voltage.
Backfeed to the utility system can cause property damage, severe injury, or death.
If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.
CAUTION
Welding the generator set.
Can cause severe electrical equipment damage.
Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).
Grounding electrical equipment.
Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards.
Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
TP-6735 9/10 Safety Precautions and Instructions 9
Welding on the generator set. Can cause severe electrical equipment damage.
Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module
(ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors.
(4) Disconnect the engine batterycharging alternator connections.
(5) Attach the weld ground connection close to the weld location.
High voltage test.
Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment manufacturer when performing high-voltage tests on the rotor or stator.
An improper test procedure can damage equipment or lead to generator set failure.
Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).
Have a qualified electrician install the battery(ies).
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 connections with tools or jewelry while making adjustments or repairs.
Remove all jewelry before servicing the equipment.
Electrical backfeed to the utility.
Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power.
Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.
Testing live electrical circuits.
Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits.
Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure.
(4) Be prepared for the system to operate automatically.
(600 volts and under)
Heavy Equipment
WARNING
Unbalanced weight.
Improper lifting can cause severe injury or death and equipment damage.
Do not use lifting eyes.
Lift the generator set using lifting bars inserted through the lifting holes on the skid.
Hot Parts
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the alternator. Hot parts can cause severe injury or death.
Avoid touching the alternator field or exciter armature.
When shorted, the alternator field and exciter armature become hot enough to cause severe burns.
Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.
The engine and exhaust system components become extremely hot during operation.
Servicing the engine heater.
Hot parts can cause minor personal injury or property damage. Install the heater before connecting it to power.
Operating the heater before installation can cause burns and component damage.
Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.
Notice
NOTICE
Canadian installations only.
For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with
Canadian Electrical Code, Part 1.
NOTICE
Electrostatic discharge damage.
Electrostatic discharge (ESD) damages electronic circuit boards.
Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about
1 megohm), not a direct short, to ground.
10 Safety Precautions and Instructions TP-6735 9/10
Introduction
This manual provides troubleshooting and repair instructions for the generator set models listed on the front cover. This manual may also be supplied for similar models not listed on the front cover.
Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.
Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.
The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service.
For engine service procedures not covered in this manual, refer to the Engine Service Manual.
List of Related Materials
Separate manuals contain operation, installation, and parts information not provided in this manual. Separate engine operation and service manuals are also available. The following table lists the available manual part numbers.
Document Description
Installation Manual
Operation Manual
Parts Catalog
Engine Service Manual, CH740
Engine Service Manual, CH1000
SiteTech t Software Operation Manual
Part Number
TP-6733
TP-6734
TP-6736
TP-2428
TP-2580
TP-6701
Figure 1 Model 20RES
6735
TP-6735 9/10 Introduction 11
Service Assistance
For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.
D
Consult the Yellow Pages under the heading
Generators—Electric.
D
Visit the Kohler Power Systems website at
KohlerPower.com.
D
Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product.
D
Call toll free in the US and Canada 1-800-544-2444.
D
Outside the US and Canada, call the nearest regional office.
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler Power Systems
3 rue de Brennus
93200 Saint Denis
France
Phone: (33) 1 49 178300
Fax: (33) 1 49 178301
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131
12 Service Assistance TP-6735 9/10
Section 1 Specifications
1.1 Introduction
The specification sheets for each generator set provide specific generator and engine information. Refer to the generator set specification sheet for ratings and other data not supplied in this manual. Consult the generator set installation manual, engine operation manual, and engine service manual for additional specifications.
Consult the generator set nameplate for specific generator set ratings.
1.2 Controller Specifications
Model 14RES and 20RES generator sets are equipped with the Residential Digital Control (RDC). Model
14RESL and 20 RESL generator sets are equipped with the Digital Control (DC). For a specific description of the controller, see Section 2, Operation, in the operation manual.
Environmental Specification
Operating temperature
Storage temperature
Humidity
Power requirements:
Voltage
Current (standby state)
All Models
--30
_ to 70_C
--40
_ to 85_C
0--95% condensing
12 VDC
250 mA @ 12 VDC
1.3 Engine Service
Generator sets covered in this manual are equipped with four-cycle, twin cylinder, air-cooled Kohler engines.
For engine service information and specifications not covered in this manual, see the engine service manual.
See the List of Related Materials in the Introduction section.
1.4 Engine Specifications
Engine Specification
Manufacturer
Model
Cycle
Number of cylinders
Compression ratio
Displacement, cc (cu. in.)
Rated power, propane fuel, kW (HP)
Rated power, natural gas, kW (HP)
Rpm, 60 Hz
Rpm, 50 Hz
14RES/
RESL
Kohler
CH740
4
2
9:1
725 (44)
17.6 (23.6)
15.3 (20.5)
20RES/
RESL
CH1000
4
2
8.8:1
999 (61)
23.0 (30.9)
20.2 (27.1)
Bore x stroke, mm (in.)
Valve material
Cylinder block material
Cylinder head material
Piston rings
Crankshaft material
Main bearings: number, type
Lubrication system
Oil capacity (w/filter), L (qt.)
Oil pressure, kPa (psi)
Fuel system
Minimum fuel supply pressure, kPa (in. H
2
O)
Battery voltage
Battery ground
Spark plug gap, mm (in.)
Ignition system
Starter motor
Cooling system
3600
3000
83 x 67
(3.27 x 2.64)
90 x 78.5
(3.54 x 3.1)
Steel/Stellite r
Aluminum w/cast iron liners
Aluminum
2 compression/ 1 oil
Heat-treated ductile iron
2, parent material
Full pressure
1.9 (2.0) 2.8 (3.0)
172--241 (25--35)
LP gas or natural gas
LP and NG: 1.2-- 2.7 (5--11)
12 VDC
Negative
0.76 (0.030)
Capacitor discharge
Electric, solenoid shift
Air-cooled
TP-6735 9/10 Section 1 Specifications 13
1.5 Alternator Specifications
Alternator Specification
Frequency Hz
Phase
Number of leads
Excitation method
Voltage regulator type
Coupling type
Insulation (rotor and stator)
14RES/RESL
50/60
Single-Phase
4
20RES/RESL
50/60
Single-Phase
4
Static Excited
Digital
Static Excited
Digital
Direct Direct
Epoxy varnish, vacuum impregnated
Winding material
Bearing, number and type
Circuit protection
Battery charger inline fuse F1
Fuel solenoid/starter relay/throttle control fuse F2
Controller power, fuse F3
Aux. winding mini-breaker
Generator AC output line circuit breaker
Rotor resistance, ohms, cold
Stator resistance, ohms,* cold
Single-Phase Leads 1-2, 3-4
11-44
55-66
Stator output voltage with separately excited rotor using 12-volt battery, minimum
Copper
1, Sealed Ball
10 amps
7.5 amps
3 amps
20 amps
70 amps
5.2
0.06
0.13
0.60
Class 180 (H)
Copper
1, Sealed Ball
10 amps
7.5 amps
3 amps
20 amps
100 or 125 amps
5.6
0.02
0.04
0.44
Leads: 1-2, 3-4
11-44
55-66
Rotor field voltage/current readings at rated output voltage, hot
105 V
210 V
142 V
88 V
176 V
117 V
No load
Full load
19 V/3.2 A
48 V/7.2 A
19 V/3.9 A
53 V/7.4 A
Brush length, new 19.05 mm (0.75 in.) 19.05 mm (0.75 in.)
* Most ohmmeters do not give accurate readings when measuring less than 1 ohm. The stator can be considered good if a low resistance reading (continuity) is obtained and there is no evidence of shorted windings (discoloration). Do not confuse a low resistance reading with a reading indicating a shorted winding.
1.6 Torque Specifications
Torque Specifications,
Nm (ft. lb.)
Alternator overbolts
Alternator thrubolt
Generator adapter screws
Muffler flange bolts
Oil filter
Spark plug
* Not applicable to the 20RES/RESL.
14/20RES/RESL
15 (11)
85 (63)
40 (28) *
24 (17.7)
3/4 to 1 turn after gasket contact
24.4--29.8 (18--22)
14 Section 1 Specifications TP-6735 9/10
1.7 Service View
11
1
10
7, 8
9
6
5
2, 4
3
24
AIR INTAKE SIDE --PANEL
REMOVED TO SHOW DETAIL
12
13
14
15
16
17
18, 19
CONTROLLER
TOP VIEW
20
21
AIR
INTAKE
SIDE
17
18, 19
20
EXHAUST
SIDE
22
23
24
23
26
25
ADV-7876
TP-6735
1. Field-connection terminal block
2. Digital spark advance ignition (DSAI) leads
3. Fuel inlet
4. Fuel solenoid valve
5. Engine starting battery location (battery purchased separately)
6. Battery cables
7. Battery charger location (charger not shown)
8. 120 VAC receptacles for battery charger and optional carburetor heater (not shown)
9. Nameplate location
10. Gas regulator assembly
11. Fuel block or LP orifice location (inside hose fitting)
12. Muffler (located below cover plate)
13. Oil check dipstick
14. Governor assembly
15. Air cleaner
16. Oil filter
17. RDC or DC controller
18. Fuses
19. USB connector (for firmware updates)
20. Line circuit breaker
21. Oil fill
22. Spark plugs
23. Lifting holes
24. Oil drain hose
25. Oil drain valve
26. Alternator
Figure 1-1 Generator Set Service View
TP-6735 9/10 Section 1 Specifications 15
Notes
16 Section 1 Specifications TP-6735 9/10
Section 2 Scheduled Maintenance
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the exhaust system.
Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.
WARNING
See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized distributor/dealer perform generator set service.
Alternator Service. Under normal operating conditions the generator set alternator does not require scheduled service. Refer to the service schedule for items that require maintenance.
Engine Service. Perform generator set engine service at the intervals specified by the engine service literature.
Contact an authorized Kohler r service distributor/ dealer to obtain engine service literature.
All generator sets have emission-certified engines. The carburetors on emission-certified engines are not adjustable.
Generator Set Service. See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized Kohler r service distributor/ dealer perform all generator service.
Routine Maintenance. Refer to the following generator set service schedule, the engine service schedule, and the runtime hours displayed on the generator set controller to determine when to schedule routine maintenance.
Service the generator set more frequently if it is subject to extreme weather, long operating hours, or dusty or dirty conditions.
Service Schedule. Perform maintenance on each item in the service schedule at the designated interval for the life of the generator set.
Tools. Tools and instruments used to perform some maintenance items are not generally available to the generator set owner.
Therefore, have service performed by an authorized distributor/dealer.
2.1 Service Schedule
Perform the items listed in the service schedule at the designated intervals for the life of the generator set. For example, an item serviced every 100 hours or 3 months must also be serviced after 200 hours or 6 months,
300 hours or 9 months, etc.
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
TP-6735 9/10 Section 2 Scheduled Maintenance 17
System Component or Procedure
Fuel
Flexible lines and connections
Main tank supply level (LP)
Fuel piping
Lubrication
Oil level
Change oil
Replace filter
Crankcase breather hose
Oil cooler
Cooling
Air ducts, louvers
Exhaust System
Leakage
Insulation, fire hazards
Obstructions or combustible materials near exhaust outlet
DC Electrical System
Battery charger operation, charge rate
Remove corrosion, clean and dry battery and rack
Clean and tighten battery terminals and inspect boots
Tighten DC electrical connections
AC Electrical System
Tighten control and power wiring connections
Remote control system, if equipped
Visible wear or damage
Wire abrasions where subject to motion
Wire-cable insulation condition
Engine and Mounting
Visible wear or damage
Air cleaner service *
Spark plugs
Replace stepper motor coupling and bushing
Generator
Visible wear or damage
Exercise generator set
Brushes and collector ring
Measure and record resistance readings of windings with insulation tester (Megger r, with controller or rectifier and load leads disconnected)
General Condition of Equipment
Evidence of vibration, leakage, deterioration, unusual or excessive noise or temperature
Interior of sound enclosure
* Service more frequently under extremely dusty/dirty conditions.
Megger r is a registered trademark of Biddle Instruments.
See
Section
2.2
2.2.2
2.2.4
2.2.4
2.2.6
2.5
2.7
2.8
2.4
2.3
2.6
5.5, 5.6
Visually
Inspect
Q
Y
Y or 500
Y
W
Y
W
M
Y
Y
Q
Check
W
8 or E
Y
W
Y
Y
Y
6 months 6 months
3Y or 500
E Each use
W Weekly
M Monthly
Q Quarterly
Y Yearly
W
Q
Y (D)
W
Q
150
150
W
Procedure
Change
R
Y or 150
Y or 150
300
300
500 (D)
Clean
Y or 100
Y
Y
Y (D)
W
Q
Number = hours of operation
D Authorized distributor/dealer only
R Replace as necessary
S/M Service Manual
Test
M
W
3Y (D)
Figure 2-1 Service Schedule
18 Section 2 Scheduled Maintenance TP-6735 9/10
2.2 Lubrication System
See Section 2.1, Service Schedule, for oil change and oil filter replacement intervals. See Section 1.7, Service
View, for the oil drain, oil check, oil fill, and oil filter locations.
2.2.1
Low Oil Pressure Shutdown
The low oil pressure (LOP) shutdown feature protects the engine against internal damage if the oil pressure drops below a minimum pressure because of oil pump failure or other malfunction.
Note: The LOP shutdown feature does not protect against damage caused by operating when the oil level is low; it is not a low oil level shutdown.
Check the oil level regularly, and add oil as needed.
2.2.2
Oil Check
The generator set is shipped with oil. Before operating the generator set, check the engine oil in the crankcase.
See Figure 2-2 for the dipstick location.
Maintain the oil level at or near, not over, the full mark on the dipstick. Add 5W-30 synthetic oil when the oil level is low. See Section 2.2.3, Engine Oil Recommendation.
Check the oil level before each use. For extended operation, check the oil level every 8 hours. Do not check the oil level when the generator set is running.
Shut down the generator set and wait several minutes before checking the oil.
Figure 2-2 Oil Check
6515
2.2.3
Engine Oil Recommendation
Use 5W-30 API (American Petroleum Institute) Service
Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner.
Model
14RES/RESL
20RES/RESL
Oil Capacity, L (qt.)
1.9 (2.0)
2.8 (3.0)
Figure 2-3 Oil Capacity (approximate)
2.2.4
Oil Change Procedure
Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner.
Drain the oil while it is still warm.
1. Drain the oil.
a. Press the OFF button on the controller.
b. Disconnect the power to the battery charger.
c. Disconnect the generator set engine starting battery, negative (--) lead first.
d. Remove the housing intake panel.
e. Clean the area around the dipstick and oil fill cap.
f. Remove the cap from the oil drain hose and lower the hose into an oil collection container.
g. Open the oil drain valve on the engine.
h. Remove the dipstick and oil fill cap. Allow time for the engine oil to drain completely.
i. Close the oil drain valve. Replace the cap on the oil drain hose. Replace the oil drain hose in its retaining clip.
j. Replace the dipstick.
2. Replace the oil filter.
a. Clean the area around the oil filter. Remove the oil filter by rotating it counterclockwise with an oil filter wrench.
b. Clean the gasket sealing surface of the oil filter adapter.
c. Apply a light coat of clean oil to the rubber seal of the new oil filter.
TP-6735 9/10 Section 2 Scheduled Maintenance 19
d. Install the new oil filter following the instructions provided with the filter.
3. Fill with oil.
a. Fill the engine to the F mark on the dipstick.
Section 2.2.3, Engine Oil Recommendation, for oil selection. See Figure 2-3 for the engine oil capacity.
b. Reinstall the dipstick and the oil fill cap.
c. Check that the generator set is off (the OFF
LED is on).
d. Reconnect the generator set engine starting battery, negative (--) lead last.
e. Reconnect the power to the battery charger.
f. Start and run the generator set for a minute to allow the oil pressure to reach operating range.
g. Stop the generator set, wait 1 minute, and then recheck the oil level. Add oil to bring the level up to the F mark on the dipstick.
4. Check for leaks.
a. Check for oil leaks.
b. Fix leaks and recheck the oil level.
c. Reinstall the housing side panel.
2.2.5
Oil Cooler, 14RES/RESL
Inspect and clean the oil cooler at the intervals shown in the Service Schedule. The oil cooler must be kept free of debris.
Remove the front enclosure panel to access the oil cooler. See Section 6.2 for instructions to remove the front panel.
See Figure 2-4 for the oil cooler location. Clean the outside of the oil cooler with a brush or compressed air.
If it is necessary to clean the back of the oil cooler, remove the two screws holding the oil cooler unit to the blower hosing. Tilt the cooler and clean with a brush or compressed air as shown in Figure 2-5. After cleaning, reinstall the oil cooler and secure with the mounting screws.
1
1. Oil filter
2. Oil cooler
Figure 2-4 Oil Cooler Location, 14RES/RESL
2
24 590 01--A
Figure 2-5 Cleaning the Oil Cooler
24 590 01--A
20 Section 2 Scheduled Maintenance TP-6735 9/10
2.2.6
Oil Cooler, 20RES/RESL
Inspect and clean the oil cooler at the intervals indicated in the service schedule. The oil cooler must be kept free of debris.
Remove the front enclosure panel to access the oil cooler. See Section 6.2 for instructions to remove the front panel.
See Figure 2-6 for the oil cooler location. The oil cooler is located under the No. 2 cylinder shroud. Remove the top mounting screw and loosen the two side screws, then lift off the cylinder shroud. Clean the outside of the oil cooler fins with a brush or with compressed air.
2.3 Spark Plugs
Reset the spark plug gap or replace the plugs with new plugs as necessary.
1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.
2. Remove the spark plug and check its condition.
Replace the spark plug if it is worn or if its reuse is questionable.
3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 in.) by carefully bending the ground electrode.
See
Figure 2-7 and Figure 2-8.
4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to 24.4--29.8 Nm
(18--22 ft. lb.)
1
1. Oil cooler
Figure 2-6 Oil Cooler Location, 20RES/RESL
62 590 01
Figure 2-7 Checking the Spark Plug Gap
1--514
Figure 2-8 Adjusting the Spark Plug Gap
1--511
TP-6735 9/10 Section 2 Scheduled Maintenance 21
2.4 Air Cleaner Service
2.4.1
Air Cleaner, 14RES/RESL Models
The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner. See
Figure 2-9.
1
6
7
2
3
4
5
586536
1. Cover knob
2. Air cleaner cover
3. Element cover nut
4. Element cover
5. Foam precleaner
6. Air cleaner element
7. Air cleaner base
Figure 2-9 Air Cleaner Components, 14RES/RESL
Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.
Note: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.
Precleaner Service
Use the following procedure to wash and reoil the precleaner as indicated in the service schedule. Wash and reoil the precleaner more often under extremely dusty or dirty conditions.
1. Press the OFF button on the generator set controller.
22 Section 2 Scheduled Maintenance
2. Disconnect the power to the battery charger.
3. Disconnect the battery, negative (--) lead first.
4. Loosen the cover retaining knob and remove the cover.
Remove the precleaner from the paper element. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry.
5. Saturate the precleaner with new engine oil.
Squeeze out all of the excess oil.
6. Reinstall the precleaner over the paper element.
7. Reinstall the air cleaner cover. Secure the cover with the cover retaining knob.
8. Reconnect the power to the battery charger.
9. Reconnect the generator set engine starting battery, negative (--) lead last.
Paper Element Service
Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions.
1. Press the OFF button on the generator set controller.
2. Disconnect the power to the battery charger.
3. Disconnect the generator set engine starting battery, negative (--) lead first.
4. Loosen the cover retaining knob and remove the cover.
5. Remove the element cover nut, element cover, and the paper element with precleaner.
6. Remove the precleaner from the paper element.
Note: Do not wash the paper element or clean it with pressurized air, as this will damage the element.
7. Replace the element if it is dirty, bent, or damaged.
8. Check the air cleaner base. Make sure it is secure and not bent or damaged. Also check the element cover for damage and fit. Replace all damaged air cleaner components. Remove any loose dirt or debris from the air cleaner base. Wipe the base carefully so that no dirt drops into the intake throat.
TP-6735 9/10
Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary.
9. Reinstall the paper element, precleaner, element cover, element cover nut, and the air cleaner cover.
Secure the cover with the cover retaining knob.
10. Reconnect the power to the battery charger.
11. Reconnect the generator set engine starting battery, negative (--) lead last.
2.4.2
Air Cleaner, 20RES/RESL Models
The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 2-10.
1
2
3
4 tp6515
1. Knobs (qty. 2)
2. Cover
3. Paper element
4. Base
Figure 2-10 Air Cleaner Components, 20RES/RESL
Check the air cleaner daily or before starting the engine.
Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.
Note: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.
Paper Element Service
Replace the paper element at the intervals indicated in the service schedule. See Figure 2-1 for the service schedule.
See Figure 2-10 for the air cleaner components. When element replacement is necessary, order genuine Kohler parts.
TP-6735 9/10
1. Loosen the two cover retaining knobs and remove the cover.
2. Remove the paper element.
3. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element.
Handle new elements carefully; do not use if the sealing surfaces are bent or damaged.
4. When servicing the air cleaner, check the air cleaner base. Make sure it is secured and not bent or damaged. Also, check the element cover for damage or improper fit. Replace all damaged air cleaner components.
Note: If any loose dirt or debris fell on the air cleaner base when the element was removed, carefully remove it and wipe the base clean. Be careful that none of it drops into the intake throat.
5. Reinstall the paper element onto the air cleaner base. Make sure the element is flat and properly seated.
6. Install the air cleaner cover and secure with the two retaining knobs.
2.5 Cooling System
The engine fan draws cooling air through the openings in the sides and end near the battery. The alternator fan draws cooling air through openings on the side walls of the enclosure. The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet. See
Figure 2-11. To prevent generator set damage caused by overheating, keep the housing cooling inlets and outlets clean and unobstructed at all times.
Note: Do not block the generator set cooling air inlets or mount other equipment above them.
Overheating and severe generator damage may occur.
1
1
2
REAR VIEW
1. Air intake
2. Exhaust outlet
Figure 2-11 Cooling Air Intake and Exhaust tp6733
Section 2 Scheduled Maintenance 23
2.6 Stepper Motor Coupling
Replace the stepper motor coupling and bushings at the intervals shown in the service schedule. See the Parts
Catalog for replacement part numbers.
Figure 2-12 shows the location of the coupling assembly under the air cleaner. Loosen the set screw to remove the coupling from the motor shaft.
2.7 Exhaust System
Remove all combustible materials from the exhaust location.
Combustible materials include building materials as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material a minimum of 1.5 m (5 ft.) from the exhaust outlet.
Periodically inspect the exhaust system components for cracks, leaks, and corrosion.
D
Check for corroded or broken metal parts and replace them as needed.
D
Check that the exhaust outlet is clear.
2.8 Battery
WARNING
1
1. Coupling and bushing
Figure 2-12 Stepper Motor Coupling
1
2 tp6518_9
1. Coupling
2. Bushing
Figure 2-13 Stepper Motor Coupling and Bushing tp6519
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and burn skin.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup.
Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
24 Section 2 Scheduled Maintenance TP-6735 9/10
Battery gases.
Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire.
To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
This section contains general battery information and maintenance instructions.
Also consult the battery manufacturer’s instructions for battery maintenance.
All generator set models use a negative ground with a
12-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage.
Consult the generator spec sheet for battery capacity recommendations for replacement purposes.
Wiring diagrams provide battery connection information. See
Figure 2-14 for typical battery connections.
1
2
EZ-273000-J
1. To positive (+) terminal on starter solenoid.
2. To ground (--) terminal on or near starter motor.
Figure 2-14 12-Volt Engine Electrical System Single
Starter Motor, Typical Battery Connection
Clean the battery and cables and tighten battery terminals using the service schedule recommendations.
To prevent corrosion, maintain tight, dry electrical connections at the battery terminals.
To remove corrosion from battery terminals, disconnect the cables from the battery and scrub the terminals with a wire brush. Clean the battery and cables with a solution of baking soda and water. After cleaning, flush the battery and cables with clean water and wipe them with a dry, lint-free cloth.
After reconnecting the battery cables, coat the battery terminals with petroleum jelly, silicone grease, or other nonconductive grease.
2.9 Battery Charger
The generator set is equipped with a battery charger to maintain the engine starting battery. See Section 1.7,
Service Views, for the battery charger location.
The charger’s DC leads are factory-wired. Periodically tighten all connections. See the generator set operation manual for battery charger troubleshooting instructions.
TP-6735 9/10 Section 2 Scheduled Maintenance 25
2.10 Storage Procedure
Perform the following storage procedure before removing the generator set from service for three months or longer. Follow the engine manufacturer’s recommendations for storage, if available.
Note: Run the generator set monthly whenever possible.
2.10.1 Lubricating System
1. Operate the generator set until it reaches operating temperature, or about 15 minutes.
2. Stop the generator set.
3. While the engine is still warm, drain the engine lubrication oil from the engine crankcase.
4. Refill the engine crankcase with oil.
See
Section 2.2.3 for oil recommendations.
5. Run the generator set for a few minutes to distribute the clean oil.
6. Stop the generator set.
2.10.2 Fuel System
1. Start the generator set.
2. With the generator set running, shut off the gas supply.
3. Run the generator set until the engine stops.
4. Press the OFF button on the controller.
2.10.3 Cylinder Lubrication
1. Remove the spark plugs.
2. Pour one tablespoon of engine oil into each spark plug hole. Install the spark plugs and ground the spark plug leads. Do not connect the leads to the plugs.
3. Press RUN and then OFF to crank the engine two or three revolutions to lubricate the cylinders.
2.10.4 Exterior Preparation
1. Clean the exterior surface of the generator set.
2. Seal all openings in the engine with nonabsorbent adhesive tape.
3. Mask all areas to be used for electrical contact.
4. Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion.
2.10.5 Battery
Perform battery storage last.
1. Press the OFF button on the generator set controller.
2. Disconnect the battery, negative (--) lead first.
3. Clean the battery.
4. Place the battery in a warm, dry location.
5. Connect the battery to a float/equalize battery charger, or charge the battery monthly using a trickle charger.
Follow the battery charger manufacturer’s recommendations.
26 Section 2 Scheduled Maintenance TP-6735 9/10
Section 3 Troubleshooting
3.1 Introduction
Corrective action and testing in many cases requires knowledge of electrical systems and electronic circuits.
Have an authorized distributor/dealer or trained service technician perform testing and service.
Refer to the engine service manual for engine service information. See the List of Related Materials for the document part number.
If the troubleshooting procedures in this section identify a failed part, refer to the parts catalog for replacement part numbers. See the List of Related Materials in the
Introduction for the parts catalog number.
3.2 Initial Checks
When troubleshooting, always check for simple problems first.
Check for the following common problems before replacing parts:
D
Loose connections or damaged wiring.
D
Dead battery.
D
Fault shutdown.
Check for a fault code on the controller display. Section 4.8 describes the warning and shutdown fault codes. If a fault code is displayed, identify and correct the cause of the fault condition.
Then reset the controller.
D
Blown fuses. Two controller fuses are located in the controller’s service access area. See Figure 3-1. A battery charger fuse is located in the positive battery lead. Always check for and replace any blown fuses before replacing other components.
Identify and correct the cause of the blown fuse.
See
Section 5.14.2 for fuse part numbers.
D
Incorrect controller settings. Always check the controller configuration settings before replacing the controller. Section 4.11 contains the instructions for checking and changing the controller configuration.
D
Inadequate fuel supply.
Check for damaged primary or secondary fuel regulators, loose connections to the fuel solenoid valve, a damaged or closed fuel shutoff valve, an empty LP fuel tank, or other problems with the fuel supply. Check the fuel supply pressure to the generator set.
Section 5.11, Fuel Systems.
See
3.3 Controller Service Access
The controller fuses and alternator winding circuit breaker are accessible from the front of the controller.
Remove the service access door to reach the circuit breaker and fuses. See Figure 3-1.
Obtain replacement fuses from a Kohler authorized distributor/dealer.
1
2
4
GM62860
3
1. USB port (for computer connection for SiteTech software)
2. Alternator winding circuit breaker
3. Controller fuses F2 and F3
4. Run and crank LEDs
Figure 3-1 Controller Service Access (cover removed)
3.4 Troubleshooting Chart
Use the following table as a reference in troubleshooting individual problems. Generator set faults are listed in groups and include likely causes and remedies. The simplest and most likely causes of the problem are listed first; follow the recommendations in the order shown.
The reference column provides additional sources of information in this and related manuals regarding the problem and solution.
TP-6735 9/10 Section 3 Troubleshooting 27
Problem
Generator set engine does not crank
Possible Cause Test
Battery connections Check for reversed or poor battery connections.
Weak or dead battery
Open circuit in engine/controller connections
Test the battery voltage.
Test battery according to battery manufacturer’s recommendations.
If battery is weak or dead, check the battery charger.
Check battery charger fuse and connections.
Check 120VAC power supply to the charger.
Test charger operation.
Check for loose connections.
Check the wire harness continuity.
Corrective Action
Correct and tighten battery connections.
Recharge or replace battery.
Tighten connections and replace charger fuse if blown.
Connect 120VAC power to charger.
Replace charger if necessary.
Tighten connections.
Replace harness or harness leads if damaged.
Reference
—
O/M
O/M
Section 5.13
Section 7
Blown controller fuse F3
Blown fuse F2
Crank relay K3 on controller circuit board
Use a test lamp or meter to check fuse F3.
Use a test lamp or meter to check fuse F2.
Check connections to the controller.
Check for a good ground connection.
Check the crank LED to verify
12VDC to relay K3.
Replace fuse; if fuse blows again, check circuit and components.
Section 5.14.2
Section 7
Section 5.14.2.
Replace fuse.
If fuse blows again, disconnect the following leads. Reconnect one at a time and attempt to start to identify the cause of the blown fuse:
Lead 70A at the fuel valve
Lead IGN at the ignition module
Lead 71A at the starter relay
Leads FP and FN at the rotor
Repair or replace the component causing the blown fuse.
Section 7
Tighten connections.
Replace wiring if damaged.
Section 4.13
Tighten/repair ground connection.
Section 7
If the Crank LED is not lit, check for 12VDC to the board.
If the Crank LED is lit but relay K3 does not operate, replace the controller circuit board.
Section 7
Section 4.13
W/D = Wiring Diagram(s) (Section 7)
I/M = Generator Set Installation Manual
S/S = Generator Set Specification Sheet
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech software. DC controller settings can only be changed using SiteTech.
28 Section 3 Troubleshooting TP-6735 9/10
Problem
Generator set engine does not crank, continued
Cranks but does not start
Possible Cause
Poor ground (--) connection
Test
Test ground connection.
Corrective Action
Clean and retighten.
Reference
—
Starter relay
Check connections to the starter relay.
Check continuity of circuit.
Tighten connections.
Replace wiring if damaged.
Section 1.7
Section 5.13
Section 7
Check that the starter relay picks up when 12VDC is applied at lead
71A connection.
Check starter connections.
Replace starter relay.
Section 7
Starter Tighten connections.
Replace wiring if damaged.
Section 1.7
Section 7
Controller
No fuel
Troubleshoot the starter. See the engine service manual for instructions.
Check the controller settings.
Test the controller as described in
Section 3.5.
Verify that manual fuel valve is open.
Check fuel supply tank (LP).
Rebuild or replace starter.
Engine S/M
Section 4.11
Section 3.5
Insufficient fuel pressure
Contact fuel supplier to add fuel to fuel supply tank (LP).
Contact fuel supplier to replace fuel supply lines with larger pipe and replace gas meter if fuel pressure is insufficient.
Fuel regulator/valve Check regulator/valve operation.
Check regulator/valve operation.
Section 5.11
Section 4
Spark plugs or spark plug connections
Check fuel pressure to the generator set. Verify adequate fuel pressure and pipe size for the generator set plus all other gas appliances.
Check spark plug wires and connections.
Check spark plugs.
Tighten connections. Replace spark plug wires if damaged.
Replace or clean and regap spark plugs.
Tighten connections.
Replace wiring if damaged.
Section 5.11.3
O/M
Section 7
Loose connection or open circuit
Check for loose or open connection at the fuel valve (lead
70A) and at the engine spark control module (leads IGN and
70A). Check controller/engine wiring continuity.
Air cleaner clogged Check for a dirty air cleaner element.
Magnetic pickup Check for 3.0 volts or higher from the magnetic pickup during cranking. Test magnetic pickup and check gap according to the procedure in Section 5.9.4.
Adjust controller settings.
See Section 3.5.
Open (turn on) manual fuel valve.
Replace air cleaner element.
Check and replace air cleaner element at the intervals shown in the Service Schedule.
Tighten loose connections or replace wiring as necessary.
Adjust magnetic pickup air gap if necessary. Replace mag pickup if necessary after testing.
—
O/M
Section 5.9.4
W/D = Wiring Diagram(s) (Section 7)
I/M = Generator Set Installation Manual
S/S = Generator Set Specification Sheet
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech software. DC controller settings can only be changed using SiteTech.
TP-6735 9/10 Section 3 Troubleshooting 29
Problem
Cranks but does not start, continued
Possible Cause
Incorrect controller configuration
Ignition system spark control or ignition coil
Digital spark advance (DSAI) leads incorrectly connected or disconnected
Test
Check for correct engine configuration parameter (EC).
Test according to instructions in the engine service manual.
Check DSAI leads.
Check for loose connections.
No engine rotation sensed (check for an overcrank fault shutdown)
Check mag pickup. See magnetic pickup, above.
Starts hard
Low battery voltage Check battery voltage during cranking.
Check battery charger connections, power supply, and operation.
Air cleaner clogged Check for a dirty air cleaner element.
Fuel mixture adjustment incorrect
Use oxygen sensor to check fuel mixture.
Starts but shuts down
DSAI leads incorrectly connected or disconnected
Spark plug(s)
Check DSAI connection.
Check spark plug condition and gap.
Spark plug wire(s) Check spark plug wires and connections.
Ignition components (spark control or ignition module)
Insufficient fuel pressure
Test ignition components according to instructions in the engine service manual.
Worn piston rings, valves
Fault shutdown
W/D = Wiring Diagram(s) (Section 7)
I/M = Generator Set Installation Manual
Check fuel pressure to the generator set. Verify adequate fuel pressure and pipe size for the generator set plus all other gas appliances.
Check compression. See the engine service manual.
Check for a fault shutdown code on the controller display. Identify the cause of the fault.
Corrective Action
Enter the correct controller configuration parameters.
Adjust or replace components as indicated in engine service manual.
Connect for natural gas.
Disconnect for LP.
Tighten connections.
Replace wiring if damaged.
See magnetic pickup, above.
Charge battery. Replace battery if necessary.
Tighten loose connections.
Replace element.
Adjust fuel mixture.
Connect for natural gas.
Disconnect for LP.
Replace or regap spark plug(s).
Tighten connections. Replace spark plug wires if damaged.
Replace ignition components if necessary.
Contact fuel supplier to replace fuel supply lines with larger pipe and replace gas meter if fuel pressure is insufficient.
See engine service manual.
Correct the fault and then press the controller’s OFF button to reset the controller.
S/S = Generator Set Specification Sheet
Engine S/M = Engine Service Manual
Reference
Section 4.11
Engine S/M
Section 5.11.2
Section 5.9.4
O/M
O/M
Section 5.11
Section 5.11.2
O/M
Engine S/M
Engine S/M
Section 5.11.3
Engine S/M
Section 5.10
O/M = Generator Set Operation Manual
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech software. DC controller settings can only be changed using SiteTech.
30 Section 3 Troubleshooting TP-6735 9/10
Problem
Stops suddenly
Possible Cause
Fault shutdown
No fuel
Test
Check for a fault shutdown code on the controller display. Identify the cause of the fault.
Corrective Action
Correct the fault and then press the controller’s OFF button to reset the controller.
Check fuel valves and fuel supply. Open manual fuel valve. Contact fuel supplier to replenish fuel supply.
Fuel line restriction Inspect fuel lines.
Fuel lines too long Check fuel line length and pipe size.
Clear restriction.
Contact fuel supplier to replace fuel lines with larger pipe.
Replace air cleaner element.
Air cleaner clogged Check for a dirty air cleaner element.
Blown fuse Check fuses F2 and F3 on the controller.
Spark plug(s)
Engine overheated
(hot engine only)
Check spark plug(s).
Check air intake and generator set enclosure air inlets and outlet.
Use oxygen sensor to check fuel mixture.
Check oil level.
Replace fuse. If fuse blows again, test generator components.
Replace or regap plug(s).
Clear air intake and enclosure air inlets and outlets.
Adjust fuel mixture.
Low oil pressure
(LOP) switch
Fuel valve/fuel regulator
Check oil pressure.
Attempt startup. If unit shuts down, remove lead from LOP switch and reset controller. A successful restart attempt indicates a faulty LOP shutdown switch.
Note: Check engine oil pressure before performing test and/or replacing LOP shutdown switch.
Check fuel valve connections.
Check regulator/valve operation.
Check fuel pressure.
Add oil. Check and replace oil at the intervals shown in the Service
Schedule.
See engine S/M.
Replace faulty LOP shutdown switch.
Note: Check engine oil pressure before performing test and/or replacing LOP shutdown switch.
Tighten fuel valve connections.
Replace damaged wires.
Replace regulator or valve .
Engine overloaded Reduce electrical load and check operation.
Magnetic pickup connections
Ignition module
Check for loose connections to the mag pickup.
Loss of generator output voltage to controller
Test the ignition system according to the instructions in the engine service manual.
Check connections at P2 plug.
Check continuity of AC sensing leads 11 and 44 (1 ph) or V7, V8, and V9 (3 ph).
See Section 5 for alternator test procedures.
Unplug some lights or appliances connected to the generator set.
Tighten connections to the mag pickup. Replace damaged wiring.
Service the ignition system according to the instructions in the engine service manual.
Tighten connections at P2 plug.
Replace wiring if damaged.
Repair or replace components if necessary, as indicated by tests in Section 5.
Overheats Inadequate cooling Inspect engine and enclosure for air intake obstructions.
Fuel mixture adjustment incorrect
Use an oxygen sensor to check the fuel mixture.
Readjust fuel mixture.
Note: Adjusting the fuel mixture may void the emission certification.
Reference
Section 4.8
Section 5.10
—
—
Generator set
S/S, I/M
O/M
Section 5.14.2
O/M
O/M
Section 5.11
O/M
Engine S/M
Section 5.10.2
Section 5.11
—
Section 5.9
Engine S/M
Section 7
Section 5.3
Section 5
Clear any air intake obstructions.
O/M
Section 5.11
W/D = Wiring Diagram(s) (Section 7)
I/M = Generator Set Installation Manual
S/S = Generator Set Specification Sheet
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech software. DC controller settings can only be changed using SiteTech.
TP-6735 9/10 Section 3 Troubleshooting 31
Problem
Noisy operation
Erratic operation
Light flicker
Possible Cause
Exhaust system leaks
Test
Check silencer and connections for leaks.
Corrective Action
Replace gaskets and exhaust system components as necessary.
Reference
—
See “Erratic operation,” this table.
See “Erratic operation,” this table.
— Engine not running smoothly
Broken or damaged vibromount(s)
Inspect vibromounts.
Loose or vibrating sheet metal/housing
Check for loose screws and rivets.
Exhaust piping or air inlets/outlets not securely installed
Excessive engine/generator vibration
Inspect for loose parts.
Check rotor, crankshaft, bearing, etc. (disassembly of engine and/or alternator may be required).
Air cleaner clogged Check air filter element.
Spark plug(s) Check spark plug condition and gap.
Spark plug wire(s) Check spark plug connections and wires.
DSAM leads incorrectly connected or disconnected
Check DSAM/DSAI lead connection.
Fuel line restriction Check fuel lines.
Check fuel pipe size.
Use oxygen sensor to check fuel mixture.
Replace as necessary.
Retighten screws, replace rivets.
Secure loose parts as necessary.
Check, rotor, crankshaft, bearing, etc. (disassembly of engine and/or alternator may be required).
Replace element.
Replace or regap plugs.
Tighten connections. Replace damaged spark plug wires.
Connect for natural gas.
Disconnect for LP.
Clear restricted fuel lines.
Contact fuel supplier to install larger diameter pipe.
Adjust fuel mixture.
Section 6
—
—
Section 6
Engine S/M
O/M
O/M
Engine S/M
Section 5.11.2
Section 5.11.3
Section 5.11
Fuel mixture adjustment incorrect
Magnetic pickup connections
Governor adjustment incorrect
Ignition system
Check for loose connections to the mag pickup.
Check governor operation.
Check controller engine speed
(frequency) adjustment. *
Test ignition system according to instructions in engine service manual.
Check air inlet and outlet.
Tighten mag pickup connections.
Replace damaged wiring.
Adjust governor.
Adjust controller engine speed. *
Service ignition system according to instructions in engine service manual.
Clear air inlet and outlet.
Section 5.9
Section 5.9
Section 4.11 and
Installation Man.
Engine S/M
— Inadequate cooling
(hot engine only)
Other engine service required
Voltage stability
(gain) setting
See engine service manual.
Check the voltage stability (gain) setting using the RDC controller. *
Service according to instructions in engine service manual.
Adjust the voltage stability (gain) setting using the RDC controller. *
Engine S/M
Section 4.11.5
W/D = Wiring Diagram(s) (Section 7)
I/M = Generator Set Installation Manual
S/S = Generator Set Specification Sheet
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech software. DC controller settings can only be changed using SiteTech.
32 Section 3 Troubleshooting TP-6735 9/10
Problem
High output voltage
Lacks power
Possible Cause
Incorrect controller configuration
Incorrect controller voltage settings
Loose voltage sensing connections
Controller
Test
Check the controller configuration parameters. *
Check the controller voltage settings. *
Check connections: stator leads 11 and 44 and
P2 controller connection.
Check the controller settings.
Air intake restriction, inadequate cooling
Generator overloaded
Test the controller as described in
Section 3.5.
Inspect air intakes and exhaust for obstructions.
Check air cleaner.
Reduce electrical load and check operation.
Spark plug(s) Check spark plugs.
Spark plug wire(s) Check tightness and condition of spark plug wires.
DSAI leads incorrectly connected or disconnected
Insufficient fuel pressure
Fuel line restriction
Fuel regulator
Engine not running at rated rpm
Governor malfunction or misadjustment
Ignition system
Check DSAI leads. Connect for natural gas. Disconnect for LP.
Check fuel pressure at carburetor outlet. Check for adequate fuel pipe size and meter capacity for generator set and all gas-fired appliances.
Check fuel pipe size.
Corrective Action
Adjust the controller configuration parameters. *
Adjust the controller voltage settings. *
Tighten connections.
Adjust controller settings.
See Section 3.5.
Inspect air intakes and exhaust for obstructions.
Check air cleaner.
Unplug some lights or appliances connected to the generator set.
Check function of fuel regulator.
Repair or replace fuel regulator.
Check controller setting for engine type (EC). *
Check engine speed.
Reset controller setting for engine type (EC). *
Adjust engine speed.
Engine power loss Refer to the engine service manual for troubleshooting and repair instructions.
Test governor.
See the engine service manual for service procedures.
Regap and/or replace plug(s).
Tighten or replace spark plug wires.
Connect for natural gas.
Disconnect for LP.
Contact fuel supplier to replace pipe and/or meter as required to provide sufficient fuel supply pressure for the generator set and all gas-fired appliances.
Contact fuel supplier to provide larger pipe.
Refer to the engine service manual for troubleshooting and repair instructions.
Adjust governor.
See the engine service manual for service procedures.
Reference
Section 4.11.2
Section 4.11.5
Section 7 W/D
Section 4.11
Section 3.5
O/M
O/M
—
O/M
Engine S/M
Section 5.11.2
Section 5.11
Section 5.11
Section 5.11
Section 4.11
Engine S/M
Section 5.9
Engine S/M
W/D = Wiring Diagram(s) (Section 7)
I/M = Generator Set Installation Manual
S/S = Generator Set Specification Sheet
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech software. DC controller settings can only be changed using SiteTech.
TP-6735 9/10 Section 3 Troubleshooting 33
Problem
Low output or excessive drop in voltage
Possible Cause
Generator overloaded
Incorrect controller configuration
Incorrect controller voltage settings
Alternator or control system
Controller
Rotor
Stator
Brush connection
Low engine speed causing voltage roll-off
Test
Reduce electrical load and check operation.
Check the controller configuration parameters. *
Check the controller voltage settings. *
Perform separate excitation procedure to isolate problem to the alternator or the control system.
Check the controller settings.
Test the controller as described in
Section 3.5.
Test rotor for open, grounded, or shorted windings.
Test stator for open, grounded, or shorted windings.
Check for loose brush connections.
Check for loose brush mounting.
Check the resistance through the brushes. Resistance through the brushes should be low, 0.1--0.2
ohms without meter lead resistance.
Check system voltage/frequency
(Uu) and engine type (Ec) parameters. *
Check engine speed.
Engine problem.
Corrective Action
Unplug some lights or appliances connected to the generator set.
Adjust the controller configuration parameters. *
Adjust the controller voltage settings. *
Troubleshoot the alternator or control system as indicated by test results.
Adjust controller settings.
See Section 3.5.
Replace rotor if faulty windings are found.
Replace stator if faulty windings are found.
Tighten loose brush connections.
Tighten mounting screws.
Replace brushes if they show uneven wear or are worn to one-half their original length.
Change system voltage/frequency
(Uu) and engine type (Ec) parameters if not correct. *
Adjust engine speed.
Troubleshoot the engine.
Reference
—
Section 4.11
Section 4.11.5
Section 5.2
Section 4.11
Section 3.5
Section 5.4
Section 5.3
Section 5.6
Section 4.11.2
Section 4.11.5
Engine S/M
W/D = Wiring Diagram(s) (Section 7)
I/M = Generator Set Installation Manual
S/S = Generator Set Specification Sheet
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech software. DC controller settings can only be changed using SiteTech.
34 Section 3 Troubleshooting TP-6735 9/10
Problem
No output voltage
Possible Cause
AC output circuit breaker open
Alternator or control system
Blown fuse
Controller
Test
Check for AC voltage on the generator side of circuit breaker.
If there is AC voltage on the generator side of the breaker, then a problem in the load circuits is causing the line circuit breaker to trip.
Perform separate excitation procedure to isolate the problem to the alternator or the control system.
Check fuse F2.
Check the controller settings.
Test the controller as described in
Section 3.5.
Check fuses and wiring.
Corrective Action
Check for and correct short circuits or overloading on the load side before resetting the circuit breaker.
Troubleshoot the alternator or control system components as described below and elsewhere in this table.
Replace fuse F2.
Adjust controller settings.
See Section 3.5.
Reference
—
Section 5.2
Section 5.14.2
Section 4.11
Section 3.5
Open wiring, terminal, or pin in buildup circuit
Brushes
Replace fuses or wiring as necessary.
Section 5.14.2
Section 7 W/D
Inspect brushes.
Check for brushes sticking in brush holder or broken brush spring.
Check that brush holder is securely mounted.
Check slip ring condition.
Replace brushes if worn.
Replace brush spring or brush assembly.
Tighten brush holder screws.
Section 5.6
Section 5.6
Section 5.6
Rotor slip rings dirty or corroded
Rotor (open, grounded, or shorted windings)
Stator (open, grounded, or shorted windings)
Aux. winding circuit breaker tripped
Check voltage and continuity as described in Section 5.4.
Check voltage and continuity as described in Section 5.3.
Clean slip rings as described in
Section 5.5. Machine slip rings if necessary.
Repair or replace rotor if indicated by the tests.
Repair or replace the stator if indicated by the test results.
Section 5.5
Section 5.4
Section 5.3
W/D = Wiring Diagram(s) (Section 7)
I/M = Generator Set Installation Manual
Check the breaker in the service access area of the controller.
If breaker trips again, check stator.
Reset breaker.
If breaker trips again, check stator.
S/S = Generator Set Specification Sheet
Engine S/M = Engine Service Manual
Figure 3-1
Section 5.3
O/M = Generator Set Operation Manual
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech software. DC controller settings can only be changed using SiteTech.
TP-6735 9/10 Section 3 Troubleshooting 35
3.5 Controller Troubleshooting
Refer to the controller troubleshooting table in this section when troubleshooting procedures in Section 3.4
indicate a possible controller problem. Always check the controller configuration settings before replacing the controller.
The RDC controller settings can be checked and adjusted through the controller user interface or using a personal computer and Kohler r SiteTecht software.
The generator set installation manual contains the instructions for checking and changing the controller configuration. The DC controller settings can only be changed using SiteTech t. See TP-6701, SiteTech
Software Operation Manual.
Kohler r SiteTecht software is available to authorized distributors and dealers.
Also check the controller display for fault codes and refer to Section 4.8, Faults.
The following RDC/DC controller functions require connection to a Kohler r Model RRT automatic transfer switch.
D
Utility voltage display on the RDC or DC controller
D
Automatic exercise initiated using the RDC down arrow button or the DC Exercise button, loaded or unloaded
D
Ultra-quiet diagnostic test
D
Loaded test initiated from the RDC or DC controller
D
Engine cooldown
D
Load control
D
Automatic generator set startup and load transfer when utility power is lost (also available with other
Kohler model transfer switches connected to engine start leads 3 and 4)
Check the connection to the Model RRT transfer switch when troubleshooting problems with the functions listed above. See Section 4.10 for more information about these operations. See Section 4.10.6 for connections.
Test
Check controller settings. *
Corrective Action
Adjust controller settings as required. *
Reference
Section 4.11
Check for power to the controller at lead P
(connection P1--1).
Check controller fuse F3.
Check controller fuse F2.
Check/replace fuse F3. If fuse blows again, check the wiring harness for shorts to ground.
Check connections and wiring. Tighten connections and repair/replace wiring as needed.
Check battery and battery charger.
Replace controller fuse. If fuse blows again, check the wiring harness for shorts to ground.
If fuse F3 blows repeatedly in RUN mode, check the stepper motor.
Replace controller fuse. If fuse blows repeatedly, check the components listed in Section 4.13.2.
Section 5.14.2
Wiring diagrams,
Section 7
Installation manual.
Section 5.14.2
Section 7
Section 5.9.2
Section 4.13.2
Check controller wiring and connections.
Tighten connections and/or replace wiring.
Wiring diagrams,
Section 7
Section 4.13
Check RUN and CRANK LEDs and relays.
See Section 4.13 for instructions.
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech software. DC controller settings can only be changed using SiteTech. See TP-6701, SiteTech Software Operation Manual.
Figure 3-2 Controller Troubleshooting
36 Section 3 Troubleshooting TP-6735 9/10
Section 4 Controller
4.1 Introduction
This section covers operation, configuration, adjustment, and replacement of the RDC and DC controllers.
procedures.
See Section 3 for troubleshooting
See the service view and Figure 4-1 for the controller location.
1
4.2 RDC and DC Generator Set/
Transfer Switch Controllers
The Residential Digital Control (RDC) and Digital
Control (DC) control the power system generator set and Model RRT automatic transfer switch (ATS) (if equipped). The controller receives voltage sensing data from the ATS and operates the generator set and transfer switch to provide standby power when utility power is lost.
If the generator set is not connected to a Kohler r Model
RRT ATS, the RDC/DC controller functions as a generator set controller only. ATS communication and functions do not operate with other ATS models. The ultra-quiet diagnostic test/exercise is not available with other ATS models.
4.3 Controller Power
The RDC and DC controllers are powered by the generator set engine starting battery.
Note: The generator sets are equipped with factoryinstalled battery chargers to prevent battery discharge.
The battery charger must be connected to utility power.
1. Controller
Figure 4-1 Controller Location
TP-6735 9/10 Section 4 Controller 37
4.4 Controls and Indicators
Figure 4-2 illustrates the RDC and DC controller user interfaces.
1
2
3
4
9
8
7
6
Residential Digital Controller (RDC)
1. LED display
2. Up button (RDC only)
3. Select button (RDC only)
4. Down/Exercise button (RDC)
5. Exercise button (DC)
Figure 4-2 RDC and DC Controls and Indicators
1
9
8
7
Digital Controller (DC)
6. Service access (see Section 3.3)
7. RUN button and LED
8. AUTO button and LED
9. OFF button and LED
5
6
38 Section 4 Controller TP-6735 9/10
4.4.1
LED Display
When the system is in AUTO and the generator set is not running, the LED display shows the engine run time hours. During cranking, the display shows the crank cycle information.
When the generator is running, the display steps through the status messages shown in Figure 4-3, as applicable. The generator set must be connected to a
Model RRT transfer switch for the utility voltage display.
When a fault or warning condition exists, the controller will show the respective message. The following table shows the various generator conditions and expected display or messages.
Test or exercise mode, if applicable.
tnLd, t LD, EnLd, or E Ld
Engine Runtime
XXX.X or XXXX hours
Battery Voltage bXX.X VDC
Engine Temperature tXXX
Utility Voltage
UXXX VAC
Generator Voltage
EXXX VAC tp6734
D Generator set is running.
D Model RRT transfer switch is required for utility voltage display.
D Display steps through the parameters in sequence for
2 seconds each.
Figure 4-3 Data Displays, Generator Running
Display
Blank (dark) u#.#
XXX.X
XXXX bXX.X
tXXX
UXXX
EXXX tnLd t Ld
EnLd
E Ld
CC1, 2, or 3
Fault code
Description
Controller is off.
Controller software version number
Engine hours to 999.9
Engine hours, 1000 to 9999
Battery voltage
Engine temperature
Utility voltage
Generator voltage
Test, no load
Test, loaded
Exercise, no load
Exercise, loaded
Engine crank cycle 1, 2, or 3. Flashes during crank pause.
Warning or fault. See Figure 4-7.
Figure 4-4 RDC Controller Display
4.4.2
Controller Keypad
The Run, Off, Auto, and Down arrow or Exercise buttons control the generator set as described in Figure 4-5.
See Section 4.5 for operation instructions.
RDC controller (RES models) only: The Select, Up, and Down buttons on the controller keypad are used to adjust the controller parameters.
The system configuration and performance is factory-set and should not require changes under normal operating conditions.
To prevent inadvertent changes, a pass code is required to access the controller parameter settings. See the generator set Installation Manual for controller configuration instructions.
See Section 5.8 of this manual for performance adjustment instructions.
For the DC controller (RESL models), a personal computer with Kohler r SiteTecht software is required for system configuration changes and performance adjustment.
TP-6735 9/10 Section 4 Controller 39
Button
Press
OFF
AUTO
RUN
DOWN arrow/
EXERCISE
Select and
UP Arrow
Buttons
(RDC only)
Response in AUTO or OFF Mode
Stops the generator set and places the controller in OFF mode. The
OFF LED turns ON and then flashes every 2 seconds.
Pressing OFF during the engine crank cycle will stop the crank cycle.
If a fault code is displayed, pressing OFF resets the controller.
Press and hold the OFF button for
3 seconds to view the event history.
Places the controller in AUTO mode. AUTO LED turns ON.
Generator set will respond to remote start/stop signals.
Response during EXERCISE
Immediately ends the exercise and shuts down the generator. The engine cooldown time delay is ignored. The AUTO LED turns
OFF. The OFF LED turns ON and then flashes every 2 seconds.
Response during TEST
Immediately ends the test and shuts down the generator. The engine cooldown time delay is ignored. The RUN LED turns OFF.
The OFF LED turns ON and then flashes every 2 seconds.
Shuts down the engine through normal timing sequences and goes to the AUTO mode. AUTO LED turns ON. RUN LED turns OFF.
Shuts down the engine through normal timing sequences and goes to the AUTO mode. AUTO LED turns ON. RUN LED turns OFF.
Starts the generator set in unloaded test mode. The generator set starts and the display indicates an unloaded test, tnLd.
RUN LED turns on.
From AUTO mode: Press once to start an unloaded exercise. The engine starts and EnLd appears on the display.
From OFF mode: No effect.
Ends the exercise time period but does not shut down the generator set. Engine ramps up to normal operating speed of 3600 RPM.
RUN LED turns on, and AUTO LED turns off. Generator continues to run in test mode until stopped by the OFF or AUTO buttons.
Press during an unloaded exercise to change to a loaded exercise.
Engine ramps up to normal operating speed and the ATS transfers to the emergency source.
Display changes to indicate a loaded exercise, E Ld. Future exercise periods will be loaded and will start at the time of the first button press.
Pressing this button again during a loaded exercise run has no effect.
No effect when a test is already running.
Press during an unloaded test to change to a loaded test, causing the ATS to transfer to the emergency source. The display indicates a loaded test, t Ld.
Used for RDC controller configuration and performance adjustment. See the generator set installation manual and Section 5.8 of this manual.
Figure 4-5 Controller Pushbutton Operation
4.4.3
LED Indicators
LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 4-6.
Mode
RUN
OFF
LED Indication
RUN LED is on
OFF LED lights for 2 seconds, then flashes every 2 seconds.
AUTO LED is on
Description
The generator set was started by pressing the RUN button. Generator set is running. Remote start and stop commands are ignored.
The OFF button was pressed. Generator set and controller are off. Remote start/stop commands have no effect.
AUTO Automatic mode. Generator set will respond to engine start and stop commands from an ATS or from Kohler r SiteTecht software. Time delays operate as described in Section 4.5.
Figure 4-6 Operation Modes and LED Indicators
40 Section 4 Controller TP-6735 9/10
4.5 Generator Set Operation
4.5.1
Engine Start Crank Cycle
The controller attempts to start the generator set three times (three crank cycles, 15 seconds crank and
15 seconds off). See Figure 4-4 for display information during the crank cycle. If the generator set does not start in three attempts, the system shuts down on an overcrank fault. See Section 4.8.
Pressing the OFF button during the crank cycle stops the cranking.
No other buttons are acknowledged during the crank cycle.
4.5.2
Local Starting and Stopping
Start
Press the RUN button to immediately start the generator set. The engine start time delay will be ignored.
The controller attempts to start the generator set three times.
If the generator set does not start in three attempts, the system shuts down on an overcrank fault.
See Section 4.8.
Stop
1. Run the generator set with no load for at least
2 minutes to ensure adequate engine cooldown.
2. Press the OFF button. The engine stops.
4.5.3
Automatic Operation with Model
RRT Transfer Switch
The Model RRT transfer switch connects to the RDC/DC controller through the ATS interface board on the transfer switch.
Also see Section 4.10, Model RRT
Transfer Switch Operation.
The controller must be in AUTO mode. Press the AUTO button to put the controller into automatic mode.
Automatic Start
The RDC/DC controller receives utility source voltage sensing data from the Model RRT transfer switch.
1. If the utility source voltage falls below an acceptable level, the controller starts the engine start time delay.
2. If the utility source is not restored before the time delay expires, the generator set starts.
3. After the Normal-to-Emergency time delay, the
ATS is signaled to transfer the load to the emergency source.
Automatic Stop with Engine Cooldown
1. When the utility source is restored, the
Emergency-to-Normal time delay starts.
2. When the Emergency-to-Normal time delay expires, the load is transferred to the utility.
3. The controller runs the generator set for the cooldown time and then stops the generator set.
4.5.4
Automatic Operation with Model
RDT or RSB Transfer Switches
If a Kohler r Model RDT or RSB transfer switch is used, the engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator set.
The controller must be in AUTO mode to respond to remote start/stop signals from an ATS or remote switch.
Press the AUTO button to put the controller into automatic mode.
Automatic Start
The engine start contacts on the ATS close to signal the generator set to start, and remain closed while the generator set is running.
Automatic Stop
Open the contact across engine start leads 3 and 4 to signal the generator set to stop.
TP-6735 9/10 Section 4 Controller 41
4.6 Exercise
Note: A Kohler r Model RRT transfer switch is required for operation of the automatic exercise function on the RDC and DC controllers.
A power system that includes a Model RES or RESL generator set and a Model RRT transfer switch can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly is required in order to keep the engine and alternator in good operating condition.
Follow the instructions in this section to start a 20-minute exercise run and set the exerciser to run at the same time every 7 days.
Figure 4-5 summarizes the operation of the controller buttons.
Other transfer switches: If a transfer switch other than the Model RRT is used with the generator set, refer to the instructions provided with the transfer switch to set the exerciser.
4.6.1
Unloaded Exercise with
Diagnostic Test
An unloaded exercise runs the generator set without signaling the transfer switch to transfer the electrical load from the utility source to the generator set. To start an unloaded, ultra-quiet diagnostic test, the control must be in the AUTO mode with the AUTO LED ON and the
Utility power available.
1. Press the down arrow button (RDC) or exercise button (DC) to initiate the engine start signal.
2. The generator begins its crank cycles. During the crank cycles CCn appears on the display. No button presses are acknowledged during the crank cycles.
3. EnLd appears on the display once the generator is running. The generator runs at low speed. The
AUTO LED will be illuminated.
The controller monitors the system during the unloaded exercise as described in Section 4.6.2, Low Speed
Diagnostics.
4. The generator runs at low speed for 20 minutes and then shuts down.
Note: If the engine temperature has risen to 104
_C
(219
_F) or higher, the unit will run at full speed for 5 minutes to allow engine cooldown before shutting down.
The exercise time is set to the time the down arrow or exercise button was pressed. An unloaded, ultra-quiet diagnostic test will occur at the same time every seven days.
4.6.2
Low-Speed Diagnostics
During the unloaded diagnostic test, the controller monitors the following data.
The controller display indicates an unloaded exercise run (EnLd) during the diagnostics, unless a fault is detected as described below.
D
Battery voltage. If the controller detects low battery voltage, a low battery warning is indicated and the exercise does not start.
D
Generator output frequency and voltage.
The controller verifies that the voltage and frequency are within acceptable limits for the run speed.
D
ATS connection. The controller verifies that the ATS interface board, if connected, remains connected. An
ATS Communication Lost fault will be displayed if the connection is lost.
D
Oil pressure. The controller verifies the engine oil pressure during low speed operation.
4.6.3
Loaded Exercise
A loaded test or exercise starts the generator set and then transfers the electrical load from the utility source to the generator set. The load is transferred back to the utility source before the generator set shuts down.
To start a loaded full-speed exercise, the control must be in the AUTO mode with the AUTO LED on and utility power must be available.
1. Press the down arrow button (RDC) or the exercise button (DC) to initiate the engine start signal.
2. The generator begins its crank cycles. During the crank cycles CCn appears on the display. No button presses are acknowledged during the crank cycles.
3. EnLd appears on the display once the generator is running. The AUTO LED will be illuminated. The generator is running at low speed with no load.
4. Press the down arrow button (RDC) or exercise button (DC) a second time. The generator ramps up to normal operating speed (typically 3600 RPM) and the ATS transfers the load.
5. E Ld appears on the display. The AUTO LED is illuminated.
The generator runs at normal operating speed for twenty minutes with load.
42 Section 4 Controller TP-6735 9/10
6. After 20 minutes, the ATS transfers the load back to utility power. The engine runs for the cooldown cycle and then shuts down.
The exercise time is set to the time the down arrow button (RDC) or exercise button (DC) was initially pressed. A loaded, full-speed exercise will occur at the same time every seven days.
4.6.4
Exerciser Reset and Disable
To reset the exerciser to run at a different day and/or time, or to switch between a loaded and unloaded exercise, follow the procedures above to start an unloaded or loaded exercise on the desired time and day. The previous exercise setting is replaced by the new time, day, and loaded or unloaded condition.
To disable the exerciser, press and hold the OFF and
DOWN arrow or EXERCISE buttons together for
3 seconds.
4.6.5
Power Failure During Exercise
Cycle
If the utility power is lost during an unloaded exercise, the ATS transfers to the emergency source, the exercise is ended and the control remains in the AUTO mode.
If the utility power is lost during a loaded exercise, the exercise is ended. The ATS remains in the emergency position and the control goes into the AUTO mode.
When utility power is restored, the ATS will re-transfer to the utility source through normal timing sequences.
4.7 Test
An operator can use the buttons on the RDC/DC controller to test the generator set and transfer switch
(Model RRT only) operation at any time. Unlike the exercise function, a test does not start or stop automatically.
The operator must use the RDC/DC controller to start and stop the test.
Follow the instructions below to run an unloaded or loaded test.
4.7.1
Unloaded Test
An unloaded test runs the generator set without signaling the transfer switch to transfer the electrical load from the utility source to the generator set.
Unloaded Test Procedure
1. Press the RUN button to start an unloaded test.
The engine cranks and starts.
Note: Pressing the OFF button during the crank cycle stops the cranking. No other buttons are acknowledged during the crank cycle.
2. tnLd appears on the display once the generator is running. The RUN LED is illuminated. The engine runs at normal operating speed (3600 RPM) during the test sequence.
3. To end the test, press the AUTO button to shut down the generator set and enter AUTO mode.
Ending an Unloaded Test
There are two ways to end an unloaded test:
D
Press the AUTO button to shut down the generator set and enter AUTO mode.
D
Press the OFF button to shut down the generator set immediately. The cooldown time delay is ignored.
Figure 4-5 describes the effect of pressing the buttons during a test when there are no active faults.
TP-6735 9/10 Section 4 Controller 43
4.7.2
Loaded Test
A loaded test starts the generator set and then signals the Model RRT transfer switch to transfer the electrical load from the utility source to the generator set. The load is transferred back to the utility source before the generator set shuts down.
Loaded Test Procedure
1. Press the RUN button to start an unloaded test as described in Section 4.7.1. tnLd appears on the display once the generator is running.
2. Press the down arrow button (RDC) or the exercise button (DC) to signal the ATS to transfer the load.
The display indicates a loaded test, t Ld.
3. To end the test, press the AUTO button to shut down the generator set through normal timing sequences.
The engine cooldown cycle runs before the generator set engine stops.
The generator set goes into Auto mode.
Immediate Shutdown During a Loaded Test
Press the OFF button to shut the generator set down immediately, if necessary. The cooldown time delay is ignored, and the controller goes to OFF mode. The controller signals the RRT transfer switch to transfer the load back to utility power.
Note: Running the generator set with no load for at least
2 minutes is recommended to ensure adequate engine cooldown. Use the OFF button to stop a loaded test only if necessary.
4.7.3
Power Failure During Test Cycle
If the utility power is lost during an unloaded test, the
ATS transfers to the emergency source and the test is ended. The control goes into the AUTO mode.
If the utility power is lost during a loaded test, the test is ended and the ATS remains in the emergency position.
The control goes into the AUTO mode.
When utility power is restored, the ATS re-transfers to the utility source through normal timing sequences.
44 Section 4 Controller TP-6735 9/10
4.8 Faults
Fault codes and conditions are shown in the table on the following pages, Figure 4-7.
Fault conditions are classified as warnings or shutdowns.
4.8.1
Warnings
The controller displays a fault code but the generator set does not shut down on a warning. The controller resets automatically after a warning condition is corrected.
4.8.2
Shutdowns
Under a fault shutdown condition, the generator set shuts down automatically and the controller displays a fault code. In some cases, the engine cooldown cycle runs before the engine shuts down.
Shutdown switches (such as the low oil pressure switch or high engine temperature switch) on the generator set will automatically reset when the problem is corrected.
However, the fault condition at the controller does not clear until the controller is reset.
The generator set cannot be restarted until the fault condition is corrected and the controller is reset. See
Section 4.8.4 to reset the controller after a fault shutdown.
4.8.3
ATS Communication Errors
An ATS fault can be caused by the following conditions.
D
When a Model RRT transfer switch is used, an ATS fault indicates that communication with the interface board on the transfer switch has been lost.
The generator set shuts down. Check the connection to the ATS interface board.
D
When a Model RDT or RSB transfer switch is used, an ATS fault indicates that connection to the ATS interface board is detected when it is not expected. A warning is displayed but the generator set does not shut down.
If an RDT or RSB transfer switch is replaced with a
Model RRT ATS, disconnect and then reconnect power to the controller to cause the controller to recognize and establish communication with the new ATS.
4.8.4
Resetting the Controller after a
Fault Shutdown
Always identify and correct the cause of a fault shutdown before resetting the controller. Check the fault code displayed on the controller and refer to
Figure 4-7 to identify and correct the fault condition before proceeding.
Contact an authorized distributor/dealer for service, if necessary.
Procedure to Reset the Controller after a Fault
Shutdown
1. Press OFF to turn off the generator set.
2. Disconnect the generator set from the load using the line circuit breaker or ATS. See the safety precautions at the beginning of this manual before proceeding.
3. Identify and correct the cause of the fault shutdown.
See the safety precautions at the beginning of this manual before proceeding. Refer to Section 3, Troubleshooting.
4. Start the generator set by pressing RUN. Check the generator set operation to verify that the cause of the shutdown has been corrected.
5. Press the OFF button to stop the generator set.
6. Reconnect the generator set to the load using the line circuit breaker or ATS.
7. Press AUTO to put the generator set into automatic mode.
TP-6735 9/10 Section 4 Controller 45
Code Fault
AF
HE
LOP
OC
Lr
OF
OS
US
Auxiliary fault input
High engine temperature
Low oil pressure
Overcrank
Locked rotor
Over frequency
Overspeed
Underspeed
W or SD* Condition
SD
[
An optional customer-connected input is closed.
W or SD
[
Engine coolant temperature exceeds the maximum temperature for more than
5 seconds. Function becomes active after crank disconnect.
Warning at 300
_ F.
Shutdown at 325
_ F.
SD
[
The LOP switch indicates low oil pressure for more than
5 seconds. Function becomes active 30 seconds after crank disconnect (30 second inhibit).
Note: The low oil pressure shutdown does not protect against low oil level. Check the engine oil level regularly as recommended in the O/M.
SD Three unsuccessful starting attempts.
SD
SD
SD
[
[
No engine rotation is sensed during cranking. Shuts down 3 seconds after the fault is detected.
Governed frequency exceeds
110% of the system’s frequency setpoint for more than 5 seconds. Function becomes active 10 seconds after engine start (10 second inhibit).
Check
Check customer-supplied equipment.
Check for blocked air inlets and exhaust outlets.
Check for leaks in the lubrication system.
Check the oil level and add oil if the level is low.
Check low oil pressure switch connections and operation.
Check the oil pump and lubrication system.
Check the fuel supply valves and pressure.
Check spark plug and battery.
See Troubleshooting Chart, generator set cranks but does not start.
Check mag pickup connections and operation.
Check for a locked rotor.
Check system frequency setting
(parameter UU) on controller.
Measure output frequency and adjust, if necessary.
Check governor system condition and operation.
Check governor settings and operation.
SD
[
Engine speed exceeds 115% of the normal running speed for more than 0.3 seconds.
Engine speed drops below 85% of the normal running speed for more than 0.3 seconds.
Reduce the load.
Check for throttle linkage obstruction.
Check for a loose or disconnected governor stepper motor harness.
Check for bad leads in the harness.
Check the stepper motor operation.
See Section
—
1.7
—
O/M
5.10
Engine S/M
5.11
O/M
3.4
5.9.4
5.4
4.11
5.9.5
5.9
5.9
—
5.9.2
5.9.2
5.9.2
5.9.4
* W = Warning; SD = Shutdown
[ Engine cooldown runs before shutting down.
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
46 Section 4 Controller TP-6735 9/10
Code
OU
UF
UU
Hb
Lb
Fault
Overvoltage
Underfrequency
Under voltage
High battery voltage
Low battery voltage
W or SD*
SD
SD
SD
W
W
[
[
[
SS Speed sensor failure
SD
* W = Warning; SD = Shutdown
[ Engine cooldown runs before shutting down.
Condition
Output voltage exceeds 120% of the system nominal voltage for more than 2 seconds.
Check
Check output voltage and adjust, if necessary (parameter 1P, voltage adjust).
Check controller settings for system voltage (Parameter Uu).
Check the calibration (SiteTech software required). Controller firmware version 2.04 or higher is required for calibration.
Governed frequency falls below
90% of the system frequency setting for more than 5 seconds, or 1 Hz below the system frequency setting for more than
60 seconds.
Function becomes active 10 seconds after engine start.
(10 second inhibit).
Output voltage falls below 80% of the nominal system voltage for more than 10 seconds.
Reduce the load and restart the generator set.
Check controller setting for system frequency.
Check the engine governor settings, and adjust if necessary.
(Parameter 4P, governor speed)
Reduce the load and restart the generator set.
Check wiring and connections.
Check controller configuration, system voltage and frequency
(parameter Uu).
Check AC voltage and adjust, if necessary (parameter 1P, voltage adjust).
Check the calibration (SiteTech software required). Controller firmware version 2.04 or higher is required for calibration.
Separately excite unit.
Check stator continuity.
Check the battery rating and condition.
Engine starting battery voltage rises above 125% of the battery voltage setting for more than 10 seconds when the engine is running. Not operative during the engine crank cycle.
Clears when the battery voltage returns to an acceptable level.
Engine starting battery voltage falls below the battery voltage setting (typically 12 volts) for more than 90 seconds when the engine is not running. Not operative during the engine crank cycle.
Clears when the battery voltage returns to an acceptable level.
Check the battery charger operation.
Check the battery rating and condition.
Check the battery charger operation.
Charge or replace the battery.
Engine speed sensor has failed.
Check the mag pickup gap and operation.
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
See Section
5.8
I/M
4.12
—
I/M
5.9.5
—
7
4.11
5.7
4.12
5.2
5.3
Battery mfr’s instructions
O/M
Battery mfr’s instructions
O/M
5.9.4
TP-6735 9/10 Section 4 Controller 47
Code Fault
AC Loss of AC sensing
W or SD*
W (1 sec.)
SD (3 sec.)
[
Condition
Generator output AC sensing is lost. Starts 10 seconds after crank disconnect.
Warning: after 1 second if no output detected after crank disconnect.
Fault: after 3 seconds if voltage was present and then lost.
LCb Low cranking voltage
ATS ATS communication error
W
SD (RRT)
[
W (other
ATS)
LrC Loss of voltage regulator communication
SD
[
* W = Warning; SD = Shutdown
[ Engine cooldown runs before shutting down.
Figure 4-7 Controller Fault Codes
Battery voltage falls below 60% of system battery voltage for more than 6 seconds while the starter is engaged.
RRT: Shutdown if ATS interface connection is lost.
Other ATS: Warning is displayed if ATS interface board is connected when it is not expected.
No communication between controller and voltage regulator.
Check
Check for loose connections.
Check all AC leads connected to the controller for continuity.
Alternator excitation failure:
Inspect the brushes and check the
FN and FP connections.
Voltage Regulator failure: check for voltage on the output leads.
Charge or replace the battery.
See Section
Wiring
Diagrams
5.6
Section 7,
Wiring
Diagrams
—
Check connection to Model RRT transfer switch interface board.
Replace the controller.
Engine S/M = Engine Service Manual
O/M = Generator Set Operation Manual
I
/M
Section 7,
Wiring
Diagrams
Section 4.8.3.
4.14
4.9 Event History
The last ten controller faults can be viewed from the controller display when the controller is off. Each event is displayed with the fault code followed by the engine hours at which time the event occurred. During event history viewing, the OFF LED flashes once per second.
Procedure to View Event History
1. Press and hold the OFF button for 3 seconds. The first event appears on the screen. The OFF LED flashes once per second.
2. Press the OFF button to cycle through the engine hours and subsequent events. After cycling through all ten events, the control automatically turns off.
The OFF LED flashes once every 2 seconds.
To stop viewing the event history before the last event, press the down arrow or exercise button. The controller will turn off.
Not in Auto: The code nIA (Not In Auto) may be shown in the event history but is not displayed on the controller when in run or off modes.
48 Section 4 Controller TP-6735 9/10
4.10 Model RRT Transfer Switch
Operation
The RDC/DC generator set/transfer switch controller manages automatic transfer switch (ATS) functions when connected to a Kohler r Model RRT transfer switch through the ATS interface board.
4.10.1 Source Availability
The Model RRT transfer switch supplies voltage sensing data to the RDC/DC controller through the ATS interface board. If the source voltage falls below the undervoltage dropout setting, the source is considered to have failed. See Figure 4-8.
Item
Accuracy
Undervoltage Dropout
Undervoltage Pickup
Setting
±5%
90% of Pickup
90% of Nominal
Figure 4-8 Voltage Sensing Parameters
4.10.2 ATS Control Sequence of
Operation
See Figure 4-9 for time delay settings.
Preferred Source Fails:
1. The load control contact opens.
2. The engine start time delay times out.
Time Delay
Engine Start
Setting
3 seconds
Transfer, Normal to Emergency 3 seconds
Transfer, Emergency to Normal 2 minutes
Load Control
Engine Cooldown
5 minutes
5 minutes
3. The generator set is signaled to start.
4. The generator starts and the emergency source becomes available.
5. The normal-to-emergency time delay times out.
6. The transfer switch transfers to the emergency source.
7. The load control contact time delay times out.
8. The load control contact closes.
Normal Source Returns:
1. The emergency-to-normal time delay times out.
2. The contactor transfers to the normal source.
3. The engine cooldown time delay times out.
4. The generator is signaled to stop.
4.10.3 Time Delays
Time delays are factory-set to the values shown in
Figure 4-9. An authorized distributor/dealer can adjust time delays using a personal computer and Kohler r
SiteTech t software.
Time delays described in this section operate only when the controller is connected to a Kohler r Model RRT transfer switch.
Description
Time delay after utility source is lost until the engine start cycle begins.
Guards against starting the generator set because of a brief change in the utility source.
Time delay after emergency source becomes available until transfer to emergency source.
Time delay after the utility source returns until transfer back to normal.
Ensures that the the utility source is stable before transferring from the emergency source.
Allows delayed connection of selected loads to the generator set.
Prevents simultaneous starting of large motors after transfer to the emergency source. Recommended for delayed starting of air conditioners.
Runs the engine with no load after transfer from the generator set.
Engine stops before the time delay expires if the temperature drops below the cooled-down temperature level, or if the temperature rises during the cooldown cycle.
Figure 4-9 Time Delays
TP-6735 9/10 Section 4 Controller 49
4.10.4 Engine and Transfer Time Delays
The engine start and transfer time delays prevent engine start and load transfer caused by brief variations in the utility power source.
The engine cooldown time delay allows the engine to run after the loads have been removed. The engine stops before the cooldown time delay expires if the temperature drops below the cooled-down temperature level, or if the temperature rises during the cooldown cycle.
4.10.5 Load Control Time Delay
The load control time delay allows delayed starting of large motor loads (such as air conditioners), preventing
Generator
Set
1 simultaneous starting of large motors after transfer to the generator set. The load control time delay is fixed at
5 minutes. It is not adjustable.
The load must be connected to the load control output on the interface board of the Model RRT transfer switch.
See the transfer switch operation and installation manual for connection instructions.
4.10.6 Model RRT ATS Connection
See Figure 4-10 for Model RRT transfer switch connection to the generator set.
2
ATS
GM66565
Customer connections
12--24 AWG
3
4
1. RES or RESL generator set terminal block TB1
2. Controller interface module location on the ATS, typical
3. Interface module connector P14
4. ATS1 through ATS4 on generator set field-connection terminal block TB1
Figure 4-10 Model RRT Transfer Switch Connection to Generator Set Terminal Block
GM63552
ADV-7598
50 Section 4 Controller TP-6735 9/10
4.11 Controller Configuration and
Adjustment
The first step in troubleshooting the controller is to verify that the controller is correctly configured for the generator set.
The RDC controller’s configuration modes allow selection of the system voltage and frequency and generator set configuration. Follow the instructions in the generator set installation manual to check the controller settings and change them, if necessary. A Kohler-authorized distributor or dealer can also check and adjust the RDC controller configuration and settings using a personal computer and Kohler r SiteTecht software.
The DC controller configuration and settings cannot be viewed or adjusted at the controller.
However, a
Kohler-authorized distributor or dealer can check and adjust the DC controller configuration and settings using a personal computer and Kohler r SiteTecht software.
4.11.1 SiteTech Software
A personal computer running Kohler r SiteTecht software can be used to configure and adjust the RDC and DC controllers. See TP-6701, SiteTech Software
Operation Manual, for PC connection and software operation instructions.
Appendix F contains a list of controller parameters that can be viewed and adjusted using SiteTech.
The
Access column in the table shows which parameters can only be viewed (Read or Locked), and which parameters can be changed using the software (Write).
SiteTech software is also used to update the firmware on the RDC and DC controllers.
See TP-6701 for instructions.
SiteTech can be used to calibrate the voltage. See
Section 4.12.
4.11.2 Controller Configuration
The controller configuration for each generator Model is set at the factory. If the controller is replaced, check the configuration of the new controller and change the settings, if necessary.
See Figure 4-11.
Follow the instructions in the generator set installation manual to check controller settings and change them if necessary.
Do not use settings Uu07--Uu22. These settings may appear as choices during configuration but do not apply to the 14RES/RESL or 20RES/RESL generator sets.
Parameter
System voltage and frequency *
Engine
Configuration *
Setting
Uu01
Uu06
Uu07
Uu11
Uu15
Uu16
Uu19
Uu21
Uu22
Ec13
Ec14
Phases
1
Definition
Hz VAC
60 120/240
1 50 115/230
DO NOT USE
DO NOT USE
DO NOT USE
DO NOT USE
DO NOT USE
DO NOT USE
DO NOT USE
14RES/RESL
20RES/RESL
Figure 4-11 Controller Configuration Settings
4.11.3 Controller Time Out
The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed.
Start the configuration procedure again from the beginning if the controller exits the configuration mode before the settings have been saved.
Changes in voltage and speed adjustments are also lost if they are not saved before the generator set shuts down. The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup. Be sure to save your changes immediately after making adjustments.
4.11.4 Controller Firmware Version
Number
The controller firmware version number is displayed on the LED screen during the key sequence to enter the configuration mode. Press and hold the Select and UP buttons together. After about 5 seconds, the firmware version number will be displayed on the controller display.
For example, 01.10 will be displayed for firmware version 1.10.
The DC controller firmware version number is displayed during the first 2 seconds of the crank cycle.
TP-6735 9/10 Section 4 Controller 51
4.11.5 Voltage and Frequency
Adjustments
Voltage and/or frequency adjustments may be required after controller replacement or other service procedures. See Section 5.8 for instructions to adjust the generator set output voltage and frequency using the RDC controller.
Use a personal computer and
Kohler r SiteTecht software to make adjustments on
RESL models equipped with the DC controller.
The generator set must be running during these adjustments. Use a multimeter to measure generator set output voltage and frequency during adjustments.
Refer to Sections 5.8, Voltage Adjustment, and 5.9.5,
Frequency Adjustment, for instructions to measure and adjust the output voltage and frequency.
Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings when turneed off.
4.12 Calibration
The controller can be calibrated for utility voltage using using a personal computer connected to the RDC/DC controller. Kohler r SiteTecht software is required for calibration.
Note: Controller firmware version 2.04 or higher is required for calibration. See Section 4.11.4 for instructions to check the firmware version number.
4.12.1 Calibrate Function
The RDC/DC controller can be calibrated using
SiteTech. Measure the actual utility voltage across L1 and L2, and enter the measured value into SiteTech as described below. See Figure 4-12.
Calibration Procedure
1. Measure the actual utility voltage across L1 and L2.
Use a digital voltage meter and observe the safety precautions in the generator set installation manual.
2. Click on Calibrate in the ribbon at the top of the
SiteTech screen. See Figure 4-12.
3. The Device Calibration window appears. Type the measured voltage into the space provided.
4. Click the Calibrate button in the Device Calibration
Window.
After the calibration procedure, view the utility voltage in the Source 1 metering window.
Voltage L1--L2 and average line-to-line voltage are displayed.
4.12.2 Calibration Factor
The Source 1 Calibration Factor Voltage L1--L2 parameter in SiteTech shows the ratio of measured voltage to the source 1 system voltage.
52 Section 4 Controller TP-6735 9/10
1
1. Click on Calibrate in the ribbon at the top of the screen.
2. Enter the measured voltage.
3. Click Calibrate in the Device Calibration window.
Figure 4-12 Calibration Using SiteTech Software
2
3
TP-6735 9/10 Section 4 Controller 53
4.13 Controller Circuit Board
4.13.1 Relays and LEDs
The K1 flash, K2 crank, and K3 run (fuel) relays are located on the controller’s logic board. The CRANK and
RUN LEDs are associated with relays 2 and 3 and are visible in the service access area on the front of the controller assembly. See Figure 4-13.
The RUN and CRANK LEDs indicate power to the corresponding relay. If the LED is illuminated but the relay is not activated, the relay is faulty.
Power to the governor stepper motor is tied to the K3 run relay. If the stepper motor does not operate, check the
K3 relay.
The individual relays are not replaceable. If one or more relays are faulty, replace the controller.
4.13.2 Controller Fuse F2
D
D
D
D
The controller board is protected by a 7.5-amp fuse (F2) located on the controller. If the fuse blows repeatedly, disconnect the following leads one at a time to identify the cause of the blown fuse:
Lead 70A at the fuel valve
Lead IGN at the ignition module
Lead 71 at the starter relay
Leads FP and FN at the rotor
Repair or replace the component causing the blown fuse.
1
2
3
Service Access Area
1. Controller’s service access area
2. Run LED (K3) and crank LED (K2)
3. Controller fuse F2
4. K1 flash relay
5. K2 crank relay
6. K3 run relay
4
Figure 4-13 Relays and LEDs on Controller Circuit Board
5 6
GM62865
54 Section 4 Controller TP-6735 9/10
4.14 Controller Replacement
If the troubleshooting procedures in Section 3 identify a failed controller, use the procedure in this section for controller replacement.
Always check the controller configuration, fuse, wiring, and connections before replacing the controller.
Before removing the old controller, you may be able to save the controller settings to a file using a computer running SiteTech software. You can then use SiteTech to load the settings onto the new controller after it is installed. See TP-6701, SiteTech Software Operation
Manual, for instructions to export and import settings.
Note: Export the old controller settings to the new controller only if you are certain that the settings are correct. Many controller operation problems can be traced to incorrect settings.
DANGER
1
1. Roof
2. Intake panel screws (2 ea.)
3. Intake panel
Figure 4-14 Enclosure Roof and Door
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.
1
Controller Replacement Procedure
1. Open the enclosure roof. See Figure 4-14.
2. Press the OFF button on the controller.
3. Remove two (2) screws on the intake panel. See
Figure 4-14.
4. Disconnect power to the battery charger.
5. Disconnect the generator set engine starting battery, negative (--) lead first.
6. Remove the four (4) screws securing the controller to the junction box and carefully lift the controller.
Note connections to the panel and disconnect as necessary to access the inside of the junction box.
See Figure 4-15.
Note: Be careful of the leads and harness connected to the controller panel.
1. Controller screws (qty. 4)
Figure 4-15 Controller in Junction Box
1
3
2
TP6735
GM66569
TP-6735 9/10 Section 4 Controller 55
7. Note the connections on the back of the controller, and then disconnect. See Figure 4-16 or the wiring diagram.
8. Remove the old controller.
9. Reconnect all harnesses to the new controller assembly.
10. Install the controller onto the junction box using the four (4) screws removed in step 6.
11. Reconnect the engine starting battery, negative (--) lead last.
12. Reconnect power to the battery charger.
13. Replace the air intake end panel and secure with two screws.
4
1 b. Use a voltmeter to check the output voltage.
Follow the instructions in Sections 4.11.5,
Voltage and Frequency Adjustments, and 5.8,
Voltage Adjustment, to adjust the output voltage and stability.
c. Check the output frequency.
Follow the instructions in Sections 4.11.5, Voltage and
Frequency Adjustments, and 5.9.5, Frequency
Adjustment, to adjust the output frequency and stability.
d. Use Kohler r SiteTecht software to enter the following generator set information into the new controller:
D
Genset Model Number (from generator set nameplate)
D
Genset Serial Number (from generator set nameplate)
D
Engine Model Number (from engine nameplate)
D
Engine Serial Number (from engine nameplate)
15. Press the AUTO button to place the controller in automatic mode if an ATS or remote start/stop switch is used. Press OFF if no ATS or remote start/stop switch is used.
16. Close and latch the enclosure roof.
3
GM69754
1. P1
2. P3
3. P2
4. 20 amp mini breaker
2
Figure 4-16 Controller Connections
14. Check controller settings and adjustments. The
RDC controller can be set up using the buttons on the controller or using Kohler r SiteTecht software. Use SiteTech t software to check and adjust controller settings on the DC controller. See the generator set installation manual for instructions to change settings at the RDC controller.
a. Set the new controller’s voltage/frequency and unit configuration settings. See Figure 4-11.
56 Section 4 Controller TP-6735 9/10
Section 5 Component Testing and Adjustment
5.1 Theory of Operation
The generator set utilizes a rotating-field alternator to produce AC voltage. See Figure 5-1. After the engine starts and reaches a predetermined speed (RPM), DC current from the battery magnetizes the rotor (field).
When the magnetized rotor rotates inside the stator windings, an electrical voltage develops in the stator.
The controller feeds rectified stator current to the rotor through the brushes and slip rings to change the strength of the rotor field as the load changes. As the rotor field strength increases, the generator power output increases (up to the rating shown on the nameplate).
The controller monitors the generator output voltage through leads 11 and 44 and adjusts the
DC current to the rotor to meet load requirements while maintaining the output voltage.
RDC/DC Controller
1
2
3
5.2 Separate Excitation
To determine the cause of no or low AC output, refer to the troubleshooting flowchart in Figure 5-2.
Before beginning the test procedures, read all safety precautions at the beginning of this manual. Many of the test procedures include additional safety precautions.
Check the condition of the alternator circuit breaker before performing the separate excitation procedure.
The circuit breaker is located in the service access area on the controller. See Figure 5-1. If the breaker is not tripped, use the following procedure to separately excite the generator using an external voltage source (a
12-volt automotive battery).
Separately exciting the generator can identify faulty voltage regulation by the controller or reveal a running fault in the rotor and/or stator. An external power source duplicates the role of the voltage regulator and excites the generator field (rotor). A generator component that appears to be in good condition while stationary may exhibit a running open or short circuit while moving.
Centrifugal forces acting on the windings during rotation cause a broken circuit to open, or increasing temperatures cause the insulation to break down, resulting in a running fault. If this test shows that the rotor and stator are in good condition, test the voltage regulation using the tests in Section 5.7.
8
7
4
1. Circuit breaker
2. Power lead (55)
3. Excitation to rotor
4. Brushes
6
5
TP6735
5. Slip rings
6. Main field (rotor)
7. Stator windings
8. Sensing leads (11--44)
Figure 5-1 Single-Phase Generator Schematic
No Generator Output
Separate Excitation
Erratic or No Output
Output within
Specifications
Check Wiring, Fuses,
Circuit Breaker, and
Controller
Check Rotor Check Stator
TP563273
Figure 5-2 Generator Troubleshooting
TP-6735 9/10 Section 5 Component Testing and Adjustment 57
Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards.
Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
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 connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.
Separate Excitation Procedure
Perform the following procedure to use an external voltage source to excite the main field (rotor).
1. Disconnect the black FN and FP leads from the alternator at the brush holder terminals.
2. Connect a DC ammeter, 10-amp fuse, and a
12-volt automotive battery to the positive (FP) and negative (FN) brush leads as shown in Figure 5-3.
Note and record the ammeter reading.
Note: The approximate ammeter reading should be the battery voltage divided by the specified rotor resistance. See Section 1,
Specifications, for specified rotor resistance values.
Example:
12 volts (battery voltage)
4 ohms (rotor resistance)
=
3 amps
(rotor current)
3. Start the engine and check that the ammeter reading remains stable.
An increasing meter reading indicates a shorted rotor. A meter reading decreasing to zero or an unstable reading suggests a running open. Refer to Section 5.4,
Main Field (Rotor), to test the rotor. If the ammeter reading is stable, proceed to step 4.
4. Check for AC output across the stator leads; see
Section 5.3, Stator. Compare the readings to the
AC output
8 values shown in Section 1,
Specifications. If the readings vary considerably, a faulty stator is likely. Refer to Section 5.3, Stator, for further information.
5. If this test shows that the rotor and stator are in good condition, check the wiring and fuses. Check the controller settings and connections.
Section 4, Controller.
1 2
FN
+
FP
6
7
3
+
1. FN lead disconnected in step 1
2. FP lead disconnected in step 1
3. 10-amp fuse
4. DC ammeter
5. 12V battery
6. Brushes
7. Slip rings
8. Main field (rotor)
Figure 5-3 Separate Excitation Connections
4
See
-
5
TP-6735
58 Section 5 Component Testing and Adjustment TP-6735 9/10
5.3 Stator
The stator contains a series of coils of wire laid in a laminated steel frame.
The stator leads supply AC voltage to the load and voltage regulator. Before testing the stator, inspect it for heat discoloration and visible damage to housing lead wires, exposed coil windings, and exposed areas of frame laminations. Be sure the stator is securely fastened to the stator housing.
Note: Disconnect all stator leads before performing all stator tests.
WARNING
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment manufacturer when performing high-voltage tests on the rotor or stator. An improper test procedure can damage equipment or lead to generator set failure.
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 connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.
Stator Continuity and Resistance Tests
1. Press the OFF button on the controller to turn off the generator set.
2. Disconnect power to the battery charger.
3. Disconnect the generator set engine starting battery, negative (--) lead first.
4. Disconnect all stator leads before performing all stator tests.
5. To check for stator continuity, set the ohmmeter on
R x 1 scale. First set the ohmmeter zero by holding the red and black meter leads together and setting the ohmmeter reading to zero. Then check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 5-4.
R14807-14
Figure 5-4 Testing Stator Windings
Note: For single-phase models. leads 1, 2, 3, and 4 are the generator output leads. Leads 11, 44, 55, and
66 are the controller sensing and supply leads.
Refer to the schematic in Figure 5-5 when performing the following steps.
4
3
44
66
55
2
1
11
6196
Figure 5-5 Single-Phase Alternator Stator Leads
6. Contact the ohmmeter leads and readjust the ohmmeter to read zero ohms.
7. Check the cold resistance of the stator windings by connecting the meter leads to stator leads 1-2, 3-4, and 55-66.
See Section 1.5, Alternator
Specifications, for stator winding resistances.
Most ohmmeters do not provide accurate readings below 1 ohm. Low resistance readings (continuity) and no evidence of shorted windings (heat discoloration) indicate a stator in good condition.
See Figure 5-6.
TP-6735 9/10 Section 5 Component Testing and Adjustment 59
Leads
1 and 2
1 and 11
2 and 11
3 and 4
3 and 44
4 and 44
55 and 66
1 and 3, 4, 44, 55, or 66
2 and 3, 4, 44, 55, or 66
3 and 1, 2, 11, 55, or 66
4 and 1, 2, 11, 55, or 66
Any stator lead and ground on stator housing or frame laminations
Continuity
Yes
No
Figure 5-6 Continuity Test Results on a Good Stator
(single-phase)
8. If the resistance test proves inconclusive, use a megohmmeter to test the stator as described in the next step.
Note: Because ohmmeter accuracy varies, resistance readings are approximate readings. Take readings of the rotor and stator at room temperature.
Note: Make sure that all stator leads are disconnected before running the megohmmeter test.
9. Use a megohmmeter to determine whether the stator is shorted to ground.
a. Apply 500 volts DC to any stator lead and the stator frame. Perform the megohmmeter test following the instructions of the megohmmeter manufacturer.
b. Repeat the test on the other stator leads until each coil is tested.
Note: A reading of approximately 500 kOhms
(1/2 megohm) and higher indicates a good stator.
c. Repair or replace the stator if any reading is less than approximately 500 kOhms. A reading of less than 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground.
60 Section 5 Component Testing and Adjustment TP-6735 9/10
5.4 Main Field (Rotor)
The two-pole rotor creates the magnetic field needed to produce alternating current in the stator windings.
Before testing, inspect the rotor for visible damage to pole shoes, insulation, exposed coil windings, and slip ring surfaces. Rotate the bearing to check for wear, heat discoloration, or noise.
5.4.1
Rotor Continuity and Resistance
Tests
WARNING
5. Check the rotor for continuity and resistance.
Raise the brushes from the slip rings while performing ohmmeter tests.
Measure the rotor resistance (ohms) between the two slip rings; see
Figure 5-7. See Section 1.5 for rotor resistance readings.
If the resistance readings are low, perform a megohmmeter test on rotor as described in the next step.
Note: Because ohmmeter accuracy varies, resistance readings are approximate. Take readings at room temperature.
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment manufacturer when performing high-voltage tests on the rotor or stator. An improper test procedure can damage equipment or lead to generator set failure.
Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards.
Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
Rotor Test Procedure
1. Press the OFF button on the controller to turn off the generator set.
2. Disconnect power to the battery charger.
3. Disconnect the generator set engine starting battery, negative (--) lead first.
4. Remove the brush cover from the alternator end bracket.
2-221
R13929-7
Figure 5-7 Rotor Resistance Check
6. Perform a megohmmeter test to determine whether the rotor is shorted to ground.
a. Raise and secure the brushes away from the slip rings by inserting a retaining wire in the brush holder hole.
b. Using a megohmmeter, apply 500 volts DC to one rotor slip ring and the rotor poles or shaft.
Follow the instructions of the megohmmeter manufacturer when performing this test.
Note: A reading of approximately 500 kOhms
(1/2 megohm) or higher indicates a good rotor.
c. Repair or replace the rotor if the reading is less than approximately 500 kOhms. A reading of less than 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground.
d. Following the test, remove the retainer wire from the brush holder and check the brush positions on the slip rings. See Section 5.6,
Brushes.
e. Reinstall the brush cover on the end bracket.
TP-6735 9/10 Section 5 Component Testing and Adjustment 61
5.5 Slip Rings
Slip rings acquire a glossy brown finish in normal operation.
Do not attempt to maintain a bright, newly-machined appearance on the slip rings. Cleaning with a dry, lint-free cloth is usually sufficient. Use very fine sandpaper (#00) and apply light pressure to remove roughness. Do not use emery or carborundum paper or cloth. Clean all carbon dust from the generator after sanding the slip rings. If the rings are black or pitted, remove the rotor and use a lathe to remove some of the slip ring surface material.
5.6 Brushes
The brushes transfer current to the slip rings.
The brushes should last the life of the generator. However, abrasive dust on the slip rings shortens the life of the brushes.
Excessive arcing at the brushes could damage the controller. Weak springs, damaged slip rings, sticking brushes, a loose brush holder, or poor brush contact causes arcing.
The brushes must be free to move within the holder and be held in contact with the slip rings by the springs.
When correctly positioned, spring pressure on the brush surface causes the brush to wear evenly. The entire brush must ride on the ring or arcing occurs and causes burned rings or voltage regulator failure. Figure 5-8 shows the correct positioning of the brushes. Add or remove shims as necessary to center the brushes on the slip rings. Replace the brushes if they show uneven wear or are worn to one half their original length.
Check the resistance through the brushes. Resistance through the brushes should be low, 0.1--0.2 ohms without meter lead resistance.
5
4
3
3
2
1
1
4
6
New 19.0 mm (0.75 in.)
7
Correct
1
GM67344
Incorrect
8
1
2
2
1. Brush(es)
2. Slip rings
3. Brush holder
4. Retainer wire (for service only)
Side View
TP5867
5. Shim
6. Spring
7. Correctly positioned brush
8. Incorrectly positioned brush
Figure 5-8 Brush Assembly
62 Section 5 Component Testing and Adjustment TP-6735 9/10
5.7 Voltage Connections
5.7.1
Voltage Connections,
Single-Phase Models
Single-phase generator sets are available from the factory connected for 115/230 volt 50 Hz or 120/240 volt
60 Hz.
See Figure 5-9 for the factory connections.
Generator sets are not reconnectable.
Load
Side
LO (Neutral)
Ground
LO
GRD
L2
L1
Factory two-pole circuit breaker
Line
Side
The DC controller is not equipped with a keypad. A personal computer running Kohler SiteTech software is required for all adjustments to the DC controller.
SiteTech software is available to Kohler authorized distributors and dealers (through their distributor).
The controller will time out and exit the adjustment mode after approximately 1 minute if no buttons are pressed.
Any unsaved changes are discarded if the controller times out before the settings are saved. Refer to Section
4.11 for instructions to save your settings.
Voltage Adjustment.
Adjusts generator output between 100 and 130 volts.
Gain (Stability) Adjustment.
Fine tunes regulator circuitry to reduce light flicker.
Volts/Hz Adjustment (voltage droop). Determines frequency (Hz) at which generator output voltage begins to drop. The controller maintains generator output at the specified voltage under load until the generator engine speed drops to a preset level (see Figure 5-11 for cut-in frequencies). Then the controller allows the generator voltage and current to drop. The voltage/current drop enables the engine to pick up the load.
When the generator speed returns to normal (60 Hz or 50 Hz) as load is accepted, the generator output also returns to normal. See Section 5.8.2 for instructions to adjust the voltage droop. (SiteTech software required.)
WARNING
4 3 2 1
Stator Leads
L0-L1
L0-L2
L1-L2
60 Hz
120 volt
120 volt
240 volt
50 Hz
115 volt
115 volt
230 volt
TP-5867
Figure 5-9 115/230 and 120/240 Volt, 3-Wire
Configurations
5.7.2
Voltage Regulation
Voltage regulation is performed by the controller. The controller monitors generator output voltage and adjusts the excitation current to the rotor.
5.8 Voltage Adjustment
The factory sets the voltage for correct generator operation under a variety of load conditions. Usually, the voltage needs no further adjustment.
Adjust the voltage when necessary according to the following procedure.
The adjustment procedure requires a meter that can measure voltage and frequency.
Use the RDC controller keypad or a personal computer running Kohler r SiteTecht software to adjust the voltage, gain, and volts/Hz.
This section contains instructions to adjust each setting and save the changes using the controller keypad.
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
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 connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.
Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards.
Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
TP-6735 9/10 Section 5 Component Testing and Adjustment 63
5.8.1
Voltage Adjustment Procedure
Refer to Figure 5-12 during the adjustment procedure.
1. Connect a digital voltmeter to measure output voltage across L1 or L2 and L0. Set the meter to measure AC volts.
2. Start the generator set.
3. Follow the controller instructions in Figure 5-12 to enter the adjustment mode. Increase or decrease voltage (parameter 1P) until the output reaches the desired voltage. See Figure 5-10.
Models
1 phase, 60 Hz
1 phase, 50 Hz
Voltage
Measurement
L -- L0
L - L
L -- L0
L - L
Figure 5-10 Voltage Measurement
Approximate
Voltage, VAC
120
240
115
230
4. Follow the controller instructions to step to the voltage gain (parameter 2P) adjustment menu.
Adjust the voltage gain (2P) until the light flicker minimizes. Save the settings. See Figure 5-12.
5. Check and readjust the voltage if necessary.
6. Save the settings.
Refer to Figure 5-12 for instructions.
Note: The controller will revert to the previous settings at the next startup if the changes are not saved.
7. Stop the generator set.
5.8.2
Volts per Hertz (Hz) Adjustments
(Droop)
The volts per hertz (droop) setting can only be adjusted using a personal computer running Kohler r SiteTecht software. Follow the instructions in this section and refer to TP-6701, SiteTech Software Operation Manual, to adjust the Voltage Regulator Volts per Hertz Slope parameter.
When the frequency falls below the cut-in frequency
(see Figure 5-11), output voltage is reduced to relieve the engine. The magnitude of the voltage reduction is set by the voltage regulator volts per hertz slope. To determine whether droop adjustment is required, monitor engine speed and output voltage as loads are applied, and watch for the following conditions.
D
If there is excessive droop in engine speed and little droop in voltage, increase the volts per hertz value.
D
If there is little engine speed droop but excessive voltage droop, decrease the volts per hertz value.
D
Readjust the voltage stability (2P) and voltage (1P) parameters after adjusting the volts/Hz setting, if necessary.
D
Remember to save your settings.
Frequency
60 Hz
50 Hz
Cut-In Frequency
57.5 Hz
47.5 Hz
Figure 5-11 Cut-In Frequencies
Volts/Hz Adjustment Procedure
1. Set the voltmeter to measure frequency. Adjust the engine speed to the cut-in frequency shown in
Figure 5-11 by adjusting the engine governor speed.
2. Set the voltmeter to measure voltage. Adjust the volts/Hz until the voltage level measured by the voltmeter begins to drop. When set, the generator
(as load is applied) attempts to maintain normal output until the engine speed drops below the cut-in frequency.
3. Set the voltmeter to measure frequency. Adjust the engine speed to the operating frequency (50 or
60 Hz) by adjusting the engine governor speed.
4. Readjust the voltage gain until the light flicker minimizes, if necessary.
5. Check the voltage.
Readjust the voltage, if necessary.
6. Stop the generator set.
64 Section 5 Component Testing and Adjustment TP-6735 9/10
Hold select and up buttons for 5 seconds
S A U E
Enter pass code
Generator Set
Running?
Yes
RUN mode
Coarse Voltage Adjust
1 P 3 3
Press
Fine Voltage Adjust
1 P 3 6
OFF mode
No
Adjust
Adjust
Coarse Gain Adjust
2 P 1 4
Adjust
Fine Gain Adjust
2 P 1 7
Engine Governor
Speed Adjust
4 P 1 1
Engine Governor
Gain Adjust
5 P 0 5
Adjust
Adjust
Figure 5-12 RDC Controller Adjustment
TP-6735 9/10
System Voltage Setting
U u 1
Engine Configuration
Adjust Setting
E c 1 3
Adjust
Adjust
Y E S
Save Changes
Save Changes?
S A U E n o
Discard Changes
Exit Setup
Section 5 Component Testing and Adjustment 65
5.9 Governor System
The governor system consists of an electromechanical stepper motor (actuator) and a magnetic pickup. The
RDC/DC controller controls the governor system operation.
See Section 7, Wiring Diagrams, for the governor connections.
5.9.1
Operation
The frequency of the alternator output is determined by the speed of the engine. A two-pole alternator must be driven at 3600 rpm to provide 60 Hertz. (A 50 Hz model must be driven at 3000 rpm.) The engine speed is maintained by an electronic governor system that consists of a magnetic pickup and electric actuator
(stepper motor). The governor system is controller by the generator set controller.
The magnetic pick-up, which monitors the speed of the flywheel ring gear, provides the speed reference signal to the controller.
The controller provides regulated power to the bidirectional stepper motor actuator, which is linked to the carburetor throttle arm.
At cranking speed a properly adjusted pick-up should produce a minimum of 3.0 VAC. The magnetic pick-up air gap is factory-set to 0.5 mm (0.020 in.). Failure or loss of the input speed signal from the magnetic pick-up will result in erratic speed.
A setting on the RDC controller allows adjustment of the engine speed. See Section 5.9.3.
A gain adjustment may be required if an unstable
(hunting/surging) condition occurs. Adjusting the gain may require readjustment of the engine speed. See
Section 5.9.3.
5.9.2
Initial Checks
The factory sets the electronic governor. Under normal circumstances the electronic governor requires no further adjustment. Verify that the governor stepper motor moves smoothly and steadily during operation. If the engine operates erratically check the following connections and conditions before adjusting the governor.
D
Power to the governor stepper motor is tied to the K3 run relay. If the stepper motor does not operate, check the K3 relay. See Section 4.13.1.
D
Verify that the electrical connections are clean and tight.
D
Check the magnetic pickup connections. Poor connections may cause an erratic signal or an overspeed condition. An erratic signal causes the generator set to govern poorly but not shut down.
D
Verify that the battery connections are clean and tight.
D
Check for dirt buildup on the magnetic pickup. Metal filings or caked-on dirt or grease decreases the output signal of the magnetic pickup.
D
Check for a loose or worn stepper motor/throttle shaft coupling. Replace the shaft and bushing every 500 hours of engine operation.
D
Check the carburetor for dirt, grime, or misadjustment. Check for a loose mixer assembly.
D
Check the idle-adjustment screw. The screw should not prevent the throttle plate from closing completely.
D
Check the throttle linkage for any binding, dirt, damage, or other visible problems.
D
Observe the stepper motor operation. The stepper motor should open the throttle fully before cranking, and pull back after the crank disconnect.
D
Check for electronic governor faults. The fuel shutoff solenoid deenergizes and the generator set shuts down under the following conditions:
D
D
D
D
D
Closed throttle
Engine overspeed
Broken fuel shutoff solenoid lead
Broken stepper motor leads (erratic performance)
Failed actuator linkage (erratic performance)
5.9.3
Hunting/Surging
Often hunting/surging problems thought to be caused by the governor are actually caused by engine or carburetor problems.
Check engine speed stability using the following procedure before testing the governor.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the exhaust system.
Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.
66 Section 5 Component Testing and Adjustment TP-6735 9/10
1. Open the generator set line circuit breaker.
2. Start the generator set.
3. Hold the throttle linkage steady while the engine is running. See Figure 5-13. If the engine runs at a steady speed with no hunting or surging when the throttle is held steady, then the hunting/surging problems during operation are probably caused by the governor. Proceed to Section 5.9.4.
4. If the engine speed hunts or surges while the throttle is held steady, check the carburetor and engine operation.
Refer to the engine service manual for engine diagnostic and service information.
5.9.4
Governor System/Magnetic
Pickup Operation Test
If the engine continues to operate erratically after the previous checks, test the governor system operation using the following procedure.
The procedure is summarized in the flowchart in Figure 5-14.
Check that the carburetor throttle linkage is connected to the stepper motor as shown in Figure 5-13.
14RES/RESL
1
Check for broken or loose wiring or connections and other items in step 2.
Yes
Check stepper motor operation at startup. Does it move to fully open and then move to and stay in the fully closed position?
See step 3.
No
2
20RES/RESL
1
3
Check the magnetic pickup.
See steps 4--6.
Check the magnetic pickup connections to the controller: red and black leads to P1-5 and P1-6, and P1-18.
Disconnect the magnetic pickup and check the stepper motor operation again.
See steps 7--9.
Check the stepper motor connections to the controller.
See step 10.
2
3
Check the stepper motor coils.
See step 11.
1. Electronic governor stepper motor
2. Carburetor throttle linkage
3. Carburetor
Figure 5-13 Stepper Motor and Carburetor
Troubleshoot the controller.
See step 12.
Figure 5-14 Governor System Operation Test
Procedure Summary (Section 5.9.4) tp5867
TP-6735 9/10 Section 5 Component Testing and Adjustment 67
Governor System Operation Test Procedure
1. Verify that the carburetor throttle linkage is connected to the stepper motor as shown in
Figure 5-13.
2. Look for broken or loose wiring or plug connections if the stepper motor moves erratically. Check the condition of the throttle linkage, and verify that the throttle plate closes completely.
3. Check the operation of the stepper motor at startup.
a. If the throttle moves to the fully open throttle position and then steps to and remains in the fully closed position, the engine speed input is probably missing. The engine starts and then shuts down on an overspeed fault. Proceed to step 4 to check the magnetic pickup.
b. If the throttle linkage moves erratically or not at all at during startup, proceed to step 7 to check the stepper motor.
4. Verify the operation of the magnetic pickup by connecting a voltmeter to the magnetic pickup leads. See Figure 5-15.
If the air gap is correct, the voltage should be
3.0 volts AC RMS minimum during engine cranking.
6519
Figure 5-15 Magnetic Pickup Leads
5. If the voltmeter displays less than 3.0 volts AC, check the air gap as described in the following steps before replacing the sensor. Verify that the magnetic pickup air gap is 0.5 mm (0.020 in.).
Measure the air gap at 3 or 4 places to get an accurate reading. See Figure 5-16.
1
5
4
3
2
1. Ignition module
2. Air gap, 0.5 mm (0.020 in.)
3. Top of flywheel ring gear tooth
4. Locknut
5. Magnetic pickup
A-358000B-C
Figure 5-16 Magnetic Pickup Air Gap a. Stop the generator set.
Remove housing panels as required to gain access to the front of the engine.
b. Remove the engine blower housing.
c. Use a feeler gauge to check the gap. The gap should be 0.5 mm (0.020 in.).
d. Adjust the air gap, if necessary, by loosening the locknut and turning the pickup.
See
Figure 5-16.
e. Hold the pickup in position and retighten the locknut.
f. Verify the magnetic pickup air gap after tightening the locknut.
g. Reinstall the engine blower housing.
h. Reinstall the junction box and housing panels removed to gain access to the front of the engine.
6. After adjusting the air gap, check the voltage again as described in step 4. If the voltage does not measure 3.0 VAC minimum, replace the magnetic pickup.
7. To test controller’s governing function, disconnect the magnetic pickup leads and open the generator set circuit breaker.
68 Section 5 Component Testing and Adjustment TP-6735 9/10
8. Manually move the throttle shaft/governor stepper motor fully counterclockwise (closed throttle).
9. Start the generator set. The stepper motor should step clockwise to the wide open throttle position.
The stepper motor should remain in the clockwise
(throttle fully open) position. If the stepper motor does not operate as described here, proceed to the next steps to check the governor and stepper motor.
10. Stop the generator set by pressing the OFF button on the controller.
Check the stepper motor connections to the controller.
See the wiring diagrams in Section 7.
11. Check the stepper motor coil resistance across pins 2 and 3 and across pins 1 and 4. Only two stepper motor leads of each coil group are used
(BLK-YEL and RED-WHT). See Figure 5-17. The resistance per half coil is 38.5 ohms. If one of the coils has a significantly higher resistance or is shorted, replace the stepper motor.
PIN 3, BLK
PIN 2, YEL
PIN 5, GRN
(not used)
PIN 4,
RED
PIN 1,
WHT
PIN 6, BLUE
(not used)
SB555
Figure 5-17 Actuator Coil Group
12. If there is power and a good ground connection to the controller and the stepper motor coil resistances are good, but the stepper motor does not operate as described in step 9, the problem is with the controller. Check controller connections, fuses, wiring, and settings.
Refer to the troubleshooting procedures in Section 3.
TP-6735 9/10 Section 5 Component Testing and Adjustment 69
5.9.5
Frequency Adjustment
The engine speed determines the generator output frequency; 60 Hz units operate at 3600 rpm and 50 Hz units run at 3000 rpm. Adjust the engine governor to change the output frequency using the following procedure.
The RDC controller can be adjusted using the controller keypad or using a personal computer running Kohler
SiteTech software. The DC controller has no keypad, and must be adjusted using SiteTech software.
Note: See Section 5.8 for instructions to adjust engine governor speed (frequency) and gain.
Frequency Adjustment Procedure
1. Open the generator set line circuit breaker.
2. Attach a frequency meter to the AC output leads.
3. Start and run the generator set until it reaches normal operating temperature (at least 10 minutes).
4. Use the RDC controller to adjust the electronic governor speed (parameter 4P) to obtain a frequency reading of 60 Hz (or 50 Hz on 50 Hz models).
Note: Often hunting/surging problems thought to be caused by the governor are actually caused by engine or carburetor problems. If the generator set speed is unstable, hunts, or surges, check for the cause using the procedure in Section 5.9.3
before proceeding.
5. Check stability with the generator set running and with no load applied. If the generator set speed is unstable, hunts, or surges, decrease the gain
(parameter 5P) until the generator set becomes stable with no hunting or surging. Observe the frequency reading.
6. Repeat steps 4 and 5 to obtain the rated frequency and stable operation.
7. Save the settings.
Refer to Section 5.8 for instructions.
Note: The controller will revert to the previous settings at the next startup if the changes are not saved within one minute after the last change.
8. Apply rated load to the generator set and observe the frequency reading. The no load and full load frequencies should be within 0.4 Hz of the rated generator frequency; if not, check that the carburetor throttle plate opens completely without sticking and check the carburetor adjustment. If these procedures do not correct the problem, replace the controller.
9. Check for hunting and surging at full load. Increase the gain (parameter 5P) until the engine hunts and surges. Then decrease the gain in small steps using the governor gain fine adjust parameter until the engine operation stabilizes. Save the controller changes.
10. Remove the load and observe the frequency. The frequency should return to the value stated in step 4. Gain adjustment may affect the generator set speed/frequency.
If the frequency has changed, repeat step 4.
Note: Speed adjustments have no effect on gain adjustments. It is not necessary to repeat the gain adjustments (steps 5 and 8) after adjusting the engine speed.
Check the overspeed shutdown operation when investigating a shutdown problem. See Section 5.10.1
for the overspeed shutdown test procedure.
70 Section 5 Component Testing and Adjustment TP-6735 9/10
5.10 Fault Shutdown Tests
Verify the operation of the generator set overspeed, overcrank, and low oil pressure shutdowns by performing the following tests.
If these tests are inconclusive, test individual shutdown circuit components (wiring harness, switch, etc.) as described elsewhere in this section.
WARNING
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
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 connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.
5.10.1 Controller Fault Shutdown
Functions
Check the operation of the fault functions programmed in the controller by performing the following tests. If the controller does not operate as described, check the controller configuration settings; see Section 4.11.2.
Also check the controller wiring and connections.
Overspeed Shutdown
The overspeed setting is factory-set and is not adjustable.
Verify that the following controller configuration parameters are set correctly for your unit.
See the generator set installation manual for the settings.
D
D
System voltage/frequency parameter (UU)
Engine configuration parameter (EC)
WARNING
Servicing the exhaust system.
Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.
Open the generator set output circuit breaker before beginning the test.
(See Figure 4-1 for the circuit breaker location.)
Connect a digital voltmeter (DVM) to measure the output frequency. Start the generator set and manually adjust the engine speed by moving the throttle linkage.
Note: Be careful not to touch the hot silencer when reaching in to adjust the throttle linkage.
Increase the engine speed (parameter 4P) to at least
115% of the rated engine speed, 69 Hz on 60 Hz models or 58 Hz on 50 Hz models. Verify that the generator set shuts down on an overspeed fault (OS).
If the overspeed shutdown does not operate, the generator set should shut down on an overfrequency fault (OF) after approximately 5 seconds.
If the controller does not indicate an overspeed fault
(OS), check the wiring to the magnetic pickup (red and black leads, P1-5 and P1-6).
Check the magnetic pickup air gap and voltage output; see Section 5.9.4.
Low Oil Pressure (LOP) Shutdown
Connect a jumper wire from the LOP switch (lead 13) to the generator set ground. Start the generator set. Verify that the generator set shuts down after approximately
25--35 seconds of operation. Remove the jumper wire from the LOP switch and ground. Start the generator set and run it for at least 25--35 seconds to verify that the generator set does not shut down.
Overcrank Shutdown
Disconnect the starter motor lead at the starter solenoid terminal and the fuel solenoid valve. Press the RUN button on the controller. Observe that the generator set simulates cranking for 15 seconds and then rests for 15 seconds. Check that the generator set shuts down after the third crank/rest cycle.
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
TP-6735 9/10 Section 5 Component Testing and Adjustment 71
High Engine Temperature Shutdown
Disconnect the harness (connector P5) at the engine temperature sensor (CTS).
See Figure 5-18 for the
CTS location.
Connect a jumper wire across the temperature sensor (CTS) connections in connector P5.
See Figure 5-19. Press RUN to start the generator set.
After 5 seconds, verify that the controller display shows
HE, indicating a high engine temperature fault. If a
Model RRT transfer switch is connected, the generator set will run for 5 minutes in engine cooldown mode. The display will alternate HE and COOL.
Press the OFF button on the controller and remove the jumper wire. Start the generator set and verify that the generator set does not enter the engine cooldown cycle or shut down on an HE fault. Reconnect P5 to the CTS.
1
1. CTS location
Figure 5-18 Temperature Sensor CTS Location
GM66561
Figure 5-19 Temperature Sensor Connector P5
GM69754
5.10.2 Fault Shutdown Switches
Check the low oil pressure and high engine temperature shutdown switches on the engine by performing the following tests.
If the sensor does not function as described, replace it.
WARNING
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running.
Replace guards, screens, and covers before operating the generator set.
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 connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.
Temperature Sensor (CTS)
The temperature sensor (CTS) is used to monitor engine temperature for the high engine temperature fault shutdown (HE). See Figure 5-18 for the coolant temperature sensor location. Press the OFF button on the controller to stop the generator set and allow the generator set to cool. Disconnect the CTS and use an ohmmeter to measure the resistance across the sensor.
The sensor resistance varies with temperature and should be within the values shown in Figure 5-20. If the resistance is very low (indicating a short circuit) or very high (indicating an open circuit), replace the CTS.
Note: The CTS is located in the engine oil pan. Drain the engine oil before removing the switch.
Temperature,
_C (_F)
30 (86)
100 (212)
Resistance, Ohms
2100--2400
180--200
Figure 5-20 Temperature Sensor CTS Resistance
Readings
72 Section 5 Component Testing and Adjustment TP-6735 9/10
Low Oil Pressure (LOP) Switch
The low oil pressure (LOP) switch is located under the engine air cleaner. See Figure 5-21.
Remove the LOP switch and install an oil pressure gauge to verify that the engine oil pressure is within the range specified in Section 1, Specifications, before testing or replacing the LOP switch. To test the LOP switch, reinstall the switch and start the generator set. If the unit shuts down, disconnect lead 13 from the LOP switch and reset the controller. Restart the generator set and verify that it does not shut down. A successful restart indicates a faulty LOP switch. Replace switch.
tp6519
1. Oil pressure switch
1
Figure 5-21 Oil Pressure Switch Location (under the air cleaner)
TP-6735 9/10 Section 5 Component Testing and Adjustment 73
5.11 Fuel Systems
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
The fuel supplier provides and maintains manual shut-off valves and the primary regulator.
See the generator set installation manual for fuel pipe size recommendations. Verify that the fuel system capacity is adequate to supply the generator set plus all other gas appliances.
A factory-installed secondary regulator and 12 VDC solenoid valve are located in the front air intake compartment.
The controller energizes the fuel solenoid valve to open at startup and deenergizes the valve to close at shutdown.
The secondary fuel regulator reduces fuel pressure for delivery to the fuel block.
The fuel flows from the fuel block to the carburetor in a gaseous state. The carburetor mixes the fuel with intake air for consumption by the engine.
1
2
(Enlarged to show detail)
Refer to the troubleshooting instructions in Section 3,
Troubleshooting, to identify generator set operation problems that may be caused by an inadequate fuel supply, incorrect adjustments, or damaged fuel system components. Then use the instructions in this section to check fuel system components.
5.11.1 Fuel Solenoid Valve
A solenoid valve upstream of the regulator and the flexible fuel connector provides automatic fuel on/off control. See Figure 5-22. The engine starting battery powers the solenoid valve and the engine starting controls open the valve when the engine cranks or runs.
Fuel Valve Operation Test Procedure
1. Disconnect the positive (+) battery lead from the gas valve terminal.
2. Apply 12 VDC to the gas valve terminal and listen for an audible click, indicating that the valve actuates.
3. Replace the gas valve if it does not actuate in step 2.
1. Regulator
2. Fuel block (not shown) or LP orifice location (see
Figure 5-24)
Figure 5-22 Fuel System
3
4
DSAI Lead Connection
GM66563
3. Fuel inlet, 1/2 in. NPT female
4. Fuel solenoid valve and digital spark advance ignition (DSAI) leads
74 Section 5 Component Testing and Adjustment TP-6735 9/10
5.11.2 Digital Spark Advance Ignition
(DSAI) Timing
The digital spark advance ignition (DSAI) optimizes the engine timing for the selected fuel, natural gas or LP.
The DSAI timing leads are located near the fuel solenoid valve.
See Figure 5-22.
Connect the DSAI leads together for natural gas fuel. Disconnect the leads if LP is used. See Figure 5-22 or Figure 5-23.
See the engine service manual for ignition system service information.
Natural Gas
LP
DSAI Timing Lead Connection
Connect
Disconnect
Figure 5-23 DSAI Lead Connection
6
5.11.3 Fuel Regulators
The typical gaseous fuel system uses two regulators.
The primary regulator reduces the line pressure to an allowable inlet pressure for the secondary regulator.
The fuel supplier provides and maintains the primary regulator. The secondary regulator is factory-installed on the generator set and is designed for a maximum inlet pressure of 2.7 kPa (6 oz./in.
2
) or 280 mm (11 in.) water column.
Note: Do not attempt to adjust the fuel mixture or engine speed by adjusting the regulators.
The fuel lockoff prevents fuel flow when the engine is not operating. See Figure 5-24. Do not try to adjust the fuel pressure, fuel mixture, or engine speed using the fuel lockoff.
Checking the Fuel Pressure
Use a gauge or manometer to check the fuel pressure at the secondary regulator inlet.
See Figure 5-24.
Measure the fuel pressure with the generator set running at rated load.
The fuel pressure should be
5--11 in. water column or 1.2--2.7 kPa. Contact the fuel supplier if the inlet pressure is not within the specified range.
5
2
5
1
2
3
4
4
3
8
7
14RES/RESL
1. Fuel block (14RES/RESL)
2. Secondary regulator
3. Fuel lockoff (do not adjust)
4. Fuel inlet, 1/2 in. NPT
Figure 5-24 Fuel Regulators
20RES/RESL
5. Hose fitting
6. LP orifice fits inside hose fitting (20RES/RESL)
Regulator, side view
TP-6735
7. Regulator vent hose (20RES/RESL only)
8. Inlet pressure check location
TP-6735 9/10 Section 5 Component Testing and Adjustment 75
5.11.4 Fuel Conversion, 20RES/RESL
For LP vapor fuel, an orifice is used in the fuel line. The unit is typically shipped set up for natural gas, with the loose orifice tied near the fuel solenoid valve. To convert to LP vapor, install the orifice and disconnect the spark advance leads as described below. See Figure 5-22 for the fuel system component locations.
1
2
LP setup shown
3
4
1. LP orifice
2. Hose fitting
3. Regulator
4. Fuel inlet, 1/2 in. NPT female
5. Vent hose
5
Figure 5-25 Fuel Regulator and LP Orifice,
20RES/RESL
GM66563
Procedure to Convert from NG to LP, 20RES/RESL
1. Press the OFF button on the generator set controller.
2. Disconnect the power to the battery charger.
3. Disconnect the generator set engine starting battery, negative (--) lead first.
4. Turn off the fuel supply.
5. Remove the hose clamp and fuel hose from the hose fitting. See Figure 5-25.
6. Insert the orifice into the hose fitting.
See
Figure 5-25.
7. Slide the hose onto the hose fitting and secure it with the clamp.
8. Disconnect digital spark-advance module (DSAI) leads 65 and N5 for LP.
See Figure 5-28 and
Figure 5-26.
9. Connect and turn on the new fuel supply.
10. Check that the generator set is off. Check that the
OFF LED on the controller is flashing.
11. Reconnect the generator set engine starting battery leads, negative (--) lead last.
12. Reconnect power to the battery charger.
13. Start the generator set by pressing the RUN button on the generator set controller.
14. Check for leaks using a gas leak detector.
15. Run the generator set and check the operation.
Use the controller to adjust the output and stability if necessary.
16. Press the OFF button to shut down the generator set.
To convert from LP vapor to natural gas, remove the fuel orifice and connect the DSAI leads together.
Fuel
Natural Gas
LP
DSAI Leads 65 and N
Connect lead 65 to N
Disconnect
Figure 5-26 DSAI Connections
76 Section 5 Component Testing and Adjustment TP-6735 9/10
5.11.5 Fuel Conversion, 14RES/RESL
Two fuel connections on the fuel block allow fieldconversion between natural gas and LP vapor. The fuel metering valves are factory-set and sealed to comply with applicable emission standards and to provide the best possible hot and cold starting.
Note: Do not adjust the factory-sealed fuel-metering adjustments on the fuel block. Changing the fuelmetering adjustments may violate federal or state laws.
Use the following procedure to convert from natural gas
(NG) to LP vapor, moving the fuel connection from the natural gas to the LP port, plugging the natural gas port, and disconnecting the leads for the digital spark advance ignition (DSAI). See Figure 5-22 for the fuel system component locations.
Procedure to convert from NG to LP, 14RES/RESL
1. Press the OFF button on the generator set controller.
2. Disconnect the power to the battery charger.
3. Disconnect the generator set engine starting battery, negative (--) lead first.
4. Turn off the fuel supply.
5. Remove the hose clamp and fuel hose from the hose fitting in the fuel block. See Figure 5-27.
5
1
2
4
Natural gas setup shown
3
6. Remove the hose fitting from the natural gas outlet port in the fuel block. See Figure 5-27.
7. Remove the plug from the LP port in the fuel block.
See Figure 5-27.
8. Clean the plug with a dry cloth or brush, apply fresh pipe sealant, and install the plug into the natural gas outlet port.
9. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant to the threads, and install the fitting into the LP port.
Note: Do not adjust the fuel metering valves.
10. Slide the hose onto the hose fitting and secure it with the clamp.
11. Disconnect the DSAI leads for LP. See Figure 5-22 for the location of the DSAI leads.
Fuel
Natural Gas
LP
DSAI Leads 65 and N
Connect lead 65 to N
Disconnect
Figure 5-28 DSAI Connection
12. Connect and turn on the new fuel supply.
13. Check that the generator set is off. Check that the
OFF LED on the controller is flashing.
14. Reconnect the generator set engine starting battery leads, negative (--) lead last.
15. Reconnect power to the battery charger.
16. Start the generator set by pressing the RUN button on the generator set controller.
17. Check for leaks using a gas leak detector.
18. Run the generator set and check the operation.
Use the controller to adjust the output and stability if necessary.
19. Press the OFF button to to shut down the generator set.
To convert from LP vapor to natural gas, follow the same fuel conversion procedure, moving the hose fitting to the natural gas port and plugging the LP port. Connect the
DSAI leads for natural gas. See Figure 5-28.
1. Fuel block
2. Fuel metering valves—factory-sealed, do not adjust
3. Fuel inlet, 1/2 in. NPT
4. Hose fitting
5. Plug
GM66563
Figure 5-27 Fuel Block, 14RES/RESL
TP-6735 9/10 Section 5 Component Testing and Adjustment 77
5.11.6 Fuel Metering Valve Adjustment,
14RES/RESL Only
The fuel system is factory-adjusted to comply with applicable emission standards and to provide the best possible hot and cold starting. The fuel metering valves are sealed to prevent field adjustments.
If the fuel metering valve requires adjustment, do not break the seals on the factory-installed fuel metering valve.
Obtain a new fuel metering valve to replace the factory-installed valve, and adjust the fuel mixture according to the instructions in this section.
See
Figure 5-27 for the fuel metering valve location. Refer to the generator set Parts Catalog for the fuel metering valve part number.
Note: Adjusting the factory-installed fuel metering valves on emissions-certified generator sets will void the emission certification.
Use a universal exhaust gas oxygen (UEGO) sensor to check the fuel mixture after replacing the fuel regulator, carburetor, or silencer. Use the following procedure to check the fuel mixture after the engine has reached normal operating temperature.
Only trained, authorized service technicians may adjust the new fuel metering valve. The adjustment procedure requires a digital voltmeter (DVM), UEGO oxygen sensor service kit GM29385, and a load bank capable of the rated kW for the fuel being used. Always use an oxygen sensor when adjusting the fuel metering valves.
Observe the following safety precautions while performing the procedure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the exhaust system.
Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.
Fuel Mixture Check/Fuel Metering Valve
Adjustment Procedure
1. Press the OFF button on the RDC/DC controller.
2. Disconnect power to the battery charger.
3. Remove the oxygen sensor plug from the exhaust manifold and install the oxygen sensor.
See
Figure 5-29 for location.
1
GM74908
1. Oxygen sensor mounting location
Figure 5-29 Oxygen Sensor Mounting Location on the 14RES/RESL
4. Connect the oxygen sensor to the engine starting battery, control module, and voltmeter as shown in
Figure 5-31.
5. Reconnect power to the battery charger.
6. Press the RUN button on the controller to start the generator set.
7. Allow the generator set to run until the engine reaches normal operating temperature.
8. With the generator set at normal operating temperature, apply rated load.
9. Connect one of the DVM leads to the oxygen sensor lead.
Connect the other DVM lead to ground and measure the output voltage of the oxygen sensor (potential to ground).
10. Adjust the fuel metering valve as required to obtain the output from the oxygen sensor specified in
Figure 5-30.
The output of the oxygen sensor reads high when the mixture is fuel-rich and close to zero volts when the mixture is lean.
Model
14RES/RESL
Oxygen Sensor Reading,
VDC
Natural Gas
2.70
±0.05
2.70
LP
±0.05
Figure 5-30 Acceptable Oxygen Sensor Readings
11. When the fuel mixture is correct, use thread sealant to seal the metering valve adjustment screws.
78 Section 5 Component Testing and Adjustment TP-6735 9/10
12. Remove the load and allow the generator set to run unloaded to cool for at least 5–10 minutes.
13. Stop the generator set by pressing the OFF button on the controller.
14. Disconnect the generator set engine starting battery, negative (--) lead first.
15. Allow the generator set exhaust system to cool.
16. Disconnect the DVM leads from the oxygen sensor.
17. Remove the oxygen sensor from exhaust manifold.
18. Apply a small amount of antiseize compound to exhaust plug and reinstall the plug into the exhaust manifold.
19. Check that the generator set is off by checking the
OFF LED on the controller.
20. Reconnect the generator set engine starting battery, negative (--) lead last.
21. Reconnect power to the battery charger.
3
1
2
GM-28981-
4
1. Battery power supply connection
2. Digital voltmeter (DVM) connection
3. Air/fuel control module connection
4. Oxygen sensor connection
Figure 5-31 UEGO Sensor Interface Harness GM28981 Electrical Connections
TP-6735 9/10 Section 5 Component Testing and Adjustment 79
5.12 Starter Relay
The starter relay is located under the controller. See
Figure 5-32.
1
GM66566
1. Starter relay
Figure 5-32 Starter Relay Location
The starter relay contains an internal diode across the relay coil. See Figure 5-33. Continuity checks across the coil terminals will show continuity (low resistance) in one direction and an open circuit in the other.
Figure 5-34 shows the starter relay connections.
Figure 5-33 Starter Relay
Relay Terminal
30
85
86
87
87A
Lead
14P
N7
71
14S
NC
Figure 5-34 Starter Relay Connections
259391
80 Section 5 Component Testing and Adjustment TP-6735 9/10
5.13 Continuity Checks
WARNING
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
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 connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.
To further check generator set components, disconnect the battery and remove wiring harness plugs from the controller circuit board. Use an ohmmeter to check the continuity of the components listed in Figure 5-35. Also see Section 7, Wiring Diagrams.
Figure 5-35 gives resistance readings for functional components. A zero reading on the ohmmeter indicates continuity. No ohmmeter reading indicates very high resistance or an open circuit.
A measurement that varies significantly from the value shown in the table indicates a faulty component; replace faulty components.
Note: Disconnect the generator set battery before performing continuity checks to prevent damage to the ohmmeter.
For rotor and stator resistance and continuity checks, see Section 5.3, Stator, and Section 5.4, Main Field
(Rotor).
Component
P1 wiring harness
Controller fuse and wiring
Auxiliary winding breaker (20-amps)
Low oil pressure (LOP) switch *
Temperature sensor
(CTS) *
Ohmmeter
Connections
P1-2 and ground
P2-6 and P2-7 (stator leads 11 and 44)
P2-3 and P2-4 (stator leads 55 and 66)
P1-1 and battery positive
(+)
P2-3 and stator lead 55
Lead 13 and ground
(engine block)
P1-9 and P1-10
Ohmmeter
Scale
R x 1
R x 1
R x 1
R x 100
R x 100
R x 100
R x 1000
Generator Set
State
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Ohmmeter Readings for Operative
Components
Zero ohms (continuity)
Any other reading indicates a poor ground connection.
Zero ohms (continuity). If no continuity, check wiring.
Zero ohms (continuity). If no continuity, check fuse F1 and wiring.
Zero ohms (continuity). If no continuity is found, check fuse F3 and wiring.
Zero ohms (continuity). If no continuity is found, check for an open circuit and/or a blown fuse.
Zero ohms (continuity). No continuity indicates a faulty switch and/or wiring.
180--2500 ohms, depending on engine temperature. See
Section 5.10.2. Zero ohms or an open circuit indicates faulty wiring or a faulty switch.
* See Section 5.10.2, Fault Shutdown Switches
Figure 5-35 Continuity Checks
TP-6735 9/10 Section 5 Component Testing and Adjustment 81
5.14 Circuit Protection
If the generator set circuit breaker trips or the fuses blow repeatedly, see Section 3, Troubleshooting, for possible causes.
5.14.1 Line Circuit Breaker
A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. The line circuit breaker location is shown in Figure 1-1. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position. With the breaker in the OFF position the generator set runs but the generator output is disconnected from the load.
5.14.2 Fuses and Mini-Breaker
Two fuses and a mini-breaker protect the alternator and electrical controls. The fuses and breaker are located in the service access area of the RDC/DC controller. A battery charger fuse is located in the positive battery lead. Check for and replace any blown fuses or reset the breaker before replacing other components.
See Figure 5-36 for fuse part numbers. Always identify and correct the cause of a blown fuse before restarting the generator set. Refer to Section 3, Troubleshooting, for conditions that may indicate a blown fuse. Replace blown fuses with identical replacement parts.
Fuse/Breaker
Auxiliary winding
Rating,
Amps
20
Starter/Fuel/Flash
(Violet)
Controller (Brown)
Battery charger
7.5
3
10
Figure 5-36 Circuit Protection
Label
BRDCB
F2
Part Number
Resettable mini-breaker
GM66129
F3
—
GM66128
AGS 10
82 Section 5 Component Testing and Adjustment TP-6735 9/10
Section 6 Disassembly/Reassembly
This section provides instructions for the disassembly and reassembly of the generator set alternator. Before beginning the generator disassembly or reassembly procedure, carefully read all safety precautions at the beginning of this manual.
The engine and generator set may use both American
Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.
WARNING
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
DANGER
6.1 Initial Steps
Perform the following steps before disassembling the generator set.
1. Disconnect AC power to the generator set by opening the upstream circuit breaker. (AC power is connected to the generator set for AC-powered accessories.)
2. Shut off the fuel supply. Disconnect the fuel system if necessary to tilt the generator set. Ventilate the area to clear fumes.
3. Allow the generator set and engine to cool.
4. Verify that any hoists or lifting devices used in the disassembly or reassembly procedure are rated for the weight of the generator set, which is approximately 227 kg (500 lb.).
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.
TP-6735 9/10 Section 6 Disassembly/Reassembly 83
6.2 Disassembly
The disassembly procedure explains how to disassemble the generator set enclosure and other parts in order to access the alternator for service. The procedure provides important information to minimize disassembly time and indicates where special configurations exist which may require taking notes.
Remove enclosure
Remove the generator set enclosure as described in the following steps. See Figure 6-1.
1. Open the enclosure roof.
2. Press the OFF button on the generator set controller.
3. Remove 6 nuts and remove the roof.
See
Figure 6-2.
1
2
Right Side
5
1. Roof
2. Rear panel (exhaust end)
3. Left side panel
4. Front panel (air intake end)
5. Right side panel
Figure 6-1 Enclosure
3
4
Front (air intake end)
ADV7341
1
1
GM72523
1. Remove three nuts on each side
Figure 6-2 Roof Removal
84 Section 6 Disassembly/Reassembly TP-6735 9/10
4. Remove the exhaust duct panel over the muffler by removing four screws. See Figure 6-3.
5. Remove the top exhaust panel.
1
1
6. Disconnect the latch rods at the red plastic connectors. See Figure 6-4.
1
2
1. Exhaust duct panel. Remove 4 screws
2. Top exhaust panel. Remove 2 screws.
Figure 6-3 Heat Shield
GM66564
GM72523
1. Disconnect latch rods
Figure 6-4 Door Latch Detail
7. See Figure 6-5.
Reach inside the enclosure to move each latch hinge aside. Remove two nuts on each side (total of four nuts).
8. Remove one screw near the controller area.
9. Pull the right side panel up and off.
Note: Part of the right side panel is cut away in this view to reveal the fasteners.
1
1
2
1. Remove 4 nuts inside the enclosure (2 left and 2 right).
2. Remove screw.
Figure 6-5 Right Side Panel
TP-6735 9/10
GM72523
Section 6 Disassembly/Reassembly 85
10. Remove the front panel. See Figure 6-6.
1
16. From the inside of the enclosure, remove four nuts securing the left side panel. See Figure 6-8.
17. Pull the panel up and off.
1
ADV-7876
2
1. Remove 2 screws
Figure 6-6 Front Panel (air intake end panel)
GM72523
11. Unplug the carburetor heater (if equipped) from the
120VAC receptacle.
12. Unplug the battery charger from the 120VAC receptacle.
13. Disconnect the generator set engine starting battery, negative (--) lead first.
14. Disconnect output leads or load circuit cables at the field-connection terminal block.
15. Remove two nuts and lift off the exhaust end panel.
See Figure 6-7.
1
1. Left side panel
2. Remove 4 nuts
Figure 6-8 Left Side Panel
1
2
1. Remove 2 screws
Figure 6-7 Rear Panel (exhaust end panel)
GM72523
86 Section 6 Disassembly/Reassembly TP-6735 9/10
18. Remove the remaining exhaust duct panels and alternator air inlet duct. See Figure 6-9.
1
2
2
2
TP-6735
1. Alternator duct
2. Exhaust duct panels
Figure 6-9 Exhaust and Alternator Ducts
19. Disconnect the muffler from the engine at the two flange connections and remove the muffler. See
Figure 6-10.
Note: Use new exhaust gaskets when re-installing the muffler.
Generator Disassembly
20. Disconnect the following alternator wiring inside the controller junction box.
See the wiring diagrams in Section 7.
a. Disconnect lead 55 from the mini-breaker on the controller.
b. Disconnect P2 from the controller.
c. Disconnect leads 2 and 3 from neutral stud L0.
d. Disconnect leads 1 and 4 from the circuit breaker.
21. Remove the bolts securing the two alternator end vibromounts to the skid. Loosen the two engine vibromounts. See Figure 6-10.
22. Raise the alternator end of the generator set enough to place a wood support beneath the rear of the engine.
The wood support must be long enough to span the opening in the base.
See
Figure 6-11.
Note: Use a hoist or lifting device that is rated for the weight of the generator set.
See
Section 6.1.
1
2
GM51561
1
1. Engine support
Figure 6-11 Wood Support
4
1. Exhaust flanges (qty. 2)
2. Muffler
3. Alternator vibromounts (qty. 2)
4. Engine vibromounts (qty. 2)
Figure 6-10 Muffler and Vibromounts
3
TP-6735
TP-6735 9/10 Section 6 Disassembly/Reassembly 87
23. Remove the alternator support bracket from the alternator shell. See Figure 6-12.
1 2
5
1
TP-6735
1. Alternator support bracket
Figure 6-12 Alternator Support Bracket
24. Remove the cable tie that attaches the brush leads to the end bracket. See Figure 6-13.
25. Check the brushes. See Figure 6-13.
Note: The brushes are spring-loaded. Be sure to insert a retaining wire to hold the brushes as described below.
a. Raise the brushes in the brush holder and insert a small piece of wire into the brush holder retainer wire hole.
b. Remove the brush holder from the end bracket.
c. Inspect the brushes. Replace brushes if they show uneven wear or when they are worn to half of their original size.
See Section 5.6,
Brushes.
7
1
4
2
5
3
6
1. Brush holder
2. Brush(es)
3. Cable tie
4. Slip rings
2
5. Retainer wire
6. Spring
7. Shim
Figure 6-13 Alternator End Bracket and Brush
Assembly
GM67344
88 Section 6 Disassembly/Reassembly TP-6735 9/10
26. Remove the alternator overbolts and centering washers. See Figure 6-14.
1
2
3
4 b. Loosen the rotor assembly by striking the side of the rotor with a soft-faced hammer to loosen it from the tapered crankshaft fitting.
See
Figure 6-15. Rotate the rotor and strike it on alternate sides until it can be rocked slightly back and forth.
Note: Do not strike the slip rings.
c. Remove the thrubolt and the rotor. Set the rotor assembly aside.
3
Note: Do not strike the slip rings when removing the rotor.
2
5
1. End bracket (brush assembly shown attached)
2. Stator windings (outer)
3. Rotor (inner). Also see Figure 6-15.
4. Stator shell
5. Overbolts (qty. 4)
Figure 6-14 Alternator Assembly
27. Using a soft-faced hammer, strike the sides of the end bracket with medium-force blows to remove the end bracket from the stator or remove the end bracket from the stator using a puller. Set the end bracket assembly aside.
28. The stator leads are routed through the bulkhead and into the controller junction box. Carefully pull the leads out of the junction box. Pull the leads and conduit out through the bulkhead to free the alternator for removal.
29. Carefully pull the stator from the rotor.
See
Figure 6-14.
30. Remove the rotor as follows: a. Loosen but do not remove the rotor thrubolt.
Use a strap wrench on the rotor to keep the rotor from turning during loosening, if necessary. See Figure 6-15.
1
1. Rotor thrubolt
2. Slip rings
3. Generator adaptor (14RES/RESL only)
GM67344
Figure 6-15 Rotor Assembly with Thrubolt
31. 14RES/RESL only: Remove the four generator adapter mounting bolts to remove the generator adapter, if necessary. See Figure 6-16.
1
1. Adapter mounting holes
Figure 6-16 Generator Adapter (14RES/RESL)
GM60283
TP-6735 9/10 Section 6 Disassembly/Reassembly 89
6.3 Reassembly
1. 14RES/RESL only: Reinstall the generator adapter onto the engine, if necessary.
a. Attach the generator adapter to the engine using four 7/16-14 x 1.0 in. hex cap bolts and washers. See Figure 6-16.
b. Torque the bolts to 40 Nm (28 ft. lb.).
2. Install the rotor. See Figure 6-17.
a. Clean the crankshaft stub and mating surface on the fan hub. Do not use antiseize compound when reassembling the rotor.
b. Install the rotor onto the engine crankshaft.
c. Thread the thrubolt with hardened washer through the actuator and rotor into the crankshaft. Do not tighten the thrubolt at this time.
3
2
1
1. Rotor thrubolt
2. Hardened washer
3. Fan
Figure 6-17 Rotor Assembly
3. Install the stator and end bracket.
a. Re-attach the alternator support bracket to the alternator shell. The hole in the bracket must face the engine. See Figure 6-18.
1
GM67344
GM67344
1. Alternator support bracket
Figure 6-18 Alternator Support Bracket b. Align the stator so that the alternator support bracket is at the bottom.
Install the stator assembly around the rotor.
c. Align the alignment mark on the top of the stator with the center of the slot in the generator adapter.
d. Route the leads connected to the alternator end bracket through the opening in the base of the alternator frame.
90 Section 6 Disassembly/Reassembly TP-6735 9/10
e. Place the end bracket onto the stator assembly, lining up the alignment marks on the top of the stator and end bracket. See Figure 6-19.
f. Thread the four overbolts with locating washers through the end bracket and into the generator adapter.
See Figure 6-19 and Figure 6-20.
Position the locating tab of each washer to the outer edge of the oblong (OBROUND) hole on the end bracket.
The overbolts should be parallel to the outside of the alternator. If the overbolts are slanted, rotate the locating washer 1/2 turn.
Do not final tighten the overbolts at this time.
1
2
3
4
1. End bracket (brush assembly shown attached)
2. Stator windings (outer)
3. Rotor (inner). Also see Figure 6-15.
4. Stator shell
5. Overbolts (qty. 4)
Figure 6-19 End Bracket and Brush Assembly
5
4
1
2
6519
3
1. End bracket
2. Alternator
3. Alternator frame vibromount
4. Overbolts
Figure 6-20 Generator Set, Right Side
4. Secure the generator set to the skid.
a. Raise the alternator end of the generator set and remove the wood support block(s).
b. Lower the end of the generator set and reinstall the screws and washers that secure the vibromounts to the skid.
Tighten all four vibromounts (for the alternator and engine) to
5.4 Nm (4 ft. lbs.). Do not overtighten. See
Figure 6-21.
5. Tighten the four alternator assembly overbolts to
14.9 Nm (11 ft. lb.). See Figure 6-21.
6. Tighten the rotor thrubolt to 85 Nm (63 ft. lb.). It may be necessary to keep the engine flywheel from turning while torquing the rotor thrubolt.
1
TP-6735 9/10
3
2
1. Alternator overbolts (qty. 4)
2. Alternator vibromounts (qty. 2)
3. Engine vibromounts (qty. 2)
Figure 6-21 Vibromounts and Overbolts
TP-6735
Section 6 Disassembly/Reassembly 91
7. Reinstall the end bracket components.
a. Inspect the brushes. If brushes show uneven wear or are worn to less than half their original length, replace them. See Section 5.6.
b. Install the brush holder with shim onto the end bracket. Verify that the brushes are not sticking in the holder.
c. Verify that the brushes are centered on the slip rings. If required, insert spacers between the mounting surface and brush holder to center the brushes on the slip rings. See Figure 6-22.
See Section 5.6, Brushes, for more information.
d. Use the cable tie to secure the brush leads to the end bracket.
4
1
1
3
2
3
4
5
6
7
New 19.0 mm (0.75 in.)
8
Correct
3
GM67344
Incorrect
9
3
2
2
1. Brush holder
2. Slip ring (s)
3. Brush(es)
4. Retainer wire
5. Cable tie
Side View
TP5867
6. Shim
7. Spring
8. Correctly positioned brush
9. Incorrectly positioned brush
Figure 6-22 Brush Assembly and Positioning
92 Section 6 Disassembly/Reassembly TP-6735 9/10
8. Install the exhaust system. See Figure 6-23.
a. Install the heat shield onto the alternator exhaust support.
b. Using new gaskets, connect the engine exhaust muffler to the engine at the flanges. Do not final tighten the mounting hardware.
c. Secure the muffler mounting tab to the heat shield.
d. Torque the nuts securing the engine muffler flange to the engine to 24 Nm (17.7 ft. lb.).
9. Reinstall the alternator and exhaust duct panels shown in Figure 6-24.
1
4
1. Exhaust flanges (qty. 2)
2. Muffler
3. Alternator vibromounts (qty. 2)
4. Engine vibromounts (qty. 2)
Figure 6-23 Exhaust System
2
3
TP-6735
2
2
1
2
TP-6735
1. Alternator duct
2. Exhaust duct panels
Figure 6-24 Alternator and Exhaust Ducts
10. Reconnect the following alternator wiring inside the controller junction box. See the wiring diagrams in
Section 7.
a. Reconnect lead 55 to the mini-breaker on the controller.
b. Reconnect P2 to the controller.
c. Reconnect leads 2 and 3 to neutral stud L0.
d. Reconnect leads 1 and 4 to the circuit breaker.
e. Reconnect any other controller connections that were removed during disassembly.
11. Press the OFF button on the generator set controller.
12. Reconnect the generator set engine starting battery, negative (--) lead last.
13. Reconnect the carburetor heater (if equipped) to the 120VAC receptacle.
14. Reconnect the battery charger to the 120VAC receptacle.
15. Reconnect output leads or load circuit cables at the field-connection terminal block.
TP-6735 9/10 Section 6 Disassembly/Reassembly 93
16. Reinstall the enclosure panels in reverse order of removal.
See Figure 6-25 and refer to the disassembly instructions, if necessary.
a. Install the left side panel.
b. Install the exhaust end panel.
c. Install the front panel.
d. Install the right side panel and reconnect the door latch rods. See Figure 6-26.
e. Install the exhaust panels shown in
Figure 6-27.
f. Install the front panel.
g. Install the generator set housing roof.
17. Re-apply the 120VAC power supply to the generator set by closing the upstream circuit breaker.
18. Turn on the fuel supply. Press RUN to start the generator set and check for leaks with the engine running.
19. Press OFF to turn off the generator set. Then press
AUTO if an automatic transfer switch or remote start/stop switch is used.
20. Lower and secure the roof.
1. Reconnect latch rods
Figure 6-26 Door Latch Detail
2
1. Exhaust duct panel (4 screws)
2. Top exhaust panel (2 screws)
1
Figure 6-27 Exhaust Duct Top Panels
1
2
3
GM72523
1
GM66564
4
Right Side
5
1. Roof
2. Rear panel (exhaust end)
3. Left side panel
4. Front panel (air intake end)
5. Right side panel
Figure 6-25 Generator Set Enclosure
Front (air intake end)
ADV7341
94 Section 6 Disassembly/Reassembly TP-6735 9/10
Section 7 Wiring Diagrams
Figure 7-1 lists the wiring diagram numbers and locations.
Wiring Diagram Description
Schematic Diagram
Point-to-Point Wiring Diagram
Figure 7-1 Wiring Diagrams and Schematics
Drawing Number Page
ADV-7697
GM69754
96
97
TP-6735 9/10 Section 7 Wiring Diagrams 95
Figure 7-2 Schematic Diagram, ADV-7697
96 Section 7 Wiring Diagrams TP-6735 9/10
-
Figure 7-3 Point-to-Point Wiring Diagram, GM69754
TP-6735 9/10 Section 7 Wiring Diagrams 97
-
Notes
98 Section 7 Wiring Diagrams TP-6735 9/10
Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere
ABDC
AC
A/D
ADC after bottom dead center alternating current analog to digital adj.
ADV advanced digital control; analog to digital converter adjust, adjustment advertising dimensional drawing
Ah
AHWT
AISI amp-hour anticipatory high water temperature
American Iron and Steel
Institute
ALOP alt.
Al
ANSI
AO
APDC
API approx.
approximate, approximately
AQMD Air Quality Management District
AR as required, as requested
AS anticipatory only
Air Pollution Control District
American Petroleum Institute
ASE
ASME as supplied, as stated, as suggested
American Society of Engineers
American Society of
Mechanical Engineers assy.
ASTM anticipatory low oil pressure alternator aluminum
American National Standards
Institute (formerly American
Standards Association, ASA)
ATDC
ATS auto.
aux.
assembly
American Society for Testing
Materials after top dead center automatic transfer switch automatic auxiliary avg.
AVR
AWG
AWM bat.
BBDC
BC
BCA
BCI average automatic voltage regulator
American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator
Battery Council International
BDC
BHP before dead center brake horsepower blk.
black (paint color), block
(engine) blk. htr.
block heater
BMEP bps br.
brake mean effective pressure bits per second brass
BTDC
Btu before top dead center
British thermal unit
Btu/min.
British thermal units per minute
C cal.
CAN
CARB
CB cc
Celsius, centigrade calorie controller area network
California Air Resources Board circuit breaker cubic centimeter
CCA ccw.
CEC cert.
cfh cold cranking amps counterclockwise
Canadian Electrical Code certificate, certification, certified cubic feet per hour cfm
CG
CID
CL cm
CMOS cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogeneration cogen.
com coml communications (port) commercial
Coml/Rec Commercial/Recreational conn.
cont.
CPVC crit.
CRT
CSA connection continued chlorinated polyvinyl chloride critical cathode ray tube
Canadian Standards
Association
CT
Cu cUL
CUL cu. in.
cw.
CWC cyl.
D/A
DAC dB dB(A)
DC
DCR deg.,
° dept.
current transformer copper
Canadian Underwriter’s
Laboratories
Canadian Underwriter’s
Laboratories cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter decibel decibel (A weighted) direct current direct current resistance degree department
DFMEA Design Failure Mode and
Effects Analysis dia.
DI/EO diameter dual inlet/end outlet
DIN
DIP
DPDT
Deutsches Institut fur Normung e. V. (also Deutsche Industrie
Normenausschuss) dual inline package double-pole, double-throw
DPST
DS
DVR e.g.
EG
EGSA double-pole, single-throw disconnect switch digital voltage regulator
E, emer.
emergency (power source)
ECM electronic control module, engine control module
EDI
EFR electronic data interchange emergency frequency relay for example (exempli gratia) electronic governor
EIA
EI/EO
EMI
Electrical Generating Systems
Association
Electronic Industries
Association end inlet/end outlet electromagnetic interference emiss.
eng.
EPA
EPS
ER
ES
ESD emission engine
Environmental Protection
Agency emergency power system emergency relay engineering special, engineered special electrostatic discharge
TP-6735 9/10 Appendix 99 freq.
FS ft.
ft. lb.
ft./min.
ftp g ga.
gal.
gen.
genset
GFI est.
E-Stop etc.
exh.
ext.
F fglass.
FHM fl. oz.
flex.
estimated emergency stop et cetera (and so forth) exhaust external
Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute file transfer protocol gram gauge (meters, wire size) gallon generator generator set ground fault interrupter
GND, gov.
gph gpm gr.
GRD ground governor gallons per hour gallons per minute grade, gross equipment ground gr. wt.
gross weight
H x W x D height by width by depth
HC hex cap
HCHT
HD
HET hex high cylinder head temperature heavy duty high exhaust temp., high engine temp.
hexagon
Hg
HH
HHC
HP hr.
HS hsg.
HVAC mercury (element) hex head hex head cap horsepower hour
HWT
Hz
IC
ID heat shrink housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) integrated circuit inside diameter, identification
IEC
IEEE
IMS
International Electrotechnical
Commission
Institute of Electrical and
Electronics Engineers improved motor starting in.
inch in. H
2
O inches of water in. Hg inches of mercury in. lb.
Inc.
ind.
J
JIS inch pounds incorporated industrial int.
internal int./ext.
internal/external
I/O input/output
IP
ISO iron pipe
International Organization for
Standardization joule
Japanese Industry Standard
k
K kA
KB
KBus kg kg/cm
2 kgm kg/m
3 kHz kilo (1000) kelvin kiloampere kilobyte (2
10 bytes)
Kohler communication protocol kilogram kilograms per square centimeter kilogram-meter kilograms per cubic meter kilohertz kJ kilojoule km kilometer kOhm, k
Ω kilo-ohm kPa kilopascal kph kV kilometers per hour kilovolt kVA kVAR kW kWh kWm kWth kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical kilowatt-thermal
L
LAN liter local area network
L x W x H length by width by height lb.
lbm/ft
3
LCB pound, pounds pounds mass per cubic feet line circuit breaker
LP
LPG
LS
L wa
LWL
LWT
LCD liquid crystal display ld. shd.
load shed
LED
Lph light emitting diode liters per hour
Lpm
LOP liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level, A weighted low water level low water temperature m
M meter, milli (1/1000) mega (10
6 units), male when used with SI m
3 m
3
/hr.
cubic meter cubic meters per hour m
3
/min.
cubic meters per minute mA man.
milliampere manual max.
MB
MCCB maximum megabyte (2
20 bytes) molded-case circuit breaker
MCM one thousand circular mils meggar megohmmeter
MHz mi.
mil min.
misc.
MJ megahertz mile one one-thousandth of an inch minimum, minute miscellaneous megajoule mJ millijoule mm millimeter mOhm, m
Ωmilliohm
MOhm, M
Ωmegohm
MOV metal oxide varistor
MPa mpg megapascal miles per gallon mph
MS ms m/sec.
MTBF miles per hour military standard millisecond meters per second mean time between failure psi psig pt.
PTC
PTO
PVC qt.
qty.
R
OV oz.
p., pp.
PC
PCB pF
PF ph.,
∅
PHC
MTBO mtg.
MTU
MW mean time between overhauls mounting
Motoren-und Turbinen-Union megawatt mW
μF milliwatt microfarad
N, norm.
normal (power source)
NA not available, not applicable nat. gas natural gas
NBS National Bureau of Standards
NC
NEC
NEMA normally closed
National Electrical Code
National Electrical
Manufacturers Association
NFPA
Nm
NO no., nos.
number, numbers
NPS National Pipe, Straight
NPSC National Pipe, Straight-coupling
NPT
National Fire Protection
Association newton meter normally open
NPTF
NR
National Standard taper pipe thread per general use
National Pipe, Taper-Fine not required, normal relay ns
OC
OD
OEM nanosecond overcrank outside diameter original equipment manufacturer
OF opt.
OS
OSHA
PHH
PHM
PLC
PMG pot ppm
PROM overfrequency option, optional oversize, overspeed
Occupational Safety and Health
Administration overvoltage ounce page, pages personal computer printed circuit board picofarad power factor phase
Phillips r head Crimptiter
(screw)
Phillips r hex head (screw) pan head machine (screw) programmable logic control permanent magnet generator potentiometer, potential parts per million programmable read-only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart, quarts quantity replacement (emergency) power source rad.
RAM
RDO radiator, radius random access memory relay driver output ref.
rem.
reference remote
Res/Coml Residential/Commercial
RFI
RH
RHM rly.
radio frequency interference round head round head machine (screw) relay
SPDT
SPST spec specs sq.
sq. cm sq. in.
SS std.
stl.
tach.
TD
TDC
TDEC
TDEN
TDES
TDNE scfm
SCR s, sec.
SI
SI/EO sil.
SN
SNMP rms rnd.
ROM rot.
rpm
RS
RTU
RTV
RW
SAE
VDC
VFD
VGA
VHF
W
WCR w/ w/o wt.
xfmr
UF
UHF
UL
UNC
UNF univ.
US
UV
V
VAC
VAR
TDOE
TDON temp.
term.
THD
TIF
TIR tol.
turbo.
typ.
root mean square round read only memory rotate, rotating revolutions per minute right side remote terminal unit room temperature vulcanization read/write
Society of Automotive
Engineers standard cubic feet per minute silicon controlled rectifier second
Systeme international d’unites,
International System of Units side in/end out silencer serial number simple network management protocol single-pole, double-throw single-pole, single-throw specification specification(s) square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency
Underwriter’s Laboratories, Inc.
unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer
100 Appendix TP-6735 9/10
Appendix B Common Hardware Application Guidelines
Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made.
Bolt/Screw Length: When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method.
Washers and Nuts: Use split lock washers as a bolt locking device where specified. Use SAE flat washers with whiz nuts, spiralock nuts, or standard nuts and preloading (torque) of the bolt in all other applications.
See Appendix C, General Torque Specifications, and other torque specifications in the service literature.
Preferred Nut/Bolt Clearance
1
2
Steps for common hardware application:
1. Determine entry hole type: round or slotted.
2. Determine exit hole type: fixed female thread
(weld nut), round, or slotted.
For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter, or
1/2 inch in diameter or less.
Hardware that is greater than 1/2 inch in diameter takes a standard nut and SAE washer. Hardware 1/2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut. See Figure 2.
3. Follow these SAE washer rules after determining exit hole type: a. Always use a washer between hardware and a slot.
b. Always use a washer under a nut (see 2 above for exception).
c. Use a washer under a bolt when the female thread is fixed (weld nut).
4. Refer to Figure 2, which depicts the preceding hardware configuration possibilities.
Unacceptable Nut/Bolt Clearance
3
1
2
3
G-585
1. 1/2 of bolt diameter
2. Min. 1 full thread beyond top of nut
3. Below top of nut
Figure 1 Acceptable Bolt Lengths
5
6
4
1. Cap screw
2. Entry hole types
3. Standard nut and SAE washer
4. Whiz nut or spiralock: up to 1/2 in. dia. hardware
5. Weld nuts: above 1/2 in. dia. hardware
6. Exit hole types
Figure 2 Acceptable Hardware Combinations
G-585
TP-6735 9/10 Appendix 101
Appendix C General Torque Specifications
Size
8-32
10-24
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
1-8
1-12
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
American Standard Fasteners Torque Specifications
Assembled into Cast Iron or Steel
Torque
Measurement
Nm (in. lb.)
Nm (in. lb.)
Nm (in. lb.)
Nm (in. lb.)
Nm (in. lb.)
Nm (in. lb.)
Nm (in. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Nm (ft. lb.)
Grade 2
1.8
(16)
2.9
(26)
24.0
27.0
39.0
43.0
60.0
66.0
2.9
(26)
6.8
(60)
8.1
(72)
13.6
(120)
14.9
(132)
(18)
(20)
(29)
(32)
(44)
(49)
81.0
91.0
(60)
(67)
113.0
(83)
128.0
(94)
199.0
(147)
222.0
(164)
259.0
(191)
283.0
(209)
Grade 5
2.3
(20)
3.6
(32)
38.0
42.0
60.0
68.0
92.0
103.0
3.6
(32)
10.8
(96)
12.2
(108)
21.7
(192)
23.1
(204)
(28)
(31)
(44)
(50)
(68)
(76)
133.0
(98)
148.0
(109)
183.0
(135)
208.0
(153)
325.0
(240)
363.0
(268)
721.0
(532)
789.0
(582)
Grade 8
—
—
—
14.9
(132)
16.3
(144)
29.8
(264)
32.5
(288)
53.0
60.0
85.0
95.0
(39)
(44)
(63)
(70)
130.0
(96)
146.0
(108)
187.0
(138)
209.0
(154)
259.0
(191)
293.0
(216)
458.0
(338)
513.0
(378)
1109.0
(818)
1214.0
(895)
Assembled into
Aluminum
Grade 2 or 5
See Note 3
Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)
Size (mm)
M6 x 1.00
Assembled into Cast Iron or Steel
Grade 5.8
6.2
(4.6)
Grade 8.8
9.5
(7)
Grade 10.9
13.6
(10)
Assembled into
Aluminum
Grade 5.8 or 8.8
M8 x 1.25
M8 x 1.00
M10 x 1.50
M10 x 1.25
M12 x 1.75
M12 x 1.50
M14 x 2.00
M14 x 1.50
M16 x 2.00
M16 x 1.50
M18 x 2.50
M18 x 1.50
15.0
16.0
30.0
31.0
53.0
56.0
83.0
87.0
(41)
(61)
(64)
127.0
132.0
(94)
(97)
179.0
(132)
189.0
(140)
(11)
(11)
(22)
(23)
(39)
23.0
24.0
45.0
47.0
80.0
85.0
126.0
133.0
(63)
(93)
(98)
194.0
(143)
201.0
(148)
273.0
(201)
289.0
(213)
(17)
(18)
(34)
(35)
(59)
33.0
34.0
65.0
68.0
115.0
122.0
(90)
180.0
(133)
190.0
(140)
278.0
(205)
287.0
(212)
390.0
(288)
413.0
(305)
(24)
(25)
(48)
(50)
(85)
See Note 3
Notes:
1.
The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or assembly drawings when they differ from the above torque values.
2.
The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are used.
3.
Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to prevent stripped threads.
4.
Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength and a friction coefficient of 0.125.
102 Appendix TP-6735 9/10
Appendix D Common Hardware Identification
Screw/Bolts/Studs
Head Styles
Hex Head or Machine Head
Hex Head or Machine Head with Washer
Flat Head (FHM)
Round Head (RHM)
Nuts
Nut Styles
Hex Head
Lock or Elastic
Square
Cap or Acorn
Pan Head
Hex Socket Head Cap or
Allen t Head Cap
Hex Socket Head or Allen t
Head Shoulder Bolt
Sheet Metal Screw
Wing
Washers
Washer Styles
Plain
Stud
Drive Styles
Hex
Split Lock or Spring
Spring or Wave
External Tooth Lock
Internal Tooth Lock
Hex and Slotted
Phillips r
Slotted
Internal-External Tooth Lock
Hex Socket
Allen t head screw is a trademark of Holo-Krome Co.
Phillips r screw is a registered trademark of Phillips Screw Company.
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
Sample Dimensions
American Standard (Screws, Bolts, Studs, and Nuts)
1/4-20 x 1
Length In Inches (Screws and Bolts)
Threads Per Inch
Major Thread Diameter In Fractional Inches Or Screw Number Size
Metric (Screws, Bolts, Studs, and Nuts)
M8-1.25 x 20
Length In Millimeters (Screws and Bolts)
Distance Between Threads In Millimeters
Major Thread Diameter In Millimeters
Plain Washers
9/32 x 5/8 x 1/16
Thickness
External Dimension
Internal Dimension
Lock Washers
5/8
Internal Dimension
TP-6735 9/10 Appendix 103
Appendix E Common Hardware List
The Common Hardware List lists part numbers and dimensions for common hardware items.
American Standard
Part No.
Dimensions
Hex Head Bolts (Grade 5)
X-125-33
X-125-23
X-125-3
X-125-31
X-125-5
X-125-24
X-125-34
X-125-25
X-125-26
230578
X-125-29
X-125-27
X-125-28
X-125-22
X-125-32
X-125-35
X-125-36
X-125-40
X-465-17
X-465-6
X-465-2
X-465-16
X-465-18
X-465-7
X-465-8
X-465-9
X-465-10
X-465-11
X-465-12
X-465-14
X-465-21
X-465-25
X-465-20
X-125-43
X-125-44
X-125-30
X-125-39
X-125-38
X-6238-2
X-6238-10
X-6238-3
X-6238-11
X-6238-4
X-6238-5
X-6238-1
X-6238-6
X-6238-17
X-6238-7
X-6238-8
X-6238-9
X-6238-19
X-6238-12
X-6238-20
X-6238-13
X-6238-18
X-6238-25
1/4-20 x .38
1/4-20 x .50
1/4-20 x .62
1/4-20 x .75
1/4-20 x .88
1/4-20 x 1.00
1/4-20 x 1.25
1/4-20 x 1.50
1/4-20 x 1.75
1/4-20 x 2.00
1/4-20 x 2.25
1/4-20 x 2.75
1/4-20 x 5.00
1/4-28 x .38
1/4-28 x 1.00
5/16-18 x .50
5/16-18 x .62
5/16-18 x .75
5/16-18 x .88
5/16-18 x 1.00
5/16-18 x 1.25
5/16-18 x 1.50
5/16-18 x 1.75
5/16-18 x 2.00
5/16-18 x 2.25
5/16-18 x 2.50
5/16-18 x 2.75
5/16-18 x 3.00
5/16-18 x 4.50
5/16-18 x 5.00
5/16-18 x 5.50
5/16-18 x 6.00
5/16-18 x 6.50
5/16-24 x 1.75
5/16-24 x 2.50
5/16-24 x .75
5/16-24 x 2.00
5/16-24 x 2.75
3/8-16 x .62
3/8-16 x .75
3/8-16 x .88
3/8-16 x 1.00
3/8-16 x 1.25
3/8-16 x 1.50
3/8-16 x 1.75
3/8-16 x 2.00
3/8-16 x 2.25
3/8-16 x 2.50
3/8-16 x 2.75
3/8-16 x 3.00
3/8-16 x 3.25
3/8-16 x 3.50
3/8-16 x 3.75
3/8-16 x 4.50
3/8-16 x 5.50
3/8-16 x 6.50
X-129-51
X-129-45
X-129-52
X-6021-3
X-6021-4
X-6021-2
X-6021-1
273049
X-6021-5
X-6021-6
X-6021-7
X-6021-12
X-6021-11
X-6021-10
X-6021-9
X-6239-1
X-6239-8
X-6239-2
X-6239-3
X-6239-4
X-6239-5
X-6239-6
X-129-15
X-129-17
X-129-18
X-129-19
X-129-20
X-129-21
X-129-22
X-129-23
X-129-24
X-129-25
X-129-27
X-129-29
X-129-30
X-463-9
X-129-44
X-792-1
X-792-5
X-792-8
Part No.
Dimensions
Hex Head Bolts, cont.
X-6238-14
X-6238-16
X-6238-21
X-6238-22
X-6024-5
X-6024-2
X-6024-8
X-6024-3
X-6024-4
X-6024-11
X-6024-12
3/8-24 x .75
3/8-24 x 1.25
3/8-24 x 4.00
3/8-24 x 4.50
7/16-14 x .75
7/16-14 x 1.00
7/16-14 x 1.25
7/16-14 x 1.50
7/16-14 x 2.00
7/16-14 x 2.75
7/16-14 x 6.50
1/2-13 x .75
1/2-13 x 1.00
1/2-13 x 1.25
1/2-13 x 1.50
1/2-13 x 1.75
1/2-13 x 2.00
1/2-13 x 2.25
1/2-13 x 2.50
1/2-13 x 2.75
1/2-13 x 3.00
1/2-13 x 3.50
1/2-13 x 4.00
1/2-13 x 4.50
1/2-13 x 5.50
1/2-13 x 6.00
1/2-20 x .75
1/2-20 x 1.25
1/2-20 x 1.50
5/8-11 x 1.00
5/8-11 x 1.25
5/8-11 x 1.50
5/8-11 x 1.75
5/8-11 x 2.00
5/8-11 x 2.25
5/8-11 x 2.50
5/8-11 x 2.75
5/8-11 x 3.75
5/8-11 x 4.50
5/8-11 x 6.00
5/8-18 x 2.50
3/4-10 x 1.00
3/4-10 x 1.25
3/4-10 x 1.50
3/4-10 x 2.00
3/4-10 x 2.50
3/4-10 x 3.00
3/4-10 x 3.50
1-8 x 2.25
1-8 x 3.00
1-8 x 5.00
Part No.
Dimensions Type
Hex Nuts
X-6009-1 1-8 Standard
X-6210-3
X-6210-4
X-6210-5
X-6210-1
X-6210-2
X-6210-6
X-6210-7
X-6210-8
X-6210-9
X-6210-10
X-6210-11
X-6210-12
X-6210-15
X-6210-14
X-85-3
X-88-12
X-89-2
6-32
8-32
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
1/2-13
7/16-20
1/2-20
5/8-11
3/4-10
1/2-20
Whiz
Whiz
Whiz
Whiz
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Spiralock
Standard
Standard
Standard
Washers
Part No.
ID
Bolt/
OD Thick. Screw
X-25-46 .125
X-25-9 .156
X-25-48 .188
X-25-36 .219
X-25-40 .281
X-25-85 .344
X-25-37 .406
X-25-34 .469
.812
.922
X-25-26 .531
1.062
X-25-15 .656
1.312
X-25-29 .812
1.469
X-25-127 1.062
2.000
.250
.375
.438
.500
.625
.687
.065
.065
.095
.095
.134
.134
.022
.049
.049
.049
.065
.065
3/8
7/16
1/2
5/8
3/4
1
#4
#6
#8
#10
1/4
5/16
104 Appendix TP-6735 9/10
Metric
Hex head bolts are hardness grade 8.8 unless noted.
Part No.
Dimensions
Hex Head Bolts (Partial Thread)
M931-05055-60
M931-06040-60
M931-06055-60
M931-06060-60
M5-0.80 x 55
M6-1.00 x 40
M6-1.00 x 55
M6-1.00 x 60
M931-06060-SS M6-1.00 x 60
M931-06070-60 M6-1.00 x 70
M931-06070-SS M6-1.00 x 70
M931-06075-60 M6-1.00 x 75
M931-06090-60
M931-06145-60
M931-06150-60
M6-1.00 x 90
M6-1.00 x 145
M6-1.00 x 150
M931-08035-60
M931-08040-60
M931-08045-60
M931-08050-60
M931-08055-60
M931-08055-82
M931-08060-60
M931-08070-60
M931-08070-82
M931-08075-60
M931-08080-60
M931-08090-60
M931-08095-60
M931-08100-60
M931-08110-60
M931-08120-60
M931-08130-60
M931-08140-60
M931-08150-60
M931-08200-60
M931-10040-82
M931-10040-60
M931-10045-60
M931-10050-60
M931-10050-82
M931-10055-60
M931-10060-60
M931-10065-60
M931-10070-60
M931-10080-60
M931-10080-82
M931-10090-60
M931-10090-82
M931-10100-60
M931-10110-60
M931-10120-60
M931-10130-60
M931-10140-60
M931-10180-60
M931-10235-60
M931-10260-60
M960-10330-60
M931-12045-60
M960-12050-60
M960-12050-82
M931-12050-60
M931-12050-82
M931-12055-60
M931-12060-60
M931-12060-82
M931-12065-60
M931-12075-60
M931-12080-60
M931-12090-60
M931-12100-60
M931-12110-60
M8-1.25 x 35
M8-1.25 x 40
M8-1.25 x 45
M8-1.25 x 50
M8-1.25 x 55
M8-1.25 x 55*
M8-1.25 x 60
M8-1.25 x 70
M8-1.25 x 70*
M8-1.25 x 75
M8-1.25 x 80
M8-1.25 x 90
M8-1.25 x 95
M8-1.25 x 100
M8-1.25 x 110
M8-1.25 x 120
M8-1.25 x 130
M8-1.25 x 140
M8-1.25 x 150
M8-1.25 x 200
M10-1.25 x 40*
M10-1.50 x 40
M10-1.50 x 45
M10-1.50 x 50
M10-1.25 x 50*
M10-1.50 x 55
M10-1.50 x 60
M10-1.50 x 65
M10-1.50 x 70
M10-1.50 x 80
M10-1.25 x 80*
M10-1.50 x 90
M10-1.50 x 90*
M10-1.50 x 100
M10-1.50 x 110
M10-1.50 x 120
M10-1.50 x 130
M10-1.50 x 140
M10-1.50 x 180
M10-1.50 x 235
M10-1.50 x 260
M10-1.25 x 330
M12-1.75 x 45
M12-1.25 x 50
M12-1.25 x 50*
M12-1.75 x 50
M12-1.75 x 50*
M12-1.75 x 55
M12-1.75 x 60
M12-1.75 x 60*
M12-1.75 x 65
M12-1.75 x 75
M12-1.75 x 80
M12-1.75 x 90
M12-1.75 x 100
M12-1.75 x 110
Part No.
Dimensions
Hex Head Bolts (Partial Thread), continued
M960-16090-60
M931-16090-60
M931-16100-60
M931-16100-82
M931-16120-60
M931-16150-60
M16-1.50 x 90
M16-2.00 x 90
M16-2.00 x 100
M16-2.00 x 100*
M16-2.00 x 120
M16-2.00 x 150
M931-20065-60
M931-20090-60
M931-20100-60
M931-20120-60
M931-20140-60
M931-20160-60
M931-22090-60
M931-22120-60
M931-22160-60
M931-24090-60
M931-24120-60
M931-24160-60
M931-24200-60
M20-2.50 x 65
M20-2.50 x 90
M20-2.50 x 100
M20-2.50 x 120
M20-2.50 x 140
M20-2.50 x 160
M22-2.50 x 90
M22-2.50 x 120
M22-2.50 x 160
M24-3.00 x 90
M24-3.00 x 120
M24-3.00 x 160
M24-3.00 x 200
Hex Head Bolts (Full Thread)
M933-04006-60 M4-0.70 x 6
M933-05030-60
M933-05035-60
M933-05050-60
M933-06010-60
M933-06012-60
M933-06014-60
M933-06016-60
M933-06020-60
M933-06025-60
M933-06030-60
M933-06040-60
M933-06050-60
M933-07025-60
M933-08010-60
M933-08012-60
M933-08016-60
M933-08020-60
M933-08025-60
M933-08030-60
M933-08030-82
M933-10012-60
M961-10020-60
M933-10020-60
M933-10025-60
M961-10025-60
M933-10025-82
M961-10030-60
M933-10030-60
M933-10030-82
M961-10035-60
M933-10035-60
M933-10035-82
M961-10040-60
M5-0.80 x 30
M5-0.80 x 35
M5-0.80 x 50
M6-1.00 x 10
M6-1.00 x 12
M6-1.00 x 14
M6-1.00 x 16
M6-1.00 x 20
M6-1.00 x 25
M6-1.00 x 30
M6-1.00 x 40
M6-1.00 x 50
M7-1.00 x 25
M8-1.25 x 10
M8-1.25 x 12
M8-1.25 x 16
M8-1.25 x 20
M8-1.25 x 25
M8-1.25 x 30
M8-1.25 x 30*
M10-1.50 x 12
M10-1.25 x 20
M10-1.50 x 20
M10-1.50 x 25
M10-1.25 x 25
M10-1.50 x 25*
M10-1.25 x 30
M10-1.50 x 30
M10-1.50 x 30*
M10-1.25 x 35
M10-1.50 x 35
M10-1.50 x 35*
M10-1.25 x 40
* This metric hex bolt’s hardness is grade 10.9.
TP-6735 9/10
Part No.
Dimensions
Hex Head Bolts (Full Thread), continued
M933-12016-60
M933-12020-60
M12-1.75 x 16
M12-1.75 x 20
M961-12020-60F M12-1.50 x 20
M933-12025-60 M12-1.75 x 25
M933-12025-82
M961-12030-60
M12-1.75 x 25*
M12-1.25 x 30
M933-12030-82 M12-1.75 x 30*
M961-12030-82F M12-1.50 x 30*
M933-12030-60
M933-12035-60
M961-12040-82
M933-12040-60
M933-12040-82
M12-1.75 x 30
M12-1.75 x 35
M12-1.25 x 40*
M12-1.75 x 40
M12-1.75 x 40*
M961-14025-60
M933-14025-60
M961-14050-82
M961-16025-60
M933-16025-60
M961-16030-82
M933-16030-82
M933-16035-60
M961-16040-60
M933-16040-60
M961-16045-82
M933-16045-82
M933-16050-60
M933-16050-82
M933-16060-60
M933-16070-60
M933-18035-60
M933-18050-60
M933-18060-60
M933-20050-60
M933-20055-60
M933-24060-60
M933-24065-60
M933-24070-60
M14-1.50 x 25
M14-2.00 x 25
M14-1.50 x 50*
M16-1.50 x 25
M16-2.00 x 25
M16-1.50 x 30*
M16-2.00 x 30*
M16-2.00 x 35
M16-1.50 x 40
M16-2.00 x 40
M16-1.50 x 45*
M16-2.00 x 45*
M16-2.00 x 50
M16-2.00 x 50*
M16-2.00 x 60
M16-2.00 x 70
M18-2.50 x 35
M18-2.50 x 50
M18-2.50 x 60
M20-2.50 x 50
M20-2.50 x 55
M24-3.00 x 60
M24-3.00 x 65
M24-3.00 x 70
Pan Head Machine Screws
M7985A-03010-20 M3-0.50 x 10
M7985A-03012-20 M3-0.50 x 12
M7985A-04010-20 M4-0.70 x 10
M7985A-04016-20 M4-0.70 x 16
M7985A-04020-20 M4-0.70 x 20
M7985A-04050-20 M4-0.70 x 50
M7985A-04100-20 M4-0.70 x 100
M7985A-05010-20 M5-0.80 x 10
M7985A-05012-20 M5-0.80 x 12
M7985A-05016-20 M5-0.80 x 16
M7985A-05020-20 M5-0.80 x 20
M7985A-05025-20 M5-0.80 x 25
M7985A-05030-20 M5-0.80 x 30
M7985A-05080-20 M5-0.80 x 80
M7985A-05100-20 M5-0.80 x 100
M7985A-06100-20 M6-1.00 x 100
Flat Head Machine Screws
M965A-04012-SS M4-0.70 x 12
M965A-05012-SS M5-0.80 x 12
M965A-05016-20 M5-0.80 x 16
M965A-06012-20 M6-1.00 x 12
Appendix 105
Metric, continued
Part No.
Dimensions Type
Hex Nuts
M934-03-50 M3-0.50
Standard
M934-04-50
M934-04-B
M4-0.70
M4-0.70
Standard
Brass
M934-05-50 M5-0.80
M934-06-60
M934-06-64
M6-1.00
M6-1.00
M6923-06-80 M6-1.00
M982-06-80 M6-1.00
M934-08-60 M8-1.25
M6923-08-80 M8-1.25
M982-08-80 M8-1.25
M934-10-60 M10-1.50
M934-10-60F M10-1.25
M6923-10-80 M10-1.50
M6923-10-62 M10-1.50
M982-10-80 M10-1.50
M934-12-60 M12-1.75
M934-12-60F M12-1.25
M6923-12-80 M12-1.75
M982-12-80 M12-1.75
M982-14-60 M14-2.00
M6923-16-80 M16-2.00
M982-16-80 M16-2.00
M934-18-80
M982-18-60
M18-2.5
M18-2.50
M934-20-80
M982-20-80
M934-22-60
M20-2.50
M20-2.50
M22-2.50
M934-24-80
M982-24-60
M934-30-80
M24-3.00
M24-3.00
M30-3.50
Standard
Standard
Std. (green)
Spiralock
Elastic Stop
Standard
Spiralock
Elastic Stop
Standard
Standard
Spiralock
Spiralock
[
Elastic Stop
Standard
Standard
Spiralock
Elastic Stop
Elastic Stop
Spiralock
Elastic Stop
Standard
Elastic Stop
Standard
Elastic Stop
Standard
Standard
Elastic Stop
Standard
Washers
Part No.
Bolt/
ID OD Thick. Screw
M125A-03-80 3.2
7.0
M125A-04-80 4.3
9.0
M125A-05-80 5.3
10.0
M125A-06-80 6.4
12.0
M125A-08-80 8.4
16.0
M125A-10-80 10.5
20.0
M125A-12-80 13.0
24.0
M125A-14-80 15.0
28.0
M125A-16-80 17.0
30.0
M125A-18-80 19.0
34.0
M125A-20-80 21.0
37.0
M125A-24-80 25.0
44.0
0.5
M3
0.8
M4
1.0
M5
1.6
M6
1.6
M8
2.0
M10
2.5
M12
2.5
M14
3.0
M16
3.0
M18
3.0
M20
4.0
M24
[ This metric hex nut’s hardness is grade 8.
106 Appendix TP-6735 9/10
Appendix F Controller Parameters (SiteTech)
The following table lists controller parameters that can be viewed and adjusted using Kohler r SiteTecht software. The Access column in the table shows which parameters can only be viewed (Read or Locked), and which parameters can be changed using the software
(Write).
Parameters are factoy-set according to the generator set model. Use SiteTech to change settings if necessary during service or after controller replacement.
Group
Identity
Parameter
Vendor
Access
Read
Units
Engine Metering
Engine Speed Governor
Generator Metering
Genset Info
Genset Run Time
Genset Personality Profile
Product
Firmware Version
Engine Speed
Engine Target Speed
Engine Oil Pressure
Battery Voltage
Lube Oil Temperature
Genset Controller
Temperature
Engine Low Oil Pressure
Switch
Engine Speed
Adjustment
Read
Read
Read
Read
Read
Read
Read
Read
Read
Write
Engine Speed Gain
Adjustment
Write
Generator Voltage L1-L2 Read
Generator Frequency Read
Generator Metering
Firmware Version
Read
Genset Model Number
Genset Serial Number
Alternator Part Number
Engine Part Number
Engine Model Number
Engine Serial Number
Genset State
Genset Controller Total
Operation Time
Engine Total Run Time
Engine Total Run Time
Loaded
Engine Total Number Of
Starts
Engine Number Of
Flywheel Teeth
Engine Cooled Down
Temperature
Engine Crank Disconnect
Speed
Write
Write
Write
Write
Write
Write
Read
Read
Read
Read
Read
Locked
Locked
Read
Engine Run Speed Locked
* Factory set. Enter these numbers on a new controller after controller replacement.
h h
R/min
R/min kPa
V
_C
_C
V
Hz h
_C
R/min
R/min
TP-6735 9/10 Appendix 107
*
*
*
*
*
*
Off (0)
—
—
—
50
—
—
—
Default
Setting
Kohler
Company
RDC (38)
—
—
—
—
—
—
—
Off (0)
50
65
—
—
—
—
Adjustment
Range
—
—
—
—
—
—
—
—
—
—
0--99
0--99
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Group
Genset System Configuration
Parameter
Genset System Voltage
Genset System
Frequency
Genset Voltage Phase
Connection
Genset System Battery
Voltage
Measurement System
Access
Write
Write
Write
Locked
Write
Units
V
Hz
V
Voltage Regulator
Engine Timing
Genset Protection
Voltage Regulator
Average Voltage
Adjustment
Voltage Regulator Volts
Per Hertz Slope
Write
Write
Voltage Regulator Volts
Per Hertz Cut In
Frequency
Voltage Regulator Gain
Voltage Regulator
Firmware Version
Engine Start Delay
Write
Write
Read
Engine Number Of Crank
Cycles
Write
Engine Cool Down Delay Write
Engine Crank On Delay Write
Engine Crank Pause
Delay
Write
Write
After Crank Disconnect
Fault Inhibit Delay
Genset Low Battery
Voltage Warning Delay
Read
Read
Genset High Battery
Voltage Warning Delay
Genset Low Battery
Voltage Warning Limit
Read
Write
Genset High Battery
Voltage Warning Limit
Genset Battery Low
Cranking Voltage
Warning Delay
Write
Read
Genset Battery Low
Cranking Voltage
Warning Limit
Read
* Factory set. Enter these numbers on a new controller after controller replacement.
V
%
Hz s s s s s s s
%
% s
%
1--10
42--62
1--255
—
0--300
0--600
10--30
1--60
1--6
—
—
—
80--105
110--135
—
—
Adjustment
Range
110--600
50/60
0--3
12/24
English (0)
Metric (1)
108--660
Default
Setting
*
60
*
12
English (0)
*
5
57.5
30
90
10
100
128
—
0
300
15
15
3
125
6
60
108 Appendix TP-6735 9/10
Group
Engine Protection
Generator Protection
ATS Metering Summary
Source 1 Metering
ATS Connection Configuration
Source 1 System Configuration
Source 1 Calibration
Parameter
Engine High Oil
Temperature Shutdown
Delay
Engine Low Oil Pressure
Shutdown Delay
Engine Locked Rotor
Shutdown Delay
Genset Low Engine
Speed Shutdown Limit
Genset High Engine
Speed Shutdown Limit
Loss Of AC Sensing
Shutdown Delay
Genset Low Voltage
Shutdown Delay
Genset High Voltage
Shutdown Delay
Genset Low Voltage
Shutdown Limit
Genset High Voltage
Shutdown Limit
Genset Short Term Low
Frequency Shutdown
Delay
Genset Long Term Low
Frequency Shutdown
Delay
Genset High Frequency
Shutdown Delay
Genset Low Frequency
Shutdown Limit
Access
Read
Read
Write
Write
Write
Read
Write
Write
Write
Write
Read
Read
Read
Write
Genset High Frequency
Shutdown Limit
ATS Contactor Position
ATS Sources Available
Source 1 Voltage L1-L2
Write
Read
Read
Read
Source 1 Voltage
Average Line To Line
Read
ATS Source Read
Source 1 System Voltage Write
Write Source 1 System
Frequency
Source 1 Voltage
Debounce Delay
Write
Source 1 Low Voltage
Pickup
Source 1 Low Voltage
Dropout
Source 1 Calibration
Factor Voltage L1-L2
Write
Write
Write
Units s s
V
V s
%
%
%
%
V
Hz s s s
%
% s s
% s s
%
Default
Setting
5
5
5
85
115
3
10
2
80
120
10
60
10
90
110
—
—
—
—
—
240
60
0.5
90
90
1.0
Adjustment
Range
—
—
1--5
75--95
105--120
—
5--30
2--10
70--95
105--135
—
—
—
80--95
102--140
—
—
—
—
—
110--600
48--62
0.1--9.9
85--100
75--98
0.65--1.5
TP-6735 9/10 Appendix 109
Group
Source 2 System Configuration
ATS Exercise
Parameter
Source 2 Voltage
Debounce Delay
Source 2 Low Voltage
Pickup
Source 2 Low Voltage
Dropout
Exercise Interval
Exercise Run Duration
Exercise Mode
Access
Write
Write
Write
Write
Write
Write
Units s
%
% min
ATS Delays ATS Transfer From
Preferred Delay
ATS Transfer From
Standby Delay
ATS Source 2 Engine
Start Delay
Write
Write
Write s s s
Adjustment
Range
0.1--9.9
85--100
75--98
Weekly (5)
2 Weeks (6)
10--30
Unloaded (1)
Economy (2)
Loaded (3)
1--10
1--600
1--10
Default
Setting
0.5
90
90
Weekly (5)
20
Unloaded (1)
3
120
3
110 Appendix TP-6735 9/10
TP-6735 9/10
E 2010 by Kohler Co. All rights reserved.
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455
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Key Features
- Residential/Commercial applications
- Air-cooled Kohler engines
- Single-Phase output
- Digital control
- Automatic transfer switch
- Low oil pressure shutdown