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Kohler 8.5RES Service

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See also: Service Manual , Installation & Operation
Service
Residential/Commercial Generator Sets
Models:
8.5RES
12RES
12RESL
12RESM1
12RESNT
12TRES
Controllers:
ADC 2100
ADC-RES
DC 2200
DC-RET
TP-6196 10/09a
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Summary of Contents for Kohler 8.5RES

  • Page 1 Service Residential/Commercial Generator Sets Models: 8.5RES 12RES 12RESL 12RESM1 12RESNT 12TRES Controllers: ADC 2100 ADC-RES DC 2200 DC-RET TP-6196 10/09a Downloaded from www.Manualslib.com manuals search engine...
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  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 Table of Contents, continued ADC 2100 Controller Configuration and Adjustment ......4.5.1 Controller Time Out ..........4.5.2 Controller Configuration .
  • Page 5 Table of Contents, continued Electromechanical Governor System ........6.9.1 Operation .
  • Page 6 Notes TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...

  • Page 7: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. WARNING Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be Explosion. Can cause severe injury or death.

  • Page 8: Fuel System

    Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms. severe injury or death. Battery gases fire can cause severe injury or death. Carbon monoxide can cause severe can cause an explosion. Do not smoke Do not smoke or permit flames or nausea, fainting, or death.
  • Page 9 The fuel system. Explosive fuel Hazardous Noise CAUTION vapors can cause severe injury or death. Vaporized fuels are highly CAUTION 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.

  • Page 10: Hot Parts

    High voltage test. Hazardous Heavy Equipment Servicing the exhaust system. Hot voltage can cause severe injury or parts can cause severe injury or death. Follow the instructions of the death. Do not touch hot engine parts. WARNING test equipment manufacturer when The engine and exhaust system performing high-voltage tests on the components become extremely hot...

  • Page 11: Introduction

    Information in this publication represents data available available. The following table lists the available manual at the time of print. Kohler Co. reserves the right to part numbers. change this publication and the products represented...

  • Page 12: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPower.com. Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product.

  • Page 13: Section 1 Specifications

    CARB certification. The generator sets are equipped with four-cycle, twin For engine service information and specifications not cylinder, air-cooled Kohler engines. Some of the engine covered in this manual, see the Engine Service Manual. features include: TP-6196 10/09...

  • Page 14: Engine Specifications

    40 (28) 8.5 kW 12 kW Cylinder head nuts 30 (40.7) (60 Hz) (60 Hz) Engine Specification Generator adapter screws 40 (28) Manufacturer Kohler Muffler flange bolts 24 (17.7) Model CH20 CH740 Oil filter 5.7--9.0 (4.2--6.7) Cycle Spark plug 24.4--29.8 (18--22)

  • Page 15: Alternator Specifications

    1.6 Alternator Specifications Alternator Specification 8.5/12 kW 1 phase 12TRES 3 phase Frequency Hz 50/60 Phase Single-Phase Three Number of leads Excitation method Static Excited Voltage regulator type Digital Coupling type Direct Thrubolt torque, Nm ( ft. lb.) 40 (28) Overbolt torque, Nm (in.

  • Page 16: Service Views

    1.7 Service Views See control detail ADV-7466- Control Detail Fuel System Detail 1. Muffler 16. Equipment ground 2. Oil check 17. Starter relay 3. Oil fill 18. Battery charger 4. Air cleaner 19. DSAI lead location 5. Controller user interface (switch membrane) 20.
  • Page 17 GM66010 1. Emergency stop button 2. Field-connection terminal block and circuit breakers 3. Cable inlet area Figure 1-2 Additional Components, 3-Phase Models TP-6196 10/09 Section 1 Specifications Downloaded from www.Manualslib.com manuals search engine...
  • Page 18 ADV6823 Starter (non-service side) Fuel System Detail 1. Enclosure 17. Oil filter 2. Muffler 18. Air intake, alternator 3. Oil check 19. Exhaust 4. Oil fill 20. Spark arrestor (not visible in this view) 5. Air cleaner 21. Relay interface board (RIB) 6.

  • Page 19: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance See the Safety Precautions and Instructions at the WARNING 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 Accidental starting.
  • Page 20 Action Refer to Section Inspect Check Change Clean Test Interval System—Component Lubrication Oil level 2.2.2 8 hr. or before use Crankcase breather hose Yearly or 500 hr. Change oil 2.2.4 Yearly or 100 hr. Replace filter(s)* 2.2.4 Yearly or 200 hr. Oil cooler* 2.2.5 Yearly or 100 hr.

  • Page 21: Lubrication System

    2.2 Lubrication System 2.2.3 Engine Oil Recommendation Use synthetic oil of API (American Petroleum Institute) See Section 2.1, Service Schedule, for oil change and Service Class SG or higher. Synthetic oil causes fewer oil filter replacement intervals. See Figure 2-2 for the oil deposits on the engine intake valves and pistons drain, oil check, oil fill, and oil filter locations.

  • Page 22: Oil Cooler

    2. Replace the oil filter. a. Remove filter rotating counterclockwise with an oil filter wrench. b. Apply a light coat of clean oil to the rubber seal of the new oil filter. c. Install the new oil filter following the instructions provided with the filter.

  • Page 23: Air Cleaner Element And Precleaner

    3. Check the spark plug gap using a wire feeler Note: Operating the engine with loose or damaged air gauge. See Figure 2-7 for the recommended gap. cleaner components could allow unfiltered air Adjust the gap by carefully bending the ground into the engine, causing premature wear and electrode.

  • Page 24: Cooling System

    b. Rinse the precleaner with warm water until the Note: Do not block the generator set cooling air inlet or water runs clear. mount other equipment above it. Overheating and severe generator damage may occur. c. Squeeze out excess water and allow the precleaner to air dry.

  • Page 25: Cleaning Battery

    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.

  • Page 26: Storage Procedure

    2.8 Storage Procedure 2. Place the generator set master switch in the OFF/ RESET position. Perform the following storage procedure before taking a If a fogging agent is not available perform the following: generator set out of service for three months or longer. Follow the engine manufacturer’s recommendations, if 1.

  • Page 27: Section 3 Troubleshooting

    Section 3 Troubleshooting 3.1 Introduction Blown fuses. Fuses in the wiring harness protect the controller, SCR module, and relay interface board. A Corrective action and testing in many cases requires battery charger fuse is located in the positive battery knowledge of electrical systems and electronic circuits. lead.
  • Page 28 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Generator Crank relay on relay Check connections to the RIB. Check for 12VDC to the RIB on Section 4.8 or set does not interface board lead 71N. 5.7; Section 8 crank, (ADC 2100) Check for a good ground connection (lead 16N) Section 8...
  • Page 29 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Air cleaner clogged Clean or replace. Section 2.4 Cranks but does not Magnetic pickup Check for 1.75 volts or higher from the magnetic pickup during Section 6.9.4 start, cranking. A lower signal will cause the stepper motor to open continued and close during cranking.
  • Page 30 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Fuel valve/fuel regulator Check regulator/valve operation. Section 2 Stops suddenly, Section 7 continued Engine overloaded Reduce electrical load. — Loss of generator output Check connections at P15 plug. Section 8 voltage to controller Check continuity of AC sensing leads 11 and 44.
  • Page 31 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference Inadequate cooling Inspect cooling system for air intake obstructions. Section 2.5 Overheats Fuel mixture adjustment Readjust fuel mixture. Section 6.12 incorrect Note: Adjusting the fuel mixture may void the emission certification. Generator overloaded Reduce load.
  • Page 32 Troubleshooting Chart, continued Problem Possible Cause Corrective Action Reference AC output circuit breaker Check for AC voltage on the generator side of circuit breaker. If — No output open there is AC voltage on the generator side of the breaker, then a voltage problem in the load circuits is causing the line circuit breaker to trip.

  • Page 33: Controller Troubleshooting

    3.4 Controller Troubleshooting Refer to the controller troubleshooting table in this section when troubleshooting procedures in Section 3.3 indicate a possible controller problem. Always check the ADC-RES controller configuration settings before replacing the controller. The installation manual contains the instructions for checking and changing the controller configuration.
  • Page 34 Notes Section 3 Troubleshooting TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...

  • Page 35: Section 4 Adc 2100 And Dc 2200 Controllers

    Section 4 ADC 2100 and DC 2200 Controllers 4.1 Introduction A silicon controlled rectifier (SCR) module works with the controller to regulate the output voltage. This section covers operation, configuration, Section 6.8. adjustment, and replacement of the ADC 2100 and A relay interface board (RIB) is used with the ADC DC 2200 controller.

  • Page 36: Controller Display And Keypad

    4.2 Controller Display and Keypad Controller Display Item Description The ADC 2100 controller has an LED display and a Crank Displays CC_1, CC_2, or CC_3 to three-button keypad. See Figure 4-2. The DC 2200 indication indicate the first, second or third attempt controller has a display, but no keypad.

  • Page 37: Sequence Of Operation

    4.3 Sequence of Operation 4.3.3 Running Sequence When the engine speed reaches 750 rpm, the crank The following sections describe the controller sequence relay deenergizes and the crank LED (3) turns off. of operation during generator start, run, stop, and fault When the output voltage on leads 11 and 44 reaches shutdown modes.
  • Page 38 shutdown. Then move the switch to the AUTO or RUN and the controller powers down after a fault shutdown, position. move the master switch to OFF/RESET and then to RUN to display the fault code. Then move the switch to Generator sets with serial numbers below 2051415 OFF/RESET again to clear the fault.
  • Page 39 Refer to Section Code Fault Description Check Auxiliary fault Not used on these models. — — High engine Shutdown occurs if the engine coolant Check for blocked air inlets and exhaust outlets. temperature temperature exceeds the maximum temperature for more than 5 seconds. This protective becomes active after the engine reaches crank disconnect speed.

  • Page 40: Adc 2100 Controller Configuration And Adjustment

    4.5 ADC 2100 Controller changed during generator set service or controller replacement. Configuration and Adjustment The controller’s configuration mode allows adjustment Note: The settings described in this section are not of the system parameters listed in this section. The adjustable on the DC 2200 cotnroller. system voltage and frequency and unit configuration and engine type are factory-set for each type of The first step in troubleshooting the controller is to verify...

  • Page 41: Voltage And Frequency Adjustments

    Advanced configuration mode (Adnc). The data The generator set must be running during these input types, battery voltage, and communications adjustments. Use a multimeter to measure the setting can be changed in the advanced configuration generator set output voltage and frequency during mode.

  • Page 42: Controller Configuration Mode

    Controller Configuration Mode: Hold the Select button: Display: * Move the generator set master switch to the RUN position. (The generator set engine will not start.) Wait about 5 seconds until the display shows the 1 0 4 program version number. (The number may be different than the one shown here.) Press the down arrow key and then the up arrow key 3 times to enter the configuration mode.
  • Page 43 Pressing the up arrow key at the Adnc display (See Figure 4-8) puts you into the Advanced Configuration Mode. Press: E d 0 5 To set the engine data input type to Ed05. To enter battery voltage selection mode. To toggle between 12 and 24 VDC. Set this B t 1 2 parameter to 12 VDC.
  • Page 44 Output Voltage and Frequency Adjustment Mode: Display :* Move the generator set master switch to the RUN position. The generator set x x x x engine starts and the controller display shows the engine runtime hours. Hold: Wait about 5 seconds until the display changes from runtime hours to the program version number.
  • Page 45 Display : * Continued from Figure 4-11: Press: To enter engine governor speed coarse adjustment mode. To raise or lower the engine speed in large increments. To enter engine governor speed fine adjustment mode. To raise or lower the engine speed in smaller increments.

  • Page 46: Continuous Power Mode Jumper

    There are 3 options when the display says SAVE: S A V E Press: To return to the first parameter, coarse voltage adjustment, to check or change settings before saving. See Figure 4-8. Y E S To save changes. To discard changes without saving. “Yes”or “no”...
  • Page 47 A jumper across controller pins P7-1 and P7-2 maintains Procedure to disconnect the continuous power power to the controller at all times. Controllers are mode jumper (optional). shipped with the jumper connected for continuous power. See Figure 4-14. Note: For most applications, it is not necessary to disconnect the continuous power mode jumper.

  • Page 48: Master Switch

    4.7 Master Switch The generator set may be equipped with an optional RIB, which contains the K4 auxiliary run relay and K1 The generator set master switch is a three-position common fault relay in addition to the standard relays. (RUN\OFF/RESET\AUTO) rocker switch. The leads The optional relay board kit includes a wiring harness for connecting to the master switch are labeled RUN, VBAT, connection of customer equipment to the K1 and K4...

  • Page 49: Controller Replacement

    4.9 Controller Replacement ADC 2100 Controller Replacement Procedure 1. Remove the enclosure service-side door. See If the troubleshooting procedures in Section 3 identify a Figure 4-17. bad controller, use the procedure in this section for controller replacement. Always check the controller 2.
  • Page 50 Note: Some versions of the controller mount from inside the controller compartment. Others are front-mounted. 6. For inside-mounted controllers: a. Remove 5 screws to remove the front panel on the air intake end of the enclosure. Remove the plastic caps to access the 2 side screws. See Figure 4-17.
  • Page 51 7. For front-mounted controllers: 12. Follow the instructions in Section 4.5.2 to change the new controller’s configuration settings to match a. Remove four mounting screws from the front of the generator set system voltage and frequency, the controller. unit configuration, engine type, engine data input types, battery voltage, and communications b.
  • Page 52 Notes Section 4 ADC 2100 and DC 2200 Controllers TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...

  • Page 53: Section 5 Adc-Res And Dc-Ret Controller

    Section 5 ADC-RES and DC-RET Controller 5.1 Introduction See Figure 5-1 for the controller location. This section covers operation, configuration, adjustment, and replacement of the ADC-RES and DC-RET controllers. See Section 3 for troubleshooting procedures. GM57149 Front View 1. Controller display 7.

  • Page 54: Controls And Display

    5.2 Controls and Display The ADC-RES controller has an LED display and a three-button keypad. See Figure 5-2. The DC-RET controller has an LED display. See Figure 5-3. A three-position generator set master switch is mounted on the controller junction box. GM57149 1.

  • Page 55: Keypad

    Control or Indicator Item Description LED display Runtime hours Displays total generator set runtime hours while the generator set is running and when no other codes are displayed. Metering display Displays AC voltage (output), frequency, and battery voltage. Press the up or (ADC-RES only) down arrow when runtime hours are displayed to step through these displays.

  • Page 56: Sequence Of Operation

    5.3 Sequence of Operation 5.3.3 Running Sequence When the engine speed reaches 750 rpm, the crank The following sections describe the controller sequence relay deenergizes and the crank LED turns off. When of operation during generator start, run, stop, and fault the output voltage on leads 11 and 44 reaches about shutdown modes.

  • Page 57: Faults

    5.4 Faults Always identify and correct the cause of a fault shutdown before restarting the generator set. Refer to Section 3, Troubleshooting, for instructions to identify 5.4.1 Warnings and correct the cause of the fault. The fault conditions listed in Figure 5-6 will cause the Move the generator set master switch to the OFF/ controller to display a fault code but will not shut down RESET position to reset the controller after a fault...
  • Page 58 Refer to Section Code Fault Description Check Auxiliary fault Indicates a shutdown initiated by the emergency stop Check the position of the switch or a tripped circuit breaker. emergency stop button. (TRES models only) (TRES models only) High engine Shutdown occurs if the engine coolant temperature Check for blocked air inlets and temperature exceeds the maximum temperature for more than...

  • Page 59: Controller Configuration And Adjustment, Adc-Res

    5.5 Controller Configuration and down. The generator set continues to run with the new settings until it shuts down but then reverts to the Adjustment, ADC-RES previous settings at the next startup. Be sure to save your changes immediately after making adjustments. Note: The settings described in this section are not adjustable on the DC-RET cotnroller.

  • Page 60: System Parameters

    5.5.4 System Parameters Voltage/frequency setting (Uu). Select the system voltage and frequency from the table in Figure 5-8. The controller configuration for each generator model is set at the factory and should not normally require Note: The Uu parameter sets the system’s rated changes.
  • Page 61 Controller Configuration Mode: Hold the Select button: Display: Move the generator set master switch to the RUN position. (The generator set engine will not start.) Wait about 5 seconds until the display shows the v 1 1 3 program version number. (The number may be different than the one shown here.) Press the down arrow key and then the up arrow key 3 times to enter the configuration mode.

  • Page 62: Voltage And Frequency Adjustments

    5.6 Voltage and Frequency 5.6.1 Voltage Adjustment Adjustments Note: Refer to the flowcharts in Figure 5-13 through Figure 5-15 during the following procedure. WARNING Voltage Adjustment Procedure 1. With the generator set off, connect a digital multimeter to the output leads or an electrical outlet on the load side of the generator set.

  • Page 63: Frequency Adjustment

    9. Reset the engine speed to the operating frequency 1. Attach a frequency meter to the AC output leads or (50 or 60 Hz) by adjusting engine the governor an electrical outlet on the load side of the generator speed (parameter 4P). set.
  • Page 64 Output Voltage and Frequency Adjustment Mode: Display :* Move the generator set master switch to the RUN position. The generator set x x x x engine starts and the controller display shows the engine runtime hours. Hold: Wait about 5 seconds until the display changes from runtime hours to the program version number.
  • Page 65 Display : * Continued from Figure 5-13: Press: To enter engine governor speed coarse adjustment mode. (Parameter 4P) To raise or lower the engine speed in large increments. To enter engine governor speed fine adjustment mode. (Parameter 4P) To raise or lower the engine speed in smaller increments.

  • Page 66: Controller Relays

    There are 3 options when the display says SAVE: S A V E Press: To return to the first parameter, coarse voltage adjustment, to check or change settings before saving. See Figure 5-13. Y E S To save changes. To discard changes without saving. “Yes”or “no”...

  • Page 67: Optional Relay Board

    5.8 Optional Relay Board The generator set may be equipped with an optional relay board, which contains the K1 common fault relay and K4 auxiliary run relay. See Figure 5-17 for the relay board location inside the controller junction box. GM51403 1.
  • Page 68 TO RELAY BOARD P14 TO ENGINE HARNESS TO CONTROL BOARD P11 GM52639 Figure 5-20 Relay Board Connection Harness GM52639 TB1 Terminal Label Description Contact Ratings 10 A @ 120 VAC 10 A @ 28 VDC COMMON FAULT NC Common fault relay normally closed contact.

  • Page 69: Relay Board Replacement Procedure

    5.8.2 Relay Board Replacement 1. Access the controller junction box to locate the relay board. See Figure 5-17. Procedure 2. Disconnect relay board harness connector P3 from WARNING connector P14 on the relay board. 3. Pull the faulty relay board off the four mounting standoffs inside the junction box.

  • Page 70: Controller Replacement

    5.9 Controller Replacement If the troubleshooting procedures in Section 3 identify a bad controller, use the procedure in this section for controller replacement. Always check the controller configuration, fuse, wiring, and connections before replacing the controller. For output voltage problems, replace the SCR module and check the operation again before replacing the controller.
  • Page 71 7. Check that the replacement board is positioned so User Interface Membrane Replacement that the display shows through the opening in the 9. Disconnect the membrane ribbon cable from cover plate and then press the board onto the connector P8 on the logic board. standoffs.
  • Page 72 Notes Section 5 ADC-RES and DC-RET Controller TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...

  • Page 73: Section 6 Component Testing And Adjustment

    Section 6 Component Testing and Adjustment 6.1 Theory of Operation 6.2 Separate Excitation These generator sets utilize a rotating-field alternator to To determine the cause of no or low AC output, refer to produce AC voltage. Upon activation of the generator the troubleshooting flow chart in Figure 6-2.

  • Page 74: Stator

    Grounding electrical equipment. Hazardous voltage can Note: The approximate ammeter reading should cause severe injury or death. Electrocution is possible be the battery voltage divided by the whenever electricity is present. Ensure you comply with all specified rotor resistance. See Section 1, applicable codes and standards.
  • Page 75 High voltage test. Hazardous voltage can cause severe Note: For three-phase models, leads 1--12 are the injury or death. Follow the instructions of the test equipment generator output leads. Leads V7, V8, V9, 55, manufacturer when performing high-voltage tests on the rotor and 66 are the controller and SCR module or stator.
  • Page 76 discoloration) indicate a stator in good condition. 8. If the resistance test proves inconclusive, use a See Figure 6-7. megohmmeter to test the stator as described in the next step. Leads Continuity Note: Because ohmmeter accuracy varies, 1 and 2 resistance readings approximate...

  • Page 77: Main Field (Rotor)

    6.4 Main Field (Rotor) 4. Remove the brush cover from the alternator end bracket. The two-pole rotor creates the magnetic field needed to 5. Check the rotor for continuity and resistance. produce alternating current in the stator windings. Raise the brushes from the slip rings while Before testing, inspect the rotor for visible damage to performing ohmmeter tests.

  • Page 78: Slip Rings

    c. Repair or replace the rotor if the reading is less Check the resistance through the brushes. Resistance than approximately 500 kOhms. A reading of through the brushes should be low, 0.1--0.2 ohms less than 500 kOhms indicates deterioration of without meter lead resistance.

  • Page 79: Voltage

    6.7 Voltage WARNING 6.7.1 Voltage Regulation Voltage regulation is performed by the Advanced Digital Control (ADC) and the SCR module. The ADC monitors Hazardous voltage. Moving parts. generator output voltage and adjusts the excitation Can cause severe injury or death. current to the rotor through the SCR module.
  • Page 80 L0 L1 L2 L3 Detail GM66010 1. Measure voltage across circuit breaker terminals L0 and L1, L2, or L3 Figure 6-14 Voltage Measurement, Three-Phase Models 7. Set the voltmeter to measure voltage. Adjust the volts/Hz (parameter 3P) until the voltage level measured by the voltmeter begins to drop.

  • Page 81: Volts Per Hertz (Hz) Adjustments (Droop)

    6.7.3 Volts per Hertz (Hz) Adjustments 6.7.4 Voltage Connections, (Droop) Single-Phase When the frequency falls below the cut-in frequency Single-phase generator sets are available from the (see Figure 6-13), output voltage is reduced to relieve factory connected for 110/220 volt 50 Hz or 120/240 volt the engine.

  • Page 82: Voltage Connections, 3-Phase

    6.7.5 Voltage Connections, 3-Phase 6.8 Silicon Controlled Rectifier Module Three-phase generator sets are connected for 230/400 Volts, 50 Hz. See Figure 6-17 for the factory The silicon controlled rectifier (SCR) module works with connections. The generator sets are not reconnectable. the ADC-RES to regulate the output voltage.
  • Page 83 SCR Module Test Procedure Required equipment: Ohmmeter (--) 12-volt test lamp (or voltmeter) 12-volt DC power source 100--500 ohm resistor Jumper 1. Set the ohmmeter to the R x 1 scale. 2. Connect the ohmmeter from (+) to (--) on the SCR module.

  • Page 84: Electromechanical Governor System

    6.9 Electromechanical Governor 6.9.2 Initial Checks and Operation Test System The factory sets the electronic governor. Under normal circumstances the electronic governor requires no Electromechanical governor systems are used on further adjustment. Verify that the governor stepper models 8.5/12RES and 12TRES. motor moves smoothly and steadily during operation.

  • Page 85: Governor System/Magnetic Pickup Operation Test

    6.9.3 Hunting/Surging 4. If the engine speed hunts or surges while the throttle is held steady, check the carburetor Often hunting/surging problems thought to be caused position and engine operation. by the governor are actually caused by engine or carburetor problems. Check engine speed stability a.
  • Page 86 Governor System Operation Test Procedure 5. If the voltmeter displays less than 1.75 volts AC, check the air gap as described in the following 1. Verify that the carburetor throttle linkage is steps before replacing the sensor. Verify that the connected to the stepper motor as shown in magnetic pickup air gap is 0.5 mm (0.020 in.).
  • Page 87 7. To test the controller’s governing function, PIN 3, BLK disconnect the magnetic pickup leads and open the generator set circuit breaker. PIN 2, YEL 8. Manually move the throttle shaft/governor stepper motor fully counterclockwise (closed throttle). PIN 5, GRN (not used) 9.

  • Page 88: Frequency Adjustment

    6.9.5 Frequency Adjustment 6. Repeat steps 4 and 5 to obtain the rated frequency and stable operation. The engine speed determines the generator output frequency; 60 Hz units operate at 3600 rpm and 50 Hz 7. Save the settings as instructed in Section 4.5. units run at 3000 rpm.
  • Page 89 6.10 Mechanical Governor Mechanical Governor Arm Adjustment Procedure Make this adjustment whenever the governor arm is Mechanical governors are used on model 12RESL, loosened or removed from the cross shaft. 12RESM1, and 12RESNT generator sets. Figure 6-26 and adjust as follows: Figure 6-25.
  • Page 90 Mechanical Governor Sensitivity Adjustment Engine Speed (Frequency) Adjustment, Mechanical Governor Note: Often hunting/surging problems thought to be caused by the governor are actually caused by Use the adjusting nut shown in Figure 6-28 to adjust the engine or carburetor problems. If the generator engine speed, if necessary.

  • Page 91: Controller Fault Shutdown Functions

    6.11 Fault Shutdown Tests WARNING 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 Hot engine and exhaust system. components (wiring harness, switch, etc.) as described Can cause severe injury or death.

  • Page 92: Fault Shutdown Switches

    Overcrank Shutdown Service View, for the coolant temperature sensor location. Set the generator set master switch to the OFF Disconnect the starter motor lead at the starter solenoid position and allow the generator set to cool. Disconnect (K20) terminal. Move the controller master switch to the the CTS and use an ohmmeter to measure the RUN position.

  • Page 93: Gas Piping

    6.12 Fuel Systems Figure 6-33 lists the maximum gas flow rates for each model. WARNING 8.5RES 12RES Natural Natural Pipe Length, m (ft.) (25) (50) Explosive fuel vapors. (100) Can cause severe injury or death. (150) 1 1/4 Use extreme care when handling,...

  • Page 94: Fuel Conversion

    The fuel lock-off prevents fuel flow when the engine is 6.12.4 Fuel Conversion not operating. See Figure 6-35. Do not try to adjust the fuel pressure, fuel mixture, or engine speed using the The multi-fuel system allows conversion from natural fuel lock-off.

  • Page 95: Digital Spark Advance Ignition

    Fuel Conversion Procedure 1. Place the generator set master switch in the OFF position. Use the following procedure to convert from natural gas to LP vapor. See Figure 6-36 for the fuel system 2. Disconnect the power to the battery charger. component locations.

  • Page 96: Fuel Metering Valve Adjustment

    11. Connect and turn on the new fuel supply. Only trained, authorized service technicians may adjust the new fuel metering valve. The adjustment procedure 12. Check that the generator set master switch is in the requires a digital volt meter (DVM), UEGO oxygen OFF position.
  • Page 97 4. Connect the oxygen sensor to the engine starting 11. When the fuel mixture is correct, use thread sealant battery, control module, and voltmeter as shown in to seal the metering valve adjustment screws. Figure 6-40. 12. Remove the load and allow the generator set to run 5.

  • Page 98: Fuses

    6.13 Fuses Relay Terminal Lead Three fuses are located on the junction box next to the controller display/keypad. (Early models may have the fuses located in the wiring harness.) See Figure 6-41. Another 10-amp fuse protects the battery charger. Fuse Label Part Number Figure 6-43 Starter Relay Connections...
  • Page 99 To further check generator set components, disconnect Zero ohms (continuity) across the battery and remove wiring harness plugs from the RUN and COM terminals controller circuit board. Use an ohmmeter to check the continuity of the components listed in Figure 6-45. Also see Section 8, Wiring Diagrams.
  • Page 100 Notes 100 Section 6 Component Testing and Adjustment TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...

  • Page 101: Disassembly

    Section 7 Disassembly/Reassembly This section provides instructions for the disassembly b. Place the generator set master switch in the and reassembly of the generator set alternator. Before OFF position. beginning the generator disassembly or reassembly c. Remove 4 roof screws. Lift the roof up and off. procedure, carefully read all safety precautions at the See Figure 7-1.
  • Page 102 h. From the inside of the enclosure, remove 5 screws to remove the rear (exhaust end) panel. See Figure 7-3. tp6196 1. Screws (5 ea.) Figure 7-3 Rear Panel Mounting Screw Locations (viewed from inside the enclosure) i. From the inside of the enclosure, remove the remaining screws to remove the non-service side housing panel.
  • Page 103 Junction Box Detail Top View GM29253 1. Exhaust shield screws 2. Alternator air inlet duct screws Figure 7-7 Shield and Alternator Air Inlet Duct, Top View a. Remove two bolts securing the exhaust shield at the exhaust end and remove the shield. b.
  • Page 104 b. Raise the alternator end of the generator set retainer wire hole. See Figure 7-10 and enough to place a thin block of wood beneath Figure 7-11. the rear of the engine. See Figure 7-9. Front View GM29253A GM29253B-P 1. Engine support block Side View Figure 7-9 Generator Set, Right Side c.
  • Page 105 7. Remove the stator and rotor. 7.2 Reassembly a. Remove the stator from the rotor. 1. Reinstall the generator adapter onto the engine. b. Loosen and remove the thrubolt. Use a strap a. Attach the generator adapter and alternator wrench on the rotor to keep the rotor from adapter guard to the engine using four turning during loosening, if necessary.
  • Page 106 e. Thread the four overbolts with locating washers through the end bracket and into the generator adapter. Position the locating tab of each washer to the outer edge of the oblong (OBROUND) hole on the end bracket. See Figure 7-15. The overbolts should be parallel to the outside of the alternator.
  • Page 107 7. Reinstall the alternator air inlet duct. Orient the 8. Install the exhaust shield. See Figure 7-18. duct as shown in Figure 7-18. GM29253C-U 1. Alternator air inlet duct 2. Mounting screws (3 ea.) 3. Exhaust shield Figure 7-18 Alternator Air Inlet Duct 9.
  • Page 108 12. Return the generator set to operation. 13. Turn on the fuel supply. Move the generator set master switch to the RUN position and check for a. Check that the generator set master switch is in leaks with the engine running. the OFF position.
  • Page 109 The drawings are arranged in numerical order on the following pages. Schematic Point-to-Point Wiring Diagram Drawing Number Page Drawing Number Page Model No. Controller ADV-6835A 8.5RES ADC 2100 GM29358 ADV-6835B 8.5RES ADC-RES ADV-7592 GM66285 ADV-6835A 12RES ADC 2100...
  • Page 110 Figure 8-2 Schematic Diagram, Single-Phase, 8.5/12RES w/ADC 2100 Controller, ADV-6835A-E 110 Section 8 Wiring Diagrams TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...
  • Page 111 Figure 8-3 Schematic Diagram, Single-Phase, 8.5/12RES w/ADC 2100 Controller, ADV-6835B-E TP-6196 10/09 Section 8 Wiring Diagrams Downloaded from www.Manualslib.com manuals search engine...
  • Page 112 Figure 8-4 Schematic Diagram, Single-Phase, 12RESL/RESM1 w/DC 2200 Controller, ADV-7296A- 112 Section 8 Wiring Diagrams TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...
  • Page 113 Figure 8-5 Schematic Diagram, Single-Phase, 12RESL/RESM1 w/DC 2200 Controller, ADV-7296B- TP-6196 10/09 Section 8 Wiring Diagrams Downloaded from www.Manualslib.com manuals search engine...
  • Page 114 Figure 8-6 Schematic Diagram, Single-Phase, 12RESL/RESM1/RESNT w/DC-RET Controller, ADV-7351-D 114 Section 8 Wiring Diagrams TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...
  • Page 115 Figure 8-7 Schematic Diagram, Single-Phase, 8.5/12RES w/ADC-RES Controller, ADV-7592- TP-6196 10/09 Section 8 Wiring Diagrams Downloaded from www.Manualslib.com manuals search engine...
  • Page 116 Figure 8-8 Schematic Diagram, Three-Phase, 12TRES w/ADC-RES Controller, ADV-7623 Sheet 3 116 Section 8 Wiring Diagrams TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...
  • Page 117 Figure 8-9 Schematic Diagram, Three-Phase, 12TRES w/ADC-RES Controller, ADV-7623 Sheet 4 TP-6196 10/09 Section 8 Wiring Diagrams Downloaded from www.Manualslib.com manuals search engine...
  • Page 118 Figure 8-10 Point-to-Point Wiring Diagram, Single-Phase, 8.5/12RES w/ADC 2100 Controller, GM29358-E 118 Section 8 Wiring Diagrams TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...
  • Page 119 Figure 8-11 Point-to-Point Wiring Diagram, Single-Phase, 12RESL/RESM1 w/DC 2200 Controller, GM49761-A TP-6196 10/09 Section 8 Wiring Diagrams Downloaded from www.Manualslib.com manuals search engine...
  • Page 120 Figure 8-12 Point-to-Point Wiring Diagram, Single-Phase, 12RESL/RESM1/RESNT w/DC-RET Controller, GM52471-C 120 Section 8 Wiring Diagrams TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...
  • Page 121 Figure 8-13 Point-to-Point Wiring Diagram, Single-Phase, 8.5/12RES w/ADC-RES Controller, GM66285- TP-6196 10/09 Section 8 Wiring Diagrams Downloaded from www.Manualslib.com manuals search engine...
  • Page 122 Figure 8-14 Point-to-Point Wiring Diagram, Three-Phase, 12TRES w/ADC-RES Controller, GM63546, Sheet 3 122 Section 8 Wiring Diagrams TP-6196 10/09 Downloaded from www.Manualslib.com manuals search engine...

  • Page 123: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E-Stop emergency stop alternating current cubic inch displacement etc. et cetera (and so forth) analog to digital centerline...
  • Page 124 Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute kilogram µF microfarad right side kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...

  • Page 125: Appendix B Common Hardware Application Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 126: Appendix C General Torque Specifications

    Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Aluminum Torque Measurement Grade 2 Grade 5 Grade 8 Size Grade 2 or 5 8-32 Nm (in. lb.) (16) (20) — 10-24 Nm (in.

  • Page 127: Appendix D Common Hardware Identification

    Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)

  • Page 128: Appendix E Common Hardware List

    Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
  • Page 129 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Full Thread), Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), continued continued M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M933-12016-60...
  • Page 130 Metric, continued Part No. Dimensions Type Hex Nuts M934-03-50 M3-0.50 Standard M934-04-50 M4-0.70 Standard M934-04-B M4-0.70 Brass M934-05-50 M5-0.80 Standard M934-06-60 M6-1.00 Standard M934-06-64 M6-1.00 Std. (green) M6923-06-80 M6-1.00 Spiralock M982-06-80 M6-1.00 Elastic Stop M934-08-60 M8-1.25 Standard M6923-08-80 M8-1.25 Spiralock M982-08-80 M8-1.25 Elastic Stop...
  • Page 131 Downloaded from www.Manualslib.com manuals search engine...
  • Page 132 US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6196 10/09a 7 Jurong Pier Road Singapore 619159 Phone (65)6264-6422, Fax (65)6264-6455 E 2004, 2008, 2009 by Kohler Co. All rights reserved. Downloaded from www.Manualslib.com manuals search engine...

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