Kohler 14RES Manual
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Kohler 14RES Manual

Residential/commercial generator sets
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Service
Residential/Commercial Generator Sets
Models:
14RES/RESL
20RES/RESL
Controllers:
RDC Residential Digital Control
DC Digital Control
TP-6735 7/17c

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Summary of Contents for Kohler 14RES

  • Page 1 Service Residential/Commercial Generator Sets Models: 14RES/RESL 20RES/RESL Controllers: RDC Residential Digital Control DC Digital Control TP-6735 7/17c...

  • Page 3: Table Of Contents

    ........... . 2.4.1 Air Cleaner, 14RES/RESL Models .......
  • Page 4 Table of Contents, continued Generator Set Operation ..........4.5.1 Local Starting and Stopping .
  • Page 5 ........5.11.6 Fuel Metering Valve Adjustment, 14RES/RESL Only ....
  • Page 6 TP-6735 7/17...

  • 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, maintained. To prevent accidents be Explosion. Can cause severe injury or death. aware of potential dangers and act safely.
  • Page 8 Remove all jewelry before servicing the Combustible materials. A fire can Carbon monoxide symptoms. equipment. Discharge static electricity cause severe injury death. Carbon monoxide can cause severe from your body before touching Generator set engine fuels and fuel nausea, fainting, or death. Carbon batteries by first touching a grounded vapors are flammable and explosive.
  • Page 9 Hazardous Noise The fuel system. Explosive fuel WARNING 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 Hazardous voltage.
  • Page 10 Welding on the generator set. Can Testing live electrical circuits. Servicing the alternator. Hot parts cause severe electrical equipment Hazardous voltage or current will can cause severe injury or death. damage. Before welding on the cause severe injury or death. Have Avoid touching the alternator field or generator set perform the following trained and qualified personnel take...

  • 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

    Phone: (86) 10 6518 7950 KOHLERPower.com. (86) 10 6518 7951 (86) 10 6518 7952 Look at the labels and decals on your Kohler product Fax: (86) 10 6518 7955 or review the appropriate literature or documents included with the product.

  • Page 13: Section 1 Specifications

    1.2 Controller Specifications Rated power, natural gas, 15.3 (20.5) 20.2 (27.1) kW (HP) Model 14RES and 20RES generator sets are equipped Rpm, 60 Hz 3600 with the Residential Digital Control (RDC). Model 14RESL and 20 RESL generator sets are equipped with...

  • Page 14: Alternator Specifications

    1.5 Alternator Specifications Alternator Specification 14RES/RESL 20RES/RESL Frequency Hz 50/60 50/60 Phase Single-Phase Single-Phase Number of leads Excitation method Static Excited Static Excited Voltage regulator type Digital Digital Coupling type Direct Direct Insulation (rotor and stator) Epoxy varnish, vacuum impregnated...

  • Page 15: Service View

    1.7 Service View Note: See Figure 5-28 for the revised fuel system. 7, 8 18, 19 2, 4 CONTROLLER TOP VIEW 18, 19 MODEL 14RES AIR INTAKE SIDE --PANEL REMOVED TO SHOW DETAIL INTAKE SIDE EXHAUST SIDE MODEL 20RES ADV-7876 TP-6735 1.
  • Page 16 Notes Section 1 Specifications TP-6735 7/17...

  • Page 17: 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 Accidental starting.
  • Page 18 Procedure Visually Inspect Check Change Clean Test Section System Component or Procedure Fuel Flexible lines and connections Main tank supply level (LP) Fuel piping Lubrication Oil level 2.2.2 8 or E Change oil 2.2.4 Y or 150 Replace filter 2.2.4 Y or 150 Crankcase breather hose Y or 500...

  • Page 19: Lubrication System

    Model Oil Capacity, L (qt.) 2.2.1 Low Oil Pressure Shutdown 14RES/RESL 1.9 (2.0) The low oil pressure (LOP) shutdown feature protects 20RES/RESL 2.8 (3.0) the engine against internal damage if the oil pressure Figure 2-3 Oil Capacity (approximate) drops below a minimum pressure because of oil pump failure or other malfunction.

  • Page 20: Oil Cooler, 14Res/Resl

    Reconnect the generator set engine starting 2. Oil cooler battery, negative (--) lead last. Figure 2-4 Oil Cooler Location, 14RES/RESL e. Reconnect the power to the battery charger. f. Reinstall the F3 fuse. g. Start and run the generator set for a minute to allow the oil pressure to reach operating range.

  • Page 21: Oil Cooler, 20Res/Resl

    2.3 Spark Plugs 2.2.6 Oil Cooler, 20RES/RESL Inspect and clean the oil cooler at the intervals indicated Reset the spark plug gap or replace the plugs with new in the service schedule. The oil cooler must be kept free plugs as necessary. of debris.

  • Page 22: Air Cleaner Service

    6. Air cleaner element 7. Air cleaner base 2. Disconnect the power to the battery charger. Figure 2-9 Air Cleaner Components, 14RES/RESL 3. Disconnect the generator set engine starting battery, negative (--) lead first. Check for a buildup of dirt and debris around the air cleaner system.

  • Page 23: Air Cleaner, 20Res/Resl Models

    See Figure 2-10 for the air cleaner 12. Reinstall fuse F3. components. When element replacement is necessary, order genuine Kohler parts. 2.4.2 Air Cleaner, 20RES/RESL Models 1. Loosen the two cover retaining knobs and remove The engine is equipped with a replaceable, high density the cover.

  • Page 24: Cooling System

    2.5 Cooling System 2.7 Stepper Motor Coupling The engine fan draws cooling air through the openings Replace the stepper motor coupling and bushings at the in the sides and end near the battery. The alternator fan intervals shown in the service schedule. See the Parts draws cooling air through openings on the side walls of Catalog for replacement part numbers.

  • Page 25: Battery

    2.8 Battery This section contains general battery information and maintenance instructions. Also consult the battery manufacturer’s instructions for battery maintenance. WARNING 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.

  • Page 26: Storage Procedure

    2.10 Storage Procedure 2.10.3 Cylinder Lubrication 1. Remove the spark plugs. Perform the following storage procedure before removing the generator set from service for three 2. Pour one tablespoon of engine oil into each spark months or longer. Follow the engine manufacturer’s plug hole.

  • Page 27: Section 3 Troubleshooting

    See Figure 3-1. Refer to the engine service manual for engine service Obtain replacement fuses from a Kohler authorized information. See the List of Related Materials for the distributor/dealer. document part number.
  • Page 28 Problem Possible Cause Test Corrective Action Reference Battery connections Check for reversed or poor Correct and tighten battery — Generator set engine battery connections. connections. does not Test the battery voltage. Recharge or replace battery. Weak or dead crank battery Test battery according to battery manufacturer’s recommendations.
  • Page 29 Problem Possible Cause Test Corrective Action Reference Check starter connections. Tighten connections. Section 1.7 Generator Starter Replace wiring if damaged. set engine Section 7 does not Troubleshoot the starter. See the Rebuild or replace starter. Engine S/M crank, engine service manual for continued instructions.
  • Page 30 Problem Possible Cause Test Corrective Action Reference Starts hard Low battery voltage Check battery voltage during Charge battery. Replace battery if cranking. necessary. Check battery charger Tighten loose connections. connections, power supply, and operation. Air cleaner clogged Check for a dirty air cleaner Replace element.
  • Page 31 Problem Possible Cause Test Corrective Action Reference Fault shutdown Check for a fault shutdown code Correct the fault and then press Section 4.8 Stops on the controller display. Identify the controller’s OFF button to suddenly Section 5.10 the cause of the fault. reset the controller.
  • Page 32 Problem Possible Cause Test Corrective Action Reference Exhaust system Check silencer and connections Replace gaskets and exhaust — Noisy leaks for leaks. system components as operation necessary. Engine not running See “Erratic operation,” this table. See “Erratic operation,” this table. —...
  • Page 33 Problem Possible Cause Test Corrective Action Reference Incorrect controller Check the controller configuration Adjust the controller configuration Section 4.10.1 High configuration parameters. * parameters. * output voltage Incorrect controller Check the controller voltage Adjust the controller voltage Section 4.10.4 voltage settings settings.
  • Page 34 Problem Possible Cause Test Corrective Action Reference Generator Reduce electrical load and check Unplug some lights or appliances — Low output overloaded operation. connected to the generator set. excessive Incorrect controller Check the controller configuration Adjust the controller configuration Section 4.10 drop in configuration parameters.
  • Page 35 Problem Possible Cause Test Corrective Action Reference AC output circuit Check for AC voltage on the Check for and correct short — No output breaker open generator side of circuit breaker. circuits or overloading on the load voltage If there is AC voltage on the side before resetting the circuit generator side of the breaker, breaker.

  • Page 36: Controller Troubleshooting

    Automatic generator set startup and load transfer when utility power is lost (also available with other Also check the controller display for fault codes and Kohler model transfer switches connected to engine refer to Section 4.8, Faults. start leads 3 and 4)

  • Page 37: Section 4 Controller

    See Section 4.8.4. power is lost. To prevent controller reset when connecting or Models 14RES and 20RES are equipped with the RDC disconnecting the battery, remove controller fuse F3 controller. The RDC controller is equipped with arrow...

  • Page 38: Controls And Indicators

    4.4 Controls and Indicators Figure 4-2 illustrates the RDC and DC controller user interfaces. Residential Digital Controller (RDC) Digital Controller (DC) 1. LED display 6. Service access (see Section 3.3) 2. Up button (RDC only) 7. RUN button and LED 3.

  • Page 39: Led Display

    4.4.1 LED Display Display Description Blank (dark) Controller is off. When the system is in AUTO and the generator set is not running, the LED display shows the engine run time u#.# Controller software version number hours. During cranking, the display shows the crank XXX.X Engine hours to 999.9 cycle information.

  • Page 40: Led Indicators

    Button Press Response in AUTO or OFF Mode Response during EXERCISE Response during TEST Stops the generator set and places Immediately ends the exercise and Immediately ends the test and the controller in OFF mode. The shuts down the generator. The shuts down the generator.

  • Page 41: Generator Set Operation

    4.5 Generator Set Operation 4.5.4 Automatic Operation with Model RRT Transfer Switch 4.5.1 Local Starting and Stopping The Model RRT transfer switch connects to the RDC/DC controller through the ATS interface board on Start the transfer switch. Also see Section 4.9, Model RRT Transfer Switch Operation.

  • Page 42: Exercise

    Note: RDC controllers with firmware version 2.08 or operator before an emergency event. higher support the unloaded variable-speed exercise with Kohler Model RRT, RDT, and RSB Procedure to Set Unloaded Variable-Speed transfer switches. Exercise Note: With the RDT and RSB transfer switches, it is 1.

  • Page 43: Loaded Exercise (With Rrt Only)

    the controller detects low battery voltage, Lb (low 6. E Ld appears on the display and the AUTO LED is battery) or LCb (low charging battery) is displayed illuminated. The generator runs at normal and the exercise does not start. operating speed for twenty minutes with load.

  • Page 44: Test

    4.7 Test Loaded Test Procedure 1. Press the RUN button to start an unloaded test as An operator can use the buttons on the RDC/DC described in Section 4.7.1. When the generator is controller to test the generator set operation. Follow the running at full speed, tnLd appears on the display.

  • Page 45: Faults

    4.8 Faults 4.8.4 Fault Code NoEC The RDC and DC controllers display the fault code Fault codes and conditions are shown in the table on the NoEC (no engine configuration setting) when the following pages, Figure 4-8. Fault conditions are controller parameters have been lost or reset to the classified as warnings or shutdowns.

  • Page 46: Resetting The Controller After A Fault Shutdown

    4.8.5 Resetting the Controller after a 4.8.6 Event History Fault Shutdown The last ten controller faults can be viewed from the controller display when the controller is off. Each event Always identify and correct the cause of a fault is displayed with the fault code followed by the engine shutdown before resetting the controller.
  • Page 47 Code Fault W or SD* Condition Check See Section Wiring Loss of AC W (1 s) Generator output AC sensing is Check for loose connections. Diagrams sensing lost. Starts 10 seconds after Check all AC leads connected to SD (3 s) crank disconnect.
  • Page 48 Code Fault W or SD* Condition Check See Section Low oil The LOP switch indicates low Check for leaks in the lubrication — pressure oil pressure for more than system. 5 seconds. Function becomes Check the oil level and add oil if active 30 seconds after crank the level is low.
  • Page 49 Code Fault W or SD* Condition Check See Section Underfrequency Governed frequency falls below Reduce the load and restart the — 90% of the system frequency generator set. setting for more than Check controller setting for 5 seconds, or 1 Hz below the system frequency.

  • Page 50: Model Rrt Transfer Switch Operation

    4.9 Model RRT Transfer Switch 3. The generator set is signaled to start. Operation 4. The generator starts and the emergency source becomes available. The RDC/DC generator set/transfer switch controller manages automatic transfer switch (ATS) functions 5. The normal-to-emergency time delay times out. when connected to a Kohlerr Model RRT transfer switch through the ATS interface board.

  • Page 51: Engine And Transfer Time Delays

    4.9.4 Engine and Transfer Time Delays the generator set. The load control time delay is fixed at 5 minutes. It is not adjustable. The engine start and transfer time delays prevent engine start and load transfer caused by brief variations The load must be connected to the load control output in the utility power source.

  • Page 52: Controller Configuration And Adjustment

    The DC controller configuration and settings cannot be 4.10.3 Controller Firmware Version viewed or adjusted at the controller. However, a Kohler-authorized distributor or dealer can check and Number adjust the DC controller configuration and settings The controller firmware version number is displayed on...

  • Page 53: Sitetech Software

    Drop-down box Genset Voltage Phase Connection Single Phase Uu01 or Uu06 Drop-down box Genset Info Engine Model Number Type in* CH--740* Ec13 (14RES or 14RESL) Drop-down box Type in* CH--1000* Ec14 (20RES or 20RESL) Drop-down box Genset Model Number 14RES 14RESL...

  • Page 54: Calibration Factor

    Calibration Procedure 4. Click the Calibrate button in the Device Calibration Window. 1. Measure the actual utility voltage across L1 and L2. Use a digital voltage meter and observe the After the calibration procedure, view the utility voltage in safety precautions in the generator set installation the Source 1 metering window.

  • Page 55: Controller Circuit Board

    4.12 Controller Circuit Board 4.12.2 Controller Fuse F2 The controller board is protected by a 7.5-amp fuse (F2) 4.12.1 Relays and LEDs located on the controller. If the fuse blows repeatedly, disconnect the following leads one at a time to identify The K1 flash, K2 crank, and K3 run (fuel) relays are the cause of the blown fuse: located on the controller’s logic board.

  • Page 56: Controller Replacement

    4.13 Controller Replacement Controller Replacement Procedure 1. Open the enclosure roof. If the troubleshooting procedures in Section 3 identify a failed controller, use the procedure in this section for 2. If desired, connect a laptop computer to the RDC controller replacement. Always check the controller controller and use SiteTech software to save the configuration, fuse, wiring, and connections before controller settings.
  • Page 57 Replace the Controller 8. Remove the four (4) screws securing the controller and carefully lift the controller. See Figure 4-17. Note: Be careful of the leads and harness connected to the controller. 9. Note the connections on the back of the controller, and then disconnect P1, P2, P3, and leads 55 and 55F at the miniature circuit breaker.
  • Page 58 18. Optional, except for use with OnCuet software as 19. Press the RUN button on the controller to start the noted below: Use Kohlerr SiteTecht software to generator set. Use a voltmeter to check the output enter the following generator set information into voltage and frequency.

  • Page 59: Section 5 Component Testing And Adjustment

    Section 5 Component Testing and Adjustment 5.1 Theory of Operation 5.2 Separate Excitation The generator set utilizes a rotating-field alternator to To determine the cause of no or low AC output, refer to produce AC voltage. See Figure 5-1. After the engine the troubleshooting flowchart in Figure 5-2.
  • Page 60 4. Check for AC output across the stator leads; see DANGER Section 5.3, Stator. Compare the readings to the output values shown Section 1, Specifications. If the readings vary considerably, a faulty stator is likely. Refer to Section 5.3, Stator, for further information.

  • Page 61: Stator

    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.
  • Page 62 Note: Make sure that all stator leads are Leads Continuity disconnected before running 1 and 2 megohmmeter test. 1 and 11 2 and 11 9. Use a megohmmeter to determine whether the 3 and 4 stator is shorted to ground. 3 and 44 a.

  • Page 63: Main Field (Rotor)

    5.4 Main Field (Rotor) 5. Check the rotor for continuity and resistance. Raise the brushes from the slip rings while The two-pole rotor creates the magnetic field needed to performing ohmmeter tests. Measure the rotor produce alternating current in the stator windings. resistance (ohms) between the two slip rings;...

  • Page 64: Slip Rings

    5.5 Slip Rings Correct Incorrect 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.
  • Page 65 GM80980 GM62996 GM80982 Spring Not New 19.0 mm (0.75 in.) Shown Length New 19.0 mm GM67344 (0.75 in.) GM80981 1. Brush(es) 4. Retainer wire (for service only) 2. Slip rings 5. Shim 1. Brush(es) 4. Shim 3. Brush holder 6. Spring 2.

  • Page 66: Voltage Connections

    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 Stator Leads distributors and dealers (through their distributor).
  • Page 67 Voltage and Frequency Adjustments Using 3. Follow the controller instructions in Figure 5-15 to SiteTech enter the adjustment mode. Increase or decrease voltage (parameter 1P) until the output reaches the When voltage frequency adjustment desired voltage. See Figure 5-13. procedures require adjusting a voltage or speed parameter, use the SiteTech parameters shown in Voltage Approximate...
  • Page 68 Readjust the voltage stability (2P) and voltage (1P) 2. Set the voltmeter to measure voltage. Adjust the parameters after adjusting the volts/Hz setting, if volts/Hz until the voltage level measured by the necessary. voltmeter begins to drop. When set, the generator (as load is applied) attempts to maintain normal Remember to save your settings.
  • Page 69 Hold select and up buttons for 5 seconds Software version Software version number displayed number displayed S A U E u 1 . 0 u 2 . 0 Enter pass code Controller Configuration OFF mode Generator Set Running? Voltage and Frequency RUN mode Adjustment...
  • Page 70 5.9 Governor System overspeed condition. An erratic signal causes the generator set to govern poorly but not shut down. The governor system consists of an electromechanical Check the resistance across the magnetic pickup. stepper motor (actuator) and a magnetic pickup. The See Section 5.9.4.
  • Page 71 2. manual for engine diagnostic and service information. Check stepper motor operation at startup. Does it move to fully open and 14RES/RESL then move to and stay in the fully closed position? See step 3. Check the magnetic Disconnect the pickup.
  • Page 72 4. Stop the engine and check the resistance of the DANGER magnetic pickup. a. Stop the generator set. Remove housing panels as required to gain access to the front of the engine. Hazardous voltage. Moving parts. b. Remove the engine blower housing. Will cause severe injury or death.
  • Page 73 5. Verify the operation of the magnetic pickup by g. After adjusting the air gap, check the voltage connecting a voltmeter to the magnetic pickup again as described in step 5. If the voltage leads. See Figure 5-19. The voltage should be does not measure 3.0 VAC minimum, replace 3.0 volts AC RMS minimum during engine the magnetic pickup.
  • Page 74 The RDC controller can be adjusted using the controller keypad or using a personal computer running Kohler 9. Check for hunting and surging at full load. Increase SiteTech software. The DC controller has no keypad, the gain (parameter 5P) until the engine hunts and and must be adjusted using SiteTech software.
  • Page 75 5.10 Fault Shutdown Tests 5.10.1 Controller Fault Shutdown Functions Verify the operation of the generator set overspeed, overcrank, and low oil pressure shutdowns by Check the operation of the fault functions programmed performing the following tests. If these tests are in the controller by performing the following tests.
  • Page 76 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.
  • Page 77 5.10.2 Fault Shutdown Switches Low Oil Pressure (LOP) Switch The low oil pressure (LOP) switch is located under the Check the low oil pressure and high engine temperature engine air cleaner. See Figure 5-25. shutdown switches on the engine by performing the following tests.
  • Page 78 5.11 Fuel Systems 5.11.1 Fuel Solenoid Valve A solenoid valve upstream of the regulator and the WARNING flexible fuel connector provides automatic fuel on/off control. See Figure 5-27 or Figure 5-28. The engine starting battery powers the solenoid valve and the engine starting controls open the valve when the engine cranks or runs.
  • Page 79 (Enlarged to show detail) DSAI Lead Connection GM66563 1. Regulator 3. Fuel inlet, 1/2 in. NPT female 2. Fuel block (not shown) or LP orifice location (see 4. Fuel solenoid valve and digital spark advance ignition (DSAI) Figure 5-29) leads Figure 5-27 Fuel System DSAI Lead Connection GM80110...
  • Page 80 14RES/RESL 20RES/RESL Regulator, side view TP-6735 1. Fuel block (14RES/RESL) 5. Hose fitting 7. Regulator vent hose (20RES/RESL only) 2. Secondary regulator 6. LP orifice fits inside 8. Inlet pressure check location 3.
  • Page 81 5.11.4 Fuel Conversion, 20RES/RESL Procedure to Convert from NG to LP, 20RES/RESL 1. Press the OFF button on the generator set For LP vapor fuel, an orifice is used in the fuel line. The controller and remove controller fuse F3. unit is typically shipped set up for natural gas, with the loose orifice tied near the fuel solenoid valve.
  • Page 82 11. Disconnect the DSAI leads for LP. See Figure 5-27 for the location of the DSAI leads. Procedure to convert from NG to LP, 14RES/RESL Fuel DSAI Leads 65 and N 1. Press the OFF button on the generator set...
  • Page 83 5.11.6 Fuel Metering Valve Adjustment, Fuel Mixture Check/Fuel Metering Valve Adjustment Procedure 14RES/RESL Only 1. Follow the instructions provided with the oxygen The fuel system is factory-adjusted to comply with sensor kit to perform the initial programming and applicable emission standards and to provide the best setup of the air/fuel (A/F) reader.
  • Page 84 2.60 ± 0.05 (Figure 5-28) * UEGO sensor readings shown for reference Figure 5-35 Acceptable Oxygen Sensor Readings, 14RES/RESL 11. Adjust the fuel metering valve as required to obtain the output from the oxygen sensor specified in Figure 5-35. 12. When the fuel mixture is correct, use thread...
  • Page 85 5.13 Continuity Checks controller circuit board. Use an ohmmeter to check the continuity of the components listed in Figure 5-39. Also see Section 7, Wiring Diagrams. DANGER Figure 5-39 gives resistance readings for functional components. A zero reading on the ohmmeter indicates continuity.
  • Page 86 5.14 Circuit Protection See Figure 5-40 for fuse part numbers. Always identify and correct the cause of a blown fuse before restarting If the generator set circuit breaker trips or the fuses blow the generator set. Refer to Section 3, Troubleshooting, repeatedly, see Section 3, Troubleshooting, for possible for conditions that may indicate a blown fuse.
  • Page 87 Section 6 Disassembly/Reassembly This section provides instructions for the disassembly WARNING 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 Hot engine and exhaust system.
  • Page 88 6.2 Disassembly disassembly procedure explains 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.
  • Page 89 4. Original design, see Figure 6-3. Remove the 5. Revised design with thermal cover, see Figure 6-4. exhaust duct panel over the muffler: Remove the thermal cover: a. Remove four screws. See Figure 6-3. a. Loosen and remove the locknuts from the front and rear hinge brackets.
  • Page 90 6. Original Design: Disconnect the latch assembly: a. Disconnect the latch rods at the red plastic connectors. See Figure 6-5. b. Reach inside the enclosure to move each latch hinge aside. Note: With the revised latch design, no latch disassembly is required. GM72523 1.
  • Page 91 10. Remove two screws and remove the front panel. 16. From the inside of the enclosure, remove four nuts See Figure 6-7. securing the left side panel. See Figure 6-9. 17. Pull the panel up and off. ADV-7876 GM72523 1. Remove 2 screws Figure 6-7 Front Panel (air intake end panel) 11.
  • Page 92 18. Remove the remaining exhaust duct panels and Generator Disassembly alternator air inlet duct. See Figure 6-10. 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.
  • Page 93 23. Remove the alternator support bracket from the alternator shell. See Figure 6-13. TP-6735 1. Alternator support bracket Figure 6-13 Alternator Support Bracket 24. Remove the cable tie that attaches the brush leads to the end bracket. See Figure 6-14 or Figure 6-15.
  • Page 94 26. Remove the alternator overbolts and centering washers. See Figure 6-16. GM80980 GM62996 1. End bracket (brush assembly shown attached) GM80982 2. Stator windings (outer) 3. Rotor (inner). Also see Figure 6-17. 4. Stator shell 5. Overbolts (qty. 4) Figure 6-16 Alternator Assembly Spring Not 27.
  • Page 95 30. Remove the rotor as follows: 31. 14RES/RESL only: Remove the four generator adapter mounting bolts to remove the generator a. Loosen but do not remove the rotor thrubolt. adapter, if necessary. See Figure 6-18. Use a strap wrench on the rotor to keep the...
  • Page 96 6.3 Reassembly 3. Install the stator and end bracket. a. Re-attach the alternator support bracket to the 1. 14RES/RESL only: Reinstall the generator alternator shell. The hole in the bracket must adapter onto the engine, if necessary. face the engine. See Figure 6-20.
  • Page 97 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 6-21. f. Thread the four overbolts with locating washers through the end bracket and into the generator adapter.
  • Page 98 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.
  • Page 99 8. Install the exhaust system. See Figure 6-27. 9. Reinstall the alternator and exhaust duct panels shown in Figure 6-28. 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.
  • Page 100 17. Reinstall the enclosure panels in reverse order of removal. See Figure 6-29 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 GM72523 1.
  • Page 101 SEE REAR HINGE SEE FRONT HINGE BRACKET VIEW BRACKET VIEW REAR HINGE BRACKET VIEW FRONT HINGE BRACKET VIEW 1. Thermal cover 2. Screw 3. Locknut GM81036 Figure 6-32 Thermal Cover (revised design) TP-6735 7/17 Section 6 Disassembly/Reassembly...
  • Page 102 Notes Section 6 Disassembly/Reassembly TP-6735 7/17...
  • Page 103 Section 7 Wiring Diagrams Figure 7-3 lists the wiring diagram numbers and page The revised design uses the revised fuel system and the numbers. revised field-connection terminal block layout shown in Figure 7-2. The original design uses the field-connection terminal block layout shown in Figure 7-1.
  • Page 104 Figure 7-4 Schematic Diagram, ADV-7697 (original design) Section 7 Wiring Diagrams TP-6735 7/17...
  • Page 105 Figure 7-5 Schematic Diagram, ADV-8033 (revised design) TP-6735 7/17 Section 7 Wiring Diagrams...
  • Page 106 Figure 7-6 Point-to-Point Wiring Diagram, GM69754 (original design) Section 7 Wiring Diagrams TP-6735 7/17...
  • Page 107 Figure 7-7 Point-to-Point Wiring Diagram, GM79591 (revised design) TP-6735 7/17 Section 7 Wiring Diagrams...
  • Page 108 Notes Section 7 Wiring Diagrams TP-6735 7/17...
  • Page 109 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 110 Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute kilogram microfarad right side F kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...
  • Page 111 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 112 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 Grade 2 or 5 Size 8-32 Nm (in. lb.) (16) (20) — 10-24 Nm (in.
  • Page 113 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 114 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 115 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 116 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 117 (Write). Adjustment Range Group Parameter Access Units Default Setting Identity Vendor Read — Kohler Company Product Read — RDC (38) Firmware Version Read — — Engine Metering Engine Speed Read R/min —...
  • Page 118 Adjustment Range Group Parameter Access Units Default Setting Voltage Regulator Voltage Regulator Average Voltage Write 108--660 Adjustment Voltage Regulator Volts Per Hertz Write 1--10 Slope Voltage Regulator Volts Per Hertz Cut Write 42--62 57.5 In Frequency Voltage Regulator Gain Write 1--255 Voltage Regulator Firmware Version Read...
  • Page 119 0.0.0.0 Static Default Gateway Write 0.0.0.0 Static DNS Server 1 Write 0.0.0.0 Static DNS Server 2 Write 0.0.0.0 Server Host Name Write oncue.kohler.com Network Status IP Address Read 0.0.0.0 (for OnCue) Subnet Mask Read 0.0.0.0 Default Gateway Read 0.0.0.0 DNS Server 1 Read 0.0.0.0...
  • Page 120 Notes TP-6735 7/17...
  • Page 121 Notes TP-6735 7/17...
  • Page 122 Notes TP-6735 7/17...
  • Page 124 Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: TP-6735 7/17c Call 1-800-544-2444 or visit KOHLERPower.com E 2010, 2011, 2017 by Kohler Co. All rights reserved.

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