KOHLER Generator Service Workshop Manual

Residential/Commercial Generator Sets Models: 14RES/RESL 20RES/RESL Controllers: RDC Residential Digital Control DC Digital Control TP-6735 9/10 Service

Table of Contents TP-6735 9/10 Table of Contents Safety Precautions and Instructions 7 ........................................................ Introduction 11 ............................................................................... List of Related Materials 11 ..................................................... Service Assistance 12 ........................................................................ Section 1 Specifications 13 ................................................................... 1.1 Introduction 13 .......................................................... 1.2 Controller Specifications 13 ............................................... 1.3 Engine Service 13 ....................................................... 1.4 Engine Specifications 13 .................................................. 1.5 Alternator Specifications 14 ............................................... 1.6 Torque Specifications 14 .................................................. 1.7 Service View 15 ......................................................... Section 2 Scheduled Maintenance 17 .......................................................... 2.1 Service Schedule 17 ..................................................... 2.2 Lubrication System 19 .................................................... 2.2.1 Low Oil Pressure Shutdown 19 .................................... 2.2.2 Oil Check 19 .................................................... 2.2.3 Engine Oil Recommendation 19 .................................... 2.2.4 Oil Change Procedure 19 ......................................... 2.2.5 Oil Cooler, 14RES/RESL 20 ....................................... 2.2.6 Oil Cooler, 20RES/RESL 21 ....................................... 2.3 Spark Plugs 21 .......................................................... 2.4 Air Cleaner Service 22 .................................................... 2.4.1 Air Cleaner, 14RES/RESL Models 22 ............................... 2.4.2 Air Cleaner, 20RES/RESL Models 23 ............................... 2.5 Cooling System 23 ....................................................... 2.6 Stepper Motor Coupling 24 ................................................ 2.7 Exhaust System 24 ...................................................... 2.8 Battery 24 ............................................................... 2.9 Battery Charger 25 ....................................................... 2.10 Storage Procedure 26 .................................................... 2.10.1 Lubricating System 26 ............................................ 2.10.2 Fuel System 26 .................................................. 2.10.3 Cylinder Lubrication 26 ........................................... 2.10.4 Exterior Preparation 26 ........................................... 2.10.5 Battery 26 ....................................................... Section 3 Troubleshooting 27 ................................................................. 3.1 Introduction 27 .......................................................... 3.2 Initial Checks 27 ......................................................... 3.3 Controller Service Access 27 .............................................. 3.4 Troubleshooting Chart 27 ................................................. 3.5 Controller Troubleshooting 36 ............................................. Section 4 Controller 37 ....................................................................... 4.1 Introduction 37 .......................................................... 4.2 RDC and DC Generator Set/ Transfer Switch Controllers 37 ................... 4.3 Controller Power 37 ...................................................... 4.4 Controls and Indicators 38 ................................................ 4.4.1 LED Display 39 .................................................. 4.4.2 Controller Keypad 39 ............................................. 4.4.3 LED Indicators 40 ................................................

Table of Contents, continued TP-6735 9/10 Table of Contents 4.5 Generator Set Operation 41 ............................................... 4.5.1 Engine Start Crank Cycle 41 ....................................... 4.5.2 Local Starting and Stopping 41 .................................... 4.5.3 Automatic Operation with Model RRT Transfer Switch 41 .............. 4.5.4 Automatic Operation with Model RDT or RSB Transfer Switches 41 ..... 4.6 Exercise 42 ............................................................. 4.6.1 Unloaded Exercise with Diagnostic Test 42 .......................... 4.6.2 Low-Speed Diagnostics 42 ........................................ 4.6.3 Loaded Exercise 42 .............................................. 4.6.4 Exerciser Reset and Disable 43 .................................... 4.6.5 Power Failure During Exercise Cycle 43 ............................. 4.7 Test 43 ................................................................. 4.7.1 Unloaded Test 43 ................................................ 4.7.2 Loaded Test 44 .................................................. 4.7.3 Power Failure During Test Cycle 44 ................................. 4.8 Faults 45 ............................................................... 4.8.1 Warnings 45 ..................................................... 4.8.2 Shutdowns 45 ................................................... 4.8.3 ATS Communication Errors 45 ..................................... 4.8.4 Resetting the Controller after a Fault Shutdown 45 .................... 4.9 Event History 48 ......................................................... 4.10 Model RRT Transfer Switch Operation 49 ................................... 4.10.1 Source Availability 49 ............................................. 4.10.2 ATS Control Sequence of Operation 49 ............................. 4.10.3 Time Delays 49 .................................................. 4.10.4 Engine and Transfer Time Delays 50 ............................... 4.10.5 Load Control Time Delay 50 ....................................... 4.10.6 Model RRT ATS Connection 50 .................................... 4.11 Controller Configuration and Adjustment 51 ................................. 4.11.1 SiteTech Software 51 ............................................. 4.11.2 Controller Configuration 51 ........................................ 4.11.3 Controller Time Out 51 ............................................ 4.11.4 Controller Firmware Version Number 51 ............................. 4.11.5 Voltage and Frequency Adjustments 52 ............................. 4.12 Calibration 52 ........................................................... 4.12.1 Calibrate Function 52 ............................................. 4.12.2 Calibration Factor 52 ............................................. 4.13 Controller Circuit Board 54 ................................................ 4.13.1 Relays and LEDs 54 .............................................. 4.13.2 Controller Fuse F2 54 ............................................ 4.14 Controller Replacement 55 ................................................ Section 5 Component Testing and Adjustment 57 .............................................. 5.1 Theory of Operation 57 ................................................... 5.2 Separate Excitation 57 .................................................... 5.3 Stator 59 ................................................................ 5.4 Main Field (Rotor) 61 ..................................................... 5.4.1 Rotor Continuity and Resistance Tests 61 ........................... 5.5 Slip Rings 62 ............................................................ 5.6 Brushes 62 .............................................................. 5.7 Voltage Connections 63 ................................................... 5.7.1 Voltage Connections, Single-Phase Models 63 ....................... 5.7.2 Voltage Regulation 63 ............................................

Table of Contents, continued TP-6735 9/10 Table of Contents 5.8 Voltage Adjustment 63 .................................................... 5.8.1 Voltage Adjustment Procedure 64 .................................. 5.8.2 Volts per Hertz (Hz) Adjustments (Droop) 64 ......................... 5.9 Governor System 66 ..................................................... 5.9.1 Operation 66 .................................................... 5.9.2 Initial Checks 66 ................................................. 5.9.3 Hunting/Surging 66 ............................................... 5.9.4 Governor System/Magnetic Pickup Operation Test 67 ................. 5.9.5 Frequency Adjustment 70 ......................................... 5.10 Fault Shutdown Tests 71 .................................................. 5.10.1 Controller Fault Shutdown Functions 71 ............................. 5.10.2 Fault Shutdown Switches 72 ....................................... 5.11 Fuel Systems 74 ......................................................... 5.11.1 Fuel Solenoid Valve 74 ........................................... 5.11.2 Digital Spark Advance Ignition (DSAI) Timing 75 ..................... 5.11.3 Fuel Regulators 75 ............................................... 5.11.4 Fuel Conversion, 20RES/RESL 76 ................................. 5.11.5 Fuel Conversion, 14RES/RESL 77 ................................. 5.11.6 Fuel Metering Valve Adjustment, 14RES/RESL Only 78 ............... 5.12 Starter Relay 80 ......................................................... 5.13 Continuity Checks 81 ..................................................... 5.14 Circuit Protection 82 ...................................................... 5.14.1 Line Circuit Breaker 82 ........................................... 5.14.2 Fuses and Mini-Breaker 82 ........................................ Section 6 Disassembly/Reassembly 83 ........................................................ 6.1 Initial Steps 83 ........................................................... 6.2 Disassembly 84 .......................................................... 6.3 Reassembly 90 .......................................................... Section 7 Wiring Diagrams 95 ................................................................ Appendix A Abbreviations 99 .................................................................. Appendix B Common Hardware Application Guidelines 101 ........................................ Appendix C General Torque Specifications 102 ................................................... Appendix D Common Hardware Identification 103 ................................................. Appendix E Common Hardware List 104 ......................................................... Appendix F Controller Parameters (SiteTech) 107 .................................................

TP-6735 9/10 6

TP-6735 9/10 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. This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice. DANGER Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage. WARNING Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage. CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage. NOTICE Notice communicates installation, operation, or maintenance information that is safety related but not hazard related. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals. Accidental Starting 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. WARNING Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. Battery 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. Isolate the battery charger from explosive fumes. WARNING Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.

TP-6735 9/10 8 Safety Precautions and Instructions Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. 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. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Engine Backfire/Flash Fire Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. WARNING Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. 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. Train all personnel on fire extinguisher operation and fire prevention procedures. Exhaust System Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. WARNING Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building. 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 generator set. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide. Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according to the manufacturer’s instructions. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following: D Light-headedness, dizziness D Physical fatigue, weakness in joints and muscles D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air. Fuel System Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. WARNING

TP-6735 9/10 9 Safety Precautions and Instructions 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. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch (10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble. LP liquid withdrawal fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi (621 kPa). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble. Hazardous Noise Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. CAUTION Hazardous Voltage/ Moving Parts Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. DANGER Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Moving parts. WARNING Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death. If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply. WARNING Welding the generator set. Can cause severe electrical equipment damage. Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM). CAUTION Grounding electrical equipment. Hazardous voltage can 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. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

TP-6735 9/10 10 Safety Precautions and Instructions 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. (5) Attach the weld ground connection close to the weld location. High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment manufacturer when performing high-voltage tests on the rotor or stator. An improper test procedure can damage equipment or lead to generator set failure. Connecting the battery and the battery charger. Hazardous voltage can 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). Have a qualified electrician install the battery(ies). 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 connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines. Testing live electrical circuits. Hazardous voltage or current can 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. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under) Heavy Equipment Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. WARNING Hot Parts Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. WARNING Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter armature. When shorted, the alternator field and exciter armature become hot enough to cause severe burns. 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. Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install the heater before connecting it to power. Operating the heater before installation can cause burns and component damage. Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts. 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. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short, to ground.

KOHLER Generator Service Workshop Manual

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