Kohler Power Systems 8RESV Service Manual
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Kohler Power Systems 8RESV Service Manual

Residential/commercial generator sets
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Service
Residential/Commercial Generator Sets
Models:
8RESV/RESVL
10RESV/RESVL
12RESV/RESVL
Controllers:
RDC2 Controller
DC2 Controller
TP-6881 7/15a

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Table of Contents
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Summary of Contents for Kohler Power Systems 8RESV

  • Page 1 Service Residential/Commercial Generator Sets Models: 8RESV/RESVL 10RESV/RESVL 12RESV/RESVL Controllers: RDC2 Controller DC2 Controller TP-6881 7/15a...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 Table of Contents, continued Initial Checks ............USB Port .

  • 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 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 7 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 8 Welding on the generator set. Can Testing live electrical circuits. Servicing the alternator. Hot parts cause severe electrical equipment Hazardous voltage or current can 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 9: 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 10: 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 decals on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product.

  • Page 11: Section 1 Specifications

    (in. H NG = 0.87--2.7 (3.5--11) covered in this manual are equipped with four-cycle, Battery voltage 12 VDC twin cylinder, air-cooled Kohler engines. Battery ground Negative Spark plug gap, mm (in.) 0.508 (0.020) For engine service information and specifications not...

  • Page 12: Alternator Specifications

    1.5 Alternator Specifications Alternator Specification 8RESV(L) 10RESV(L) 12RESV(L) Frequency Hz Phase Single-Phase Single-Phase Single-Phase Number of leads Excitation method Static Excited Static Excited Static Excited Voltage regulator type Hybrid Hybrid Hybrid Coupling type Direct Direct Direct Insulation (rotor and stator) Epoxy varnish, vacuum impregnated Class 180 (H) Winding material...

  • Page 13: Service View

    1.7 Service View ADV-8539 1. Hinged roof 10. Line circuit breaker 2. Air cleaner 11. 120 VAC receptacles for optional carburetor heater (not shown) 3. Nameplate location 12. Lock 4. Thermostat 13. Locking key, provided with generator set 5. Engine starting battery location (battery purchased separately) 14.
  • Page 14 20. Lifting holes 22. Exhaust outlet 21. Air intake Figure 1-2 Generator Set Service View Section 1 Specifications TP-6881 7/15...

  • Page 15: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance DANGER WARNING Hazardous voltage. Accidental starting. Will cause severe injury or death. Can cause severe injury or death. This equipment must be installed and Disconnect the battery cables before serviced by qualified electrical per- working generator set.

  • Page 16: Service Schedule

    The fuel system. Explosive fuel vapors can cause severe Alternator Service. Under normal operating injury or death. Vaporized fuels are highly explosive. Use conditions the generator set alternator does not require extreme care when handling and storing fuels. Store fuels in a scheduled service.

  • Page 17: Service Schedule

    2.1.1 Service Schedule Visually System Component or Procedure Section Inspect Check Change Clean Test Frequency Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather hose Yearly or 500 hours Change oil Yearly or 100 hours...

  • Page 18: Lubrication System

    2.2 Lubrication System 2.2.3 Engine Oil Recommendation Use 5W-30 API (American Petroleum Institute) Service See the service schedules in Section 2.1 for oil change Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and oil filter replacement intervals. See the service and thickens less than other oils and leaves the engine views in Section 1 for the oil drain, oil check, oil fill, and intake valves and pistons cleaner.
  • Page 19 Note: Dispose of all waste materials (engine oil, fuel, f. Lightly thread the new oil filter by hand until you filter, etc.) in an environmentally safe manner. feel Resistance. Then, tighten the filter an additional 3/4 turn with an oil filter wrench. Note: The oil change procedure requires the use of 3.

  • Page 20: Resetting The Maintenance Timer

    2.2.5 Resetting the Maintenance Timer Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the Model RESV (RDC2): generator set as follows: (1) Press the generator set off/reset button to shut down the generator set.

  • Page 21: Air Cleaner Service

    2.4 Air Cleaner Service WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before 1. Air cleaner base working generator set. 2. Air cleaner element 3. Element cover Remove the negative (--) lead first 4. Air cleaner knob when disconnecting the battery.

  • Page 22: Air Cleaner, 10/12Resv/Resvl Models

    9. Position the air cleaner cover with levers outward failure. over air cleaner; turn levers inward to lock. 10. When element replacement is necessary, order genuine Kohler parts. 11. Reconnect the power to the battery charger. 12. Reconnect the generator set engine starting battery, negative (--) lead last.

  • Page 23: Cooling System

    2.5 Cooling System Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of any building adjacent to The engine fan draws cooling air through the openings the generator set. Locate the detectors to adequately warn the in the sides and end near the battery.

  • Page 24: Stepper Motor Coupling

    2.8 Fuel System Maintenance Remove all combustible materials from the exhaust location. Combustible materials include building materials as well as natural surroundings. Keep dry WARNING field grass, foliage, and combustible landscaping material a minimum of 1.5 m (5 ft.) from the exhaust outlet.

  • Page 25: Battery

    2.9 Battery Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before WARNING servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery.

  • Page 26: Checking Electrolyte Level

    2.9.1 Checking Electrolyte Level Temperature Correction C F 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 27: 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 28 Notes Section 2 Scheduled Maintenance TP-6881 7/15...

  • Page 29: Section 3 Controller

    See the generator set Operation Manual for controller firmware. SiteTech software available operation instructions. Kohler-authorized distributors and dealers. See the SiteTech Operation Manual, TP-6701, for general This section covers adjustment and replacement of the software operation instructions. RDC2 and DC2 controllers. See Section 4.12 for troubleshooting information.

  • Page 30: Controller Parameters

    3.3 Controller Parameters The table indicates the following: The group in SiteTech that contains the parameter Adjustable parameter settings can be changed using a personal computer (or laptop) with Kohlerr SiteTecht Factory default settings software. See Section 3.2, SiteTech Software, for USB connection information.
  • Page 31 Genset Voltage Phase Connection Temperature Settings The Genset Voltage Phase Connection setting appears In SiteTech, all temperature settings are shown in in the Genset System Configuration group in SiteTech. degrees F but stored as degrees C. When you highlight Choose single-phase from the four options in the a parameter value (click it), the _F value changes to the dropdown list.
  • Page 32 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Identity Vendor Read Only Kohler Company Identity Product Read Only RDC2 Identity Firmware Version Read Only Engine Metering Engine Speed R/min Read Only Engine Metering Engine Target Speed R/min Read Only...
  • Page 33 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Generator Metering Generator Voltage Average Read Only Line To Line Generator Metering Generator Current L1 Read Only Generator Metering Generator Current L2 Read Only Generator Metering Generator Current L3 Read Only Generator Metering Generator Current Average Read Only...
  • Page 34 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset Personality Profile Engine Number Of Flywheel Locked Teeth Genset Personality Profile Engine Warmed Up 25 -- 60 _C 32_C (90_F) _C/F note in Temperature Section Genset Personality Profile Engine Cooled Down Locked 79_C _C/F...
  • Page 35 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset Personality Profile Personality Power Rating 50 Hz No effect. 220 440 Genset Personality Profile Personality Power Rating 50 Hz No effect. 208 415 Genset Personality Profile Personality Power Rating 50 Hz No effect.
  • Page 36 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset System Prime Power Application Standby or prime Standby Configuration Genset System Current Transformer Ratio Locked Configuration Genset System Local Start Mode Read Only Configuration Genset System Measurement System English or metric English Configuration Genset System...
  • Page 37 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset Calibration Genset Calibration Factor 0.9 -- 1.1 1.04 Current L3 Genset Calibration Current Transformer Calibration 0 -- 100 At No Load Genset Calibration Current Transformer Calibration 0 -- 400 121.5 At Full Load Advanced Speed Control...
  • Page 38 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Generator Protection Loss Of AC Sensing Shutdown Read Only Delay Generator Protection Genset Low Voltage Shutdown Read Only Delay Generator Protection Genset High Voltage Shutdown Read Only Delay Generator Protection Genset Low Voltage Shutdown Read Only Limit...
  • Page 39 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Digital Output B2 Digital Output B2 Event See dropdown list in Common SiteTech. Fault Digital Output B3 Digital Output B3 Value Read Only False Digital Output B3 Digital Output B3 Event See dropdown list in Battery SiteTech.
  • Page 40 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Source 2 Metering Source 2 Rotation Actual Read Only Source 2 Metering Source 2 Voltage L1-L2 Read Only Source 2 Metering Source 2 Voltage L2-L3 Read Only Source 2 Metering Source 2 Voltage L3-L1 Read Only Source 2 Metering...
  • Page 41 0.0.0.0 OnCue 255.255.255.255 Plus Network Configuration Static DNS Server 2 0.0.0.0 -- 0.0.0.0 OnCue 255.255.255.255 Plus Network Configuration Server Host Name devices.kohler.com devices. OnCue kohler.com Plus Network Status IP Address Read Only 0.0.0.0 OnCue Plus Network Status Subnet Mask Read Only 0.0.0.0...
  • Page 42 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes RXT, RBUS Devices B1 RBUS Devices B1 Serial Read Only PIM, or Number Load RBUS Devices B1 RBUS Devices B1 Type Read Only (RXT, Mgmnt§ PIM, or Load Mgmnt§) RBUS Devices B1 RBUS Devices B1 Read Only Communication Errors...
  • Page 43 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes RBUS Devices B4 RBUS Devices B4 Last Read Only Connection Date RBUS Devices B4 RBUS Devices B4 Firmware Read Only Version RBUS Devices B4 RBUS Devices B4 Connected Read Only RBUS Devices B5 RBUS Devices B5 Serial Read Only...

  • Page 44: Controller Firmware

    Overview ----> Active Alert controller firmware. Kohlerr distributors can download 1.2 h (if any) the latest software from the Kohler Power Resource Center website. Controller firmware is also available for download on the Kohler dealer portal or at www.kohlergenerators.com/usb. Genset Status...

  • Page 45: Controller Replacement

    (laptop) with Kohler SiteTech software can be used to load the settings onto the new controller. Note: Load the old controller settings onto the new controller only if you are certain that the settings are correct.
  • Page 46 6. Note the connections on the back of the controller, and then disconnect all harnesses and leads from the controller. See Figure 3-8 or the wiring diagram. 7. Remove the old controller. 8. Reconnect all harnesses to the new controller assembly.

  • Page 47: Controller Setup

    3.6 Controller Setup Controller Setup Procedure 1. Use one of the following methods to set the Controller setup is required after installation. Follow the parameters shown in Figure 3-9. instructions in this section to set the necessary parameters. a. The RDC2 controller can be set up using the buttons on the controller to navigate through If a personal computer (laptop) and Kohlerr SiteTecht the controller menus and change the settings.
  • Page 48 Genset M/N: Genset ----> 20RESA Information Genset S/N: ######## Controller S/N: ######## <---- Return tp6810 Figure 3-10 Generator Set Information Menu, RDC2 Genset ----> Fuel Type: System Voltage: See Note. Natural Gas 240 V System Next Exercise 06:30p 15Dec2011 System Freq: 60 Hz Exercise Mode: Unloaded Cycle...
  • Page 49 tt6907 1. Genset model and serial numbers 2. System settings 3. Fuel type (controller firmware version 3.5 or higher) Figure 3-12 Controller Setup Using SiteTecht TP-6881 7/15 Section 3 Controller...

  • Page 50: Voltage Calibration

    3.7 Voltage Calibration 3.7.1 Calibration using the RDC2 Controller Keypad and Menus WARNING The controller’s voltage calibration can be adjusted using the controller keypad. See Figure 3-13 and follow the procedure below. Note: A digital voltmeter is required for these Hazardous voltage.
  • Page 51 Generator ----> Metering Three-phase Single-phase Volts L1--L2: Volts: Calibrate Calibrate 240 V 240V Volts L2--L3: Frequency: Calibrate 240 V 60.0 Hz To Calibrate Voltage: 1. Press Select when the voltage is Volts L3--L1: displayed. The voltage flashes. Calibrate 240 V 2.

  • Page 52: Calibration Using Sitetech

    3.7.2 Calibration Using SiteTech ÷ V ) x F meter control Voltage calibration factors can be adjusted using SiteTech software to calibrate the RDC2 or DC2 controller. Connect a personal computer (laptop) to the = Voltmeter reading meter controller using a USB cable and follow this procedure to use Kohlerr SiteTecht software to calibrate the = Voltage displayed on controller control...

  • Page 53: Setting The Oncue Plus Password

    3.8 Setting the OnCue Plus 6. Press the Up arrow button to change the word No to Yes. Password 7. Press Select to reset the password. The generator If the Kohlerr OnCuer Plus Generator Management set serial number and new password are displayed System is used to monitor the generator set, reset the for 10 seconds.
  • Page 54 Notes Section 3 Controller TP-6881 7/15...

  • Page 55: Section 4 Troubleshooting

    Section 4 Troubleshooting 4.1 Introduction e. The start solenoid closes and energizes the starter motor, which cranks (turns) the engine. Corrective action and testing in many cases requires f. The engine rotation along with field excitation knowledge of electrical systems and electronic circuits. produces alternator voltage.

  • Page 56: Initial Checks

    4.3 Initial Checks 4.5 Circuit Protection When troubleshooting, always check for simple Line Circuit Breaker problems first. Check for the following common problems before replacing parts: The line circuit breaker interrupts the generator output in the event of an overload condition or a fault in the wiring Loose connections or damaged wiring.

  • Page 57: Thermostat Information

    4.6 Thermostat Information 4.7 OnCue Plus Troubleshooting 8RESV(L), 10RESV(L), and 12RESV(L) generators See TP-6928, OnCueR Plus Software Operation include a resettable thermostat in the air intake Manual, for troubleshooting instructions for the OnCue compartment. The thermostat detects excess heat Plus Generator Management System. inside the enclosure.

  • Page 58: Fault Messages

    4.9 Fault Messages WARNING The RDC2 controller displays fault messages to aid in troubleshooting. Fault messages, descriptions, and recommended checks are listed in Figure 4-4. Risk of fire. Fault messages will also appear in the Event History in Can cause severe injury or death. SiteTech.
  • Page 59 Fault Message Action Description/ Comments Check ATS Fail Xfr Warning Warning The RXT ATS has reported a fail to Consult ATS manual for transfer, the digital output for ATS Fail troubleshooting. (ATS fail to transfer) To Transfer (PIM) is active (contacts closed).
  • Page 60 Fault Message Action Description/ Comments Check Frequency High Shutdwn Shutdown The controller shut down the generator Troubleshoot engine because the frequency measured on operation per the engine Phase A exceeded the high frequency service manual. setting for 10 seconds, 10 seconds or more after crank disconnect.
  • Page 61 Fault Message Action Description/ Comments Check Maint Req’d Warning Warning Engine run time, or calendar days, has Change the oil and perform exceeded the maintenance reminder other maintenance according setting. to the service schedule in Section 2.1. Reset the maintenance timer after service.
  • Page 62 Fault Message Action Description/ Comments Check Spd Sens Flt Shutdwn Shutdown The controller shut down the generator Check leads 55, 66, F+, and because the speed signal was lost. F-- between the alternator and (Speed sensor fault) the controller. This fault also occurs if the engine stalls;...

  • Page 63: Status Messages

    4.10 Status Messages The following messages are displayed to show system digital input is activated; the optional Programmable status. Notices are displayed in the Event History in Interface Module (PIM) is required for display of those SiteTech when active but do not appear on the controller messages as noted in the table.
  • Page 64 Status Message Action Description/ Comments Check Gen Running Notice The digital output for Generator Running Check controller front panel (PIM) is active (contacts closed), buttons for potential RUN indicating the generator is running. command. If in AUTO, check remote start lines. Consult ATS operation manual for events that may cause the generator to start.
  • Page 65 Status Message Action Description/ Comments Check Load Shed 1 Status Info Notice The digital output for LoadPriority1Shed Remove loads as required. is active (contacts closed), indicating the Check building wiring for 1st priority load shed (load management proper load distribution. device) has been activated.

  • Page 66: Troubleshooting Chart

    4.11 Troubleshooting Chart simplest and most likely causes of the problem are listed first; follow the recommendations in the order shown. Use the following table as a reference in troubleshooting The reference column provides additional sources of individual problems. Generator set faults are listed in information in this and related manuals regarding the groups and include likely causes and remedies.
  • Page 67 Problem Possible Cause Test Corrective Action Reference No fuel. Verify that manual fuel valve is Open (turn on) manual fuel valve. Section 4.6 Cranks but open. does not Thermostat has Reset the thermostat. start tripped. Check fuel supply tank (LPG). Contact fuel supplier to add fuel to fuel supply tank (LPG).
  • Page 68 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 utility power connection to the generator set. Air cleaner clogged Check for a dirty air cleaner Replace element.
  • Page 69 Problem Possible Cause Test Corrective Action Reference Fault shutdown Check for a fault shutdown Correct the fault and then press Section 4.9 Stops message on the controller display. the controller’s OFF button to suddenly Identify the cause of the fault. reset the controller.
  • Page 70 Problem Possible Cause Test Corrective Action Reference Air cleaner clogged Check air filter element. Replace element. Erratic operation Spark plug(s) Check spark plug condition and Replace or regap plugs. gap. Spark plug wire(s) Check spark plug connections Tighten connections. Replace Engine S/M and wires.
  • Page 71 Problem Possible Cause Test Corrective Action Reference Air intake Inspect air intakes and exhaust Clear air intakes and exhaust Lacks restriction, for obstructions. area. Maintain clearances shown power 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 72 Problem Possible Cause Test Corrective Action Reference Brush connection Check for loose brush Tighten loose brush connections. Section 5.7 Low output connections. excessive Check for loose brush mounting. Tighten mounting screws. drop in Check the resistance through the Replace brushes if they show voltage, brushes.

  • Page 73: Controller Troubleshooting

    4.12 Controller Troubleshooting and adjusted through the controller’s user interface or using a personal computer and Kohlerr SiteTecht Refer to the controller troubleshooting table in software. The generator set operation manual contains Figure 4-6 when troubleshooting procedures the instructions for checking and changing the controller Section 4.11 indicate a possible controller problem.
  • Page 74 Notes Section 4 Troubleshooting TP-6881 7/15...

  • Page 75: Section 5 Component Testing And Adjustment

    Section 5 Component Testing and Adjustment 5.1 Introduction The procedures in this section cover the testing and Controller adjustment of components on the generator set. Use these procedures in conjunction to the troubleshooting in Section 4 to verify that components function properly and to locate the source of problems.

  • Page 76: Alternator Excitation

    5.3 Alternator Excitation 5.3.1 No to Low Voltage Operation This section covers the operation of the alternator WARNING excitation and troubleshooting information for low or no voltage output. Before beginning the test procedures, read all safety precautions at the beginning of this manual. Many of the test procedures include additional safety precautions.

  • Page 77: Erratic Voltage Regulation

    5.3.2 Erratic Voltage Regulation 5.3.3 Separate Excitation Dramatic variations in the alternator voltage (more than Use the following procedure to separately excite the 5 VAC) while the generator is operating at a steady load generator using an external voltage source (a 12-volt may cause flicker.

  • Page 78: Stator

    5.4 Stator Separate Excitation Procedure Perform the following procedure to use an external The stator contains a series of coils of wire laid in a voltage source to excite the main field (rotor). laminated steel frame. The stator leads supply AC voltage to the load and voltage regulator.
  • Page 79 Stator Continuity and Resistance Tests 1. Press the OFF button on the controller to turn off the generator set. 2. Disconnect utility power to the generator set. 3. Disconnect the generator set engine starting battery, negative (--) lead first. 4. Disconnect all stator leads before performing all stator tests.

  • Page 80: Main Field (Rotor)

    8. If the resistance test proves inconclusive, use a WARNING megohmmeter to test the stator as described in the next step. Note: Because ohmmeter accuracy varies, resistance readings approximate readings. Take readings of the rotor and Hazardous voltage. Moving parts. Can cause severe injury or death.
  • Page 81 Rotor Test Procedure Follow the instructions of the megohmmeter manufacturer when performing this test. 1. Press the OFF button on the controller to turn off the generator set. Note: A reading of approximately 500 kOhms (1/2 megohm) or higher indicates a 2.

  • Page 82: Slip Rings

    5.6 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 83: Voltage Connections

    5.8 Voltage Connections Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical Single-phase generator sets are available from the connections with tools or jewelry while making adjustments or factory connected for 120/240 volt 60 Hz.

  • Page 84: Voltage Regulator Average Voltage Adjustment

    Kohler Hybrid Voltage Regulator. This regulator wiring between the generator and the ATS. consists of a fast-reacting analog inner loop and a slower digital outer loop.

  • Page 85: Volts/Hz Slope And Cut-In Frequency

    At a gain setting of 1, it will take 128 seconds to adjust except under unique circumstances and under direction the voltage output 1%. At a gain setting of 255, the from a Kohler factory representative. voltage adjustment rate is related to the difference between the target voltage and the measured voltage, If the slope of the Volts/Hz curve is set too low, the but could vary up to 3.1% per second.

  • Page 86: Governor System

    5.10 Governor System Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts The governor system consists of an electromechanical and pulleys when the generator set is running. Replace stepper motor (actuator) and an engine speed guards, screens, and covers before operating the generator detection/feedback circuit.

  • Page 87: Hunting/Surging

    5.10.3 Hunting/Surging 5. Verify that the speed control parameters have not been modified. Reset the parameters to the Hunting/surging problems thought to be caused by the default settings if they have been modified. See governor system are more likely to be caused by fuel Figure 5-18, Controller Settings.

  • Page 88: Governor System Operation Test

    5.10.4 Governor System Operation Test Check that the carburetor throttle WARNING linkage is connected to the stepper motor as shown in Figure 5-15. Check for broken or Hazardous voltage. Moving parts. loose wiring or Can cause severe injury or death. connections and other items in step 2.
  • Page 89 Governor System Operation Test Procedure Check the stepper motor, carburetor, and linkage. 1. Verify that the carburetor throttle linkage is 8. To test controller’s governing function, open the connected to the stepper motor as shown in generator set circuit breaker, disconnect the Figure 5-15.

  • Page 90: Frequency Adjustment

    5.11 Frequency Adjustment Note: Hunting/surging problems thought to be caused by the governor are more likely to be caused by fuel supply, engine or carburetor WARNING problems. If the generator set speed is unstable, hunts, or surges, check for the cause using the procedure in Section 5.10.3 before proceeding.

  • Page 91: Engine Speed Gain Adjustment For The Governor

    If changing the gain makes the hunting worse, try changing the gain in the other direction. Note: Do not adjust the Advanced Speed Control settings unless instructed to do so by the Kohler Generator Service Department. 5.11.2 Engine Speed Adjustment for...
  • Page 92 1. Engine Speed Adjustment 2. Engine Run Speed Setting (changes automatically with Genset System Frequency) 3. Genset System Frequency Setting (50 or 60 Hz) Figure 5-19 Engine Speed and Frequency Parameters in SiteTech Section 5 Component Testing and Adjustment TP-6881 7/15...

  • Page 93: Fault Shutdown Tests

    5.12 Fault Shutdown Tests Verify that the controller parameters shown in Figure 5-20 are set correctly for your unit. For RESVL Verify the operation of the generator set overspeed, models, select RESV. overcrank, and low oil pressure shutdowns by Open the generator set output circuit breaker before performing the following tests.
  • Page 94 Underspeed and Underfrequency Shutdowns Close the throttle while the generator is running. The engine speed should decrease until the generator set shuts down and the controller indicates an Engine Speed Low Shutdown. To check the underfrequency shutdown, use very small movements over a longer period of time to close the throttle.

  • Page 95: Fault Shutdown Switches

    5.12.2 Fault Shutdown Switches Temperature Sensor (OTS) The temperature sensor (labelled OTS on the wiring Check the low oil pressure and high engine temperature diagram and schematic drawing) is used to monitor shutdown switches on the engine by performing the engine temperature for the high engine temperature following tests.
  • Page 96 Low Oil Pressure (LOP) Switch 8RESV For the 8RESV(L), the low oil pressure (LOP) switch is located above the oil filter and underneath the black blower housing. For the 10/12RESV(L), the low oil pressure switch is located above the oil filter. See Figure 5-24.

  • Page 97: Fuel Systems

    5.13 Fuel Systems WARNING WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Explosive fuel vapors. Can cause severe injury or death. Servicing the fuel system. A flash fire can cause severe Use extreme care when handling, injury or death.

  • Page 98: Fuel Solenoid Valve

    5.13.1 Fuel Solenoid Valve 5.13.2 Capacitive Discharge Ignition (CDI) Timing A solenoid valve upstream of the regulator and the These systems use a capacitive discharge (CD) coil. flexible fuel connector provides automatic fuel on/off With CDI fixed timing, ignition timing and spark remains control.

  • Page 99: Fuel Regulators

    5.14 Fuel Conversion 5.13.3 Fuel Regulators The typical gaseous fuel system uses two regulators. The multi-fuel system allows conversion from natural The primary regulator reduces the line pressure to an gas (NG) to LPG (or vice-versa) in the field while allowable inlet pressure for the secondary regulator.
  • Page 100 WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe 1. Fuel solenoid valve injury or death. Vaporized fuels are highly explosive. Use 2.
  • Page 101 6. Remove the cap from the fuel selector valve. See Figure 5-30. Insert a flat head screwdriver under the lip of the cap and push it upwards. Keep the cap close by as it is needed to switch fuels in the next step.

  • Page 102: Fuel Selector Valve Adjustment Screw

    5.14.1 Fuel Selector Valve Adjustment Screw The fuel system is factory-adjusted to comply with applicable emission standards and to provide the best possible hot and cold starting. If the fuel selector valve requires adjustment, obtain a new fuel selector valve to replace the factory-installed valve.

  • Page 103: Continuity Checks

    5.16 Continuity Checks To further check generator set components, disconnect the battery and remove wiring harness plugs from the controller circuit board. Use an ohmmeter to check the WARNING continuity of the components listed in Figure 5-37. Also see Section 7, Wiring Diagrams. Figure 5-37 gives resistance readings for functional components.
  • Page 104 Notes 104 Section 5 Component Testing and Adjustment TP-6881 7/15...

  • Page 105: Section 6 Disassembly/Reassembly

    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 106: Initial Steps

    6.1 Initial Steps Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LPG vapor or natural gas fuel system for leakage by using WARNING a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch (10--14 inches water column).

  • Page 107: Disassembly

    6.2 Disassembly disassembly procedure explains disassemble the generator set enclosure and other parts in order to access the alternator and engine for service. The procedure provides important information to minimize disassembly time and indicates where special configurations exist which may require taking notes.
  • Page 108 Disconnecting the electrical leads and harnesses 8. Remove the two controller screws to raise the controller and then disconnect the P2 controller plug. 9. Disconnect the following alternator harness leads in the junction box. Pull the leads and conduit through the bulkhead. See the wiring diagrams in Section 7.
  • Page 109 Hoisting the engine and alternator WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.
  • Page 110 Disassembling the alternator WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter armature.
  • Page 111 24. Remove the alternator overbolts and centering 28. Remove the rotor as follows: washers. See Figure 6-9. a. Loosen but do not remove the rotor thrubolt. Use a strap wrench on the rotor to keep the rotor from turning during loosening, if necessary.
  • Page 112 Removing the Mounting Plate and Silencer Note: Obtain a new exhaust gasket before removing the silencer. 29. Remove vibromount bolts to disconnect the mounting plate from the engine. 31. Remove the two bolts on the silencer brackets. Note: Do not remove the vibromounts unless the 32.

  • Page 113: Reassembly

    6.3 Reassembly Attaching the Mounting Plate and Silencer 1. Install the exhaust system. See Figure 6-12. Note: Use new exhaust gaskets when re-installing the silencer. a. Using new gaskets, connect the engine exhaust silencer to the engine at the flanges. Do not completely tighten the mounting hardware at this time.
  • Page 114 Correct Incorrect Side View TP5867 1. Correctly positioned brush 2. Incorrectly positioned brush 3. Slip rings Figure 6-15 Brush Position 1. End bracket (brush assembly shown attached) 2. Stator windings (outer) 3. Rotor (inner). Also see Figure 6-13. 4. Stator shell 5.
  • Page 115 Repositioning the engine and alternator 8. Position a 273 mm (10-3/4 in.) block of wood to support the back corner of the mounting plate. Note: If the corner of the mounting plate is not supported, the weight of the engine and alternator assembly can bend the sheet metal.
  • Page 116 Connecting the electrical leads and harnesses DANGER 12. Connect the engine grounding strap. 13. Connect the wires and cables on the engine block ground. Hazardous voltage. 14. Connect the P6 plug to the stepper motor, leads Will cause severe injury or death. 1A, 1B, 2A, and 2B.
  • Page 117 Installing the enclosure 24. Reinstall the enclosure panels in reverse order of removal. See Figure 6-20 and Figure 6-21. Refer to the disassembly instructions, if necessary. a. Install the front panel. b. Position the rear panel and thread the load leads through the hole in the rear panel into the junction box.
  • Page 118 Final Steps Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LPG vapor or natural gas fuel system for leakage by using WARNING a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch (10--14 inches water column).

  • Page 119: Section 7 Drawings And Diagrams

    Section 7 Drawings and Diagrams Figure 7-2 lists the wiring diagram numbers and page numbers. Note: The reduced minimum clearance from a structure contained in ADV--8774 (Figure 7-8) Genset Model 8RESV-SA1 Spec Number GM88347-GA7 only applies to generators that are compliant with Serial Number XXXXXXXX clause (2) of section 4.1.4 of NFPA 37.
  • Page 120 Figure 7-3 Dimension Drawing ADV-8539, Sheet 1 (for specification numbers GM88347--GA6 or lower) Section 7 Drawings and Diagrams TP-6881 7/15...
  • Page 121 Figure 7-4 Dimension Drawing ADV-8539, Sheet 2 (for specification numbers GM88347--GA6 or lower) TP-6881 7/15 Section 7 Drawings and Diagrams...
  • Page 122 Figure 7-5 Dimension Drawing ADV-8539, Sheet 3 (for specification numbers GM88347--GA6 or lower) Section 7 Drawings and Diagrams TP-6881 7/15...
  • Page 123 Figure 7-6 Dimension Drawing ADV-8774, Sheet 1 (for specification numbers GM88347--GA7 or higher) TP-6881 7/15 Section 7 Drawings and Diagrams...
  • Page 124 Figure 7-7 Dimension Drawing ADV-8774, Sheet 2 (for specification numbers GM88347--GA7 or higher) Section 7 Drawings and Diagrams TP-6881 7/15...
  • Page 125 Figure 7-8 Dimension Drawing ADV-8774, Sheet 3 (for specification numbers GM88347--GA7 or higher) TP-6881 7/15 Section 7 Drawings and Diagrams...
  • Page 126 Figure 7-9 Schematic Diagram, ADV-8552 Section 7 Drawings and Diagrams TP-6881 7/15...
  • Page 127 Figure 7-10 Point-to-Point Wiring Diagram, GM89012 TP-6881 7/15 Section 7 Drawings and Diagrams...
  • Page 128 Notes Section 7 Drawings and Diagrams TP-6881 7/15...

  • Page 129: 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 130 Motoren--und Turbinen--Union rnd. round kilobyte (2 bytes) megawatt read only memory KBus Kohler communication protocol milliwatt rot. rotate, rotating kilogram microfarad revolutions per minute F kg/cm kilograms per square N, norm. normal (power source)

  • Page 131: 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 132: Appendix C General Torque Specifications

    Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled Assembled into Cast Iron or Steel Torque into Aluminum Grade 2 Grade 5 Grade 8 Size Measurement Grade 2 or 5 8--32 Nm (in. lb.) (16) (20) — 10--24 Nm (in.
  • Page 133 4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength and a friction coefficient of 0.125. TP--6881 7/15 Appendix...

  • Page 134: 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 135: 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 136 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 137 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 138 Notes TP-6881 7/15...
  • Page 140 7 Jurong Pier Road 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-6881 7/15a Call 1-800-544-2444 or visit KOHLERPower.com E 2014, 2015 by Kohler Co. All rights reserved.

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