Related Manuals for Kohler 15/30RES
Summary of Contents for Kohler 15/30RES
- Page 1 Service Residential/Commercial Generator Sets Models: 15/30RES 15/30RESA 15/30REYG 15/30RYG Controller: Advanced Digital Control TP-6198 3/15b...
-
Page 3: Table Of Contents
Table of Contents Safety Precautions and Instructions ............Introduction . - Page 4 Table of Contents, continued Voltage ............. . . 5.7.1 Voltage Regulation .
-
Page 5: 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 6 Engine Backfire/Flash Battery gases. Explosion can cause WARNING severe injury or death. Battery gases Fire can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when WARNING it is charging. Do not dispose of a battery in a fire.
- Page 7 Exhaust System Carbon monoxide symptoms. The fuel system. Explosive fuel Carbon monoxide can cause severe vapors can cause severe injury or nausea, fainting, or death. Carbon death. Vaporized fuels are highly WARNING monoxide is a poisonous gas present in explosive. Use extreme care when exhaust gases.
- Page 8 Hazardous Voltage/ Gas fuel leaks. Explosive fuel CAUTION vapors can cause severe injury or Moving Parts death. Fuel leakage can cause an explosion. Check the LPG vapor or natural gas fuel system for leakage by DANGER using a soap and water solution with the fuel system test...
- Page 9 Welding on the generator set. Can Connecting the battery and the Servicing the generator set when it cause severe electrical equipment battery charger. Hazardous voltage is operating. Exposed moving parts damage. Before welding on the can cause severe injury or death. can cause severe injury or death.
- Page 10 Servicing the engine heater. NOTICE WARNING parts can cause minor personal Electrostatic discharge damage. injury or property damage. Install the Electrostatic discharge (ESD) heater before connecting it to power. damages electronic circuit boards. Operating the heater before installation Prevent electrostatic discharge can cause burns and component damage by wearing an approved...
-
Page 11: Introduction
Engine Service Manual listed below. Figure 1 lists the available manual part numbers. Information in this publication represents data available Part at the time of print. Kohler Co. reserves the right to Number Document Description 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
Section 1 Specifications 1.1 Introduction 1.3 Engine Specifications The spec sheets for each generator set provide specific Engine Specification 15 kW 30 kW generator and engine information. Manufacturer Model 1.6L OHC See the generator set specification sheets for generator Cycle ratings and other generator set data not supplied in this manual. -
Page 14: Torque Specifications
1.4 Torque Specifications 1.5 Alternator Specifications Follow the general torque specifications found in Alternator Specifications Appendix C of this manual unless noted below or listed 50 Hz (30 kW only) Frequency Hz in the engine service manual. or 60 Hz Excitation method Brush type Torque Specifications... -
Page 15: Service Views
1.6 Service Views Service-Side View Non Service-Side View GM32850D-J 1. Fuses (F1, F2, and F3) 17. Coolant overflow bottle (daily coolant check/fill location) 2. Generator set master switch (RUN\OFF/RESET\AUTO) 18. Secondary fuel regulator 3. Advanced Digital Control (ADC 2100) 19. Fuel solenoid valve 4. - Page 16 Oil Makeup Kit (optional, for 30 kW only) ADV-8159 Units with Customer Connection Box Note: The enclosure is not shown in these service views. 1. Air cleaner 18. Spark plugs 2. ECM and EPR (electronic fuel pressure regulator) 19. Oil fill (on valve cover) 3.
- Page 17 See Note GM78230 Note: See Section 1.4 for torque values. See Section 5 for alternator test procedures. 1. Drive disc 9. Overbolts (qty. 4). Upper left overbolt (as viewed from inside 2. Rotor assembly the junction box) requires a lock washer. 3.
- Page 18 Notes Section 1 Specifications TP-6198 3/15...
-
Page 19: Section 2 Scheduled Maintenance
Section 2 Scheduled Maintenance DANGER WARNING Hot engine and exhaust system. Hazardous voltage. Can cause severe injury or death. Will cause severe injury or death. Do not work on the generator set until This equipment must be installed and it cools. serviced qualified electrical... -
Page 20: Service Schedule
Alternator Service. Under normal operating to extreme weather, long operating hours, or dusty or conditions the generator set alternator does not require dirty conditions. scheduled service. Refer to the service schedule for Service Schedule. Perform maintenance on each item items that require maintenance. in the service schedule at the designated interval for the Engine Service. - Page 21 Before 100 Hr. 300 Hr. 400 Hr. Starting (3 Mo.) (6 Mo.) (Yearly) Perform Service at Intervals Indicated (X) Weekly Fuel System Check the fuel level and fill as necessary (LP) Check the solenoid valve operation * Check the fuel lines and replace as necessary * Lubrication System Check the crankcase oil level and add oil as necessary 24 hr.
-
Page 22: Battery
2.2 Battery Use a 12-volt battery with a minimum rating of 525 cold cranking amps at --18_C (0_F) The generator set uses a negative ground with a 12-volt engine electrical system. WARNING Make sure that the battery is correctly connected and the terminals are tight. -
Page 23: Checking Electrolyte Level
2.2.2 Checking Electrolyte Level Temperature Correction Check the electrolyte level of batteries with filler caps 71.1 + .032 monthly. Remove filler caps and verify that electrolyte + .030 level reaches bottom of filler holes. Refill as necessary 65.6 + .028 EXAMPLE NO. -
Page 24: Battery Charger
2.3 Fuel System Maintenance 2.2.4 Battery Charger Generator sets may be equipped with a factory-installed Routine fuel system service items include draining battery charger to keep the starting battery fully water/sediment from piping at petcock or pipe end cap, charged. Observe the battery polarity when connecting checking for fuel leakage at pipe connections, checking the battery charger. -
Page 25: Section 3 Troubleshooting
Section 3 Troubleshooting 3.1 Introduction Fault shutdown. Check for a fault code on the ADC 2100 display. Section 4.5 describes the Corrective action and testing in many cases requires warning and shutdown fault codes. knowledge of electrical systems and electronic circuits. Blown fuses. - Page 26 Troubleshooting Chart Problem Possible Cause Corrective Action Reference Generator Blown fuse F2, relay If fuse continues to blow and the previous step did not identify set does not interface board (RIB), the cause, check the continuity of leads FP and FN and the Section 4.6 crank, continued...
- Page 27 Troubleshooting Chart Problem Possible Cause Corrective Action Reference Starts hard, Spark plug wire(s) Check spark plug wires and connections. Replace spark plug Engine S/M continued wires. Ignition components Test/replace ignition components. Engine S/M (spark control or ignition module) Insufficient fuel pressure Check fuel pressure Worn piston rings, valves Check compression.
- Page 28 Troubleshooting Chart Problem Possible Cause Corrective Action Reference Operates Air cleaner clogged Replace element. erratically Spark plug(s) Replace and regap plugs. Spark plug wire(s) Replace spark plug wires. Engine S/M Fuel select leads 65 and Connect for natural gas. Disconnect for LP. 70A leads incorrectly connected or disconnected Fuel line restriction...
- Page 29 Troubleshooting Chart Problem Possible Cause Corrective Action Reference Low output Generator overloaded Reduce load. — or excessive Incorrect controller Check and adjust the controller configuration parameters. Section 4.9.2 drop in configuration voltage Incorrect controller Check and adjust the controller voltage settings. Section 4.9.2 voltage settings Alternator or control...
- Page 30 Troubleshooting Chart Problem Possible Cause Corrective Action Reference No output AC output circuit breaker Check for AC voltage on the generator side of circuit breaker. If — voltage open there is AC voltage on the generator side of the breaker, then a problem in the load circuits is causing the line circuit breaker to trip.
-
Page 31: Section 4 Controller
Section 4 Controller 4.1 Introduction A relay interface board (RIB) is used with the controller. Section 4.6 describes the standard and optional RIBs. This section describes the operation and replacement of A silicon controlled rectifier (SCR) module works with the ADC 2100 controller. Controller configuration and the controller to regulate the output voltage. -
Page 32: Controller Display And Keypad
4.2 Controller Display and Keypad A password key sequence is required to enter the configuration and adjustment menus. Section 4.9 The controller has an LED display and a three-button contains the instructions to enter the configuration and keypad. See Figure 4-2. The LED display shows adjustment menus and change the settings using the runtime hours, fault codes, application program version controller keypad. -
Page 33: Sequence Of Operation
4.4 Sequence of Operation cycle seems shorter than the factory setting, check the engine starting battery. The following sections describe the controller sequence of operation during generator start, run, stop, and fault 4.4.2 Starting Sequence, Remote Start shutdown modes. Use this as a starting point for controller and relay board fault identification. -
Page 34: Faults
4.5 Faults 4.5.1 Warnings The fault conditions listed in Figure 4-5 will cause the controller to display a fault code but will not shut down the generator set. Code Fault Description Check High Fault code is displayed if the engine starting battery voltage rises Check the battery rating and battery above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC... - Page 35 Reference Code Fault Description Check Auxiliary fault Input from a user-supplied switch that closes Check the condition and operation of the — when the fault is active. The generator set shuts customer-supplied equipment connected to down 0.3 sec. after the fault is detected and will the auxiliary fault input P21-6.
-
Page 36: Relay Interface Board
4.6 Relay Interface Board WARNING The standard Relay Interface Board (RIB) contains the K2 crank, K3 flash, and K5 run relays. Three LEDs indicate relay operation. See Figure 4-7. Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working generator set. - Page 37 connection of customer equipment to the K1 and K4 relays. See Figure 4-8 for optional relay connections. Harness Lead Connector Pin Number Number Connection Common fault normally open Common fault common Common fault normally closed Run relay normally open Run relay common Run relay normally closed Figure 4-8 Optional Common Fault and Run Relay Board Harness Connections...
-
Page 38: Silicon Controlled Rectifier Module
4.7 Silicon Controlled Rectifier 3. Connect the ohmmeter from AC1 to (+) on the SCR module. You should read high resistance in both Module directions. The silicon controlled rectifier (SCR) module works with 4. Connect the ohmmeter from AC1 to (--) on the SCR the ADC 2100 to regulate the output voltage. -
Page 39: Controller Replacement
9. Connect the positive (+) lead from the DC power configuration, fuse, wiring, and connections before source, with the lamp in series, to terminal AC1 on replacing the controller. For output voltage problems, the SCR module. The lamp should not glow. replace the SCR module and check the operation again before replacing the controller. - Page 40 10. Reconnect the engine starting battery, negative (--) lead last. 11. Reconnect power to the battery charger, if equipped. 12. Follow the instructions in Section 4.9 to change the new controller’s configuration settings to match the generator set system voltage and frequency, unit configuration, engine type, engine data input types, battery voltage, and communications settings.
-
Page 41: Controller Configuration And Adjustment
4.9 Controller Configuration and Use a voltmeter to check the output voltage. If the output voltage is not within specifications, use the ADC Adjustment controller to adjust the output voltage while the generator set is running. The flowcharts in Figure 4-13 This section contains instructions for using the and Figure 4-14 outline the adjustment procedures. - Page 42 Output Voltage 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 sec. until the display changes from runtime hours to the program version number.
- Page 43 Display : * Continued from Figure 4-13: S A V E To enter SAVE mode. Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position. S A V E There are 3 options when the display says SAVE: Press:...
-
Page 44: Controller Configuration
4.9.2 Controller Configuration The controller configuration for each generator model is set at the factory and should not normally require changes. The controller’s configuration mode allows adjustment of the system parameters listed in this section. Use the instructions in this section to check the configuration after installation and change them to match the settings shown in Figure 4-15, if necessary. - Page 45 The controller will automatically exit the configuration Advanced configuration mode (Adnc). The data mode without saving any changes after about 1 minute input types, battery voltage, and communications if no buttons are pressed. Start the configuration setting can be changed in the advanced configuration procedure over again from the beginning if the controller mode.
- Page 46 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 sec. 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 47 Pressing the up arrow key at the Adnc display (See Figure 4-17) puts you into the Advanced Configuration Mode. Press: E d 0 1 To set the engine data input type to Ed01. See Figure 4-15. To enter battery voltage selection mode. B t 1 2 To toggle between 12 and 24 VDC.
-
Page 48: Continuous Power Mode Jumper
4.10 Continuous Power Mode 4. Locate the P7 connector near the top of the controller. See Figure 4-20. Remove the jumper Jumper from pins 1 and 2 of the P7 connector. If the P7 connector has three pins, connect the jumper A jumper across controller pins P7-1 and P7-2 maintains across pins 2 and 3 for storage. -
Page 49: 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. Upon activation of the generator the troubleshooting flow chart in Figure 5-2. -
Page 50: Stator
Main Field (Rotor), to test the rotor. If the ammeter DANGER reading is stable, proceed to step 4. 4. Check for AC output across the stator leads; see Section 5.3, Stator. Compare the readings to the output values shown Section 1, Hazardous voltage. - Page 51 the red and black meter leads together and setting WARNING the ohmmeter reading to zero. Then check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 5-4. Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working generator...
- Page 52 Leads Continuity 1 and 4 2 and 5 3 and 6 7 and 10 8 and 11 9 and 12 55 and 66 1 and 2, 3, 7, 8, or 9 1 and 55 Any stator lead and ground Figure 5-8 Continuity Test Results on a Good Stator (Three-Phase) tp6198 8.
-
Page 53: 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 54: Slip Rings
5.5 Slip Rings Slip rings acquire a glossy brown finish in normal operation. Do not attempt to maintain a bright, newly-machined appearance on the slip rings. Cleaning with a dry, lint-free cloth is usually sufficient. Use very fine sandpaper (#00) and apply light pressure to remove roughness. -
Page 55: Voltage Regulation
5.7 Voltage Voltage Adjustment Procedure WARNING 5.7.1 Voltage Regulation Voltage regulation is performed by the Advanced Digital Control (ADC) and the SCR module. The ADC monitors generator output voltage and adjusts the excitation Hazardous voltage. Moving parts. current to the rotor through the SCR module. Can cause severe injury or death. -
Page 56: Voltage Reconnection
If there is excessive droop in engine speed and little droop in voltage, increase the 3P value. If there is little engine speed droop but excessive voltage droop, decrease the 3P value. The amount of voltage droop is approximately 0.5% of system voltage for each step of 3P. -
Page 57: Fault Shutdown Tests
5.10 Fault Shutdown Tests High Engine Temperature Shutdown Remove the connector from the coolant temperature Verify the operation of the generator set overspeed, sensor (CTS) and connect a jumper across terminals A overcrank, and low oil pressure shutdowns by and B (black and white leads). Start the generator set. performing the following tests. -
Page 58: Fuel Systems
Temperature Sensor (CTS) The coolant temperature sensor (CTS) is used to monitor engine temperature for the high engine temperature fault shutdown (HE). See Figure 5-14 for the coolant temperature sensor location. Set the generator set master switch to the OFF position and allow the generator set to cool. -
Page 59: Fuel System Troubleshooting
5.11.1 Fuel System Troubleshooting A factory-installed secondary regulator and 12 VDC solenoid valve are located in the front inlet air Most problems with gas fuels involve either fuel compartment. See Figure 5-16 and the service views in pressure fuel regulator function. -
Page 60: Fuel Conversion
Checking Fuel Pressure Use a gauge or manometer to check the fuel pressure at the secondary regulator inlet. See Figure 5-16. Measure the fuel pressure with the generator set running at rated load. The fuel pressure should be 178--280 mm (7--11 in.) water column or 1.7--2.7 kPa (4--6 oz./in. -
Page 61: Continuity Checks
5.13 Continuity Checks To further check generator set components, disconnect the battery and remove wiring harness plugs from the controller circuit board. Refer to the wiring diagrams in WARNING the wiring diagram manual and use an ohmmeter to check for continuity and good ground connections. A zero reading on the ohmmeter indicates continuity. - Page 62 Notes Section 5 Component Testing and Adjustment TP-6198 3/15...
- Page 63 (2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour TP-6198 3/15 Appendix 63...
- Page 64 kg/cm kilograms per square National Bureau of Standards remote terminal unit centimeter normally closed room temperature vulcanization kilogram-meter National Electrical Code read/write kg/m kilograms per cubic meter NEMA National Electrical Society of Automotive kilohertz Manufacturers Association Engineers kilojoule NFPA National Fire Protection scfm standard cubic feet per minute Association...
- Page 65 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 66 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 67 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 68 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 69 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 70 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 72 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-6198 3/15b Call 1-800-544-2444 or visit KOHLERPower.com E 2004, 2009, 2015 by Kohler Co. All rights reserved.