Kohler 6VSG Service Manual
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Kohler 6VSG Service Manual

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Service
DC Generator Sets
TP-6844 1/13a
Models:
6VSG
24VDC
36VDC
48VDC
Controller:
VSC

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Summary of Contents for Kohler 6VSG

  • Page 1 Service DC Generator Sets Models: 6VSG 24VDC 36VDC 48VDC Controller: TP-6844 1/13a...

  • Page 2: Product Identification Information

    California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Controller Identification Product identification numbers determine service parts. Record the product identification numbers in Record the controller description from the generator the spaces below immediately after unpacking the set operation manual, spec sheet, or sales invoice.

  • Page 3: Table Of Contents

    Oil Cooler, 6VSG ........20...
  • Page 4 Fuel Regulators ........79 5.8.3 Fuel Conversion, 6VSG ....... 80 5.8.4 Fuel Metering Valve Adjustment.

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. Electromechanical WARNING equipment, including generator sets, transfer switches, switchgear, WARNING accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, maintained. To prevent accidents be Explosion. aware of potential dangers and act safely. Can cause severe injury or death.
  • Page 6 Battery gases. Explosion can Servicing the air cleaner. A sudden Carbon monoxide detectors. cause severe injury death. backfire can cause severe injury or Carbon monoxide can cause severe Battery gases can cause an explosion. death. Do not operate the generator nausea, fainting, or death.
  • Page 7 Hazardous Noise The fuel system. Explosive fuel vapors can cause severe injury or CAUTION death. Vaporized fuels are highly explosive. Use extreme care when CAUTION handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children.
  • Page 8 Hot Parts Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death. Reconnect battery correctly, WARNING positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have qualified electrician install the battery(ies).

  • Page 9: Introduction

    Separate engine operation and service manuals are available at the time of print. Kohler Co. reserves the also available. Figure 2 lists the available manual part right to change this publication and the products numbers. represented without notice and without any obligation or liability whatsoever.
  • Page 10 Nameplate Emission Information The following illustration shows a typical generator set The Kohler Model CH740 engine used on the 6VSG nameplate. Copy the model, serial, and specification generator set is certified to operate using natural gas numbers from the nameplate into the spaces provided or LPG fuel.

  • Page 11: Service Assistance

    • Visit the Kohler Power Systems website at Fax: (86) 10 6518 7955 KOHLERPower.com. East China Regional Office, Shanghai • Look at the labels and stickers on your Kohler Phone: (86) 21 6288 0500 product or review the appropriate literature or Fax: (86) 21 6288 0550 documents included with the product.
  • Page 12 Notes Service Assistance TP-6844 1/13...

  • Page 13: Section 1 Specifications

    1.2 Controller Specifications Rated power, natural gas, This unit is underrated by kW (HP) limiting current to 6 kW. Model 6VSG generator sets are equipped with the Rpm, No load 2300 VSC controller. For a specific description of the Rpm, Full load 2900 controller, see the generator set operation manual.

  • Page 14: Alternator Specifications

    Do not confuse a low resistance reading with a reading indicating a shorted winding. Figure 1-3 Alternator Specifications 1.6 Torque Specifications 1.7 Rectifier Specifications Figure 1-5 Figure 1-4 Specification 36V and 48V Torque Specifications, 6VSG Nm (ft. lb.) Rated Voltage, V Alternator overbolts 15 (11) Rated Current, A Alternator thrubolt 85 (63)

  • Page 15: Service View

    1.8 Service View Figure 1-6 KPS_002 ADV-8060 1. Exhaust air outlet 12. Lifting holes 2. Air cleaner 13. Controller 3. Oil fill 14. Engine certification label 4. Oil drain 15. Line circuit breaker 5. Oil drain valve 16. Oil dipstick 6.
  • Page 16 Figure 1-7 ComKitB GM85956C 1. Interface board (factory-wired to terminal blocks) 2. Intrusion alarm switch 3. Interface board input and output connection terminal blocks 4. Fuel pressure switch Figure 1-7 Communications Kit Components Section 1 Specifications TP-6844 1/13...

  • Page 17: Section 2 Scheduled Maintenance

    Reconnect the negative (–) lead last ® literature. Contact an authorized Kohler service when reconnecting the battery. distributor/dealer to obtain engine service literature. Disabling the generator set. Accidental starting can cause severe injury or death.
  • Page 18 Figure 2-1 Procedure Visually System Component or Procedure Section Frequency Inspect Check Change Clean Test Fuel Flexible lines and connections Quarterly Main tank supply level (if LPG fueled) Weekly Fuel piping Yearly Lubrication 8 hours or Oil level before use** Crankcase breather hose Yearly or 500 hours Change oil...

  • Page 19: Lubrication System

    2.2 Lubrication System 2.2.3 Engine Oil Recommendation Use 5W-30 API (American Petroleum Institute) See Section 2.1, Service Schedule, for oil change and Service Class SG, SH, or SJ synthetic oil. Synthetic oil oil filter replacement intervals. See Section 1.8, oxidizes and thickens less than other oils and leaves Service View, for the oil drain, oil check, oil fill, and oil the engine intake valves and pistons cleaner.

  • Page 20: Oil Cooler, 6Vsg

    Reconnect the generator set engine starting 1. Oil filter 2. Oil cooler battery, negative (–) lead last. Figure 2-5 Oil Cooler Location, 6VSG d. Reconnect the power to the generator set, if applicable. Figure 2-6 e. Press the RUN button on the generator set controller.

  • Page 21: Spark Plugs

    2.4 Spark Plugs 2.5 Air Cleaner Service The engine has a replaceable high-density paper air Reset the spark plug gap or replace the plugs with new cleaner element with an oiled foam precleaner. See plugs as necessary. Figure 2-9. 1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.
  • Page 22 Precleaner Service 8. Check the air cleaner base. Make sure it is secure and not bent or damaged. Also check the Use the following procedure to wash and oil the element cover for damage and fit. Replace all precleaner as indicated in the service schedule. Wash damaged air cleaner components.

  • Page 23: Cooling System

    2.6 Cooling System 2.7 Exhaust System The engine fan draws cooling air through the openings Remove all combustible materials from the exhaust in the sides and end near the battery. The alternator location. Combustible materials include building fan draws cooling air through openings on the side materials as well as natural surroundings.

  • Page 24: Engine Starting Battery

    cause an explosion, avoid touching the battery terminals with Figure 2-12 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.

  • Page 25: Fuel System Maintenance

    2.11.3 Cylinder Lubrication After reconnecting the battery cables, coat the battery terminals with petroleum jelly, silicone grease, or other 1. Remove the spark plugs. nonconductive grease. 2. Pour one tablespoon of engine oil into each spark 2.10 Fuel System Maintenance plug hole.
  • Page 26 Notes Section 2 Scheduled Maintenance TP-6844 1/13...

  • Page 27: Section 3 Controller

    USB Cable KPS_048 GM77569 Figure 3-1 VSC Controller 3.2 SiteTech and OnCue Software Many procedures in this manual require the use of a personal computer (or laptop) with Kohler ® SiteTech™ software to change controller settings or update firmware. SiteTech software available Kohler-authorized distributors and dealers.

  • Page 28: Controller Parameters

    The following system parameters can be viewed in the Adjustable parameter settings can be changed using a Genset System menu on the user interface on the personal computer (or laptop) with Kohler SiteTech generator set’s VSC controller. software. See Section 3.2, SiteTech and OnCue Software for USB connection information.
  • Page 29 Natural Gas power output of the generator set. A 6VSG set at the system voltage shown in Figure 3-5 Next Exercise: will have an output of 6 kW. If the system voltage is 01:00p 02Dec2012 set to a higher value, the output current decreases.
  • Page 30 Operation Manual for instructions if the slows, and the load on the generator set decreases. setting needs to be changed. The 6VSG will automatically stop when the load has reached or fallen below the Auto Stop Load setting for Figure 3-8 Nominal Voltage 180 seconds (3 minutes).

  • Page 31: Notes On Selected Parameters

    SiteTech to set the Personality Installed Options dropdown list. Find the generator set serial number on parameter to 6VSG Telecom. This will set the digital the nameplate and enter it using SiteTech. inputs and outputs to the correct settings.

  • Page 32: Controller Parameter Table

    • Adjustment range for user-adjustable settings marked Read Only are not user-adjustable. Some parameters that are visible in SiteTech do not apply to the Model 6VSG generator sets. Those parameters are not listed in the table. The table indicates the following: •...
  • Page 33 Engine Idle Speed 600–3000 2200 Genset Personality Profile Engine Run Speed 1000–3900 2900 Genset Personality Profile Personality Installed Options None or 6VSG 6VSG:None; Telecom for Comm Kit: 6VSG comm. kit Telecom Genset System Configuration Genset System Voltage 24–60 24V = 27 36V = 40.5...
  • Page 34 Adjustment SiteTech Group Parameter Units Range * Default Setting Voltage Regulator Voltage Regulator Average Voltage 24–64 (Auto 27, 40.5, or 54 Adjustment select with (System Voltage) system voltage) Voltage Regulator Voltage Regulator Volts Per Hertz Slope 1–10 Voltage Regulator Voltage Regulator Gain 1–255 Engine Timing Engine Start Delay...
  • Page 35 Static DNS Server 1 0.0.0.0 – 0.0.0.0 255.255.255.25 Network Configuration Static DNS Server 2 0.0.0.0 – 0.0.0.0 255.255.255.25 Network Configuration Server Host Name oncue.kohler.co oncue. kohler.com Network Status IP Address Read Only 0.0.0.0 Network Status Subnet Mask Read Only 0.0.0.0...
  • Page 36 Adjustment SiteTech Group Parameter Units Range * Default Setting Rbus Devices B1 Rbus Devices B1 Last Connection Date Read Only Rbus Devices B1 Rbus Devices B1 Firmware Version Read Only Rbus Devices B1 Rbus Devices B1 Connected Read Only Rbus Devices B2 Rbus Devices B2 Serial Number Read Only Rbus Devices B2...

  • Page 37: Controller Firmware

    1.2 h (if any) the latest software from the TechTools area of the Kohler Power Resource Center website. Controller firmware is also available for download on the Kohler dealer portal and at www.kohlerpower.com/oncue. Genset Status Standby The firmware version number is shown in the VSC controller’s Overview menu.

  • Page 38: Controller Replacement

    ® SiteTech™ software can be used to load the settings onto the new controller. In some cases, the Kohler Generator Service Department may provide a settings file to load onto the controller for testing or troubleshooting. See TP-6701, SiteTech Software...
  • Page 39 15. Calibrate the voltage. See Section 3.7, Voltage Figure 3-13 Calibration. ® 16. If OnCue is used to monitor this generator set, reset the OnCue password on the controller and note the new password. See Section 3.9, Setting the OnCue Password. Then connect with OnCue and enter the new password.

  • Page 40: Controller Setup

    See Figure 3-12 for SiteTech to set the digital inputs and outputs. the nameplate location. 5. If the generator set is equipped with the • For the Genset Model Number, select 6VSG-24V for factory-installed communications kit,...
  • Page 41 Figure 3-17 Figure 3-16 Genset ----> System Voltage: Genset ----> Genset M/N: System 54.0 V Information 6VSG-48V Auto Start Volt: Genset S/N: 50 V ######## Auto Stop Load: Controller S/N: 40 % ######## Pct. Load Limit: <---- Return 100 %...

  • Page 42: Voltage Calibration

    The voltage can be calibrated using the controller displayed will discard the changes and reset the keypad and menus, or using a personal computer with calibration to the default settings. ® Kohler SiteTech™ software. 9. Press OFF to stop the generator set. Section 3 Controller TP-6844 1/13...
  • Page 43 Figure 3-18 Voltage reading flashes. Voltage: Generator ----> Volts: Metering 54.0 V 54.0 V Press Arrow buttons to increase or decrease voltage reading. Voltage: (new value) V See the next section for load Load: calibration instructions. Reset Reset Calibration Calibration? No <---- Return Reset Calibration...

  • Page 44: Voltage Calibration Using Sitetech

    ( V meter ÷ V control ) x F old = F new Connect a personal computer (laptop) to the controller using a USB cable and follow this procedure to use ® Kohler SiteTech™ software to calibrate the controller. V meter = Voltmeter reading The voltage calibration factors are located in the V control = Voltage displayed on controller Genset Calibration group in SiteTech™.
  • Page 45 Figure 3-20 KPS_076 1. Voltage calibration factor 2. Current transformer calibration factor Figure 3-20 Voltage and Current Transformer Calibration Factors in SiteTech™ TP-6844 1/13 Section 3 Controller...

  • Page 46: Load (Current) Calibration

    11. Verify that the load on the generator is displayed Amps). correctly. Recalibrate if necessary. Note: The 6VSG supplies current far in excess of what 12. Press OFF to stop the generator set. a digital multimeter can handle using the internal current measurement channel.
  • Page 47 Figure 3-21 Adjust the percent load limit before performing the calibration. See the Genset System Menu. Generator ----> Volts: Metering 54.0 V Press and hold (5 sec.) Load: No Load Calib. Calibrate Press Select Load? NO Calibrate Calibration Load? Yes Successful/ Failed Full Load Calib.

  • Page 48: Calibration Using Sitetech

    DC current probe and configure it to measure current supplied by the generator (DC Amps). Note: The 6VSG supplies current far in excess of what a digital multimeter can handle using the internal current measurement channel. clamp-on DC current probe or DC current meter is required.

  • Page 49: Setting The Oncue Password

    4. Press Select. Reset OnCue Password is displayed. If the Kohler OnCue Generator Management System 5. Press and HOLD the Select button until Reset is used to monitor the generator set, reset the OnCue OnCue Password? No appears. The word No password as described below for the VSC.
  • Page 50 Notes Section 3 Controller TP-6844 1/13...

  • Page 51: Section 4 Troubleshooting

    The controller is equipped with internal circuit ® keypad, or use a personal computer and Kohler protection for accessory and main power overload ™ SiteTech software.

  • Page 52: Fuel System Troubleshooting

    4.6 Fuel System Troubleshooting 4.7 Fault Messages Most problems with gas fuels involve either fuel The VSC controller displays fault messages to aid in pressure fuel regulator function. Basic troubleshooting. Fault messages, descriptions, and troubleshooting consists of verifying fuel pressures recommended checks are listed in Figure 4-2.
  • Page 53 Fault Message Action Description/Comments Check Battery Low Warning † Warning The controller has measured battery Check engine starting battery. voltage that is below the low warning Check battery charger DC setting for 90 seconds or more. output voltage from VSC on lead The battery voltage is checked before CHO to the battery.
  • Page 54 Fault Message Action Description/Comments Check High Lube Oil Temperature Warning Oil temperature higher than 300°F See Overheats in the (149°C). troubleshooting charts in Section 4.9. High Lube Oil Temperature Shutdown Oil temperature higher than 325°F (163°C). Lo Crank Vlt Warning Warning During cranking, the controller measured Check cranking battery.

  • Page 55: Status Messages

    Adjustment. * Programmable Interface Module (PIM) required. † Applies during exercise runs and normal operation. Figure 4-2 Fault Messages Displayed on the 6VSG VSC Controller 4.8 Status Messages The following messages are displayed to show system displayed when a digital input is activated; the optional status.
  • Page 56 Fault Message Action Description/Comments Check Fuel Spill * Notice The digital output for Fuel Spill (PIM) is Check customer equipment active (contacts closed), indicating any of connected to the PIM module. the digital inputs for Fuel Tank Leak Warning, Fuel Tank Leak Shutdown, Engine Fuel Level Warning or Engine Fuel Level Critically High (PIM) is active (low).

  • Page 57: Troubleshooting Chart

    4.9 Troubleshooting Chart Use Figure 4-4 as a reference in troubleshooting shown. The reference column provides additional individual problems. Generator set faults are listed in sources of information in this and related manuals groups and include likely causes and remedies. The regarding the problem and solution.
  • Page 58 Problem Possible Cause Test Corrective Action Reference Cranks but No fuel Verify that manual fuel valve is Open (turn on) manual fuel valve. — does not open. Contact fuel supplier to add fuel to start Check fuel supply tank (LPG). fuel supply tank (LPG).
  • Page 59 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. W/D Section 7 connections and power connection to the generator set. Air cleaner clogged Check for a dirty air cleaner Replace element.
  • Page 60 Problem Possible Cause Test Corrective Action Reference Stops Fault shutdown Check for a fault shutdown Correct the fault and then press Section 4.7 suddenly message on the controller display. the controller’s OFF button to reset Identify the cause of the fault. the controller.
  • Page 61 Problem Possible Cause Test Corrective Action Reference Erratic Air cleaner clogged Check air filter element. Replace element. operation Spark plug(s) Check spark plug condition and Replace or regap plugs. Engine S/M gap. Spark plug wire(s) Check spark plug connections and Tighten connections.
  • Page 62 Problem Possible Cause Test Corrective Action Reference Lacks Air intake Inspect air intakes and exhaust for Clear air intakes and exhaust power restriction, obstructions. area. Maintain clearances shown inadequate cooling on the genset dimension drawing. Check air cleaner. Replace air cleaner element. Generator Reduce electrical load and check Unplug some lights or appliances...
  • Page 63 Problem Possible Cause Test Corrective Action Reference No output DC output circuit Check for DC voltage on the Check for and correct short circuits — voltage breaker open generator side of circuit breaker. If or overloading on the load side there is DC voltage on the before resetting the circuit generator side of the breaker, then...

  • Page 64: Controller Troubleshooting

    Figure 4-5 when troubleshooting procedures using a personal computer and Kohler SiteTech Section 4.9 indicate a possible controller problem. software. The generator set operation manual Also check the controller display for fault messages contains the instructions for checking and changing and see Section 4.7, Fault Messages.

  • Page 65: Section 5 Component Testing And Adjustment

    • The output breaker is closed (check voltage at the voltage, which is equal to the System Voltage setting. rectifier). When the load on the 6VSG generator increases, the • The Voltage Regulator Average Voltage Adjustment generator controller increases the engine speed. The parameter is correct.

  • Page 66: Erratic Voltage Regulation

    Note: There should not be voltage between leads 1 Check the controller calibration – if the controller reads and 4, 2 and 5, and 3 and 6 on the 24V 6VSG accurately, check Voltage...
  • Page 67 Figure 5-3 DC Output Figure 5-5 36V and 48V 6VSG Units If the DC voltage is close to the generator rating, measure the AC voltage on the DC output. This value If all tests appear to have diode conduction, it is...

  • Page 68: Stator

    Stator Continuity and Resistance Tests Figure 5-7 1. Press the OFF button on the controller to turn off the generator set. 2. Disconnect power to the generator set (if equipped). 3. Disconnect the generator set engine starting battery, negative (–) lead first. 4.

  • Page 69: Voltage Adjustments

    Voltage regulation is performed by the controller. The controller monitors generator output voltage and adjusts the Voltage Correction Factor to change the operating speed range of the generator. The 6VSG requires no adjustment to maintain rated output voltage, as the DC output voltage is corrected to the Voltage Regulator Average Voltage Adjustment as the generator runs.
  • Page 70 Note: The protective trip points are based on the The Voltage Regulator Average Voltage Adjustment can be adjusted if the DC output voltage of the 6VSG system voltage; therefore, changing the VRAA generator is desired to track to a value other than the will not shift the protective trip points.

  • Page 71: Volts/Hz Slope

    Voltage Regulator Gain The governor system is controlled by the generator set controller. The controller provides regulated power to The 6VSG uses a closed loop voltage correction the bidirectional stepper motor actuator, which is controller to correct for long-term temperature drift.

  • Page 72: Hunting/Surging

    6. If the engine speed hunts or surges while the • Check for electronic governor faults. The fuel shutoff solenoid deenergizes and the generator set throttle is held steady, check the carburetor and shuts down under the following conditions: engine operation. Refer to the engine service manual for engine diagnostic and service ◦...

  • Page 73: Governor System Operation Test

    See steps 8 through 10. speed condition, and the controller does not shut down the generator, verify that the generator set model is set to 6VSG. Then check and verify the Check the linkage alternator connections, functionality, to the carburetor.

  • Page 74: Engine Speed Gain Adjustment For The Governor

    Note: Do not adjust the Advanced Speed Control Replace as necessary. settings unless instructed to do so by the Kohler Generator Service Department. 12. Disconnect the linkage between the stepper motor and the carburetor. Verify free, full range of...
  • Page 75 Figure 5-17 KPS_086 1. Engine Speed Governor settings Figure 5-17 Engine Speed Parameters in SiteTech TP-6844 1/13 Section 5 Component Testing and Adjustment...

  • Page 76: Fault Shutdown Tests

    5.7 Fault Shutdown Tests Figure 5-18 Parameter Setting Genset Model Number* 6VSG Verify the operation of the generator set overspeed, Genset Serial Number* From nameplate overcrank, and low oil pressure shutdowns by performing the following tests. If these tests are Natural Gas or Liquid Fuel Type†...

  • Page 77: Fault Shutdown Switches

    Locked Rotor Shutdown Figure 5-20 Remove the connector from the starter relay (see Figure 5-29). Press RUN. Verify that the engine does not turn and the controller indicates a Locked Rotor fault. High Engine Temperature Shutdown Note: Testing the high engine temperature shutdown requires connecting a jumper wire across the temperature sensor connections.

  • Page 78: Fuel Systems

    If the resistance is very low (indicating a short circuit) Figure 5-22 or very high (indicating an open circuit), replace the CTS. Note: Because the temperature sensor can be difficult to reach, the resistance can be measured across pins 9 and 10 on connector P1 at the generator set controller, if desired.

  • Page 79: Fuel Solenoid Valve

    5.8.1 Fuel Solenoid Valve Note: Do not attempt to adjust the fuel mixture or engine speed by adjusting the regulators. A solenoid valve upstream of the regulator and the The fuel lockoff prevents fuel flow when the engine is flexible fuel connector provides automatic fuel on/off not operating.

  • Page 80: Fuel Conversion, 6Vsg

    3. Inlet pressure check location Figure 5-25 Fuel Regulator 5.8.3 Fuel Conversion, 6VSG 9. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant to the threads, and install Two fuel connections on the fuel block allow field the fitting into the LPG port.

  • Page 81: Fuel Metering Valve Adjustment

    12. Reconnect the generator set engine starting battery leads, negative (–) lead last. WARNING 13. Reconnect power to the generator set. 14. Start the generator set by pressing the RUN button on the generator set controller. Hot engine and exhaust system. 15.

  • Page 82: Starter Relay

    5.9 Starter Relay 5. Follow the instructions provided with the oxygen sensor kit to connect the oxygen sensor to the The starter relay is located behind the controller. See power supply and A/F reader. Figure 5-29. 6. Reconnect power to the generator set. Figure 5-29 7.

  • Page 83: Continuity Checks

    See the wiring diagram in Section 7 for the starter further check generator components, relay connections. disconnect the battery and remove wiring harness plugs from the controller circuit board. Use an 5.10 Continuity Checks ohmmeter to check the continuity of the components listed Figure 5-31 gives resistance readings for functional WARNING...
  • Page 84 Notes Section 5 Component Testing and Adjustment TP-6844 1/13...

  • Page 85: Section 6 Disassembly/Reassembly

    Section 6 Disassembly/Reassembly This section provides instructions for the disassembly and reassembly of the generator set alternator. Before WARNING 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 86 Figure 6-1 Figure 6-2 KPS_095 1. Roof 2. Left-side panel 3. Front service door 4. Right-side panel 5. Rear panel (exhaust end) KPS_120 Figure 6-1 Enclosure 1. Three bottom screws 4. Remove the right-side panel: 2. Two top screws Note: The three bottom screw holes are slotted and Figure 6-2 Right-Side Panel only need to be loosened.
  • Page 87 Remove the Muffler Figure 6-3 1. Remove the two bolts and nuts from the muffler bracket. 2. Remove the four nuts from the exhaust flanges. Figure 6-5 KPS_121 1. Four bottom screws 2. Three top screws Figure 6-3 Left-Side Panel 6.
  • Page 88 Generator Disassembly 3. Remove the four nuts holding the end cap on the stator and remove the end cap. 1. Remove the two bolts from the center of the rubber isolators. Figure 6-9 Figure 6-7 KPS_126 1. End cap nuts 2.

  • Page 89: Assembly

    Figure 6-10 Figure 6-11 KPS_135 1. Adapter mounting bolts Figure 6-11 Adapter Plate 6.3 Assembly KPS_127 1. Prying area 2. Top bracket Assembly is done in reverse order of disassembly, 3. Stator guides except as noted. Figure 6-10 Removing Stator 1.
  • Page 90 Notes Section 6 Disassembly/Reassembly TP-6844 1/13...

  • Page 91: Section 7 Drawings And Diagrams

    Section 7 Drawings and Diagrams Figure 7-1 lists the installation drawing numbers and Figure 7-1 page numbers. Installation Drawing Description Drawing Number Page Dimension Drawing ADV-8060, Sheet 1 Dimension Drawing ADV-8060, Sheet 2 Dimension Drawing ADV-8060, Sheet 3 Schematic Diagram, 36V and 48V ADV-8460, Sheet 1 Schematic Diagram, 24V ADV-8460, Sheet 2...
  • Page 92 Figure 7-2 Figure 7-2 Dimension Drawing ADV-8060, Sheet 1 Section 7 Drawings and Diagrams TP-6844 1/13...
  • Page 93 Figure 7-3 Figure 7-3 Dimension Drawing ADV-8060, Sheet 2 TP-6844 1/13 Section 7 Drawings and Diagrams...
  • Page 94 Figure 7-4 Figure 7-4 Dimension Drawing ADV-8060, Sheet 3 Section 7 Drawings and Diagrams TP-6844 1/13...
  • Page 95 Figure 7-5 Figure 7-5 Schematic Diagram, 36V and 48V, ADV-8460, Sheet 1 TP-6844 1/13 Section 7 Drawings and Diagrams...
  • Page 96 Figure 7-6 Figure 7-6 Schematic Diagram, 24V, ADV-8460, Sheet 2 Section 7 Drawings and Diagrams TP-6844 1/13...
  • Page 97 Figure 7-7 Figure 7-7 Point-to-Point Wiring Diagram, 36V and 48V, GM81321, Sheet 1 TP-6844 1/13 Section 7 Drawings and Diagrams...
  • Page 98 Figure 7-8 Figure 7-8 Point-to-Point Wiring Diagram, 24V, GM81321, Sheet 2 Section 7 Drawings and Diagrams TP-6844 1/13...

  • Page 99: Appendix A Abbreviations

    (2 bytes) ccw. counterclockwise est. estimated KBus Kohler communication protocol Canadian Electrical Code E-Stop emergency stop kilogram cert. certificate, certification, certified etc. et cetera (and so forth) kg/cm kilograms per square centimeter cubic feet per hour exh.
  • Page 100 kilojoule NPSC National Pipe, Straight-coupling SPDT single-pole, double-throw kilometer National Standard taper pipe SPST single-pole, single-throw kOhm, kΩ kilo-ohm thread per general use spec specification kilopascal NPTF National Pipe, Taper-Fine specs specification(s) kilometers per hour not required, normal relay square kilovolt nanosecond sq.

  • Page 101: Appendix B Common Hardware Application Guidelines

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

  • Page 102: Appendix C General Torque Specifications

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

  • Page 103: 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 104: 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 (Grade 5) cont. Hex Nuts X-465-17 1/4-20 x .38...
  • Page 105 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), cont. Hex Head Bolts (Full Thread), cont. M931-05055-60 M5-0.80 x 55 M960-16090-60 M16-1.50 x 90 M933-12016-60...
  • Page 106 Metric, cont. 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 108 Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 For the nearest KOHLER authorized installation, service, and sales dealer in the the US and Canada: TP-6844 1/13a Call 1-800-544-2444 or visit © 2012, 2013 by Kohler Co. All rights reserved. KOHLERPower.com...

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