Kohler 14 RCA Manual
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Kohler 14 RCA Manual

Kohler 14 RCA Manual

Residential/commercial generator sets
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Service
Residential/Commercial Generator Sets
Models:
14/20RCA/RCAL
26RCA/RCAL
Controller:
RDC2
TP-7093 5/24b

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Summary of Contents for Kohler 14 RCA

  • Page 1 Service Residential/Commercial Generator Sets Models: 14/20RCA/RCAL 26RCA/RCAL Controller: RDC2 TP-7093 5/24b...
  • Page 2 Notes TP-7093 5/24...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............................7 Introduction ....................................13 Service Assistance................................... 15 Section 1. Specifications ............................17 Introduction ................................17 Controller Specifications ............................17 Torque Specifications, 14/20 kW Models ....................... 17 Torque Specifications, 26kW Models ........................19 Engine Service ...............................
  • Page 4 4.3.1 Controller Parameters Table ........................53 4.3.2 Notes on Selected Parameters ........................ 53 Controller Firmware ..............................63 4.4.1 Firmware Version ............................. 63 4.4.2 Firmware Update ............................. 65 Controller Replacement ............................66 Controller Setup ..............................70 Voltage Calibration ..............................73 4.7.1 Calibration Using the RDC2 Controller Keypad and Menus ..............
  • Page 5 6.8.2 Initial Checks ............................124 6.8.3 Hunting/Surging ............................. 125 6.8.4 Governor System Operation Test ......................127 Frequency Adjustment ............................129 6.9.1 Engine Speed Gain Adjustment for the Governor .................. 129 6.9.2 Engine Speed Adjustment for Governor ....................130 6.9.3 Advanced Speed Control ........................130 6.10 Fault Shutdown Tests ............................
  • Page 6 Notes TP-7093 5/24...

  • Page 7: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
  • Page 8 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well‐ventilated area.

  • Page 9: Exhaust System

    Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency.
  • Page 10 Hazardous Noise CAUTION Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. Hazardous Voltage/Moving Parts DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. DANGER Hazardous voltage.

  • Page 11: Hot Parts

    Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative (–) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine battery-charging alternator connections.
  • Page 12 Notice NOTICE Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1. NOTICE Electrostatic discharge damage. Electrostatic discharge (ESD) damages electronic circuit boards. Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits.

  • Page 13: Introduction

    • 26RCAL ® The RCAL generator sets are identical to the model RCA. Model RCA and RCAL generator sets are equipped with Kohler ® engines and alternators and the Kohler RDC2 controller. This manual may also be supplied for similar models not listed here.

  • Page 14: List Of Related Materials

    List of Related Materials Separate manuals contain operation, and installation information not provided in this manual. Separate engine operation and service manuals are also available. The following table lists the available manual part numbers. Generator Set Literature Part Number Specification Sheet, 14RCA(L) G4-270 Specification Sheet, 20RCA(L) G4-272...

  • Page 15: Service Assistance

    • Visit the Kohler Co. website at KOHLERPower.com. • Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. • Call toll free in the US and Canada 1-800-544-2444.
  • Page 16 Notes TP-7093 5/24...

  • Page 17: Section 1. Specifications

    Section 1. Specifications 1.1 Introduction The specification sheets for each generator set provide specific generator and engine information. Refer to the generator set specification sheet for ratings and other data not supplied in this manual. Consult the generator set installation manual, engine operation manual, and engine service manual for additional specifications.
  • Page 18 Adapter bolts, qty.4 Mounting bolts, qty. 4 Thrubolt GM102806 Figure 2 Alternator Bolts TP-7093 5/24...

  • Page 19: Torque Specifications, 26Kw Models

    Alternator Bolts 1.5 Engine Service Generator sets covered in this manual are equipped with four-cycle, twin cylinder, air-cooled Kohler engines. For engine service information and specifications not covered in this manual, see the engine service manual. See the List of Related Materials in the Introduction section.

  • Page 20: Engine Specifications

    1.6 Engine Specifications Engine Specification 14 kW Models 20 kW Models 26 kW Models Manufacturer Kohler Model CH740 CH1000 CH1006 Cycle Number of cylinders Compression ratio 8.8:1 10.5:1 Displacement, cc (cu. in.) 725 (44) 999 (61) Rated power, propane fuel, kW (HP) 17.6 (23.6)

  • Page 21: Alternator Specifications

    1.7 Alternator Specifications Alternator Specification 14RCA/L 20RCA/L 26RCA/L Alternator model Frequency Hz Phase Number of leads Excitation method Static excited Voltage regulator type Digital Coupling type Direct Insulation (rotor and stator) Epoxy varnish, vacuum impregnated; class 180 (H) Winding material Copper Bearing, number and type 1, Sealed ball...

  • Page 22: Service Views

    1.8 Service Views ENCLOSURE PANELS REMOVED TO SHOW DETAIL ADV8928 Hinged roof Oil drain valve Lock Exhaust outlet Air intake Muffler Enclosure key, provided with generator set USB connector (for firmware updates) High voltage electrical in RDC2 controller Lifting holes Line circuit breaker Fuel inlet Field-connection terminal block, AC power (behind panel)
  • Page 23 ADV9919 ENCLOSURE PANELS REMOVED TO SHOW DETAIL Hinged roof 16. Oil fill Lock 17. Three-pin connectors for accessories Air inlet 18. Oil level switch Enclosure key, provided with generator set 19. Oil drain valve High voltage electrical in 20. Exhaust outlet Low voltage electrical in 21.
  • Page 24 Notes TP-7093 5/24...

  • Page 25: Section 2. Scheduled Maintenance

    Section 2. Scheduled Maintenance WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead last when reconnecting the battery. Disabling the generator set.

  • Page 26: Service Schedule, 14 Kw Models

    2.1.1 Service Schedule, 14 kW Models Procedure Visually System Component or Procedure See Section Inspect Check Change Clean Test Frequency Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Lubrication System Every 8 hours Oil level of engine operation...

  • Page 27: Service Schedule, 20/26 Kw Models

    2.1.2 Service Schedule, 20/26 kW Models Procedure Frequency Visually System Component or Procedure Inspect Check Change Clean Test Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Every 8 hours of Oil level, 20kW Models operation Every 24 hours of Oil level, 26kW Models...

  • Page 28: Air Cleaner Service

    2.2 Air Cleaner Service WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.

  • Page 29: Air Cleaner, 20/26 Kw Models

    Air Cleaner Service Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions. Press the OFF button on the generator set controller. Disconnect the utility power to the generator set.

  • Page 30: Battery

    Reinstall the paper element onto the air cleaner base. Make sure the element is flat and properly seated. Install the air cleaner cover and secure with the two retaining knobs. 10. When element replacement is necessary, order genuine Kohler parts. 11. The generator set will not start if the air filter is removed.

  • Page 31: Cleaning The 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 servicing the equipment. Use tools with insulated handles. Remove the negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead last when reconnecting the battery.

  • Page 32: Checking Specific Gravity

    2.3.3 Checking Specific Gravity Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. While holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer. If the hydrometer used does not have a correction table, use the correction factors in Figure 12.
  • Page 33 Temperature °F °C Correction EXAMPLE NO. 1— Temperature below 80°F (26.7°C) Hydrometer Reading 1.250 Acid Temperature 20°F ( -6.7°C) Subtract .024 Specific Gravity Corrected Specific Gravity is 1.226 1.250 - .024 = 1.226 EXAMPLE NO. 2— Temperature above 80°F (26.7°C) Hydrometer Reading 1.235 Acid Temperature 100°F (37.8°C) Add .008 Specific Gravity Corrected...

  • Page 34: Cooling System

    2.4 Cooling System The engine fan draws cooling air through the openings in the sides and end near the battery. The alternator fan draws cooling air through openings on the side walls of the enclosure. The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet.

  • Page 35: Exhaust System

    2.5 Exhaust System WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. Remove all combustible materials from the exhaust location. Combustible materials include building materials as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material a minimum of 1.2 m (4 ft.) from the exhaust outlet.

  • Page 36: Lubrication System

    2.7 Lubrication System See the service schedules in the Scheduled Maintenance section for oil change and oil filter replacement intervals. See the service views in the Service Views section for the oil drain, oil check, oil fill, and oil filter locations. WARNING Accidental starting.

  • Page 37: Oil Check

    All season Kohler PRO 10W-50 Oil is the ideal oil for KOHLER engines. It is specifically formulated to extend the oil and filter change to 300 Hours (2 years) when paired with a KOHLER PRO extended life oil filter. The Kohler PRO kit comes with both oil and filter and can be purchased from your dealer.

  • Page 38: Oil Change Procedure

    2.7.5 Oil Change Procedure Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner. Drain the oil while it is still warm. Drain the oil. Press the OFF button on the generator set controller. Disconnect the utility power to the generator set.

  • Page 39: Resetting The Maintenance Timer

    Dipstick Oil cooler located under shroud (20/26 kW only) Oil fill location Note: 20 kW model shown; 14 kW and 26 kW models are similar. img1062 Figure 16 Oil Fill Components Reconnect the generator set engine starting battery, negative (-) lead last. Reconnect the utility power to the generator set.

  • Page 40: Oil Cooler

    2.7.7 Oil Cooler Inspect and clean the oil cooler at the intervals indicated in the service schedule. The oil cooler must be kept free of debris. Oil Cooler, 14RCA/L Remove the front enclosure panel to access the oil cooler. See the Disassembly section for instructions to remove the front panel.

  • Page 41: Spark Plugs

    Oil Cooler, 20RCA/L and 26RCA/L See the Oil Fill Components figure and Figure 19 for the oil cooler location. The oil cooler is located on the service side of the engine, under the No. 2 cylinder shroud. Remove the top mounting screw and loosen the two side screws, then lift off the cylinder shroud.
  • Page 42 Reset the spark plug gap or replace the plugs with new plugs as necessary. Clean the area around the base of the spark plug to keep dirt and debris out of the engine. Remove the spark plug and check its condition. Replace the spark plug if it is worn or if its reuse is questionable. Check the spark plug gap using a wire feeler gauge.

  • Page 43: Stepper Motor Coupling

    2.9 Stepper Motor Coupling Replace the stepper motor coupling and bushings at the intervals shown in the service schedule. See the Parts Catalog for replacement part numbers. Figure 23 shows the location of the coupling assembly under the air cleaner. Loosen the set screw to remove the coupling from ®...

  • Page 44: Storage Procedure

    Coupling Bushing tp6518_9 Figure 25 Stepper Motor Coupling and Bushing 2.10 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer. Consult the engine service manual for additional storage recommendations. Note: Run the generator set monthly whenever possible.

  • Page 45: Exterior Preparation

    2.10.4 Exterior Preparation Clean the exterior surface of the generator set. Seal all openings in the engine with nonabsorbent adhesive tape. Mask all areas to be used for electrical contact. Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion. 2.10.5 Battery Perform battery storage last.
  • Page 46 Notes TP-7093 5/24...

  • Page 47: Section 3. Generator Reconnection

    Section 3. Generator Reconnection 3.1 Voltage Reconnection The reconnection procedure explains reconnections to change the voltage configuration only. Do not attempt to change the frequency (e.g. from 60 Hz to 50 Hz) in the field. The following instructions explain the reconnection of 12-lead generators; 4-lead generators are not reconnectable. In all cases, follow the National Electrical Code (NEC) guidelines.

  • Page 48: 12-Lead (Three-Phase) Generator Sets

    See Figure 27 for alternator connections. In addition to changing the alternator lead connections and routing through the current ® transformers (CTs), you must change the system voltage by changing the voltage setting on the controller. Use Kohler ™ SiteTech software or the controller menus to change the voltage setting.
  • Page 49 Current transformers (CTs) Line circuit breaker Alternator lead entry model Figure 26 Component Locations (cover panels removed for access) TP-7093 5/24...
  • Page 50 Figure 27 12-Lead Generator Reconnection TP-7093 5/24...

  • Page 51: Section 4. Controller

    Section 4. Controller 4.1 Introduction Model RCA generator sets use the RDC2.X controller shown in Figure 28. Note that the distinction between the RDC2 and the RDC2.X is important when downloading new controller firmware. RDC2 and RDC2.X firmware are not interchangeable. The RDC2.X controller can be identified as follows: •...

  • Page 52: Sitetech Software

    4.2 SiteTech 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 is available to Kohler-authorized dealers. See the SiteTech Operation Manual, TP-6701, for general software operation instructions.

  • Page 53: Controller Parameters

    4.3 Controller Parameters ™ ® Adjustable parameter settings can be changed using a personal computer (or laptop) with Kohler SiteTech software. See the SiteTech Software section for USB connection information. See the SiteTech Operation Manual, TP-6701, for general software operation instructions.
  • Page 54 Genset Fuel Type The Genset Fuel Type setting is located in the Genset System Configuration group in SiteTech. Generator set power and current ratings are different for different fuel types (natural gas or LP). The fuel type setting is available in SiteTech with controller firmware versions 4.5 and higher.
  • Page 55 Notes † SiteTech Group Parameter Units Adjustment Range * Default Setting Identity Vendor Read Only Kohler Company Product Read Only RDC 2 Firmware Version Read Only Engine Metering Engine Speed R/min Read Only Engine Target Speed R/min Read Only Engine Oil Pressure...
  • Page 56 Notes † SiteTech Group Parameter Units Adjustment Range * Default Setting Generator Generator Current L1 Read Only Metering Generator Current L2 Read Only Generator Current L3 Read Only 3-phase Generator Current Average Read Only Generator Frequency Read Only Genset Info Genset Model Number Select Dropdown list: Factory set per...
  • Page 57 Notes † SiteTech Group Parameter Units Adjustment Range * Default Setting Genset Personality Engine High Coolant Temperature Warning No effect. Profile Delay Engine Low Coolant Temperature Shutdown No effect. Delay Engine High Coolant Temperature Shutdown No effect. Delay Engine Low Coolant Temperature Warning °C/F No effect.
  • Page 58 Notes † SiteTech Group Parameter Units Adjustment Range * Default Setting Genset System Current Transformer Ratio Locked Load Configuration Mgmt§ Local Start Mode Read Only Measurement System English or metric English ECM Power True or False False Display Contrast 0-100 Genset System Language No effect.
  • Page 59 Notes † SiteTech Group Parameter Units Adjustment Range * Default Setting Genset Protection Genset Battery Low Cranking Voltage Warning Read Only Delay Genset Battery Low Cranking Voltage Warning Read Only Limit Engine Protection Engine Low Oil Pressure Shutdown Delay Engine Locked Rotor Shutdown Delay Genset Low Engine Speed Shutdown Limit 75-95 Genset High Engine Speed Shutdown Limit...
  • Page 60 Notes † SiteTech Group Parameter Units Adjustment Range * Default Setting Digital Output B3 Digital Output B3 Value Read Only False Digital Output B3 Event See dropdown list in Low Battery SiteTech. ‡ Voltage Warning Digital Output B4 Digital Output B4 Value Read Only False Digital Output B4 Event...
  • Page 61 0.0.0.0 - 0.0.0.0 255.255.255.255 Static DNS Server 1 0.0.0.0 - 0.0.0.0 255.255.255.255 Static DNS Server 2 0.0.0.0 - 0.0.0.0 255.255.255.255 Server Host Name devices.kohler.com devices.kohler.com Network Status IP Address Read Only 0.0.0.0 OnCue Plus Subnet Mask Read Only 0.0.0.0 Default Gateway Read Only 0.0.0.0...
  • Page 62 Notes † SiteTech Group Parameter Units Adjustment Range * Default Setting Rbus Network Rbus Active Read Only False Rbus Connection Count Read Only Rbus Net Cycle Time Read Only Rbus Timeouts Read Only Rbus Errors Read Only Rbus Devices B1 Rbus Devices B1 Serial Number Read Only RXT,...

  • Page 63: Controller Firmware

    Service Support area of the Kohler Power Resource Center website or from the Downloads section of the Dealer Portal. Controller firmware is also available for download on the Kohler dealer portal and at www.KohlerGenerators.com/usb.
  • Page 64 Overview - -> Active Alert (if any) 1.2 h Genset Status Standby Voltage: 240V Freq: 60.0Hz Engine: 85F Oil Pressure: OK Battery 12.3V Engine Runtime: 25.5 h Date: 02DEC2011 Time: HR:MNpm Next Exercise: 09:00p 09Dec2011 Next Maintenance: 150 h or Mar2012 SW Version: 1.03 <...

  • Page 65: Firmware Update

    Procedure to Update Software Using SiteTech Download the latest RDC2 or RDC2.X firmware file from the Kohler Power Resource Center website or the Kohler dealer portal. Save the new firmware file on your PC. Be sure to note the file location. Firmware files are typically downloaded as .zip files and will need to be extracted.

  • Page 66: Controller Replacement

    Update Firmware Figure 33 SiteTech Update Firmware Command Figure 34 SiteTech Update Device Firmware Screen 4.5 Controller Replacement WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead last when reconnecting the battery.
  • Page 67 Some setup is required after the new controller is installed. See the Controller Setup section after replacing the controller. The ™ ® RDC2 controller can be set up using the buttons on the controller or using a personal (laptop) computer and Kohler SiteTech software.
  • Page 68 (see detail) GM101739 LOW VOLTAGE CONNECTION DETAIL GM101741c 1. Cover panel. Remove for access to utility power and load connections. 2. Cover panel screws, qty. 2 3. Load circuit breaker 4. Transfer switch and accessory low voltage connections 5. Use cable tie to secure low voltage connections 6.
  • Page 69 Disconnect the generator set engine starting battery, negative (-) lead first. Remove the two (2) screws securing the controller to the junction box and carefully lift the bottom edge of the controller. See Figure 37. Note: Be careful of the leads and harness connected to the controller panel. Note the connections on the back of the controller, and then disconnect all harnesses and leads from the controller.

  • Page 70: Controller Setup

    (when the controller was known to be operating correctly), then SiteTech software can be used to load the saved 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.
  • Page 71 Note: Load the old controller settings onto the new controller only if you are certain that the settings are correct. Many generator set operation problems can be caused by incorrect settings. System Voltage Frequency, Hz Phases Phase Connection 120/240 Single 120/208 120/240 Delta...
  • Page 72 Genset - - > System Voltage: System 240 V System Freq: 60 Hz VR Voltage Adj: 240.0 V System Phase: Single System Battery: 12 V Fuel Type LP Next Exercise 06:30p 15Mar2019 Exercise Mode: Unloaded Variable Exercise Freq: Weekly Language: English Meas System: English...

  • Page 73: Voltage Calibration

    Correct voltage calibration is necessary for proper generator set operation. Check the voltage calibration after controller replacement or generator set reconnection, and adjust if necessary. ® The RDC2 controller can be calibrated using the controller keypad and menus, or using a personal computer with Kohler ™ SiteTech software.

  • Page 74: Calibration Using Sitetech

    Voltage calibration factors can be adjusted using SiteTech software to calibrate the RDC2 controller. 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.
  • Page 75 Type the new value for Genset Calibration Factor Voltage, L1-L2 into SiteTech and click on Apply Changes. See Figure 44. Allow a few seconds for the controller to adjust to the new factor and then compare the voltmeter reading with the voltage displayed on the controller.

  • Page 76: Setting The Oncue Password

    4.8 Setting the OnCue Password ® ® If the Kohler OnCue Plus Generator Management System is used to monitor the generator set, reset the OnCue password as described in the following procedure. Refer to Figure 45 during this procedure. Press Select and then press the down arrow button to navigate to the networking Information menu.

  • Page 77: Section 5. Troubleshooting

    Section 5. Troubleshooting 5.1 Introduction Corrective action and testing in many cases requires knowledge of electrical systems and electronic circuits. Testing and service must be performed by an authorized dealer or trained service technician. Refer to the engine service manual for engine service information. See the List of Related Materials for the document part number.

  • Page 78: Initial Checks

    Use a USB cable with a mini-B connector to connect the controller’s USB port to your PC. Some settings can be ™ ® changed from the controller keypad. All other adjustable settings require a personal computer (laptop) with Kohler SiteTech software for changes. The Controller Parameters section lists controller settings.

  • Page 79: Circuit Protection

    5.5 Circuit Protection Line Circuit Breaker The line circuit breaker interrupts the generator output in the event of an overload condition or a fault in the wiring between the generator and the load. If the circuit breaker trips, reduce the load and check the wiring. Auxiliary Winding Circuit Breaker The mini-breaker in the controller’s service area protects the alternators auxiliary winding.

  • Page 80: Connections

    5.6.2 Connections The emergency stop switch is connected to leads ESS and ESN near connector P1 in the controller harness. If the controller shows an emergency stop shutdown but the button is not activated, check the ESS and ESN lead connections to the emergency stop button assembly.

  • Page 81: Shutdown Prime Mover Switch (Engine Stop Switch)

    5.7 Shutdown Prime Mover Switch (Engine Stop Switch) The generator set may be equipped with a Shutdown (Prime Mover) switch. See Figure 50. This switch, also referred to as the Engine Shutdown switch, commands an immediate shutdown and prevents an engine start if the switch is turned to the off (open, O) position.

  • Page 82: Thermostat

    5.8 Thermostat The generator set is equipped with a resettable thermostat located in the air intake area. The thermostat detects excess heat inside the enclosure. If the thermostat trips, the generator will shut down and the controller will display a fault (underspeed, underfrequency, or undervoltage).

  • Page 83: Oncue Plus Troubleshooting

    Roof Service-side panel img1079 Air intake end panel ADV-8928 Panel hanging bushings, qty. 4 Figure 52 Removing the Air Intake Panel Thermostat location Thermostat reset button Figure 53 Thermostat Location 5.9 OnCue Plus Troubleshooting ® See the OnCue Plus Operation Manual for troubleshooting instructions for the OnCue Plus Generator Management System. 5.10 Fuel System Troubleshooting Most problems with gas fuels involve either fuel pressure or fuel regulator function.

  • Page 84: Troubleshooting Engine Hunting, 20 Kw Models

    Verify that the RDC2.X controller has the latest version of firmware, and update the controller firmware if necessary. The Kohler Generator Service Department will provide the most current version if it is not yet available on the Kohler Power Resource Center website.
  • Page 85 16. Reconnect the ATS by connecting PWR and COM (RXT) or engine start leads 3 and 4 (RDT). 17. Verify the generator set operation. See the generator set Operation Manual for instructions. Note: If the generator set still hunts after performing these procedures, please contact the Kohler Generator Service Department for assistance. TP-7093...

  • Page 86: Troubleshooting Engine Hunting, 26 Kw Models

    5.12 Troubleshooting Engine Hunting, 26 kW Models Kohler has recently received feedback from the field about the general run quality of some 26RCA(L) generator sets at low or no load. Reports of misfiring, stumbling, and instability have been reported on installed units using NG fuel.
  • Page 87 Testing live electrical circuits. Hazardous voltage or current will cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry.
  • Page 88 Fault Message Action Description/Comments Check AC Sens Loss Shutdown Shutdown The controller shut down the generator because there Check for loose wiring and (Loss of AC sensing shutdown) was less than 5% of rated voltage measured on connections. Phase A for 3 seconds, only in AUTO, only after Check all AC leads.
  • Page 89 Fault Message Action Description/Comments Check Engine M/N Invalid Shutdwn Shutdown Generator model number has not been entered. Enter the generator set model (Engine model number is selected automatically number from the RDC2 keypad, based on generator set model.) or use SiteTech to select the genset model number.
  • Page 90 Fault Message Action Description/Comments Check Locked Rotor Shutdwn Shutdown The controller shut down the generator because no Check cranking circuit. rotation of the engine or alternator was detected, for 3 Troubleshoot the engine. seconds or more, during cranking. See Engine Service Manuals. Check alternator connections to controller and auxiliary winding circuit breaker.

  • Page 91: Faults Related To Paralleling

    Fault Message Action Description/Comments Check Spd Sens Flt Shutdwn Shutdown The controller shut down the generator because the Check leads 55, 66, F+, and F - (Speed sensor fault) speed signal was lost. between the alternator and the controller. This fault also occurs if the engine stalls;...
  • Page 92 Fault Text Description Possible Causes * ConCheckFail Failure to Auto-Discover APM connections. Wires 9A and 9B crossed between the generators. Wires 9A or 9B not connected. ConChecking Performing APM connection auto-discovery. This generator has started in RUN, the other generator is in OFF. ConNotDeterm APM connection auto-discovery is not complete.

  • Page 93: Status Messages

    5.14 Status Messages The messages shown in Figure 57 and Figure 58 are displayed to show system status. Notices are displayed in the Event History in SiteTech when active but do not appear on the controller display. Some status messages are displayed when a digital input is activated;...
  • Page 94 Status Message Action Description/Comments Check OB2 CommLoss (option Notice Communication with option board #2 has been lost. Check RBUS wiring to board) inoperative option board. (PIM, RXT, or load mgmnt device) ‡ OB3 CommLoss (option Notice Communication with option board #3 has been lost. Check RBUS wiring to board) inoperative option board.

  • Page 95: Troubleshooting Chart

    5.15 Troubleshooting Chart Use the following table as a reference in troubleshooting individual problems. Generator set faults are listed in groups and include likely causes and remedies. The simplest and most likely causes of the problem are listed first; follow the recommendations in the order shown.
  • Page 96 Problem Possible Cause Test Corrective Action Reference Cranks but does not Insufficient fuel Check fuel pressure to the Contact fuel supplier to Fuel Regulators section start, continued pressure generator set. Verify replace fuel supply lines adequate fuel pressure with larger pipe and replace and pipe size for the gas meter if fuel pressure is generator set plus all other...
  • Page 97 Problem Possible Cause Test Corrective Action Reference Starts hard, Spark plug(s) Check spark plug condition Replace or regap spark continued and gap. plug(s). Spark plug wire(s) Check spark plug wires and Tighten connections. Engine S/M connections. Replace spark plug wires if damaged.
  • Page 98 Problem Possible Cause Test Corrective Action Reference Stops suddenly, Engine overheated Check air intake and Clear air intake and continued (hot engine only) generator set enclosure air enclosure air inlets and Fuel Systems section inlets and outlet. outlets. Use oxygen sensor to check Adjust fuel mixture.
  • Page 99 Problem Possible Cause Test Corrective Action Reference Erratic operation, Fuel mixture adjustment Use oxygen sensor to Adjust fuel mixture. Fuel Systems section continued incorrect check fuel mixture. Governor adjustment Check governor Adjust governor. Governor System section incorrect operation. Check Adjust engine speed setting Controller Parameters controller engine speed on controller.
  • Page 100 Problem Possible Cause Test Corrective Action Reference Lacks power, Engine power loss Refer to the engine Refer to the engine Engine S/M continued service manual for service manual for troubleshooting and troubleshooting and repair instructions. repair instructions. Governor malfunction or Test governor.
  • Page 101 Problem Possible Cause Test Corrective Action Reference No output voltage Alternator or control Perform separate excitation Troubleshoot the Alternator Excitation continued system procedure to isolate the alternator or control section problem to the alternator or system components as the control system. described below and elsewhere in this table.

  • Page 102: Controller Troubleshooting

    Also check the controller display for fault messages and refer to the Fault Messages section. Always check the controller settings before replacing the controller. Controller settings can be checked and adjusted through the controller’s user interface or using a personal computer and Kohler ™ ®...

  • Page 103: Troubleshooting Load Management Problems

    RBUS device. Power relay modules connected to the load management device are not RBUS devices. 2. Use a laptop computer connected to the controller’s USB port and Kohler ® SiteTech software. In the Parameters view of SiteTech, check that the RBUS network screen shows the correct number of RBUS devices connected (one load management device, RXT transfer switch, PIM, and/or APM, if used).
  • Page 104 Networking - -> Networking - -> Information Status Networking - -> Configuration Modules Connected: RBUS - -> Information Remote - -> < - - Return Devices See Figure 61. Net Cycle Time: 123ms Module Timeouts: 1234 Module Errors: 1234 < - - Return tp6804 Figure 60 RDC2 Controller, Networking Information Menu...
  • Page 105 From Figure 60. S/N: XXXXXXXXX S/N: XXXXXXXXX … <- - Return <<*DeviceType*>> <<*DeviceType*>> Device Status: Connected Comm. Errors: 12345 Comm. Timeouts: 12345 ModBus ID: Firmware Ver.: Connected: Displays date/time device was connected. Connected: Disconnected: Displays date/time of the last successful communication. MM/DD/YY 12:12 Return - ->...
  • Page 106 Troubleshooting Tables The following tables list potential load management device operation problems and recommendations for troubleshooting. Load management functional issues. Problem Check Load shed AC relays do not activate. Verify 120 VAC supply voltage to relays. Verify correct wiring to the load management device board and AC relays. Metering always reads 0% under load.
  • Page 107 Sporadic load adds and sheds. Problem Check Load adds and then sheds after about 6 seconds. Verify that the fuel pressure to the generator set is within specification. Verify that the % load is correctly measured. Verify that the wiring between the load management device and the CT meets specifications.
  • Page 108 Notes TP-7093 5/24...

  • Page 109: Section 6. Component Testing And Adjustment

    Section 6. Component Testing and Adjustment 6.1 Theory of Operation The generator set utilizes a rotating-field alternator to produce AC voltage. See Figure 62 and Figure 63. Refer to the Wiring Diagrams section for the complete generator set schematics. When the controller receives a start signal, it energizes leads FP and 71. FP energizes the rotor field and lead 71 energizes the crank relay P16.

  • Page 110: Alternator Excitation

    Excitation to rotor Power lead 55 RDC2 Controller Circuit breaker (20 amps) Sensing leads V7, V8, V9 Main field (rotor) Brushes Stator windings adv8956 Figure 63 Three-Phase Alternator Schematic 6.2 Alternator Excitation DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.

  • Page 111: No To Low Voltage Operation

    6.2.1 No to Low Voltage Operation This section covers the operation of the alternator 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 112 Testing live electrical circuits. Hazardous voltage or current will cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry.

  • Page 113: Stator

    6.3 Stator The stator contains a series of coils of wire laid in a laminated steel frame. The stator leads supply AC voltage to the load and voltage regulator. Before testing the stator, inspect it for heat discoloration and visible damage to housing lead wires, exposed coil windings, and exposed areas of frame laminations.
  • Page 114 R14807-14 Figure 65 Testing Stator Windings Note: For single-phase models. leads 1, 2, 3, and 4 are the generator output leads. Leads 11, 44, 55, and 66 are the controller sensing and supply leads. Refer to the schematic in Figure 66 when performing the following steps. 6196 Figure 66 Single-Phase Alternator Stator Leads...
  • Page 115 Note: For three-phase models, leads 1-12 are the generator output leads. Leads V7, V8, V9, 55, and 66 are the controller sensing and supply leads. Refer to the schematic in Figure 67 when performing the following steps. MAIN FEILD 12 LEAD STATOR tp6198 Figure 67 Three-Phase Alternator Stator Leads...

  • Page 116: Main Field (Rotor)

    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, 9, 55, or 66 2 and 1, 3, 7, 8, 9, 55, or 66 3 and 1, 2, 7, 8, 9, 55, or 66 7 and 1, 2, 3, 8, 9, 55, or 66 8 and 1, 2, 3, 7, 9, 55, or 66...
  • Page 117 Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment.

  • Page 118: Slip Rings

    IMG_1055 Figure 71 Optional Brush Cover 14/20 kW Models Only 6.5 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 119: Brushes

    Brushes Screw, M6 Note: Add Blue Loctite 242 or equivalent to fan screws before reinstalling them in fan spacer. When installing the fan, tighten the screws (M6) to 10.9 Nm (8.0 ft.lb.). 6.6 Brushes The brushes transfer current to the slip rings. The brushes should last the life of the generator. However, abrasive dust on the slip ring can shorten the life of the brushes.
  • Page 120 Shim Slip rings Brushes Brush holder GM80980 Shim Brush holder GM62996 GM80982 Spring Spring Not Shown Brush Length New 19.0 mm (0.75 in.) Brush GM80981 Figure 73 Brush Assembly TP-7093 5/24...

  • Page 121: Voltage Adjustments

    Excitation current control is performed by the patented Kohler Hybrid Voltage Regulator. This regulator consists of a fast-reacting analog inner loop and a slower digital outer loop. The inner loop regulates the average output voltage to a setpoint which is controlled by the outer loop, allowing the voltage to recover very quickly during transient conditions.

  • Page 122: Volts/Hz Slope And Cut-In Frequency

    The slope and cut-in frequency of the volts/Hz curve are set at the factory to allow the generator to meet factory performance standards. They should not be adjusted except under unique circumstances and under direction from a Kohler factory representative.

  • Page 123: Voltage Regulator Gain

    Cut-In Frequency Cut-In Frequency Generator Frequency Figure 76 Volts/Hz Curves 6.7.3 Voltage Regulator Gain The gain of the inner loop of the hybrid regulator is set at the factory and is not adjustable in the field. The Voltage Regulator Gain listed in SiteTech is for the outer loop. The outer loop is responsible for correcting the setpoint to the inner loop to ensure that the generator output is regulated to the RMS regulator setpoint.

  • Page 124: Operation

    6.8.1 Operation The frequency of the alternator output is determined by the speed of the engine. A two-pole alternator is driven at 3600 rpm to provide 60 Hertz. (A 50 Hz model is driven at 3000 rpm.) The engine speed is maintained by an electronic governor system that consists of an embedded controller and electric actuator (stepper motor).

  • Page 125: Hunting/Surging

    • Observe the stepper motor operation. o The stepper motor should open the throttle while cranking, and pull back after speed feedback is detected. o Check that the stepper motor actuator arm has not dropped to the 6 o’clock position. Normal operation range is from the 10 o’clock to the 2 o’clock position.
  • Page 126 14 kW models Electronic governor stepper motor Carburetor throttle linkage Carburetor 20 kW models Electronic governor stepper motor Carburetor throttle linkage Carburetor 26 kW models Carburetor 26RCA-0 26RCA-A Carburetor throttle linkage Electronic governor Electronic governor stepper motor stepper motor Figure 77 Stepper Motor and Carburetor TP-7093 5/24...

  • Page 127: Governor System Operation Test

    6.8.4 Governor System Operation Test If the engine continues to operate erratically after the previous checks, test the governor system operation using the following procedure. The procedure is summarized in the flowchart in Figure 78. Check that the carburetor throttle linkage is connected to the stepper motor as shown in the Stepper Motor and Carburetor figure.
  • Page 128 Check the operation of the stepper motor at startup. Before starting the generator, move the throttle to the fully closed position. Press the RUN button to initiate the start sequence. If the throttle stays in the fully closed position, and the controller shows a Locked Rotor fault, verify that the generator set model is set to 14 kW or 20 kW.

  • Page 129: Frequency Adjustment

    Set the system frequency to 50 or 60 Hz before adjusting the engine speed. The system frequency can be adjusted using the ™ ® controller keypad on the RDC2 controller or using a personal computer running Kohler SiteTech software. Frequency Adjustment Procedure Use the RDC2 controller’s Genset System menu or use SiteTech to set the system frequency to 50 or 60 Hz.

  • Page 130: Engine Speed Adjustment For Governor

    Advanced Speed Control Note: Do not adjust the Advanced Speed Control settings unless instructed to do so by the Kohler Generator Service Department. The four parameters under Advanced Speed Control also permit adjustment of the governor function, but have the potential of dramatically affecting the load transient performance of the generator.
  • Page 131 Engine Speed Governor settings Engine Run Speed setting (changes automatically with Genset System Frequency) Genset System Frequency setting (50 or 60 Hz) Figure 81 Engine Speed and Frequency Parameters in SiteTech TP-7093 5/24...

  • Page 132: Fault Shutdown Tests

    6.10 Fault Shutdown Tests Verify the operation of the generator set overspeed, overcrank, and low oil pressure shutdowns by performing the tests in the Controller Fault Shutdown Functions section. If these tests are inconclusive, test individual shutdown circuit components (wiring harness, switch, etc.) as described in the Fault Shutdown Switches section. DANGER Hazardous voltage.
  • Page 133 Increase the engine speed to at least 115% of the rated engine speed, 69 Hz on 60 Hz models or 58 Hz on 50 Hz models. Verify that the generator set shuts down on an overspeed fault. If the overspeed shutdown does not operate, the generator set should shut down on an overfrequency fault after approximately 5 seconds.
  • Page 134 Temperature sensor location GM66561 Figure 83 Temperature Sensor (OTS) Location GM81217 Figure 84 Temperature Sensor (OTS) Connector P7 TP-7093 5/24...

  • Page 135: Fault Shutdown Switches

    6.10.2 Fault Shutdown Switches Check the low oil pressure and high engine temperature shutdown switches on the engine by performing the following tests. If the sensor does not function as described, replace it. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.
  • Page 136 Oil pressure switch tp6519 Figure 86 Oil Pressure Switch Location (under the air cleaner) Before testing the LOP switch, check the oil level and add oil if necessary. Inspect the generator set engine for evidence of oil leaks. To test the LOP switch: Press the OFF button to stop the engine.

  • Page 137: Fuel Systems

    6.11 Fuel Systems WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system.

  • Page 138: Fuel Solenoid Valve

    6.11.2 Fuel Solenoid Valve A solenoid valve upstream of the regulator provides automatic fuel on/off control. See Figure 87. The engine starting battery powers the solenoid valve and the engine starting controls open the valve when the engine cranks or runs. Fuel Valve Operation Test Procedure Disconnect the positive (+) battery lead from the gas valve terminal.

  • Page 139: Checking The Fuel Pressure

    Fuel selector Pressure port Fuel inlet Integral fuel solenoid valve GM118767 Figure 89 Fuel Regulator, 26 kW Model 6.11.3 Checking the Fuel Pressure Use a gauge or manometer to check the fuel pressure at the fuel solenoid valve. See the Fuel Regulator, 26 kW Model figure for the location of the fuel pressure port on 26 kW models.

  • Page 140: Ignition Timing Leads (14 Kw And 26 Kw Models Only)

    After converting the fuel system, change the Fuel Type setting on the controller. See the Operation Manual for instructions to ™ ® change settings at the controller, or use a personal (laptop) computer and Kohler SiteTech software to change the setting.

  • Page 141: Original Fuel System, 14Rca/L

    Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels: Propane (LPG)—Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer’s instructions. Natural Gas—Adequate ventilation is mandatory.
  • Page 142 Conversion from LPG to Natural Gas, 14RCA/L To convert from LPG to natural gas, repeat the steps above, removing the LPG fuel orifice and installing the NG fitting. Connect ignition timing leads 65 and N3 together for natural gas. Ignition timing leads (14RCA/L only) LPG fitting tied to bracket for shipping Fuel hose and clamp Ignition Timing Lead Connection, 14RCA/Lonly...

  • Page 143: Original Fuel System, 20Rca/L

    6.12.2 Original Fuel System, 20RCA/L For LPG fuel, an orifice is used in the fuel line. The unit is typically shipped set up for natural gas, with the loose orifice tied near the fuel solenoid valve. To convert to LPG, install the LPG orifice as described below. See the Fuel System, As Shipped figure for the fuel system component locations.

  • Page 144: Revised Fuel System, 14/20/26Rca/L

    6.12.3 Revised Fuel System, 14/20/26RCA/L The revised fuel system uses a knob that controls a valve on the regulator to select the fuel type. See Figure 97 and Figure 98. Fuel selector Fuel inlet Integral fuel solenoid valve GM114166 Figure 97 Revised Fuel System Fuel selector Pressure port...
  • Page 145 Fuel Selection, Revised Fuel System Press the OFF button on the generator set controller. Disconnect utility power to the generator set (open the corresponding circuit breaker in the distribution panel). Disconnect the generator set engine starting battery, negative (-) lead first. Turn off the fuel supply.
  • Page 146 Find the ignition timing leads 65 and N, located near the regulator. See Figure 101. For natural gas (NG), connect lead 65 to lead N3. For LPG, disconnect lead 65 from lead N3. Ignition timing leads Figure 101 Ignition Timing Leads Connect and turn on the fuel supply (Ensure that the fuel supply matches the fuel setting).

  • Page 147: Start (Crank) And Run Relays

    6.13 Start (Crank) and Run Relays The start (crank) and run relays are located under the controller. See Figure 104. Identify the relays by the connected leads shown in Figure 102. The start relay is connected to lead 71 from the controller (P1-14). The run relay is connected to lead 70 from the controller (P1-13).
  • Page 148 Start and run relays are located under controller; see detail. ADV-8928 Start and run relays; check connections to identify Relay location detail GM101741 Figure 104 Relay Location TP-7093 5/24...

  • Page 149: Continuity Checks

    6.14 Continuity Checks DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Short circuits. Hazardous voltage/current will cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage.
  • Page 150 Notes TP-7093 5/24...

  • Page 151: Section 7. Disassembly/Reassembly

    Section 7. Disassembly/Reassembly This section provides instructions for the removal and replacement 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 Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

  • Page 152: Stator Hardware Change

    The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.

  • Page 153: Initial Steps

    7.2 Initial Steps Perform the following steps before disassembling the generator set. Disconnect AC power to the generator set by opening the upstream circuit breaker. (AC power is connected to the generator set for battery charging and AC-powered accessories.) Shut off the fuel supply and disconnect the fuel line at the fuel inlet connection. See Figure 109. Ventilate the area to clear fumes.

  • Page 154: Disassembly

    7.3 Disassembly The disassembly procedure explains how to disassemble the generator set enclosure and other parts in order to access the alternator for service. The procedure provides important information to minimize disassembly time and indicates where special configurations exist which may require taking notes. 7.3.1 Remove Enclosure Remove the generator set enclosure as described in the following steps.
  • Page 155 ROOF dwgGM102548 Hinge assembly (qty.2) Remove 2 M6 screws Remove 2 M6 screws at front bulkhead on rear bulkhead Figure 111 Roof Removal The front (air intake) panel hangs on four 20 mm (0.8 in.) diameter bushings. Pull the air intake panel up and off. See Figure 112.
  • Page 156 Panel mounting bushings, qty. 4 tp7091 Figure 112 Panel Mounting Bushings (air intake end panel shown) Load connection circuit breaker and terminals Remove cover Utility power (AC) connections img1037, img1053 Figure 113 Field Connections TP-7093 5/24...
  • Page 157 Remove the right-side panel: Locate two latches at the top of the panel. See Figure 114. Pull up on the top of each latch to release the panel. Pull the right-side panel toward you until it is free from the hooks at the bottom. Pull up to release latch Latches, quantity 2 Latches, quantity 2...
  • Page 158 Remove the Left Side Panel Make sure that the fuel line has been disconnected. Label and disconnect any electrical leads that enter the enclosure through the panel. Disconnect conduit as needed to remove the enclosure panel. On the outside of the enclosure, remove four screws that secure the left side panel to the bulkhead. See Figure 115. Remove two screws that secure the left side panel to the top of the rear bulkhead on the alternator end.
  • Page 159 Remove four screws to remove the rear bulkhead. See Figure 116. Rear bulkhead screws, qty. 4 TP-7093 Figure 116 Rear Bulkhead WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Note: Allow the muffler to cool before removing it.

  • Page 160: Generator Disassembly

    Remove the heat shields from the alternator. See Figure 117. Mounting bracket Muffler Heat shields Exhaust flanges (qty. 2) 14 and 20 kW models Mounting bracket Muffler Heat shield Exhaust flanges (qty. 2) 26 kW models TP-7093 Figure 117 Muffler and Heat Shields 7.3.2 Generator Disassembly Disconnect the following alternator wiring inside the controller junction box.
  • Page 161 Remove the bolts securing the two alternator vibromounts to the skid. Loosen, but do not remove, the two engine vibromounts. See Figure 118. Engine vibromounts (qty. 2) Alternator vibromounts (qty. 2) TP-7093 Figure 118 Vibromounts Raise the alternator end of the generator set enough to place a wood support beneath the rear of the engine. The wood support must be long enough to span the opening in the base.
  • Page 162 Remove the alternator support bracket from the alternator assembly. See Figure 120. Alternator support bracket GM102806 Figure 120 Alternator Support Bracket Brushes To gain access to the brush assembly, remove the alternator duct cover with reinforcing plate. See Figure 121 and Figure 122.
  • Page 163 Brush assembly 14 and 20 kW models Brush assembly TP-7093 26 kW model Figure 122 Brush Assembly Location IMG_1055 Figure 123 Brush Cover (optional) 14/20 kW only TP-7093 5/24...
  • Page 164 Check the brushes. See Figure 124. Note: The brushes are spring-loaded and captured in the brush holder. Remove the brush holder and any shims from the end bracket by removing two mounting screws. Keep the shims for re-installation later. Inspect the brushes. Replace brushes if they show uneven wear or when they are worn to half of their original size. See the Brushes section.
  • Page 165 Alternator Remove the end bracket assembly by removing four screws shown in Figure 125. Note: The alternator duct and bellows assembly is attached to the end bracket. End bracket mounting screws (qty. 4) Alternator duct and bellows, attached to end bracket End bracket mounting screws (qty.
  • Page 166 The stator leads are routed through the bulkhead and into the controller junction box. Carefully pull the leads out of the junction box. Pull the leads and conduit out through the bulkhead to free the alternator for removal. Carefully pull the stator from the rotor. See Figure 126. Remove the rotor as follows: Loosen but do not remove the rotor thrubolt.

  • Page 167: Reassembly

    14RCA only: Remove the four generator adapter mounting bolts to remove the generator adapter, if necessary. See Figure 128. Adapter mounting holes GM60283 Figure 128 Generator Adapter (14RCA) Engine Service For engine service information, refer to the engine service manuals. 7.4 Reassembly 7.4.1 Reassemble Alternator...
  • Page 168 Tighten the rotor thrubolt to 85 Nm (63 ft. lb.). It may be necessary to keep the engine flywheel from turning while torquing the rotor thrubolt. See Figure 130. Engine crankshaft taper shaft Figure 129 Shaft (20RCA shown) Rotor Rotor thrubolt with hardened washer GM67344 Figure 130 Rotor Assembly...
  • Page 169 Install the stator and end bracket. Re-attach the alternator support bracket to the alternator shell. Assemble with the part number of the mounting foot toward the engine end of alternator. See Figure 131. Assemble with part number of mounting foot Alternator support bracket toward engine end of alternator.
  • Page 170 Alternator mounting bolts and washers (qty. 4) Stator shell (outer) Rotor (inner) Alternator mounting bolts and washers (qty. 4) Figure 133 Alternator Mounting Bolts Secure the generator set to the skid. Raise the alternator end of the generator set and remove the wood support block(s). Lower the end of the generator set and reinstall the screws and washers that secure the vibromounts to the skid.
  • Page 171 Install the end bracket. Note: See the Stator Hardware Change section for information about the stator hardware. Clean the bearing and the end bracket bore before assembly. Place the end bracket onto the stator assembly, using your hands to make the initial fitting of the end bracket over the bearing.
  • Page 172 Install the alternator duct and bellows as shown in Figure 138. Alternator duct and bellows, attached to end bracket TP-7093 Figure 138 Alternator Duct and Bellows Installation Reinstall the end bracket components. Inspect the brushes. If brushes show uneven wear or are worn to less than half their original length, replace them. See the Brushes section.
  • Page 173 Shim Slip rings Brushes Brush holder GM80980 Shim Brush holder GM62996 GM80982 Spring Spring Not Shown Brush Length New 19.0 mm (0.75 in.) Brush GM80981 Figure 141 Brush Assembly TP-7093 5/24...

  • Page 174: Reassemble Exhaust System

    7.4.2 Reassemble Exhaust System Install the exhaust system. See Figure 142. Note: Use new exhaust gaskets when re-installing the muffler. Install the heat shields onto the alternator exhaust support. Using new gaskets, connect the engine exhaust muffler to the engine at the flanges. Do not final tighten the mounting hardware.

  • Page 175: Reinstall Enclosure

    7.4.3 Reinstall Enclosure Reinstall the rear bulkhead assembly shown in Figure 143. Rear bulkhead screws, qty. 4 TP-7093 Figure 143 Rear Bulkhead Place the left side panel into position. See Figure 144. Install four screws that secure the left side panel to the bulkhead. See Figure 144. Install two screws that secure the left side panel to the top of the rear bulkhead on the alternator end.
  • Page 176 Install four (4) bulkhead screws Install two (2) rear bulkhead screws Electrical lead entrance locations Fuel inlet Install four (4) bellows screws ADV-8928 14 and 20 kW model Install four (4) bulkhead screws Install two (2) rear bulkhead screws Electrical lead entrance locations Fuel inlet Lifting hole...
  • Page 177 DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. Connecting the battery and the battery charger. Hazardous voltage will cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).
  • Page 178 Notes TP-7093 5/24...

  • Page 179: Section 8. Wiring Diagrams

    Section 8. Wiring Diagrams Figure 146 lists the drawing numbers and page numbers. Wiring Diagrams Drawing Number Page 14/20RCA/RCAL Schematic Diagram ADV-8956 Harnesses and cables Sheet 1 1 phase, 2 pole circuit breaker Sheet 2 1 phase, 1 pole circuit breaker Sheet 3 3 phase, 3 pole circuit breaker Sheet 4...
  • Page 180 Figure 147 Schematic Diagram, ADV-8956, Sheet 1 TP-7093 5/24...
  • Page 181 Figure 148 Schematic Diagram, ADV-8956, Sheet 2 TP-7093 5/24...
  • Page 182 Figure 149 Schematic Diagram, ADV-8956, Sheet 3 TP-7093 5/24...
  • Page 183 Figure 150 Schematic Diagram, ADV-8956, Sheet 4 TP-7093 5/24...
  • Page 184 Figure 151 Schematic Diagram, ADV-9909, Sheet 1 TP-7093 5/24...
  • Page 185 Figure 152 Schematic Diagram, ADV-9909, Sheet 2 TP-7093 5/24...
  • Page 186 Figure 153 Schematic Diagram, ADV-9909, Sheet 3 TP-7093 5/24...
  • Page 187 Figure 154 Schematic Diagram, ADV-9909, Sheet 4 TP-7093 5/24...
  • Page 188 Figure 155 Wiring Diagram GM102647 Sheet 1, Single Phase, 2-Pole Circuit Breaker TP-7093 5/24...
  • Page 189 Figure 156 Wiring Diagram GM102647 Sheet 2, Single Phase, 1-Pole Circuit Breaker TP-7093 5/24...
  • Page 190 Figure 157 Wiring Diagram GM102647 Sheet 3, Three Phase, 3-Pole Circuit Breaker TP-7093 5/24...
  • Page 191 Figure 158 Wiring Diagram GM118674 Sheet 1, Single Phase, 2-Pole Circuit Breaker TP-7093 5/24...
  • Page 192 Figure 159 Wiring Diagram GM118674 Sheet 2, Single Phase, 1-Pole Circuit Breaker TP-7093 5/24...
  • Page 193 Figure 160 Wiring Diagram GM118674 Sheet 3, Three Phase, 3-Pole Circuit Breaker TP-7093 5/24...
  • Page 194 Notes TP-7093 5/24...

  • Page 195: Appendix A. Abbreviations

    Appendix A. Abbreviations A, amp ampere blk. htr. block heater digital to analog converter ABDC after bottom dead center BMEP brake mean effective pressure decibel alternating current bits per second dB(A) decibel (A weighted) analog to digital Brass direct current advanced digital control;...
  • Page 196 (2 bytes) megabyte (2 bytes) gallons per hour KBus Kohler communication protocol MCCB molded-case circuit breaker gallons per minute kilogram one thousand circular mils grade, gross kg/cm kilograms per square meggar megohmmeter centimeter...
  • Page 197 N, norm. normal (power source) permanent magnet generator silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) not available, not applicable potentiometer, potential s, sec. second Systeme international d’unites, nat. gas natural gas parts per million International System of Units National Bureau of Standards PROM programmable read-only...
  • Page 198 ultrahigh frequency user interface Underwriter’s Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) univ. universal uniform resource locator (web address) undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt...

  • Page 199: Appendix B. Common Hardware Application Guidelines

    Appendix B. Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/Screw Length: When bolt/screw length is not given, use Figure 161 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method.
  • Page 200 Entry hole types Cap screw Standard nut and SAE washer G-585 Exit hole types Weld nuts: above 1/2 in. dia. Whiz nut or spiralock: up to 1/2 Hardware in. dia. Hardware Figure 162 Acceptable Hardware Combinations TP-7093 5/24...

  • Page 201: Appendix C. General Torque Specifications

    Appendix C. General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into Size Aluminum Grade 2 Grade 5 Grade 8 8-32 2.0 Nm (18 in. lb.) 3.1 Nm (27 in. lb.) 10-24 3.2 Nm (28 in. lb.) 4.9 Nm (43 in.
  • Page 202 Notes: The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or assembly drawings when they differ from the above torque values. The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are used.

  • Page 203: Appendix D. Common Hardware Identification

    Appendix D. Common Hardware Identification Hardness Grades Screw/Bolts/Studs Nuts Head Styles Nut Styles American Standard Hex Head or Machine Hex Head Grade 2 Head Hex Head or Machine Lock or Elastic Grade 5 Head with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)
  • Page 204 Notes TP-7093 5/24...

  • Page 205: 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-6024-5...
  • Page 206 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Hex Nuts M931-05055-60 M5-0.80 x 55 M933-04006-60 M4-0.70 x 6 M934-03-50 M3-0.50 Standard...
  • Page 207 Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Hex Nuts Pan Head Machine Screws † This metric hex nut’s hardness is grade 8. M931-20065-60 M20-2.50 x 65 M931-20120-60 M20-2.50 x 120 M7985A-03010-20 M3-0.50 x 10...
  • Page 208 Notes TP-7093 5/24...
  • Page 209 Notes TP-7093 5/24...
  • Page 210 Notes TP-7093 5/24...
  • Page 211 Notes TP-7093 5/24...
  • Page 212 TP-7093 5/24b KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the Original Instructions (English) US and Canada, phone 1-800-544-2444 KOHLERPower.com © 2019 Kohler Co. All rights reserved.

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